Techman_pw3000 18000 PW5000 TM (PW 8000 To 20000) 2012

User Manual: PW5000

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Pure Water Series

PW 8,000-20,000 GPD

Installation, Operation & Maintenance

Village Marine-PW 3000

Part Number: 95-0027

TABLE OF CONTENTS

1.0 SYSTEM DESCRIPTION 1

1.1 SPECIFICATIONS 1

1.1.1 PERFORMANCE CHARACTERISTICS 1

1.1.2 PHYSICAL CHARACTERISTICS 2

1.1.3 UTILITY REQUIREMENTS 2

1.1.4 ENVIRONMENTAL REQUIREMENTS 3

1.2 EQUIPMENT REQUIRED FOR OPERATION 3

1.2.1 CONSUMABLES 3

1.2.2 TEST EQUIPMENT 4

2.0 PREPARATION FOR USE, INSTALLATION AND INITIAL ADJUSTMENT 5

2.1 UNPACKING AND HANDLING 5

2.2 LOCATION 5

3.0 GENERAL THEORY OF OPERATION 9

3.1 REVERSE OSMOSIS THEORY 9

3.2 APPLICATION OF REVERSE OSMOSIS 10

3.3 PRODUCT WATER QUALITY STANDARDS 11

3.4 FACTORS AFFECTING PERMEATE PRODUCTION 11

3.4.1 VARIATIONS IN TEMPERATURE, PRESSURE AND SALINITY 11

3.4.2 TEMPERATURE CORRECTION FACTOR 12

3.5 OPERATIONAL DESCRIPTION 14

3.5.1 FILTRATION SYSTEM 14

3.5.2 REVERSE OSMOSIS SYSTEM 14

3.5.3 PRODUCT MONITORING SYSTEM 15

3.5.4 MEMBRANE CLEANING SYSTEM 15

3.6 WATER QUALITY MONITOR 16

3.6.1 PUSHBUTTONS 16

3.6.2 DISPLAYS AND LIGHTS 16

3.7 CONTROLS AND INSTRUMENTATION 16

4.0 OPERATION 19

4.1 START-UP PROCEDURE 19

4.2 SHUTDOWN PROCEDURES 21

4.2.1 SHUTDOWN PROCEDURE (SHORT TERM) 21

4.2.2 SHUTDOWN PROCEDURE (EXTENDED) 22

4.3 FRESH WATER FLUSH PROCEDURE 22

5.0 MAINTENANCE INSTRUCTIONS 23

5.1 GENERAL 23

5.2 RAW WATER STRAINER INSPECTION 24

5.3 FILTER ELEMENT CLEANING OR REPLACEMENT 24

5.4 DRIVE BELT INSPECTION AND REPLACEMENT 25

5.5 RO MEMBRANE CLEANING 26

5.5.1 CLEANING CHEMICALS 26

5.5.2 WHEN TO CLEAN 27

5.6 RO ELEMENT PRESERVATION 30

5.7 RESTARTING UNIT AFTER PRESERVATION 31

5.8 HIGH PRESS7URE PUMP OIL CHANGE 31

5.9 HIGH PRESSURE PUMP MOTOR LUBRICATION 31

5.10 INSPECTION LOG 31

6.0 PRESSURE VESSELS AND MEMBRANES 34

6.1 PRESSURE VESSEL DISASSEMBLY 34

6.3 PRESSURE VESSEL ASSEMBLY 36

7.0 PRESERVATION FOR STORAGE 38

8.0 TROUBLESHOOTING 38

9.0 SYSTEM DRAWINGS AND DIAGRAMS / PARTS LIST 39

iii

LIST OF FIGURES

Figure 2.0 - Recommended Installation (Below Water Line) ............................................ 5

Figure 2.1 - Proper Installation (Above Water Line) ......................................................... 6

Figure 3.0 - Simple (Reverse) Osmotic System ............................................................... 9

Figure 3.1 - Simplified Schematic of an RO System....................................................... 10

Figure 5.0 - Maintenance Task Chart............................................................................. 23

Figure 5.1 - Sample Operational Log ............................................................................. 32

Figure 5.2 - Sample Discrepancy Report ....................................................................... 33

Figure 6.0 - Pressure Vessel End Plug .......................................................................... 34

Figure 6.1 - Brine Seal Orientation................................................................................. 35

Figure 6.2 - End Plug Installation Aid ............................................................................. 36

LIST OF TABLES

Table 1.0 - Performance Specification ............................................................................. 1

Table 1.1 - Unit Dimensions............................................................................................. 2

Table 1.2 - Unit Weights................................................................................................... 2

Table 1.3 - HP Pump Horsepower.................................................................................... 2

Table 1.4 - Utility Requirements ....................................................................................... 2

Table 1.5 - Design Flow ................................................................................................... 3

Table 1.6 - Nominal Operating Conditions ....................................................................... 3

Table 1.7 - Consumables ................................................................................................. 4

Table 1.8 - Recommended Test Equipment..................................................................... 4

Table 3.0 - WHO Drinking Water Standards .................................................................. 11

Table 3.1 - Factors Affecting Permeate Quality.............................................................. 12

Table 3.2 - Temperature Correction Factors (TCF)........................................................ 13

Table 3.3 - Instrumentation and Controls ....................................................................... 18

Table 4.0 - Valve/Switch Line Up - Initial Start-up .......................................................... 19

Table 5.0 - Filter Tank Parts List. ................................................................................... 24

Table 5.1 - Chemical Requirements............................................................................... 26

Table 5.2 - Lubrication Requirements ............................................................................ 31

The following are the types of flags used in this technical manual. They designate safety

related items and important operational instructions and should be given special attention

when they appear in the text:

Text formatted in this manner concerns an operating procedure or practice

that, if not strictly observed, can result in injury to personnel or loss of life.

Text formatted in this manner concerns an operating procedure or practice

that, if not strictly observed, can result in damage to or destruction of

equipment.

Text formatted in this manner concerns an operating procedure or

condition that warrants special attention.

WARNING

CAUTION

NOTE

PW-3000 to PW-20000 Manual 1 Last Revised 01/12

1.0 SYSTEM DESCRIPTION

The Village Marine Tec. (VMT) Seawater Desalinator is a single-pass purification

system that uses reverse osmosis (RO) as its method of seawater desalination. This

unit produces potable (drinking) quality water with salt concentrations of < 500 ppm by

removing approximately 99% of the dissolved salt in seawater.

This manual covers the following models: PW3000, PW4000, PW5000, PW6000,

PW7000, PW8000, PW10000, PW12000, PW16000 and PW20000. The principle of

operation is the same for all models. Specific differences are noted, where applicable.

1.1 SPECIFICATIONS

1.1.1 PERFORMANCE CHARACTERISTICS

Parameter Specification

Raw water temperature range: 1-40°C (33-108ºF)

Design RO element pressure: 800 psi

Max. RO element pressure: 1000 psi

Max. feedwater residual chlorine: < 0.1 ppm

pH range (short term for cleaning): 4-10 (3-11)

Membrane type: Thin film composite

Nominal product water production: (2)

PW-3000 2.1 gpm

PW-4000 2.8 gpm

PW-5000 3.5 gpm

PW-6000 4.2 gpm

PW-7000 4.9 gpm

PW-8000 5.6 gpm

PW-10000 6.9 gpm

PW-12000 8.3 gpm

PW-16000 11.1 gpm

PW-20000 13.9 gpm

(2) Raw water temperatures less than 25°C (77ºF) will result in less than rated

product water output. Conversely, higher raw water temperatures will result in

higher than rated output.

Table 1.0 - Performance Specification

PW-3000 to PW-20000 Manual 2 Last Revised 01/12

1.1.2 PHYSICAL CHARACTERISTICS

PW3000

5000 PW6000

PW7000

12000

PW16000

20000

Length 84" 84" 84" 84”

Width 34" 44" 48" 52”

Height 35" 35" 35" 43”

Table 1.1 - Unit Dimensions

PW3000 PW4000 PW5000 PW6000 PW7000

Weight 800 LB 900 LB 1000 LB 1050 LB 1500 LB

PW8000 PW10000 PW12000 PW16000 PW20000

Weight 1600 LB 1800 LB 1900 LB 2200 LB 2250 LB

Table 1.2 – Unit Weights

1.1.3 UTILITY REQUIREMENTS

See the nameplate attached to top of the unit for power requirements.

PW3000 PW4000 PW5000 PW6000 PW7000

Motor HP 10 10 15 15 15

PW8000 PW10000 PW12000 PW16000 PW20000

Motor HP 20 20 25 25 30

Table 1.3 – HP Pump Horsepower

Utility Connection

Design Pressure

Minimum

(psi)

Design Pressure

Maximum

(psi)

Raw water inlet 1 ½” ANSI Flange 0 50

Reject discharge* 1 ½” ANSI Flange 0 15

Product water discharge 1” ANSI Flange 0 15

Flush water inlet 1 ½” NPT 20 50

* Vacuum condition at shutdown is not acceptable, syphon breaker may be reqd.

Table 1.4 - Utility Requirements

PW-3000 to PW-20000 Manual 3 Last Revised 01/12

Unit Raw water inlet

(gpm) Reject discharge

(gpm)

Product water

discharge

(gpm)

PW-3000 14 12 2.1

PW-4000 14 11 2.8

PW-5000 20 16 3.5

PW-6000 20 16 4.2

PW-7000 20 15 4.9

PW-8000 24 19 5.6

PW-10000 30 23 6.9

PW-12000 36 28 8.3

PW-16000 36 26 10.4

PW-20000 43 29 13.9

Table 1.5 – Nominal Design Flow

1.1.4 ENVIRONMENTAL REQUIREMENTS

Parameter Specification

Ambient temperature: 1-40°C (33-108ºF)

List (permanent): 15º

Trim (fore and aft): + 30º

Pitch: ± 10º (6 sec cycle)

Roll: ± 30º (12 sec cycle)

Table 1.6 - Nominal Operating Conditions

1.2 EQUIPMENT REQUIRED FOR OPERATION

1.2.1 CONSUMABLES

The following is the normal quantity of equipment consumed during 6 months of

standard unit operation:

NOTE

Only Village Marine Tec approved filters and chemicals should be used.

PW-3000 to PW-20000 Manual 4 Last Revised 01/12

Description QTY VMT Part No.

PW3000-6000 PW7000-20000

Cleaning Chemical #1, 25 lbs 2 3 85-0045

Cleaning Chemical #2, 25 lbs 2 3 85-0048

Preservative Chemical #3, 25 lbs 1 1 85-0049

Filter, 100 ft

, 5 Micron 6 6 33-5100

Filter, 100 ft

, 20 Micron 6 6 33-2100

Flushing Filter 2 2 See Parts Dwg

Oil, HP Pump, Quart 20 20 85-0050

LP Pump Mech Seal Kit 1 1 90-0108

HP Pump Service Kits 1 1 See Pump Manual

Table 1.7 - Consumables

1.2.2 TEST EQUIPMENT

The following table lists the basic equipment recommended to perform most types of

verification testing and system maintenance. The salinity meter allows the operator to

perform routine sampling of the RO membranes:

Description VMT Part No.

Kit, pH Test, 0-14 (10 strips): 90-0135

Meter, Handheld Analog, 0-5000 ppm: 40-5000

10X Range Extender for Analog Meter: 40-5001

Alternate Digital Handheld meter, 0-1000 ppm: 99-1990

Solution, Calibration, 300 ppm: 90-1300

Solution, Calibration, 30,000 ppm: 90-1301

Table 1.8 - Recommended Test Equipment

PW-3000 to PW-20000 Manual 5 Last Revised 01/12

2.0 PREPARATION FOR USE, INSTALLATION AND INITIAL

ADJUSTMENT

2.1 UNPACKING AND HANDLING

Remove unit from shipping crate and inspect for shipping damage.

CAUTION

Do not allow unit or any components to be exposed to freezing

temperatures. If it is anticipated that the unit may be exposed to freezing

temperature, please contact VMT in advance for technical assistance.

2.2 LOCATION

The RO unit should be installed in a dry, sheltered location protected from direct

weather. Some type of drainage should be provided beneath the RO unit to allow

standing water to drain when performing maintenance or repair (see system diagram in

Section 9.0 for skid size, interface locations and minimum maintenance envelope

requirements).

For units without a pressurized feed, it is recommended that the RO unit be mounted in

a location below the vessel's waterline. This will ensure a flooded suction to the unit at

all times.

Figure 2.0 - Recommended Installation (Below Water Line

without Pressurized Feed)

It is important that the product water line is

connected to the top of the storage tank with an

air gap to prevent chlorinated water from

siphoning back into the watermaker.

Raw water inlet, 1½” through

hull with sea cock, as low as

possible and towards the aft of

the boat, forward of the drive.

Reject discharge line

overboard and above

water line.

PW-3000 to PW-20000 Manual 6 Last Revised 01/12

If it is not possible to mount the watermaker below the water line, the boost pump can

lift to a maximum height of 15 feet (5 feet for 50 Hz units) above the water line with the

boost pump removed from the frame and installed below the RO frame near the through

hull. A check valve might be required in the suction line to maintain adequate system

priming. Locating the system any more than 15 feet above the water line requires

installation of external pumps to maintain a pressurized feed.

Figure 2.1 - Proper Installation

(Above Water Line)

Since every installation is unique, the mounting instructions are provided for guidance

only. It is recommended that you use your own discretion as to the exact method of

mounting and placement of any mounting bolts.

1) Place the RO unit in an appropriate location and use existing holes or drill new

holes for a minimum of four point mounting by studs or bolts. Mount the RO unit

securely making sure that the base of the unit is continuously supported.

2) Make the following plumbing connections to the RO unit's piping interfaces (refer

to Section 9.0 for the exact piping interface locations):

a) Connect the raw water supply (1½" flange connection inlet) to a clean

seawater source.

CAUTION

Raw water inlet, 1-1/2” through

hull with sea cock, low as possible

and towards the

Aft of the vessel, forward of the

drive.

Reject discharge

line overboard and

above water line.

It is important that the product water line is

connected to the top of the storage tank to prevent

chlorinated water from siphoning back into the

watermaker.

Boost pump below water line

with flooded suction.

PW-3000 to PW-20000 Manual 7 Last Revised 01/12

Inlet and discharge interconnecting lines should be constructed of a NON-

FERROUS material. Examples of some suitable materials are PVC,

copper-nickel, 316 stainless steel pipe or a reinforced non-collapsing

hose. Ferrous piping produces rust that will irreversibly foul the

membrane and void the RO unit warranty.

NOTE

Avoid connecting the inlet piping to any water line that services any other

piece of equipment. Air could be drawn through the RO unit causing

damage to the RO unit's pumps.

b) Connect the reject discharge 1½" flanged connection to an unobstructed

line connected to an appropriate drain. If the reject is discharged

overboard, the discharge port should be above the waterline. On above

waterline installations where the reject goes down more that 10 feet to its

outlet, install a vacuum breaker or vent to prevent any negative pressure

or vacuum situation at shutdown.

CAUTION

The use of galvanized steel for product piping should be avoided as small

amounts of rust may form that can be drawn back into the RO when the

system is off.

c) Connect the product water discharge 1" flanged connection to an

unobstructed line that is connected to the TOP of the product water storage

tank. If the storage tank water is chlorinated, a check valve or air gap should

be installed in the product line as a precaution to prevent chlorine damage of

the RO membranes. The air gap is often accomplished by teeing the product

connection to a tank vent or tank fill line of suitable size.

d) Connect the flush water inlet to the pressurized fresh water system on the

vessel. Do not exceed 50 psi pressure.

CAUTION

Exposing the membranes to chlorinated water may cause irreversible

damage and will void the RO unit warranty, so use the carbon flush filter

supplied.

3) Connect the following RO unit's electrical interfaces:

NOTE

PW-3000 to PW-20000 Manual 8 Last Revised 01/12

Strictly observe all applicable 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 of wire insulation

depending upon the amperage and environment. The power supply

should always be of a 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

dedicated power supply and breaker.

WARNING

Disconnect electrical power to RO unit and the power source before

connecting to RO unit interface. Failure to do so can cause serious

injury or death to personnel.

a) Connect the correct voltage/power supply to the three-phase or single phase

supply point in the Motor Starter Box. Correct high pressure pump rotation is

clockwise when viewing the motor fan (or counter-clockwise when viewing

from the shaft and pulley end. Correct rotation for the low pressure boost

pump is clockwise when viewing the motor fan.

IMPORTANT NOTE

Three phase power supplies will spin the motors and pumps either

rotation direction, depending on the phase sequence of the three hot

power legs. It is very important not to rotate the low pressure pump

backwards. Even “bumping” the motor for one second can cause

significant damage. The high pressure pump will not be damaged from

running backwards. Either use a phase meter to determine the rotation,

or use the high pressure pump only to check rotation and adjust the

input power legs accordingly prior to checking the low pressure pump. If

the low pressure pump is inadvertently “bumped” backwards, open the

pump and check the impellor is secured on the motor shaft and spins

freely prior to starting it again.

b) Connect a suitable ground to the RO unit skid (as determined by the

specifics of your installation).

PW-3000 to PW-20000 Manual 9 Last Revised 01/12

3.0 GENERAL THEORY OF OPERATION

3.1 REVERSE OSMOSIS THEORY

Reverse osmosis, like many other practical scientific methods, has been 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 is 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.

SALINE

SOLUTION

PURE

SOLUTION

SEMI-PERMEABLE MEMBRANE

ATMOSPHERIC

PRESSURE

(14.7 PSI)

SALINE

SOLUTION

PURE

SOLUTION

HIGH

PRESSURE

(800 PSI)

OSMOSIS REVERSE OSMOSIS

Figure 3.0 - Simple (Reverse) Osmotic System

PW-3000 to PW-20000 Manual 10 Last Revised 01/12

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 to 35,000 ppm (parts per

million) TDS although variations of 5000 ppm are common in various parts of the world.

The fundamental goal 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

along 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 converted to permeate is called the recovery rate and is normally somewhere

between 20% and 30%. For example, a unit with a 29% recovery rate will produce 29

gallons of permeate for every 100 gallons of feedwater with the remaining 71 gallons

discharged to waste as brine. 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.

Figure 3.1 - Simplified Schematic of an RO System

FEEDWATER

CLEANING

SYSTEM

PRODUCT

MONITORING

SYSTEM

MEMBRANE

ARRAY

HIGH PRESSURE

PUMPING SYSTEM

FEEDWATER

PERMEATE

REJECT DISCHARGE

PRODUCT DISCHARGE

RAW WATER INLET

BRINE

PERMEATE > 500PPM

PERMEATE < 500PPM

FILTRATION

SYSTEM

PW-3000 to PW-20000 Manual 11 Last Revised 01/12

It should be noted that no system is capable of removing all of the dissolved solids from

seawater. The system is actually designed to reject approximately 99% of the TDS or,

in other words, to allow 1% of the 35,000 ppm TDS in the seawater to pass into the

product water. This yields water of less than 500 ppm, the recommended TDS for

drinking water. A system such as this is said to have a salt passage percentage of 1%

or a salt rejection of 99%.

3.3 PRODUCT WATER QUALITY STANDARDS

This RO unit will produce permeate (product water) with a quality of < 500 ppm TDS

and in accordance with World Health Organization (WHO) standards for drinking water.

General specifications for acceptable drinking water quality are as follows:

Constituent Ion/Molecule Maximum Limits (ppm)

Nitrate 10

Fluorine .1

Sulfate 100

Magnesium 30

Calcium 75

Calcium Carbonate 100

Iron .1

Manganese .05

Total Dissolved Solids 500

Turbidity 5

Oil .1

Detergents (anionic) .2

Phenols .001

Bacteria - E Coli (per 100 ml) 0

Table 3.0 - Drinking Water Standards

3.4 FACTORS AFFECTING PERMEATE PRODUCTION

3.4.1 VARIATIONS IN TEMPERATURE, PRESSURE AND SALINITY

The following table illustrates how the quality and quantity of permeate produced in by

RO system is affected by changes in temperature, salinity and pressure:

PW-3000 to PW-20000 Manual 12 Last Revised 01/12

With constant.... And increasing.... Permeate

TDS Capacity

Salinity and Pressure Temperature Increases Increases

Temperature and Pressure Salinity Increases Decreases

Temperature and Salinity Pressure Decreases Increases

Table 3.1 - Factors Affecting Permeate Quality

NOTE

If feedwater salt concentration decreases, the product water flow rate

should not be allowed to increase more than 20% above rated flow.

Reject pressure will need to be lowered to maintain rated flow in brackish

water or fresh water applications.

The RO system can be adjusted to maintain a constant permeate output when

feedwater salinity is below nominal (near river mouths or in estuaries). The operator

can do this by controlling system pressure manually via the back pressure regulator

valve, V3, located in the system brine piping. For long pump life and low membrane

fouling, VMT recommends that 800 psi is not exceeded except in situations of extreme

low temperature feed water.

CAUTION

Operating the unit at more than 120% of rated capacity in low salinity

water can damage the membranes and will void the RO unit warranty.

3.4.2 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, theoretical data has been

utilized to develop Temperature Correction Factors (TCF) to compensate measured

flowrate to calculated flowrate at 25°C/77°F. This allows the operator to establish the

baseline flow for a given temperature, allowing more accurate troubleshooting. The

procedure for calculating the temperature compensated flow is as follows:

1) Measure raw water temperature and determine the corresponding correction

factor from Table 3.2 based on the measured temperature.

2) Note the actual product flow rate at the Product Flow meter. Multiply the actual

product flow meter flow rate by the correction factor from Table 3.2 to give

theoretical temperature compensated flow under standard conditions (25°C).

PW-3000 to PW-20000 Manual 13 Last Revised 01/12

Example:

Raw water temp: 15°C

TCF: 1.47

Actual product flow: 113.5 (gph)

Calculation: 113.5 x 1.47 = 167 (gph)

Temperature Corrected flow: 167 (gph)

(167 gph is the normal flow for a PW4000)

°C Factor °C Factor °F Factor °F Factor

1 3.64 26 0.97 34 3.47 84 0.88

2 3.23 26 0.94 36 3.18 86 0.82

3 3.03 28 0.91 38 3.18 88 0.79

4 2.78 29 0.88 40 2.68 90 0.79

5 2.58 30 0.85 42 2.47 92 0.77

6 2.38 31 0.83 44 2.29 94 0.75

7 2.22 32 0.80 46 2.14 96 0.73

8 2.11 33 0.77 48 2.01 98 0.70

9 2.00 34 0.75 50 1.88 100 0.68

10 1.89 35 0.73 52 1.77 102 0.65

11 1.78 36 0.71 54 1.68 104 0.63

12 1.68 37 0.69 56 1.59 106 0.61

13 1.61 38 0.67 58 1.51 108 0.59

14 1.54 39 0.65 60 1.44 110 0.57

15 1.47 40 0.63 62 1.36 112 0.55

16 1.39 41 0.61 64 1.30 114 0.53

17 1.34 42 0.60 66 1.24 116 0.51

18 1.29 43 0.58 68 1.17 118 0.49

19 1.24 44 0.56 70 1.12 120 0.47

20 1.19 45 0.54 72 1.08 122 0.45

21 1.15 46 0.53 74 1.05

22 1.11 47 0.51 76 1.02

23 1.08 48 0.49 78 1.00

24 1.04 49 0.47 80 0.93

25 1.00 50 0.46 82 0.90

Table 3.2 - Temperature Correction Factors (TCF)

PW-3000 to PW-20000 Manual 14 Last Revised 01/12

3.5 OPERATIONAL DESCRIPTION

3.5.1 FILTRATION SYSTEM

Seawater supplied to the intake of the Village Marine RO desalination unit will initially

flow through the raw water strainer, ST1, which removes large particulate matter.

Once through the strainer, the raw water is supplied to the low pressure boost pump,

P1, which raises the pressure of the water in order to provide enough positive feed

pressure to flow through the filtration system and into the suction of the high pressure

pump.

For units equipped with a (optional) Media Filtration System:

When a unit operates in areas where the raw water source of high turbidity or

organic materials, VMT recommends installing a media filtration system (IMF).

The media pump and filter, is installed upstream of the watermaker and will remove

particles as small as 25 microns in diameter. The filtration media is comprised a

multiple layers of specific materials that are specifically designed to remove

suspended particulate matter from the raw water stream. The benefit is to

significantly reduce the cleaning and replacement frequency for the micron filters.

When the media filter is fully loaded (indicated by high filter differential pressure), the

operator initiates a backwash cleaning cycle designed to flush trapped particulate

matter out of the filter and into the system drain. Please see the IMF manual or IMF

bulletin for further details.

The raw water next passes through the micron filter array, F1 & F2, which is designed

to reduce raw water turbidity to a nominal 5 microns in diameter. The micron filter array

consists of one 20 micron filter cartridge and one 5 micron filter cartridge.

Each filter housing contains one (1) filter element with an effective filtering area of 100

ft2and is equipped with an integral air/oil separator bleed. Bleed is continuously

discharged to the reject header and overboard.

The discharge pressure from the filter housings is monitored by a pressure gauge,

PG1, and pressure switch, PS1, that allow the operator to determine when the filter

elements require cleaning or replacement.

3.5.2 REVERSE OSMOSIS SYSTEM

The clean and filtered raw water (now referred to as feedwater) is supplied to the inlet of

the high pressure pump, P2. This pump raises feedwater pressure to 800 psi, the

nominal pressure required for optimal system recovery. The pressurized feedwater

PW-3000 to PW-20000 Manual 15 Last Revised 01/12

then flows directly into the membrane array. The membrane array is an arrangement

of fiberglass pressure vessels each containing a RO membrane element.

The pressurized feedwater flows along the membrane elements where reverse osmosis

takes place (see Section 3.1). The feedwater flow is divided into two streams - the high

purity product stream (referred to as the permeate) and the increasingly concentrated

reject stream (referred to as the brine or reject).

After exiting the membrane array, the brine (which contains higher concentrations of

salts) flows through the back pressure regulator valve, V3. This manually adjustable

valve is used to control the back pressure through the membrane array. After passing

through the back pressure regulator, the brine flows through the reject flow meter, FM1

and exits the RO unit.

3.5.3 PRODUCT MONITORING SYSTEM

The product water stream (or permeate) flows past a conductivity sensor, which

provides a signal to the water quality monitor. Depending on the concentration of total

of dissolved solids (TDS) in the permeate stream, the following occurs:

If permeate TDS is > 500 ppm, indicating poor quality water, a signal is sent to close the

2-way product diversion valve, V6. This causes permeate system pressure to rise

until it equals the activation set point of the permeate relief valve, V7. With the relief

valve open, the poor quality water is diverted to the reject stream and away from your

storage tanks. A product pressure gauge, PG3 is supplied to enable accurate

adjustment of the product relief valve to about 40 psi in most installations.

If the permeate has < 500 ppm TDS, indicating good quality (drinking) water, a signal is

sent to open the product diversion valve. The relief valve then shuts allowing the

permeate to pass through the product flow meter, FM2 and then on to the potable

water storage tank(s).

3.5.4 MEMBRANE CLEANING SYSTEM

This RO unit includes a membrane cleaning system which provides a means for

removing performance degrading organic foulants and scale deposits from the RO

membranes (occurs approximately every 30 – 90 days during constant use). By using

the filter housings as cleaning solution tanks, the pumps, a cleaning valve V5, and a

high pressure bypass valve V4, the membranes can be chemically cleaned in place.

Complete information and cleaning procedures can be found in Section 5.5.

PW-3000 to PW-20000 Manual 16 Last Revised 01/12

3.6 WATER QUALITY MONITOR

The Water Quality Monitor (MON) monitors and displays permeate salinity, temperature

and accumulated unit operating hours. It also provides operational mode control of the

system product valve.

3.6.1 PUSHBUTTONS

Temperature – allows the operator to display permeate temperature (as opposed to

the normal permeate salinity display). By changing a jumper located on the back of

the monitor, the temperature can be displayed in ºF or ºC.

Salinity Alarm Set Point – allows the operator to display and vary (via a control knob

located on the back of the monitor) the salinity alarm set point.

Mode – allows the operator to bypass the normal automatic operation and manually

close the product valve (called DUMP mode, used, for instance, during cleaning).

3.6.2 DISPLAYS AND LIGHTS

Normal Operation – a green light is illuminated when the product valve is energized

and permeate is flowing through the product valve.

Dump/Cleaning – a yellow light is illuminated when the product valve is de-energized

and the product valve is closed.

Salinity Alarm – a red, flashing light indicates that permeate quality is above the

salinity set point.

3.7 CONTROLS AND INSTRUMENTATION

The following table provides a brief description of each individual component along with

an explanation of its function. It is intended as a supplement to the more detailed

information contained in Section 9.0 – System/Equipment Drawings and Diagrams.

Call Out Description Function

F1 20 Micron Pre-filter Filters particles > 20 microns in diameter.

F2 5 Micron Pre-filter Filters particles > 5 microns in diameter.

PW-3000 to PW-20000 Manual 17 Last Revised 01/12

FM1 Reject Water Flow

Meter Indicates the amount of reject water discharged

from the RO unit.

FM2 Product Water Flow

Meter Indicates the amount of permeate produced by

the RO unit.

MON Water Quality Monitor See Section 3.6 for detailed description.

MS1 LP Pump Magnetic

Starter Provides ON/OFF control of LP pump.

MS2 HP Pump Magnetic

Starter Provides ON/OFF control of HP pump.

P1 Low Pressure (LP)

Boost Pump Pressurizes raw water to supply the cartridge

filters, F1 and F2.

P2 High Pressure (HP)

Pump Pressurizes feed water to supply the membrane

array at proper (high) pressure.

PG1 Pre-Filter Pressure

Gauge Indicates cartridge filter inlet and discharge

pressure.

PG2 High Pressure Gauge Indicates membrane array discharge (brine

side) pressure.

PG3 Product Water Pressure Indicates membrane array (permeate side)

discharge pressure.

PS1 Low Pressure Switch Will shut down pumps if the pressure is below

setpoint.

SR1 Product Conductivity

Sensor Conductivity probe provides signal to water

monitor (MON).

ST1 Raw Water Strainer Removes large particulate matter from the raw

water stream to prevent system fouling.

SW1 LP Boost Pump Start

Pushbutton Allows operator to START the LP boost pump.

SW2 LP Boost Pump Stop

Pushbutton Allows operator to STOP the LP boost pump.

SW3 HP Pump Start

Pushbutton Allows operator to START the HP pump.

SW4 HP Pump Stop

Pushbutton Allows operator to STOP the HP pump.

V1 Filter Gauge Selector

Valve Allows operator to select and read filter array

inlet or discharge pressure on the gauge.

PW-3000 to PW-20000 Manual 18 Last Revised 01/12

V3 HP Regulating Valve Maintains and controls system back pressure.

V4 HP Bypass Valve Allows operator to bypass the HP Regulating

Valve during start-up, shutdown and cleaning.

V5 Cleaning Valve Used to re-circulate the brine during cleaning

and preservation procedures.

V6 Product Diversion Valve Based on its salinity, directs permeate to either

the potable water tank(s) or to drain.

V7 Product Water Relief

Valve

Discharges product water when Product

Diversion Valve is closed. Typical setting 40

psi.

V8 Filter Bleed Check Valve Prevents reject flow from back flowing through

the filter housings into the feed water stream.

V9 Trim Valve Adjust to get quiet operation at regulator

V10 Flush Valve 3-way feedwater valve used to flush system

Table 3.3 - Instrumentation and Controls

PW-3000 to PW-20000 Manual 19 Last Revised 01/12

4.0 OPERATION

4.1 START-UP PROCEDURE

NOTE

The HP Pump should rotate in the counter-clockwise direction (when

facing the protruding end of the shaft).

1) Check the HP pump oil level by observing sight gauge located on the pump.

2) On initial start up, check the drive belt tension by removing the belt guard. See

Section 5.4 for detailed procedure.

WARNING

De-energize (lock out or disconnect) the electrical supply to RO unit

before attempting to check or adjust drive belt tension. Serious injury to

personnel can result if the RO unit is started while checking drive belt

tension.

3) Open the raw saltwater supply to the unit. On pressurized feed systems, water

may now be flowing through the watermaker.

4) On initial start up, check the tightness of all lines and fittings.

5) If equipped with an IMF or other media filter, backwash and rinse media filter as

required for initial startup or after long periods of standby. With fresh fill of

media, multiple backwash and rinse sequences will be required. See IMF

manual.

6) Place the RO unit's valves and switches in the positions shown in Table 4.0.

ID Description Position

V3 HP Regulating Valve Factory set to 800 psi

V4 High Pressure Bypass Valve Cleaning (open)

V5 Cleaning Valve Normal Flow

V10 Flush Valve Seawater Feed

Table 4.0 - Valve/Switch Line Up - Initial Start-up

PW-3000 to PW-20000 Manual 20 Last Revised 01/12

CAUTION

Failure to open the High Pressure Bypass Valve (which is required to

bleed any entrapped air) can result in hydraulic shock to the system.

6) Verify electrical power is supplied to the RO unit.

CAUTION

The low pressure (LP) boost pump should not be started if the feed system

pressure as read on the inlet side of the Pre-filter Pressure gauge is more than

40 psi. Operate with only the HP pump if feed pressure is in excess of 40 psi to

avoid overpressure to the feed water system components.

7) Start the pumps in turn, feed pump (if equipped), boost pump and then the HP

pump. At least 10 psi must be indicated on the discharge side of the Pre-filter

Pressure gauge.

8) Inspect all plumbing connections in the unit for leakage. Temperature variations

during shipment may cause plumbing connections to seep when initially started

on-site. Secure the unit and repair any leaks prior to proceeding. Once the leaks

have been repaired, open the raw water source and re-start the unit.

9) When flow through the reject discharge flow meter appears to be free of air

bubbles, place the High Pressure Bypass Valve, V4, in the closed position by

slowly turning the handle in the clockwise direction.

NOTE

When the High Pressure Bypass Valve is closed, the salinity of the initial

permeate produced may be temporarily high and will probably be

enough to temporarily energize the salinity alarm.

10) Observe the system pressure on the discharge side of the RO Membrane Array

Pressure gauge. For seawater applications, indicated pressure should be preset

to 800 psi. If the indication is other than 800 psi, adjust the nut on top of the back

pressure regulator valve, V3, using a wrench until the discharge side of the RO

Membrane Array Pressure gauge indicates 800 psi. In conjunction with

adjustment of the regulator, adjust the trim valve, V9, to find the quietest

operating point.

PW-3000 to PW-20000 Manual 21 Last Revised 01/12

WARNING

Pressure, as indicated on the inlet side of the RO Membrane Array gauge,

should never exceed 1000 psi.

NOTE

The system pressure required to produce equivalent amounts of permeate

is lower for fresh water sources (approximately 200 psi) and brackish

water sources (approximately 400 psi) than for seawater applications.

Reduce system pressure as necessary to maintain system output at no

more than 120% of rated capacity.

11) Normally, during start-up using seawater, the Salinity alarm (red) will remain lit

for approximately 2 minutes. When the product water quality drops below 500

ppm TDS, the green lamp will light. The water quality monitor will then open the

product diversion valve, which will direct the product water to the product water

flow meter. If the green lamp does not light within 10 minutes, sample the

product water from the pressure vessel sample valves and confirm with a

handheld salinity meter.

12) Observe the Product Flow meter. This flow meter indicates, in gallons per

minute (gpm), the product water flow rate. Record the product flow after 5 hours

of operation (use the sample log sheet provided in Figure 5.1). This indication

will provide the baseline used to determine RO membrane cleaning

requirements. Normally, a drop of 10-15% in the temperature corrected product

water production rate indicates the need for RO membrane cleaning (see Section

3.4 for a more detailed information concerning variations in product flow).

13) Observe the Reject Flow meter. This flow meter indicates, in gallons per minute

(gpm) the reject flow rate from the RO array. Record the reject flow after the first

5 hours of operation (use the sample log sheet provided in Figure 5.1).

4.2 SHUTDOWN PROCEDURES

4.2.1 SHUTDOWN PROCEDURE (SHORT TERM)

1) Release the pressure from the system by turning the High Pressure Bypass

Valve, V4, counter-clockwise to the Cleaning (open) position.

2) Secure the HP pump by pressing the red HP PUMP STOP button located on the

front panel.

PW-3000 to PW-20000 Manual 22 Last Revised 01/12

3) If required, secure the LP boost pump by pressing the red LP PUMP STOP

button located on the front panel.

4) Secure the feedwater system by closing a feedwater valve upstream of the water

maker or by turning the Flush Valve, V10, to the midway position. If the

anticipated shutdown period will be 24 hours or more, flush the system as per

Section 4.3 - Flushing Procedure.

4.2.2 SHUTDOWN PROCEDURE (EXTENDED)

Since bacteria and biologic growth increases significantly the longer stagnant water is in

contact with the membranes, the fresh flushing procedure (Section 4.3) should be used

whenever the unit will be secured for more than 1 or 2 days. 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.

CAUTION

Failure to follow the extended shutdown procedure can result in

irreversible fouling to the RO membranes.

Bacterial contamination can be avoided by following the following procedures:

Flush the RO unit with non-chlorinated fresh water for 2 - 4 minutes.

Reflush the RO unit for 2 - 4 minutes every 7 days.

Or, Pickle the RO unit with a preservative solution. Refresh the preservative

every 3 months. Follow the preservation instructions provided in Section 5.6.

4.3 FRESH WATER FLUSH PROCEDURE

Note: Fresh flushing water should pass through the carbon flush filter supplied on the

PW unit so it is non-chlorinated. Exposing the membranes to chlorinated water may

cause irreversible membrane damage. The carbon filter element should be changed

once per year or after 50 flushes. It is designed to remove normal concentrations of

free chlorine (0.5 to 1.0 ppm). Do not flush with shock-chlorinated water. Once the

watermaker is shut off and isolated, the flush procedure is:

1) Make sure the HP Bypass Valve, V4, is in the counterclockwise (open) position.

2) Turn the Flush Valve, V10, to the flush position to bring freshwater to the feed of

the watermaker.

3) Start the LP boost pump.

PW-3000 to PW-20000 Manual 23 Last Revised 01/12

4) Once you have observed fresh water flow through Reject Flow meter, run the

system for an additional 2 to 4 minutes. For greater flushing flow, start the HP

pump as well.

5) Secure the pumps. Return the Flush Valve, V10, to midway position, isolating

the watermaker.

5.0 MAINTENANCE INSTRUCTIONS

5.1 GENERAL

The service life of most of the system equipment is directly related to the raw water inlet

conditions. Improper maintenance will also significantly reduce the life expectancy of

the major unit components (such as the membranes, filters and pumps) as well as the

reliability of the unit as a whole. Under normal conditions, and with proper

maintenance, a reverse osmosis membrane (which is the major consumable item)

should have an effective service life somewhere between 1 to 2 years heavy use.

Daily

Weekly

Monthly

Quarterly

Semi-Annually

Annually

As Required

Labor Hours

(approximate)

Clean and inspect strainer basket 0.3

Clean and inspect micron filter(s) 0.5

Replace filter(s) 0.5

Clean membranes 4.0

Replace membranes 2.0

Inspect pump drive belt 1.0

Check pump oil level 0.1

Change pump oil(1) 1.0

Lubricate pump motors 1.0

Backflush media filter(2) 0.3

(1) After first 50 hours and every 500 hours thereafter

(2) For units equipped with the optional media filtration system.

Figure 5.0 - Maintenance Task Chart

PW-3000 to PW-20000 Manual 24 Last Revised 01/12

5.2 RAW WATER STRAINER INSPECTION

1) Isolate the raw water supply and open the strainer housing.

2) Remove the screen from the strainer bowl. Remove any debris from screen and

inspect the screen closely for damage. Replace as required.

3) Check the sealing gasket or o-ring is in good condition, and keeping the seal in

place install the screen and reclose the strainer housing hand tight. Start the RO

and check for leaks.

5.3 FILTER ELEMENT CLEANING OR REPLACEMENT

The filter elements should be replaced when the discharge side of the pressure gauge

drops below 5 psi or the differential pressure is 20 psi. Each PW3000-20000 employs a

filter array consisting of one (1) 20 micron, 100 ft2filter in series with one (1) 5 micron,

100 ft2filter. VMT filters can be washed and re-used 2-3 times provided it is not

contaminated with oil or organic growth.

Description Qty VMT Part #

Micron filter, 20 micron, 100 ft21 33-2100

Micron filter, 5 micron, 100 ft21 33-5100

O-ring, filter lid, 100 ft22 30-0405

Filter, complete assembly, 100 ft22 30-4353

Table 5.0 - Filter Tank Parts List.

CAUTION

VMT filter cartridges are specifically designed for RO applications and

constructed with an oil attractive polypropylene. Use of non-approved

cartridges will void the RO unit warranty.

Replace the filter element(s) using the following procedure:

1) Secure the RO unit. Close the raw water supply (external) to RO unit.

2) Loosen and remove the bolts or wing-nuts that hold the filter tank lid in place.

Remove the tank lid.

3) Remove the filter element. If required, first break the filter seal by rocking the

filter from side to side.

PW-3000 to PW-20000 Manual 25 Last Revised 01/12

4) The filter element may be cleaned by flushing it with water to remove foreign

matter from the filter pleats. If the filter element appears oil-fouled or is damaged

in any way, discard it and install a new element.

5) Reinstall the filter element. Be sure to install the filter element with the end

marked "TOP" upwards. Ensure a proper seal by pressing the filter element

down into place until it reaches the bottom and is fully seated.

6) Reinstall the filter tank lid. Tighten the bolts or nuts.

7) After the filter element has been changed, operate the RO unit and check for

leaks.

5.4 DRIVE BELT INSPECTION AND REPLACEMENT

Proper adjustment of the HP pump drive belt(s) is essential for proper operation of the

system. The drive belt(s) should be inspected for cracking, fraying and excessive wear.

Replace the belts immediately it the inspection indicates that the belt(s) are damaged.

WARNING

Disconnect electrical supply to RO unit before attempting to check.

Serious injury to personnel can result if RO unit is started when checking

drive belt.

1) Remove the mounting screws that hold the left front panel in place and remove

the panel.

2) Inspect drive belt carefully for wear and proper tension. The belt should deflect

approximately ½ " when a force of 6-9 lbs is applied at a point halfway between

the pulleys. Remember that cogged drive belts are never kept as tight as V drive

belts, and overtightened belts will create a squealing sound and can damage

bearings. Adjust the base plate as required to obtain proper belt tension.

3) If the drive belt is damaged or shows any evidence of excessive wear, replace

the drive belt:

a) Locate the HP pump's mounting nuts on the adjustable pump base.

Loosen the nuts to relax the belt tension.

b) Remove the old drive belt and install new one ensuring they are properly

positioned in the pulleys.

PW-3000 to PW-20000 Manual 26 Last Revised 01/12

c) Check the drive belt tension. Adjust the base plate as required to obtain

proper belt tension.

(d) Be sure to properly align the pump and motor pulleys using a straight

edge (at a minimum). After the belt has been sufficiently tightened and

aligned, secure the HP pump by tightening the pump mounting nuts.

4) Replace the side panel on the RO unit

5.5 RO MEMBRANE CLEANING

This section is designed to guide the operator in the periodic chemical cleaning of RO

membrane elements used in the PW3000-20000 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.

PW3000-6000 PW7000-20000

Cleaning Chemical #1 5 to 15 lbs (8 to 25 cups) 6 to 20 lbs (10 to 33 cups)

Cleaning Chemical #2 4 to 12 lbs (7 to 20 cups) 5 to 15 lbs (8 to 25 cups)

Preservative Chemical #3 4 lbs (6 cups) 5 lbs (8 cups)

Table 5.1 - Chemical Requirements

There is a large variance in the required amount of chemical due to several factors. If

RO product water is used to flush the unit prior to cleaning, the quantity required will be

on the lower side. If the fresh water flush is done with dock or city water that is hard,

then the required amount will rise. If the unit is significantly fouled, the quantity also

rises. The key is to use only enough chemical to achieve the desired pH (pH 11 for #1

and pH 3 for #2). Extreme pH will damage the membranes, so do not exceed the

recommendations. For the first cleaning of a system, use the lower quantities and

measure the pH after circulating as described below. Keep adding chemical as needed

until the cleaning solution maintains the desired pH level. Keep a record of the total

chemical needed, so that on subsequent cleanings the correct amount can be used

without the needed pH measurements and adjustments.

5.5.1 CLEANING CHEMICALS

The alkaline detergent (Cleaning Chemical #1) is used to remove biological matter and

grime from the surface of the RO membranes. The acid cleaner (Cleaning Chemical

#2) is used to remove mineral scale deposits.

CAUTION

PW-3000 to PW-20000 Manual 27 Last Revised 01/12

The use of chemicals or cleaning methods other than those outlined below

will void the RO unit warranty. Non-ionic surfactants for membrane

cleaning or other chemicals not approved in writing by VMT will void the

RO unit warranty.

5.5.2 WHEN TO CLEAN

During normal operations, mineral scale and biological matter will foul the RO

membranes. These deposits build up over time and will eventually cause a loss of

product water output, salt rejection capability, or both. The RO elements should be

cleaned whenever the temperature corrected product water output drops by 10-15%

from the initial baseline established during the first hours of operation with new

membranes. 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. See Section 3.4 for more detailed information.

NOTE

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. See Section 3.4 for more detail.

Use the following procedure to clean the RO elements:

1) Flush the watermaker per section 4.3, so it is filled with fresh water, not

seawater.

2) Dissolve the appropriate amount of Cleaning Chemical #1 (see Table 5.1) in a

pail of fresh water. Make sure that that the chemical is completely dissolved (use

warm water if necessary).

NOTE

Cleaning Chemical #1 is an alkaline detergent. Use appropriate safety

precautions.

3) Verify the High Pressure Bypass Valve, V4, is in its Cleaning (open) position.

4) Place the Cleaning Valve, V5, in the Cleaning Flow position.

5) Remove the filter elements from both filter tanks and replace the 5 micron filter

with a dedicated cleaning filter (5 micron). A dedicated cleaning filter should be

used to prevent fouling of the operational filters. When the cleaning process is

PW-3000 to PW-20000 Manual 28 Last Revised 01/12

complete the dedicated cleaning filter can be cleaned and set aside until the next

membrane cleaning is required. Pour the chemical solution into the empty 20

micron filter housing and the 5 micron housing (drain water first as necessary)

and reinstall the filter housing lids.

6) Start the LP boost pump.

7) Start the HP pump. At least 0 psi must be indicated on the discharge side of the

Pre-filter Pressure gauge. Temporarily cracking open the flush valve will boost

the cleaning loop pressure if required.

a) After the chemical solution has circulated for 3 minutes, secure the

pumps, release any loop pressure by momentarily moving the cleaning

valve, V5, to the normal position and back to cleaning. Take a sample

from the cleaning loop from the filter tank drain valve or by opening the

tank lid. Measure the pH of the sample using a pH meter or test kit VMT#

90-0135.

b) If the pH < 11 then add 10% more of the cleaning solution. Repeat this

step until the pH = 11.

c) Once a pH = 11 can be maintained start the LP and HP pumps and allow

the cleaning solution to circulate for an additional 30-40 minutes.

8) Secure the HP and LP pumps.

9) Place the Cleaning valve, V5, in the Normal Flow position.

10) Open raw water supply to the RO unit external to the unit and make sure the

Flushing Valve, V10, is turned to the Normal, seawater position.

11) Start the LP boost pump and HP pump. Allow both pumps to run for 5 minutes to

flush the chemical solution from the unit.

12) Secure the HP pump and the LP boost pump.

13) Flush the watermaker, so it is filled with fresh water, not seawater.

14) Dissolve the appropriate amount of Cleaning Chemical #2 (see Table 5.1) in a

pail of fresh water. Make sure that that the chemical is completely dissolved (use

warm water if necessary).

NOTE

Cleaning Chemical #2 is an acid used for mineral scale removal. Use

appropriate safety precautions when handling.

PW-3000 to PW-20000 Manual 29 Last Revised 01/12

15) Place the Cleaning Valve, V5, in the Cleaning Flow position.

16) Remove the lid from the 20 micron filter tank, pour the cleaning solution into the

tank (drain water first as necessary) and replace the lid.

17) Start the LP boost pump.

18) Start the HP pump. At least 0 psi must be indicated on the discharge side of the

Pre-filter Pressure gauge, PG1. Temporarily cracking open the flush valve will

boost the cleaning loop pressure if required.

a) After the chemical solution has circulated for 3 minutes, secure the boost

pump, release any loop pressure by momentarily moving the cleaning

valve, V5, to the normal position and back to cleaning. Take a sample

from the cleaning loop from the filter tank drain valve or by opening the

tank lid. Measure the pH of the sample using test kit VMT# 90-0135.

b) If the pH > 3 add 10% more of the cleaning solution. Repeat this step until

the pH < 3.

c) Once a pH of less then 3 can be maintained replace the filter tank lid, start

the LP and HP pumps and allow the cleaning solution to circulate for an

additional 30-40 minutes.

19) Secure the HP and LP pumps.

20) Place the Cleaning valve in the Normal Flow position.

21) Open raw water supply to the RO unit (external to the unit).

22) Start the LP boost pump and HP pump. Allow both pumps to run for 5 minutes to

flush the chemical solution from the unit.

23) Secure the HP pump and the LP boost pump.

24) Close raw water supply to RO unit (external to the unit).

25) Remove, set aside and retain the cleaning filter for future use. Replace the

operational 20 and 5 micron filter elements in the filter housings and replace both

housing lids.

26) Place the unit back into service using the procedure contained in Section 4.1 -

Start-up Procedure.

PW-3000 to PW-20000 Manual 30 Last Revised 01/12

5.6 RO ELEMENT PRESERVATION / PICKLING

During periods when the RO unit is to be shut down for an extended period of time, it is

necessary to circulate a preservative solution through the membranes to prevent the

growth of biological organisms. Use the following procedure to preserve the RO

elements:

1) Secure the raw water supply to RO unit (external to the unit).

2) Dissolve the appropriate amount of Cleaning Chemical #3 (see Table 5.1) in a

pail of non-chlorinated product water. Make sure that that the chemical is

completely dissolved (use warm water if necessary).

NOTE

Preservative Chemical #3 is a food-grade preservative. See warning label

on package and observe all safety precautions on label.

3) Flush the watermaker, so it is filled with fresh water, not seawater (see section

4.3)

4) Make sure the High Pressure Bypass Valve is in the Cleaning (open) position.

5) Place the Cleaning Valve in the Cleaning Flow position.

6) Remove one of the filter housing lids (draining water as necessary) and pour in

the preservative solution prepared in step #1. Reinstall the lid. Leave the filters

elements in place.

7) Start the LP boost pump.

8) Start the HP pump. At least 0 psi must be indicated on the discharge side of the

Pre-filter Pressure gauge. Temporarily cracking open the flush valve will boost

the cleaning loop pressure if required. Allow the chemical solution to circulate for

10 minutes.

9) Secure the LP and HP pumps.

10) The system is now properly conditioned and may be left idle for an extended

period of time. This preservation procedure (including the fresh flush to remove

old pickling solution) should be repeated at least every 3 months during the

shutdown. In colder climates the interval between preservation cycles may be

extended to 6 months.

PW-3000 to PW-20000 Manual 31 Last Revised 01/12

5.7 RESTARTING UNIT AFTER PRESERVATION

Restart unit using the procedure contained in Section 4.1 - Start-up Procedure. Use the

MODE button on the Water Quality Monitor to light the DUMP lamp for the first 15

minutes of production to make sure all preservative is flushed clear prior to filling the

fresh water tanks.

5.8 HIGH PRESSURE PUMP OIL CHANGE

See equipment literature in back of this manual for instructions for changing the oil on

your particular pump.

5.9 MOTOR LUBRICATION

Locate the grease fittings on the electric motor. Use a clean cloth to wipe this fitting

clean. If applicable, remove any caps. Free the drain hole of any hard grease (use a

piece of wire if necessary). Add 2-3 strokes of grease using a low pressure grease gun

(see Table 5.2 for grease type).

Location Type

High pressure pump oil VMT pump oil #85-0050

High pressure pump motor grease

Shell Oil Dolium R

Texaco Premium RB

Exxon Mobil PolyrexEM

Chevron SRI

O-rings & gaskets Glycerin or silicone lubricant

Table 5.2 - Lubrication Requirements

5.10 INSPECTION LOG

Figure 5.2 depicts a sample operation log for the PW3000-20000 RO unit. The operator

of the RO unit should establish a program for entering the required data on a regular

basis. Maintaining accurate operational data is the first, and most important, step in

determining preventative maintenance requirements and reducing system downtime.

The data maintained in the log must be provided by the Purchaser to make any RO

element warranty claim. Figure 5.3 depicts a sample discrepancy report that may be

used for reporting and tracking problems with the RO unit.

PW-3000 to PW-20000 Manual 32 Last Revised 01/12

Date Total

Operating

Hours

PG1,

Pre-filter

Inlet

Pressure

PG1,

Pre-filter

Discharge

Pressure

PG2

RO Array

Discharge

Pressure

FM1,

Reject

Flow

FM2

Product

Flow

Product

Water

TDS

(ppm)

Water

Temp,

(°C) Comments

Figure 5.1 - Sample Operational Log

PW-3000 to PW-20000 Manual 33 Last Revised 01/12

COMMENT/DISCREPANCY REPORT

Village Marine Tec.

RO Desalinator Model PW-3000 to PW-20000

Plant No: Date:

Log Task No: Time:

System Affected: Technician :

Comment/Discrepancy:

Corrective Action:

Action Taken:

Date Completed:

Printed Name:

Signature:

Figure 5.2 - Sample Discrepancy Report

PW-3000 to PW-20000 Manual 34 Last Revised 01/12

6.0 PRESSURE VESSEL AND MEMBRANES

6.1 PRESSURE VESSEL DISASSEMBLY

NOTE

It is not necessary to remove a pressure vessel from the RO unit for

disassembly.

1) Disconnect all plumbing connections from the pressure vessel to be

disassembled.

2) Remove the bolts holding each end plug in place with an Allen wrench. Place a

mark on each end plug removed and its corresponding collar. This will ensure

proper orientation during assembly.

Figure 6.0 - Pressure Vessel End Plug

3) Locate the jacking screws on opposite sides of the end cap (see Figure 6.0).

Screw in the correct size bolt until the end cap is pulled off. There are also

prying slots on either side of the end plug to assist in removal.

JACKING SCREW

HOLES

PW-3000 to PW-20000 Manual 35 Last Revised 01/12

Figure 6.1 - Brine Seal Orientation

4) Note which end of the pressure vessel the brine seal is visible from. 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. Note the feed flow

direction marked by a sticker on the outside of the pressure vessel, or trace the

flow direction from the high pressure pump to confirm the high pressure flow

direction. See Figure 6.1.

CAUTION

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

the membrane is difficult to remove, use a length of 2" plastic pipe to apply

pressure on the protected end of membrane.

5) Whenever possible, remove the membrane from the discharge end of the

pressure vessel (opposite the brine seal). This is accomplished by pushing on

the membrane from the feed end of the pressure vessel until it is visible at the

discharge end. Then grasp the protruding membrane and pull it out of pressure

vessel. Place the membrane in a clean area.

6) Remove the product water o-rings and end plug o-ring from each end plug for

inspection. The product water o-rings are internal o-rings located inside the

center hole in the end cap.

PW-3000 to PW-20000 Manual 36 Last Revised 01/12

6.2 PRESSURE VESSEL ASSEMBLY

1) Clean all parts thoroughly. Inspect the o-rings on all fittings. Replace any parts

that are damaged.

NOTE

Do not apply Teflon tape or other sealant to straight thread fittings such as

those used on HP hose assemblies and their adapters.

2) Install the product water and end plug o-rings onto the end plugs. Lubricate the

o-rings and entrances to the pressure vessel with glycerin or silicone lubricant.

Locate the discharge end of pressure vessel. Install the end plug into the

discharge end making sure to align the end plug holes and the mounting holes

on the pressure vessel while paying particular attention to the reference mark

(see Section 6.3.1, Step 2). Apply pressure to the end plug until screws can be

threaded into the collars. If the end plug will not slide into the pressure vessel

sufficiently, see Figure 6.2 for an installation aid. Install and hand tighten the

screws.

Figure 6.2 - End Plug Installation Aid

3) Lubricate the brine seal and product water tubes of RO membrane with glycerin

or silicone lubricant. Do not use a petroleum based lubricant. Orient the

membrane such that the end without the brine seal enters the feed end of the

pressure vessel first. Slide the membrane into the pressure vessel until

PW-3000 to PW-20000 Manual 37 Last Revised 01/12

resistance is felt. Continue to apply moderate pressure until the product water

tube seats in the end plug.

4) Install the remaining end plug making sure to align the end plug holes with the

mounting holes on the pressure vessel while paying particular attention to the

reference mark (see Section 6.3.1, Step 2). Apply moderate pressure to the end

plug until the screws can be threaded into the collar. If the end plug will not slide

into the pressure vessel sufficiently, see Figure 6.2 for installation aid. Install and

hand tighten the capscrews.

5) Make sure that antiseize compound is applied to each screw before the final

tightening and torque the screws to 15 ft-lbs.

6) Reconnect all plumbing connections to pressure vessels.

PW-3000 to PW-20000 Manual 38 Last Revised 01/12

7.0 PRESERVATION FOR STORAGE

When the Village Marine Tec RO unit is to be shut down for an extended period of time,

it is necessary take steps to prevent the growth of biological organisms and to prevent

the water in the RO unit from freezing. Either continue to flush the unit with fresh water

each week, or circulate a preservative solution (see section 5.6). If the unit will at any

time be exposed to air temperatures of 32ºF (0ºC) or less, the membranes must be

removed and the unit fully drained or the unit filled with an anti freeze solution such as

propylene glycol.

8.0 TROUBLESHOOTING

No amount of trouble shooting advice can replace common sense and direct plant

knowledge gained through the operation and maintenance of your unit. However our

experience taking tec calls suggests some points to check.

1. Always verify proper valve configuration for each of the operational modes

selected. Verify valve positions for valves within the unit and also external valves

are open as required.

2. Always check for positive pressure at the HP pump suction. Many problems

stem from low or erratic feed water supply. Check filters, strainer, seacock,

boost pumps, etc to be sure of flooded suction to the HP pump.

3. Always check for loose connections or broken wires when inspecting electrical

parts. Checking for continuity and solid contact can sometimes avoid hours of

troubleshooting effort.

4. Prior to cleaning or replacing membranes, verify that any reduction in product

output is not the result of a corresponding variation in raw water inlet temperature

or salinity. See Section 3.4 for more detailed information.

Call or email us at the Village Marine Tec Service representative or distributor for

assistance.

PW-3000 to PW-20000 Manual 39 Last Revised 01/12

9.0 SYSTEM DRAWINGS AND DIAGRAMS AND PARTS LIST

"Use or disclosure of data contained on this sheet is subject to the restrictions on the title page of this proposal or quotation."

Installation Layout

PW-12000

PW-16000

PW-18000

"This proposal or quotation includes data that shall not be disclosed outside the Government and shall not be duplicated,

used, or disclosed in whole or in part for any purpose other than to evaluate this proposal or quotation. If, however, a

contract is awarded to Parker Hannifin as a result of or in connection with the submission of this data, the Government shall

have the right to duplicate, use or disclose the data to the extent provided in the resulting contract. This restriction does not

limit the Government's right to use information contained in this data if it is obtained from another source without restriction.

The data subject to this restriction are contained in sheet DWG 11311.

The information contained herein is submitted as the privileged and confidential property of the Parker Hannifin Corporation

pursuant to 5 U.S.C. Section 552 (b)(3) and (b)(4), the Freedom of Information Act, exemption Number 3 and Number 4.

This information shall not be duplicated, used or disclosed in whole or in part outside the recipient organization without the

express written consent of the Parker Hannifin Corporation."

PW3000-18000 Manual 43 Last Revised 4/08

10.0 MANUFACTURER'S LITERATURE AND OPTIONS

REVISION D

TABLE OF CONTENTS

_Toc293906105

INTRODUCTION.....................................................................................................................................................................1

INITIAL START-UP INFORMATION......................................................................................................................................2

LUBRICATION.....................................................................................................................................................................2

DISCHARGE PLUMBING ...................................................................................................................................................2

STORAGE ...........................................................................................................................................................................3

PREVENTIVE MAINTENANCE SCHEDULE.........................................................................................................................4

MAINTENANCE RECORD.....................................................................................................................................................5

SERVICE.................................................................................................................................................................................8

INTRODUCTION .................................................................................................................................................................8

TOOLS NEEDED ................................................................................................................................................................8

VALVE INSPECTION AND SERVICE ................................................................................................................................9

DETACHING THE MANIFOLD FROM THE CRANKCASE ................................................................................................9

SEAL REPLACEMENT .....................................................................................................................................................10

SERVICING THE CRANKCASE .......................................................................................................................................10

PLUG, OIL DRAIN, O-RING REPLACEMENT..................................................................................................................10

BEARING CAP O-RING/SEAL REPLACEMENT..............................................................................................................12

COVER, CRANKCASE O-RING REPLACEMENT ...........................................................................................................12

CRANKSHAFT BEARING, CONNECTING ROD-PISTON SERVICE..............................................................................13

CRANKSHAFT REMOVAL................................................................................................................................................13

CRANKSHAFT INSTALLATION........................................................................................................................................15

SERVICING THE MANIFOLD...........................................................................................................................................17

ADAPTER O-RING REPLACEMENT................................................................................................................................17

VALVE ASSEMBLY SERVICING ......................................................................................................................................17

MANIFOLD SEAL SERVICING .........................................................................................................................................19

ATTACHING THE MANIFOLD TO THE CRANKCASE ....................................................................................................21

OIL CHANGE PROCEDURE ............................................................................................................................................21

5P50 DRAWINGS.................................................................................................................................................................22

LIST OF FIGURES

Fig. 1: Oil Level Sight Glass Detail.......................................................................................................................................................2

Fig. 2: Valve Assembly...........................................................................................................................................................................9

Fig. 3: Manifold Assembly Removal.....................................................................................................................................................9

Fig. 4: Plunger Assembly View ...........................................................................................................................................................10

Fig. 5: Plunger Retaining Nut Assembly............................................................................................................................................11

Fig. 6: Seal Retainer.............................................................................................................................................................................11

Fig. 7: Bolt tightening sequence..........................................................................................................................................................13

Fig. 8 Keep parts organized.................................................................................................................................................................14

Fig. 9 Removal of the Crankshaft bearing.........................................................................................................................................15

Fig. 10 Correct Connecting Rod Pairing............................................................................................................................................16

Fig. 11 Incorrect Connecting Rod Pairing..........................................................................................................................................16

Fig. 12: Manifold Assembly..................................................................................................................................................................17

Fig. 13: Valve Assembly.......................................................................................................................................................................18

Fig. 14: Orientation for Manifold Seal Servicing ...............................................................................................................................19

Fig. 15: Weep Ring Extraction ...........................................................................................................................................................20

Fig. 16: High-Pressure Seal Installation View..................................................................................................................................20

Fig. 17: Pump Assembly Orientation View........................................................................................................................................21

LIST OF TABLES

Table 2: Tool List For Pump Service.......................................................................................................................................8

INTRODUCTION

Aqua Pro Pumps “Titan 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: 5

Bore: 1.259”

Stroke: 1.516”

Oil Capacity: 5.8 Qts.

Oil Type: Village Marine Tec. High Pressure Pump Oil

(Part No. 85-0050-quart size)

Maximum Inlet pressure: Flooded (zero) to 60 PSI

Maximum Fluid Temperature: 120 degrees Fahrenheit (82 degrees Celsius)

Model Number GPM Inlet Port Size Discharge Port

Size Dimensions

L x W x H Weight Shaft

5P50 20-50 1.5” MS16142-24 1” MS16142-16 18.5”x 14.5” x 9” 157 lbs. 1.625

5P50 Titan Series

High Pressure Titanium Positive Displacement Pump

INITIAL START-UP INFORMATION

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 the pump be filled with Village Marine Tec’s specially blended high pressure pump oil (PN 85-

0050). To check the oil level, ensure the pump has stopped running. Observe oil level through the sight glass in the

crankcase cover. The oil should be level with the mark on the sight glass (Fig. 1).

Fig. 1: Oil Level Sight Glass Detail.

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

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.

DISCHARGE PLUMBING

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.

NOTE

Change the original oil in the pump after 50 hours of operation. After the initial oil change, the oil should be changed at

500-hour service intervals.

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.

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.

CAUTION

DO NOT RUN PUMP WITH FROZEN FLUID. DO NOT RUN PUMP DRY.

5P50 Titan Series

High Pressure Titanium Positive Displacement Pump

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

Determined

Condition

FIRST

50 HRS. EVERY

500 HRS. EVERY

1500 HRS. EVERY

10000 HRS.

Inspect for Water Leaks/

Oil Leaks X

Check Oil Level X

Check Belt Tension X

Inspect Plumbing X

Inspect Pump Valves X

Change Pump Oil X X

Replace Pump Valves X

Replace Seals X

Crankcase Service and

Inspect Connecting Rods

and Crank Bearings X

Manifold Rebuild X

Replace Connecting Rods

and Bearings X

MAINTENANCE RECORD

Keep record of all maintenance activities to ensure maintenance is performed. Note trends and increase maintenance as

necessary.

HOURS RECOMMEND

SERVICE ACTIONS / NOTES ACTUAL

HOURS SIGNATURE DATE

50 Oil

550 Oil

1050 Oil

1550 Valve Inspection, Oil

2050 Oil

2550 Oil

3050 Valve Inspection, Oil

3550 Oil

4050 Oil

4550 Valve Inspection, Oil

5050 Oil

5550 Oil

6050 Valve Inspection, Oil

6550 Oil

7050 Oil

7550 Valve Inspection, Oil

8050 Oil

8550 Oil

9050 Valve Inspection, Oil

9550 Oil

10000 Crankshaft Bearing,

Manifold Rebuild, Oil

*HP seal is not routinely replaced during low pressure seal change. HP seal is replaced only in case of seal failure (see

low-pressure troubleshooting, pg.6).

** Oil changes are mandatory at the specified hour intervals.

5P50 Titan Series

High Pressure Titanium Positive Displacement Pump

TROUBLESHOOTING

Use the troubleshooting table below. If problems persist, 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 t

ighten. 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

improperly sized Clear the obstruction, or use adequate size for inlet

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;

abrasives in pump fluid, severe

cavitation; inadequate water

supply; stressful inlet conditions.

Replace seals with rebuild kit. Install and maintain

proper filter, check line size and flow available to

pump

Pulsation Pump runs

extremely rough, pressure low Faulty pulsation dampener (if a

pulsation dampener has been

installed.)

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.

Slight water leakage from

under the manifold Possible Condensation No fix needed.

Worn low pressure seals Replace seals with seal kit, check inlet pressure and

inspect ceramic plunger for damage.

Excessive oil leak between

crankcase and pumping

section (1 drop every 15 min)

Worn crankcase oil seals Replace crankcase oil seals.

PROBLEM PROBABLE CAUSE SOLUTION

Oil leaking from crankshaft

area Worn crankshaft oil seal Replace damaged oil seals.

Bad bearing Replace bearing.

Cut or worn o-ring on bearing

cap Replace o-ring on bearing cap.

Water in crankcase Humid air condensing into water

inside the crankcase Change oil every three months or 500 hours

Excessive play in the end of

the crankshaft Worn bearing Replace bearing.

Oil leaking in the rear portion

of the crankcase Damaged or improperly installed

crankcase cover, crankcase

cover o-ring, drain-plug, or drain-

plug o-ring.

Replace crankcase cover o-ring or drain-plug o-ring.

Loud knocking noise in pump Pulley loose on crankshaft Check key and pulley bushing.

Restricted Inlet Clear obstruction or replace valve.

Worn bearing, connecting rod or

crankshaft. Service crankcase.

Worn belts Replace belts.

Frequent or premature failure

of the seals Running pump dry NEVER RUN THE PUMP WITHOUT WATER.

Abrasive material in the fluid

being pumped Install proper filtration on pump inlet plumbing.

Excessive temperature of

pumped fluid (120 degrees F

max.)

Reduce fluid inlet temperature to specifications.

5P50 Titan Series

High Pressure Titanium Positive Displacement Pump

SERVICE

Pump rebuild kits are available for valve or 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 the utmost

cleanliness be maintained during the rebuild of your Aqua Pro Pump. The numbers following the parts are callout

numbers. They correspond to the parts shown in the figures and in the assembly drawings at the end of the manual.

READ THE INSTRUCTIONS COMPLETELY BEFORE ATTEMPTING TO PERFORM ANY SERVICE.

Before assembling, clean all parts to make free of oil, grease, dirt, and lint. Use a lint-free cloth to wipe any part of the

pump.

TOOLS NEEDED

Table 2: Tool List for Pump Service

3/16” Allen Wrench Wrench Hex Jaw

1/4” Allen Wrench Pick

3/8” 12-point Socket Wrench Pry-bar

9/16" Socket/ Socket Wrench or Combination Wrench Snap Ring Pliers

15/16” Socket/ Socket Wrench or Combination Wrench Torque Wrench (50 ft.-lb.)

1" Socket/ Socket Wrench or Combination Wrench Seal Insertion Tool (PN 91-7228)

1-1/2” Socket/ Socket Wrench or Combination Wrench Weep Ring Removal Tool (PN 91-7230)

Flat-Head Screwdriver Die M7 X 1.0

Phillips-head Screwdriver Bearing Puller

Tap M7 X 1.0 Anti-Seize Lubricant (PN 85-0094)

Silicon Grease (PN 21-1122) Ceramic Lubricant (PN 85-0087)

Arbor press for Connecting Rod/Plunger Pin Press for Crankshaft removal

Torque Wrench Red Loctite

Dead Blow Hammer

CAUTION

Ensure pump is disconnected from the motor or any driving devices. Service the pump in a clean, dirt-free environment.

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.

VALVE INSPECTION AND SERVICE

Remove ten valve plugs (44) from the manifold using a 1 ½“ socket wrench. Remove the valves (41) and springs (42)

from each valve port. Inspect the curved valve surface for damage or distortion. A circular mark from the valve seat is

normal, but should not advance to distorting the valve shape. If a valve is broken or pitted, use a flashlight to examine the

seat inside the valve port. Inspection will ensure that the valve seat has not been damaged by debris.

Depending on the condition, either replace or clean and reuse valves and springs. A set of 10 valve and 10 springs is

available as PN 70-1057. Apply a light coat of silicon grease (PN 21-1122) to the valve plug o-ring (43). Apply anti-seize

lubricant (PN 85-0094) to the valve plug threads. Assemble the valves, springs and plugs as shown in Fig. 9, and tighten

the valve plugs back into the manifold.

Fig. 2: Valve Assembly

DETACHING THE MANIFOLD FROM THE CRANKCASE

Remove the 2 manifold nuts (53), see Fig. 13, with a 15/16” socket wrench or Combination Wrench. Loosen the manifold

assembly by prying off the manifold using the slots in the crankcase as shown in Fig 2. Set the manifold assembly aside

in a clean work area. If the manifold assembly locating dowel pins (50) fall out, reinsert them into the manifold alignment

pin hole.

Fig. 3: Manifold Assembly Removal

Valves may be serviced while the manifold assembly is attached to the crankcase assembly. In most cases, service can be

completed while the pump is in place within the watermaker system.

5P50 Titan Series

High Pressure Titanium Positive Displacement Pump

SEAL REPLACEMENT

If condition based seal service is required (Seal Kit PN 70-3080), use the following instructions outlined in the OIL SEAL

REPLACEMENT section. To determine the need of condition based service, look for signs of oil or water drip under the

pump. Once the manifold is detached from the crankcase, the low pressure water seals (40) are exposed on the manifold

surface and can easily be replaced. If undertaking the complete 10,000 hour service with kits 70-3075 and 70-3078, then

follow the detailed instructions.

SERVICING THE CRANKCASE

The following are the procedures for servicing the crankcase assembly using the 5P50 Crankcase Rebuild Kit

(PN. 70-3078). The manifold assembly must be detached from the crankcase to do the following service.

PLUG, OIL DRAIN, O-RING REPLACEMENT

Remove the oil drain plug (5) with a 1” wrench and drain the crankcase oil. Clean the drain plug (5), and remove the o-

ring (4) with the aid of the pick if necessary. Replace the o-ring with the new one supplied with kit. Apply anti-seize lube

to the threads of the drain plug (5) and reinstall.

OIL SEAL REPLACEMENT

Remove the seal retainer (33) and set aside, see Fig. 6. Remove the plunger retainer nut (32) with a 9/16” wrench and set

aside. Remove the plunger retainer washer (31) and back-up ring (29), Fig. 5, and remove the ceramic plunger (8).

Remove the keyhole washer (26), then remove the slinger (25), see Fig. 4. Using a flat head screwdriver and hammer,

drive the screwdriver into the meat of the seal (6). Be careful not to scratch the inner or outer metal sealing surfaces. A

quick twist of the screwdriver will remove the seal. Do not attempt to preserve the seal for reuse. Inspect the seal retainer

washers for damage; if none is evident then reuse.

Insert new plunger rod oil seal (6) into crankcase ensuring that the seal is fully seated. Place slinger (25) onto the plunger

rod (8), followed by the keyhole washer (26) as shown in Fig. 4. Chase the thread of the plunger rod and the retainer stud

with the tap and die to ensure the removal of any left over loctite prior to reassembly.

Fig. 4: Plunger Assembly View

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.

Slide ceramic plungers (27) onto plunger rod, and insert the new plunger retainer washer (31) into the plunger. Clean the

plunger retaining nuts (32), Fig. 5. With the aid of a pick remove the plunger retainer back-up ring (29) and the plunger

retainer o-ring (30). Replace the o-ring (30) and back-up ring (29) with the new one supplied in the kit as shown in Fig. 5.

Fig. 5: Plunger Retaining Nut Assembly

Apply Red Loctite # 262 to retainer stud (28) threads. Reinstall the plunger retainer nut (32) and torque to 100 in. lb.

using a 9/16” socket.

Apply Aqua Pro’s special Ceramic Lubricant (PN. 85-0087) to the ceramic plungers (27). Slide the seal retainer (33) over

the ceramic plungers (27). Make sure that the flanged side is in close proximity to the manifold assembly, and that the

hole is oriented downward ensuring that the seal retainer has adequate water drainage. Slide manifold assembly over

plungers and reinstall manifold nuts (53).

Fig. 6: Seal Retainer

NOTE

Examine the ceramic plungers (27), Fig. 6, for cracks, heavy scoring, or unusual wear.

NOTE

Be careful not to get the red loctite on any other components. Failure to use loctite on the retainer stud and nut could lead

to catastrophic failure of the pump.

5P50 Titan Series

High Pressure Titanium Positive Displacement Pump

BEARING CAP O-RING/SEAL REPLACEMENT

You will need these tools and parts to do the following:

1/4" Allen Wrench

Pick

Seal, Oil, Crankshaft (16): PN. 70-0701

O-Ring, Bearing Cap (15): PN. 70-0703

Silicon Grease Lubricant: PN. 21-1122

Anti-Seize Lubricant: PN. 85-0094

Remove the 4 socket head cap screws (17) with a 1/4” Allen Wrench from each of bearing side plates (13), (14). With the

aid of a pick remove the o-rings from the grooves and remove the crankshaft oil seal (16) from the pulley side bearing cap

(14).

Press new crankshaft oil seal (16) into pulley side bearing cap (14), install o-ring (15) in o-ring groove on the crankshaft

bearing caps (13) and (14), and reinstall caps on pump.

Install the 4 socket head cap screws (17) onto each of the bearing side plates and tighten with a 1/4” Allen Wrench.

COVER, CRANKCASE 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:

3/16” Allen Wrench

Phillips-head Screwdriver

Pick

Silicone Grease Lubricant: PN. 21-1122

Red Loctite # 262

Anti-Seize Lubricant: PN. 85-0094

Unscrew the 12 crankcase cover screws (24) with the 3/16” Allen wrench. Remove the 6 sight glass retaining screws (23)

with the Phillips-head screwdriver. Remove the sight glass retaining frame (22) and the sight glass (21). With the aid of

the pick remove the sight glass o-ring (20), and remove the crankcase cover o-ring (18).

CAUTION

Crankshaft oil seal is press-fit at the factory, so care is to be exercised during removal to prevent any damage 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.

NOTE

A light coating of Anti-Seize Lubricant (PN. 85-0094) should be applied on all threaded parts, unless otherwise stated.

Install the new sight glass o-ring (20) and the crankcase cover o-ring (18) provided with the rebuild kit.

Install the sight glass (21) and the sight glass frame (22). Apply Red Loctite #262 to the 6 sight glass retaining screws

(23) and tighten. Reinstall the crankcase cover (19) and tighten the 10 crankcase cover screws (24) with the 3/16” Allen

wrench in the sequence shown in Fig. 7.

Fig. 7: Bolt tightening sequence

CRANKSHAFT BEARING, CONNECTING ROD-PISTON SERVICE

When feasible, it is recommended that any service to the Crankshaft (11), Connecting Rods (10), and Plunger

Rods (8) be done by sending the pump back to the factory for rebuilding.

CRANKSHAFT REMOVAL

Crankshaft removal is not necessary for overhaul of seals.

NOTE: The Manifold, Plunger assembly, Bearing Side Plates, and Crankcase Cover must be removed before attempting

to remove the crankshaft.

You will need these tools and parts to do the following:

3/8” 12-point Socket Wrench

Arbor press for Connecting Rod/Plunger Pin

Bearing Puller

Snap Ringer Pliers

Using a 23-point socket, unscrew the connecting rod Bolts (10)

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.

NOTE

A light coating of Anti-Seize Lubricant (PN. 85-0094) should be applied on all threaded parts, unless otherwise stated.

5P50 Titan Series

High Pressure Titanium Positive Displacement Pump

(NOTICE: Unscrew one connecting rod cap at a time. Keep the bolts in the same hold it came out of. Store the

connecting rod caps like the picture below in order from 1-5. Fig. 8)

Fig. 8 Keep parts organized

Push the connecting rod assembly in as far as possible away from the Crankshaft (11).

Make sure the Connecting Rods (10) are clear from the path of the crankshaft.

Rotate the Crankshaft (11) by hand to feel for smooth bearing movement. If movement is rough, Bearings (12) needs to

be replaced. Inspect the bearing surface of the connecting rod end caps. Some scoring is considered acceptable, but

irregular wear patterns are not. This is where the decision is made on whether to replace the connecting rods and crank

bearings. If bearing surface passes inspection, reassembly can begin.

If not already done, remove both Bearing Side Plates (13)(14).

Using a press, press out the Crankshaft (11) from the key slotted side.

The crankshaft should come out of the crankcase with one Bearing (12) on the non-key slotted side and one Bearing (12)

still in the Crankcase (1).

Pull off the Bearing (12) on the Crankshaft (11) with a bearing puller (fig. 9).

Fig. 9 Removal of the Crankshaft bearing

Slide out the Connecting Rods (10) and the Plunger Rod Assembly (8). Check for abnormal wear or scoring.

***Note: Remember where each connecting rod came out of the crankcase. Keep them in the same order. The

connecting Rods and Caps are numbered for this reason. (Lay down connecting rods and caps in order removed.

Ensure connecting rods remain in order with caps.)

Remove the Plunger Rod Seal (6). (Do this step only if not already done.)

The Connecting Rod (10) is attached to the Plunger Rod Assembly (8) by a press fit Pin (9). Unless necessary, do not

disassemble.

CRANKSHAFT INSTALLATION

You will need these tools and parts to do the following:

Arbor press for Connecting Rod/Plunger Pin

Press for Crankshaft removal

Torque Wrench

¼” Allen wrench

3/8” 12-point Socket Wrench

Silicone Grease – PN. 21-1122

Anti-seize lubricant – PN. 85-0094

Red Loctite

Snap Ring Pliers

Press in the Crankshaft Bearing (12) into the right Crankshaft bore of the Crankcase (1). If any wear, rough spinning, or

looseness is noted, then use new bearings. (Freezing the bearing may help with the press fit.)

Apply silicone grease onto the O-ring (15) and the Crankshaft Seal (16). Install the Bearing Plate O-ring (15) and

Crankshaft Seal (16) into the pulley side Bearing Plate (14).

5P50 Titan Series

High Pressure Titanium Positive Displacement Pump

Apply a light coat of anti-seize to the 4 Socket Head Cap Screws (17). Install the pulley side Bearing Side Pate (14) using

the 4 Socket Head Cap Screws (17) with a ¼” Allen wrench

Insert Plunger oil Seal (6) into crankcase. Make sure that the seal is fully seated. (Do this step only if not already done.)

Attach the Connecting Rod (10) and Plunger Rod Assembly (8) using the Press Fit Pin (9). Press the pins in using an

arbor press (Freezing the Pins (9) and assembling while cold may help in this process.)

Insert the Connecting Rod (10) and the Plunger Rod Assembly (8) in the Crankcase (1) in the same order as when they

were take out. (The connecting rods are numbered 1, 2, 3… Make certain that the order is correct and that the

connecting rod caps’ number corresponds to the connecting rods’ number. The number one Connecting Rod should be

closest to the pulley side of the Crankshaft.)

Push the connecting rod assembly in as far as possible away from the Crankshaft (11) insertion path. Make sure the

Connecting Rods (10) are clear from the path of the crankshaft.

Slide in the Crankshaft (11), keyed side first, from the right side of the Crankcase (1) to the left side, through the

Crankshaft Bearing (12). A press may be needed to accomplish this step. The connecting rod bearing surfaces must

exactly align with the plunger bores to avoid bending pressure on the connecting rods.

Press in the left Crankshaft Bearing (38) (closed center hole side).

Apply a light coat of silicone grease to the new Bearing Side Plate O-rings (15).

Apply a light coast of anti-seize to the 4 Socket Head Cap Screws (17). Install the Closed Bearing Side Plate (13) using

the 4 Socket Head Cap Screws (17) with a ¼” Allen Wrench.

Apply red loctite to the threads of the Connecting Rod Cap Bolts. Install the Connecting Rod Caps to their corresponding

Connecting Rods (10) (There are numbers inscribed on the connecting rods and the connecting rod caps. Make sure that

they match up, e.g. 1 and 1, 2 and 2, and 3 and 3.) Pre torque the Connecting Rod Bolts to 100 in. lb. Then torque the

Connecting Rod Bolts to 230 in. lb. with a 3/8” 12-point Socket Wrench

Fig. 10 Correct Connecting Rod Pairing

Fig. 11 Incorrect Connecting Rod Pairing

***Make sure the flat sides numbers are matched up together on the Connecting Rods (10) (like figure 10 not figure 11).

SERVICING THE MANIFOLD

The following are the procedures for servicing the manifold assembly using the 5P50 Manifold Rebuild Kit (PN. 70-3075).

The manifold assembly must be detached from the crankcase to do the following service.

Fig. 12: Manifold Assembly

ADAPTER O-RING REPLACEMENT

You will need these tools and parts to do the following:

Wrench Hex Jaw

Pick

O-Ring, Inlet Plug Adapter (43): PN. 70-3002

O-Ring, Discharge Plug Adapter (45): PN. 70-3074

Silicone Grease Lubricant: PN. 21-1122

Anti-Seize Lubricant: PN. 85-0094

Remove the Inlet/Discharge/Plug, (46), (47), (48), and (49) adapters from the manifold assembly with a hex jaw wrench.

With the aid of a pick remove the o-rings (45) and (43) from each of the adapters.

Install the new o-rings, (45) and (43), provided with the kit onto each of the adapters.

Reinstall each of the adapters onto the manifold assembly, then tighten adapter with hex jaw wrench.

VALVE ASSEMBLY SERVICING

You will need these tools and parts to do the following:

1 1/2" Socket Wrench or Combination Wrench

Pick

Spring, Valve (42): PN. 70-7049

Assembly, Valve (41): PN. 70-3004

O-Ring, Valve Plug (43): PN. 70-3002

Silicone Grease Lubricant: PN. 21-1122

Anti-Seize Lubricant: PN. 85-0094

Lint-Free Cloths

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.

NOTE

A light coating of Anti-Seize Lubricant (PN. 85-0094) should be applied on all threaded parts, unless otherwise stated.

5P50 Titan Series

High Pressure Titanium Positive Displacement Pump

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 1 1/2” socket wrench or combination wrench.

Remove the valve (41) from the assembly, followed by the valve spring (42). With the aid of a pick remove the o-ring (43)

from the valve plug.

Clean and inspect all valve plugs (44) prior to reassembly. Once all valve plugs (44) are clean and dry, install new valve

plug o-ring (43) onto valve plug (44). Install the valve spring (42) onto the valve plug (44). Press the valve (41) onto the

valve spring (42). Complete valve assembly shown in Fig. 13.

Fig. 13: Valve Assembly

Inspect the manifold (34) for debris or other fouling and clean if necessary. Inspect the valve seat surface in the manifold.

Reinstall all the valve plug assemblies with a 1 1/2" socket wrench or combination wrench and tighten.

NOTE

Valves may be serviced while the manifold assembly is attached to the crankcase assembly.

NOTE

Valve plugs (44) 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.

NOTE

A light coating of Anti-Seize Lubricant (PN. 85-0094) should be applied on all threaded parts, unless otherwise stated.

MANIFOLD SEAL SERVICING

You will need these tools and parts to do the following:

Snap Ring Pliers

Tool, Seal Insertion: PN. 91-7228

Flat screw driver

Seal, HP (36): PN. 70-2502

Ring, Snap (38): PN. 70-3009

Ring, Weep (37): PN. 70-3008

Seal, LP (40): PN. 70-2501

Silicone Grease Lubricant: PN. 21-1122

Lint-Free Cloths

Routine seal service is the replacement of the exposed low pressure seal (40) only. The following instructions are for a

complete manifold rebuild at the 10,000 hour service mark.

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. 14.

Fig. 14: Orientation for Manifold Seal Servicing

With a flat screw driver remove the low-pressure seal (40). Manually remove the low-pressure seal spacer (39). With the

snap ring pliers remove the snap ring (38). Using the weep ring extracting tool, remove the weep ring (37) as shown in

Fig. 15.

NOTE

Pump manifold assembly must be detached from the crankcase assembly to service the seals.

NOTE

Extraction of the weep rings is accomplished by inserting tool in relaxed state into the inner diameter of the rings, then

tightening the expansion bolt to grip the ring.

5P50 Titan Series

High Pressure Titanium Positive Displacement Pump

Fig. 15: Weep Ring Extraction

With a flat screwdriver remove the high-pressure seals (36). Manually remove the high-pressure seal spacer (35).

Insert the high-pressure seal spacer (35) into the bore.

Insert the high-pressure seal (36) into the bore until the seal is fully seated on the high-pressure seal spacer (35), using

the seal insertion tool. See Fig. 12 for high-pressure seal installation view.

Fig. 16: High-Pressure Seal Installation View

Insert the weep ring (37) into the bore after the installation of the high-pressure seals (36), using the driver from the seal

insertion tool. Install the snap ring (38) using the snap ring pliers.

Insert the low-pressure seal spacer (39), then install the new low-pressure seal (40). The manifold seal servicing is

complete.

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.

NOTE

Ensure that the snap ring (38) is fully seated in the snap ring groove before continuing.

ATTACHING THE MANIFOLD TO THE CRANKCASE

You will need these tools and parts to do the following:

15/16” Socket/ Socket Wrench or Combination Wrench

Dead Blow Hammer

Manifold Nut (53): PN. 70-1305

Ceramic Lubricant: PN. 85-0087

Anti-Seize Lubricant: PN. 85-0094

If a crankcase seal rebuild was not performed at this time then ensure that the dowel locating pins (50) 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.

Align manifold assembly to crankcase assembly as shown in Fig. 13 and tighten the two manifold nuts (53) with a 15/16”

socket wrench or combination wrench, torque to 90 ft-lbs.

Fig. 17: Pump Assembly Orientation View

OIL CHANGE PROCEDURE

You will need these tools and parts to do the following:

1” Socket/ Socket Wrench

Lint-free Cloths

Funnel, 4 oz, plastic

Village Marine High-Pressure Pump Oil, PN. 85-0050

Clean area around the oil filler cap (3) and the oil drain plug. Remove the oil filler cap, and then drain the crankcase oil.

Once the used oil is completely drained, slowly add high-pressure pump oil to the level shown on the sight glass.

Reinstall oil filler cap (3) and wipe off any excess oil.

NOTE

A light coating of Anti-Seize Lubricant (PN. 85-0094) should be applied on all threaded parts, unless otherwise stated.

5P50 Titan Series

High Pressure Titanium Positive Displacement Pump

5P50 DRAWINGS

5P50 PUMP SPECIFICATIONS

5P50 CRANKCASE ASSEMBLY

5P50 MANIFOLD ASSEMBLY

5P50 MAIN ASSEMBLY

4 3

REV

SHEET

125

.X±.020

DECIMALS

DIMENSIONS & TOLERANCING ARE IN INCHES

PER ANSI Y14.5 M & MIL-STD-100

ANGULAR

± 0°30"

UNLESS OTHERWISE SPECIFED

TITLE

SIZE

SCALE

WEIGHT

DRAWN

FINISH

.XX±.010

.XXX±.005

MAT'L

APPROVED

CHECKED

DATE

± 1/32

FRACTIONAL

DWG NO

2/5/07

LBS

VARIOUS

1:8

70-3000

ASSEMBLY, 5P50 CRANKCASE

4/28/08

3 2 14

2 1

14 2

21-1122 SILICON GREASE

85-0087 CERAMIC LUBRICANT

85-0094 ANTISIEZE

NOTES:

1) ASSEMBLY PART NUMBERS ARE AS FOLLOWS:

70-3073 ASSY, CRANKCASE, 5P50 TITAN SERIES

70-3078 KIT, SERVICE, CRANKCASE, 5P50

70-3080 KIT, PUMP SEAL, 5P50

2) THE FOLLOWING PART NUMBERS ARE NOT SHOWN

IN DRAWING BUT ARE INLCUDED IN EACH KIT:

--1CRANKCASE, TITAN SERIES 5P50, AL70-30821

-11O-RING, OIL FILLER CAP70-60292

--1CAP, OIL FILLER70-3044

ITEM PART

NUMBER DESCRIPTION QTY

(70-3073)

QTY KIT

(70-3078)

QTY KIT

(70-3080)

33 70-3012 RETAINER, SEAL 5 - -

32 70-3016 NUT, PLUNGER RETAINER 5 - -

31 70-3017 WASHER, PLUNGER RETAINER 5 5 5

30 70-3411 O-RING, PLUNGER 5 5 5

29 70-3019 RING, BACK-UP, SPLIT 5 5 5

28 70-3020 STUD, M7x1.0, 3.40, PLUNGER 5 - -

27 70-3021 PLUNGER, CERAMIC 5 - -

26 70-3022 WASHER, KEYHOLE 5 - -

25 70-3023 SLINGER, PLUNGER 5 - -

24 86-0151 SCREW, REAR COVER 12 - -

23 86-0120 SCREW, SIGHT GLASS 6 - -

22 70-3060 FRAME, SIGHT GLASS 1 - -

21 70-3039 SIGHTGLASS, OIL, 3P20/5P100 1 - -

20 70-3040 O-RING, SIGHT GLASS 1 1 -

19 70-3087 COVER, CRANKCASE, TITAN SERIES 5P50 1 - -

18 70-6101 O-RING, REAR COVER 1 1 -

17 86-0256 SCREW, SIDE CAP 8 - -

16 70-0701 SEAL, OIL, CRANKSHAFT 1 1 -

15 70-0703 O-RING, BEARING CAP 2 1 -

14 70-3081 CAP,PULLEY BEARING,5P50,AL 1 - -

13 70-3079 CAP, BEARING, CLOSED 1 - -

12 70-0439 BEARING,TAPERED ROLLER,4130-STL 2 - -

11 70-3034 CRANKSHAFT, 5P50 1 - -

10 70-3098 ASSY, CONNECTING ROD, 5P50 5 - -

9 70-3027 PIN, DOWEL 5 - -

8 70-0344M ASSEMBLY, PLUNGER ROD 5 - -

7 70-3006 STUD, MANIFOLD RETAINING 2 - -

6 70-3062 SEAL, OIL, PLUNGER, 3P20/5P50 5 5 5

5 70-3046 PLUG, OIL DRAIN 1 - -

4 30-1286 O-RING, PLUG, OIL DRAIN 1 1 -

REVISIONS

REV. DESCRIPTION DATE APPROVED

- INITIAL RELEASE 2/5/2007 BC

A MODIFIED BOM QTY TITLE 3/17/2010 CC

B ADDED PUMP SEAL KIT 5/20/2011 CC

85-0094 CERAMIC LUBRICANT

85-0087 ANTISIEZE

21-1122 SILICON GREASE

NOTES:

1) ASSEMBLY PART NUMBERS ARE AS FOLLOWS:

70-6120 ASSY, MANIFOLD, 5P50 TITAN SERIES

70-3075 KIT, REBUILD, MANIFOLD, 5P50

70-1057 KIT, PUMP VALVE

70-3080 KIT, PUMP SEAL, 5P50

2) THE FOLLOWING PART NUMBERS ARE NOT SHOWN

IN DRAWING BUT ARE INLCUDED IN EACH KIT:

REV

SHEET

125

.X±.020

DECIMALS

DIMENSIONS & TOLERANCING ARE IN INCHES

PER ANSI Y14.5 M & MIL-STD-100

ANGULAR

± 0°30"

UNLESS OTHERWISE SPECIFED

TITLE

SIZE

SCALE

WEIGHT

DRAWN

FINISH

.XX±.010

.XXX±.005

MAT'L

APPROVED

CHECKED

DATE

± 1/32

FRACTIONAL

DWG NO

LBS

1:1

70-3000

ASSEMBLY, 5P50 MANIFOLD

3 2 14

24 1

5 5 - -

35 70-0407 RING, SPACER, HP SEAL 5 5 - -

34 70-3005 MANIFOLD, TITAN SERIES 5P50 1 - - -

ITEM PART

NUMBER DESCRIPTION QTY

(70-6120)

QTY KIT

(70-3075)

QTY KIT

(70-3080)

QTY KIT

(70-1057)

50 70-3050 PIN,DOWEL 2 - - -

49 70-3066 PLUG,MS18229-16,TI 1 - - -

48 70-3065 PLUG,MS18829-24 1 - - -

47 70-3059 ADTR, FACE SEAL 1 - - -

46 70-3064 ADTR, 2.0 HB, MS18229-24 1 - - -

45 70-3074 O-RING, APTR, HOSE-BARB 2 2 - -

44 70-3001 PLUG, VALVE, MS18229-16 10 - - -

43 70-3002 O-RING, VALVE 12 12 - -

42 70-7049 SPRING, VALVE, 3P20/5P50, TI 10 10 - 10

41 70-3004 ASSY, VALVE, 3P20/5P50 TITAN SERIES 10 10 - 10

40 70-2501 SEAL, LP,3P20/5P50, XYLAN, BLUE PTFE 5 5 5 -

39 70-3010 SPACER, LOW PRESSURE SEAL 5 5 - -

38 70-3009 RING, RETAINING,3P20/5P50 5 5 - -

37 70-3008 ASSEMBLY, WEEP RING,3P20/5P50 5 5 - -

36 70-2502 SEAL, HIGH PRESSURE

REVISIONS

REV. DESCRIPTION DATE APPROVED

- INITIAL RELEASE - -

AMODIFIED BOM QTY TITLE, NOTE

INCLUDES ITEMS NOT IN BOM TABLE 3/26/10 CC

B ADDED PUMP AND SEAL KITS 5/20/11 CC

Racor 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.

Pressure Vessel

Assemblies

Contact Information:

Parker Hannin Corporation

Racor Division/Village Marine Tec.

2000 W. 135th St.

Gardena, CA 90249

phone 310 516 9911

fax 310 538 3048

racor@parker.com

www.villagemarine.com

www.parker.com/racor

Key Features:

• Operating Pressure: 1000 psi/68 bar

• Shell: Filament Wound berglass

• 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

For Seawater Elements

Description

Vessel Assembly**

Product O-ring

End Plug O-ring

End Plug

End Ring

Capscrews

Shell White

Gray

Item

Quantity per

Assembly

***

2.5” x 19”

32-2519

32-2116

32-2228

32-2513*

32-4013

86-0106

32-0025

32-0098

5/2

2.5” x 38”

32-2538

32-2116

32-2228

32-2513*

32-4013

86-0106

32-0026

32-0099

7/3

4” x 40”

32-0444

32-2116

32-4342

32-4012

32-4014

86-0123

Please Call

32-4001

22/10

6” x 40”

32-6040

32-2229

32-0640

32-6012

32-0096

86-0136

Please Call

32-0001

45/20

Weight (lbs/kg)

Notes:

*End Plug 32-2517 is also available

for 2.5” vessels, which oers straight,

coarse thread feed/reject port used on

some VMT PW watermakers

**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

Pressure Vessel

Assemblies

For Seawater Elements

Part Numbers:

2 3 4 5 6

Aqua Pro® Sea Water

RO Membranes

Contact Information:

Parker Hannin Corporation

Racor Division/Village Marine Tec.

2000 W. 135th St.

Gardena, CA 90249

phone 310 516 9911

fax 310 538 3048

racor@parker.com

www.villagemarine.com

www.parker.com/racor

Aqua Pro® thin lm composite

membranes deliver high salt

rejection while maintaining high

production rates to obtain the

energy efciency 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

Aqua Pro® products.

Key Feature:

• 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 (30 min)

Cleaning: 2.5-11

Aqua Pro®

Sea Water RO

Membranes

Notes:

Recommended

Operating Limits:

TYP

15°

Nominal

Size

2519

2538

4040

6040

Product Flow

GPD m3/day

220 - 0.83

550 - 2.08

1200 - 4.54

2500 - 9.47

Typical Salt

Rejection %

99.4

VMT

Part No.

33-2519

33-0238

33-0440

33-0036

Dimensions

inches/cm

19/48

38/96.5

40/101.6

1.1/2.8

1.0/2.5

1.27/3.2

0.75/1.9

1.5/3.8

2.4/6.1

3.96/10.1

5.98/15.2

• Keep elements moist at all

times

• Permeate obtained from rst

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. e standard storage

solution for long or short term

storage should contain 1.0

percent (by weight) sodium

metabisulte (food grade)

• Standarized 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%

Filter Housings

FRP Shell with Nylon Caps

100X-FRP

Contact Information:

Parker Hannin Corporation

Racor Division/Village Marine Tec.

2000 W. 135th St.

Gardena, CA 90249

phone: 310 516-9911

800 C-Parker

fax: 310 538-3048

email: racor@parker.com

www.villagemarine.com

www.parker.com/racor

Racor Village Marine oers

berglass lter housings

specically designed for

seawater use. Simple but secure

closure systems allow quick

cartridge change. Aluminum

collars are bonded to berglass

shells oer superior corrosion

resistance. e base and lid are

nylon.

e housings t VMT pleated

cartridge elements of 100 square

feet area. Available in 0.5, 1, 5,

20, and 100 micron ratings.

Filter Housings

FRP Shell with Nylon Caps

100X-FRP

DWG

Part Number

30-4353

M4353-4

M1157-1

M4353-2

30-0405

86-0022

86-0264

86-0006

86-0269

86-0260

Description

Filter Assembly

Vessel Shell

Base

Lid

O-Ring

Nuts - Bottom

Studs

Washer

Wingnut

Bolt - Bottom

Speciﬁcations

Design Pressure* 80 psi

Test Pressure 120 psi

Inlet 1.5” FPT

Outlet 1.5” FPT

Height 33”/84 cm

Diameter 13”/33 cm

To maintain peak performance always use genuine Parker Racor Village Marine replacement parts.

We reserve the right to change our speciﬁcations or standards without notice.

*Filter Housing Vessel is designed in accordance with ASME section x pressure vessel code.

Print Reorder Number 7940 Rev-B 09-26-2011

8 Req’d

2 Req’d

8 Req’d

e Village Marine Tec. line of pleated

lters are designed specically for

the RO watermaker industry and

are superior to wound or polyspun

cartridges to give you a longer lter

life as well as increasing ow rates and

keeping cartridge size down.

Available in a wide arrange of sizes

and micron ranges to ensure that every

type of watermaker lter need is taken

care of. Stock sizes t most standard

lter housings, if the size you need is

not shown please contact us with the

dimensions required.

Pleated Filters and

Filter Cartridge Kits

Contact Information:

Parker Hannin Corporation

Racor Division/Village Marine Tec.

2000 W. 135th St.

Gardena, CA 90249

phone: 310 516-9911

800 C-Parker

fax: 310 538-3048

email: racor@parker.com

www.villagemarine.com

www.parker.com/racor

Single use Cleaning and Preservative

Cartridge Kits are designed specically

for small RO Systems. e Cartridges

allow for easy and eective membrane

maintenance.

e Cleaning and Preservative

Cartridge Kits eliminate the trouble

and mess of measuring powdered

chemicals and ensuring correct

chemical concentrations. e Chemical

cartridges t 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

• 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 lter seal

to eliminate bypass

• High packing density reduces

lter size while keeping ow

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. is

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) lter cartridges

Pleated Filters and Filter Cartridge Kits

Features:

Carbon Flushing Filters

Cartridge Filter Kits

Pleated Sediment Elements

Part Number

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

Microns

100

0.5

Filter Area

ft3/m3

30/2.79

100/9.29

Diameter

inch/cm

2.75/7

4.5/11.4

8.63/22

4.5/11.4

8.63/22

Length

inch/cm

9.75/25

7.75/20

20/51

24.3/62

Diameter

inch/cm

2.75/7

4.5/11.4

Length

inch/cm

9.75/25

20/50.8

Part Number

33-0311

33-0315

33-0083

Part Number

85-0102

85-0103

Description

Cleaning Kit

Preservation Kit

Contents

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.

Techman_pw3000 18000 PW5000 TM (PW 8000 To 20000) 2012

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