Thanks for your input. Regarding:
"To be exact, yet another leaking end cap, this time at the hose
connection end. Water had got pass the two 1.5mm x 9mm o-rings
and eroded the nylon, creating a serious leak. This was my 5th end
cap failure in just over 200 hours of operation! My end caps are
white. Has anyone else had a similar problem? Amel say that it is
very rare! I don't believe them."
I am not sure why you are having such leakage problems.
I have had no leaks from my end caps. My first set of end caps where
white plastic (?nylon) (see photo's in the photo section where I am
trying to remove the white end caps). They looked pristine when
removed during the replacement of my membranes that failed at
the 185 hour mark. I replaced the end caps anyway at the suggestion
of Amel's Olivier Beatue at that time (185 hours). I ordered the end
caps from Dessalator and received the black caps depicted in the
photo's section. I currently only have about 240 hours on the water
maker but I am still leak free.
Just a thought. Could it be that you got a batch of poor guality
o-rings? This might explain the recurrent leaks. The other
possibility is that the o-rings aren't seating well when installed.
Perhaps they have a twist in them?
When I install aircraft o-rings I lube them with a silicone lube, then
after meticulous cleaning of the o-ring groove, I roll the o-ring
into the groove. I then use a plastic pic to to lift a point on the
o-ring circumference and run the pic around the circumference
a couple of times to insure there are no twists.
Is it possible that your high pressure gauge is out of calibration
and the system is being over pressurized? Not sure if any of
these things are the actual cause but it certainly seems that you
are suffering from a higher failure rate than I have experienced
or heard about.