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Water Maker Operator’s Preventive Maintenance and Pre Run
Joe R
Posted: Thursday, December 9, 2010 2:25 PM
Joined: 02/12/2008
Posts: 11


The Factory Recommends that approximately every 50 hours of use the system should be inspected for the following: • Mounting Hardware; Due to the fact that the system is subject to vibrations transferred from the vessel and the equipment all mounting hardware should be inspected for tightness. Inspect all screws, brackets, nuts bolts and fittings. Pay special attention to the High Pressure Pump and Motor since this will be subject to the most vibrations. • High Pressure Pump; Regularly check the oil level in the crankcase when the pump is horizontal the minimum oil level should be at the center of the sight glass the maximum level should be at the top. Typically, high-pressure pump oil should be changed after the first 50 hours of system operation, and then after every 500 hours of usage. Be sure to use the correct recommended oil for your system. Check the high-pressure pump on the water maker for leaks. If found, you might have to replace the high-pressure pump seals and/or valves.( It is recommended to replace seals after every 1500 hours of use and valves after every 3000 hours of use.) • Regularly clean any salt water or residue found on or near the equipment with a rag wetted with fresh water.(Finding salt residue would indicate a leak of some sort) • Check for fluid leaks either from oil or water from any part of the system. • Be sure to only tighten the black parflex fittings by hand only and always use caution when tightening PVC fitting over tightening can result in cracking the fitting. • Check all tubing and high pressure hoses for ware and friction chaffing against abrasive surfaces. Replace if necessary. • Inlet Sea Cock Valve; Check the Water Maker intake through-hull to make sure there are no restrictions or obstructions. Clean any debris or marine growth from the sea strainer. Make sure that the sea strainer gasket is not brittle (if so, replace it). • Inlet thru hull fitting; Test the seacock on the intake through-hull, to be sure it functions properly (that it opens and closes correctly) If the seacock is “frozen” applying any forcing movement can break it. Before the marine water maker is tested, make sure that the seacock is in the OPEN position. And that any over board valves or product water valves are open as well. • Make sure all feed water and brine discharge hoses are free of leaks and that all hose clamps are secure. If clamps show signs of corrosion replace them, we recommend double clamps on all pressurized hoses. • Booster Pump; Check the low pressure pump to ensure that the pump freely turns, that the pump is properly fastened down, that there are no signs of leaks from the housings or shaft seal. It is recommended to have the Low Pressure Pump Seals replaced every 1200-1500 hours of use. • Pre Filters; Replace the pre filters on the water maker, and also make sure the seals on the pre filter housings are in good condition. If commercial pre filter and oil water separator housings are used it is recommended that when changing or cleaning the elements that the bottom of the housings be sucked out with a wet vac to prevent any debris from entering the High Pressure Pump or membranes. • Check/replace the fresh water flush filter and carbon post filter element • This should be done every 3-6 months on average • Fresh Water Flush; Test the fresh water flush line to make sure that the water from the fresh water tank reaches the water maker during the fresh water flush cycle. This assures that there were no valves that were inadvertently shut or that the line is somehow obstructed. • Salinity probe; Remove and inspect, clean with a scotch bright pad We highly recommend you have a pocket Salinity meter on board to check water quality and recalibrate electronics if needed Now test the operation of the water maker It is best to test the water maker in open ocean conditions where the seawater is exposed to good tidal exchange. Back the pressure regulator “off” all the way (turning it counter-clockwise as far as it will go). Start the low-pressure pump (only) on the system and let seawater circulate through the system for about 10 to 15 minutes. During this time, visually inspect the system, all components and all hoses to make sure that there are no leaks or other abnormalities. Confirm the feed water inlet pressure is in the approximate range of 20 to 40 psi After this period of time; gradually increase the system pressure (turning the pressure regulator clockwise) until the system is at 820 PSI or making its rated product water output. (Which ever comes first?) Confirm the system operating pressure, feed water TDS, and system output. If the system comfortably makes its rated product water output, there is no further testing to do on the water maker. If the system is unable to make its rated output, then the user should call a service technician to conduct further testing on the membranes. Once the system testing is complete, turn the system “off” and hear the system fresh water flush solenoid activate. The user will hear the fresh water flushing through the system. Once the fresh water flush is complete, the water maker is ready to use for the season. If you’re planning some long-haul cruising, important spare parts to carry on board include ; Pre and post filters, high-pressure pump oil, salinity Probe, high and low pressure switches, Seal kit for booster pump, high pressure pump seals and high-pressure pump valves.
 
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