DESSALATOR D60 Cruise Navigator Fully Automatic Marine Watermaker User Manual

DESSALATOR D60 Cruise Navigator Fully Automatic Marine Watermaker

Specifications

• Model: AC CRUISE-60 v2.5
• Date: 03/2023
• Manufacturer: Dessalator
• Address: ZI des 3 Moulins 282 rue des Cistes 06600 Antibes, France
• Website: www.dessalator.com
• Email: [email protected]
• Phone: +33 4 93 95 04 55

Assembly

1. List of supplies necessary for assembly.
2. Seawater inlet:
3. Seawater inlet valve.
4. Cartridge prefilter.
5. Positions: Seawater for desalinization mode, Fresh water for manual rinsing or sterilization, Closed for filter cartridge change.
6. Connections:
7. Protect pipes passing through walls or sharp corners with sheath or larger pipe.
8. Motor/Pump Block:
9. Fix motor/pump block with stainless steel legs.
10. Connect prefilter outlet to pump intake.
11. Electric Connections:
12. Turn off power before working.
13. Connect phase wire, neutral wire, and ground wire according to specifications.
14. Membrane Block.
15. Control Panel:
16. Mount on a vertical panel with easy access to the back.
17. Place where light indicators are visible.
18. Connect high-pressure membrane outlet to high-pressure control valve.
19. Cables to be connected: 230V (or 120V) power supply.

FAQ

1. Q: What should I do if the motor block cannot be installed beneath the waterline?
   A: In such cases, it is recommended to install the optional booster pump as an alternative solution.

2. Q: How should I handle the 120V model in terms of ventilation for the motor block?
   A: Ensure significant ventilation for the motor block in the case of the 120V model to prevent overheating and ensure proper operation.

3. Q: What is the procedure for manual rinsing and changing the filter cartridge?
   A: Follow the instructions outlined in Appendix A3 for manual rinsing and Appendix A4 for changing the filter cartridge. Be cautious not to lose the tank’s O-ring during the process.

List of Components

Hull Valve

• Must be placed as low as possible in the boat so as to avoid drawing in any air
• Must be installed towards the back for a motorboat, or centered near the keel for a sailboat. The ribs of the strainer should be placed towards the front the boat to force the entry of water by scooping during
• The  strainer of the hull valve helps stop large particles at the entrance of the system.

Prefilter

• Must be placed as close as possible to the hull valve and, if possible, beneath the waterline to ensure a better yield/output. If this is not possible, you must install a pre-pump (optional).
• Helps stop solid particles in seawater at the inlet of the motor/pump block. Up to 5 microns.
• Comes with a tool for screwing / unscrewing the tank.
• Comes equipped with a solenoid valve for automated rinsing.
• Comes equipped with a 3-way valve.

Front Control Panel

Composed of the following elements:

• A high-pressure manometer
• A flowmeter
• A start switch
• A know for pressure adjustment
• An operating hours counter
• Three indicator lights

Motor/Pump Block

Must ideally be placed beneath the waterline for optimal yield/output.

➥ Note: If it is not possible to install the motor block beneath the waterline, it is recommended to install the optional booster pump.

• Composed of the 120 or 230 Volts motor.
• Must be installed in a ventilated space.
• A circuit breaker is provided.

WARNING
For the 120V model, you must ensure significant ventilation of the motor block.

Membrane Block

• The membrane block includes 2 seawater membranes mounted together in a compact block.

Piping (supplied by Dessalator®)

• High-pressure piping from the pump to the membranes and from the membranes to the control panel. An 8-meter pipe is provided, it should be cut into two parts. The length of each part is to be determined according to the distance of the different elements.
  • 4 special DESSALATOR® fittings* for high-pressure piping (see assembly procedure in Appendix A2).
• Including one 90° elbow fitting for the back of the control panel, which can swivel 360°.
• Fresh water production piping going from the outlet of the membrane block to the dashboard (6 meters long).

Assembly

1. List of supplies necessary for assembly
   • Screws (self-tapping and more).
   • Stainless steel ties, Ø 8-16mm and Ø 12-22mm.
   • ‘Electrician’ plastic ties.
   • Teflon tape.
   • Loctite 542 liquid or Loctite 577 paste.
   • Polyurethane sealant, Sicaflex or equivalent.
   • Corrugated sheath for electric cables and high-pressure tubes.
   • Braided-core flexible hose,
   • 10mm and Ø 12mm inner diameter (Tricoflex) and 3mm thick.
   • Various tools (drills, saws,
   • 21mm hole saws, etc.).
2. Seawater inlet
   • The strainer should be placed as low as possible beneath the waterline so that it does not draw in any air. It should be placed far from the discards.
   • Pierce the hull with a Ø 21mm hole saw.
   • The streaks of the strainer must be placed towards the front of the boat to allow the water to naturally enter by scooping during navigation.
   • Seal the junction with the hull properly using polyurethane sealant or Sicaflex. Do not forget to paint the submerged part with special underwater paint.
   • The hull valve must remain accessible for maintenance operations.
   • Seal the valve/strainer and valve/hose connections with Loctite 577.

Cartridge prefilter

1. Seawater position:
   For use in desalinization mode

2. Fresh water position:
   For manual rinsing or sterilization when needed (see Appendix A3)

3. Closed position:
   For changing the filter cartridge (see Appendix A4)

• The prefilter must also be installed beneath the waterline to ensure a better yield/output. It must be easy to access.
• The fixing bracket is reversible to allow you to adjust the installation height.
• Piping connections must be made with Tricoflex Ø 12 mm (inside diameter), for the entire seawater system as well as the pressurized rinsing system.
  • Do not forget to fasten 2 stainless steel collars on each fitting.
• Allow a minimum of 3 cm below the filter body for the clearance of the tank when opening it. A screw is provided for screwing / unscrewing it.
• The connection for fresh water rinsing must be done with water from the pressurized freshwater system.
• A solenoid valve is mounted behind the prefilter for automatic rinsing.
• The valve handle must be in seawater position (see diagram above with the 3 positions of the 3-way valve).

For manual rinsing, put the valve handle in fresh water position (see diagram above with the 3 positions of the 3-way valve) and follow the instructions in Appendix A3.
To replace the filter cartridge, follow the procedure in Appendix A4.
During this procedure, be careful not to lose the tank’s O-ring. Fill the system with fresh water for 30 seconds to 1 minute before putting the valve handle back into the seawater position (see diagram above with the 3 positions of the 3-way valve).

Connections

• Use Tricoflex Ø 12mm (inside diameter) for the seawater system and for pressurized rinsing.
• Fasten two stainless steel collars on each connection, with the clamping heads positioned opposite one another.
• Connect the pressurized fresh water from the outlet of the water unit to the 3-way valve.
• Connection can be made under a sink, a washbasin or on the path of the pressurized cold water piping.
• The valve handle must be aligned with the filter.

Tip: If the pipes are to pass through walls or be in contact with sharp corners, provide protection against wear and friction by inserting them into a sheath or pipe of greater diameter.

Motor/Pump Block

• To ensure optimal production, the assembly of the high-pressure motor block must be completed as low as possible in the boat, in a horizontal position and in an area protected from water sprays.
• Use the 2 stainless steel legs under the 2 motors to fix the motor block. Leave a few centimetres of wiggle room around it.
• Provide sufficient airflow for the ventilation of the motors.
• The connection of the prefilter outlet to the inlet of the pump on the suction-side pump should be done using Tricoflex piping Ø 12mm (inside diameter) and 2 stainless steel collars at each connection.
• The connection of the pump’s high-pressure head to the membrane inlet (red mark) should be done using a high-pressure hose that is cut to size (follow closely the assembly instructions in Appendix A2).
• Put a little liquid Loctite or threadlock on the male and female cones before each connection.

• Stainless steel legs for fixing the motor/pump block
• and : Connect the prefilter outlet to the pump intake  Tricoflex piping Ø 12mm (inside diameter) for the water system

Electric connections

WARNING!
Never work with the power on! Turn off the power of your entire system.

• The control panel must always be supplied with direct current.
• The 230V (or 120V) motor connection is made with the cable coming from the control panel (see page 12, cable 5) and respecting the connections on the terminal block: phase wire on terminal , neutral wire on terminal and ground wire on terminal .

230V or 120V Motor

• Connect the phase cable (brown wire)
• Connect the neutral cable (blue wire)
• Connect the ground wire
• (yellow/green wire)

Membrane Block

• The membrane block should preferably be mounted horizontally (on the base or side).

• A vertical position might lead to a yield/output loss over time.
  Fastening is done using self-tapping screws in the stainless steel brackets .

• It is necessary to sheath the pipe connecting the output of the high pressure pump to the inlet of the membranes because of the vibrations, which might lead to leaks if the pipe is attached or in direct contact with something.

• The installation of the high-pressure nozzles must be carried out according to their assembly instructions (see Appendix A2).

• Put some Loctite or threadlock on the 2 male and female cones before tightening.

• Available as an option: 90° elbow high-pressure nozzle for the inlet and outlet of the membranes .

1. Stainless steel legs to fix the membrane block
2. Connection of the high-pressure pump to the inlet of the membrane block Membrane heads (optional 90° elbow connection for membrane heads)
3. Hose for the high-pressure water system (supplied)

Control panel

The control panel must be mounted on a vertical panel.
Ensure unrestricted access to the back of the control panel, this will make connections easier. You should place it in a place where the light indicators are visible. Example: below or on the sides of cupboards, under the chart or centre table, on the front panel of a rear berth etc.

1. Hose for connecting the high-pressure membrane outlet to the high-pressure control valve on the back of the front panel. (Black high-pressure hose supplied)
2. Hose for connecting the water outlet of the membranes to the inlet of the probe of the panel. (Outside diameter Ø 10mm pipe supplied)
3. Hose for connecting the fresh water outlet of the panel to the tanks, dispensing clarinet or water inlet or with a tee provided that there is no valve on the outlet of the water tank. (Outside diameter Ø 10mm pipe not supplied, use preferably Tricoclair)
4. Hose to connect the discharge of panel. To be connected preferably to a water disposal system like the evacuation of a sink, washbasin, cockpit etc. In this case, do not forget to open the drain valves during use. (Ø 12mm inside diameter pipe not supplied)
5. Cables to be connected:
   • 230V (or 120V) power supply. The provided circuit breaker must be placed on this line, if you do not already have one available on your 230V switchboard
   • Motor power supply 230V (or 120V). See instructions for connection on page 10.

Micro-Command (optional)

General presentation:
The Dessalator® Micro Remote Control Dessalator allows you to stop and monitor the watermaker.
The 3 LEDs on the Micro-Control have the same functionality as the 3 LEDs on the watermaker itself.

Note : Only the Automatic version allows starting or rinsing directly from the Micro-Control.

1. RED LIGHT – ALARM
2. YELLOW LIGHT – POOR QUALITY
3. GREEN LIGHT – GOOD QUALITY
4. BLU LIGHT – STATUS LIGHT
5. ON / OFF BUTTON

Note : in the event of an alarm, the machine must be restarted from the control panel (and not from the Micro-Command).

Start-Up

1. Precautions before start-up
   WARNING!

   • Before starting-up, check that the valves are open.
     Mandatory:

   • When using the device for the first time, after changing the filter, after the boat has been grounded or stopped for a long time, you should flush the system using fresh water by operating the three-way valve on the prefilter (see Appendix A3).
     Purge the system for 1 minute: watermaker must be stopped and the pressure regulator open (counterclockwise).

   • Once the system is filled, put the valve back in seawater position (see Appendix A3).Note: If you are not going to use the watermaker at all for a month or more, we recommend to either sterilize the membranes for storage (for a maximum duration of 6 months) or to rinse it out at least once a month.

   • Before starting the system back up, we recommend rinsing it out for two minutes (see Appendix A3).

2. Starting-up the watermaker Set the switch to ON. Once the engine has started, gradually turn the pressure regulator knob to the right to increase the pressure towards the middle of the orange zone then continue gradually increasing the pressure until it reaches the green zone on the pressure gauge.

   • This pressure build-up procedure should last approximately 1 minute.
   • Once this procedure is done, your watermaker will start producing fresh water, whose quality will be checked.
     Note: The fresh water yield depends on the temperature and salinity of the sea water.

3. Stopping the watermaker: without rinsing of the membranes
   It is not necessary to rinse your membranes if you use your watermaker regularly.
   Set the switch to OFF, the watermaker will stop. You can now lower the pressure regulator knob (towards the left, the initial position).
   Beyond 10 days without use, it is best to rinse the membranes before the watermaker is started-up again (see manual rinse procedure in Appendix A3).

4. Stopping the watermaker: with automatic rinsing of the membranes A rinsing must be carried out if the watermaker is not going to be used for more than 10 days.

   • After using the watermaker, do not turn it off. Start turning the knob of the pressure regulator (counterclockwise) to engage the rinsing mechanism, the pressure of the manometer will drop .
   • The watermaker will then start the rinsing procedure. The green and yellow LEDs on the control panel will illuminate, indicating that the flushing procedure is started. The procedure lasts 30 seconds. Once it is complete, the green and yellow LEDs will turn off and the only remaining light will be the flashing blue LED on the switch . If you do not have a Mini Remote Control, you can turn off the system by position the switch to OFF.
     

5. Using the Micro-Command (optional)
   Once the first start-up was been done with control panel, you can use the Micro-Command to: monitor the status of the system or stop the watermaker.

Note : Only the Automatic version allows starting or rinsing directly from the Micro-Control.

STOPPING YOUR WATERMAKER :

Operation

Membranes are delicate components

• Reverse osmosis membranes must be carefully maintained as they are the most sensitive parts of your system. Follow the instructions given to avoid damaging them and voiding the warranty. The nominal production capacity of the watermaker is given for a temperature of 25°C for seawater and depend on the salinity of the seawater in your navigation area. Each degree below this given temperature decreases the flow rate by 2.5 to 5%.

Extremes temperatures
The membranes should not be exposed to temperatures below 0°C. Overpressure, caused by expansion resulting from freezing, can rupture the membranes and prevent the salt from being filtered out.
The membranes must not be exposed to temperatures above 60°C, as high temperatures may also prevent salt from being removed.

Drying out of the membranes
After the first use, the membranes should be kept immersed in liquid, either in treated seawater, in a mix of fresh water and sterilizing solution or, temporarily, in fresh water (see Sterilization methods, Appendix A4).

Recommendations for use
The different quality and salinity level of seawater influence the yield of the membranes.

WARNING!
Do not use this system in areas where the water is muddy or polluted and at the mouth of rivers or brackish water. This will prevent clogging the prefilter and damaging the membranes.

Maintenance

WARNING!
In case of risk of frost, we recommend emptying the flowmeter located on the control panel, disconnect the output pipe (blue) and blow or inject air into this pipe while alternating pressing on the small button of the solenoid valve located at the back of the control panel. You should also protect your membranes against the cold using blankets or insulation.

1. Membranes maintenance
   • `Over time, it is normal for the flow to drop by 10 to 15%.
   • If yield/output is no longer satisfactory, you should consider replacing the membranes.
   • The output volume of your watermaker is established within the first 24 to 48 hours of operation. The fresh water output depends on the salinity and temperature of the seawater, as well as on the working pressure of the membranes.
   • Rinsing the membranes can improve the yield/output.
2. Rinsing frequency of the membranes
   • It is therefore not necessary to rinse the membranes after each use. Rinsing them too often can lead to premature deterioration of the membranes.
   • There are two methods to flush the system: one manual and the other automatic.
   • Both methods use the water in the boat’s tanks.
   • It is necessary to rinse the watermaker if it is not going to be used for several days.

Reminder : All flushing procedures should be done with the motor/pump block off. The biggest enemy of membranes is pressurized fresh water.

Manual Rinsing

There is a valve next to the prefilter. This valve is connected to the freshwater tank of the boat. When turned, it will automatically start the boat’s freshwater system and send fresh water from the tank to the watermaker.

1. Do not put the watermaker on “ON”; leave it in its “OFF” position.
2. Turn the pressure regulator all the way in the counterclockwise direction.
3. Turn the fresh water inlet valve, located next to the prefilter, for 2 minutes. The boat pump will start and fresh water will flow into the watermaker.

Automatic Rinsing

See page 16 “Stopping the watermaker: with automatic rinsing of the membranes”

Sterilizing the membranes

When should the membranes be sterilized?

• Under normal circumstances, a monthly and regular rinsing of the membranes is enough for their maintenance. If you do no use the watermaker for a while and cannot perform a monthly rinsing, membrane sterilization is necessary. The protective effect of sterilizing does not exceed 6 months. The sterilization should never be renewed more than twice a year but should include, between these two operations, a mandatory rinse with fresh water.
• An excessive concentration of sterilizing solution can corrode the membrane heads. We recommend the sterilizing cartridge ST2 and our specified dose of sterilizing solution, adapted to your system. Failure to comply with these recommendations or use of another sterilizing solution void the warranty.

Membranes sterilizing procedure

1. Easy method using the ST2 sterilization cartridge (reusable):
   We have developed a sterilization cartridge that greatly facilitates handling. The instructions for this cartridge are given in Appendix 4.

2. Manual method without the ST2 sterilization cartridge:
   With the watermaker turned off, thoroughly rinse it for 10 minutes with fresh water using the 3-way valve on the prefilter. Pour the sterilizing product (whole bag) into a bucket containing 8 litres of water. Uncouple the seawater inlet pipe and immerse it in the bucket. Start the watermaker without increasing the pressure until the bucket is empty. Once the bucket is empty and the operation completed, reconnect the pipe.

3. Method using a garden sprayer:
   Pour the sterilizing product (whole bag) into a bucket containing 8 litres of fresh water and mix everything together. Fill the garden sprayer with this mixture and increase the pressure to 3 or 4 bar. Then inject the sterilizing solution at the inlet of the membranes (red mark side).
   ➥ Note: Before using the watermaker again simply rinse it with fresh water for a few seconds, using the 3-way valve located on the pre-filter, in order to eliminate the sterilant.

4. High-pressure pump
   The high-pressure pump is half filled with oil to the level indicated on the gauge. The oil used in the pump is a 15W40 or 20W40 multigrade oil. You not exceed the level (as shown on the gauge). The oil does not need to be change over time.

Spare Parts

DESSALATOR® devices, which have a high reliability and long lifetime, generally do not require costly servicing. An accident is always possible (operation with low water level, accidental overpressure, impact, etc.).
We keep the following spare and maintenance parts at your disposal:

• 5µm 10-inch filter
• Transmission belt
• Electronic card
• Membranes head
• Nozzle for high-pressure piping
• Flowmeter tube, sold by the meter

Accessories

• Mini Remote Control
• Micro Remote Control
• Complete ST2 sterilizing cartridge
• Sterilizer in sachet
• Mineralizer cartridge
• Mineralizer in sachet
• Nipple for high pressure tube
• HP nozzle elbow

Appendix A1: How do watermakers work?

• How does reverse osmosis work?
  • Pressurized seawater enters the membranes which, similarly to “molecular sieves”, only let the fresh water molecules pass.
  • Most of the dissolved solid particles do not cross the membranes. These residues are evacuated with the discharge water.
  • Reverse osmosis extracts 99% of impurities.
  • The drinking water produced by your reverse osmosis system can be consumed. If stored in your tanks you can, if needed, treat this water with commercially available products. Make sure to follow the manufacturer’s dosage instructions.
  • We sell a mineralizing cartridge if you plan to drink the produced fresh water long-term.
• How does your watermaker work?
  • Seawater is draw in through the inlet valve of the thru-hull. It then passes through the 5-micron prefilter. The filtered water is then pressurized in the membrane tube by the high-pressure pump (operating pressure is in the green zone of the pressure gauge). The pressurized water passes through the orifices of the membrane surface, freed from the salt and bacteria, which are poured back into the sea along with the remainder of the solution used to self-clean the membranes. The now fresh water goes through a probe measuring the salt content: if the water is sufficiently desalinated, the 3-way valve is automatically
  • switched to direct the fresh water to the tanks. On the other hand, if the salinity sensor registers a salt content that is too high (conductivity greater than 1,000 μSiemens), the valve will reject the output water at sea.
  • The amount of drinking water being produced is controlled by a flowmeter located on the control panel. The fresh water production capacity is given for a seawater temperature of 25°C. Yield is reduced by 2.5 to 5% per degree Celsius of temperature drop.

Appendix A2: Mounting of the DESSALATOR® high-pressure nozzles

Appendix A3: Manual Rinsing Procedure

Appendix A4: Instructions for the Sterilizing Cartridge

With the watermaker OFF

• Close the seawater inlet valve.
• Open the sterilizing cartridge: be careful not to lose the O-ring.
• Remove the top screen.
• Place the foam at the bottom of the filter.
• Pour the sterilizing powder into the cartridge.
• Replace the top screen and close the cartridge.
• Check that the seal is correctly in place.
• Remove the 5-micron cartridge from the prefilter.
• Turn the rinsing valve to the fresh water position (see Appendix A3) so that the sterilizing powder mixes with the water, the valve must be closed before all of the powder disappears (there must be a little left inside the bowl).
• Please note that this procedure is very quick. The watermaker should not be turned on
  Duration of sterilization: 6 months maximum (to be repeated beyond that)

Important: Before the next start-up, rinse the system out using fresh water for 10 minutes. Remove the ST2 sterilizing cartridge and replace it with a 5-micron cartridge.

WARNING!
The ST2 cartridge can be reused.

Appendix A5: Troubleshooting

Appendix A6: Guide of the Indicator Lights of the Micro Remote Control

Appendix A7: Circuit diagram of the electronic board

Appendix A8: Schematic drawing

ZI des 3 Moulins, 282 rue des Cistes Bâtiment Euro 92

• 06600 Antibes, France
• www.dessalator.com
• [email protected]
• +33 4 93 95 04 55

References

• Dessalator

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