Matrix S3600 Installation Manual

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OPERATION & INSTALLATION MANUAL

MATRIX S3600 SILVER SERIES

REVERSE OSMOSIS

SYSTEM

TABLE OF CONTENTS

PREFACE ....................................................................................................................... 5

A DISCUSSION OF REVERSE OSMOSIS ..................................................................... 6

THE MAIN COMPONENTS OF A WATERMAKER ........................................................ 8

THE SUBCOMPONENTS AND ACCESSORIES ......................................................... 10

DESIGN CONSIDERATIONS ....................................................................................... 13

TEMPERATURE CORRECTION TABLE ............................................................................................................ 15

OPERATING INSTRUMENTS ............................................................................................................................... 16

OPERATING INSTRUMENTS ............................................................................................................................... 17

PRODUCT WATER CONDUCTIVITY MEASUREMENT ................................................................................ 17

PRODUCT AND CONCENTRATE FLOW MEASUREMENT .......................................................................... 17

OPERATING PRESSURE MEASUREMENT ....................................................................................................... 17

FEED PRESSURE MEASUREMENTS .................................................................................................................. 17

MATRIX WATERMAKER LOG SHEET ............................................................................................................. 19

INSTALLATION INSTRUCTIONS ................................................................................ 20

PIPING MATERIAL ................................................................................................................................................ 20

FEED PIPING ................................ ................................................................ ............................................................ 20

CONCENTRATE PIPE ............................................................................................................................................ 20

OPERATING INSTRUCTIONS ..................................................................................... 26

MANUAL UNIT INITIAL START UP PROCEDURES ....................................................................................... 26

MANUAL UNIT NORMAL OPERATION ............................................................................................................ 28

AUTOMATIC UNIT INITIAL START UP PROCEDURES ................................................................ ................ 29

AUTOMATIC UNIT NORMAL OPERATION ..................................................................................................... 31

AUTOMATIC UNIT MANUAL START UP AND SHUT DOWN PROCEDURES .......................................... 32

ROUTINE MAINTENANCE ........................................................................................... 33

SILVER SERIES MAINTENANCE SCHEDULE ................................................................................................. 33

MAINTENANCE OF PRE-FILTRATION COMPONENTS ............................................................................... 34

TO CHANGE THE BAG .......................................................................................................................................... 36

THE WATERMAKER .................................................................................................... 38

MEMBRANE STERILIZATION AND CLEANING PROCEDURES ............................... 39

TROUBLESHOOTING .................................................................................................. 44

ENGINEERING DATA .................................................................................................. 47

COMPONENT ILLUSTRATIONS ................................................................................. 48

PREFACE

This material is restricted and is for use only by the personnel who need this information. It shall not be reproduced in any manner or distributed for any purpose, whatsoever, except by written permission of MATRIX Desalination, Inc.

The illustrations and instructions in this manual are based on information available at the time of issue. We reserve the right to make subsequent changes, or revise pages or sections, and to replace existing copies without penalty.

INTRODUCTION

This manual is intended to aid you in understanding the principles of Reverse Osmosis, and instruct you on how to properly operate the MATRIX watermaker system.

Before you operate your new MATRIX watermaker it is recommended that you READ THIS MANUAL FIRST!

Familiarize yourself with this manual now so that in the event of complications, you can competently evaluate and correct the situation.

SEAWATER DESALINATION:

A Discussion of Reverse Osmosis Seawater contains many kinds of solids dissolved in solution. The most prevalent is

common table salt (Sodium Chloride). Present as well are other minerals, including Calcium, Magnesium, Sulfate, Bicarbonate Alkalinity, Silica, and others. The sum of these dissolved solids is referred to as the Total Dissolved Solids or T.D.S.

When sodium chloride (NaCl) is dissolved in water, the sodium (Na+) and the chloride (Cl-) actually separate. When this occurs, each is called an ion and each has an electrical charge. Sodium has a positive charge and is referred to as a cation (Na+). Chloride has a negative charge and is referred to as an anion (Cl-). As the number of these cations and anions increases, the ability of the water to conduct an electrical current increases, thus one can measure the T.D.S. of the water by its ability to conduct current.

Most seawater averages between 35,000 and 38,000 PPM T.D.S., although variations of up to 7,000 ppm are common in Middle East waters.

Required of any desalination process is the reduction of dissolved solids in water. Thermal, membrane, or ion exchange processes are the most common methods of desalination.

Reverse Osmosis (RO) is essentially a process for reducing dissolved solids in water. This is accomplished by passing pressurized water over a semi-permeable membrane. The membrane can be visualized as containing numerous tiny holes that allow the water molecules to pass through. However, the holes are so small that they do not allow most of the dissolved solids to pass through the membrane. These solids and the remaining water (called the concentrate or brine) flow past the membrane surface and are piped to drain. The water which goes through the membrane is called the permeate, or product water.

The equipment used to desalinate water is referred to as a Reverse Osmosis system. It must be remembered that the system cannot remove (“reject”) all the dissolved solids from seawater. It is actually designed to reject approximately 99% of the T.D.S. or, in other words, to allow 1% of the 38,000 PPM T.D.S. of the seawater to pass into the fresh water. This yields water of less than 500 PPM of T.D.S (380 PPM). In this case, one would refer to the system as having a T.D.S. passage, or salt passage, of 1%. However, if the T.D.S. of the feed increases, there will be a corresponding increase in the level of dissolved solids in the product water.

The fraction of the feedwater entering the system that then passes through the membrane

as product water is called the “recovery” (also called the conversion), and is usually stated

as a percentage, i.e., 25% recovery. Obviously, 100% of the feedwater cannot go through

the membranes because there would be no water left to flush away the solids, which do not pass through the membranes.

Normal recoveries for small seawater conversion units are in the range of 15-30%. At 20% recovery, for every 100 gallons of raw water fed to the RO system, 20 gallons are recovered as purified water and 80 gallons are routed to waste as concentrated rejected salts (brine). The same concept holds true for numbers expressed as gallons per minute, cubic meters per hour, etc.

The rate at which water flows through the membrane is directly proportional to the driving force available. The driving force is basically the difference between the pressure on the feedwater (system pressure) and product water sides of the membrane and the difference in osmotic pressure of the solutions on opposite sides of the membrane. The greater the feed pressure the greater the driving force and product flow rate will be. Increasing the pressure on the product side of the membrane decreases the driving force and therefore lowers the product flow. The difference in salt concentration between the feedwater and product water also reduces the driving force due to the difference in osmotic pressure, which must be overcome.

It follows that if the pressure is raised and the concentrate flow rate consequently decreases, the recovery increases. On the other hand, if the system pressure is held fixed and the concentrate flow rate is made to decrease, the recovery also goes up. If, at constant pressure, the concentrate flow is stopped altogether, the recovery is 100%. This condition cannot last long. Most of the solid materials in the feedwater will adhere to the membrane if not flushed from the membrane surface and vessel. Eventually, these materials will so heavily coat the membrane that all flow will cease. This will result in the rapid deterioration of the membrane. There must always be sufficient concentrate flow

to carry away the rejected dissolved solids and prevent concentrations that would allow precipitation and resulting scaling of the membranes.

Pressure is not the only factor, which affects the product flow rate of the RO system. Temperature of the feedwater can change the output by as much as 50% in the range from nearly freezing to 95 degrees F (35 degrees C). As a general rule of thumb, product flow from thin film composite RO systems will decrease by approximately 1.5% per 1 degree C decrease in feedwater temperature unless pressure corrections are made. The capacity of the system therefore may vary seasonally with temperature.

The physical or chemical nature of many natural waters and industrial process waters is such that it is not suitable to pump some waters directly into a Reverse Osmosis system. Among the characteristics of water that may necessitate pre-treatment are suspended solids (turbidity), the limited solubility of some salts, and strong chemicals such as acid or chlorine, which chemically attack the membrane. Suspended solids (not to be confused with dissolved solids) within the spiral wound element may gradually clog the flow path. Some salts will crystallize from solution when concentrated, and may also clog the flow paths.

A common method of pretreatment is pre-filtration, which removes most of the suspended matter from the feedwater. Although the RO system incorporates a pre-filter, some very small particles pass through and have a tendency to collect on the membranes. In time ranging from months to years, depending on what is in the water - enough particles collect inside the membrane housing that the membranes require cleaning. This is usually done with detergents or other chemicals, as described in this manual.

Oxidizing chemicals, such as chlorine or bromine, dissolved oxygen, petroleum, solvents, or halogens will degrade the salt rejection capability of the membranes. Adequate pretreatment measures or operating procedures must ensure against their introduction into the membrane systems.

Chemical post-treatment of RO water is often advisable. This is desirable to protect the product water from re-contamination by harmful organisms such as bacteria while storing the potable water. While the Reverse Osmosis process effectively removes bacteria from seawater, the product water should be sterilized by chlorinating to guard against contamination of the water after leaving the RO system's storage tanks.

Due to the very pure nature of RO product water, additional chemicals may be required to protect against corrosion and add certain ions to the water for stability and/or taste.

THE MAIN COMPONENTS OF A WATERMAKER

The main components of any water maker, in order, are: The supply pump, which supplies the feed water necessary for the high-

pressure pump to operate. The supply pump must have sufficient capacity and good suction head properties to prevent cavitation. Dissolved gasses in the feed water cause cavitation. As the feed water passes into the eye of the impeller it is exposed to a low pressure. If the pressure is low enough for the gasses to come out of solution it will make a crackling noise as the gasses expand then collapse. Repeated or constant cavitation can be detrimental to the pump impeller and casing. The noise level from cavitation will usually increase and decrease with flow rate.

Another cause of noise in the supply pump is from air leaks in the suction piping. This noise is usually constant. Air in the feed water will cause damage to the ceramic plungers in the high-pressure pump as well as possible damage to the membranes.

Filtration is the next and the most important part of any water-making unit. This is done in various ways and usually in stages.

Cartridge filters are found on nearly all reverse osmosis systems. The cartridge filter elements can be composed of different materials such as paper, or polypropylene. They can be in a pleated, spun, melt-blown, or

wound design. They are designed to be changed after they have become fouled or clogged. Every water maker must have a final filter no larger than five microns to help prevent fouling of the membranes. A 2-stage cartridge filtration system incorporating a 30-micron filter followed by a 5-micron filter is often used. This 2-stage configuration reduces the frequency at which the filter elements become clogged.

Bag filters are another method of pre-filtering the water prior to the final cartridge filter. These filters have a bag or sock inside, which are available in different levels of micron filtration. These filters can be removed and cleaned for reuse. The bag filter element can be cleaned several times before it needs to be replaced.

A less common prefiltration type is the use of a multimedia tank, which will have several different types of media (gravel, garnet, sand, etc.) loaded inside, that will filter out the larger particles (25 microns) found in water. In comparison, the diameter of a cross section of a human hair is 84 microns. The advantage of using a media tank is in operating cost savings, as there are no consumables required. To clean the filter, the flow of water is reversed, and the particles that have been trapped by the filter, are then flushed out, and dumped to waste.

Another type of filter, is an activated carbon filter. These filters can be provided in configurations similar to the cartridge filter, or the media filter. The activated carbon will absorb chlorine and organics in the water. Carbon filter elements must be changed out periodically to remain effective.

High-pressure pumps or booster pumps vary in design, usually depending on a specific application. Matrix uses only positive-displacement, plunger type high-pressure pumps.

Pressure vessels house the membranes for a water maker. They are manufactured from aluminum, stainless steel, or fiberglass. Generally fiberglass pressure vessels are the most widely used because of their resistance to corrosion, and lower cost. Pressure vessels can be produced in assorted lengths, the shortest being for a single element (membrane).

Membranes consist of a semi-permeable thin-film composite layer sandwiched between a permeate channel spacer and a feed channel spacer. These layers are then spirally wound over a perforated plastic tube (product tube). The layers are then covered with a shell of fiberglass. The actual membrane is a thin porous film between two mesh like layers that serve as spacers for the water to flow over. There are different types of membranes for different purposes. The three basic types are freshwater, brackish, and seawater. Their names refer to the type of feed water that will be applied. Each membrane is designed for a specific rate of salt rejection, meaning that

the membrane will only allow a certain amount of salts to pass through. When two or more membranes are used in a pressure vessel, the product tubes are connected by interconnects. These interconnects allow the product water to flow continuously from one product tube of a membrane to another, without being contaminated with the salt water feed flowing over them. The product water then flows out the product tube and into the permeate port of the end plug. The product water is then collected from each permeate port into a manifold where there are sensors to detect the flow rate of water and the quality of water.

The regulating valve is the primary means of controlling the operating pressure of the system by restricting the concentrate flow rate.

THE SUBCOMPONENTS AND ACCESSORIES

Freshwater Flush Assembly

In order to extend the life of the membranes, MATRIX offers 4 fresh water flush options, Manual, Solenoid Operated, Automatic, and Automatic with a flush tank. The first three

options use ship’s fresh water to flush the unit, and include a carbon filter to remove any

residual chlorine from the ship’s fresh water supply.

Manual System: This option incorporates a manual ball valve to isolate the feed

(seawater) and allow ship’s fresh water to the watermaker inlet. Ship’s pressure will flush

fresh water through the unit. Solenoid Operated System: This option incorporates a solenoid-operated valve in place of

the manual ball valve, with a pushbutton on the RO unit control panel. Pressing the fresh

flush pushbutton starts the flush sequence. The solenoid valve will open allowing ship’s

water to flush the unit. After a pre-set time period, the solenoid valve will close. Automatic System: This option is similar to the solenoid-operated system, except that the

flush sequence runs automatically whenever the unit shuts down, without operator intervention.

Because the ship’s water may contain chlorine, the flush water is routed through a carbon filter prior to the unit. The carbon filter will neutralize any residual chlorine in order to protect the membranes from oxidation.

CAUTION: The carbon filter should be changed frequently to prevent damage to the membranes by oxidation.

Automatic System with Flush Tank: This option includes a tank to store RO product water to be used for flushing, and a flush pump to force the flush water through the unit. In this configuration, the flush tank can also be used for chemical cleaning of the unit.

Chemical Valve Assembly (Optional)

There are two (2) three way chemical valves that are available as an option that can be plumbed to the suction port of the feed pump and the concentrate discharge on the unit. Quick release fittings on one side of the valves enable chemical hoses to be stored when the watermaker is in normal operation. In applications requiring a remote-mounted supply pump, a separate cleaning system with pump can be provided for convenience.

Pressure gauges are used to indicate the pressure of the water at different points in the system.

Flow meters show the flow of the concentrate (concentrated salt water that is going to waste), and the product water. They are invaluable as they indicate the recovery rate along with the production of the water maker. Again there are different types such as the flow through indicators, and the digital or dial type, which have small paddle wheels that spin as the water flows pass them. The digital or dial type needs to be calibrated on a regular basis to insure their accuracy.

Pressure switches are provided for safety, and for pump and membrane protection. There are low pressure and high-pressure switches, each having a certain function. The low-pressure switch is installed to shut down the water maker in the event that the supply of water has been diminished for one reason or another. This action protects the high-pressure pump. The high- pressure switch is in place to shut down the water maker in the event that the pressure after the high-pressure pump becomes too high. This action prevents possible damage to the membranes, or other high-pressure components.

Pressure relief valves are installed to prevent the build up of excessive pressure in pipes and components. High-pressure relief valves are for safety and to provide back up for the high-pressure switch, in case of failure. Lowpressure relief valves are used primarily for the accidental build up of pressure in the PVC piping.

Conductivity Meters are included to monitor the quality of the water being produced, and ensure that if the product quality does not meet specifications, the water is diverted to waste. These monitors need to be calibrated on a

regular basis to ensure their accuracy.

ORP meters (optional) are used to monitor the incoming feed water to insure that the oxidant level is low enough not to harm the membranes. They are generally used to serve as a precautionary device. They measure the millivolt level of the water, and they can be set up to shutdown the water maker in the

event that an oxidant is found in the water. This action prevents membrane damage.

Chemical injection systems (optional) are used to feed chemical solutions to the feed and/or product water. Different chemicals can be applied to the feed water depending on the need. The chemical tanks may have mixers if the chemical is a powder and needs to stay mixed, to stay soluble. Since the water that is produced is soft, from the lack of minerals and has no alkalinity, chemicals may be added to raise the pH level and add minerals to reduce the corrosivity and improve taste.

Accumulators (optional, depending on model) are containers, which have a bladder inside that can dampen the pulsations that are produced from a positive displacement pump. Pulsation dampener is another name for the same component. Low-pressure accumulators use air to fill the bladder, high pressure accumulators use nitrogen as it is inert and is not a flammable gas. The pressures used, are generally 50 to 75% of the operating pressure that the accumulator is in contact with.

Electrical control panels are used to provide the sequencing needed to have a sequenced startup, and shut down of a reverse osmosis unit. They also house the electrical controls and instruments. Matrix uses electric control panels that are constructed to the NEMA 4X standard. The 4X rating ensures that the electrical components will be protected from water, even if the water is sprayed on the panel under pressure.

Remineralizers (optional) are vessels that contain a mixture of calcite and corosex to add alkalinity and raise the pH of the product water in order to reduce corrosivity and improve taste. The remineralizer incorporates a glove valve to regulate the amount of minerals being added to the product water. The remineralizer also includes a bypass valve to bypass the remineralizer when it is out of service. The remineralizert should be located between the product outlet on the RO unit and the inlet to the water storage tank.

The remineralizer load (calcite and corosex) will slowly lose it’s effectiveness over time. The load should be replaced when the pH of the water leaving the remineralizer is not higher than the pH of the water entering the remineralizer.

Ultraviolet Sterilizers (optional) are components that will destroy any biological organisms in the water. Although the reverse osmosis system will effectively remove all microorganisms, a UV sterilizer is recommended at the outlet of the product water storage tank to ensure that any recontamination that occurs in the tank (such as from contaminated shore water added to the tank) is not passed to the point of use.

DESIGN CONSIDERATIONS

WATER TEMPERATURE EFFECT

The water temperature significantly affects the product water flow rate through the membrane. At any given pressure this flow increases with increasing feedwater temperatures and decreases at lower feedwater temperatures. The system design is based on expected product water output at 77°F. The water temperature conversion chart illustrates the percent variance observed in product water flow at temperatures other than the design basis (77°F). This data set assumes that the operating pressure remains constant.

The graph of Production Capacity vs. Temperature demonstrates the capacity of the watermaker versus temperature, when operating pressure adjustment is taken into consideration. Starting at the right side of the graph, the watermaker can be operated at constant production capacity as feedwater temperature decreases, as long as the operating pressure is increased by closing the concentrate control valve. At some minimum feedwater temperature, the maximum operating pressure is reached, and no more adjustment can be made. As the feedwater temperature continues to decline, the unit’s production capacity will decline, since the operating pressure can no longer be increased to compensate. The temperature at which the inflection point occurs varies with watermaker model, feedwater salinity, membrane age, and a number of other variables.

It is important that the maximum product flowrate, maximum operating pressure, and maximum recovery rate of the watermaker are not exceeded.

It is recommended that the system not be operated at maximum pressures if temperatures are significantly higher than 85°F for any length of time.

PRESSURE

The operating pressure has a direct effect on product water quality and quantity. Both factors will increase as the system pressure increases (within design limits). The system must be operated at the LOWEST pressure required to achieve the designed product water flow rate. Always adjust the system pressure to the specified PRODUCT flow, but do not exceed the specified recovery rate or maximum operating pressure limit (950 psi).

BRINE VELOCITY

The brine flow over the membrane is very important to both product water quality and quantity. The brine flow through an element should be maintained as given

in the Design Data Sheet. At lower brine flows, concentration of sparingly soluble salts will foul the membrane surface.

High brine velocities can also be a source of difficulty. At excessive flows the elements are subjected to severe stress and physical damage such as telescoping, glue-line fracture, etc. Irreparable membrane damage will result. The total system has been designed with these factors in mind, and should be controlled as specified in the operating procedures.

TEMPERATURE CORRECTION PROCEDURES Procedure for correcting reverse osmosis system flow rate to compensate for

feed water temperature.

1. Refer to Section I of this manual for the Engineering Data on your unit.

2. Note the designed product flow at 77º Fahrenheit (25º C).

3. Note the temperature of the water presently being fed to the membranes.

4. From the “TEMPERATURE CORRECTION TABLE” find the correction factor for the feed water temperature.

5. Divide the design product flow rate by the correction factor to get the product flow rate for the feed temperature.

6. This quotient is the desired flow rate at the present temperature.

7. It may be possible to increase the product flow rate at lower temperatures by increasing the operating pressure (by closing the concentrate control valve). Caution should be exercised not to exceed the maximum product flowrate, maximum operating pressure, or the maximum recovery rate of the watermaker.

Note: In cold water expect to have less product flow from your watermaker. In warm water your unit will produce more but you will extend the life of the membranes by not exceeding the design flow rate. See the Temperature Correction Chart for additional information on flow rates.

°C

CORRECTION

°C

CORRECTION

°F

CORRECTION

°F

CORRECTION

FACTOR

3.64

0.97

3.47

0.90

3.23

0.94

3.18

0.88

3.03

0.91

2.93

0.82

2.78

0.88

2.68

0.79

2.58

0.85

2.47

0.79

2.38

0.83

2.29

0.77

2.22

0.80

2.14

0.75

2.11

0.77

2.01

0.73

2.00

0.75

1.88

0.70

1.89

0.73

1.77

100

0.68

1.78

0.71

1.68

102

0.65

1.68

0.69

1.59

104

0.63

1.61

0.67

1.51

106

0.61

1.54

0.65

1.44

108

0.59

1.47

0.63

1.36

110

0.57

1.39

0.61

1.30

112

0.55

1.34

0.60

1.24

114

0.53

1.29

0.58

1.17

116

0.51

1.24

0.56

1.12

118

0.49

1.19

0.54

1.08

120

0.47

1.15

0.53

1.05

122

0.45

1.11

0.51

1.02

1.08

0.49

1.00

1.04

0.47

0.97

1.00

0.46

0.93

TEMPERATURE CORRECTION TABLE

Production Capacity vs. Temperature

Temperature (Deg F)

Product Capacity (GPD)

Operating Pressure vs. Temperature

Temperature (Deg F)

Operating Pressure (psi)

OPERATING INSTRUMENTS

PRODUCT WATER CONDUCTIVITY MEASUREMENT

The conductivity meter that is located at the front of the electrical panel measures the electrical conductivity of the product water. The meter is equipped with an adjustable high point setting that allows the poor quality water to be

dumped to waste. This meter displays the salinity of the water in micromho’s or

microsiemens.

PRODUCT AND CONCENTRATE FLOW MEASUREMENT The flow meters, located on the hydraulic control panel, monitor the flow rate of

the product and concentrate streams. Reduced feedwater temperature, membrane fouling, etc., will cause a decrease

in product flow. An adjustment of the pressure control valve towards the closed position will result in higher operating pressure; and increase the product flow.

OPERATING PRESSURE MEASUREMENT The water pressure to which the membrane elements within the pressure

vessels are exposed is normally described as the R/O operating pressure. Pressure gauges are mounted on the hydraulic panel for precise measurement of the operating conditions.

Frequent reading and recording of each of these measurements is HIGHLY important for evaluating system performance and in determining corrective measures that may be required.

FEED PRESSURE MEASUREMENTS Pressure gauges are provided at selected points in the feed system to monitor

the condition of the pretreatment components. The final feed pressure at the high-pressure pump suction should never fall below 20 psi.

MATRIX WATERMAKER LOG SHEET

Date

System

Hours

Media/ Bag

Filter

Inlet

PSI

Media/

Bag

Filter

Outlet

PSI

Fine

Filter

Inlet

PSI

Fine Filter

Outlet

PSI

Mem. Feed

Press.

PSI

Product

Flow

GPM

Conc.

Flow

GPM

Product

Quality

Panel

(mmho)

Product

Quality

Hand Meter

(mmho)

Initial

Date

Maintenance / Comments

INSTALLATION INSTRUCTIONS

PIPING MATERIAL In marine installations, when possible, the through-hull fitting, seacock, and feed piping

should be of non-corrosive materials such as fiberglass or thermo-plastics. However, in cases where classification societies or insurance companies require metal through-hull fittings and seacocks, the first choice of materials is 70/30 cupro-nickel. In cases where other materials must be used, such as stainless steel or copper based alloys, it is recommended to consult with MATRIX prior to installation.

In land-based applications, the recommended piping material is PVC Schedule 80. PVC piping should be protected from direct sunlight, as UV light will cause the PVC material to degrade over time.

NOTE: Iron, steel, copper, galvanized, or aluminum materials should never be used.

FEED PIPING MATRIX recommends to increase the feedwater piping above the inlet size for the

system by one pipe diameter (except for stainless steel) whenever possible. Also increasing the through-hull and seacock in marine applications, by one pipe size, is normally a good practice.

Never reduce piping or valving diameters under the minimum specified size for your particular watermaker.

CONCENTRATE PIPE In normal conditions the concentrate overboard piping can remain the same size as

recommended in the watermaker specification sheet. Backpressure should be kept as low as possible. Normal backpressure should be less than 25 psi.

PRODUCT WATER PIPING No increase in product water piping, above the specified dimension, is normally

required. It is very important to keep the pressure (membrane backpressure) of the product water

to a minimum. The membrane backpressure is ideally kept under 10 psi and in no case should ever exceed 30 psi. It is strongly recommended that the product water piping be configured such that there is an air gap where the product piping enters the product

holding tank. The air gap will ensure that no stored water (which may contain chlorine) can be drawn back into the watermaker when the watermaker is not in operation.

CAUTION: Rupture of the membrane envelope may occur if the product backpressure is exceeded.

GENERAL INTAKE LOCATION The intake (feedwater) location and associated plumbing is an aspect to be carefully

considered. Any restrictions in the feedwater plumbing could degrade the performance of the watermaker as well as compromise the life of the system.

In marine installations, the through-hull fitting should be located as far below the water line and normally as far forward as possible. Consideration of hull design should be taken into account.

If the intake is to be incorporated into a sea chest, then locate this as low as practical on the chest. Never take suction from the top of the sea chest, as air introduction may occur.

If the ship has a sewage treatment system, the RO feed should be located as far away as possible from the sewage plant discharge (preferably on the opposite side of the hull). The treated sewage effluent usually contains high levels of chlorine, and if ingested by the watermaker, will destroy the membranes.

CAUTION: Never place zinc anodes within 6 feet of the watermaker intake.

For land-based installations where a well or direct seawater intake is to be used, the user must ensure that the feedwater is clean, and does not contain silt, suspended solids, oils, or oxidizing agents.

FEED (SUPPLY) PUMP The feed pump must have a flooded suction, as the pump is not self-priming. If the

pump is mounted above the vessel waterline, a suitable foot/check valve must be installed and the pump primed prior to start up. The pump should be located as close to the feed water supply as possible, with short and direct plumbing. Avoid high points, which form air pockets.

If the feed pump is remote mounted (such as in a land-based application), ensure that it is properly secured to a firm base. It will be necessary to run power wiring from the RO cabinet to the remote mounted feed/supply pump. A suitable electrical disconnect should be installed at the remote pump location in order to ensure personnel safety and meet electrical code requirements.

If you desire to provide your own supply pump, contact Matrix so that we can ensure that the pressure and flow of the pump are sufficient, and that the control of the pump can be properly integrated into the watermaker control system.

BAG FILTER (Optional) This filter should be mounted vertically. It should be firmly secured at the base. In

marine installations, the filter should also be secured higher up on the chamber. Allowance should be made to be able to unfasten the lug bolts securing the top plate of the filter. Adequate clearance should be given at the top of the filter to enable bag change when necessary.

Isolation valves can be installed on the suction and discharge lines to the housings to reduce spillage when changing bags. These can be supplied as an option by request

MEDIA FILTER (Optional) The media tank should be mounted vertically and, in marine installations, located with

consideration to unit weight and vessel displacement. The filter should be mounted firmly at the base and, in marine applications also higher up on the tank. Ensure that direction of flow through the tank is consistent with that indicated on the tank hub. Gauges are supplied on the inlet and outlet to this filter for monitoring of the differential pressure across it.

MEDIA TANK LOADING INSTRUCTIONS After locating the MATRIX media filter to its permanent location the media tank will

have to be loaded. The media load will consist of bags and or boxes of pre-measured ingredients, i.e. gravel, sand, garnet, carbon or anthracite. The media will have to be loaded into the tank in the correct sequence and to the proper levels. The first media to be loaded is the gravel. Before loading, some disassembly of the tank head and plumbing is required.

The media tank assembly consists of a tank with a threaded head (cap) on top. This head has two (2) ports on each side, which are plumbed to two (2) 3-way valves. There

is a small engraved “I” and “O” above the ports on the top of the head. To remove the

head from the tank, the two valves nuts must be unscrewed at the valves. The head may now be unscrewed from the tank. Upon removal of the head, a PVC tube will be found inserted into the center hole. This tube will have to be pulled out of the head, and capped off with tape to prevent any media to fall inside and plugging the distributor on the bottom of the tube. This PVC tube should be placed into the tank during the loading of the media and held into position, so that the top end is flush with the top of the tank and that it is in the center of the opening. After the media has been loaded, the tape should be removed from the PVC tube. This procedure will enable the replacement of the head to the tank.

Once the head has been removed, mask off the tank internal threads with tape to protect the threads during media loading. Locate the first load associated with that particular tank. After the proper media is set aside for the tank, loading may begin.

First scoop or pour the gravel into the opening on top of the tank where the head was. This first layer should cover the top of the distributor. Remember to hold the PVC tube during this procedure. After all of the gravel has been loaded for that tank, use a pole or piece of PVC pipe to level out the first layer. This should be done after each different media is loaded. After the gravel is loaded, the pipe should stay in place, and will not have to be held any longer.

The second media to load is the garnet #12; this is slightly coarser and larger in size than the garnet #50. Again when a particular media is finished loading, level that layer.

The third media to be loaded is the garnet #50. The next (fourth) media to be loaded is the sand. The fifth and final load is the anthracite. After the tank has been loaded, the top of the media should fill the tank two thirds (2/3)

to three-fourths (3/4) full. Remove the tape protecting the tank internal threads. Place a hose in the tank to slowly fill the tank with water, without disturbing the media. During this time the threads on top of the tank should be washed thoroughly to aid the replacement of the head.

The head contains two (2) o-rings, which should be lubricated with a silicone-based lubricant. Check that they are installed, and that they are in correct position. Remember to remove the tape from the PVC pipe and slowly turn the head to install the head into the tank. After this check the alignment of the piping and turn the tank if needed to ensure proper alignment.

It is very important that the inlet (I) and outlet (O) are in the correct position after all the plumbing has been reconnected. In the Service mode, the water will exit the supply pump and enter the media tank through the inlet port. The water will then exit the outlet port of the media tank and flow to the inlet of the cartridge filter(s).

In the Back flush mode the three way valves on either side of the head will be turned 180 degrees. This will reverse the flow of water so that it will enter the outlet of the tank and exit the inlet side and be discharged to waste. It will be necessary to install a waste discharge hose from the media filter backwash discharge fitting, and route the effluent overboard. The backwash process removes any small debris or material that have accumulated in the media filter. This process can take as little as fifteen (15) minutes or as much as four hours depending on what has been accumulated during Service.

After the tank is loaded, and the plumbing has been replaced the tank can now be backflushed. The initial backwash will sometimes take two to four hours to discharge all of the loose material in the media. During this time, loosen the vent plugs located on the tank heads. This will expel the air in the system.

After the initial backwash is completed, and all air has been purged from the tank, the media filter can be placed into service.

THE WATERMAKER CABINET

The cabinet requires a solid base. The cabinet should not be mounted above any electrical apparatus. Allowances, with regard to access, should be made for ease of

maintenance. Ideally, there should be 48” of clearance on either side of the cabinet and

36” above the cabinet for easy maintenance.

Holes should be drilled in the base on which the watermaker is to be mounted that line up with the vibration mounts for the watermaker. Once in place, the watermaker should be secured to the base using stainless steel bolts, nuts, and lockwashers.

COMPONENT MODELS Mount the individual components (hydropanel, supply pump, high-pressure pump

assembly, pressure vessel rack, and prefilters) in such a way to allow easy access for maintenance, and to minimize piping lengths between components.

Make piping connections between each of the individual components using the piping and hoses provided in the installation kit. Each individual IN/OUT connection is lableled. Simply connect piping between matching letters (“A” to “A”, “B” to “B”, etc.). See connection table at the end of this manual.

FRESHWATER FLUSH (Optional) If the unit is using ship’s water (or house water) for flushing, plumb a hose from the

pressurized fresh water supply to the flush inlet on the watermaker. If the unit incorporates a flush tank, ensure that the tank is securely mounted and plumb a hose from the flush pump discharge to the flush inlet on the watermaker.

AUTOMATIC START/STOP If your watermaker is configured to accept external inputs to start and stop the unit,

note the following information. Typically, 2 float switches are installed in the product water storage tank. When the level in the storage tank becomes low, the LOW level float switch is activated, closing a contact in the control circuit causing the unit to start. When the product tank is full, the HIGH level float switch is activated, opening a second

contact in the control circuit causing the unit to shut down. The unit will automatically fresh flush after shutdown. No operator intervention is required when the unit is in automatic operating mode.

Refer to the electrical schematic at the end of this manual for float switch wiring instructions.

REMINERALIZER (Optional) The remineralizer tank should be mounted vertically and, in marine installations, located

with consideration to unit weight and vessel displacement. The flow through a remineralizer is reverse that of normal media filtration as the purpose is to chemically modify the water and any filtration would be redundant. Connect the product outlet on the RO watermaker to the fast&tite fitting inlet on the remineralizer tank assembly. Connect the outlet to the product storage tank.

The filter should be mounted.

OPERATING INSTRUCTIONS

MANUAL UNIT INITIAL START UP PROCEDURES

Normally after installation of the R/O either a MATRIX technician or authorized representative should be present on initial system start up.

In all cases, if working with electricity, a qualified electrician should be present.

1. Ensure that all switches on the RO control panel are in the OFF position.

2. Turn the main breaker on.

3. Ensure that both the line voltage and frequency are correct for the unit.

4. Ensure all suction and discharge valves are in the correct position. Ensure that chemical clean suction and discharge valves are in the correct position. Disconnect the product water line to the storage tanks and direct to waste. This is to ensure that all chemicals are adequately flushed out that were placed into the system at the factory.

5. Ensure the high pressure-regulating valve is fully opened (counter-clockwise). This valve is often in a closed position for membrane sterilization.

6. Ensure that the oil level of the high-pressure pump is half way up on the pump sight glass.

7. Check rotation of the pumps. Open the electrical panel on the watermaker and locate the contactor for the high-pressure pump, it should be labeled M1 and be located at the bottom right of the panel. Turn the Off/Run/Start switch to the Run position and then momentarily press the manual button on the contactor to supply voltage to the high-pressure pump. The pump will momentarily start up. With the aid of a second person check the rotation of the pump. Ensure the rotation complies with the arrow found on top face the pump. If rotation is opposite to the direction of the arrow and the unit is three-phase, turn off the control power and the main breaker then switch two of the three wires supplying the main power to the electrical panel. If the unit is single phase then the wiring will have to be corrected at each motor. Repeat the process for the supply pump using the contactor labeled M2.

8. If the unit is equipped with a media filter, place the media filter valves in backwash mode, restart the supply pump, and perform a thorough backwash of the media filter.

9. Once correct rotation has been verified, restart the supply pump by turning the Off/Run/Start switch to Start and while the supply pump is running, check for leaks. If leaks are observed turn off the control power and make necessary repairs.

10. With the supply pump running, purge air from the cartridge filter(s) by pressing the small red button on the top of the cartridge filter housing. Hold the button in until no more air escapes. If a media or bag filter is installed, purge air from the tank or filter housing by opening the vent valve on the top of the tank or housing and allow all air to escape.

11. When no large air bubbles are visible in the water flow in the concentrate flowmeter, the high-pressure pump can be started up by turning the Off/Run/Start switch to the Run position.

12. With both pumps running, check for leaks. If leaks are observed, turn off the control power, and make necessary repairs.

13. With both pumps running, the high-pressure regulating valve should be adjusted to achieve the desired flow rate of product water. The regulating pressure valve should be slowly turned in the clockwise direction when bringing the system up to pressure. If any leaks are observed, the pressure should be backed off slowly by turning the regulating pressure valve counter clockwise.

14. After a period of one hour, the product water line can be reconnected to the storage tanks.

15. With the unit operating at the correct product flow rate, record initial system readings on the logsheet found in this manual.

YOU MUST ALWAYS USE EXTEME CAUTION WHEN ENTERING THE ELECTRICAL CONTROL PANEL, OR WORKING ON ANY PART OF THE ELECTRICAL SYSTEM OF THIS UNIT.

FAILURE TO DO SO CAN RESULT IN DEADLY SHOCK. FAILURE TO COMPLY WITH ANY INSTRUCTIONS ABOVE, WILL, IN MOST

CASES, RESULT IN EQUIPMENT DAMAGE, AND POSSIBLY VOID THE WARRANTY.

MANUAL UNIT NORMAL OPERATION

1. Turn the main breaker on.

2. Ensure all suction and discharge valves are in the correct position.

3. Ensure the high pressure-regulating valve is fully opened (counter-clockwise).

4. Turn the Off/Run/Start switch to the Start position. The Feed Pump running light will illuminate.

5. When there is water flowing in the Concentrate Flowmeter and the red Low Pressure light has shut off, the high-pressure pump can be started.

6. Turn the Off/Run/Start switch to the Run position. The High-Pressure Pump running light will illuminate.

7. With both pumps running, the high-pressure regulating valve can now be slowly increased to achieve the desired flow rate for the product water.

8. With the unit operating at the correct pressures and flow rates, record system readings on the logsheet. This will aid in diagnosing any problems that may occur in the future.

9. When ready to shut down the unit, the regulating valve should be fully opened to reduce the pressure.

10. After the pressure is reduced, turn the Off/Run/Start switch to the Off position.

11. The unit is now ready to be flushed. a. If the unit has the “Automatic Solenoid Flush on Shutdown” option, flushing is

initiated by turning the Off/Run/Start to the “Off” position. If there is need to stop the flush simply turn off the panel disconnect. Daily flushing can be

accomplished by momentarily placing the Off/Run/Start switch to “Run” and

returning to “Off”. The solenoid will automatically close after a preset time limit

(4-7 minutes).

b. If the unit has an automatic flush the switch should be returned to the run

position and the fresh water flush button depressed. It will automatically time itself and shut off. The solenoid will automatically close after a preset time limit (2-7 minutes).

c. If the unit has a manual fresh flush, open the flush valve, and allow fresh water

to flush the unit for 5 minutes.

AUTOMATIC UNIT INITIAL START UP PROCEDURES

Normally after installation of the R/O either a MATRIX technician or authorized representative should be present on initial system start up.

In all cases, if working with electricity, a qualified electrician should be present. Turn the OFF/RUN/START switch to OFF. Turn the MANUAL/AUTO switch to

MANUAL. Turn the RUN/OFF/FLUSH switch to OFF. Turn on the main breaker supplying power to the unit. Ensure line voltage and frequency is correct for the unit. Ensure all suction and discharge valves are in the correct position. Ensure that

chemical clean suction and discharge valves are in the correct position. Disconnect the product water line to the storage tanks and direct to waste. This is to ensure that all chemicals are adequately flushed out that were placed into the system at the factory.

Ensure the high pressure-regulating valve is fully opened (counter-clockwise). Ensure that the oil level of the high-pressure pump is half way up on the pump sight

glass. Check rotation of the pumps as follows: Turn the OFF/RUN/START switch to the RUN position and then back off. The supply

pump will briefly operate. Ensure that the rotation is correct. Restart the supply pump by turning the OFF/RUN/START switch to RUN. While the supply pump is running, check for leaks. If leaks are observed turn off the control power and make necessary repairs. Allow the supply pump to run to fully flush the feed piping. If a media filter is installed, perform a backwash of the media filter.

Open the electrical panel on the watermaker and locate the contactor for the highpressure pump, it should be labeled M1 and be located at the bottom right of the panel. Turn the OFF/RUN/START switch to the RUN position and then momentarily press the manual button on the contactor to supply voltage to the high-pressure pump. The pump will momentarily start up. With the aid of a second person check the rotation of the pump. Ensure the rotation complies with the arrow found on top face the pump. If rotation is opposite to the direction of the arrow and the unit is three phase, turn off the control power and the main breaker then switch two of the three wires supplying the main power to the electrical panel. If the unit is single phase then the wiring will have to be corrected at each motor.

When no large air bubbles are visible in the water flow in the concentrate flowmeter, the unit can be started (see Startup and Shutdown Procedures)

With the unit running, check for leaks. If leaks are observed, turn off the unit, and make necessary repairs.

With the unit running, the high-pressure regulating valve should be adjusted to achieve the desired flow rate of product water. The pressure-regulating valve should be slowly turned in the clockwise direction when bringing the system up to pressure. If any leaks are observed, the pressure should be backed off slowly by turning the regulating pressure valve counter clockwise.

After a period of one hour, the product water line can be reconnected to the storage tanks.

With the unit operating at the correct product flow rate, record initial system readings on the logsheet found in this manual.

YOU MUST ALWAYS USE EXTEME CAUTION WHEN ENTERING THE ELECTRICAL CONTROL PANEL, OR WORKING ON ANY PART OF THE ELECTRICAL SYSTEM OF THIS UNIT.

FAILURE TO DO SO CAN RESULT IN DEADLY SHOCK. FAILURE TO COMPLY WITH ANY INSTRUCTIONS ABOVE, WILL, IN MOST

CASES, RESULT IN EQUIPMENT DAMAGE, AND POSSIBLY VOID THE WARRANTY.

AUTOMATIC UNIT NORMAL OPERATION

Prior to setting the unit to AUTO for the first time, run the unit in MANUAL to ensure that the high-pressure regulating valve is set to the correct position. Once this has been accomplished, shut the unit down.

Place the MANUAL/AUTO switch in AUTO Turn the OFF/RUN/START switch to the RUN position. Turn the FLUSH switch to RUN. This will arm the flush system to start automatically

after the unit shuts down. When the product storage tank level is low, the tank level switch will close a contact,

commanding the unit to start automatically. The supply pump will start first, followed by the high-pressure pump after a time delay.

With the unit operating at the correct pressures and flow rates, record system readings on the logsheet. This will aid in diagnosing any problems that may occur in the future.

When the product storage tank is full, the level switch contact will open, and the unit will automatically shut down. Once the unit has shut down, the fresh flush sequence will automatically run.

After the fresh flush sequence is complete, the unit is in standby mode, and will restart when the product storage tank level switch indicates a low condition.

It is recommended that the unit be tested in automatic mode by manually activivating the float switches (bench test) prior to allowing the unit to operate unattended.

AUTOMATIC UNIT MANUAL START UP AND SHUT DOWN PROCEDURES

If external float switches are not installed, it will be necessary to install a jumper wire on terminals 3 and 4 in the control panel to simulate a normally closed contact from the product storage tank level switch.

Ensure all suction and discharge valves are in the correct position. Ensure the high pressure-regulating valve is fully opened (counter-clockwise). Verify that the OFF/RUN/START switch is in the OFF position. Place the MANUAL/AUTO switch in AUTO. Place the RUN/OFF/FLUSH switch to RUN. Turn the OFF/RUN/START switch to the START position and release. The switch is

spring loaded to return to the RUN position. The supply pump will start. After a time delay, the high-pressure pump will start.

With both pumps running, the high-pressure regulating valve can now be slowly adjusted to achieve the desired flow rate of product water.

To shut down the unit, turn the RUN/OFF/FLUSH switch to OFF. The unit will shut down, and the fresh flush sequence will run automatically. At the end of the flush sequence, turn the RUN/OFF/FLUSH switch to RUN.

The unit is now in standby mode. To restart the unit, turn the OFF/RUN/START switch to START and release.

ROUTINE MAINTENANCE

SILVER SERIES MAINTENANCE SCHEDULE

Seacock – Open and close each month to ease operation Sea Strainer - Check every two weeks or when it is suspected that it needs cleaning. Supply Pump – Replace mechanical seal when leakage occurs. Check impeller for

debris when rebuilding pump and when loss of flow occurs. Supply Pump Motor – Grease motor bearings once every three months with MATRIX

SRI No. 2 Grease. Media Filter – Backflush when there is a 15 psi or more differential between the inlet

and outlet of the filter. Sterilize filter with D-20 if the unit is not going to be used for two weeks or more. Back flush filter for 30 minutes when returning to service.

Bag Filter – Change bag when there is a 15 psi or more differential between the inlet and outlet of the filter. Ensure that the filter housing is clean of debris when replacing bag by rinsing the housing and allowing to drain.

Cartridge Filter – Change filter(s) when the pump suction/fine filter outlet pressure is between 15 and 20 psi. Ensure housing is free of debris and clean and rinse as is necessary. Flush filters with fresh water before changing, this will prevent salt water from spilling on other components.

CAUTION: Failure to completely clean all dirt and debris from the filter housing will allow debris to enter the membranes. The will foul the membranes, and will void the warranty.

Carbon Filter – Change filter(s) every three months.

CAUTION: Failure to change the carbon filter regularly may allow chlorine contamination of the membranes. The will destroy the membranes, and will void the warranty.

High Pressure Pump – Replace seals and valves when there is leakage or when there is a loss of flow. Flush pump after each use with fresh water. Change pump oil first 50 hours and after every 500 hours with MATRIX Pump Oil.

High Pressure Pump Motor – Grease motor every three months with MATRIX SRI No. 2 grease.

Membranes – Clean membranes every six months with general cleaning chemicals or as needed. If there is suspected fouling then clean the membranes with the chemical that is best prescribed. Always sterilize the membranes when they will not be used for one week or more to prevent bacteria from growing. Flush the membranes with fresh water after each use.

Gauges – Replace gauges when necessary. Clean glass and base when needed. Flow Meters – Clean with mild detergent when necessary. Do not expose the flow

meters to Zylene or similar solvents and thinners. Flush flow meters after cleaning with fresh water.

PVC Fittings – Threaded fittings should be removed and new Teflon tape applied when leaks occur. The fitting should be replaced if necessary. Fittings should be cleaned on the exterior when necessary.

Stainless Steel Fittings – The fittings should be cleaned and polished when necessary. Leaks should be attended to immediately to prevent corrosion damage. Threaded fittings should be removed and new Teflon tape applied when leaks occur. The fitting and ferrules should be replaced if necessary.

High Pressure Switch – Should be adjusted as necessary to ensure the correct setting of 950 psi. Switch should be replaced immediately if malfunctioning.

Low Pressure Switch – Should be adjusted as necessary to ensure the correct setting of 15 psi. Switch should be replaced immediately if malfunctioning.

Electrical Components – Replace as is necessary. Fuses - Replace as is necessary. Frame, Supports and Brackets – Clean and polish when necessary. Touch-up any

marred or chipped paint to prevent corrosion.

MAINTENANCE OF PRE-FILTRATION COMPONENTS The pretreatment of the feedwater is one of the most critical aspects of reliable, long-

term performance of the R/O elements. Turbidity and suspended particles must be removed from the feedwater prior to the R/O

portion of the system, otherwise damage will occur to the sensitive instruments, highpressure pump, and specifically the membrane elements.

Mechanical plugging of the elements by particles is one of the most difficult forms of fouling to correct. In some cases, mechanical fouling can be irreversible, resulting in costly element replacement.

Although this system utilizes the finest prefiltration available, improper service can still result in this problem. By changing filters and not flushing out the chamber, or re-using old cartridges; a "sludge" of particle contaminated water will flow to the elements and some particles will become lodged within the brine spacer, or if large enough, plug the feedwater end of the element. Repeated occurrences will obviously increase this fouling problem.

Also, using other than specified types and qualities of prefilter replacements can increase the potential of mechanical fouling.

MEDIA TANK FILTRATION The media is designed to catch particles of 25 micron or greater. When the pressure

drop across the media filter exceeds 15 psi, it is necessary to backflush the system. Only the supply pump is used to clean the media tank, pushing seawater through the

media, but in the opposite direction of normal flow. BACKFLUSH PROCEDURE

1. Place the two three way valves in the backflush mode. This requires turning the valve handles 180 degrees from the normal operating position.

2. Turn the Off/Run/Start switch to the Start position. The supply pump will then start up and provide water to the media filter.

3. The duration of the time of the backflush depends on how badly the media tank is clogged. With the watermaker in continuous duty it is recommended that the operator perform this operation at least once a week.

4. Generally one hour is sufficient to adequately backflush the filter. Once this is done, turn the Off/Run/Start switch to the Off position.

5. Place the valves in the normal service operating position.

6. The system is now ready for return to service. Note all pressure and flow rates on system when restarted.

The high-pressure pump does not run in the media tank backflush mode.

BAG FILTER The bag filter assembly is provided with a polypropylene large capacity bag filter. These

bags provide a large holding capacity and good particle retention while being substantially lighter than media filters. Approximate wet weight of each of the filters is 250 pounds compared with a properly sized media filter, which would weigh between

1000-2000 pounds. The bag filters are non-corrosive and are rated up to 150 psi. operating pressure.

There is no backflushing procedure for this type of filter. When the pressure gauge shows a pressure drop of 15 psi., simply remove the bag, and clean with fresh, dechlorinated water. The bag can be cleaned several times before replacement. After cleaning, carefully inspect the bag for holes or signs of wear. Replace the bag if any defects are noted.

TO CHANGE THE BAG

1. Shut down the system.

2. Isolate the filter by closing valving on the intake and discharge (if installed ) of the unit.

3. Remove the line that is attached to the top of the filter, if necessary. If hard piped, there should be a union for easy removal. If connected by hose there should be adequate hose to remove the cover with out disconnecting the hose.

4. Loosen the wing nuts found on top of the chamber which secure the cover plate. The bolts should swing down to the sides.

5. Apply steady pressure and evenly lift up the cover plate.

6. Loosen the collar on top of the cover by holding the disk that is inside the bag, while unscrewing the collar. Be careful not to fully unscrew the disk, only loosen enough for bag removal.

7. If particles are noticed in the remaining water left in the chamber, flush out well with dechlorinated fresh or salt water until cleared.

8. Carefully place a new bag in the chamber and place so that there are no folds or pleats in the bag.

9. Replace cover and lugs. Do not overtighten these lugs. Hand tightening is adequate.

10. Return all valves to normal service positions.

11. Start the supply pump and purge air from the chamber with the air bleed fitting (if installed) on the top of the cover plate.

12. Return system to normal operation. Note all pressure and flow rates.

CARTRIDGE FILTRATION Cartridge filter assemblies are provided for removal of suspended solids of 5 micron, or

greater, that could damage the high-pressure pump and/or foul the membranes. A pressure gauge is provided to facilitate the monitoring of the feedwater supply

pressure to the H.P. pump. The cartridge elements should normally be changed before the pressure to the high-

pressure pump suction falls below 15 psi. Each filter chamber requires one cartridge element rated at five (5) microns.

NOTE: DO NOT OPERATE THE SYSTEM WITHOUT FILTER CARTRIDGE ELEMENTS INSTALLED!

TO CHANGE THE FILTER CARTRIDGES

1. Shut down system.

2. Flush system with fresh water.

3. Press the small red button on top of the filter housing to release any pressure.

4. Unscrew the blue lower half of the prefilter housing.

5. Remove the old cartridge and discard.

6. Rinse or wash out the chamber with dechlorinated water being careful to remove all accumulated dirt.

CAUTION: Failure to completely clean all dirt and debris from the filter housing will allow debris to enter the membranes. This may foul the membranes, and will void the warranty.

7. Place the new filter cartridge in the housing. An o-ring on top of the housing makes the watertight seal. Inspect the o-ring for nicks or cuts and replace if necessary. Lubricate the o-ring with silicone grease before reinstallation of the cartridge filter housing.

8. Reinstall the lower half of the prefilter by screwing it into the head. Tighten to handtight plus ¼ turn using the wrench provided.

9. The prefilter is now ready to be put back into service.

10. Once the supply pump is running, press the small vent button to expel any air.

THE WATERMAKER

GENERAL Wash and rinse down equipment routinely. Touch up marred or chipped painted

surfaces, and spray equipment (except electrical parts) with a corrosion inhibitor such as T-9 spray.

HIGH PRESSURE PUMP Maintain the oil level in the crank end of the pump to one half the sight glass level. The

oil must be changed after the first fifty-(50) hours of running. Always use MATRIX Pump Oil to maintain the warranty. Subsequent oil changes are at 500 hours or every three months.

Lubricate the High Pressure Pump Motor every three-(3) months with MATRIX SRI #2 grease. Tighten drive belts (if supplied) when the deflection exceeds .5" or if a reduced flow is observed when the high-pressure pump is running. Tighten belts with the control power off.

REMINERALIZER The remineralizer bed (corosex and calcite) should be replaced when there is a

noticeable drop in water pH at the remineralizer discharge. In general, the bed will require replacement every 1-2 years, depending on usage.

CALIBRATION PROCEDURES Calibration of electronic flowmeters can be accomplished by operating the unit, and

collecting the flow (either product or concentrate) in a measured container for a fixed period of time to determine the actual flow rate. The meter is then adjusted to match the measured flow rate.

Mechanical flowmeters do not require periodic recalibration. Conductivity meter calibration is accomplished by measuring the conductivity of the

product water using a hand-held meter, and adjusting the unit’s meter to match the hand-held reading. The hand-held meter should be calibrated periodically by using standard calibration solutions available from Matrix.

Perform additional maintenance as specified in the individual components O&M Manuals

CHEMICAL

USE

QUANTITY

A-10

ALKALINE CLEANER

FOR ORGANICS

REMOVAL

4 OUNCES

A-11

ELEVATING THE pH

WHEN USING A-10 AND

A-20

AS NEEDED TO RAISE

pH TO 10-12

A-20

ALKALINE CLEANER

FOR ORGANICS

REMOVAL

1 PINT

B-10

ACID CLEANER FOR

REMOVAL OF METAL

OXIDES

1 PINT

C-15

ACID CLEANER FOR

REMOVAL OF METAL

OXIDES

1 PINT

D-20

SHORT TERM

STERILIZER FOR LESS

THAN 30 DAYS

4 OUNCES

E-25

LONG TERM

STERILIZER FOR

MORE THAN 30 DAYS

1 GALLON

M5-SW

ENZYME CLEANER

FOR OVERALL

CLEANING

4 OUNCES

MEMBRANE STERILIZATION AND CLEANING PROCEDURES

The following chemical cleaning procedures are intended to be applied through the use of a standard Matrix cleaning system. Cleaning should be performed only by qualified personnel. Contact Matrix for assistance if required.

The quantity of mixed cleaning solution required is as follows: Silver A Series (600-1500 GPD) 5 Gallons

Silver B Series (2600-4400 GPD) 10 gallons Silver C Series (6800-12000 GPD) 15 Gallons

MIXING INSTRUCTIONS (PER FIVE GALLON SOLUTION)

MEMBRANE STERILIZATION PROCEDURES

SOLUTION D-20 - FOR SHORT-TERM SHUTDOWN - (FOUR WEEKS OR LESS) AND SOLUTION E-25 - FOR LONG-TERM SHUTDOWN (FOUR WEEKS TO SIX MONTHS)

STEP 1: Prepare Watermaker

1. Flush system with copious amounts of fresh, dechlorinated water. This step is to remove all saline water and chemicals from the system and membrane elements.

2. The watermaker and any additional (optional) prefiltration equipment (i.e., media filter, bag filter, etc.), should be flushed and sterilized prior to shutdown.

3. Install the chemical cleaning hoses to the cleaning connection fittings on the unit, and the cleaning tank. Turn the chemical cleaning valves so the supply pump feed is isolated and Concentrate water returns to the tank. This will allow recirculation of the chemical solution through the watermaker.

4. If the supply pump is being used to recirculate the chemicals, the cleaning container must be placed above the level of the pump since the pump is not self-priming.

5. Disconnect the product water supply tube from the storage tank. This will prevent chemicals from entering the fresh water system.

STEP 2: Prepare Chemical Solution

READ CHEMICAL MSDS SHEET (PROVIDED WITH CHEMICAL) BEFORE PROCEEDING

WHEN HANDLING CHEMICALS ALWAYS USE APPROPRIATE SAFETY EQUIPMENT

1. Mix solution according to the mixing instructions described previously

STEP 3: Sterilizing Procedure

1. Start the cleaning/recirculation Pump ensuring that the regulating valve is fully

open, and re-circulate for forty-five (45) minutes. REMEMBER! ALL CHEMICALS

ARE RE-CIRCULATED UNDER "MINIMUM PRESSURE"! CHEMICAL SOLUTION TEMPERATURE MUST NEVER EXCEED 35°C (110°F).

2. During recirculation, the temperature of the cleaning solution will rise. Do not

allow the temperature to exceed 110 degF

3. After re-circulation, close all inlet and discharge valves to isolate the watermaker

and prevent the solution from draining out of the watermaker.

4. Disconnect the electrical power source (breaker) to the system.

MEMBRANE STERILIZATION IS NOW COMPLETED

STEP 4: Return Watermaker to Service

1. Set all valves to service positions.

2. Disconnect the product water line and allow it to dump to waste.

3. Fully open the concentrate control (pressure regulating valve) by turning counterclockwise.

4. Start the system, and allow it to operate at low pressure for at least 30 minutes. This should flush the majority of the preservation solution from the system.

5. Slowly increase pressure control valve to normal operating pressure.

6. After producing potable water for sixty (60) minutes, reconnect the product water line so the product water may now go to the fresh water tank.

CHEMICAL CLEANING INSTRUCTIONS

FOR USE WITH A-10, A-20, B-10, C-15, and M5-SW Solutions

STEP 1: Prepare Watermaker:

1. Flush system with copious amounts of fresh, dechlorinated water. This step is to remove all saline water and chemicals from the system and membrane elements.

2. The watermaker and any additional (optional) prefiltration equipment (i.e., media filter, bag filter, etc.), should be flushed and sterilized prior to shutdown.

4. If the supply pump is being used to recirculate the chemicals, the cleaning container must be placed above the level of the pump since the pump is not self-priming.

5. Disconnect the product water supply tube from the storage tank. This will prevent chemicals from entering the fresh water system.

STEP 2: Prepare Chemical Solution:

READ CHEMICAL MSDS SHEET (PROVIDED WITH CHEMICAL) BEFORE PROCEEDING

WHEN HANDLING CHEMICALS ALWAYS USE APPROPRIATE SAFETY EQUIPMENT

1. Mix solution according to the mixing instructions described previously

2. Cleaning chemicals A-10 and A-20 are most effective at a pH level between 10 and

12. When using these chemicals only, check the pH of the mixed solution. Add A11 as required to raise the pH to between 10 and 12. pH adjustment is not required for B-10, C-15, and M5-SW cleaners.

STEP 3: Cleaning Procedure:

1. Start the cleaning/recirculation pump ensuring that the regulating valve is fully open, and re-circulate for forty-five (45) minutes. REMEMBER! ALL CHEMICALS ARE

RE-CIRCULATED UNDER "MINIMUM PRESSURE"! CHEMICAL SOLUTION TEMPERATURE MUST NEVER EXCEED 35°C (110°F).

2. During recirculation, visually inspect the condition of the cleaning solution. If the solution becomes very dirty, discard the solution and mix a new batch. When using cleaners A-10 and A-20 only, periodically, check the pH of the solution. The pH will normally fall as the membrane foulants are removed. Add small amounts of A-11 as required to maintain the pH of the solution between 10 and 12.

3. During recirculation, the temperature of the cleaning solution will rise. Do not allow the temperature to exceed 110 degF

4. After re-circulation for 45 minutes, disconnect the return line from the chemical cleaning tank and direct the line to waste.

5. Restart the cleaning pump, and pump the cleaning solution to waste. Do not allow the pump to dry run.

WHEN HANDLING CHEMICALS ALWAYS WEAR APPROPRIATE SAFETY EQUPMENT

STEP 4: Return Watermaker to Service:

1. Set all valves to service positions.

2. Disconnect the product water line and allow it to dump to waste.

3. Fully open the concentrate control (pressure regulating valve) by turning counterclockwise.

4. Start the system, and allow it to operate at low pressure for at least 30 minutes. This should flush the majority of the preservation solution from the system.

5. Slowly increase pressure control valve to normal operating pressure.

6. After producing potable water for sixty (60) minutes, reconnect the product water line so the product water may now go to the fresh water tank.

STEP 5: Document all pressure, flow, and water quality and temperature parameters after each chemical treatment.

PROBLEM

INDICATION

SOLUTION

“Low Feed Pressure”

Light Not Working

 Red Light Burned Out  No Control Power  L.P. Switch Out

 Replace Bulb  See Below  Adjust Or Replace Switch.

No Control Power

 Feed Power Off  Internal Fuse Blown  Transformer Open Or Burned  Motor Overload Trip

 Check Feeder To Unit  Change Fuse  Replace Transformer  Reset Overload

Feed Pump Running No Green Light

 Light Bulb Faulty  Loose Wire

 Check Bulb  Check Wiring

Feed Pump Not Running

 Improper Switch Position  Supply Pump Fuse Or Circuit

Breaker Off

 Supply Voltage Or Phase

Incorrect

 Thermal Overloads Are

Tripped

 Motor Contactor Contacts Or

Coil Bad

 Turn Switch To START  Replace Fuse Or Turn On

Supply Pump Breaker

 Locate Proper Power Supply  Wait For Overload To Cool

Then Reset

 Replace Contactor

Feed Pump Running, No Feed Pressure

 Suction Valve Not Open  Pump Not Primed  Pump Rotation Wrong

 Open Suction Valve  Prime Pump  Correct Pump Wiring

Feed Pump Running, Feed Pressure Good, No Flow Through Concentrate Flow Meter

 Improper Valve Position

 Check All Valves For Correct

Operating Position

Feed Pump Running Low Pressure And Flow

 Broken Or Obstructed Supply

Piping

 Fouled Filter Cartridges  Fouled Media Filter  Fouled Bag Filter  System Valves Improperly

Positioned

 Repair Piping/Remove

Obstruction

 Replace Cartridges  Backflush Filter  Clean or Replace Bag  Place Valves In Normal

Service Position

TROUBLESHOOTING

GENERAL After correct installation and start up of the MATRIX Watermaker by authorized personnel,

most problems occur with the normal wear and tear of components. Many problems can be eliminated by following the correct maintenance procedures and also maintaining the operating logs described in this manual.

Problem

Indication

Solution

High Pressure Pump Running, Low Flow

 Defective Pump Fluid End  Foreign Mater In Fluid End

 Defective Motor  Belts Slipping

 Replace Pump  Disassemble Pump, Check

Valves

 Replace Motor  Tighten Belts, Check Pulleys

For Wear.

Unit Shutdown On High Pressure

 Faulty High Pressure Switch  Unit Pressure Too High  High Pressure Switch Needs

Adjustment.

 Belts Slipping Intermittently

 Replace High Pressure

Switch

 Run Unit Within Correct

Operating Parameters

 Adjust High Pressure Switch  Tighten Belts

Membrane Product Quality Low

 Fouled Membranes  Feedwater Salinity Increase  Improper Chemical

Pretreatment (Optional Equipment)

 Conductivity Probe Needs

Cleaning

 RO Membrane Feed Pressure

Low

 Defective Pressure Vessel “O”

Ring, Brine Seal, or Membrane Interconnect

 Conductivity Meter Out Of

Adjustment

 Clean/ Replace Membrane  Check Sea Water Salinity  Consult MATRIX Service

Department

 Clean Probe  Adjust Pressure For Correct

Flow Rate

 Replace “O” Ring, Brine

Seal, or Interconnect

 Calibrate Conductivity Meter

Membrane Product Flow Low

 Fouled Membranes  Temperature Decrease

 Low Membrane Feed Pressure

 Clean / Replace Membranes  Check Seawater Correction

Table

 Adjust Pressure For Correct

Flow

Membrane Housing

V-shaped Brine Ring

Membrane inlet

Seawater Flow

V-RING

MEMBRANE

Membrane Installation

& Position of Brine Ring

To install the membrane, observe that there is one outer seal (called the “Brine Seal”) on only one end of

the membrane – SEE DRAWING. This “V-shaped” seal ensures that the feedwater goes through the membrane, not around the outside (path of least resistance). The water flows from one side (inlet with Brine Seal) to the other side (concentrate outlet) of the membrane in the vessel. Lubricate the brine seal and the inner edge of the pressure vessel. When installing the membrane, load the membrane into the pressure vessel in the direction of the feedwater flow. This will ensure that the Brine Seal is positioned on the feed (inlet)

The “V-shaped” portion of the seal should have the open portion of the “V” facing the flow, so that it will flare open and seal against the inside diameter of the pressure vessel. FLOW

side.

ENGINEERING DATA

COMPONENT ILLUSTRATIONS

Matrix S3600 Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual