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DC Genset/Watermaker

Operations Manual

CAUTION!

Please read ALL of the specific information included in this manual. Failure to do so could

result in poor genset performance, mechanical and/or electrical damage, and serious injury

to the operater and/or installer. Improper installation and/or operation may also nullify the

manufacturer's warranty (see the "Warranty" page in this manual).

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19009 61st Ave. NE #4,Arlington, WA 98223

Phone: (360) 435-6100, Fax: (360) 435-3210

E-Mail: balmar@balmar.net, Web: www.balmar.net

Setting Up Your Genset

Unpacking Your Genset .................................................... 1

Preparation For Installation

Space & Ventilation Requirements ................................ 2

Ventilation ............................................................................2

Exhausting............................................................................2

Fuel System ........................................................................2

Maintenance........................................................................2

Installation Procedures

Seawater & Freshwater Supply ...................................... 3

Exhaust System ..................................................................3

Starting System ..................................................................4

Cooling System....................................................................4

Fuel System ........................................................................4

System Alternator ..............................................................4

Voltage Regulator ..............................................................4

Alternator Direct Coupling Device ................................5-6

Key Panel ............................................................................7

Parts Required For Installation

Mounting Genset................................................................ 7

Seawater Supply ................................................................ 7

Exhaust System.................................................................. 7

Starting System.................................................................. 7

Troubleshooting ........................................................................ 8

Warranty ...................................................................................... 8

Aqua Pac Voyager Operations

Introduction ........................................................................ 9

Central Processing Module............................................ 10

Pre-Filtration Module ...................................................... 10

Reverse Osmosis Module .............................................. 10

Pressure Regulator ........................................................ 11

Control Panel.................................................................... 11

Feedwater Pump ............................................................ 11

Emulsion Removal Module ............................................ 11

Plankton Filter Assembly .............................................. 11

UV/Charcoal Sterilizer .................................................... 11

Supplemental Filters ...................................................... 11

Freshwater Flush Assembly .......................................... 11

Watermaker Specifications .......................................... 12

Replacement Parts ........................................................ 12

Desalinator Operation

Initial Watermaker Startup............................................ 12

Routine Startup .............................................................. 13

Routine Watermaker Shutdown .................................. 14

Prolonged Watermaker Shutdown .............................. 14

Temperature Effects on Performance.......................... 14

Freshwater Output Correction ...................................... 14

Properties Of RO Water.................................................. 15

Watermaker Installation

Central Processor Module Mounting............................ 15

Product Water Outlet Connection ................................ 16

Waste Product Water Outlet Connection .................... 16

Input 12VDC Power Connection.................................... 16

Connecting Electrical Control Cable ............................ 16

Watermaker PRe-Filtration Module.............................. 16

Water Connections .......................................................... 17

Reverse Osmosis Module Assembly/Installation ...... 18

Pura UV Disinfection/Filtration System ...................... 19

Prior To Running DC Genset

Electrical Connections .................................................... 20

High-Output Alternator Cables ...................................... 20

Cooling and Lubrication Systems ................................ 21

Fuel System...................................................................... 21

System Control Panel .................................................... 21

Toggle Speed Control ...................................................... 21

Regulator Programming ................................................ 21

Starting Engine ................................................................ 21

Automatic Alarm Shutdown .......................................... 22

Activation of Charging System ...................................... 22

To Terminate Operation.................................................. 23

APV Checklist

Activation of APV............................................................ 23

High Pressure Test .......................................................... 24

Manual Override Mode .................................................. 24

Filter Pack ........................................................................ 25

Final Thoughts ................................................................ 25

TABLE OF CONTENTS

Summary of content (26 pages)

PAGE 1
DC Genset/Watermaker Operations Manual 19009 61st Ave. NE #4,Arlington, WA 98223 Phone: (360) 435-6100, Fax: (360) 435-3210 E-Mail: balmar@balmar.net, Web: www.balmar.net TABLE OF CONTENTS Setting Up Your Genset Unpacking Your Genset .................................................... 1 Preparation For Installation Space & Ventilation Requirements ................................ 2 Ventilation ............................................................................2 Exhausting................
PAGE 2
SETTING UP YOUR DC GENSET Unpacking Your Genset Your genset was carefully packaged and inspected prior to shipping. Before uncrating the genset, inspect the shipping container carefully for any signs of damage. If major damage to the exterior of the shipping container is noted, notify the driver of the delivery vehicle immediately. Arrangements for inspection by a claims representative of the shipper should be arranged with the driver or with a shipping company customer services representative.
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PREPARATION FOR INSTALLATION Space and Ventilation Requirements Several issues should be addressed when determining the optimal installation location for your DC genset: Ventilation, Cooling, Fuel Supply, Exhausting, Ease of Maintenance and Repair, Protection from the Elements. Ventilation: Both the genset’s diesel engine and high-output alternator require substantial airflow to ensure adequate cooling. The installation site should be free of any potential obstructions that could inhibit airflow.
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INSTALLATION PROCEDURES Seawater and Freshwater Supply Seawater supply hose must be a minimum of 5/8" ID and must not be obstructed by undersized sea water strainers, fittings, or sea cock valves. We recommend seawater hose and fittings be a minimum of 3/4". The larger the sea strainer, the better. Do not share the seawater inlet with the main engine through-hull unless a sea chest is available.
PAGE 5
Starting System The DC genset is equipped with its own dedicated charging system to support an independent starting battery. Should you choose to utilize a dedicated battery, or start the genset with the ship’s battery, ensure that battery cables are properly sized to support the genset’s starting load. The battery (+) lead will connect to the positive post of the small alternator attached to the genset’s engine. A jumper wire is already connected to the starter solenoid.
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Alternator Direct Coupling Device (Lovejoy #LF4 Coupler) The alternator is coupled to the genset engine via a flexible torsional coupling (Lovejoy #LF4). The coupling is installed prior to shipping and should require no user adjustment thereafter. Should you need to remove and replace the alternator and coupling, re-installation will require strict adherence to the following procedural guidelines: 1.
PAGE 7
5. Once aligned, insert the 30mm Capscrews into the three radial cavities in the Lovejoy. Tighten each capscrew just far enough to ensure proper threading until all screws are properly aligned and threads are started. 6. When all three capscrews are in place, Tighten to 20 ft.lb. It may be necessary, once all capscrews are in place, to turn the crank pulley on the engine to access all of the capscrews for torqueing. 7. Inspect the Lovejoy for proper alignment as illustrated at right.
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Key Panel Electrical Connections for 12VDC motor functions are made at the molded plugs at the engine. One 20' extension cable is supplied with each system. There is a 25-amp fuse at the engine for panel and wire protection. The engine is supplied with oil pressure and temperature switces, and will shut down the engine in the advent of a malfunction. A red LED on key panel would indicate this. Key Panel includes: 1. Key Switch 2. Hour Meter 3.
PAGE 9
PARTS REQUIRED FOR INSTALLATION (Continued) Battery Box Alternator System System Battery Cables (minimum #1\0 AWG - determined by length of run & percentage of line loss). TROUBLESHOOTING Balmar equipment manuals contain a user friendly troubleshooting section. This information is also available at our web site: www.balmar.net. Personal assistance in troubleshooting equipment is available through our Technical Support Department via E-mail (balmar@balmar.net) or phone (360435-6100, ext. 3).
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Aqua Pac Voyager Operations Manual Pre-Filtration Module Control Panel & CPM Feedwater Pump RO Membranes Introduction The Aqua Pac Voyager is a revolutionary concept in providing fresh water from seawater for pleasure boats and for remote residences and encampments. The integrated desalinator is nominally rated at either 20 or 40 gallons per hour. The APV system is modular in design, combining required components, whether installed on a Balmar PC-750 or PC-850 DC Genset or used on its own.
PAGE 11
From the flow meter, the product water enters a chamber called the "salinity cell" where two probes measure the electrical resistance of the product water. The residual ion content of the product water is inversely proportional to its electrical resistance, totally de-ionized having infinite resistance. Typical resistance of the product water will be in the neighborhood of 1500 ohms. The purity of the product water may also be expressed in mhos where the value would be the reciprocal of that in ohms.
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Pressure Regulator The Pressure Regulator consists of a manual pressure regulator and a pressure gauge mounted on the control panel. The regulator maintains the proper back pressure on the membrane. Control Panel The Control Panel permits operation and monitoring of the system from a convenient location such as in the living quarter of a boat. Feedwater Pump The Pre-feed pump consists of a separate relay controlled pump that forces feed-water through the pre-filters.
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Watermaker Specifications Feed-w water pH Range: 3-1 11 Feed-w water Temperature Range: 40° to 100°F (4.4°C to 37.8°C) Membrane Salt Rejection: 98.
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5. Start the engine. 6. Set the Master System switch to "manual" at the control panel. 7. Turn the RO pressure valve all the way counter-clockwise, to ensuring that no membrane preservatives enter the product water storage tank. 8. Press and release the desalinator start switch. 9. Check the entire system for leaks. If any are found, stop the system and correct as necessary. 10. If the system should stop automatically, refer to “Troubleshooting Section” for possible causes. 11.
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2. Ensure that all feed-water valves are open. 3. Start the engine. Allow a few minutes to warm up. 4. Activate the desalinator start switch. 5. Verify that the "CLUTCH ENGAGED" light is on. Periodically, verify that the product water flow--meter indicates approximately the proper product water flow for the given feed-water temperature. (Refer to Section 1.4) (This should be done immediately whenever it is suspected that the feed-water salinity has changed such as when cruising from a river to open ocean.
PAGE 16
Feedwater Temperature Correction Factor 40°F (4.44 °C) .373 50°F (10°C) .535 60°F (15.6°C) .695 70°F (21.2°C) .895 77°F (25°C) 1.00 80°F (26.7°C) 1.08 90°F (32.2°C) 1.27 100°F (37.8°C) 1.47 Properties of Reverse Osmosis Water The purpose of a reverse osmosis desalination system is to remove a large percentage of the dissolved minerals (salt) in sea or brackish water.
PAGE 17
Product Water Outlet Connection The product water outlet on the CPM is a barbed fitting for connection to 3/8" ID hose. The fitting is attached to the diversion valve that is mounted on the back of the CPM. The product water outlet hose will carry water to the storage tank. Use only food-grade hose (suitable for carrying fluids for human consumption and capable of withstanding working pressures of 50 PSI). Suitable hose is available from your dealer (P/N 210-005).
PAGE 18
and high pressure pump seal life will be unacceptable. It should be noted that a Feed-water Pump Module will enhance the operation of any system, regardless of where the PFM is mounted in relation to the feed-water supply level and is supplied with this system. Water Connections Use 3/4" ID food-grade suction hose to connect the outlet of the Feedwater Pump Module to the inlet of the Pre-filtration Module (PFM) and the outlet of the PFM to the feed-water inlet of the Pump/Clutch Assembly.
PAGE 19
appropriate intervals. Remember to use 2 hose clamps at all below-waterline connections. WARNING: Inlet pressure in excess of 50 PSI may explosively burst the PFM, possibly causing injury to personnel and/or damage to property. Reverse Osmosis Membrane Module Assembly and Installation Do not assemble the membrane and vessel until the watermaker system is ready to operate. Removing the membrane from the sealed package initiates the warranty period.
PAGE 20
High Pressure Inlet Connection A special, custom fabricated and separately priced hose is required to connect the outlet of the ROM to the inlet of the Control Panel. The hose can be purchased from an independent source if so desired. Aeroquip FC 300-5 hose with a 411-5B fitting on each end will be suitable. Connect one end of the hose to the brass flare fitting on the ROM and the other end to the inlet of the PRM.
PAGE 21
DC Genset / Watermaker Pre-Run Checklist Prior to Running the DC Generator The following checklist is intended to ensure dependable DC genset and watermaker operation. Please follow the instructions carefully to ensure proper system performance. Electrical Connections Proper wiring connections are essential to genset operation. Ensure that all electrical plugs are properly plugged in, wiring is complete, and fuses on engine are in place and functional.
PAGE 22
Cooling and Lubrication Systems Engine fluids must be inspected and levels adjusted prior to startup. Add engine oil, if needed, to ensure that the engine has adequate oil. See check and fill locations at right. Fresh water coolant (50% anti-freeze, 50% fresh water) is filled to the bottom of the overflow tube on the coolant reservoir. If watermaker option is installed, be sure the Cat Pump has adequate oil (to the top of the window's inner ring). See photo at right.
PAGE 23
1. Exhaust heat detector. 2. Block temperature sensor. 3. Oil pressure sensor. Automatic Alarm Shutdown All sensors on the engine open their circuits in the alarm state, which will automatically shut the engine down by discontinuing electrical current to the fuel solenoid. The three automatic shutdown sensors include: 1.) Exhaust Water Inject Elbow Heat detector; 2.) Engine Block Temperature Sensor; and, 3.) Oil Pressure Sensor.
PAGE 24
Apply electrical load to ship's DC system. Insure that voltage remains stable. If necessary, accelerate engine rpms to meet load demand. It should be noted that alternator output will not exceed the acceptance rate of the battery bank. Heavy loads produced by large inverters operating air conditioners, or windlass loads may be better handled by low resistance batteries such as Optima or AGM types. To Terminate Operation Turn alternator switch to the 'off' position.
PAGE 25
system. 3. Once the system is in operation, clutch engaged and the feed water pump in operation, the start button may be released. The regulator may now be turned clockwise to increase system pressure. It is suggested that pressure be brought up to 250-300 pounds and a general inspection of all water system fittings be made. 4.
PAGE 26
Open the small spigot valve on the bottom of the flow Auto/Manual gauge. Sample the water by tasting or using a hand held Switch salinity probe. If water is acceptable, close the spigot valve and rotate primary control panel valve from normal to manual tank fill. Operating in this manner reduces the system to its simplest form and assures water production without necessitating complex electronic components.