Parker AQUA DUO A455C-2800, Technical Manual

Page 1: ...1 AQUA DUO A455C 2800 6800 GPD Technical Manual Parker Water Purification 2630 E El Presidio Street Carson CA 90810 www parker com waterpurification ...

Page 2: ... 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 ...

Page 3: ...ECTRICAL CONNECTIONS 30 2 7 PLUMBING CONNECTIONS 30 3 0 THEORY OF OPERATION AND GENERAL DESCRIPTION 34 3 1 REVERSE OSMOSIS THEORY 34 3 2 PRODUCT WATER QUALITY STANDARDS 35 3 3 FACTORS AFFECTING PERMEATE PRODUCTION 36 3 4 TEMPERATURE CORRECTION FACTOR 37 3 5 CONTROLS AND INSTRUMENTATION 38 3 6 RO FILTRATION SYSTEM DESCRIPTION 38 3 7 REVERSE OSMOSIS SYSTEM 38 3 8 PRODUCT MONITORING SYSTEM 39 3 9 FRE...

Page 4: ...ion 48 5 5 Controller Operations 49 6 0 MAINTENANCE REPAIR 52 6 1 GENERAL 52 6 2 MICRON FILTER ELEMENT REPLACEMENT 52 7 0 TROUBLESHOOTING 53 7 1 System Shuts Down During Operation 53 7 2 Product Water Flow and Product Water Quality 55 7 3 3 way Product Water Diversion Valve Abnormalities 57 7 4 Booster Pump Abnormalities 59 ...

Page 5: ...55 kg 8x 2724011433 Table 1 0 Performance Specification Production May Vary 20 GPD Gallons per Day LPD Liters per day GPH Gallons per Hour LPH Liters per Hour Parameter for All Aqua Duo Systems Specification Sea Water Feed Inlet water quality Open Ocean Sea Water Feed TDS Less than 42 000 ppm TDS Product Water TDS 500 PPM TDS WHO standard Seawater Temperature Range 0 C to 32 C 32 90 F Design Produ...

Page 6: ...o units Operating both units simultaneously will require double the Horsepower Kilowattage 1 3 RECOMMENDED SPARE PARTS LIST Table 1 4 Recommended Spare Parts 1 4 SPECIAL TOOLS LIST Table 1 5 Special Tools Spare Parts and Special Tools Description Part Number Filter 32 5 Ft2 5 Micron 0801063357 Filter 32 5 Ft2 20 Micron 0801133257 Carbon Flushing Filter 33 0311 Filter AIR OIL WATER SERPARTOR 080207...

Page 7: ...7 1 5 PHYSICAL CHARACTERISTICS INCHES MILIMETER Figure 1 0 2800 3600 GPD RO System Dimensions Figure 1 1 4400 5800 GPD RO System Dimensions ...

Page 8: ...8 Figure 1 2 5200 6800 GPD RO System Dimensions Figure 1 3 Mounting and Lifting lugs Dimensions of RO System ...

Page 9: ...o avoid drying out or biological fouling of the RO membranes 2 2 RO SYSTEM 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 The following two diagrams that show the RO System located relative to the seawater level The ...

Page 10: ... mounting of the system components does not cause bending or warping Any damage caused by attaching the system or its components to an uneven surface is attributed to improper installation is the liability of the installer and is not covered by the Parker Hannifin warranty 2 Make the following plumbing connections to the RO unit s piping interfaces provided on the General Arrangement drawing CAUTI...

Page 11: ... 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 CAUTION Exposing the membranes to chlorinated water may cause irreversible damage and will voi...

Page 12: ...umps inoperable within just a few short months The System Warranty does not cover damage resulting from electrolysis or improper or inadequate grounding 2 4 COMPONENTS All components supplied by Parker both standard and optional are described in this section along with items required or desired by the installer The location operation and purpose of each major component are briefly explained in thi...

Page 13: ...R FOR UNIT 1 REMOVES CHLORINE AND ORGANIC COMPOUNDS CF 2 CHARCOAL FILTER FOR UNIT 2 REMOVES CHLORINE AND ORGANIC COMPOUNDS CV 1 CHECK VALVE TEE FOR UNIT 1 STOPS BACK FLOW OR ALLOWS FLOW IN ONE DIRECTION CV 2 CHECK VALVE TEE FOR UNIT 2 STOPS BACK FLOW OR ALLOWS FLOW IN ONE DIRECTION FIL 1 5 MICRON PRE FILTER FOR UNIT 1 REMOVES PARTICLES LARGER THAN 5 MICRONS FIL 2 5 MICRON PRE FILTER FOR UNIT 2 REM...

Page 14: ... UNIT 2 SEPARATES OIL AND AIR FROM THE INLET WATER P1 HIGH PRESSURE PUMP FOR UNIT 1 PROVIDES SYSTEM WITH HIGH PRESSURE P2 HIGH PRESSURE PUMP FOR UNIT 2 PROVIDES SYSTEM WITH HIGH PRESSURE P3 BOOSTER PUMP FOR UNIT 1 PROVIDES SYSTEM WITH INLET PRESSURE P4 BOOSTER PUMP FOR UNIT 2 PROVIDES SYSTEM WITH INLET PRESSURE PG 1 1 PG 2 1 LOW PRESSURE GAGE MEASURES INLET PRESSURE WITH RANGE 0 300 PSI PG 1 2 PG ...

Page 15: ...15 Figure 2 4 Piping and Instrumentation Diagram 2800 3600 GPD ...

Page 16: ...16 Figure 2 5 Piping and Instrumentation Diagram 2800 3600 GPD with Optional 20 Micron Prefilter ...

Page 17: ...17 Figure 2 6 Piping and Instrumentation Diagram 4800 6200 GPD ...

Page 18: ...18 Figure 2 7 Piping and Instrumentation Diagram 4800 6200 GPD with Optional 20 Micron Prefilter ...

Page 19: ... 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 Figure 2 8 Component TIE Point Connection Callouts ...

Page 20: ...ticles and debris coming in from seawater Parker recommends mounting a sea strainer BELOW the vessel s waterline The strainer can be installed before or after the Feed Water Inlet as long as it is below the waterline Figure 2 10 Optional Strainer ST 1 ST 2 included in Installation KIT KIT PART NUMBER INSTALLATION KIT 2800 6800 GPD 61012126 ...

Page 21: ...sembly Kit includes the Media filters the media filter skid frame and the plumbing required to plumb with the booster pump The Kit allows the user to install the booster pumps and the Media filters on the same skid see Figure below Figure 2 11 Optional Media Filter Assembly Booster Pumps not included in KIT Figure 2 12 Optional Media Filter Assembly MMF 1 MMF 2 KIT PART NUMBER MEDIA FILTER ASSYEMB...

Page 22: ... every time the System shuts down and repeats on a preset frequency in days Fresh Water Flushing replaces the sea water in the System with less corrosive fresh water which also reduces the biological growth and subsequent decay that naturally occurs if the sea water is not flushed from the System with fresh water The FWF filters on the Aqua DUO have their own special inlet connections TIE 1004 100...

Page 23: ...lush Filter FWF 1 FWF 2 Figure 2 15 Freshwater Flush Check Valve Assemblies Fresh Water Flush 2 way Solenoid Valve Automatically actuates at System shut down and at a preset frequency in days to flush the system with Fresh Water ...

Page 24: ...nlet Valve used in conjunction with the Rinse Clean Outlet Valve simplifies the storage and cleaning procedures by allowing the Operator to turn a valve rather than disconnect a hose Also used for manual Fresh Water Flush if the Automatic Fresh Water Flush System is not installed Note that the Rinse Clean Valves are available on single or double valve mounting plates 5 Booster Pump Two Included wi...

Page 25: ...ble 2 2 Booster Pump Spec 6 Oil and Water Separator Filter included This filter separates any unwanted particles oils and air bubbles before prefiltration The OWS Filter Housing 32 5 sqft assembly is located on the skid to allow the operator to conveniently change filters An optional upgrade to a 20 micron filter is available for enhanced prefiltration Figure 2 18 Oil Water Separator OWS 1 OWS 2 A...

Page 26: ...ce will result in a very short life and will damage the element rendering it useless Change the element after the first or second cleaning Clean or replace the element when plugged to the extent that the Low Pressure Gauge at the control panel reads 10 to 6 psi At slightly below 6 PSI the Low Pressure Switch shuts the system off Important Do not use string wound or fiber prefilter elements These t...

Page 27: ...ilizer is a device that kills bacteria and other microbes using UV radiation Plumbing of this device should be located after the charcoal filter conveniently on the skid The UV Sterilizer lamp emits a low frequency form of light This light degrades and loses intensity and the ability to sterilize biological matter over approximately 4 000 hours of use Therefore the lamp may remain lit but requires...

Page 28: ...PHASE 4400 6200 GPD 380 460 AC 50 60 Hz B016510001 THREE PHASE SINGLE 2800 3600 GPD 110 230 AC 50 60 Hz B016080026 SINGLE Table 2 3 High Pressure Pump and Motor Assembly 11 Manifold Assembly The manifold connects all the necessary plumbing and displays the instrumentation for the system The low pressure and high pressure transducers for the systems are directly connected to the manifold they make ...

Page 29: ...Assembly can be removed and relocated as needed New HP hoses will need to be created to connect the remotely located Vessel Assembly Contact your local distributor to purchase additional length HP hose Figure 2 24 Two Vessel Assembly FLOWMETER LOW PRESSURE TRANSDUCER HIGH PRESSURE TRANSDUCER FLOWMETER VALVE ...

Page 30: ...on and ground respectively 220 VAC 60 hertz units need a four wire supply black blue white and green for hot hot neutral and ground respectively bring a separate neutral from the generator if necessary 230 VAC 50 hertz units need a three wire supply black white and green for hot hot and earth respectively Connect power to the main terminal block in the electrical enclosure following the above wire...

Page 31: ...edia Filter Optional Fresh Water Flush Check Valve Inlets Fresh Water Flush Check Valve Inlets TIE TIE 1001 TIE 1005 Tube Fitting Connections Assembly 1 Cut tube end square and clean 2 Loosen nut on fitting three turns 3 Insert tube into fitting until it bottoms Loosen nut completely and remove tube with attached parts from body Check to ensure that the O Ring is seated onto the tube under the spa...

Page 32: ...32 Figure 2 26 Hose Tube Connection Instructions Figure 2 27 Tubing Fitting Internals ...

Page 33: ...he bowl for element replacement Mount the Booster Pumps near the system 3 The Booster Pump is mounted to a flat surface using the 4 supplied 10 x 1 1 4 long Type A screws The Booster Pump is mounted below water level to assist priming and in an accessible location to allow access for maintenance Mount Booster Pump close to the Inlet Thru Hull Sea Cock Valve and the Sea Strainer if purchased If the...

Page 34: ...er 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 no...

Page 35: ...r 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 2 PRODUCT WATER QUALITY STANDARDS This RO unit will produce permeate product water with a quality of 500 ppm TDS and in accordan...

Page 36: ...Temperature Salinity Pressure Increases Increases Decreases Increases 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 Membrane Reject pressure will need to be lowered to maintain rated flow in brackish water or freshwater applications The RO sy...

Page 37: ...s Table 3 2 Temperature Correction Factors TCF C Factor C Factor F Factor F Factor 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 ...

Page 38: ...ation section of the system The fresh water passes through the Freshwater Flush Filter which is designed to reduce chlorine of the fresh water entering the unit when flushing The filter housing consists of one carbon filter cartridge see section 1 4 The automatic valve for the freshwater flush filter located on the top of the filter housing diverges water coming to the unit The raw seawater is byp...

Page 39: ...ivert the product water to the reject line If permeate TDS is 500 ppm indicating good quality water a signal is sent to divert the product water to the product line In addition there is a product water flow meter and transducer to allow the operator to determine how much water is being made 3 9 FRESH WATER FLUSH SYSTEM This RO unit includes a freshwater flush system which provides a means for remo...

Page 40: ...sure all electrical connections to all external devices are connected properly per the electrical schematics 2 Install micron filters 3 Install Fresh Water Flushing Filter 4 Install Membranes 5 Valve Alignment 6 Ensure that the installation has been properly performed 7 Check the RO Membrane Element as describedbelow 8 Check the oil level in the HP pump Be sure it is at the proper level ...

Page 41: ...e connection to the system to ensure that the installer has properly connected and routed each hose and tube Ensure that there are no kinks or blockages in any of the hoses or tubes leading to and from the Aqua Duo Improper routing and any blockage in any line causes damage to the system Do not rely on the installer s word check it yourself 11 Make sure that the electrical power source the boat s ...

Page 42: ...salinity of the product water diminishes gradually and is measured by the salinity probe When the salinity of the product water has diminished to the factory setting the salinity controller will energize the 3 Way Product Water Diversion Valve At that instant product water will be routed to the charcoal filter and optional UV sterilizer onward to the potable water storage tank 25 Check for the fol...

Page 43: ...t The system design specifications are based on feed water temperature of 77 F 25 C and a feed water salinity of 35 000 PPM TDS parts per million total dissolved solids Each RO membrane element can vary 15 which will cause the final operating pressure to decrease or increase accordingly However assuming the perfect RO Membrane at this temperature and salinity the system will operate at the standar...

Page 44: ...ne Element is new and on the plus 15 side of the specifications By monitoring feed water salinity temperature and resulting system operating pressure it is possible to measure and monitor the fouling of the RO Membrane Element over time and use As the feed water vane pump becomes worn from normal use it will lose flow and the ability to build up pressure ...

Page 45: ...______ Telephone Number ________________________________ Name of Installer _________________________________ System Power _____Volts AC ____Hz FeedWaterTemperature Fahrenheit or Celsius HourMeterReading ____Hours PRESSURE GAUGE READINGS Inlet Low Pressure Gauge Reading ____ PSI ____ Bar ____KPa or ____Kg Cm2 RO Membrane Vessel Assy Outlet High Pressure Gauge Reading ____ PSI ____ Bar _____KPa or _...

Page 46: ...______ Telephone Number ________________________________ Name of Installer _________________________________ System Power _____Volts AC ____Hz FeedWaterTemperature Fahrenheit or Celsius HourMeterReading ____Hours PRESSURE GAUGE READINGS Inlet Low Pressure Gauge Reading ____ PSI ____ Bar ____KPa or ____Kg Cm2 RO Membrane Vessel Assy Outlet High Pressure Gauge Reading ____ PSI ____ Bar _____KPa or _...

Page 47: ...on System produces the following System One Unit Turned ON GPH LPH Two Units Turned ON Simultaneously GPH LPH A455C 2800 58 3 265 116 6 530 A455C 3600 75 0 341 150 682 A455C 4400 91 7 417 183 4 834 A455C 5200 108 3 492 216 6 984 A455C 5800 120 8 549 241 6 1098 A455C 6800 141 7 644 283 4 1288 Table 5 0 System Capacity with one Unit Two Units in function Caution The maximum Operating Pressure allowe...

Page 48: ...lt The High Pressure switch stops the system if pressure exceeds 950 psi 1 After the cause of the fault condition has been corrected press Fault Reset and repeat the steps in Startup Procedure Section 5 3 2 Slowly adjust the backpressure regulator until the system produces the specified product water gallon perhour flow at the Product Flow meter DO NOT exceed 950 psi See Temperature Effects and Sa...

Page 49: ... is producing water and the START STOP button is pushed the system stops all pumps anddiverts water into the sea 3 Resets all faults Note that this button performs its designated action regardless of whether or not you are browsing a menu Cycle button This button allows the operator to cycle through the process and configuration parameters Press the CYCLE button once to view to view the Display Me...

Page 50: ...ostics 16 Version software version Configuration Change Menu Thismenushowsalistofconfigurationparametersthat canbechangedbytheoperator Press the CYCLE buttonand hold for 5 seconds to view this menu and CYCLE again to scroll through the menu items Every time CYCLEispressed thenextitemisshown HoldingtheCYCLEbutton for more than 5 seconds selects the displayed menuitem Note that this menu does not al...

Page 51: ...t Product flow meter installed yes or no 5 Brine Flow Inst Brine flow meter installed yes or no 6 Tank Full Inst Tank level full sensor installed yes or no 7 Tank Empty Inst Tank level empty sensor installed yes or no 8 Time to AutoShut Auto shutdown after X hours in state FWP HH mm ss 9 AutoShut Time Auto shutdown after time yes or no 10 AutoShut Tank Auto shutdown on tank full yes or no 11 FWF D...

Page 52: ...y Weekly Monthly Quarterly Semi Annually Annually 300 HRS As Required Labor Hours approximate Fresh Water Flush 0 1 Replace micron filter s 0 5 Fresh Flush Charcoal Filter Replacement 0 2 Air Oil Separator 0 5 Sea Strainer 0 2 Inspect High Pressure Pumps for leakage 0 1 Replace membranes 1 0 Clean membranes 2 0 Transducer 0 5 High Pressure Pump Oil 0 1 Replace Pump Seal Kit 0 5 Replace Pump Valve ...

Page 53: ...valve must be fully open Check for air suction leaks at all components and fittings prior to the Boost Pump Check sea strainer screen and clean clear debris Check for any suction leaks Check the prefilter Element clean manufacturing or installation debris Check the plankton Filter Element clean manufacturing or installation debris No kinks or blockages in the inlet line and check for air suction l...

Page 54: ...oltage at the system inside the Control Panel The system must receive adequate voltage at start up and during operation in order for it to operatenormally AC systems shut down by design when the voltage falls below 10 of the set voltage Check power cable wire size from the power source to the system to ensure that it is not undersized and causingvoltage drop to the system Check power cable wire co...

Page 55: ...embrane Element has been in use for a period of time and is fouled from use If RO Membrane Element has been stored improperly without proper flushing and or storage solution or if it has simply slowly degraded over time and use then the membrane may be fouled and cleaning may restore performance If not membrane should be replaced 5 Membrane has chemical fouling If RO Membrane Element has been perf...

Page 56: ... thecondition without resulting in a noticeable increase in Product Water Flow 3 Crack in one of the End Plugs within the High Pressure Vessel is allowing Feed Water to mix with Product Water This would usually also result in higher than normal Product Water Flow However a small crack mayallow enough Feed Water to mix with the Product Water to cause the condition without resulting in a noticeablei...

Page 57: ... ballast is very sensitive to voltage changes Ensure that the voltage supplied to the UV sterilizer iswithin 11 5 VDC to 13 VDC 7 3 3 way Product Water Diversion Valve Abnormalities When the system is producing unpotable water and the Water Quality lamp is illuminated red the 3 way ProductWater Diversion Valve coil will not receive voltage from the controller This allows the 3 way Product Water Di...

Page 58: ...lectric motor may be Bearing failure Replace motor Winding failure Generally caused by low or high power below or above the specified voltage requirements of the system and feeding the motor This is NOT economically repairable Capacitor failure Generally caused by low power feeding the motor Also caused by rapidly repeating starting and stopping of the motor Replace motor Potential Scenarios High ...

Page 59: ...otor contactor coil It should read 12V DC when activated 8 If the contactor coil is receiving 12V DC but inoperative then the contactor s coil may be bad Replace thecontactor 9 If 12V DC is not present when the High Pressure Pump is activated trace the orange and orange black wiresto the main circuit board and measure the DC voltage at the terminals It should read 12V when activated 7 4 Booster Pu...

Page 60: ...the voltage drops below this standard during the system startup the system will not start Highcurrent is necessary to excite the electric motors At the time of attempting to start the electric motors theywill consume high current This may cause the voltage from the Power Source to drop dramatically for a fraction of a second which can be enough to cause the electronic circuit to shut off Provide a...

Page 61: ...e overboard Danger ELECTRICAL SHOCK HAZARD A Volt Ohm Meter will be necessary The following proceduresexpose the technician to High Voltage and electrical shock hazard Only attempt this if you are a qualifiedelectrician and only if surrounding conditions are safe With the system in operation and The Water Quality less than 1000ppm remove the Controller Enclosurefront panel to expose the inside of ...

Page 62: ...ure that Sea Strainer if installed is clean and does not restrict flow 3 Check the level of the High Pressure Pump crankcase oil The minimum oil level is the center of the sightglass located at the side of the High Pressure Pump the maximum oil level is at the top of the sight glass window Use only Parker High Pressure Pump oil DO NOT USE MOTOR OR OTHER HYDRAULIC OIL 4 Clean any salt water or salt...

Page 63: ...63 8 DRAWINGS DIAGRAMS ...

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Page 74: ...011433 570 258 kg 591 269 kg A455C 4400 110 220AC 50 60Hz 1 3PH 0151009 4400 183 1567283319 12180523CO 1544182210 1217514773 6x 2724011333 600 272 kg 623 283 kg A455C 5200 110 220 380 440AC 50 60Hz 1 3PH 0151009 5200 217 1567283319 12180523CO 1544182210 1217514773 6x 2724011433 650 296 kg 676 307 kg A455C 5800 110 220 380 440AC 50 60Hz 1 3PH 0151009 5800 217 1567283319 12180523CO 1544182210 121751...

Page 75: ...110 220 11 2 SEE TABLE MOTOR 50 HP 110 230 50 60 1PH 12 4 07620310WA FILTER HOUSING 32 5 SQFT 13 2 08020723KD ELEMENT OWSE 32 5 SQFT 14 2 0204091969 FITTING PP 3 8 ODx1 2 MT 15 2 0713020573 FILTER HOUSING LID 375 X 10 ASM 16 2 0713020873 FILTER HOUSING 50 X 10 17 2 0801063357 ELEMENT CPFE 5 MIC 32 5 SQFT 18 4 0803004773 ELEMENT CHARCOAL 2 5 x10 0 19 2 10181421CC GAUGE 0 1400 CBM O RING SEAL 20 2 1...

Page 76: ...76 4 Wiring Diagrams ...

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