English Manual Katadyn PowerSurvivor 40E
Contents
1. 7 Turn on the watermaker Discard any solution coming from the reject brine hose for about 30 seconds Then run the reject brine water hose back into the container of cleaning solution to allow recirculation of the cleaner 8 Continue to run the watermaker for about 15 minutes to assure that the cleaning solution is well circulated through the pump and membrane 9 Turn off the watermaker and allow the membrane to soak in the cleaning solution for 5 to 10 hours or overnight For severe fouling repeat steps 8 and 9 of this procedure 10 When the soaking is finished remove the reject brine hose from the cleaning solution container and run the watermaker again Discard the first pulses of the reject brine water When the reject brine flow becomes cleaner return the reject brine hose to the cleaning solution container for recirculation 11 Continue to run the watermaker and recirculate the cleaning solution for another 30 to 60 minutes 12 When cleaning is complete turn off the watermaker Reconnect the reject brine hose to its normal drain location 13 Remove the alternate intake hose and strainer from the cleaning solution and place them into a container of clean warm non chlorinated freshwater If freshwater is not available clean seawater may be used if its temperature is above 68 F 20 C 14 Turn on the watermaker and flush warm water through the system for 5 minutes If the watermaker will be stored for more than a2. Intake Valve Seat 8012585 Intake Poppet Valve with o ring installed 8012978 Reject Valve Seat with o ring installed 8012977 Reject Poppet Valve with o ring installed 8012978 Poppet Valve Spring 8013120 Check Valve Plate 8012581 O ring 2 501 2588 Tu Membrane be Plug 8012595 Pump Body A Pa O ring X O ring 8012697 8012594 Capscrews 8013019 8012967 Bushing 8012797 e Piston Shaft Relief Cleaning Valve Assembly Factory preset do not disassemble Piston Shaft Seal 4 8013013 Wiper Block Membrane Housing O ring 8012947 Block 8012779 Wiper 7 Spacer Block 8012904 27 Retaining Ring 8012700 Housing End Plug Assembly includes o ring and housing end plate Seal 012776 O ring 8012588 Poppet Valve with Qty 2 i O ring installed 2 256 0 103 8012978 gt pe Qty 2 Poppet Valve Seat with O ring Installed 8012977 Qty 2 Poppet Valve Spring 8013120 aty 2 PIP Ring B 8012796 O ring Qty 1 0 187 ien so ae 0 103 _ kx Cup Seal 0 210 0 750 8012775 0312 ec eG ea 8012776 Qty 1 NOTE Some dimensions are approximate Figure A 3 28 Piston Shaft Bushing 8012797 l 0 340 v pom F Q L 8012947 Piston Shaft Seal Qty 2 8013013 2 1 484 l e 0 750 0 125 Pa O ring Backup Washer n white nylon yc 5 80129
3. 5 Turn the lever on the prefilter 3 way valve to the alternate intake position Run the 3 16 alternate intake hose with the strainer attached into the container of membrane preservative solution 6 Turn on the watermaker and run it until almost all of the membrane preservative has been drawn from the container and foamy membrane preservative solution is ejecting from the reject brine hose If there is a chance that the watermaker will be subjected to freezing conditions continue to run until air is being ejected from the reject brine hose Note If the membrane freezes it must be slowly and completely thawed before the watermaker may be used again 7 Turn off the watermaker It is now ready for storage for up to one year If seawater was used instead of freshwater repeat the membrane preservative procedure with freshwater as soon as possible Repeat the above procedure at least once a year if the watermaker is not being operated Cleaning the Membrane We do not recommend casual or regular cleaning of the reverse osmosis membrane in the watermaker it should only be done when needed Under normal use conditions when only open ocean seawater is being processed cleaning the membrane should rarely or never be Note necessary Proper membrane preservative treatments prior to extended periods of non use will reduce biological growth on the membrane surface Under these conditions and with proper care a membrane can be used for years wi
4. KATADYN MAKING WATER DRINKING WATER PowerSurvivor 40E Endurance Series 12 Volt amp 24 Volt Watermakers OWNER S MANUAL Thank you for purchasing a Katadyn PowerSurvivor 40E watermaker It was built to rigorous specifications and designed to produce potable freshwater from clean seawater using minimal power It is simple to install and operate and with reasonable care and maintenance can be expected to provide years of useful service Please before installing or operating your watermaker take the short time needed to read this User s Manual in its entirety That small investment of time will help assure many years of trouble free operation from your system We ve worked hard to provide you with a reliable product that is affordable compact simple to operate and easy to maintain the rest is up to you Contact us Be sure to fill in the enclosed warranty card and return it to us as soon as possible This is required to fulfill the terms of your warranty For Customer Service or information about this and other products from Katadyn please use our toll free phone numbers or visit our website at www katadyn com Katadyn North America 6325 Sandburg Road Minneapolis MN 55427 Phone 800 755 6701 or 763 746 3500 Fax 800 548 0406 or 763 746 3540 Website www katadyn com Customer Service Technical Support 800 755 6701 or 763 746 3500 International Collect Calls Accepted Email marine katadyn com W
5. and possibly larger if it is a shared inlet Note If there is the possibility that in the future you will want to upgrade to a higher capacity unit or perhaps a second PowerSurvivor 40E to implement redundant systems you should consider substituting 1 2 1 D hoses and hose fittings during your initial installation An easy to reach seacock should be installed on the thru hull immediately inside the hull A coarse seawater strainer is strongly recommended It should be easy to reach and clean e The easiest and most commonly used approach is to tee into an existing seawater intake system Because the flow rate and volume of seawater intake for the PowerSurvivor 40E are both extremely low the pump can be adequately supplied by most pre existing intakes even inlets that operate at modest negative pressures such as the cooling water inlet for an engine or generator When teeing into an existing seawater supply we recommend installing a separate seacock or valve in addition to the one at the thru hull to independently control the supply to the watermaker 5 Install Reject Brine Plumbing The reject brine water can be teed into an existing scupper or sink drain hose for draining overboard Use the 3 8 reinforced hose and supplied hose clamps A tee of the correct size will have to be supplied Alternatively a dedicated thru hull may be installed at a convenient location In this case we recommend that a seacock be installed at th
6. pencil to press it into its seat It is designed to be a light press fit and when installed correctly it should stay vertical in place during the next step B Use needle nosed pliers to carefully lower one of the new poppet valves into the bore The poppet valve should rest on top of the spring with the poppet s cross side facing up C Lower the new reject valve seat into the bore and use a finger to press it down as far as it will go Note that the hole in the middle of the valve seat has a beveled edge on one side The side with the beveled edge must face downward i e it must face the poppet valve When properly installed the valve seat should fit neatly over the poppet valve Test the poppet valve by pressing it with the eraser end of a pencil It should move up and down slightly and seat squarely in the valve seat D Locate the small depression in the center of one end of the poppet valve retainer and press the second valve spring into the depression It was designed as a light press fit and should stay in place after being installed Then lower the poppet valve retainer into the bore in the check valve plate with the spring facing upward E Lower the second poppet valve into the bore in the check valve plate and rest it carefully on top of the valve spring F Remove the old o ring 8013015 from the intake valve seat and replace it with the new one from the RSK Carefully screw the intake valve seat into the check valve plate and ti
7. purpose of the prefilter assembly is to trap any particulates in the intake seawater that are larger than 30 microns A coarse strainer if installed performs the same chore for contaminants of larger size In each case trapped material remains in the prefilter housing or strainer bowl until removed Much of the trapped material is organic plankton seaweeds and flotsam of all types After a watermaker has been turned off this material soon begins to decompose As it does it breaks down into a number of chemicals composed of smaller molecules Some of these molecules are small enough to pass through the watermaker membrane along with the product freshwater Perhaps the best known example of such a chemical is hydrogen sulfide a gas which in small concentrations smells like rotten eggs Two main factors affect the speed with which these products of organic decomposition will contaminate a watermaker system 1 the ambient temperature and 2 the quantity of trapped material We realize that many users of our equipment run their watermakers in near shore situations while anchored The amount of trapped material is usually high in such locations and the prefilter assembly will require more frequent attention Moreover the high ambient temperatures in tropical locations greatly accelerate the rate of such decomposition Users in temperate climate areas or users processing open ocean seawater during offshore passages are less likely to requir
8. s Manual describes both the routine and the long term maintenance requirements of the PowerSurvivor 40E Much of our knowledge of maintenance requirements watermaker performance and potential problems is a result of feedback from actual users over many years Following these instructions will help keep your product freshwater quality good and your watermaker running trouble free Pump Maintenance Once properly installed the main watermaker pump and drive assembly requires little attention You should regularly inspect the equipment and check for any leakage of seawater or oil leaks from the drive assembly Any leakage is a sign of a problem and should be corrected Make certain that the watermaker remains dry Exposure to saltwater can cause rapid corrosion of the drive assembly and or Figure 11 damage to the electric motor Keep all electrical connections clean dry and tight After every 1000 hours approximately of use replace the seals in the pump See Seal Replacement below After approximately 5000 hours of use have the electric motor inspected for brush wear and commutator condition Pump Piston Shaft Lubrication it is extremely important to lubricate the pump piston shaft periodically especially after cleaning the membrane The piston shaft is visible at the side of the drive assembly Piston Shaft where the pump connects to the drive see Figure 11 Jog run the watermaker and stop it when the piston shaft is
9. to remove the impurities found in clean open ocean seawater Processing of seawater with other kinds of impurities 1 may not remove those impurities and 2 may damage or destroy the membrane See Maintenance and Service Prefilter Maintenance below for more information on typical problems associated with foul water intake Low Battery Voltage will dramatically reduce the volume of seawater throughput and product freshwater output We recommend not operating the watermaker if battery voltage is below 11 VDC Note on Red Tides In many areas of the ocean a phenomenon generally known as a red tide can occur This generic name is used to describe an invasion of local waters by huge populations of micro organisms which turns the seawater red Occasionally a red tide is accompanied by the death of local fish and other sea life which can cause serious local pollution of the seawater Although the watermaker membrane can remove the microorganisms that cause the red tide it can not remove all of the chemical pollutants caused by large scale biological decomposition Therefore we do not recommend using the watermaker to process seawater when a red tide is present 12 Maintenance and Service A little love goes a long way We ve worked hard to design a product that is simple to operate and maintain However regular attention to the few maintenance requirements of this equipment is critically important This section of the Owner
10. valve plate from the pump body If it is difficult to remove try rotating the Piston Shaft check valve plate 90 This provides a better grip for Seals black 5 pulling the check valve plate from the pump body E03 Bushing 9 After the check valve plate has been separated from white the pump body the membrane tube plug will remain in either the check valve plate or the pump end of the membrane housing Use one of the following PumpBack Backup procedures to remove it Plate Nri A If the membrane tube plug remains in the uds membrane housing insert a hard thin edge e g a dull pocket knife between the tube plug and the fiberglass molding of the membrane housing Work the blade sideways to pry the tube plug out slightly until there is enough of a gap between the tube plug body and the membrane housing to insert a flat blade screwdriver Then use two screwdrivers on opposite sides of the tube plug to carefully work it out of the membrane housing Avoid gouging or damaging the membrane housing or the tube plug B If the membrane tube plug remains in the check valve plate use a thin edge and or flat blade screwdrivers on opposite sides of the membrane tube plug to carefully pry the plug out of the check valve plate Avoid damaging the membrane tube plug 10 Disassemble the valves in the check valve plate see Figure R 5 Use a 5 8 open end wrench to unscrew the Intake Valve Seat intake valve seat Remove the inta
11. 30 micron prefilter element constructed of polyester fibers Two standard elements are included with each system In some exceptional circumstances an optional second prefilter assembly with a 5 micron prefilter element may be needed see Kits amp Accessories The prefilter assembly is separate from the pump which allows it to be installed in a convenient and accessible location Valves Two high quality plastic 3 way valves are supplied The prefilter 3 way valve selects between two input sources for the prefilter assembly and pump e Clean seawater during normal operation An alternate intake line for inputting membrane preservative or a cleaning solution The product 3 way valve allows easy selection between the two required destinations for the product freshwater e A freshwater collection tank for normal operation e A convenient drain location for testing and discarding product freshwater membrane preservative and cleaners Note if you collect and discard the product freshwater at the same location manually directing the output from the product freshwater hose may be the most practical approach In this case the product 3 way valve need not be installed Hoses and Hardware Each PowerSurvivor 40E watermaker is shipped with hardware sufficient to perform a normal installation The 3 8 I D reinforced plastic hose is used for seawater intake and reject brine The smaller 3 16 I D clear plastic hose is for routing product
12. 67 Qy 2 0 504 Piston Seal Installation Tool 8012812 Qty 1 NOTE Some dimensions are approximate Figure A 4 29 Kits amp Accessories Preventive Maintenance Package Part 8012607 An expanded cruise kit which includes all components of the Extended Cruise Kit plus a Silt Reduction Kit This kit is strongly recommended for extended cruising and variable water conditions Silt Reduction Kit Part 8012859 This kit is intended to protect the high pressure pump and reverse osmosis membrane from excessive exposure to silt and other suspended particulates It should be used in brackish water shallow water inland waterways areas of glacial runoff and other similar situations The Silt Reduction Kit includes a 5 micron prefilter which follows the standard 30 micron filter supplied with the watermaker Also included is a 1 amp boost pump to ensure adequate intake flow to the watermaker Extended Cruise Kit Recommended Part 8012606 Includes items needed for regular care and seasonal maintenance and or storage Contains 1 Repair Seal Kit 1 container Acid Cleaner 2 containers Alkaline Cleaner 1 container of Membrane Preservative and 6 30 micron prefilter elements Repair Seal Kit Recommended Part 8012610 A set of all user serviceable seals and parts for the high pressure pump This kit also includes replacement gear oil for the drive assembly A Repair Seal Kit should be installed
13. Cleaner and check for improvement in product freshwater output If output remains poor repeat the cleaning process using the Acid Cleaner Never mix the two types of cleaners Always flush well with clean water between processes if performing both alkaline and acid cleaning The following directions apply for both types of membrane cleaners 16 1 Lift the lever on the cleaning valve on the pump to place it in its clean or up position see Figure 12 2 Discard any dirty seawater in the prefilter assembly Clean the housing and install a clean filter 3 Fill a clean plastic container or bucket with one gallon approximately 4 liters of clean water Freshwater is preferable but clean seawater may be used if freshwater is not available Caution Never use chlorinated freshwater This may damage the membrane 4 Mix four spoonful approximately 40 grams of either Acid Cleaner or Alkaline Cleaner not both with the water in the container and stir until the cleaner is completely dissolved The water should be warm but not over 120 F 49 C 5 Turn the lever on the prefilter 3 way valve to the alternate intake position Run the 3 16 alternate intake hose with the strainer attached into the container of cleaning solution 6 Disconnect the reject brine water hose from its drain or use a separate length of hose to route the reject brine water back into the container of cleaning solution during the following procedure
14. a filter placed in a desalinator system to remove suspended solids from the feed water before it reaches the high pressure pump and reverse osmosis membrane Pressure Relief Valve a valve that relieves pressure in a system to prevent damage to system components In the PowerSurvivor 40E the relief valve is set to open at 1000 psi to prevent damage to the pump and membrane Product Freshwater potable water produced by the reverse osmosis process PSI pounds per square inch a unit for measuring pressure Reverse Osmosis RO a reversal of the natural osmosis process between two fluids which occurs when water is forced under pressure through a semipermeable membrane It produces potable water Salinity a measure of the amount of salts minerals and other dissolved solids contained in a water source Salinity see TDS is measured in ppm Salt the common name for the chemical sodium chloride Open ocean seawater is about 3 3 96 dissolved salt or about 33 000 ppm of sodium chloride Seal a device such as an o ring used to prevent fluid leakage between two system components Semipermeable the characteristic of some materials e g a reverse osmosis membrane that makes them relatively porous to some substances while blocking the passage of others Unlike normal filters semipermeable membranes usually operate at the molecular or atomic level allowing much finer filtering than simple mechanical filters TDS Total Dissolved Solids a ty
15. aft seal in exactly the same way It too should be installed with its flared side facing down Next install the second white backup washer and finally the white bushing Slide the installation tool used in Step 2 above over the piston shaft with the narrow end facing the white bushing Use the installation tool to press the shaft washers seals and bushing all the way into the bore When finished the outside end of the bushing should be flush with the bore opening 5 Install a new wiper block seal into the wiper block The seal must be pressed into a groove inside the bore in the middle of the wiper block with the narrower side of the seal facing outwards Form the seal into an oval shape by squeezing it between your fingers and press One side of the seal into the groove in the wiper block Once an edge of the seal is started into the groove carefully work the rest of the seal into place After the seal has been installed slide the spacer if present and wiper block onto the piston shaft The side of the wiper block from which the seal was installed should be facing outward Refer to Figure R 3 6 Prepare the check valve plate for reassembly by installing the new poppet valves Note that both the intake and reject poppet valves and valve springs are identical Refer to Figure R 5 during the following procedure A Lower a new poppet valve spring into the bottom of the bore in the check valve plate Use your little finger or the eraser end of a
16. after each approximately 1000 hours of use Cleaning amp Storage Chemicals Acid Cleaner 8 02 Part 8013608 1 Alkaline Cleaner 8 oz Part 8013615 1 Membrane Preservative 8 oz Part 8013609 1 Note You may order parts and kits through our retailers or from Katadyn North America directly at 800 755 6701 If ordering directly you ll need to provide detailed shipping instructions as well as credit card information QUESTIONS CALL 800 755 6701 30 Service Log Preserv i Date eserved Cleaned Membrane Other Service Membrane 31 WARRANTY LIMITED WARRANTY FOR POWERSURVIVOR 40E WATERMAKER THIS LIMITED WARRANTY AND THE REMEDY PROVIDED HEREIN ARE EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS WARRANTIES AND UNLESS STATED HEREIN ANY STATEMENTS OR REPRESENTATIONS MADE BY OTHER PERSON OR FIRM ARE VOID THE DURATION OF ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SHALL BE LIMITED TO THE DURATION OF THE EXPRESS LIMITED WARRANTY NEITHER KATADYN NORTH AMERICA INC KATADYN NOR ITS AFFILIATES SHALL BE LIABLE FOR ANY INCIDENTAL CONSEQUENTIAL OR SPECIAL LOSSES OR DAMAGES RESULTING FROM THE USE OR INABILITY TO USE THE POWERSURVIVOR 40E WATERMAKER WHETHER RESULTING FROM BREACH OF WARRANTY OR ANY OTHER LEGAL THEORY This Limited Warranty gives you specific legal rights and you may also have other rights which vary from State to State Some States do not allow limitations on how
17. and set the drive unit aside Remove the black rubber boot from the piston shaft 5 Align the holes in the handle bracket with the two pump bolts that are located above the piston shaft Figure 7 Slide the bracket over the bolts and secure it with two of the hex nuts that held the drive assembly to the pump body Do not over tighten these nuts 6 Remove the clevis pin from the free end of the linkage attached to the handle assembly Line up the holes in the handle linkage with the hole in the piston shaft Insert the clevis pin through the linkage and the piston shaft and secure with a split ring Figure 8 7 Orient the hole in the handle located above the linkages between the holes in the handle bracket Insert the second clevis pin through the holes and secure with the split ring Figure 9 8 If not already attached connect seawater intake reject brine and product freshwater hoses to be used for manual operation Freshwater Hose Split ring is rotated onto the X D zz S So LA TA LY S 25 Figure 7 11 9 Operate the pump handle back and forth through Clevis Pin its full range of travel in both directions Pump at a rate of approximately one complete cycle every two seconds one second in each direction This is about the same rate at which the pump is driven by T g 3 J located above the motor during powered operation Do not pump LOB linkages too fast 10 To return the watermaker to
18. at its point of farthest travel away from the pump i e towards the drive assembly Assure that the watermaker is off and can not be started accidentally while you work Clean the exposed piston shaft with a clean rag and lubricate the shaft with non petroleum silicon lubricant 13 Prefilter Maintenance Background Maintaining a healthy watermaker largely involves taking proper care of the prefilter assembly and seawater intake plumbing Failure to do so is the most common cause of the two most frequent types of watermaker failure we hear about 1 producing diminished or no freshwater output or 2 producing bad smelling product freshwater Here is what happens No Freshwater Output The most common cause of diminished or no product freshwater output is air entering the seawater intake system at some point The pump volume is small and the pressure required to press water through the membrane is rather high about 800 psi Since air is highly compressible a very small amount of air can keep the pump from producing enough pressure to produce product freshwater Periodically inspect and test the entire seawater intake system to assure that all joints and fittings are airtight especially the connections at the prefilter assembly Note Be aware that a stable air gap at the top of the prefilter housing is not uncommon and doesn t necessarily mean that air is getting to the pump itself Bad smelling Product Freshwater The
19. d connections Is the watermaker Is seawater leaking running without any from around the seawater leaks piston shaft Damaged or defective seal or o ring Install Repair Seal Kit Damaged or defective piston shaft or Enjoy your watermaker piston shaft seals Damaged pump body It s working normally Replace defective parts part Return to factory 24 Appendix A collection of useful information for the Katadyn watermaker owner Glossary Membrane Preservative a chemical used to inhibit biological growth in the reverse osmosis membrane during storage or extended periods of non use Filter a device which removes suspended solids from a fluid stream A filter is not the same as a reverse osmosis membrane Micron a metric unit of measurement equal to one thousandth of a millimeter or one millionth of a meter Osmosis the process of diffusion between two water sources through a semipermeable membrane resulting in both water sources striving to reach an equilibrium in the concentrations of dissolved substances Pickling a slang term for the process of flushing the membrane with membrane preservative see Membrane Preservative Potable suitable for drinking especially water With regard to a desalinator it is generally defined as water with 1500 ppm or lower of dissolved solids that is relatively free of harmful microorganisms PPM parts per million Used as a measure of the quantities of substances dissolved in water Prefilter
20. e suggest you keep a record of your Katadyn dealer s name contact information and the serial number of your watermaker in the space below Dealer Name Address Phone Fax Website Serial Number Table of Contents System Description BM 2 Product Sp cificati nS sssrinin auai 3 Energy Recovery ida iet neran maana M CR xk EAE UM aa ra UR ERR TIERRA da aiena anaana DAR e PN rrien ini 4 VIPS TAU AON E TM 5 DELHI DO icici S 5 InStallatiOm DON TS c 5 Plan Ahead for Manual Operation e eeeeeeeeeeeeeeeeeeeeeenen nennen nnn 6 Installation ProcedUr s ioci urai aa UE KURSE cR ARN VU D SEO DS e CO ARN RA RUM DEN RE EDU Ra 6 USING your i giiaaaia 9 misi Reni 9 Mahitial Operation ss unire cn eii dad Secondi Res rc saco e DT ATUS dS LEY eal RR VV FREE nei iat 11 Special Conditions ausiani iac d EEG FETU REE EXE ER MEREEUR EUER ERAR nnmnnn LUCR ARN 12 Maintenance and SerViCe iuiiisi iiia ILI FERE RAEAIRFE AME DA FEEARE AER EARE ARE ERA MIEEAER Pa RESI Pa FERA O 13 PUMP MaiNteNaNCe e 13 Prefilter Maintenance PETRUS 14 Membrane Storage Preserving amp Cleaning ceres 15 Seal ReplaceMent ee P 18 Troubleshooting Flowchart aima raa nonni to ta uaa Cana rada tuna a tna aaa ania a
21. e the same diligence Prefilter Maintenance At the end of each run of your watermaker examine the prefilter assembly and the coarse strainer if installed for trapped material If anything is visible perform the following procedure 1 Unscrew the prefilter housing remove the dirty prefilter element and discard the water in the bowl Do not lose the large o ring at the top of the bowl 2 Clean the inside surface of the prefilter bowl Inspect and clean the o ring at the top of the bowl Lubricate the o ring and the threads of the prefilter housing with a light coat of silicon grease 3 Install a clean filter element and screw the prefilter bowl back on securely 14 Warning If you purchase after market filter elements be certain they are made from polyester fibers In particular be wary of elements made of paper materials They look very similar but are designed for use with other types of water purification systems and are harmful to the mem branes and high pressure pumps used in reverse osmosis watermakers Be certain you purchase only polyester filters of 30 micron or finer size 4 lf the watermaker will not be used within the next three days treat it with membrane preservative see Membrane Storage below 5 Tie a line through the center of the dirty filter element and if underway tow it behind the vessel for a few minutes If the vessel is anchored hang the dirty filter over the side of the boat
22. e thru hull 6 Install Product Freshwater Plumbing Your product freshwater plumbing design should allow for both saving and discarding of product freshwater This normally requires 1 a drain location and 2 a container for collecting good product freshwater In no case should the product freshwater hose be permanently plumbed into the ship s potable water storage tank s without providing a way to reject the product freshwater when necessary Note that product freshwater should always be rejected during the first few minutes after startup and especially after treating with membrane preservative or chemical cleaners For that reason alone a means must be provided for disposing of unwanted product freshwater In general we do not recommend that the output of product freshwater be routed directly into a vessel s freshwater storage tank s If for any reason the watermaker should fail during operation there is a good chance that the entire supply of freshwater in the storage tank could become contaminated by unpurified seawater This is especially important if e you have only a single tank for storing potable water e you wil be making extended offshore passages and depending on your watermaker for your potable water supply The preferred method for collecting product freshwater is to use portable 5 or 6 gallon jerry jugs or a separate day tank which is isolated from the main storage tank Some method should be devised for testing
23. ed by fine hard suspended particulates e putrid water red tides or any seawater that smells or looks contaminated M Make sure the cleaning valve lever on the pump is in the down or run position It is important to remember that the watermaker is designed to process clean open ocean seawater Any departure from that standard for your seawater intake runs the risk of causing excessive wear or damage to internal pump parts and or the vulnerable reverse osmosis membrane or producing contaminated product freshwater Note Judging the quality of seawater input always involves a certain calculated risk We know of watermaker systems that have been destroyed far offshore by intaking fresh whale excrement or oil contaminants from natural seepages still the chance of such things happening is normally small On the other hand regularly running a watermaker in an enclosed marina or harbor runs a much higher risk of harmful contamination If you need to test a new installation while in a marina or harbor monitor the water quality around your vessel carefully while testing Most of the time you should be able to run the watermaker safely for enough time to check out the system Don t sail away without testing a new installation Startup and Run Turn on the electric power to the watermaker If there is air in the seawater intake plumbing the pump may require several minutes to draw up enough water to fill the hoses p
24. ent draw should settle at the above specification Reject Brine Seawater Intake uo SS VE Product Freshwater Output CA E 9 o PN E N c o ae L 17 5 Figure 1 Energy Recovery The technology behind Katadyn reverse osmosis watermakers Reverse osmosis desalination was first developed over three decades ago It was a major breakthrough in desalting technology but the original process required a lot of power By recovering 90 of the energy lost in conventional reverse osmosis systems we ve made small desalinators practical so you can have freshwater when and where you need it Conventional Reverse Osmosis Desalination The lower left portion of Figure 2 shows the basic principle of reverse osmosis Reverse Osmosis desalination When saltwater is forced through a semipermeable membrane at high enough pressure Katadyn Improved typically 800 psi pure water High pressure Technology will pass through the pu seco wee Ane membrane but salts will not eee he back aida The membrane acts as a E of pump piston barrier to contaminants such i as salts viruses and bacteria separating them from the pure Membrane water i m i Bet ile n When seawater is forced preseurixed ge ohhh igh pressure amp valve against a membrane only a DEN Mmm 1096 passes through as pure pude throes h water In a conventional 2 membrane ae Conventional system the remaining waste brine stream
25. ffectiveness the freshwater supply When the watermaker is not to be used for an extended period of time you should preserve the membrane A membrane preservative treatment is effective for approximately one year storage temperature 25 C 77 F If longer storage is required the membrane preservative treatment should be repeated every year In temperate climates the maximum period of time the watermaker should be stored without preserving the membrane is approximately one week In hot or tropical climates the watermaker membrane should be preserved if it will not be used within the next three days Follow these directions to preserve the membrane of your watermaker 1 Lift the lever on the cleaning valve on the pump to place it in its clean or up position see Figure 12 2 Fill a clean plastic container or bucket with two quarts approximately 2 liters of clean water Freshwater is preferable but clean seawater may be used if freshwater is not available Seawater Intake Figure 12 Caution Never use chlorinated freshwater This may damage the membrane 15 3 Mix two spoonful approximately 20 grams or 1 by weight of dry Membrane Preservative chemical with the water in the container and stir until completely dissolved 4 Use your product 3 way valve or move the product water output hose to be sure that any water flowing from the product freshwater output is properly discarded
26. freshwater There are also hose clamps and mounting bracket hardware for the prefilter assembly Customer supplied Equipment Every installation represents a unique challenge You or your installer will have to provide a reliable source of clean seawater for input to the prefilter 3 way valve e plumbing to an appropriate drain location for the reject brine water e a plumbing solution for your freshwater collection tank Our Promise Every Katadyn PowerSurvivor 40E watermaker includes a three year factory warranty and a long history of outstanding customer support Our reputation for providing a quality product along with service when and where you need it is unequaled in the industry Of course you may never need us but if you do we ll be there Product Specifications Power Requirements VDC Construction 4 amps 12 VDC 3 amps 24 316 Stainless Steel Pump Housing Rate of Water Production 1 5 U S gal hr 5 6 liters hr 15 13 8 VDC Feed Water Flow Rate 15 U S gal hr 56 liters hr Pump Weight 25 lbs 11 3 kg Pump Height 6 15 2 cm Pump Length 17 5 44 5 cm Pump Width 16 40 5 cm Prefilter Housing Dimensions 12 x 6 30 cm x 15 cm The electric current requirement is an average figure Instantaneous current will vary during a complete cycle of the pump Also upon initial installation you may experience modestly higher current draw Within a matter of hours the average curr
27. ght seal Note Teflon tape is not recommended Basic Electrical Diagram Fuse and Circuit Breaker 12V 10A Terminal 2440 A Strip Dimension of the cable 16 gauge 12 V 16 gauge 24 V 12Vor24 V Battery or Power Source Figure 4 1 Carefully thread the middle port of the prefilter 3 way valve into the IN port of the pre filter housing Do not over tighten this connection When assembled correctly the long axis of the 3 way valve should be vertical See Figure A 1 2 Fasten the supplied right angled mounting bracket for the pre filter assembly to a bulkhead Orient it so the pre filter assembly will be vertical with the bowl underneath We recommend that it be thru bolted with corrosion resistant hardware 3 Screw the top of the pre filter housing to the bracket with the supplied screws One port of the pre filter 3 way valve should project above the housing through the notch in the mounting bracket 4 Install Seawater Intake Plumbing There are two common approaches to providing the seawater intake circuit Tee into an existing seawater intake e g engine cooling water or manual seawater pump inlet Install a dedicated thru hull for the watermaker Either of these configurations should meet the following criteria e It should be at a low point on the vessel s hull to minimize the chance of air intake during heeling or rough conditions The thru hull should be a minimum of 1 2 D
28. ghten with a 5 8 open end wrench Use the eraser end of a pencil or a small allen wrench to test the operation of the intake poppet valve The poppet valve should move down slightly and then spring back up against its seat 22 7 10 11 12 13 Replace the two large o rings 8012947 and the two smaller o rings 8013006 on the membrane tube plug with new o rings from the RSK Insert the small end of the membrane tube plug into the exposed hole in the membrane element which should have been left installed in the membrane housing and press the tube plug into the membrane housing as far as it will go The ridge on the outside of the tube plug should be flush against the end of the membrane housing Press the piston as far as it will go toward the pump back plate Install a new o ring 8012588 into its groove in the check valve plate Press the check valve plate over the exposed end of the membrane tube plug If necessary rotate the check valve plate to align it accurately with the pump body and install the 3 4 and the 3 socket head cap screws Check that the two large o rings Figure R 8 8012588 in the check valve plate and the pump back plate are still Slider Shaft seated in their grooves and then tighten the four caps crews evenly Back Plate with a 1 4 allen wrench Slide the two 5 socket head cap screws through the holes in the check valve plate and the back plate Slide the rubber boot onto the piston shaft See Fi
29. gure R 8 Insert a small screwdriver or an allen wrench through the hole in the piston shaft and rotate the shaft to align its Piston Shaft hole with the hole in the slider shaft of the drive assembly When they are aligned slide the holes in the drive assembly bracket over the studs projecting from the pump back plate Insert the coupling pin through the aligned holes in the slider shaft and piston shaft Push the rubber boot over the coupling pin to hold it in place Install the four hex nuts on the Rubber Boot Align Holes studs projecting from the pump Sockethead back plate through the drive Capscrews assembly bracket and tighten evenly with a 1 2 open end 6 NN Cleaning Valve wrench and 1 4 allen wrench Do Assembly not over tighten these fasteners To replace the o rings beneath the cleaning valve assembly refer to Figure R 9 Unscrew the two socket head cap screws using a 5 32 allen wrench and remove the assembly from the pump body Remove old o rings 8012594 and 8012697 and replace them with new o rings from the RSK Replace the cleaning valve assembly on the pump body and install the two cap screws This completes the procedure for reassembly of the watermaker When operation is commenced again carefully inspect the watermaker for proper operation and any leaks or other signs of incorrect assembly Figure R 9 23 Troubleshooting Flowchart Use the flow chart below to diagnose and solve the most c
30. has its roots in our original products which were designed as military quality survival equipment Our deep experience in this technology combined with many years of active user feedback allowed us to design a watermaker that is easy to operate with little or no technical knowledge There are no complicated adjustments to make or gauges to monitor By following the instructions below and paying attention to system maintenance you can expect years of trouble free operation Powered Operation Pre Run Checklist Before running your watermaker always check the following v Any valves in the seawater intake reject brine and product freshwater lines should be open MI Check for bad rotten egg smell from the water in the prefilter assembly Replace the element and clean the housing as required Also check for foul water in any in line coarse strainer MI Assure that the product freshwater output is routed to a drain for testing discarding M Check battery or power supply voltage Operating your watermaker below about 11 VDC is hard on the electric motor and dramatically reduces the output of product freshwater M Observe the seawater around your vessel Is it clean enough to use for your seawater intake There are several things to avoid feeding to your watermaker e petroleum products such as oil fuel thinners paints paint removers etc e chlorine treated water e g most dock water e silty water water contaminat
31. he new PIP Installation Tool and ring cup seal and the installation gnto the piston tool with silicon grease With the grooved side facing up slide the PIP ring down the installation tool and onto the piston Repeat this process for the cup seal Note that the grooved side of the cup seal Figure R 7 should be facing down i e the grooved sides of the PIP ring and the cup seal should be facing each other When finished with the installation remove the installation tool from the piston shaft 3 Lightly lubricate the cylinder in the pump body with silicon grease Slide the finished piston assembly shaft first into the pump body from the side of the O ring pump body that faces the check valve plate Install the large o ring 8012588 into its groove in the pump back plate and lower the pump back plate Figure R 6 Pump Back Plate j E Pump Body over the piston shaft The side of the back plate ips with the large o ring should be facing the pump Assembly body See Figure 1 R 7 21 4 Refer to Figure R 4 Slide one of the white backup washers over the piston shaft and press it into its bore in the pump back plate Next slide one of the two black rubber piston shaft seals over the piston shaft and work it into the bore on top of the backup washer Note that the shaft seals are flared out on one side It is important that the flared wider side should be down facing the shaft bore Install the second piston sh
32. he single most important decision you will make plan it carefully VI Provide a shutoff valve or seacock in the seawater intake line N Install a coarse strainer in the seawater intake line M We recommend using properly sized ring terminals and a terminal strip near the pump to connect electric power This allows for easy testing removal and servicing when required Installation DON Ts Don t use a thru hull installed high on your vessel s hull for your source of seawater intake This is especially important for sailboats Even a normal amount of heel when under sail can cause the thru hull to be out of the water allowing air into the intake system A rolling anchorage can do the same Don t locate the pump assembly above gear or materials that could be damaged if it leaked Don t locate the pump assembly near to sleeping quarters bunks or other areas that are normally quiet areas for you or crew members Plan Ahead for Manual Operation The PowerSurvivor 40E watermaker was never intended to be part of a vessel s Abandon Ship equipment Its capability for manual operation is useful when normal ship s power is unavailable If you perform a typical installation it is unlikely that you would have time to remove the watermaker when abandoning ship Katadyn produces other desalinators that are specifically designed to be part of your survival equipment Please visit our website for information on the S
33. igh pressure positive displacement pump Unlike the centrifugal pumps found in some systems a positive displacement pump is self priming It can also draw water when mounted several feet above the waterline of a vessel Thus the watermaker may be installed in a most any location and orientation The most important part of a good installation is proper planning Although the design and operating requirements of the PowerSurvivor 40E allow much latitude for equipment location there are several cautions and suggestions you should consider before proceeding with an installation Installation DOs When choosing a location for the watermaker drive pump membrane assembly Vl Avoid areas with excessive heat Ambient temperatures above 105 F 40 C exceed the ratings for the electric motor and excessive heat can damage or destroy the membrane Note Most engine rooms get hotter than 105 F M Choose a dry area The motor drive assembly is not waterproof and can corrode W Choose an area free of fuel vapors The electric motor is not vapor proof and should not be operated if explosive or flammable materials are present M Find a location which allows comfortable access for routine inspection and servicing In addition you should M Install the pre filter assembly in an easily accessible location It needs regular sometimes daily inspection and maintenance For ease of routine maintenance the choice for this location is probably t
34. in acad 24 p 101 0 gent 25 LE o r a rennen enc DT DCN T RTI TT THOUR E ENT IEE 25 DI rr M m 26 Kits amp Accessories encore edis enc icr ee E CE 30 SERVICE LOG odit betta detet ubetbdiidetedusutete fihi detedisitetafus idet is utet o frt dbrbed su dei ee cue 31 WARRANT Y iiti cei petxreS pue eaae PUDE FECE FREE V PECEUN Nu SEE NAR aaa aa NEU xEY UM YU EFER E YI VPA cen 33 System Description The Katadyn PowerSurvivor 40E watermaker system has several components Refer to the System Diagram Figure A 1 in the Appendix for an overview of the components of the system and their interconnections Motor Drive Pump Membrane Assembly At the heart of the watermaker system is a high pressure positive displacement pump The pump is powered by a reliable 12 or 24 VDC electric motor An oil bath gearbox drive assembly converts the rotary motion of the electric motor to a powerful reciprocating linear motion for driving the pump piston The pump pressurizes input seawater to approximately 800 psi pounds per square inch The high pressure forces product freshwater through a semipermeable membrane located in the membrane housing All of these main components have been integrated into a single compact piece of equipment with low power consumption quiet operation and a small footprint Prefilter Assembly The prefilter assembly consists of one prefilter housing and a standard
35. k plate when it a was removed pull the piston out of the back plate and set it aside If the piston stayed in the main pump body pull it out of the cylinder If the piston assembly is difficult to remove from the pump body insert a small allen wrench or Phillips screwdriver through the coupling pin hole This will provide a t handle with a better grip for extracting the piston assembly Be aware not to damage the surface of the piston shaft 6 Remove the large o ring 8012588 from its groove in the side of the pump back plate that faces the pump body Remove the wiper block and spacer if present from the pump back plate Use needle nosed pliers to pull the old wiper block seal out of the wiper block See Figure R 3 Note This seal is usually damaged during removal Be P sure you have a replacement on hand before removing Pump Back it Plate 3 Sockethead Capscrews Figure R 3 19 7 From the side of the pump back plate that contained the large o ring insert a round drift of slightly smaller diameter than the hole for the piston shaft Note a small socket on an extension or a wooden dowel makes a suitable drift Tap the drift with a mallet to drive the two backup washers two piston shaft seals and the piston shaft bushing out of the pump back body See Figure R 4 8 Remove the remaining two 3 4 socket head cap screws from the check valve plate using a 1 4 allen Figure R A wrench Separate the check
36. ke O ring poppet valve and its spring If NSS necessary use needle nosed pliers to Intake Poppet Valve O remove the poppet valve retainer Then Intake Poppet use the pliers to lift out the reject Valve Spring poppet valve and its seat Grip the x shaped ribs of the reject poppet valve Poppet Valve Retainer and pull straight up The seat will be o pulled out along with the valve After Reject Valve Seat 7 the reject poppet valve and its seat l 0 have been removed retrieve the reject Reject Poppet Valve poppet valve spring from the bottom of Reject Poppet Valve the check valve plate cavity Spring This completes the disassembly of all user serviceable parts of the Katadyn Check Valve Plates PowerSurvivor 40E watermaker Figure R 5 20 Reassembly Before you begin reassembly of the watermaker clean all parts using clean lint free rags At this time all parts should be carefully inspected for wear or damage Use a 10x magnifier or loupe to examine the seals o rings and other small parts Stubborn rust stains and other deposits on metal parts can be cleaned with a soft metal wire brush e g stainless steel or brass Do not use polishes cleaning compounds containing abrasive materials or regular steel wire brushes During reassembly refer to Figures A 3 and A 4 in the Appendix for full size drawings and identification of the components included in the Repair Seal Kit In the following procedure for
37. ll not be run again within the next three days Before doing repairs or maintenance work on a PowerSurvivor close the seawater inlet valve after turning off the system Otherwise the possibility exists that hose failure for example could cause the boat to sink At the end of a watermaker run check the condition of water in the prefilter housing If there is evidence of trapped material clean the prefilter housing and install a clean prefilter element 10 Manual Operation Manual operation of the PowerSurvivor 40E is useful if the ship s electric power supply fails seawater Intake Use the following instructions to convert your Reject Brine Hose watermaker to manual operation 1 Jog run the watermaker and stop it when the piston has traveled the maximum distance away from the pump toward the pgs drive assembly Qe es 2 If necessary disconnect the seawater d intake reject brine and product freshwater hoses Figure 5 and move the watermaker to a location convenient for manual operation 3 Slide the black rubber boot on the piston shaft toward the pump to expose the coupling pin Pull or tap out the coupling pin which connects the pump piston shaft to the drive slider shaft Figure 6 The pin is a fairly loose fit and should come out easily Be careful not to lose it 4 Using a 1 2 wrench remove the four hex nuts holding the pump body to the drive assembly Separate the drive assembly from the pump body
38. long an implied warranty lasts or do not allow the exclusion or limitation of incidental or consequential damages so the above limitations or exclusions may not apply to you What Is Covered KATADYN warrants to the original purchaser that the PowerSurvivor 40E Watermaker enclosed with this Limited Warranty conforms to the manufacturer s specifications and is free from defects in workmanship and material for a period of three years from the date of original purchase If the original purchaser transfers the PowerSurvivor 40E Watermaker to another person this Limited Warranty will not be enforceable by the person to whom the product is transferred What We Will Do To Correct Problems Should your PowerSurvivor 40E Watermaker prove defective during this period you must notify KATADYN at 6325 Sandburg Rd Suite 400 Minneapolis MN 55427 or an authorized distributor or dealer of KATADYN You must permit KATADYN or its representatives to make such investigation examination and tests as KATADYN deems appropriate and if requested to do so you will return the product to the factory at the address set forth above KATADYN s sole obligation under this Limited Warranty is at its option to repair or replace the defective unit without charge for parts or labor Postage insurance or shipping costs incurred in presenting your PowerSurvivor 40E Watermaker product for warranty service are your responsibility What Is Not Covered This Limited Warranty i
39. n the preceding pages decide on a location for the main pump drive assembly It should be mounted with the long axis of the membrane housing in a horizontal position The purpose of this requirement is to avoid two problems If the pump develops a seawater leak and is located directly above the drive assembly the drive assembly and or electric motor may be damaged Figure 3 left e If the drive assembly develops an oil leak and is located directly above the pump oil may find its way into the pumping system and damage the membrane Figure 3 right We recommend securely thru bolting the pump drive assembly to a sturdy bulkhead or platform using corrosion resistant 1 4 fasteners with flat washers See Figure A 1 Pick a location that allows ample space for routing the required hoses and electrical wires to the pump and motor Figure 3 2 Connect Electrical Power to Pump To provide 12 or 24 VDC electric power to the motor use a minimum of 16 gauge stranded copper wire We recommend 14 gauge or larger wire for distances over 20 feet Tinned stranded copper wire is preferred for marine installations and is available in most marine hardware stores Figure 4 shows a typical electrical power configuration 3 Mount Pre filter Assembly and 3 Way Valve Lightly coat the male threads of the middle port of the pre filter 3 way valve with a non hardening paste type thread sealant e g Permatexe to assure an airti
40. ommon problems associated with use of the PowerSurvivor 40E watermaker The information in this chart is a distillation of the experience of many users our field representatives and customer support staff Use it first if you encounter a problem If the problem persists our Customer Support department is ready to help Does the watermaker run Is 12 or 24 VDC Main battery switch off when the electric power available at the motor Circuit breaker off or is turned on connections tripped Blown fuse Remove coupling pin Electric motor or from piston shaft Does gearbox defective motor run now Return to factory Piston is seized or pump damaged Disassemble Are seawater intake repair amp lubricate and reject brine seacocks open Is reject brine water being discharged NO Open intake and reject seacocks Is the prefilter 3 way valve in the normal run position Turn prefilter 3 way valve to normal run position Defective poppet valve or spring Install new Is a normal volume of Is the cleaning valve in 8 Repair Seal Kit good product water its normal run position being produced Move the cleaning valve lever to the run position Bypass intake system run hose from bucket of clean seawater directly to intake hose barb Does product water flow now Internal problem with spool valve or cleaning valve Return to factory for service Air ingress in intake system Check fittings an
41. pe of measure commonly used to indicate the purity of water usually expressed in ppm A standard TDS meter measures only the electrical conductivity of the water being tested Therefore it is only able to measure dissolved substances that are ionized in solution e g sea salt In particular they do not indicate the presence of non ionized substances such as bacteria viruses and many other soluble chemicals 25 Diagrams System Diagram Drive Assembly Product Freshwater _ To Drain or in Manual Fill Test Seacock or Shutoff Valve va piod Freshwater Collection ee Tank Prefilter To Seawater n Intake Source supplied by Assembly i customer 4 Se 2 Intake Line N Reject Brine Alternate Line Intake Line to overboard for membrane Seawater Strainer drain preservative and Strainer supplied by cleaner solutions D d customer ius tmt fea brer PSU We ale nn ARA E Figure A 1 26 Pump Assembly Exploded Parts View O ring 8013015 Poppet Valve Spring 8013120 Poppet Valve Retainer 5 Sockethead 18012609 Capscrews 8012590 3 Sockethead Capscrews 8012599 3 4 Sockethead Capscrews 8013389 Cleaning Valve Factory preset do not disassemble lt PIP Ring se uM CE Cup Seal Q Oz 8012775 We RQ Piston Assembly O ring P ad 8012588 Back Plate Figure A 2 Hose Barb Sockethead 8013340
42. pe or magnifier 5 8 open end wrench silicone grease 1 4 allen wrench included in Repair Seal Kit medium flat blade screwdriver clean rags small standard pliers 18 Disassembly 1 Before beginning disassembly run the watermaker and stop it when the piston shaft is at its farthest point of travel away from the pump i e toward the drive assembly This provides enough room for sliding the rubber boot toward the pump in Step 3 2 Disconnect the pump from the drive assembly by first removing the two hex nuts and 5 socket head cap screws from the check valve plate using the 1 2 open end wrench and 1 4 allen wrench Also remove the two hex nuts securing the pump back plate to the drive assembly See Figure R 1 3 Slide the black rubber boot on Hex Nuts the piston shaft toward the pump to expose the drive shaft coupling pin Use a small allen wrench or similar tool to push the coupling pin out of the drive shaft see Figure 6 Be aware that the coupling pin fits loosely in the drive shaft and may fall out when the rubber boot is removed Be careful not to lose it Separate the drive assembly from the pump and set the drive 5 Sockethead assembly aside Capscrews 4 Remove the two 3 socket head caps crews using a 1 4 allen wrench Separate the pump back plate and piston assembly 2 5f D Piston Assembly from the pump body see Figure S R 2 z 5 If the piston assembly remained r4 Pump Back Plate with the pump bac
43. powered operation reverse the above procedure When coupling the pump piston shaft to the drive shaft align the hole in the piston shaft with the mating hole in the drive Figure 9 shaft insert the coupling pin and slide the rubber boot over the pin to hold it in place Then secure the drive assembly to the pump with the four hex nuts Tighten the nuts evenly Do not over tighten Special Conditions Product freshwater output volume will vary somewhat depending on the salinity and Temperature vs Output temperature of the seawater being processed Figure 10 illustrates the relationship between feed Capacity water temperature and the quantity of product water 120 Range of Membrane and Factors which are known to affect output or is sanity Variations performance include e High Salinity will decrease output slightly Mid and lead to a modest increase in current 607 draw Effectively the pump must work 40 harder to remove a larger percentage of i Rn a S dissolved solids from the seawater Feedwater Temperature F Cold Water will have an effect similar to Figure 10 that of high salinity Silt or Sand can damage the membrane and internal pump components if not removed during pre filtration If you must regularly process such water consider installing a Silt Reduction Kit see Kits amp Accessories e Foul Intake Seawater can seriously affect the quality of the product freshwater The watermaker membrane is designed
44. reassembling the watermaker it is assumed that all parts have been cleaned and that all o rings seals and mating surfaces have been lightly lubricated with non petroleum silicon grease supplied with the Repair Seal Kit References to the Repair Seal Kit will be abbreviated to RSK Warning Use only non petroleum silicon grease to lubricate your watermaker Lubricants with a petroleum base will damage several watermaker components including the reverse osmosis membrane Be especially cautious of lubricants that contain teflon silicon etc such products could also contain petroleum based components An ample supply of silicon grease is included with each RSK 1 Make a note of the correct orientation of the old cup ring and PIP seal and then remove them from the piston assembly Since these components are made of rather stiff rubber it is usually easier to cut them off Use a small screwdriver to wedge under the cup seal and pry it up While holding it up cut it with a small pair of scissors Repeat this process for the PIP ri ng Installation O 2 Refer to Figure R 6 during the Piston Shaft ta EPEN NS 2 following procedure Place the SER Grey areo pa piston assembly on a flat stable R heonbly Sed surface with the shaft pointing e PIP Ring up Slide the installation tool QN provided in the RSK over the PIP Ring Piston Assembly piston shaft with the wide end Cup Seal EEA down Lubricate t
45. refilter housing pump and membrane housing Since the pump is self priming there is no need to prime the system prior to running Shortly after the hoses and prefilter housing have filled with seawater reject brine water should start discharging from the pump When all air has been forced out of the system which may take several minutes more product freshwater should begin to flow from the hose barb at the end of the membrane housing Test and reject the product freshwater until the water quality is acceptable When good quality water is flowing continuously direct the product freshwater output to your freshwater collection tank Continue to run until the desired quantity of water has been produced Shutdown and Storage When the desired amount of water has been produced the product freshwater quality should be checked again If water quality is good at both the beginning and end of the run it is likely that the collected water is good and can be safely transferred to the ship s potable water storage tank If you plan to run the watermaker again within a couple of days it can simply be turned off If you do not intend to use your watermaker again within a week it should be treated with membrane preservative to prevent organic growth on the membrane Note Organic growth is much more rapid in warm or tropical climates If using the watermaker in a tropical environment we recommend a membrane preservative treatment if the watermaker wi
46. s contingent upon proper use and maintenance of the product it does not cover products that have been improperly shipped or improperly installed or that have been misused abused neglected or improperly maintained cleaned or stored or that have been serviced other than by an authorized KATADYN distributor or dealer The PowerSurvivor 40E Watermaker can be damaged by oil grease chlorine and certain other organic or inorganic substances It must be cleaned carefully after use and requires periodic maintenance Failure to observe the precautions listed in the User s Manual may constitute improper use or maintenance of the product and causes this Limited Warranty not to apply This Limited Warranty does not cover products from which the KATADYN label or logo or the rating label or serial number has been removed This Warranty does not extend to normal wear or to replacement items including but not limited to filter cartridges pump seals and O rings 33 Katadyn North America 6325 Sandburg Road Minneapolis MN 55427 USA Phone 800 755 6701 Fax 800 548 0406 www katadyn com marine katadyn com Katadyn Products Inc Birkenweg 4 8304 Wallisellen Switzerland Phone 41 1 839 2111 Fax 41 1 830 7942 www katadyn ch info katadyn ch Print No 8012602 4
47. so that it is underwater and jerk it up and down a few times to dislodge the contaminants 6 Dry the filter element thoroughly preferably in the sun Then store it for use as a clean filter the next time the prefilter assembly is serviced We do not recommend scrubbing filter elements with brushes or other abrasive tools or materials as such treatment is unnecessary and greatly shortens the life of the filter element If filter elements are cleaned regularly as directed and not allowed to become extremely dirty they can be expected to last for many months of service with nothing more than the gentle cleaning described above Clean filter elements also help assure unrestricted flow of intake seawater to the pump Membrane Storage Biociding amp Cleaning The reverse osmosis membrane inside the membrane housing is an expensive and delicate component of your system When properly cared for it can be expected to last for several thousand hours of use Improper use maintenance or handling can damage or destroy the membrane very quickly Membrane Preservative Treatment The primary purpose of a membrane preservative Warning Be sure to follow the treatment is to keep membrane moist and reduce flushing procedures described below biological growth on the membrane surface Over to ensure that the membrane time biological matter can adhere to the membrane preservative solution does not get into surface thus gradually decreasing its e
48. still under high RO Technology Figure 2 pressure passes through a pressure reducing valve and is discharged overboard For every gallon of pure water made up to ten gallons of seawater must be pressurized Therefore 9096 of the energy used in conventional reverse osmosis is lost Energy Recovery Makes It Possible The upper right portion of Figure 2 illustrates how Katadyn systems are configured to recover and effectively re use the energy wasted in conventional reverse osmosis The waste brine stream contains up to 9096 of the energy expended By recovering this energy we are able to dramatically reduce the power needed to desalt seawater To do this we developed and patented a high pressure energy recovery pump It recycles the high pressure brine by redirecting it to the backside of the pump s piston By balancing the opposing force on the piston s front side the brine provides a power assist to the pumping operation Seawater can then be pressurized with much less effort Katadyn Watermakers Katadyn watermakers are simple affordable energy efficient and easy to use and maintain The PowerSurvivor 40E represents the latest advancements in watermaker technology featuring an improved oil bath drive assembly an all 316 stainless steel pump body and simplified construction for easier and less frequent maintenance Installation Do it right the first time and reap the rewards The PowerSurvivor 40E watermaker utilizes a low volume h
49. the product freshwater quality at the beginning and at the end of each operation When you are certain that the quality of the collected product freshwater is acceptable it can be transferred to the main storage tank Note The important concept is to always have a minimum quantity of known good potable water available at all times either in your main storage tank or in the collection container s The length of your expected voyage and maximum distance from a source of potable water will determine the size of the adequate minimum amount Arrange your water making schedule to assure that you always have the minimum of known good potable water on board in one or both of your containers To route the product freshwater output of their watermakers many users simply run a single 3 16 I D hose directly from the output hose barb on the membrane housing to a single location where the water is tested and either discarded or run into a collection container Should you prefer to have your product freshwater output routed to two separate locations for testing discarding and collection the watermaker system includes a product 3 way valve for use in your output plumbing Refer to Figure A 1 for a routing diagram Using your Watermaker Watermakers like to be run often Just like its predecessor the PowerSurvivor 35 the PowerSurvivor 40E watermaker can be operated in either manual or powered mode This dual purpose feature of the watermaker
50. thout requiring a cleaning Buildup of deposits and reduction in product freshwater flow usually take place gradually over extended periods of time Sudden Cleaning the membrane is only necessary if contaminants are reduction or stopping of deposited on and adhere to the membrane surface in sufficient product water output is amounts to affect the output of product freshwater Usually this rarely caused by a dirty condition also causes battery current to increase There are two membrane main types of such deposits and a different chemical cleaner is needed for each type e Organic Growth usually caused by processing brackish water or failure to properly store a membrane during extended periods of non use Use Alkaline Cleaner e Mineral Scale caused by mineral impurities in the intake water supply Use Acid Cleaner The only indication that a membrane might benefit from cleaning is a substantial reduction in the quantity of product freshwater output all other factors being normal e g battery voltage salinity seawater temperature The best way to detect such a problem is by keeping an accurate log of product freshwater output at known battery voltages Such a practice is highly recommended If you have determined that your membrane needs cleaning and you know the type of deposits mineral or organic use the appropriate cleaner If you do not know the nature of the deposits try cleaning first with the Alkaline
51. urvivor 35 and Survivor 06 watermakers both of which are intended for inclusion in survival kits Before finalizing your installation plans consider how you would manually operate your watermaker should the need arise You will require a source of seawater input and a place to drain the reject brine as well as a product freshwater collection container Typically the watermaker will have to be moved to a location convenient for manual pumping There are two common approaches to implementing such an arrangement During your installation leave adequate service loops in the three hoses to allow the watermaker to be moved to a nearby location convenient for manual operation This arrangement eliminates the need to disconnect any of the hoses Prepare a separate set of hoses to be used during manual operation recommended This approach allows the watermaker to be moved to any location for manual operation More than likely the plan you choose will be dictated by the location of the space available In any case consider how you would manually operate your watermaker before finalizing your installation plans Installation Procedures Although every installation has custom as pects the following general instructions Incorrect Pump Orientations should be useful to the typical installer Refer to Figure A 1 in the Appendix for information on parts identification and system connections 1 Install Pump After reading the comments o
52. week three days in warm climates it should be treated with the membrane preservative solution 17 Seal Replacement After approximately every 1000 hours of use the watermaker should be partially disassembled cleaned and lubricated with non petroleum silicon grease At that time the seals should be inspected and replaced as required The standard Repair Seal Kit included in the Extended Cruising Kit see Kits and Accessories is available from Katadyn and most marine retail stores It includes a complete set of replacement seals and other components for all user serviceable parts of the watermaker It is unlikely that you will have to replace all of the seals contained in the kit at every servicing The dynamic seals work harder and wear faster than others and will need to be replaced more often We recommend that you save old seals Most of them are still useable and could be kept in a kit for emergency repairs Preparation Before beginning to disassemble the watermaker read the following instructions completely Have a Repair Seal Kit on hand Refer to the drawings in Figures A 2 A 3 and A 4 in the Appendix to identify the major components of the pump and the parts contained in the kit to make sure none are missing Prepare a clean flat workspace with good lighting Have the following tools and materials available for a complete rebuild Tools Needed piston seal installation tool small scissors 1 2 open end wrench 10x lou
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