The Little Wonder Modular

The Little Wonder Modular
Village Marine LWM 145-200
Part Number: 95-0024
The Little Wonder Modular
145-200
Installation, Operation & Maintenance
TABLE OF CONTENTS
1.0
INTRODUCTION
1
1.1
UNPACKING AND HANDLING
2
1.2
PERFORMANCE SPECIFICATIONS
2
1.3
ENVIROMENTAL REQUIREMENTS
2
1.4
CONSUMABLES
3
1.5
MAINTENANCE EQUIPMENT
3
2.0
INSTALLATION
4
2.1A
TO CONNECT PLUMBING
4
2.1B
TO CONNECT THE ELECTRICAL
7
3.0
GENERAL THEORY OF OPERATION
8
3.1
REVERSE OSMOSIS THEORY
8
3.2
APPLICATION OF REVERSE OSMOSIS
8
3.3
PRODUCT WATER QUALITY STANDARDS
9
3.4
FACTORS AFFECTING PERMEATE PRODUCTION
10
3.4A
TEMPERATURE CORRECTION FACTOR
11
4.0
OPERATION
12
4.1A
TO START THE LITTLE WONDER MODULAR UNIT
12
4.1B
TO SHUT DOWN THE UNIT
13
5.0
MAINTENANCE
14
FRESHWATER FLUSH / SHORT TERM STORAGE
14
5.1
TO FLUSH THE LITTLE WONDER MODULAR UNIT
15
5.2
MEMBRANE CLEANING AND PRESERVATION
16
5.3
CLEANING CHEMICALS
16
5.4
WHEN TO CLEAN
16
STEPS FOR CLEANING CHEMICALS #1, #2, AND #3 (CARTRIDGE FORM)
17
5.5
18
OIL CHANGE PROCEDURE
VMT- v. MARCH 2013
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TABLE OF CONTENTS
6.0
MEMBRANE REPLACEMENT
20
6.1
PRESSURE VESSEL DISASSEMBLY
20
6.2
PRESSURE VESSEL ASSEMBLY
21
7.0
FREEZE PROTECTION
22
8.0
TROUBLESHOOTING
24
9.0
PLUMBING DIAGRAMS
25
10.0
PARTS REFERENCE
27
11.0
MANUFACTURER’S LITERATURE
28
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VMT A v. MARCH 2013
SYSTEM START UP LOG
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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vii
INTRODUCTION
1.0
INTRODUCTION
SYSTEM DESCRIPTION
Village Marine Tec’s (VMT) Little Wonder watermakers are well-engineered reverse osmosis (RO) systems,
designed and built for simple operations and maintenance for the cruising sailor, or sport fisherman, or where space
is at a premium. These modular 12 Volts DC desalination systems will produce seven to eight 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).
HOW TO USE YOUR MANUAL
This User Guide & Reference Manual contains important information about the safe operation and maintenance of
your Little Wonder Vertical 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.
VMT- v. MARCH 2013
1
INTRODUCTION
1.1
UNPACKING AND HANDLING
The Little Wonder reverse osmosis units are shipped pre-assembled, however, connection of the
modules will be required. Inspect the RO unit to verify it was not damaged in transit. Also, please refer
to the plumbing diagram to verify all components for the watermaker are shipped prior to installation.
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)
Raw water temperature (nominal)
Raw water temperature (maximum)
Min. raw water inlet pressure
Max. raw water inlet pressure*
Flush water recommended max. pressure*
Design RO element pressure
Max. RO element pressure
Max. feedwater chlorine residual
Cleaning solution pH range
Membrane type
33 F (1C)
77 F (25C)
113 F (45C)
Flooded suction pressure
30 psi
35 psi
800 psi
1000 psi
< 0.1 ppm
10-11 (chem. 1), 2-3 (chem. 2)
Thin film composite
Table 1.0 - Performance Characteristics
*
NOTE:
For inlet pressure greater than recommended limits, install pressure regulator.
REGARDING WATER PRODUCTION:
The RO series number (i.e. LWM 145, LWM 200) refers to gallons per day (GPD) production produced
with new membranes at design optimum conditions.
To achieve optimum production:
(1) The feed flow must be unrestricted (positive water pressure at the inlet to high pressure pump).
(2) Seawater temperature at 77F (25C).
(3) Seawater salinity at 32,000 parts per million (ppm) total dissolved solids (TDS).
(4) 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 (environmental, temperature, and frequency of use) 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 membrane to membrane
can vary + 15%.
1.3
ENVIROMENTAL REQUIREMENTS
Parameter
List (Permanent):
Trim (Fore and Aft):
Pitch:
Roll:
Specifications
15
+ 30
10 (6 sec cycle)
30 (12 sec cycle)
Table 1.1 - Nominal Operating Conditions
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INTRODUCTION
1.4
CONSUMABLES
Table 1.2 lists the consumables required for the RO unit. Use ONLY Village Marine Tec. approved filters
and chemicals.
Description
LW 145/200
QTY
Chemical Cleaning Cartridge Kit #1, #2
Preservative Cartridge Kit, Chemical #3
Filter, 5 micron, 10 sq-ft.
Filter, Carbon, 10 sq-ft.
Aqua Pro High Pressure Pump Oil
VMT Part No.
1ea/box
2/box
1ea
1ea
1 qt
85-0102
85-0103
33-0117
33-0311
85-0050
Table 1.2 – VMT Approved Consumables
1.5
MAINTENANCE EQUIPMENT
Table 1.3 lists the test equipment required for performance verification and maintenance of the RO unit.
Description
Kit, Pump, Service
Economy Mini Water Tester, TDS
VMT Part No.
70-6181
99-1990
Table 1.3 – Maintenance Equipment List
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3
INSTALLATION
2.0
INSTALLATION
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).
The portion of the watermaker up to and including the high pressure pump should be installed BELOW
waterline (Refer to Figure 2.1). If the high pressure pump cannot be below waterline, then contact your
VMT distributor for the high lift LP pump, p/n 70-0512. The pressure vessel tube and instruments can
be ABOVE waterline. 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 2.1: Recommended installation BELOW waterline.
Locate or create a ½” dedicated through-hull for the feedwater intake of the RO unit. The through-hull
must be attached with a ball valve (seacock), and optionally a sea strainer.
The Little Wonder MODULAR SHOULD NOT SHARE a through-hull feedwater intake. Village
Marine Tec. recommends the Little Wonder HAVE its OWN 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 as VOIDING the RO unit’s warranty with VMT.
2.1a
TO CONNECT PLUMBING
Step 1:
Refer to Section 9 for the EXPANDED detailed Little Wonder MODULAR plumbing diagram.
Figure 2.1: Little Wonder MODULAR Plumbing Diagram.
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INSTALLATION
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 2.3 for a view of the carbon filter and freshwater flush valve.
Figure 2.2: Carbon Filter with Freshwater Flush Valve – Isometric Views.
NOTE:
Village Marine Tec. recommends the Manual Freshwater Flush Assembly be installed BELOW
waterline. However, the valve can be removed from the filter housing and relocated below
waterline, leaving the filter housing ABOVE waterline. A hose can be plumbed from the filter
housing to the valve. This way the seawater feed does not go above waterline to avoid trapping
air and creating a priming problem.
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5
INSTALLATION
Figure 2.4: Connecting the Carbon Filter Outlet to the Separated Freshwater Flush Valve.
Step 3:
Connect ½” diameter PVC hoses to connect all the feed water components up to the high pressure
pump. Note the boost pump outlet is a 3/8” diameter barb fitting. Use a short section of 3/8” hose and
jump to ½” diameter using the step size adaptor supplied.
BRINE DISCHARGE
Locate a convenient spot in the boat to install an overboard discharge through-hull with an ½” diameter.
Discharge line is required to be ABOVE waterline. Refer to Figure 2.1. If connecting to a common drain,
tee in from above so that backflow contamination to the watermaker from other drains is not possible.
PRODUCT WATER AND SAMPLE WATER
Connect a ¼” diameter PVC hose (or potable water hose) from the product elbow off the back of the
product flowmeter to a sample valve (Refer to Figure 2.5). On both outlets of the sample valve, connect
a ¼” inner diameter PVC hose (or potable water hose), one hose for product water sampling and the
other hose 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, to prevent any possible backflow (refer to Figure 2.1).
Figure 2.5: Little Wonder MODULAR Sample Valve Connection.
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
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
Tap into your boat’s freshwater pressure system (Tee into the cold pressurized side) with a ½” diameter
hose to the carbon flush filter. If the freshwater pressure on board is above 35 psi, install a pressure
regulator.
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INSTALLATION
2.1b
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 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 the OFF position.
Step 2
Connect power source wire (Positive +) to line side on RO unit’s breaker.
Step 3:
AC POWERED 110V/220V Little Wonder MODULAR:
Connection will be from the separate control box supplied to the onboard circuit breaker panel. VMT
recommends use of a 15 amp fuse or circuit breaker.
DC POWERED 12V Little Wonder MODULAR:
12 VDC units require 6 gauge wire and a 25 amp fuse or circuit breaker. Connect RO unit’s power
supply red wire (Positive +) from load side of unit’s breaker, to power input on the Little Wonder
MODULAR’s terminal strip (Refer to Figure 2.6).
Step 4:
Connect a negative black wire from the ground bus bar behind main breaker panel to negative power
source input on unit.
Step 5:
With the DC units, connect the boost pump wires red and black to the same terminals at the side of the
high pressure pump as shown in figure 2.6.
Figure 2.6: Little Wonder MODULAR (DC UNIT) Electrical Interface Views.
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7
GENERAL THEORY
3.0
GENERAL THEORY OF OPERATION
3.1
REVERSE OSMOSIS THEORY
Reverse osmosis, like many other practical scientific methods, was developed from processes first
observed in nature. Osmosis is a naturally occurring phenomenon in which a semi-permeable
membrane separates a pure and a concentrated solution (a semi-permeable membrane is defined as
one that preferentially passes a particular substance). Every fluid has an inherent potential that is
directly related to the type and amount of solids in solution. This potential, referred to as osmotic
pressure, increases in proportion to relative concentration of a solution. A concentrated solution,
therefore, has an osmotic pressure that is higher than that of a pure solution.
In an osmotic system, the less concentrated solution will attempt to equalize the concentrations of both
solutions by migrating across the semi-permeable membrane. When enough pure solution migrates
across the membrane such that the inherent potential difference between the solutions in no longer
higher than the osmotic pressure of the membrane, the purer solution will stop flowing. If the pressure
on the concentrated solution is increased to above the osmotic pressure, fluid flow will be reversed. This
condition, called Reverse Osmosis, can be established by artificially pressurizing the more concentrated
solution using a high pressure pump. In this type of system, the concentrated solution (normally referred
to as feedwater) will become more concentrated as pure water flows out of solution and across the
membrane to the permeate side. Discounting the effects of feedwater temperature and salinity, the
operating pressure normally required to produce significant amounts of pure water is at least twice the
osmotic pressure of the membrane being used.
ATMOSPHERIC
PRESSURE
(14.7 PSI)
PURE
SOLUTION
HIGH
PRESSURE
(800 PSI)
SALINE
SOLUTION
PURE
SOLUTION
SALINE
SOLUTION
SEMI-PERMEABLE MEMBRANE
OSMOSIS
REVERSE OSMOSIS
Figure 3.1 - Simple (Reverse) Osmosis Process.
3.2
APPLICATION OF REVERSE OSMOSIS
Seawater contains many kinds of solids dissolved in solution. The most prevalent is common table salt
(sodium chloride). Other minerals that may be present in solution are substances that usually contain
various compounds of calcium and sulfate. The sum of all of the solids dissolved in a particular sample
of water is referred to as Total Dissolved Solids or TDS. Seawater normally averages 32,000 ppm
(parts per million) TDS although variations of 5000 ppm are common in various parts of the world. The
fundamental goal of any desalination process is a significant reduction in the amount of dissolved solids
in water.
In a Reverse Osmosis desalination system, most of the dissolved solids do not pass through the
membrane but are instead carried along the membrane surface. This rejected water, referred to as
brine, becomes increasingly more concentrated as it flows across the surface of the membranes and is
eventually piped to drain. The product water that flows through the membrane is referred to as
permeate. The percentage of feedwater that enters the unit converted to permeate is called the
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VMT A v. MARCH 2013
GENERAL THEORY
recovery rate. A higher than optimal recovery rate (which can be obtained by increasing the back
pressure on the unit above the recommended range) results in greatly increased membrane fouling
rates and a significant decrease in the operational life of the membranes.
It should be noted that no system is capable of removing all 100% of the dissolved solids from
seawater. Designed to reject approximately 99% of the TDS, the system allows 1% of the 32,000 ppm
TDS in the seawater to pass into the product water. This yields product water of less than 500 ppm, the
recommended TDS for drinking water. A system such as this is said to have a salt passage of 1%.
Figure 3.2: Simplified Schematic of an RO System.
3.3
PRODUCT WATER QUALITY STANDARDS
This RO unit will produce permeate (product water) with a quality of less than 500 ppm TDS and in
accordance with World Health Organization (WHO) guidelines for drinking water. General WHO
specifications for acceptable drinking water quality are as follows:
Constituent Ion / Molecule
Nitrate
Fluorine
Sulfate
Magnesium
Calcium
Calcium Carbonate
Iron
Manganese
Total Dissolved Solids
Turbidity
Oil
Detergents (Anionic)
Phenols
Bacteria – E. Coli (per 100 ml)
Maximum Limits (ppm)
10
1
100
30
75
100
0.1
0.05
500
5
0.1
0.2
0.001
0
Table 3.0 - WHO Drinking Water Guidelines.
VMT- v. MARCH 2013
9
GENERAL THEORY
3.4
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:
With constant....
And increasing....
Salinity and Pressure
Temperature and Pressure
Temperature and Salinity
Temperature
Salinity
Pressure
Permeate
TDS
Capacity
Increases
Increases
Decreases
Increases
Decreases
Increases
Table 3.1 - Factors Affecting Permeate Quality
The RO system can be adjusted to maintain a constant permeate output when feedwater 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 PRODUCT FLOW IS NO MORE THAN 120% OF
DESIGN FLOW TO AVOID MEMBRANE DAMAGE.
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GENERAL THEORY
3.4a
TEMPERATURE CORRECTION FACTOR
As previously described, the output capacity of any RO unit is highly dependent on feedwater
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 feedwater 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)
2)
3)
4)
Measure sea water temperature.
Determine the corresponding correction factor from Table 3.2 based on the measured temperature.
Note the product flow rate at the Product Flow meter.
Multiply the measure (uncorrected) product flow meter flow rate by the correction factor from Table
3.2 to give the calculated system output under standard conditions (25°C).
Example:
Raw water temp:
TCF:
Actual product flow:
Calculation:
Calculated product flow:
(Adjusted to 75 F)
15°C
1.47
5.67 (gph)
5.67 x 1.47 = 8.3349 (gph)
8.3 (gph)
(This is the normal flow for a LW 200)
°C Factor
°C
Factor
°F
Factor
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
26
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
0.97
0.94
0.91
0.88
0.85
0.83
0.80
0.77
0.75
0.73
0.71
0.69
0.67
0.65
0.63
0.61
0.60
0.58
0.56
0.54
0.53
0.51
0.49
0.47
0.46
34
36
38
40
42
44
46
48
50
52
54
56
58
60
62
64
66
68
70
72
74
76
78
80
82
3.47
3.18
3.18
2.68
2.47
2.29
2.14
2.01
1.88
1.77
1.68
1.59
1.51
1.44
1.36
1.30
1.24
1.17
1.12
1.08
1.05
1.02
1.00
0.93
0.90
3.64
3.23
3.03
2.78
2.58
2.38
2.22
2.11
2.00
1.89
1.78
1.68
1.61
1.54
1.47
1.39
1.34
1.29
1.24
1.19
1.15
1.11
1.08
1.04
1.00
°F
84
86
88
90
92
94
96
98
100
102
104
106
108
110
112
114
116
118
120
122
Factor
0.88
0.82
0.79
0.79
0.77
0.75
0.73
0.70
0.68
0.65
0.63
0.61
0.59
0.57
0.55
0.53
0.51
0.49
0.47
0.45
Table 3.2 - Temperature Correction Factors
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11
OPERATION
4.0
OPERATION
4.1a
TO START THE LITTLE WONDER MODULAR UNIT
Figure 4.1: Little Wonder MODULAR Instrument Detail.
Step 1:
Turn the sample valve to SAMPLE position to direct the flow of water to the sample line.
Step 2:
Turn the High Pressure Bypass Valve (Black Valve) to CLEANING POSITION, counterclockwise, to
release air trapped within the system.
Verify the Cleaning Valve (Gray Valve) is positioned to NORMAL discharge, allowing brine water to flow
overboard. Also check the gray Freshwater Flush Valve (Refer to Figure 2.3) is positioned for seawater
intake, NOT freshwater.
FAILURE TO OPEN THE HIGH PRESSURE BYPASS VALVE COULD RESULT IN HYDRAULIC
SHOCK TO THE SYSTEM.
Step 3:
Verify the seawater intake is open at the through-hull. Start-up time can be expedited by filling the prefilter housing by temporarily turning the flush valve to freshwater position before the RO unit is turned
on.
Step 4:
AC POWERED 110V/220V Little Wonder MODULAR Models:
Turn Power Switch ON located on the unit’s supplemental control box, to start RO. Start the LP booster
pump first, then the HP pump.
DC POWERED 12V Little Wonder MODULAR Models:
Switch ON the breaker at the main breaker panel to power up the unit.
Step 5:
Upon initial 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.
Step 6:
Verify brine discharge is flowing overboard. If so, gradually turn the High Pressure Bypass Valve (Black
Valve) to NORMAL/RO position. The High Pressure Regulator is factory set at 800psi. If High Pressure
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VMT A v. MARCH 2013
OPERATION
Gauge does not read 800 psi, slowly tighten or loosen in small increments the screw atop the High
Pressure Regulator and adjust to a reading of 800psi. For location of High Pressure Regulator, refer to
Figure 4.1.
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 high pressure production should NEVER EXCEED 950 psi, doing so risks damage to RO unit
VOIDING factory warranty.
NOTE:
At initial start-up of RO unit, keep the product water diverted out of the water storage tank. IF the
unit is filled with preservative storage solution, production must be diverted AT LEAST 10
MINUTES to clear preservative solution from system.
Step 7:
With the Sample Valve at SAMPLE position, taste the water quality or test it with a hand-held test
meter. If quality is good, turn the Sample Valve over to PRODUCT direction, routing the product water
into the vessel’s storage tank.
Step 8:
Check the RO unit for water leakage periodically at the initial start-up. Observe Product Flow meter.
Record the product flow after 3 and 24 hours of operation (use the start up sheet provided on page vii).
4.1b
TO SHUT DOWN THE UNIT
Step 1:
As the RO unit operates, turn the High Pressure Bypass Valve (Black Valve) to CLEANING POSITION.
This will release the high pressure within the RO system.
Step 2:
AC POWERED 110V/220V Little Wonder Modular Models:
Turn the HP pump off, then the booster pump off at the control box. Then turn OFF your breaker at the
main breaker panel.
DC POWERED 12V Little Wonder MODULAR Models:
Turn OFF your breaker at the main breaker panel.
The RO unit may be left in this “stand by” condition with the seawater for one day. If the RO unit will be
out of service for extended time periods, please refer to the Maintenance section of this manual for
flushing instructions.
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13
MAINTENANCE
MAINTENANCE
The service life of most system equipment is related to the sea water inlet conditions and proper maintenance. Under
normal conditions, a reverse osmosis membrane (which is the major consumable item) should have an effective
service life somewhere between 3 and 6 years.
Labor Hours
(approximate)
As Required
Annually
Semi-Annually
Quarterly

Check Belt Tension/Wear
Clean/inspect micron prefilter
Monthly
The RO unit must be cleaned when product water output drops by 15%.
Weekly
NOTE:
Daily
5.0
0.5

0.5

Replace 5 micron filter

Replace carbon flush filter
0.5
0.5
Clean membranes

2.0
Replace Membranes

1.0

Check pump oil level
Change pump oil
0.1

**
0.5
Table 5.0: Maintenance Task Chart.
*
VMT prefilter cartridges can be rinsed with freshwater and be reused up to 3 times.
**
Change pump oil after first 50 hours of RO use. After the first oil change at 50 hours, change the
pump oil every 500 hours thereafter or once annually which ever interval comes first.
FRESHWATER FLUSH / SHORT TERM STORAGE
Ideally, the Little Wonder 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. The flush pushes
out older stagnant seawater (saltwater) out of the membranes and replacing it with freshwater, 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 one day. 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.
PERFORM A FRESHWATER FLUSH TO THE RO UNIT WITH NON-CHLORINATED FRESH WATER
ONLY. THE FRESHWATER FLUSH SYSTEM USES A CARBON FILTER INLINE BEFORE SYSTEM
TO REMOVE CHLORINE THAT MAY BE PRESENT IN DOCK WATER SUPPLIES.
14
VMT A v. MARCH 2013
MAINTENANCE
5.1
TO FLUSH THE LITTLE WONDER MODULAR UNIT
Step 1:
Turn the High Pressure Bypass Valve to CLEANING (ensuring zero pressure in system). Verify the gray
Cleaning Valve is positioned to NORMAL/REVERSE OSMOSIS position.
Step 2:
Turn the gray Freshwater Flush Valve to FRESHWATER position. Freshwater should now start flowing
through the watermaker from the “house” pump.
Step 3:
AC POWERED 110V/220V Little Wonder MODULAR Models:
Turn the pump switches located on the control box panel to ON position to power up motor. Run unit for
two minutes.
DC POWERED 12V Little Wonder MODULAR Models:
Turn ON the breaker at the main breaker panel and allow the unit to run for two minutes.
Step 4:
Turn the gray Freshwater Flush Valve to SEAWATER position. Leave RO unit in standing condition, for
up to three weeks. Then reflush or preserve.
VMT- v. MARCH 2013
15
MAINTENANCE
5.2
MEMBRANE CLEANING AND PRESERVATION
This section is to guide the operator in the periodic care and cleaning of the RO membrane elements
used in the LW unit. The basic procedure for all cleaning and preservative treatments is the same – a
specific chemical solution is circulated through the system for a pre-determined length of time.
NOTE:
All cleaning and preservation procedures should be performed with freshwater to optimize
performance of cleaning process.
NOTE:
Allow your unit’s product water to run with product to SAMPLE for the first 10 minutes after
cleaning or upon startup after preservation.
Description
Cartridge Form
Powder Form
Cleaning Chemical #1
1 Cartridge (Blue Stripe)
10 TBSP
Cleaning Chemical #2
1 Cartridge (Red Stripe)
10 TBSP
Preservative Chemical #3
1 Cartridge (Green Stripe)
3 TBSP
Table 5.1: Chemical Requirements
5.3
CLEANING CHEMICALS
CLEANING CHEMICAL #1 IS AN ALKALINE DETERGENT, USED TO REMOVE OIL, GREASE,
BIOLOGICAL MATTER, AND GRIME FROM THE SURFACE OF THE RO MEMBRANES. SEE
WARNING LABEL ON SIDE OF PACKAGE AND OBSERVE ALL SAFETY PRECAUTIONS ON
LABEL.
CLEANING CHEMICAL #2 IS AN ACID, A MINERAL SCALE REMOVER. SEE WARNING LABEL
ON SIDE OF PACKAGE AND OBSERVE ALL SAFETY PRECAUTIONS ON LABEL.
PRESERVATIVE CHEMICAL #3 IS A FOOD GRADE PRESERVATIVE. SEE WARNING LABEL ON
SIDE OF PACKAGE AND ADHERE TO ALL SAFETY PRECAUTIONS ON LABEL.
THE USE OF CHEMICALS OR CLEANING METHODS OTHER THAN THOSE OUTLINED IN THIS
MANUAL WILL VOID THE RO UNIT WARRANTY. NON-IONIC SURFACTANTS USED FOR
MEMBRANE CLEANING OR ANY OTHER CHEMICALS NOT APPROVED IN WRITING BY
VILLAGE MARINE TEC., WILL VOID THE RO UNIT WARRANTY.
5.4
WHEN TO CLEAN
The RO unit must be chemically cleaned when product water output drops below 85% of original
production. The frequency of this occurring will vary greatly upon feed water and usage pattern. Fouling
from the membrane will naturally occur through regular RO use.
Prior to cleaning the membranes, verify that any reduction in product output is not the result of a
corresponding variation in raw water inlet temperature or salinity. Refer to Section 3.4: FACTORS
AFFECTING PERMEATE PRODUCTION for more information.
NOTE:
16
Product water output of the system is dependent upon feedwater temperature, RO feed pressure
and feedwater salinity. Reductions in product water output due to these factors are normal and
may not indicate the need for membrane cleaning.
VMT A v. MARCH 2013
MAINTENANCE
STEPS FOR CLEANING CHEMICALS #1, #2, AND #3 (CARTRIDGE FORM)
Single Use Cleaning Cartridges:
Chemical #1 and Chemical #2
Single Use Preservative Cartridge:
Chemical #3
Step 1.
Prior to cleaning the RO, complete a freshwater
flush to the system. (REFER TO SECTION 5.1)
Step 1.
Prior to preserving the RO, complete a freshwater
flush to the system. (REFER TO SECTION 5.1)
Step 2.
Remove 5 micron prefilter from housing.
Step 2.
Remove 5 micron prefilter from housing.
Step 3.
Place cleaning filter Chemical # 1 (Blue Stripe) into Step 3.
prefilter housing and fill with water. Screw housing
back into place.
Place preservation filter Chemical # 3 (Green
Stripe) into prefilter housing and fill with water.
Screw housing back into place.
Step 4.
Make sure the High Pressure Bypass Valve is in
the Cleaning position.
Step 4.
Make sure the High Pressure Bypass Valve is in
Cleaning position.
Step 5.
Turn cleaning valve to clean/recirculate position.
Step 5.
Turn cleaning valve to clean/recirculate position.
Step 6.
Start RO unit and let unit run for 30 minutes, in the
recircluate mode.
Step 6.
Start RO unit and let unit run for 20 minutes, in the
recircluate mode.
Step 7.
Turn Unit OFF after running for 30 minutes;
Place cleaning valve to overboard position;
Remove the cleaning chemical cartridge from the
prefilter housing;
Step 7.
Turn Unit OFF after running for 20 minutes.
Step 8.
Leave all valves in position they are now in.
Install a 5 micron prefilter cartridge in housing and
resecure housing place.
Step 8.
Run the unit with seawater feed for 5 minutes to
clear out cleaner #1.
Step 9.
To use Cleaning Chemical #2 (Red Stripe) return to Step 9.
Step 1 to follow steps 1 to 8 with the #2 cartridge.
Unit is now preserved and can be left as is for 6
months in temperate climates or 4 months in the
tropics. After that, flush unit and represerve.
Step 10. After 5 minutes running, close the bypass valve to
bring the unit up to pressure. Record production
flow rate before and after cleaning to determine
effectiveness.
NOTE:
For resuming normal RO operation (unpreserving or “unpickling”), install a FIVE MICRON filter
into the prefilter housing. Begin system Start Up Procedures by referring to Section 4.0.
NOTE:
When single use chemical cartridges are not available, the LW watermaker can be treated with
powdered VMT cleaners. In step 3 above, substitute 10 tablespoons of cleaner #1 or 10
tablespoons of cleaner #2 or 3 tablespoons of preservative #3. Leave the 5 micron filter in place,
and dissolve the powder in enough water to fill the filter housing.
VMT- v. MARCH 2013
17
MAINTENANCE
5.5
OIL CHANGE PROCEDURE
An oil change is recommended after the first 50 hours of RO use. Subsequent oil changes are to be
performed every 500-hour intervals OR changed annually. Change oil any time moisture is detected or
if oil is cloudy. For additional pump information, refer to Section 11.0: MANUFACTURER’S
LITERATURE in back of this manual.
DO NOT RUN PUMP WITHOUT OIL IN THE CRANKCASE.
Step 1:
Turn off all power sources and switches.
Step 2:
Before changing the oil, obtain a container (i.e. tray or catch basin) to collect the oil drainage.
Step 3:
Remove the oil plug (Refer to Figure 5.1) and direct the oil to a catch basin. Allow the oil to drain empty.
Step 4:
Reconnect the oil plug or oil drain stopper. Then unscrew the oil cap and refill oil to fill line (located on
HP Pump sight glass). Check for leaks and re-secure oil cap.
Figure 5.1: High Pressure Pump and Drain Plug – Isometric Views.
18
VMT A v. MARCH 2013
MAINTENANCE
Date
Total
Hours
HP Pump Inlet
Pressure
(AC UNITS)
RO Array
Pressure
Product Flow
GPH
Brine Flow
GPH
(IF KNOWN)
Prod water
TDS, ppm
Water
Temp, °C
Table 5.4: Sample Operational Log
VMT- v. MARCH 2013
19
MEMBRANE REPLACEMENT
6.0
MEMBRANE REPLACEMENT
6.1
PRESSURE VESSEL DISASSEMBLY
Step 1:
Disconnect plumbing from pressure vessel for disassembly. Remove the pressure vessel from the LW
vertical frame and continue on a workbench.
Step 2:
Remove the six fasteners and cap ring holding each end plug with an Allen wrench. Place a mark on
each end plug to be removed, place a corresponding mark on each end collar. This will ensure proper
orientation during assembly. Refer to Figure 6.2.
Figure 6.1 - Pressure Vessel End Plug Assembly Callout.
Step 3:
Locate the screwdriver slots located on opposite ends of the pressure vessel end collar. Place an
appropriate sized slot screwdriver in each slot. Twist both screwdrivers until the end plug breaks loose
from the pressure vessel. The screwdrivers can now be placed between the end plug and collar. A
prying motion on both sides of the end plug with the screwdrivers will quickly remove it. Use this
procedure for both end caps.
Step 4:
Push or pull the membrane element out of the pressure vessel tube.
Step 5:
Note which end of the pressure vessel the brine seal was installed at. The brine seal is a black u-cup
seal on the membrane outer diameter near one end (Refer to Figure 6.3). This is the feed end of the
pressure vessel. When reinstalling the RO membrane the brine seal must be located at the feed end
of the pressure vessel.
Figure 6.2 – Membrane Corresponding Mark Placement.
20
VMT A v. MARCH 2013
MEMBRANE REPLACEMENT
NEVER FORCE A MEMBRANE OUT OF A PRESSURE VESSEL BY APPLYING PRESSURE ON
THE PRODUCT WATER TUBE (CENTER TUBE), AS THIS WILL DAMAGE THE MEMBRANE. IF
MEMBRANE IS DIFFICULT TO REMOVE, USE A 2” DIAMETER PLASTIC PIPE (PVC) TO APPLY
PRESSURE ON THE PROTECTED END OF THE MEMBRANE.
6.2
PRESSURE VESSEL ASSEMBLY
Step 1:
Inspect all O-Rings; product O-Rings, end plug O-Rings, and Brine seal. Replace O-Rings if there is
visible damage. The product water O-Rings are internal O-Rings, inside the center hole in the end cap.
Refer to Figure 6.1.
Step 2:
Clean all parts thoroughly.
Step 3:
Lubricate O-Rings and entrances to pressure vessel with glycerin or silicone lubricant. Locate
discharge end of pressure vessel. Install discharge end plug by lining up with the holes of the
pressure vessel, paying attention to the reference mark. Position end cap ring and insert fasteners by
hand.
NEVER USE ANY TYPE OF LUBRICANT CONTAINING PETROLEUM OIL. OIL CAN DAMAGE
YOUR UNIT AND REDUCE MEMBRANES PERFORMANCE.
Step 4:
Align the membrane so the end without the brine seal enters the feed end of the pressure vessel first.
Slide membrane into pressure vessel until resistance is felt. Continue applying pressure until the
product water tube sits into the end plug.
Step 5:
Install the remaining end plug (align end plug holes with mounting holes properly), use the reference
mark made in step 3 for correct assembly.
Step 6:
Tighten the six fasteners for each end cap.
Step 7:
Install the vessels and reconnect plumbing.
NOTE:
Do not apply Teflon tape or sealant to SAE fittings such as those used on High Pressure
assemblies and their adapters.
NOTE:
For replacement parts call numbers, refer to Parts Reference section at the end of the manual
and for additional information about the membranes and the pressure vessel, refer to the
Manufacturer’s Literature section at the back of this manual.
Item Description
1
Vessel - 2538
1
Vessel - 2519
2
Membrane - SW 2538
2
Membrane - SW 2519
3
End cap
4
End cap ring
5
Brine Seal
6
Product O-rings
7
End Plug O-ring
8
Fasteners
Figure 6.3 - Exploded View of Pressure Vessel with Membrane.
VMT- v. MARCH 2013
21
FREEZE PROTECTION
7.0
FREEZE PROTECTION
There is a high probability of damaging your RO by exposing it to severe cold or icy conditions. Therefore protecting
your RO against freeze damage is recommended. The following information provides steps towards safeguarding
your RO and extending its plumbing life against freezing temperatures.
DO NOT USE ETHYLENE GLYCOL (FOUND IN AUTOMOTIVE ANTIFREEZE PRODUCTS)
TOWARDS FREEZE PROTECTING YOUR RO. ETHYLENE GLYCOL IS A TOXIC SUBSTANCE
AND MUST NOT BE INGESTED NOR COME INTO CONTACT WITH YOUR RO SYSTEM.
USE ONLY FOOD GRADE NON-TOXIC PROPYLENE GLYCOL. DO NOT USE PROPYLENE
GLYCOL BLENDED WITH SUPPLEMENTARY ADDITIVES.
FREEZE PROTECT YOUR RO UNIT
Adhere to the packaging label directions of the food grade propylene glycol, for the amount of propylene glycol to be
mixed based on the level of temperature protection required. Use non-chlorinated freshwater and make up sufficient
solution to fill your prefilter housing.
Step 1:
Close inlet seacock and flush unit with fresh water. Refer to Section 5.1: TO FLUSH LITTLE WONDER
UNITS
Step 2:
Remove the 5 micron filter from the prefilter housing and empty the prefilter housing.
Step 3:
Pour the winterizing solution into filter housing and reattach the prefilter canister.
Step 4:
Make sure the black High Pressure Bypass Valve is in CLEANING POSITION. Turn the gray Cleaning
Valve to CLEANING position.
Step 5:
Turn on the RO pumps and run for at least 15 minutes to circulate the winterizing solution into the
membranes, hoses, fittings, and pumps.
Step 6:
Shut off the unit. Unit can be left in standby mode for up to 6 months.
The freeze protection solution is now circulated throughout the feed and reject sides, including the
membrane and the pumps. To protect the product side, open the blue hoses and drain out the water
from the membrane outlets, the product solenoid valve, the product manifold, the product flowmeter,
and product relief valve, if equipped.
Step 7:
22
Then switch OFF at your breaker at the main breaker panel.
VMT A v. MARCH 2013
FREEZE PROTECTION
TO FLUSH WINTERIZATION SOLUTION FROM THE RO UNIT
To return your machine to operating condition after freeze protecting it, adhere to the following steps.
Step 1:
Verify the High Pressure Bypass Valve is in CLEANING (ensuring zero pressure in system). Turn the
gray Cleaning Valve is positioned to NORMAL/REVERSE OSMOSIS position.
Step 2:
Open the micron filter housing and put a new 5 micron filter inside. Fill the prefilter housing with
freshwater by turning the flush valve temporarily to freshwater position.
Step 3:
Verify the seacock intake to the RO is open.
Step 4:
Run the unit to seawater for 10 minutes, and then close the HP bypass valve slowly and check fresh
water generation. Record into your log sheet.
ALTERNATIVE FREEZE PROTECTION METHOD
Instead of applying propylene glycol to the RO system, an alternative method to freeze protect the RO is available.
Step 1:
Perform a Chemical #3 preservation to the unit. To preserve the LITTLE WONDER, refer to instructions
in SECTION 5.2: STEPS FOR PRESERVATION CHEMICAL #3
Step 2:
Remove membrane vessels from the boat, placing caps over the fittings. This is a more practical
alternative for Little Wonder MODULAR systems.
REMINDER: Membranes must be kept wet with preservative solution, so the fittings must be
capped.
Step 3:
Store the membranes in an environment protected from freezing.
Step 4:
Refresh the preservative every 6 months as recommended.
Step 5:
Drain all the remaining parts of the RO of all water.
VMT- v. MARCH 2013
23
TROUBLESHOOTING
8.0
TROUBLESHOOTING
Below is a list of frequently encountered operational problems and some guidelines and trouble shooting checks. This
section can only be a guide to solving potential problems with the RO unit and does not contain all possible
malfunctions. The best troubleshooting tool is your knowledge of the RO gained through experience. Situations not
covered in this section may be resolved by contacting the Village Marine Tec  Service Department via phone calls
and e-mail.
1.
Check for proper valve configuration. Especially make sure the cleaning valve is in the overboard “Normal”
position. Confirm by checking water is flowing overboard through the brine discharge. Flow should be about a
quart a minute.
2.
Always check for loose connections or broken wires when checking electrical parts. Check for good voltage at
the high pressure pump motor; and if it is low then follow back with the voltmeter until the loose connection is
found.
3.
Confirm that a free sea water feed is supplied. A) The through-hull is clear of trash or kelp. B) Seacock is open.
C) Sea strainer is clear. D) Boost pump is running. E) 5 micron filter is clean.
4.
To flush the unit, the black handled BYPASS VALVE is in cleaning position, but the gray handled CLEANING
VALVE must be in the “Normal” position. During flush, water must be flowing overboard through the brine
discharge.
5.
Low production GPH may be caused by cool seawater. Poor salt rejection may be caused by warm and/or salty
seas. Do not interpret environmental factors as equipment problems.
24
VMT A v. MARCH 2013
PLUMBING DIAGRAMS
9.0
PLUMBING DIAGRAMS
VMT- v. MARCH 2013
25
Lit t l e Wo n d er Mo d u l ar
Pl u mbin g Diag r am
26
J u l y-2 0 0 4
Fr es h wat er Fr o m t h e Sea
Vil l ag e Mar in e Tec .
PLUMBING DIAGRAMS
VMT A v. MARCH 2013
145
200
200
200
200
12/24V
12V
110V/220V
220V
24V
FILTER, 5 MICRON (10 SQFT)
(33-0117)
MICRON FILTER HOUSING
(33-1034)
*INCLUDED WITH PRESSURE VESSEL ASSEMBLY
32-2519 VESSEL ASSY FOR LWM-145
32-2537 VESSEL ASSY FOR LWM-200
BASE, PUMP AND MOTOR
(15-8038) 12/24V
(90-1480) 110V/220V
LOW PRESSURE PUMP
110V 60HZ (70-7504)
220V 50HZ (70-7505)
LOW PRESSURE PUMP
12V (70-9304)
24V (70-9305)
MOTOR
(20-0480):
(20-0087):
(20-0501):
(20-0392):
(20-0480):
HIGH PRESSURE PUMP
(70-6073): 145
(70-6074): 200
OIL, HP PUMP
(85-0050)
145 12V
145 24V
200 12V/24V/110V
200 220V
PULLEY, PUMP
(70-0597): 145 12V/24V
(70-0597): 200 12V/24V/110V/220V
BELT
(70-0036):
(70-4567):
(70-4567):
(70-0168):
PULLEY, MOTOR
(70-0451): 145
(70-0438): 145
(70-0363): 145
(70-0134): 200
(70-0363): 200
110V/220V
12V
24V
12V
24V
VALVE, CLEANING
(60-0140)
FLOWMETER, PRODUCT
(40-1017)
FILTER, CARBON F.W. FLUSH
(33-0311)
CARBON FILTER HOUSING
(33-1034)
VALVE, FRESHWATER FLUSH
(60-0014)
MARCH 2013
Freshwater From the Sea
Village Marine Tec.
HIGH PRESSURE GAUGE
(40-0302)
PRESSURE VESSEL*
19": (32-0025)
38": (32-0018)
*O-RING, ENDPLUG, BRINE
(32-2228)
*ENDPLUG, 2.5" 2-PORT, OLD
(32-2513)
REGULATOR, PRESSURE
(60-4547)
HP BYPASS VALVE
(60-0064)
VALVE, SAMPLE
(60-0140)
*SCREWS, 316, 10/32*
(86-0106)
ELEMENT, SEAWATER
(33-3000): LWM-145 12V/24V
(33-3001): LWM-200 2 SHORT MEMBRANES
(33-3002): LWM-200 1 LONG MEMBRANE
*O-RING, ENDPLUG, PRODUCT
(32-2116)
*RING, ENDPLUG, 2.5" ALUM
(32-4013)
BELT GUARD
(90-1850)
Little Wonder Modular 145-200 - Main Parts Reference
TABLE OF CONTENTS
INTRODUCTION..................................................................................................................................................................... 1
INITIAL START-UP INFORMATION...................................................................................................................................... 2
LUBRICATION .................................................................................................................................................................... 2
PUMP FLOW DESIGN ........................................................................................................................................................ 2
MOTOR SELECTION.......................................................................................................................................................... 3
MOUNTING THE PUMP ..................................................................................................................................................... 3
DISCHARGE PLUMBING ................................................................................................................................................... 4
PUMPED FLUIDS ............................................................................................................................................................... 4
INLET CONDITION CHECKLIST ........................................................................................................................................... 5
INLET SUPPLY ................................................................................................................................................................... 5
INLET LINE SIZE ................................................................................................................................................................ 5
INLET PRESSURE.............................................................................................................................................................. 5
INLET ACCESSORIES ....................................................................................................................................................... 6
PREVENTIVE MAINTENANCE SCHEDULE......................................................................................................................... 7
MAINTENANCE RECORD ..................................................................................................................................................... 8
TROUBLESHOOTING............................................................................................................................................................ 9
SERVICE............................................................................................................................................................................... 12
INTRODUCTION ............................................................................................................................................................... 12
TOOLS NEEDED (VERIFY TOOL LIST) .......................................................................................................................... 12
DETACHING THE MANIFOLD FROM THE CRANKCASE .............................................................................................. 13
ROUTINE SERVICE KIT ...................................................................................................................................................... 13
VALVE ASSEMBLY ROUTINE SERVICE ........................................................................................................................ 13
MANIFOLD SEAL ROUTINE SERVICE............................................................................................................................ 14
CRANKCASE SEAL ROUTINE SERVICE........................................................................................................................ 15
SERVICING THE CRANKCASE .......................................................................................................................................... 15
OIL DRAIN PLUG O-RING REPLACEMENT.................................................................................................................... 17
PLUNGER ROD SEAL REPLACEMENT.......................................................................................................................... 17
BEARING SIDE PLATE O-RING/SEAL REPLACEMENT ................................................................................................ 18
CRANKCASE COVER O-RING REPLACEMENT ............................................................................................................ 19
CRANKSHAFT BEARING, CONNECTING ROD-PISTON ASSEMBLY SERVICE ......................................................... 20
SERVICING THE MANIFOLD .............................................................................................................................................. 20
INLET/DISCHARGE ADAPTER O-RING REPLACEMENT 708-3 & 708-5...................................................................... 21
VALVE ASSEMBLY SERVICING...................................................................................................................................... 21
MANIFOLD SEAL SERVICING ......................................................................................................................................... 23
ATTACHING THE MANIFOLD TO THE CRANKCASE .................................................................................................... 24
LIST OF FIGURES
Fig. 1: Oil Level Sight Glass Detail...........................................................................................................................................................2 Fig. 2: Manifold Assembly Removal .......................................................................................................................................................13 Fig. 3: Valve Assembly............................................................................................................................................................................14 Fig. 4: Orientation for Manifold Seal Servicing ......................................................................................................................................15 Fig. 5: Plunger Retaining Bolt Assembly ................................................................................................................................................16 Fig. 6: Seal Retainer.................................................................................................................................................................................16 Fig. 5: Plunger Retaining Bolt Assembly ................................................................................................................................................18 Fig. 6: Seal Retainer.................................................................................................................................................................................18 Fig. 7: Manifold Assembly ......................................................................................................................................................................21 Fig. 8: Valve Assembly............................................................................................................................................................................22 Fig. 9: Orientation for Manifold Seal Servicing ......................................................................................................................................23 Fig. 10: Weep Ring Extraction ...............................................................................................................................................................24 LIST OF TABLES
Table 1: Approximate Horsepower Required.......................................................................................................................... 3
Table 2: Tool List For Pump Service..................................................................................................................................... 12
INTRODUCTION
Aqua Pro Pumps “708 Series” High Pressure Pumps are the product of our years of experience in the water treatment
industry, and have been specifically designed and engineered for corrosive and high-pressure applications. Your new
Aqua Pro Pump is made with dependable and proven technology to meet your highest demands.
SPECIFICATIONS
Specifications subject to change without notice.
Pump type: Reciprocating Plunger
Number of Plungers:
Bore:
Stroke:
Oil Capacity:
708-1
(15 GPH)
1
.707”
.2”
6 oz
Oil Type:
Maximum Inlet pressure:
Maximum Fluid Temperature:
Model
Number
708-1
708-1
708-1
708-3
708-3
708-5
Capacity
15 GPH
22 GPH
29 GPH
2.3 GPM
3.5 GPM
8 GPM
708-1
(22 GPH)
1
.707”
.3”
6 oz
708-1
(29 GPH)
1
.707”
.4”
6 oz
708-3
(2.3 GPM)
3
.707”
.276”
19.5 oz
708-3
(3.5 GPM)
3
.707”
.512”
19.5 oz
708-5
(8 GPM)
5
.707”
.625”
32 oz
Village Marine Tec. High Pressure Pump Oil
(Part No. 85-0050-quart size)
Flooded to 60 PSI
120 degrees Fahrenheit (82 degrees Celsius)
Inlet Port
Size
.50 NPT
.50 NPT
.50 NPT
.75 NPT
.75 NPT
.75 NPT
Discharge Port
Size
.25 NPT
.25 NPT
.25 NPT
.5” MS16142-8
.5” MS16142-8
.5” MS16142-8
Dimensions
LxWxH
9.125”x 5.5” x 4”
9.125”x 5.5” x 4”
9.125”x 5.5” x 4”
7.5”x 6” x 4.5”
7.5”x 6” x 4.5”
11.5”x 9.5” x 5.5”
Weight
Shaft
11 lbs.
11 lbs.
11 lbs.
18.9 lbs.
18.9 lbs.
27.6 lbs.
∅.625
∅.625
∅.625
∅.650
∅.650
∅.938
1
708 Series
High Pressure Titanium Positive Displacement Pump
INITIAL START-UP INFORMATION
WARNING
This is a positive displacement pump. A properly designed pressure relief safety valve must be installed in the discharge
piping. Failure to install such a relief mechanism could result in personal injury or damage to the pump or system. Aqua
Pro Pumps does not assume any liability or responsibility for the operation of a customer’s high-pressure system.
The performance of the pump depends on the entire fluid system and will operate best with the proper installation of
plumbing, operation, and maintenance of the pump.
LUBRICATION
It is recommended that pump be filled with Village Marine Tec’s specially blended high pressure pump oil. To check the
oil level, ensure the pump has stopped running. Then look into the sight glass in the side cover. Oil level should be level
with the mark on the sight glass (Fig.1).
Fig. 1: Oil Level Sight Glass Detail.
NOTE
Change the original oil that came in the pump after running the pump for 100 hours. After the initial oil change, the oil
should be changed at 500-hour service intervals.
PUMP FLOW DESIGN
To drive the pump to give the desired discharge volume for your specific application equation 2.1 is to be used.
Desired Pump RPM :
Rated GPM " Desired" GPM
=
Rated RPM
" Desired" RPM
(2.1)
PULLEY SELECTION
It is essential that an appropriate pulley size be selected to meet your application needs. Based on the required pump
discharge volume (in GPM), the correct pulley size can be selected using equation 2.2.
2
CAUTION
Pulley should be sized to not exceed the maximum pump RPM rating.
Pulley Size :
Motor Pulley O.D. Pump Pulley O.D.
=
Pump RPM
Motor RPM
(2.2)
MOTOR SELECTION
To ensure desired pump output, the motor or engine driving the pump must possess sufficient horsepower to maintain full
RPM when the pump is under load. Using equation 2.3 an appropriate electric motor can be sized for the application.
This motor sizing approach is based on pump discharge volume and maximum pump discharge pressure. The constant
in the equation accounts for drive and system losses, which implies a mechanical efficiency of 85%. Consult the
manufacturer of a gas or diesel engine for selection of the proper engine size. Refer to Table 1 for sample horsepower
applications.
HP Required :
GPM × PSI
= Electric Brake HP
1460
Table 1: Approximate Horsepower Required
HP Required (708-1 – 15 GPH) Working Pressure [PSI]
Flow [GPH]
Speed [RPM]
800
1000
15
734
.14
.17
14
686
.13
.16
13
637
.12
.15
12
588
.11
.14
HP Required (708-1 – 29 GPH) Working Pressure [PSI]
Flow [GPH]
Speed [RPM]
800
1000
29
710
.26
.33
28
686
.26
.32
27
661
.25
.31
16
637
.24
.30
HP Required (708-3 – 3.5 GPM) Working Pressure [PSI]
Flow [GPM]
Speed [RPM]
800
1000
4
1530
2.19
2.74
3.5
1339
1.92
2.40
3
1148
1.64
2.05
2
765
1.10
1.37
(2.3)
HP Required (708-1 – 22 GPH) Working Pressure [PSI]
Flow [GPH]
Speed [RPM]
800
1000
22
718
.20
.25
21
686
.19
.24
20
653
.18
.23
19
620
.17
.22
HP Required (708-3 – 2.3 GPM) Working Pressure [PSI]
Flow [GPM]
Speed [RPM]
800
1000
2.5
1774
1.37
1.71
2.3
1632
1.26
1.58
2.0
1419
1.10
1.37
1.5
1064
.82
1.03
HP Required (708-5 – 8 GPH) Working Pressure [PSI]
Flow [GPM]
Speed [RPM]
800
1000
8
1504
4.38
5.48
7
1316
3.84
4.79
6
1128
3.29
4.11
5
940
2.74
3.42
MOUNTING THE PUMP
The pump should be located as close to the source of supply as possible. Mount the pump on a rigid, horizontal surface
allowing easy access for crankcase oil draining. The pump should also be mounted in such a way that inspection can be
done with ease.
Ensure drive belt is adequately sized for system and shaft bearings. Pulley alignment is critical to the proper operation of
the system. To check for proper alignment, place a straight-edge, square, or rule against the pulleys to make sure they
3
708 Series
High Pressure Titanium Positive Displacement Pump
are in line. Proper alignment of the drive pulleys will minimize crankshaft bearing and belt wear. Over tensioning of the
drive belt may cause pump crankshaft bearing damage.
If the pump will be in service in an environment with a high debris presence or in a humid environment, it is recommended
that the pump be enclosed. Do not store or operate in excessively high temperature areas without proper ventilation.
DISCHARGE PLUMBING
CAUTION
Start system with all valves open or with minimal flow restriction to avoid deadhead overpressure conditions and severe
damage to the pump or system. Discharge regulating devices should be at minimum pressure setting at start-up.
In installations utilizing a Pulsation Dampening device, the device should be mounted directly to the discharge line.
Consult dampening device manufacture for optimum pre-charge.
A reliable pressure gauge should be installed near the discharge outlet of the manifold. This is extremely important for
adjusting pressure-regulating devices; and when appropriate, for sizing of the nozzle or restricting orifice. The pump is
rated for a maximum pressure; this is the pressure measured at the discharge manifold of the pump.
A pressure relief or unloader valve must be installed to prevent over-pressure in the event that the discharge or downstream plumbing becomes restricted or is turned off. Severe damage to the pump will result if this condition occurs
without a relief valve in the line.
CAUTION
FAILURE TO INSTALL A SAFETY RELIEF VALVE WILL VOID THE WARRANTY ON THE PUMP.
On fittings not using o-ring seals, use PTFE liquid sparingly, or tape to connect accessories or plumbing. Do not wrap
tape beyond the last thread to prevent tape from becoming lodged in the pump or accessories. This condition will cause a
malfunction of the pump or system.
PUMPED FLUIDS
Some fluids may require a flush between operations or before storing. For pumping fluids other than water, contact your
supplier or Village Marine Tec.
CAUTION
DO NOT RUN PUMP WITH FROZEN FLUID. DO NOT RUN PUMP DRY.
STORAGE
For extended storage or between uses in cold climates, drain all pumped fluids from pump and flush with antifreeze
solution to prevent freezing and damage to the pump.
4
INLET CONDITION CHECKLIST
Review this checklist before operation of system. It is critical that all factors are carefully considered and met.
INLET SUPPLY
Inlet supply should be adequate to accommodate the maximum flow being delivered by the pump.
1. Open inlet valve and turn on supply to avoid starving the pump.
CAUTION
DO NOT RUN PUMP DRY.
2. Avoid closed loop systems, especially with high temperature, ultra-high pressure or large volumes. Conditions
vary with regulating/unloader valve.
3. Low vapor pressure fluids, such as solvents, require positive heads to assure adequate inlet supply.
4. Higher viscosity fluids require that the pump be flooded to 60 PSI to assure adequate inlet supply.
5. Higher temperature fluids tend to vaporize and require positive heads to assure adequate inlet supply.
6. When using an inlet supply reservoir, size it to provide adequate supply of fluid to accommodate 6-10 minutes
retention time at the rated GPM (however, a combination of system factors can change this requirement).
Provide adequate baffling in the tank to eliminate air bubbles and turbulence. Install diffusers on all return lines to
the tank.
INLET LINE SIZE
Inlet line size should be adequate to avoid starving the pump. Pump suction should never operate in a vacuum.
1. Line size must be sufficient to allow free flow of influent fluid at the pumping flow rate. Minimize the use of thickwalled fittings, tees, 90-degree elbows, or valves in the inlet line of the pump to reduce the risk of flow restriction,
vacuum, and cavitation.
2. The inlet line MUST be a FLEXIBLE hose, NOT a rigid pipe, and REINFORCED ON SUCTION SYSTEMS to
avoid collapsing.
3. The simpler the inlet plumbing, the less the potential for problems. It is recommended to keep the length, number
of joints, and the number of inlet accessories to a minimum.
4. Use pipe sealant as appropriate to ensure airtight positive sealing pipe joints.
INLET PRESSURE
Inlet pressure should be between flooded (zero) to 60 PSI.
1. High RPM, high temperatures, low vapor pressures, or high viscosity reduces inlet pressure. The pump may
require a pressurized inlet to maintain adequate inlet supply.
5
708 Series
High Pressure Titanium Positive Displacement Pump
2. Optimum pump performance and service life is obtained with 20 PSI (1.4 BAR) inlet pressure. With adequate
inlet plumbing, most pumps will perform with flooded suction. Maximum inlet pressure is 60 PSI (5 BAR).
3. After prolonged storage, the pump should be purged of air to facilitate priming. With the pump not running,
disconnect the discharge port and allow fluid to pass through pump, then reconnect the discharge port.
INLET ACCESSORIES
Inlet accessories are designed to protect against over pressurization, control inlet flow, contamination or temperature and
provide ease of servicing.
1. An inlet/supply shut-off valve is recommended to facilitate maintenance.
2. A standpipe can be used in some applications to help maintain a positive head in the inlet line.
3. Inspect and clean the inlet filters on a regular schedule, if applicable.
4. A vacuum/pressure gauge should be installed to monitor the inlet pressure. A gauge should be mounted as close
to the pump inlet as possible. Short term, intermittent cavitation will not register on a standard gauge.
5. All accessories should be sized to avoid restricting the inlet flow.
6. All accessories should be compatible with the solution being pumped to prevent premature failure or malfunction.
6
PREVENTIVE MAINTENANCE SCHEDULE
The Required Maintenance Schedule specifies how often you should have your pump inspected and serviced. It is
essential that your pump be serviced as scheduled to retain its high level of safety, dependability, and performance. Not
performing these tasks could result in catastrophic failure.
TASKS
DAILY
WEEKLY
FIRST
100 HRS.
EVERY
500 HRS.
EVERY
1500
HRS.
PLAN
FOR
EVERY
3000 HRS.
EVERY
10000
HRS.
INSPECTION TASKS
Clean Filters*
X
Water Leaks
X
Oil Level
X
Pulley
X
Belts
X
Inspect Plumbing
X
SERVICE TASKS
Pump Oil
Routine Service Kit
X
X
X
Crankcase Rebuild Kit
X
Manifold Rebuild Kit
X
Crankshaft Bearings
X
* If applicable for system
7
708 Series
High Pressure Titanium Positive Displacement Pump
MAINTENANCE RECORD
Keep record of all maintenance below to ensure maintenance is performed. Note trends and increase maintenance as
necessary.
HOURS**
RECOMMEND
SERVICE
100
Oil
500
Oil
1000
Oil
1500
Service Kit, Oil
2000
Oil
2500
Oil
3000
Service Kit/Full Kit*, Oil
3500
Oil
4000
Oil
4500
Service Kit, Oil
5000
Oil
5500
Oil
6000
Service Kit/Full Kit*, Oil
6500
Oil
7000
Oil
7500
Service Kit, Oil
10000
Crankshaft Bearing, Oil
ACTIONS / NOTES
ACTUAL
HOURS
SIGNATURE
DATE
*Replace HP seal only in case of failure (see low-pressure troubleshooting, pg.9). Hours are for reference only (for
maintenance planning purposes).
** Oil changes are mandatory at the specified hour intervals.
8
TROUBLESHOOTING
Use the troubleshooting table below. If problem persists, contact your dealer.
PROBLEM
PROBABLE CAUSE
SOLUTION
Low Pressure
Belt slippage
Make sure the correct belt is used. If the correct belt
is used and the belt is slipping, then tighten. Replace
belt if worn.
Leaky discharge hose
Check connections. Replace hose if worn or
cracking.
Pressure gauge inoperative or
not registering correctly.
Check pressure with new gauge and replace as
needed.
Air leak in inlet plumbing
Use PTFE liquid or tape to seal the threads. Make
certain that the PTFE does not go beyond the last
thread. Doing so may damage the pump.
Inlet suction strainer clogged or Clear the obstruction, or use adequate size for inlet
improperly sized
pump connection and fluid being pumped.
Relief valve stuck, partially
plugged or improperly sized
Clean and reset relief valve to system pressure and
correct bypass. Check supply tank for
contamination.
Worn or dirty valves
Clean valve or replace with a rebuild kit.
Worn high-pressure seals;
Replace seals with manifold rebuild kit(not service
abrasives in pump fluid, severe kit). Install and maintain proper filter, check line size
cavitation; inadequate water
and flow available to pump
supply; stressful inlet conditions.
Faulty pulsation dampener (if a
Pulsation pump runs
extremely rough, pressure low pulsation dampener has been
installed.)
Slight water leakage from
under the manifold
Excessive oil leak between
crankcase and pumping
section
Check pre-charge. Check manufacturer’s literature
on recommended pressure.
Restricted inlet, or air entering
inlet plumbing
Be sure that inlet hose is the proper size. Check
filters and clean as needed. Check fittings and use
PTFE liquid or tape for airtight connection.
Valve or spring damage
Clean or replace valve and spring, check inlet supply
tank for contamination
Seal damage
Replace seals with manifold rebuild kit(not service
kit).
Possible condensation
No fix needed.
Worn low pressure seals
Replace seals with Manifold Service Kit (not Rebuild
Kit), check inlet pressure and inspect ceramic
plunger for damage.
Worn crankcase oil seals
Replace crankcase oil seals.
9
708 Series
High Pressure Titanium Positive Displacement Pump
PROBLEM
PROBABLE CAUSE
SOLUTION
Oil leaking in the area of the
crankshaft
Worn crankshaft oil seal
Replace damaged oil seals. (Purchase crankcase
rebuild kit, not service kit)
Bad bearing
Replace bearing.
Cut or worn o-ring on bearing
case
Replace o-ring on bearing case.
Water in crankcase
Humid air condensing into water Change oil every three months or 300 hours
inside the crankcase
Worn or improperly installed
crankcase oil seals
Replace seals; follow proper installation procedure.
Excessive water leaking through Replace seals with manifold rebuild kit(not service
low pressure seals
kit).
Excessive play in the end of
the crankshaft
Worn bearing
Replace bearing.
Oil leaking in the rear portion Damaged or improperly installed Replace crankcase cover o-ring or drain-plug o-ring.
crankcase cover, crankcase
of the crankcase
cover o-ring, drain-plug, or drainplug o-ring.
Loud knocking noise in pump Pulley loose on crankshaft
Restricted Inlet
Check key and tighten setscrew.
Clear obstruction or replace valve.
Worn bearing, connecting rod or Consult supplier for crankcase servicing.
crankshaft.
Worn belts
Frequent or premature failure Running pump dry
of the seals
Abrasive material in the fluid
being pumped
Excessive temperature of
pumped fluid (120 degrees F
max.)
10
Replace belts.
NEVER RUN THE PUMP WITHOUT WATER.
Install proper filtration on pump inlet plumbing.
Reduce fluid inlet temperature to specifications.
PROBLEM
PROBABLE CAUSE
SOLUTION
Strong surging at the inlet and low
pressure
Foreign particles in the inlet or
discharge valve or worn inlet or
discharge valves
Check for smooth surfaces on inlet
and discharge valve seats. If signs of
wear or damage are present return to
factory for service.
Check supply tank for contamination,
regularly clean filter. Do not pump
abrasive fluid.
Check the Inlet Conditions Checklist.
Restricted fluid flow
11
708 Series
High Pressure Titanium Positive Displacement Pump
SERVICE
An authorized technician should perform all service.
CAUTION
Ensure pump is disconnected from the motor or any driving devices. Service the pump in a clean, dirt-free environment.
Pump rebuild kits are available for seal overhauls. Contact your dealer for ordering information.
INTRODUCTION
All tasks should be performed in a clean environment, free from dust and debris. It is imperative that utmost cleanliness
be maintained during the rebuild of your Aqua Pro Pump. The numbers following the parts are call out numbers. They
correspond to the parts on the drawings.
READ THE INSTRUCTIONS COMPLETELY BEFORE ATTEMPTING TO PERFORM ANY SERVICE.
Before assembling any parts, clean all parts to make free of oil, grease, dirt, and lint. Use a lint free cloth to wipe any part
of the pump.
NOTE
A light coating of Anti-Seize Lubricant (PN. 85-0094) should be applied on all threaded parts, unless otherwise stated.
Only silicon grease (PN. 21-1122) should be used on all o-rings and seals. Use of any other type of grease may result in
o-ring or seal failure.
TOOLS NEEDED
Table 2: Tool List for Pump Service
3/16”
1/4”
Allen Wrench
Allen Wrench
Phillips Head Screwdriver
Pick
7/16"
Socket/ Socket Wrench or Combination Wrench
Snap Ring Pliers
9/16"
Socket/ Socket Wrench or Combination Wrench
Torque Wrench (220 in.-lb.)
1/2”
Socket/ Socket Wrench or Combination Wrench
Weep Ring Removal Tool (PN 91-3827)
3/4"
Socket/ Socket Wrench or Combination Wrench
Dead Blow Hammer
7/8"
Socket/ Socket Wrench or Combination Wrench
Flat Head Screwdriver
7/8"
Combination Wrench
12
DETACHING THE MANIFOLD FROM THE CRANKCASE
You will need these tools and parts to do the following:
ƒ 9/16” Socket/ Socket Wrench (for 708-5)
ƒ 1/2” Socket/ Socket Wrench (for 708-3)
ƒ 3/16” Allen Wrench (for 708-1)
ƒ Dead Blow Hammer
Remove the two manifold bolts (58) with a 9/16” socket wrench for the 708-5, with a 1/2” socket wrench for the 708-3, or
the 4 socket head bolts with the 3/16” Allen wrench for the 708-1. Loosen the manifold assembly by lightly tapping off the
manifold using the dead blow hammer, as seen in Fig. 2. Tap the manifold from both sides to apply even force to the
manifold. Failing to do so can result in damage to the Ceramic Plungers. Set the manifold assembly aside in a clean work
area. If the manifold assembly locating dowel pins (53) fall out, reinsert them into the manifold alignment pin holes.
Fig. 2: Manifold Assembly Removal
ROUTINE SERVICE KIT
The following are the part numbers for the 708 Series Routine Service Kits.
708-1 Routine Service Kit (PN. 70-6181).
708-3, 2.3 Routine Service Kit (PN. 70-6182).
708-3, 3.5 Routine Service Kit (PN. 70-6183).
708-5 Routine Service Kit (PN. 70-6184).
The Manifold Assembly must be detached from the crankcase to do the following service.
VALVE ASSEMBLY ROUTINE SERVICE
You will need these tools and parts to do the following:
ƒ 7/8" Socket Wrench or Combination Wrench
ƒ Pick
ƒ Spring, Valve (45): PN. 70-6003
ƒ Valve, Standard, 708 Series (44): PN. 70-6093 (For 708-1 & 708-3 2.3)
ƒ Assembly, Valve, Heavy Duty, 708 Series (44): PN. 70-6104 (For 708-3 3.5 & 708-5)
ƒ O-Ring, Valve Plug (46): PN. 70-6002
ƒ Silicone Grease Lubricant: PN. 21-1122
ƒ Anti-Seize Lubricant: PN. 85-0094
ƒ Lint-Free Cloths
13
708 Series
High Pressure Titanium Positive Displacement Pump
When the manifold assembly has been removed from the crankcase assembly, place the assembly on a clean work
surface. Remove all of the valve plug assemblies from the manifold assembly using a 7/8” socket wrench or combination
wrench. Remove the valve (44) from the assembly, followed by the valve spring (45). With the aide of a pick remove the
o-ring (46) from the valve plug.
NOTE
Valve plugs (47) will be reused.
A light coating of silicon grease (PN. 21-1122) should be used on all new o-rings and seals.
Use of any other type of grease may result in o-ring or seal failure.
Clean and inspect all valve plugs (47) prior to reassembling. If there is a problem, contact your dealer. Once all valve
plugs (47) are clean and dry, install new valve plug o-ring (46) onto valve plug (47). Install the valve spring (45) onto the
valve plug (47), it should now be attached to the plug. Press the valve (44) onto the valve spring (45). Complete valve
assembly shown in Fig. 3.
Fig. 3: Valve Assembly
(NOTE: There are two different valve plug designs)
NOTE
A light coating of Anti-Seize Lubricant (PN. 85-0094) should be applied on all threaded parts, unless otherwise stated.
Inspect the manifold (38) for debris or other fouling and clean if necessary. Inspect the valve seat surface in the manifold.
If there is a problem contact your dealer. Reinstall all the valve plug assemblies with a 7/8" socket wrench or combination
wrench and tighten.
MANIFOLD SEAL ROUTINE SERVICE
NOTE
Pump manifold assembly must be detached from the crankcase assembly to service the seals.
You will need these tools and parts to do the following:
ƒ Flat screw driver
ƒ Seal, LP (45): PN. 70-6009
ƒ Silicone Grease Lubricant: PN. 21-1122
ƒ Lint-Free Cloths
14
For manifold seal servicing purposes the manifold must be placed with the valve plugs sitting on a flat surface and the
plunger bores facing upward. This will facilitate service technician access to the seals for removal and installation, as
shown in Fig. 4.
Fig. 4: Orientation for Manifold Seal Servicing
A light coating of silicon grease (PN. 21-1122) should be used on all new o-rings and seals.
Use of any other type of grease may result in o-ring or seal failure.
With a flat screw driver remove the low-pressure seal (43). Ensure that the low-pressure seal spacer (39) was not
accidentally removed when the low-pressure seal was removed and press in the new low-pressure seal (43).
CRANKCASE SEAL ROUTINE SERVICE
Remove the seal retainer (29) and set aside. Remove the plunger retainer bolt (28) with a 7/16” wrench, set aside. There
is no need to remove the plunger retainer washer (28) or plunger retainer o-rings (27) from the plunger retainer bolt (28).
Remove the ceramic plunger (26). Remove the slinger (25) and the outer washer (6). With the aid of the pick remove the
plunger rod oil seal (7) from the crankcase. Inspect the seal retainer washers (8) for damage, if none evident then reuse,
if damage is evident consult the factory.
A light coating of silicon grease (PN. 21-1122) should be used on all new o-rings and seals.
Use of any other type of grease may result in o-ring or seal failure.
Insert new plunger rod oil seal (7) into crankcase making sure that the seal is fully seated, place outer washer (6) on seal.
Place slinger (25) onto the plunger rod (9).
NOTE
Examine the ceramic plungers (26) for cracks, heavy scoring, or unusual wear. If there is a problem, contact your dealer.
Slide ceramic plungers (26) onto plunger rod and insert the plunger retainer washer (28) into the plunger. Clean the
plunger retaining bolt’s (29) threaded area. If they were removed replace the o-rings (27) onto the plunger retainer (29).
Slide the plunger retaining washer (28) onto the plunger retainer (29).
15
708 Series
High Pressure Titanium Positive Displacement Pump
Fig. 5: Plunger Retaining Bolt Assembly
Apply Red Loctite # 262 to retainer bolt (29) threads. Reinstall the plunger retainer bolt (29) and torque to 100 in. lb. using
a 7/16” socket.
NOTE
Be CAREFUL not to get the red loctite on any other components.
Apply Aqua Pro’s special Ceramic Lubricant (PN. 90-1604) to the ceramic plungers (26). Slide the seal retainer over the
ceramic plungers (26). Make sure that the flanged side is close proximity to the manifold assembly, and that hole is
oriented downward ensuring that the seal retainer has adequate water drainage.
Fig. 6: Seal Retainer
Routine service is now complete.
16
SERVICING THE CRANKCASE
The following are the procedures for servicing the crankcase assembly using the
708-1 Crankcase Rebuild Kit (PN. 70-6113).
708-3 Crankcase Rebuild Kit (PN. 70-6112).
708-5 Crankcase Rebuild Kit (PN. 70-6107).
The manifold assembly must be detached from the crankcase to do the following service.
OIL DRAIN PLUG O-RING REPLACEMENT
You will need these tools and parts to do the following:
ƒ 7/8” Socket/ Socket Wrench
ƒ Pick
ƒ O-Ring, Drain Plug (4): PN. 30-1286
ƒ Anti-Seize Lubricant: PN. 85-0094
ƒ Silicon Grease Lubricant: PN. 21-1122
Remove the oil drain plug with a 7/8” wrench and drain the crankcase oil. Clean the drain plug (5), remove the o-ring (4)
with the aide of the pick if necessary. Replace with the new one supplied in the kit. Apply anti-seize lube to the threads of
the drain plug (5) and reinstall.
PLUNGER ROD SEAL REPLACEMENT
You will need these tools and parts to do the following:
ƒ 7/16” Socket/ Socket Wrench
ƒ Torque Wrench
ƒ Seal, Oil, Plunger Rod (7): PN. 70-6018
ƒ Washer, Plunger Retainer (27): PN. 70-6035
ƒ O-Ring, Plunger Retainer (26): PN. 70-6012
ƒ Slinger Barrier (24): PN. 70-6015
ƒ Ceramic Lubricant: PN. 85-0087
ƒ Silicone Grease Lubricant: PN. 21-1122
ƒ Red Loctite # 262
ƒ Lint-free Cloths
Remove the seal retainer (29) and set aside. Remove the plunger retainer bolt (28) with a 7/16” wrench, set aside.
Remove the plunger retainer washer (28) and remove the ceramic plunger (26). Remove the slinger (25) and the outer
washer (6). With the aide of the pick remove the plunger rod oil seal (7) from the crankcase. Inspect the seal retainer
washers (8) for damage, if none evident then reuse, if damage is evident consult the factory.
NOTE
A light coating of silicon grease (PN. 21-1122) should be used on all new o-rings and seals.
Use of any other type of grease may result in o-ring or seal failure.
Insert new plunger rod oil seal (7) into crankcase making sure that the seal is fully seated, place outer washer (6) on seal.
Place slinger (25) onto the plunger rod (9).
17
708 Series
High Pressure Titanium Positive Displacement Pump
NOTE
Examine the ceramic plungers (26) for cracks, heavy scoring, or unusual wear. If there is a problem, contact your dealer.
Slide ceramic plungers (26) onto plunger rod and insert the plunger retainer washer (28) into the plunger. Clean the
plunger retaining bolts (29). With the aide of a pick, remove the plunger retainer o-ring (27). Replace the o-ring (27) with
the new one supplied in the kit as shown in Fig. 6. Slide the plunger retaining washer (28) onto the plunger retainer (29).
Fig. 5: Plunger Retaining Bolt Assembly
Apply Red Loctite # 262 to retainer bolt (29) threads. Reinstall the plunger retainer bolt (29) and torque to 100 in. lb. using
a 7/16” socket.
NOTE
Be CAREFUL not to get the red loctite on any other components.
Apply Aqua Pro’s special Ceramic Lubricant (PN. 90-1604) to the ceramic plungers (26). Slide the seal retainer over the
ceramic plungers (26). Make sure that the flanged side is close proximity to the manifold assembly, and that hole is
oriented downward ensuring that the seal retainer has adequate water drainage.
Fig. 6: Seal Retainer
BEARING SIDE PLATE O-RING/SEAL REPLACEMENT
You will need these tools and parts to do the following:
ƒ 3/16" Allen Wrench
ƒ Philips Head Screw Driver
18
ƒ
ƒ
ƒ
ƒ
ƒ
ƒ
Pick
Seal, Oil, Crankshaft (18): PN. 70-6038 (708-1, 708-3) 70-6061 (708-5)
O-Ring, Bearing Side Plate (15): PN. 70-6039
O-Ring, Sight Glass (22): 70-6082
Silicon Grease Lubricant: PN. 21-1122
Anti-Seize Lubricant: PN. 85-0094
Remove the 4 socket head cap screws (19) with a 3/16” Allen Wrench from each of bearing side plate (16), (17), this
applies to the 708-1, 708-3 3.5 GPM, and the 708-5 pumps. With the aide of a pick remove the o-rings from the grooves,
remove the crankshaft oil seal (18) from the pulley side bearing cap (17).
For 708-3 2.3 GPM pumps with direct drive, uncouple the pump from the motor. Remove the 4 Philips head screws (36)
holding the bell housing (34) to the pump. Now remove the bearing side plate (17), o-rings and seal can now be replaced.
Remove the sight glass retainer (24) from the bearing side plate (16). With the aide of a pick remove the sight glass
o-ring (22). Replace o-ring with the one provided in the kit.
CAUTION
Crankshaft oil seal is press fit at the factory, care is to be exercised during removal so damage does not occur to sealing
surface.
NOTE
A light coating of silicon grease (PN. 21-1122) should be used on all new o-rings and seals.
Use of any other type of grease may result in o-ring or seal failure.
Press new crankshaft oil seal (18) into pulley side bearing cap (17), Install o-ring (15) in o-ring groove on the crankshaft
bearing caps (16), (17) and reinstall caps on pump.
NOTE
A light coating of Anti-Seize Lubricant (PN. 85-0094) should be applied on all threaded parts, unless otherwise stated.
Install the 4 socket head cap screws (19) onto each of the bearing side plates and tighten with a 1/4” Allen Wrench. This
applies to the 708-1, 708-3 3.5 GPM, and the 708-5 pumps. For the 708-3 2.3 GPM pump, reinstall the bell housing (34)
by installing the 4 Philips head screws (36).
CRANKCASE COVER O-RING REPLACEMENT
In this procedure you will replace the o-rings on the crankcase cover as provided in the rebuild kit.
You will need these tools and parts to do the following:
ƒ 3/16” Allen Wrench
ƒ Phillips Head Screwdriver
ƒ Pick
ƒ Silicone Grease Lubricant: PN. 21-1122
ƒ Red Loctite # 262
ƒ Anti-Seize Lubricant: PN. 85-0094
19
708 Series
High Pressure Titanium Positive Displacement Pump
Unscrew the crankcase cover screws (19) with the 3/16” Allen wrench. With the aide of the pick remove the crankcase
cover o-ring (20).
NOTE
A light coating of silicon grease (PN. 21-1122) should be used on all new o-rings and seals.
Use of any other type of grease may result in o-ring or seal failure.
Install the new crankcase cover o-ring (20) provided with the rebuild kit.
NOTE
A light coating of Anti-Seize Lubricant (PN. 85-0094) should be applied on all threaded parts, unless otherwise stated.
Reinstall the crankcase cover and tighten the crankcase cover screws (19) with the 3/16” Allen wrench.
CRANKSHAFT BEARING, CONNECTING ROD-PISTON ASSEMBLY SERVICE
It is recommended that any service to the crankshaft bearings (16) or to the connecting rod-piston assembly be done by
the factory. Due to the high precision required only factory trained personnel are recommended for this service.
Performing any maintenance other than rebuild and service kits voids the warranty if not performed by factory trained
personnel.
SERVICING THE MANIFOLD
The following are the procedures for servicing the crankcase assembly using the
708-1 Manifold Rebuild Kit (PN. 70-6079).
708-3 2.3 GPM Manifold Rebuild Kit (PN. 70-6110).
708-3 3.5 GPM Manifold Rebuild Kit (PN. 70-6111).
708-5 Manifold Rebuild Kit (PN. 70-6105). 8 GPM Pump Manufactured After Feb 2002
708-5 Manifold Rebuild Kit (PN. 70-6108). 7 GPM Pump Manufactured Before Aug 2002
The manifold assembly must be detached from the crankcase to do the following service.
20
Fig. 7: Manifold Assembly
INLET/DISCHARGE ADAPTER O-RING REPLACEMENT 708-3 & 708-5
You will need these tools and parts to do the following:
ƒ 3/4” Socket/ Socket Wrench
ƒ Pick
ƒ O-Ring, Discharge Plug Adapter (48): PN. 30-1286
ƒ Silicone Grease Lubricant: PN. 21-1122
ƒ Anti-Seize Lubricant: PN. 85-0094
Remove the Discharge/Plug (50) and (49) adapters from the manifold assembly with the 3/4” Socket/ Socket Wrench.
With the aide of a pick remove the o-rings (48) from each of the adapters.
NOTE
A light coating of silicon grease (PN. 21-1122) should be used on all new o-rings and seals.
Use of any other type of grease may result in o-ring or seal failure.
Install the new o-rings (48) provided with the kit onto each of the adapters.
NOTE
A light coating of Anti-Seize Lubricant (PN. 85-0094) should be applied on all threaded parts, unless otherwise stated.
Reinstall each of the adapters onto the manifold assembly, tighten adapter with 3/4” Socket/ Socket Wrench.
VALVE ASSEMBLY SERVICING
You will need these tools and parts to do the following:
ƒ 7/8" Socket Wrench or Combination Wrench
ƒ Pick
21
708 Series
High Pressure Titanium Positive Displacement Pump
ƒ
ƒ
ƒ
ƒ
ƒ
ƒ
Spring, Valve (45): PN. 70-6003
Valve (44): PN. 70-6093
O-Ring, Valve Plug (46): PN. 70-6002
Silicone Grease Lubricant: PN. 21-1122
Anti-Seize Lubricant: PN. 85-0094
Lint-Free Cloths
NOTE
Valves may be serviced while the manifold assembly is attached to the crankcase assembly.
If manifold assembly has been removed from the crankcase assembly, place the assembly on a clean work surface.
Remove all of the valve plug assemblies from the manifold assembly using a 7/8” socket wrench or combination wrench.
Remove the valve (44) from the assembly, followed by the valve spring (45). With the aide of a pick remove the o-ring
(46) from the valve plug.
NOTE
Valve plugs (47) will be reused.
A light coating of silicon grease (PN. 21-1122) should be used on all new o-rings and seals.
Use of any other type of grease may result in o-ring or seal failure.
Clean and inspect all valve plugs (47) prior to reassembly. If there is a problem, contact your dealer. Once all valve plugs
(47) are clean and dry, install new valve plug o-ring (46) onto valve plug (47). Install the valve spring (45) onto the valve
plug (47), it should now be attached to the plug. Press the valve (44) onto the valve spring (45). Complete valve
assembly shown in Fig. 9.
Fig. 8: Valve Assembly
(NOTE: There are two different valve plug designs)
NOTE
A light coating of Anti-Seize Lubricant (PN. 85-0094) should be applied on all threaded parts, unless otherwise stated.
Inspect the manifold (38) for debris or other fouling and clean if necessary. Inspect the valve seat surface in the manifold.
If there is a problem contact your dealer. Reinstall all the valve plug assemblies with a 7/8" socket wrench or combination
wrench and tighten.
22
MANIFOLD SEAL SERVICING
NOTE
Pump manifold assembly must be detached from the crankcase assembly to service the seals.
You will need these tools and parts to do the following:
ƒ Snap Ring Pliers
ƒ Tool, Weep Ring Puller, 708 Series: PN. 91-3827
ƒ Flat screw driver
ƒ Seal, HP (40): PN. 70-0071
ƒ Ring, Snap (42): PN. 70-6010
ƒ Assembly, Weep Ring (41): PN. 70-3018
ƒ Seal, LP (43): PN. 70-6009
ƒ Silicone Grease Lubricant: PN. 21-1122
ƒ Lint-Free Cloths
For manifold seal servicing purposes the manifold must be placed with the valve plugs sitting on a flat surface and the
plunger bores facing upward. This will facilitate service technician access to the seals for removal and installation, as
shown in Fig. 10.
Fig. 9: Orientation for Manifold Seal Servicing
With a flat screw driver remove the low-pressure seal (43). Manually remove the low-pressure seal spacer (39). With the
snap ring pliers remove the snap ring (42). Using the weep ring extracting tool remove the weep ring assembly (41) as
shown in Fig. 11.
NOTE
Extraction of the rings is accomplished by inserting tool in relaxed state into the inner diameter of the rings, then tighten
the expansion bolt to grip the ring. Install the extraction stand and nut, tightening nut will extract to weep ring and isolating
ring from manifold.
23
708 Series
High Pressure Titanium Positive Displacement Pump
Fig. 10: Weep Ring Extraction
With a flat screwdriver remove the high-pressure seals (40). Manually remove the high-pressure seal spacer (40).
You must clean and inspect the following parts for re-use:
• Spacer, High-Pressure Seal (39): PN. 70-6016
• Spacer, Low-Pressure Seal (39): PN. 70-6016
Insert the high-pressure seal spacer (39) into the bore.
NOTE
A light coating of silicon grease (PN. 21-1122) should be used on all new o-rings and seals.
Use of any other type of grease may result in o-ring or seal failure.
Insert the high-pressure seal (40) into the bore until the seal is fully seated on the high-pressure seal spacer (39).
Insert the weep ring (41) into the bore after the installation of the high-pressure seals (39). Install the snap ring (42) using
the snap ring pliers.
NOTE
Ensure that the snap ring (42) is fully seated in the snap ring groove before continuing.
Insert the low-pressure seal spacer (39) and press in the new low-pressure seal (43). The manifold seal servicing is
complete.
ATTACHING THE MANIFOLD TO THE CRANKCASE
You will need these tools and parts to do the following:
ƒ 9/16” Socket/ Socket Wrench (for 708-5)
ƒ 1/2” Socket/ Socket Wrench (for 708-3)
ƒ 3/16” Allen Wrench (for 708-1)
ƒ Dead Blow Hammer
ƒ Dead Blow Hammer
ƒ Manifold Bolt (58): PN. 70-6055 (for 708-5)
ƒ Manifold Bolt (58): PN. 70-6008 (for 708-3)
ƒ Manifold Screw (58): PN. 70-6046 (for 708-1)
ƒ Ceramic Lubricant: PN. 85-0087
ƒ Anti-Seize Lubricant: PN. 85-0094
24
If a crankcase seal rebuild was not performed at this time then ensure that the dowel locating pins (53) are pressed into
their corresponding hole. Ensure that ceramic lubricant is applied to the ceramic plunger assemblies and that the seal
retainers are installed with the flange located away from the crankcase assembly.
NOTE
A light coating of Anti-Seize Lubricant (PN. 85-0094) should be applied on all threaded parts, unless otherwise stated.
Align manifold assembly to crankcase assembly and tighten the two manifold bolts (58) with a 9/16” socket wrench for the
708-5, with a 1/2” socket wrench for the 708-3, or the 4 socket head bolts with the 3/16” Allen wrench for the 708-1.
25
708 Series
High Pressure Titanium Positive Displacement Pump
26
708-1 DRAWINGS
A
B
C
D
7
6
PART
NUMBER
ITEM
8
70-6046
70-6121
70-6131
70-6130
70-6129
72
71
70
70
70
7
DESCRIPTION
SCREW, .25-20UNC-2A SHC X 2.50
ASSEMBLY, 708-1 MANIFOLD
ASSEMBLY, 708-1 CRANKCASE
ASSEMBLY, 708-1 CRANKCASE
ASSEMBLY, 708-1 CRANKCASE
6
4
1
1
QTY
708-1
200 GPD
NOTES:
1: ASSEMBLY PART NUMBERS ARE AS FOLLOWS:
70-6073 PUMP, 708-1, .200 CRANKSHAFT
70-6074 PUMP, 708-1, .300 CRANKSHAFT
70-6075 PUMP, 708-1, .400 CRANKSHAFT
2. APPLY A LAYER OF GRAPHITE ANTISEIZE 85-0094
ON THREADS OF ITEM # 72 BEFORE MOUNTING.
8
1
QTY
708-1
300 GPD
4
1
4
1
1
QTY
708-1
400 GPD
5
5
4
4
70
3
3
2
C
REV.
A
B
71
2
1
SHT
REVISION
STATUS OF
SHEETS
DATE: 05-27-05 B CHAIDEZ
1
SHEET 1 OF 3
ASSEMBLY, 708-1 MAIN
REV
REV
C
C
TH TQD GA
TH TQD
APPROVED
BC
B
2
C
3
B
1/10/2013
DATE
5/27/05
4/21/10
11/15/12
1
SIZE TITLE
72
REVISIONS
DESCRIPTION
INITIAL RELEASE
SHEETS 2 AND 3 HAVE BEEN REVISED
ADD PULLEY, SEE SHT 2
PER ECO-0031589: ADD NOTE 2; RENUMBER
PARTS LIST; REVISE P2, P3 - AS NOTED ON SHEETS
2
A
B
C
D
A
B
C
D
8
7
6
5
7
DESCRIPTION
PART
NUMBER
ITEM
8
SILICONE GREASE
ANTISIEZE, NM.91
LOCKTITE 262, THREAD LOCKER
NOT USED
NOT USED
CRANKSHAFT,708-1,.200
PULLEY
SPACER,CRANKSHAFT,708-1
PLUG, CRANKCASE
RETAINER,SEAL,708-1/3 SERIES
WASHER, PLUNGER RETAINER, 708 SERIES
BOLT, PLUNGER RETAINER, 708 SERIES
O-RING, PLUNGER RETAINER
PLUNGER, 708 SERIES
SLINGER, PLUNGER, 708 SERIES
RETAINER, SIGHTGLASS
SIGHTGLASS, OIL
O-RING, OIL SIGHTGLASS
COVER, CRANKCASE, 708-1
O-RING, REAR COVER, 708-1
CAPSCREW, SKT HD, .25-20UNC-2A, .75, 316 CRES
SEAL, OIL, CRANKSHAFT, 708-1/3
CAP, PULLEY BEARING, 708 SERIES
CAP, GUIDE BEARING, 708 SERIES
O-RING, BEARING CAP
BEARING, CRANKSHAFT, 708-1/3
RING, SNAP, 708 SERIES
CRANKSHAFT, 708-1, 29 GPH (.4" STROKE)
CRANKSHAFT, 708-1, 22 GPH (.3" STROKE)
ASSY, CONNECTING ROD, 708 SERIES
PIN, DOWEL, M9, 22, STL
PLUNGER, 708 SERIES
WASHER, OIL SEAL, INNER, 708 SERIES
SEAL, OIL, 708 SERIES
WASHER, OIL SEAL, OUTER, 708 SERIES
PLUG, MS18829-08
O-RING, PLUG, OIL DRAIN
CAP, OIL FILLER, PUMP, 708 SERIES
O-RING, OIL FILLER CAP
CRANKCASE,708-1,AL
21-1122
85-0087
90-0225
70-6050
70-0597
70-0031
30-1106
70-6014
70-6035
70-6011
70-6012
70-6013
70-6015
70-6043
70-6044
70-6082
70-6049
70-6048
86-0151
70-6038
70-6041
70-6042
70-6039
70-6037
70-1281
70-6052
70-6051
70-6033
70-0382
70-6067
70-6019
70-6018
70-6017
70-0696
30-1286
70-6030
70-6029
70-6045
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
12
11
10
9
8
7
6
5
4
3
2
1
AR
1
2
2
1
1
2
1
1
1
1
1
1
1
12
1
1
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
AR
1
2
2
1
1
2
1
1
1
1
1
1
1
12
1
1
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
-
2
1
1
1
2
-
1
1
1
-
1
1
-
6
5
QTY
QTY
QTY .200 QTY .300 QTY .400 REBUILD
SERVICE
STROKE STROKE STROKE
KIT
KIT
(70-6129) (70-6130) (70-6131) (70-6113)
(70-6181)
AR
1
1
2
2
1
1
1
2
1
1
1
1
1
1
1
12
1
1
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
NOTES:
1) ASSEMBLY PART NUMBERS ARE AS FOLLOWS:
70-6129 ASSY, CRANKCASE, 708-1, .200 CRANKSHAFT
70-6130 ASSY, CRANKCASE, 708-1, .300 CRANKSHAFT
70-6131 ASSY, CRANKCASE, 708-1, .400 CRANKSHAFT
70-6113 KIT, REBUILD, CRANKCASE, 708-1
70-6181 KIT, ROUTINE SERVICE, 708-1
2) PART NUMBER 85-0087 AND 21-1122 ARE NOT SHOWN IN DRAWING
3) ITEMS 9,10 AND 11 MAY BE PURCHASE UNDER THE FOLLOWING PART NUMBER:
70-6128 ASSY, DRIVE , 708 SERIES PUMPS
4) PUMP CRANKSHAFTS ARE STAMPED WITH A NUMBER 2, 3, OR 4 ON THE END THIS
DENOTES THE OFFSET OF THE CRANKSHAFT STROKE. SEE DESCRIPTION FOR ITEM (12).
5
33
19
4
17
4
4
21
15
39
18
20
34
14
32
12X TORQUE
TO 50 IN-LBS
3
3
11
10
2
DATE
1
APPROVED
3
31
1
25
2
39
22
27
6
26
1
SHEET 2 OF 3
C
REV
TORQUE TO
55 IN-LBS
30
ASSEMBLY, 708-1 CRANKCASE
24
7
28
37
DATE: 05-26-05 B CHAIDEZ
B
8
29
23
SIZE TITLE
39
16
27
39
INITIAL RELEASE
5/26/05
BC
MODIFIED BOM QTY TITLE, NOTE INCLUDES ITEMS NOT IN 3/26/10
CC
BOM TABLE
ADD ITEM 32 & 33, PART 34 WAS PART 37
11/15/12 TH TQD
ADD PART 33 TO SHEET 2
PER ECO-0031589: ADD ITEM 37 - THREAD LOCKER:
1/10/13 TH TQD GA
ADD ITEMS 37 & 39 BALLOONS; ADD: TORQUES
2X TORQUE
TO 95 IN-LBS
37
9
13
39
C
B
A
-
REV.
REVISIONS
DESCRIPTION
2
A
B
C
D
A
B
C
D
7
6
PART NUMBER
ITEM
8
21-1122
85-0094
70-3018
30-0453
30-0946
70-6087
70-6001
70-6002
70-6003
70-6093
70-6009
70-6010
70-0071
70-6016
70-6047
7
DESCRIPTION
SILICONE GREASE
ANTISIEZE, GRAPHITE, FOOD GRADE
ASSY, WEEP RING, 708 SERIES
ADAPTER, LP INLET, 708-1
ADAPTER, HP DISCHARGE, 708-1
PIN, MANIFOLD, 708 SERIES
PLUG,VALVE,STANDARD,708 SERIES
O-RING, OIL DRAIN/VALVE PLUG
SPRING, VALVE, 708 SERIES
VALVE, 708 SERIES
SEAL, LP, 708 SERIES
RING, SNAP, 708 SERIES
SEAL, HP, 708 SERIES
RING, SPACER, SEAL, 708 SERIES
MANIFOLD, 708-1
6
1
1
1
1
2
2
2
2
2
2
1
1
1
1
2
QTY
QTY
QTY
REBUILD SERVICE
(70-6121)
KIT
KIT
(70-6079) (70-6181)
1
1
1
2
2
2
2
2
1
1
1
2
1
APPLY A LAYER OF GRAPHITE ANTISEIZE ITEM 64 (OR P/N 90-0928) TO
ALL CONTACT THREADS OF ITEMS 58 & 60 BEFORE MOUNTING.
4
65
64
63
62
60
59
58
57
56
55
54
53
52
51
50
APPLY A THIN LAYER OF SILICONE GREASE ITEM 65 (21-0022) TO ALL O-RINGS.
3
NOTES:
1) ASSEMBLY PART NUMBERS ARE AS FOLLOWS:
70-6121 ASSY, MANIFOLD, 708-1
70-6079 KIT, REBUILD, MANIFOLD, 708-1
70-6181 KIT, SERVICE KIT, 708-1
2) PART NO. 8500087 AND 21-0022 ARE NOT SHOWN IN DRAWING.
8
5
5
59
54
4
51
53
62
4
63
52
4 58
51
3
50
3
55
56
4
60
55
2
B
1
SHEET 3 OF 3
ASSEMBLY, 708-1 MANIFOLD
REV
GH TQD GA
APPROVED
BC
CC
B
4
1/10/13
DATE
5/27/05
3/26/10
1
SIZE TITLE
3
58
DATE: 05-27-05 B CHAIDEZ
56
57
PER ECO-0031589: DEL: NOTE 2; ADD: NOTES 3,4; RENUMBER P/LIST.
B
57 3
REVISIONS
DESCRIPTION
INITIAL RELEASE
MODIFIED BOM QTY TITLE, NOTE INCLUDES ITEMS NOT IN BOM TABLE
2
REV.
A
A
B
C
D
AquaPro® Sea Water
RO Membranes
Contact Information:
Parker Hannifin Corporation
Filtration Group-Parker Village Marine
2630 E. El Presidio Street
Carson, CA 90810
Toll free: 1800 C-Parker
Phone: 310 608 5600
Fax: 310 608 5692
Email sales:
waterpurification@parker.com
Tech support:
watertech@parker.com
www.villagemarine.com
www.parker.com/watermakers
AquaPro® thin film composite
reverse osmosis membranes
deliver high salt rejection while
maintaining high production
rates to obtain the energy
efficiency demanded by plant
operators.
By selecting the highest grade of
materials and thoroughly testing
performance, Racor Village
Marine is able to offer the highest
quality products.
Aqua Pro® membranes are
designed for use in Racor Village
Marine pressure vessel housings
as well as other brand housings.
AquaPro®
Sea Water RO
Membranes
•
•
•
Recommended
Operating Limits:
•
Maximum Operating
Pressure: 1000 psi
Maximum Operating
Temperature: 113°F (45°C)
Maximum Feed Turbidity:
1 NTU
Free Chlorine Tolerance:
0 PPM
•
Maximum Feed Silt Density
Index: SDI 5
pH Range:
Continuous Operation: 4-11
Short-term for Cleaning:
(30 minute duration) 2.5-11
•
A
B
TYP
D C
15°
VMT
Part No.
Nominal
Size
Product Flow
GPD m3/day
Typical Salt
Rejection %
33-2519
33-3000 **
33-3001**
33-0238
33-3002**
33-0440
33-0036
33-0840
2519
2519
2519
2538
2538
4040
6040
8040
220 - 0.83
150 - 0.57
105 - 0.40
550 - 2.08
210 - 0.80
1200 - 4.54
2500 - 9.47
7250-27.36
99.4
99.0
99.0
99.4
99.0
99.4
99.4
99.4
Dimensions
inches/cm
A*
19/48
19/48
19/48
38/96.5
38/96.5
40/101.6
40/101.6
40/101.6
B
1.1/2.8
1.1/2.8
1.1/2.8
1.1/2.8
1.1/2.8
1.0/2.5
1.27/3.2
0
C
0.75/1.9
0.75/1.9
0.75/1.9
0.75/1.9
0.75/1.9
0.75/1.9
1.5/3.8
1.125/29
D
2.4/6.1
2.4/6.1
2.4/6.1
2.4/6.1
2.4/6.1
3.96/10.1
5.98/15.2
7.9/201
* All 19” and 38” elements come with a 2” removable extender so that the stocked size also fits 21” and 40” housings
** Elements are specially designed for low feed flow applications. Use only with certain Sea Quencher and Little Wonder
watermakers.
Notes:
• Keep elements moist at all
times
• Permeate obtained from first
two hours of operation should
be discarded
• To prevent biological growth
during storage, shipping,
or system shutdowns it is
recommended that elements
be immersed in a protective
solution. The standard
solution for long or short term
storage should contain 1.0
percent (by weight) sodium
metabisulfite (available as
VMT p/n 85-0103, 85-0038,
85-0044 or 85-0049)
• Standardized test conditions
are 32,000 ppm NaCl at 77°
F (25° C), with 800 psi feed.
Production rates for individual
elements may vary +/- 20% and
rejection may vary +/- 0.4%
To maintain peak performance always use genuine Parker-Racor/Village Marine Tec. replacement parts.
We reserve the right to change our specifications or standards without notice.
© 2016 Parker Hannifin Corporation
Print Reorder Number 7897 Rev-C
02-17-2016
Pressure Vessel
Assemblies
For Seawater Elements
Contact Information:
Key Features:
Parker Hannifin Corporation
Filtration Group-Parker Village Marine
2630 E. El Presidio Street
Carson, CA 90810
Parker Village Marine RO
membrane pressure vessels
feature non-metallic wetted
surfaces for excellent
corrosion resistance.
Simple end plug design allows
quick removal for element
servicing.
If the size you require is not
shown please contact us for
custom builds.
Toll free: 1800 C-Parker
Phone: 310 608 5600
Fax: 310 608 5692
Email sales:
waterpurification@parker.com
Tech support:
watertech@parker.com
www.villagemarine.com
www.parker.com/watermakers
•
•
•
•
•
•
Operating Pressure:
1000 psi/68 bar
Shell: Filament Wound fiberglass
Collars: 6061 T-6 Powdercoated
aluminum
End Plugs: Thermoplastic
End Ring:
6061 T-6 Anodized aluminum on
2.5” and 4” size
SS316 on 6” size
Fasteners: SS316
Pressure Vessel
Assemblies
For Seawater Elements
7
2
3
4
5
6
1
Part Numbers:
Item
Description
1
Vessel Assembly**
2
Product O-ring
3
Quantity per
Assembly
2.5” x 19”
2.5” x 38”
4” x 40”
6” x 40”
32-2519
32-2537*
32-0444
32-6040
4
32-2116
32-2116
32-2116
32-2229
End Plug O-ring
2
32-2228
32-2228
32-4342
32-0640
4
End Plug
2
32-2513*
32-2513*
32-4012
32-6012
5
End Ring
2
32-4013
32-4013
32-4014
32-0096
6
Capscrews
***
86-0106
86-0106
86-0123
86-0136
1
1
32-0025
32-0098
32-0026
32-0099
Please Call
32-4001
Please Call
32-0001
5/2
7/3
22/10
45/20
7
Shell
White
Gray
Weight (lbs/kg)
Notes:
*End Plug 32-2517 is also available for 2.5”
vessels, which offers straight, coarse thread
feed/reject port used on some VMT PW
watermakers. Use of coarse thread end plug
changes the vessel assembly p/n to 32-2538
**Membrane not included.
For applicable membrane elements
see bulletin No. 7897 (Aqua Pro RO
Membranes)
*** Capscrews:
Order 6 per end plug on 2.5” size
Order 8 per end plug on 4” size
Order 10 per en plug on 6” size
To maintain peak performance always use genuine Parker-Racor/Village Marine Tec. replacement parts.
We reserve the right to change our specifications or standards without notice.
© 2016 Parker Hannifin Corporation
Print Reorder Number 7898 Rev-B
02-17-2016
Pleated Filters and
Filter Cartridge Kits
Contact Information:
The Village Marine Tec. line of pleated
filters are designed specifically for
the RO watermaker industry and
Parker Hannifin Corporation
Filtration Group-Parker Village Marine are superior to wound or polyspun
cartridges to give you a longer filter
2630 E. El Presidio Street
life as well as increasing flow rates and
Carson, CA 90810
keeping cartridge size down.
Toll free: 1800 C-Parker
Available in a wide arrange of sizes
Phone: 310 608 5600
and micron ranges to ensure that every
Fax: 310 608 5692
type of watermaker filter need is taken
Email sales:
care of. Stock sizes fit most standard
waterpurification@parker.com
filter housings, if the size you need is
Tech support:
not shown please contact us with the
watertech@parker.com
dimensions required.
www.villagemarine.com
www.parker.com/watermakers
Single use Cleaning and Preservative
Cartridge Kits are designed specifically
for small RO Systems. The Cartridges
allow for easy and effective membrane
maintenance.
The Cleaning and Preservative
Cartridge Kits eliminate the trouble
and mess of measuring powdered
chemicals and ensuring correct
chemical concentrations. The Chemical
cartridges fit directly into 2.5” x 10” or
4.5” x 10” housings and contain the
correct amount of chemical for a single
use.
Pleated Filters and Filter Cartridge Kits
Features:
Pleated Filters
• Polypropylene pleated
construction
• Longer service life over wound
or polyspun cartridges
• Easily cleaned and reused
• Chemically compatible with
a wide range of alkalies, most
acids and saline solutions
• 0.5, 1, 5, and 20 micron
nominal ratings available
• Pliable ends ensures filter seal
to eliminate bypass
• High packing density reduces
filter size while keeping flow
rates up
Filter Cartridge Kits
• Cartridge with Blue stripe
contains cleaner #1, a
biological cleaner to remove
algae, fungi and bacteria
• Cartridge with Red stripe
contains cleaner #2, an acidic
cleaner to remove scale from
the membrane
• Cartridge with Green stripe
contains the preservative. This
chemical is used for pickling
the membranes
• Cartridges are capable of
being used in any housing that
takes a standard 2.5” (64mm)
x 10” (254mm) filter cartridges
Pleated Sediment Elements
Part Number
Microns
33-0118
33-0117
33-0053
33-0052
33-0020
33-0005
33-0058
33-0057
33-0172
33-2100
33-5100
33-1100
33-1105
20
5
20
5
20
5
20
5
100
20
5
1
0.5
Filter Area
ft2/m2
30/2.79
30/2.79
100/9.29
100/9.29
100/9.29
100/9.29
100/9.29
Diameter
inch/cm
2.75/7
2.75/7
4.5/11.4
4.5/11.4
8.63/22
8.63/22
4.5/11.4
4.5/11.4
8.63/22
8.63/22
8.63/22
8.63/22
8.63/22
Length
inch/cm
9.75/25
9.75/25
9.75/25
9.75/25
7.75/20
7.75/20
20/51
20/51
24.3/62
24.3/62
24.3/62
24.3/62
24.3/62
Carbon Flushing Filters
Part Number
33-0311
33-0315
33-0083
Diameter
inch/cm
2.75/7
4.5/11.4
4.5/11.4
Length
inch/cm
9.75/25
9.75/25
20/50.8
Cartridge Filter Kits
Description
Part Number
Contents
Cleaning Kit
85-0102
Preservation Kit
85-0103
One Blue stripe cleaner #1 plus
One Red stripe cleaner #2
Two Green stripe preservative
To maintain peak performance always use genuine Parker-Racor/Village Marine Tec. replacement parts.
We reserve the right to change our specifications or standards without notice.
© 2016 Parker Hannifin Corporation
Print Reorder Number 7905 Rev-C
02-17-2016
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