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                 Fresh Water Auto Flush          Installation and operation Manual                                        For                               All Models               

                                                                         Cruise RO Water                                     2448 Carroll Lane                      Escondido, California 92027 USA                 Manufacturing Facility: 619‐990‐6696              Sales & Technical Support: 619‐609‐3432                                   Fax: 760‐741‐9900                  On the Web: www.cruiseROwater.com                        Email: info@cruiseROwater.com                        Skype contact at: CruiseROwater 

2015 

 

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Table of Contents Fresh Water Auto Flush Installation .............................................................................................. 4 Introduction ............................................................................................................................... 4 Installation Instructions ............................................................................................................. 4 Mounting Instructions ............................................................................................................... 5 

Commissioning .............................................................................................................................. 5 Wiring ......................................................................................................................................... 5 Plumbing .................................................................................................................................... 6 System Control Voltage Verification .......................................................................................... 6 Boost Pressure Regulating Valve ............................................................................................... 7 Valving and Cleaning Valve Position .......................................................................................... 7 Air Purge Valve ........................................................................................................................... 7 Manual Pump Control Mode Verification ................................................................................. 7 Off /Auto  Control Mode Verification ........................................................................................ 7 

Normal Unattended Operation Instructions ................................................................................. 8 Timer Setting .............................................................................................................................. 8 Auto Operation .......................................................................................................................... 8 

Restoring from Fresh Water Auto Flush ........................................................................................ 8 Process Flow Diagram with Auto Flush Norma Mode .................................................................. 9 Electrical Schematic ..................................................................................................................... 10 Auto Flush Control Box Electrical Layout .................................................................................... 11 Auto Flush Timer as Shipped Settings ......................................................................................... 12 Auto Flush Timer Typical Settings ............................................................................................... 13 Main 15 Amp Fuse Block ............................................................................................................. 14 Timer  3 Amp Fuse Block ............................................................................................................. 15 Terminal Block Wire Insertion and Removal ............................................................................... 16 

Table of Figures Figure 1: Fresh Water Flush Solenoid Valve Assembly ................................................................. 6 Figure 2: Fresh Water Auto Flush Process Flow Diagram ............................................................. 9 Figure 3: Fresh Water Flush Electrical Schematic ....................................................................... 10 Figure 4: Control Box Electrical Layout ....................................................................................... 11 Figure 5: Timer as Shipped Settings ............................................................................................ 12 Figure 6: Timer Typical Setting .................................................................................................... 13 Figure 7: Main 15 Amp Fuse Block with Fuse Showing ............................................................... 14 Figure 8: 3 Amp Timer Fuse Block Showing Fuse ........................................................................ 15 Figure 9: Wire Removal and Insertion ......................................................................................... 16 

 

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FreshWaterAutoFlushInstallation

Introduction Cruise RO Water is constantly looking for ways to improve our product’s design and quality. We have added an automatic fresh water flush module that can be easily retrofitted into a current installation or installed with new water maker installations. This allows for automatic fresh water flushing of the water maker while unattended or automating fresh water flush during water making sessions. The upgrade includes a pre-wired control box, timer, off/auto switch, solenoid valve with bypass feature, fittings and tubing with instructions. All components are pre-wired and tested. The timer has been pre-set for a three minute off cycle and a one minute on cycle for the customer to be able to test the unit immediately after installation. The customer is responsible for external wiring from the boost pump motor, fresh water control solenoid valve, and power supplies to the alarm box. Warning: Only qualified personnel should install and wire in this system. Only personnel knowledgeable in the installation of high and low voltage AC and DC systems as well as troubleshooting should work on this system.

InstallationInstructions

Prior to beginning the actual installation process, please read the entire installation procedures and review the diagrams and pictures relevant to your particular installation. This retrofit manual covers installations that have diaphragm pumps with a bypass spring check valve. If your boost pump has a bypass hand valve and not a spring relief check valve please contact us at Cruise RO Water for a replacement valve. DO NOT OPERATE SYSTEM WITH A HAND VALVE ACROSS THE BOOST PUMP. The installation has several components.

12 VDC power supply wiring and fuse from the power supply to the control box 12 VDC wiring for the low pressure boost pump motor to the control box Mounting the NEMA 4X control box Mounting, plumbing, and wiring in the fresh water on / off solenoid control valve

     

 

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MountingInstructions The control box can be mounted in any orientation although vertical would be the preferred position. This allows for mounting at an appropriate height for visual ease of operation and troubleshooting. The box has four wings that can be rotated out. The wings are pre-drilled allowing for the box to be bolted or screwed to a surface. All other components are already mounted as this is an addition to a running system. If the customer chooses to he may at this time re-mount or re-position other components to facilitate this retrofit. When installing the wiring refer to the electrical schematic and the wiring diagram that are supplied with the kit. A single page electrical schematic is supplied this gives an overall view of the entire system and how it functionally operates. Terminal board positions are also given on the schematic to assist in wiring. The wiring diagrams give point to point wiring to each component. All wire gage sizes are called out on the electrical wiring diagrams. When installing wires into the box you must drill holes into the sides and install weatherproof connectors that have seals to prevent moisture from entering the box. These are not supplied as there is no way of knowing what size and type of insulated wire is used.

Commissioning

Wiring Leave the fuse out of FU220 while wiring the system. Run the power wires last. Verify that the following components have been wired into the Control Box 220. The low pressure boost pump motor wiring has been run to Control Box 220 and landed

on TB220 as shown on the electrical schematic The fresh water shut off solenoid valve L220 wiring has been run to Control Box 220

and landed on TB220 as shown on the electrical schematic Verify that the positive wire has been run from the 12 VDC power source to the 15 amp

fuse holder FU220 in Control Box 220 as shown on the electrical schematic Verify that the negative wire has been run from the 12 VDC power source to Control

Box 220 and landed on TB220 as shown on the electrical schematic Verify that the remote control panel switch for the boost pump and the high pressure

pump are in the off position if you have the standard remote panel option Verify that the Off / Auto switch S220 on the Control Box 220 door lid is in the off

position.     

 

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Plumbing The fresh water on / off solenoid valve L220 should be plumbed into the low pressure seawater supply immediately after the boost pump and before the pre-filter assembly. This supplies pressurized water to the solenoid L220. The solenoid requires a differential pressure across it in order to open and to operate properly. There is a directional arrow on the lower side of the solenoid body. The arrow should point towards the pre-filters.  

 Figure 1: Fresh Water Flush Solenoid Valve Assembly 

 

SystemControlVoltageVerification Once all the above wiring has been verified move switch S220 which is mounted on the Control Box 200 to the off position. The switch was shipped in the off position. Install the 15 amp fuse into FU220 and close the switch. Take a volt meter and verify that you have 12 VDC or higher from TB220-1 positive to TB220-2 negative. This proves that you have 12 VDC control voltage to the alarm box. Verify that the boost pump did not try to start. If the pump tries to

 

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start, kill the power to the control box and troubleshoot what could be wrong using the wiring diagram and schematic.

BoostPressureRegulatingValveVerify that the boost pump regulating valve on the water maker remote panel is turned fully clockwise in the closed position for the following tests.

ValvingandCleaningValvePositionTurn the valves on the valving and cleaning module to the fresh water flush position. This will block seawater from coming in and allow fresh water to enter the system when required.

AirPurgeValveOpen the air purge valve that is located between the high pressure pump and the pre‐filter assembly.

ManualPumpControlModeVerification At this point in the verification process we are determining that you still have control of the boost pump from the remote water maker panel. Once you have verified 12 VDC voltage to the control box keep Switch S220 in the off position. In this position you still have manual control over the low pressure boost pump motor from the remote control panel. Verify that the bypass valve that goes around the fresh water flush solenoid valve L220 is closed. With the rocker switch on the water maker remote control panel turn the low boost pump motor switch on. The boost pump motor should run. Verify proper motor rotation using the water maker manual for reference. Leave the switch on and verify the pump runs and water is purging out of the air purge valve. Bleed all the air out of the system using the ½” purge valve that is before the high pressure pump. Close the valve and verify no leaks are present and that pressure builds on the boost pressure gage. It will be normal to see 20 to 25 psig on the gage. Turn off the boost pump from the remote panel and leave the switch in the off position. Since the wiring from the control panel was spliced into the wiring from the auto flush control box we needed to verify that the rotations are correct and that pressure builds when the pump is turned on.

Off/AutoControlModeVerification With both the high pressure pump and the low pressure boost pump switches on the remote water maker panel in the off position turn S220 switch on the auto flush control box to the auto position. The logic is designed that the low pressure boost pump motor will start with the cycle off period before the cycle on period. The operator will observe several things. One, that there is power to the system as the timer led lights will start flashing signifying that the timer is timing. Two, that there is power to the boost pump motor because the power to the timer and the boost pump are common to each other. The timer is now timing. The timer is initially setup

 

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for three minutes off and one minute on. Upon initial installation you now need to wait the approximate three minutes for the boost pump to turn on automatically. Once the boost pump runs it will now run for approximately one minute. The boost pump will turn off at the end of one minute and the cycle will start over again. Let the system complete several cycles to verify proper operation before moving the timers in the next section for unattended operation.

NormalUnattendedOperationInstructions 

TimerSettingThe timer was factory set for 3 minutes off and one minute on. You will now need to move the timer settings to the time you prefer. We recommend five days off and three minutes on. Using the instructions on sheet 14 set the timer as illustrated. When this has been done you will now have the timer set for unattended operation. If there is a different timer setting preferred follow the timer setting instructions to accomplish that.

AutoOperation Once all the commissioning sections have been completed you may now operate the fresh water auto flush system in the normal auto mode. Begin the process by turning both the high pressure pump and the low pressure pump off on the water maker remote panel. Leave the boost pump bypass regulating valve closed on the remote panel. This will force all the fresh water from the boost pump into the high pressure pump and through the system quicker. Close the fresh water on / off solenoid valve L220 bypass hand valve. This prevents fresh water from bypassing the solenoid valve and always staying on draining your fresh water tank. Move the switch S220 on the control box 220 door lid to the auto position. The boost pump will turn on and at the same time the fresh water flush on / off solenoid valve L220 will open for three minutes every five days. The cycle will continue until the switch S200 on control box 220 is turned to the off position. If the pressurized freshwater supply system is plumbed to the valving and cleaning carbon filter assembly, make sure you have the power onto the ships pump otherwise you will not have fresh water being pumped to the auto flush system.

RestoringfromFreshWaterAutoFlushTurn switch S220 on the control box 220 to the off position. Move the fresh water on / off solenoid valve L220 bypass hand valve to the open position. Move the valving and cleaning valves back to the water maker normal position for making water. This will allow seawater to enter the system and block the fresh water. Refer to the operations manual that was provided for the water maker for normal water making.   

  

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ProcessFlowDiagramwithAutoFlushNormaMode                               Figure 2: Fresh Water Auto Flush Process Flow Diagram 

 

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ElectricalSchematic                                

Figure 3: Fresh Water Flush Electrical Schematic 

 

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AutoFlushControlBoxElectricalLayout                             Figure 4: Control Box Electrical Layout 

 

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AutoFlushTimerasShippedSettings                                      

Figure 5: Timer as Shipped Settings 

 

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AutoFlushTimerTypicalSettings   

    

                       Figure 6: Timer Typical Setting 

 

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Main15AmpFuseBlock                            Figure 7: Main 15 Amp Fuse Block with Fuse Showing   

 

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Timer3AmpFuseBlock  

                

 Figure 8: 3 Amp Timer Fuse Block Showing Fuse 

 The timer is protected by a 3 amp fuse located within the cover of the terminal block.  The upper portion swings away from the terminal block.  This disconnects the circuit.  The flap on the side of the swinging door is where the fuse is located.  This can be seen in the picture to the right.    

 

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TerminalBlockWireInsertionandRemoval 

                    

Figure 9: Wire Removal and Insertion   

  The wire can be inserted into the terminal board by pushing down on the orange tab that is located next to the hole for the wire.  The wire can also be removed by pushing down on the orange tab.  A small blunt screw driver can work for this procedure.