Cape Horn Extreme 330 User Manual
Contents
1. SPECTRA WATERMAKERS CAPE HORN XTREME INSTALLATION amp OWNER S MANUAL fr if nat ha NI a a 7 S ce 5 1 2 eene lr Katadyn Desalination LLC Spectra VVatermakers 20 Mariposa Road San Rafael CA 94901 Phone 415 526 2780 Fax 415 526 2787 www spectrawatermakers com Rev May 2015 SPECTRA WATERMAKERS Table of Contents E Tl aaa e ee A 4 instalioHhOh endo NA NAGA e NENENG 5 INTO CUCID aiar i 7 imstallaton Basi rea ae anaa ieee 8 Cape Horn Extreme PIUMBDIN Buscas 9 Product Water and Pressure Gauge Tube Installation 10 Parker Tube Fitting Assembly Procedure 11 Spectra High Pressure Fitting instructions 12 Cape Horn Extreme VII ae en 13 Optional Z lon and Z Brane Installation and Instructions 15 23 New System sl 5090 99 5 0 25 Dry Testing with an Artificial OCC Mircoles 27 Normal Operation and Fresh Water 28 Service amp Maintenance 29 7072200600 r s b o en 31 VEE Ae EE 0 32 Introduction to Spectra Chemicals rie 34 Storage OC T ee nati 36 Winterizing with Propylene Glycol 37 Membrane Cleaning Procedure cccccccsscccsscccsec2. 1 4 1 4 48 Cape Horn Xtreme Part Numbers continued Pump to Pressure Vessel 1 8 FPTX1 4 Tube Fitting Ell Upper SS Tube Long 1 8NPT Nylon Hex Plug PL FTE 1 8X1 4P PL TB HPTPVUL PL HP 1 8 Pressure Vessel End Cap FT PV EP1 nn 7 PM gt e 3 SPECTI Ae x SPECTRA 5 f W ATE RM ACHI NEE W ATE RMACHINE 5 CI v m cee tee ne pa men mate 3 8 NPTX1 2 Tube SS Fitt St PL MTS 3 8X1 2S Pump to Pressure Vessel 40 High Pressure Vessel Lower SS Tube Long FT PV 40 Connector O ring PL TB HPTPVLL SO HPP CT Pressure Vessel Ring FT PV ER 3 4 MPT X 5 8 HB High Pressure Filter Housing PL TEE 3 4M5 8B Complete Assembly Feed Pump Module B FT FTH 10H 8 Hose Clamp PL CLP 8SS 3 4 NPT X 5 8 Hose Barb Ell PL HBE 3 4X5 8 Cooling Fan Kit KIT FK 12 24 Heat Sink EL FP FPHS 5 Micron Filter Cartridge FT FTC 5 3 8 NPT X 5 8 Hose Barb Ell PL HBE 3 8X5 8 Ventura Intake Module FM VT ITM Feed Pump Assemblv Complete Pump With Heat Sink Pump Head Assembly With Pressure Switch PL PMP SFPH Pressure Switch EL FP PS Pressure switch and diaphram Strainer Seal KIT FP SESK SO STN 5SS Strainer Screen FT STN 5S 49 Cape Horn Xtreme Part Numbers continued 3 8 NPT Quick Disc Coupling Body PL QDC BD3 8 5 8 Quick Disc Fitting Hose Barb PL QDC HB5 8 Pump to Pressure Vessel Upper SS Tube PL TB HP HPTVUS Nickel Bronze High Pressure Elbow P
3. 38 Membrane Cleaning Procedures Note Procedures are the same for the SC 2 and SC 3 cleaners A Spectra cleaning compound SC 2 or SC 3 must be mixed with fresh water at a ratio of 1 container of compound to 3 gallons 12L of unchlorinated fresh water An average of two gallons 8 liters of water is alreadv present inside a Cape Horn Xtreme svstem and this water must figured into the mixture Warm water is ideal for cleaning membranes Use a large stainless steel pot to heat the solution to 120 49 C You might have to periodically stop and reheat the solution 1 Performa fresh water flush page 28 Stop the feed pumps and close the grey flush valve 2 Connect the inlet service hose to the service intake on the feed pump module A Connect the brine discharge service hose to the quick disconnect on the Clark Pump Lead the hoses into a bucket Open the grey flush valve and run feed pump A until you have one gallon 4 liters of water in the bucket 3 Turn off the feed pump and close the grey fresh water flush valve 4 Turn the yellow service valve on feed pump module A to SERVICE 5 Make sure the pressure relief valve on the Clark Pump is OPEN 1 2 a turn system is un pressurized OR THE MEMBRANE WILL BE DAMAGED 6 Mix the cleaning chemical with the water in the bucket 7 Start feed pump A and circulate the chemical through the system for 45 minutes if the solution is warm Let the solution sit in the unit overnight if the clea
4. 51 5 16 3 1 4 SS AH Bolts gt Spool Assembly Exploded View TITO 7EFUDCUZUURU il DU m Il QAD Th a LANS Relief Valve O Ring SO HPP RV Annular Rings 4 Spool Assembly KIT HP 10VSA KA Relief Valve HP TB BV Annular Ring O Rings Mount inside Valve Block SO HPP AR Valve Block HD CPS 5 162 75 5 16 2 3 4 SS A H bolts Reset button and O ring End blockB x SO HPP SP PS20 Piston O ring HP TB VSP VSP20 Spool piston HP TB SR Spacer ring Valve block SO HPP VB Valve bore Spacer ring N Spool piston N End block A Pa N E Valve bore O ring Brine port O ring SO HPP VP Valve spool Pilot port O rings SO HPP PLP Reversing Valve gt End Blocks 52 Valve port seals SO HPP VP Pilot valve port seals SO HPP PLP l Piston rod Center block cylinder O rings SO HPP ECCB Pilot spool O rings 4 Mount inside block SO HPP PV 8 Pilot orifice HP CB PO HP CB PVS Pilot spool HP CB PPS Pilot valve pin SO HPP PS Pin seal O rings 5 Pin seals HP CB PVCR Clip rings O Center block Rod hp seals Mount inside block SO HPP PR7 PR10 PR15 Check valve port O rings SO HPP CV gt b Check valve SO HPP CVS O ring Check valve seat HP CB CVS Check valve assembly N Check valve poppet HP CB CV C enter Block zz Check valve spring Check valve washer s
5. Pump repairs should be done before continuing with these tests If no asymmetry is noted continue with this test You will need a graduated bucket either a graduated pitcher or large measuring cup and a stopwatch Before the flow test change all filters and clean the sea strainer Carefully check for water or air leaks as air in the system will cause low production and erratic salinity Observe the feed pressure and ensure that the Clark Pump cycles symmetrically Log the voltage at the feed pumps at the same time Confirm at least 12 5 Volts at the feed pump on 12 Volt DC systems 25 volts on 24 Volt DC systems Take two measurements and compare them with the table on page 28 of this manual The first measurement is the product flow alone The second is the product flow combined with the brine discharge flow to get the total flow or feed flow You may take these measurements by two methods 1 Time the product flow into a graduated pitcher then divert both the product flow and brine discharge together into a bucket to measure total flow OR 2 Divert the product flow into the pitcher while diverting the brine discharge into the bucket Time the flow of both After calculating the product flow pour the pitcher of product into the bucket of brine to measure total flow The ratio of product flow to total flow gives us the recovery rate expressed as a percentage If the percentage is below the minimum it indicates an internal leak in the C
6. below 10V or above 56V the LED will flash red every two seconds and the unit will shut down Each fresh water flush with the Z lon will protect your watermaker for up to 30 days after which the process must be repeated After 720 cycles the service light on the front of the control box will light up indicating that the probes on your Z lon may be wearing down and should be tested The service light is just a re minder and the Z lon will go on functioning while it is lit For testing procedures see the next page To reset the service counter touch two magnets at the same time to the two red reed switch es on the Z lon circuit board labeled Switch 1 and Switch 2 below Z lon Circuit Board Layout Pin 1 Pin 7 Switch 1 Switch 2 Testing the Z lon Normally no adjustment is necessary as the unit has been set up at the factory for your water maker however it is advisable to make sure the Z lon is working properly Likewise the fol lowing test is the only way to know if the probes on the Z lon need replacement There is no way to test for silver ions but we can test for copper ions The Z lon puts both into the flush water and where there is one there is the other You will need Spectra test kit EL ZION TESTKIT or a similar copper test kit for pools and spas Once the installation is complete and the unit is powered up carry out a fresh water flush per the instructions on page 28 The LED on the Z ION controller should
7. the clip C Clip and retaining screw Shipping Plug NOTE your watermaker will only have one membrane In these pictures there are three mem branes C Clip groove in Anode Z Brane Wiring The Z Brane system is integral with the watermaker and only requires continuous 12V or 24V DC power to operate Note There is no reason to open the transformer enclosure Do not service this unit unless it is disconnected from the power source There may be high volt age present We recommend that the Z Brane be connected to a discreet continuous power source The power must be on when the watermaker is in operation and when the Z Brane is used for membrane storage If the power is obtained from the MPC circuit board then the MPC must be powered up at all times during storage This may not be desirable Fuse the power at the source with a 1 amp fuse or circuit breaker Red is Positive Black is Ground Transformer Enclosure Z Brane Power Harness 21 22 Z Brane Operation During normal operation the Red LED should be on Power needs to be supplied to the Z Brane unit whenever vou wish to prevent bio fouling and have protection against scaling We recommend flushing vour watermaker with fresh water after each use which will pro tect vour membrane and also prevent corrosion in the feed water svstem Thoroughiv Fresh Water Flush the watermaker several times before leaving the vessel for extended periods The Z Brane
8. SC 1 SC 2 SC 3 and propvlene glycol antifreeze SC 1 and propvlene glvcol are for svstem storage while SC 2 and SC 3 are for membrane cleaning Do not use metasodium bisulfate citric acid or anv other storage chemical not supplied bv Spectra These chemicals used to store other watermaker brands are verv acidic and will damage the Clark Pump and void the warrantv Note Never use any chemicals with the system pressurized Always open the pressure relief valve 1 2 turn Always follow the instructions for purging the chemicals as shown in the New System Startup section on pages 25 26 Storage SC 1 prevents biological growth when your system is idle It should not be used as a cleaning chemical nor will it protect your system from freezing A jar of SC 1 is mixed with 1 to 3 gal lons of product or dechlorinated fresh water in a bucket and circulated through the system for 10 minutes This treatment will protect the system for six months after which the SC 1 treat ment must be repeated To use SC 1 follow the instructions for Storage Procedure on page 36 Spectra systems should be stored with propylene glycol if freezing is likely to occur Propylene glycol can be used instead of Spectra SC 1 storage chemical for storage in any climate and treatment is effective for one year Propylene glycol is a food grade antifreeze used to winter ize RV s boats and cabins Do not use ethylene glycol automotive antifreeze which is toxic and will
9. a pairof Wire size guide for 24 Volt system with a pair of wires led to each feed pump module Protect with 15 Amp Fuse or Circuit Breaker 10 Gauge 10mm up to 25 feet 7 5M 8 Gauge 16mm up to 35 feet 10 6M wires led to each feed pump module Protect with 7 5 Amp Fuse or Circuit Breaker 14 Gauge 4mm up to 10 feet 3M 12 Gauge 6mm up to 25 feet 7 6M 10 Gauge 10mm up to 35 feet 10 6M 13 Cape Horn Ktreme Wiring continued Method 2 One Pair of Wires from Distribution Panel to Cape Horn Ktreme To streamline the wiring one of the terminal blocks for the feed pump modules may be eliminat ed with the power leads for both feed pump modules led to a single terminal block Route a sin gle pair of heavv wires from a fuse or breaker on the main DC electrical panel to the terminal block Bv this method the whole svstem mav be powered on and off from the main distribution panel but the individual feed pump module switches must be used to control each pump While the main supplv wires will be protected bv a fuse or breaker on the main distribution panel each feed pump must still have overcurrent protection The simplest wav to do this is to add in line fuse holders installer provided to the positive wires between the terminal block and feed pumps On 12 Volt svstems each pump should be protected with a 7 5 Amp fuse on 24 Volt svs tems each pump should be protected with a 4 Amp fuse Refer to wire guides belo
10. damage the system The propylene glycol formulations sold in marine and RV stores are usually diluted with water The water remaining in the watermaker before the storage procedure will further dilute the antifreeze reducing the microbial protection and increasing the temperature at which the mix ture will freeze Antifreeze labeled Minus Fifty is a 25 solution and will begin to form an icv slush at about 15Degrees F 10C and will only provide burst protection to about Zero F 18C After a fur ther 50 percent dilution by water remaining in the watermaker Minus Fifty antifreeze will only protect from bursting down to about 25F 4C Therefore if low temperature freezing protection is required a 60 or stronger antifreeze should be used 60 solutions are labeled Minus 100 and will provide burst protection to 15F 27C even after a 50 percent dilution with residual water Minus 200 formulations are pure propylene glvcol Introduction to Spectra Chemicals continued Complete microbial preservative protection requires a 25 solution of propvlene glycol so care must be taken that the solution remaining in the watermaker during long term storage is at least 25 even if freeze protection is not required For these reasons Spectra recommends that all pickling be carried out with a 60 or greater concentration See Winterizing with Propylene Glycol on page 37 Propylene glycol can be difficult to flush from a mem
11. flash as the unit cycles Close to the end of the flush cycle take a sample of the brine discharge If the brine discharge thru hull isn t accessible you will need take a sample from the brine outlet on the Clark Pump or use the brine discharge service hose Once you have obtained a sample first check it with a salinity meter to make sure the salinity is below 1000 PPM Next use the copper test kit to make sure the flush water contains between 5 and 1 Parts Per Million of copper Note A new carbon filter will sometimes absorb some of the copper ions causing a copper test to read low Samples should be taken after a new carbon filter has been wet for a few days If the flush water does not have adequate copper content then please contact our technical support for instructions on how to adjust the system Copper test kit 19 20 Z Brane Installation Spectra ships the High Pressure Module with the white Z Brane anode s removed from their socket s to prevent shipping damage Before the High Pressure Module Clark Pump and Membrane is mounted the anodes should be installed The membrane housing has been capped with shipping plugs to keep the membranes clean and moist during shipping and storage Remove the C clips that secure the shipping plugs then remove the plugs Insert an anode into the membrane until the groove is flush with the membrane end plug The C clip will then slip into the groove and the C clip screw will secure
12. fouling is biological growth that forms when the system is left unused without flushing or pickling Fouling from mineral scaling can happen during operation under certain seawater conditions and from rust Monitor the product salinity and feed pressure for higher than normal readings and take environmental conditions into consideration e Cold feed water or clogged filters can cause high pressure Low product flow is usually due to low voltage a worn feed pump or a worn Clark Pump Test to see if biological growth has occurred Before running the system remove the pre filter and examine its condition If the filter housing is full of smellv discolored water the sys tem was not properly stored Install a clean pre filter Next check the membrane Attach the brine discharge service hose and lead it into a bucket Open the pressure relief valve half a turn and manually run the system for 30 seconds metal toggle switch on feed pump module Examine the brine water If it is discolored and smells bad perform an SC 2 cleaning with unchlorinated water before running the system pressur ized If the brine is fairly clean follow the New System Startup procedure on pages 25 26 and run normally Check for performance Clean the membranes only if performance is reduced See the Cleaning Procedure on page 38 for complete instructions 33 34 SPECTRA WATERMAKERS Introduction to Spectra Chemicals We use four types of chemicals
13. handle points in the direction of flow Pressure Gauge Use accumulator port to connect the pressure gauge with the supplied 1 4 black nylon tub ing Tubing must be pressure rated to 150 PSI 10 BAR Product Flow Meter Use the supplied 1 4 Back view of instrument panel black nylon tubing for the product plumbing Product output fitting 10 Fast amp Tite Thermoplastic Fittings Fast amp Tite fittings are the most complete line of plastic fittings for thermoplastic tubing in the industry NUT O RING TUBING SPACER GRAB RING Fast amp Tite thermoplastic tube fittings from Parker will prove to be the answer to your tubing connector needs Patented Fast amp Tite fittings install in seconds without tools and provide a tight sure leak proof seal without clamps or adjustments A unique 302 stainless steel grab ring for tube retention coupled with a Nitrile O Ring for positive seal assures good tube connection with only hand tight assembly A plastic grab ring is also available upon special request Vibration or tube movement will not break the seal and cause leakage Preassembled in either highly inert polypro pylene or strong durable nylon Fast amp Tite fittings are the answer to full flow thermoplastic tubing system requirements When necessary Fast amp Tite fittings can be disassembled by hand for fast system drainage Fittings are completely reusable Fast Assemb
14. in tropical waters or after a week or two in higher latitudes In crystal clear blue water condi tions the filters may need to be cleaned much less frequently If handled gently and changed regularly before they get too smelly filters can be cleaned and reused several times Our filter element part number is FT FTC XX The last digits indicate the micron rating e g FT FTC 5 is for a 5 micron element 43 44 SPECTRA WATERMAKERS CHARCOAL FILTERS The charcoal filter element FT FTC CC removes chlorine from the fresh water flush water supply The RO membrane can only handle small amounts of chlorine without permanent damage If the fresh water flush water contains chlorine the membrane will be exposed to it for days and will produce high salinity water The charcoal filter used for the fresh water flush system will not plug up unless you have very dirty domestic water in your boat s supply tank About six months after installation the char coal filter element will lose its effectiveness and must be replaced This is purely a function of time The charcoal filter we supply removes 99 7 of the chlorine Beware when buying other char coal filters If they don t specify the percentage of chlorine removed don t use them Cheap ones may remove only 60 or 70 Also there are aftermarket filters which are very close to but not exactly the same dimensions and will not seal properly in the housing If you skimp on the
15. screw with a Allen wrench Invert the flow meter and catch the ball as it falls out You can use tooth paste or plastic window polish to polish the inside using a small bottle brush Clean the ball and give it a few coats of wax If the O rings are damaged or the unit has been leaking install new O rings using a little silicone grease to ease assembly These are standard O rings and should be available at most larger auto parts or bearing stores Reassemble in re verse ACCUMULATOR PRESSURE Your Spectra watermaker is supplied with a pressure accumulator tank PL ACC TK which should be installed in the feed water line between the pre filters and the Clark Pump The purpose of the feed line accumulator is to reduce the spikes in the feed pressure caused by the cycling of the Clark Pump If the accumulator is not properly charged it can lead to problems with the Shurflo pump pressure cutout switches see page 46 The accumulator has a Schrader air valve like a car tire which allows the internal air bladder of the accumulator to be pre charged The accumulator should be pumped up to about 65 psi 4 5 bar for best re sults Add air using a tire pump or air compressor You can experiment with the exact pressure that will give the best pulsation dampening on your installation Connections to feed Mia gt hose between Shurflo i pump and Clark Pump Schrader Valve SPECTRA WATERMAKERS PRE FILTERS A Cape
16. tra system 15 16 Z lon Installation If you did not order your Cape Horn Xtreme system with the optional Z lon you may disregard this section of the manual If vou ordered vour Cape Horn Xtreme with a Z lon the feed pump module will come with the Z lon installed in place of the standard fresh water flush module as shown with a separate Z lon electronic control box Feed Pump Module A Fresh water flush valve man ually opened at the start of the cycle and closed at the end Flow regulator Flow sensor or trigger Starts Z lon cycle when it senses water flow Generator bowl with charcoal filter System electrical bus bar Z lon will connect here or any conven ient connection to ship s power Control Box Z lon control box Mount in a visible location near the feed pump module Z lon power cable with in line fuse Connect to the system electrical bus or other source of ship s power Connector for flow sensor Connector for generator bowl Control Box Connections The control box comes with four foot cables for flexibilitv in mounting on the bulkhead adjacent to the feed pump module Plug the connector from the generator bowl and the flow sen sor into their corresponding connectors from the control box It is impossible to reverse them but it is possible to connect the generator bowl to the flow sensor which is incorrect Z lon Installation continued Connections from ge
17. H Position RUN Maintenance Storage and Troubleshooting 30 Suggested Spares Short term cruising weekends etc We suggest a basic Cruise Kit A This kit consists of six 5 micron filters and SC 1 storage chem ical Cruising 2 to 6 months at a time Two basic cruise kits one replacement charcoal filter one replacement feed pump head Longer than 6 months Additional filters Offshore Cruising Kit consisting of Clark Pump seals O rings tools and membrane cleaning chemicals One replacement strainer screen O ring for strainer screen O rings for filter housings Additional feed pump head and or feed pump diaphragm Common Parts SC 1 STORAGE CHEMICAL SC 2 CLEANER SC 3 CLEANER BASIC CRUISE A OFFSHORE REBUILD KIT 5 MICRON FILTER CHARCOAL FILTER 5 STRAINER SCREEN OIL WATER FILTER FEED PUMP FEED PUMP HEAD FEED PUMP DIAPHRAGM 5 STRAINER O RING FILTER HOUSING O RING CHARCOAL FILTER HOUSING O RING Part Number KIT CHEM SC1 KIT CHEM SC2 KIT CHEM SC3 KIT BCK A KIT OFFSH FT FTC 5 FT FTC CC FT STN 5S FT FTC OW EL FP 12V or 24V PL PMP SFPH EL FP DP SO STN 5SS SO FHS 10H SO FHS 3PCS10 31 32 Maintenance General Periodicallv inspect the entire system for leakage and chafing Repair any leaks as soon as you find them Some crvstal formation around the Clark Pump blocks is normal Wipe down anv salt encrusted areas with a damp cloth Watermakers are at their best when run regulari
18. Horn Extreme svstem uses two different filters to prevent damaging foreign materials from entering the svstem A single 5 micron filter cleans the feed water of abrasive materials while the svstem is in operation an additional carbon filter prevents the entrance of chlorine during fresh water flushing During normal operation the feed water is filtered in two stages First it passes through a fine mesh metal sea strainer which protects the feed pump from foreign materials and sea crea tures After passing through the feed pump the feed water passes the filter housing contain ing 5 micron element removing very fine particles that could damage the Clark Pump and shorten membrane life Replacement schedules will vary widely depending on how and where the system is used If large amounts of feed water are run through the svstem over a relativelv short period of time in biologically fertile near shore waters the pre filter will plug up water production and quali tv will drop and the svstem pressure will change dramaticallv If the pressure gauge was in stalled after the pre filters as pictured on page 9 and 10 the pressure will decrease as the fil ter becomes more clogged When operated for only an hour or two a day in inland or near shore waters the trapped plankton will begin to decay in the filter long before it plugs up The decaying plankton and bacteria will cause a rotten egg smell in the product water This decay will set in overnight
19. L MTE 3 4S1 2B Plate Bracket End FM PVB PBE 1 y oy 4 4 Accumulator Tank PL ACC TK 1 2 X 1 4 Bushing Reducer PL BSH 1 2X1 4N 1 2 NPT X 5 8 Hose Barb PL HBS 1 2X5 8 1 2 Nipple PL NP 1 2N 1 2 Female Tee PL TEE 1 2FN Pump to Pressure Vessel Lower SS Tube PL TB HP HPTPVLS 1 4MPT X 1 4 TUBE Straight Fitting PL MTE 1 4X1 4 Nickel Bronze High Pressure Straight Fitting SUB MTS 3 8X1 2 Rear View Plate Bracket Pressure Vessel End Cap FT PV EP 3 4 16 Straight Thread O RING Rubber Mount Pressure Vessel End Ring SO FT STF HD RBP RM FT PV ER Plastic Spacer 1 2 Stainless Ferrule HD SPN MKINS PL HWR 1 2FR 50 r m 111 Am 3 Connector O RING SO HPP CT Stainless Fitting Hex Nut PL HWR 1 2HN Nickel bronze high pres sure 90 degree fitting PL MTE 3 451 2B End block B AL NG HP TB VEB B Valve block LP 2 End block A lt Composite cylinder and base HP CYL CCA HP TB VEB A Pressure relief valve HP TB BV Center block Feedin P Stainless steel tube en y End Cap IR C lark Pump Front View HP CYL EC End block A LA Valve block a N End block B N Composite cvlinder Alternate brine ou and base High pressure in L Test port Center block High pressure out Stainless steel tube Cylinder ring End cap Clark Pump Back View
20. ater testing may be accomplished with an artificial ocean You will need 1 3 Ibs of non iodized salt rock salt sea salt or aquarium salt to make 5 gallons 605 grams of salt per 20 liters of seawater that is about 33 000 PPM salinity average Seawater salinity A good rule of thumb is 1 2 cup 12 liters of salt per gallon 4 liters of water Make sure the domestic water system is powered up and the boat s tank has at least 30 gallons 120 Liters of water to purge the storage chemicals from the system Confirm that the char coal filter is installed and the domestic water line is connected 1 Open the pressure relief valve on the Clark Pump half a turn Remove the green tag and spacer 2 Turn the yellow service valve on feed pump module A to OFF 3 Open the grey flush valve on the charcoal filter housing on feed pump module A 4 Start a feed pump Flip metal toggle switch to ON located on the top right corner of feed pump module A Let feed pump run for 20 minutes to purge the storage chemicals 5 Stop the feed pump metal toggle switch to OFF 6 Connect the inlet service hose to the service port on feed pump module A then connect the brine discharge ser vice hose to the quick disconnect on Clark Pump Refer to the photos below Route both hoses into a 5 gallon 20 Liter bucket Turn product sample valve to the sample position and route the product water into the bucket 7 Open the grey flush valve and turn on the feed pum
21. auge assembly e Installation fittings kit e 5 8 Hose 2 x 25 o e Servicekit Installation Introduction to the Cape Horn Ktreme The Cape Horn Xtreme is designed to be efficient simple and durable Properlv installed and maintained it will supplv vears of reliable service Prudent operation is required with anv marine equipment Always maintain enough reserve water to get safelv into your next port The Spectra Intensifier known as the Clark Pump was introduced in 1997 and has continuallv im proved since It is built of modern non corrosive composites and comes with a 40 high rejection membrane The Clark Pump and membrane module are pre mounted and plumbed together as a single unit to save time and add reliabilitv Pressure Relief Valve Front View Quick disconnect fitting to facilitate maintenance nggi gr e WATERMACHINES Rund fam Rant SABI et 415 h t 2788 Fam 13 SDA ITOT rt mn Double rubber mounts to absorb vibration Charcoal Filter and Housing Fresh Water On Off Flush Valve On Off Switch Switch Cooling Fan Motor Service Port Shurflo l pump Service head Valve CE VOLTAGE uz oc sf 5 Micron Filter 58 and Housing Feed Pump Module A Feed Pump Module B Includes primarv feed pump switch cooling Includes secondarv feed pump same as fan charcoal filter flush valve service valve in module A 5 micron filter housing and service port The
22. brane especially after extended storage periods This results in high salinity water high PPM and residual flavor in the product water We recommend flushing the system WITH THE PRESSURE RELIEF VALVE OPEN for 4 6 hours after storage with propylene glycol the longer the better If after extended flushing you still experience low product water quality cleaning with SC 2 usually removes all traces of propyl ene glycol and returns the salinity to the level it was before storage with propylene glycol See the Cleaning Procedure on page 38 Cleaners Cleaning can be detrimental to the membrane and shorten its life Avoid unnecessary clean ing and avoid cleaning as a diagnostic tool SC 2 is an alkaline cleaner used to remove light oil grime and biological growth It is most effective if heated to 120 deg F 49 deg C which is difficult on a boat In most cases the wa ter quality will increase in PPM salinity after an SC 2 cleaning After a few hours it should re cover to near the level it produced before the cleaning SC 3 is an acid cleaner used to remove mineral and scale deposits In most cases this is used first and if there is no improvement go on to the SC 2 SC 3 will in most cases lower the prod uct PPM and overall pressures Scaling is a slow process that may take several months or years SC 3 is less harmful to the membrane and will almost always improve the performance of an older membrane For cleaning with either SC 2 o
23. cenececsecececeeeuceteueesenecseeeceeeuseneneeteneetens 36 FON TO 39 TLOLD MOG e i n biyan 41 Technical BOGS asses eee sei ea a INA 42 Parts Identification 8 8 8888 8 88 8888 88888883 8 48 Getting Started Unpack the system and inspect it for damage during shipping Freight damage must be report ed to the carrier within 24 hours Refer to the shipping list for vour svstem to ensure vou received all of the components listed Do not discard anv packaging until vou have found and identified all of the parts The small installation parts are listed on the kit list Warningl We will not be held responsible for shortages and or freight damage that are not reported within thirtv davs of the ship date Studv the svstem lavout diagram component photos and descriptions before beginning in stallation Lay out the system Before starting the installation identify where each module and compo nent will be placed Insure that there is enough clearance around the components for removal of filters and system service Make sure you have adequate tubing and hose before starting Additional parts may be ordered Cape Horn Extreme Shipping List 10 Clark Pump and reverse osmosis membrane module Feed pump module A with fresh water flush system e Feed pump module B with pre filter 5 Accumulator tank assembly E e Analogue g
24. ch pump alone should produce 1 5 gallons per minute 5 7 LPM of brine discharge PLUS product water Running on both pumps the flow should be 2 7 GPM 10 LPM Compare the product flow to the total feed flow Product flow should be 9 5 of total flow for a Cape Horn Xtreme If product percentage is low you may have an internal leak in the Clark Pump For every 20 of a GPM feed water flow loss we will lose about gallon per hour of product flow and the salinitv will go up 100 PPM Low feed flow combined with low system pressures is most frequently due to worn Shurflo pump heads PL PMP SFPH Troubleshooting Cape Horn Extreme Svstems Symptom Pump runs intermittently cycling on off Feed pump runs with loud noise Feed pumps run but no pressure Feed Pumps start but shut down on high pressure Low Water Production High Amperage High Feed Pressure Low Water Production Low Feed Pressure Water Production normal but High Feed Pressure High Amperage Water Production normal but Lower Pressure Lower amperage Asymmetrical pressure and flow readings between pump shifts Cause Overpressure switch on Shurflo pump opening Intake blocked Air in system Feed pump air locked Pressure relief valve open Pre filter excessively clogged Closed valve or blockage in flow Strainer or pre filter clogged Pressure Relief valve partially open Worn Pump head Cold seawater temperature Fouled memb
25. charcoal filter you risk damaging a 600 00 membrane on the first flush The other fac tor is the flow rate that the filter can handle Because the chlorine is adsorbed by the char coal it must remain in contact with the charcoal for a sufficient period of time for the all of the chlorine molecules to be captured The filters we use can handle 1 5 gallons 6 liters per minute flow and are good for 3000 gallons 12 000 liters at 1 5 GPM or six months whichev er comes first Regardless of the flow the charcoal loses its effectiveness after six months Charcoal filter Spectra part number FT FTC CC SPECTRA WATERMAKERS SHURFLO PUMP WONT RUN If the pump has power to it but the pump won t run first check the pressure switch The pres sure switch EL FP PS is located on the wet end of the pump and has two red wires plugged into it Jump the two red wires together and see if the pump runs Vou can safelv run the svs tem with the pressure switch jumped just keep an eye on the pressure gauge and don t let svstem pressure exceed 110 PSI Replace the switch when a spare is available The pressure switch should never open unless there is a problem with the svstem or it is incorrectiv adjust ed Check the accumulator pressure page 42 the operating feed pressure and the switch cut out setting page 46 If the pump will not run with the pressure switch jumped then it is most likely a problem with the brushes or overheat protection
26. concentration see pages 34 35 into the bucket with the intake service hose Make sure that the pressure relief valve on the Clark Pump is OPEN a 1 2 turn OR THE MEMBRANE WILL BE DAMAGED Turn on one of the feed pumps until about a gallon of water has flowed from the brine discharge or propylene glycol appears Propylene glycol will look slightly different and feel more slippery than wa ter Stop the pump Add more antifreeze to the intake bucket if necessary Lead the brine discharge service hose into the bucket of propylene glycol The system will now draw propylene glycol from the bucket and return it via the brine discharge hose Circulate the antifreeze in this manner for about 10 minutes alternating feed pumps Stop the feed pumps Reconnect the brine discharge hose that leads to thru hull Run the feed pump until the bucket is empty Close the seawater intake Turn yellow service valve to OFF Drain the seawater strainer and the hose leading to the feed pump modules Disconnect the product tubing from the membrane housing and blow residual water out of the tubing Empty the charcoal filter housing and flush water lines Your watermaker is now protected from biological growth and freezing for one year Feed Pump Module Valves in Opening the pressure relief valve on Clark Pump 1 2 turn flush position Service Valve OFF Flush Valve CLOSED Service Intake Hose ATTACHED Service Valve to SERVICE 37
27. e tube with water Push the tube Straight into fitting until it bottoms on the fitting s shoulder Tighten nut by hand Additional tightening should not be necessary but 1 4 additional turn may be added if desired Do not overtighten nut as the threads will strip and the fitting will not function properly A proper assembly will not show the insertion mark extending beyond the nut If the insertion mark is visible then steps 1 thru 4 must be repeated Step 5 When using clear vinyl tubing or urethane tubing it is necessary to use a TS tube support Disassemble the fitting and place the nut grab ring spacer and tube support in that order on the tube Locate the grab ring at the insertion mark as shown Seat the O ring in the body then proceed with Step 4 Note Provide adequate fail safe mechanisms such as leakage detection sensors automatic shut off controlls or other industry and code appropriate fail safe devices in the design of your water handling appliance to protect against personal injury and property damage Plastic fittings containing an o ring that are used in water applications should be replaced at least every five years or more frequently depending on the environment and severity of the application 11 12 Spectra High Pressure Fitting Instructions The Cape Horn Ktreme has eight high pressure fittings two on each cylinder on the Clark Pump two on the pressure vessel end caps and two 90 degree elbows on the bac
28. ea Check valve retainer HP CB CVR 53 S S compression 1 2 SS tube fittings HP CVL SST PL MTS 3 8X1 28 s SS z Sv Y Composite cylinder and base HP CYL CCA RR U n 4 Cvlinder Ring HP CVL R Cylinder Assembly 55
29. esn t push out if it does push it back into place 45 46 MAR SPECTRA WATERMAKERS ADJUST SHURFLO PRESSURE SWITCH Shurflo feed pumps are equipped with a high pressure cutout switch EL FP PS This is the small black unit on the end of the wet end of the pump head PL PMP SFPH where the two red wires connect If the pressure switch is not properlv adjusted the pump mav cut out each time the Clark pump cvcles and the feed pressure spikes When this happens the production will drop and salinitv will increase The points in the switch will fail quickly if set too low be cause of the constant arcing each time the Clark Pump shifts On the very center of the switch is a small 5 64 Allen screw While running the system close the brine discharge seacock or kink the discharge hose to block the flow Watch the pressure gauge and adjust the pressure switch to shut off at 125 psi Turn the Allen screw clockwise to increase the cut off set point Pressure Switch Adjusting Screw SPECTRA WATERMAKERS Poor Product Water Qualitv With any product water qualitv issue you must ensure accurate calibration if you are using a salinitv meter For general qualitv evaluation vour taste is alwavs good enough Membranes are not an exact science and two identical svstems can have different product qualitv World health standards deem water of up to 1000 PPM of total dissolved solids ac ceptable for drinking consumption We conside
30. etractable snorkel type thru hull fitting is preferred because it picks up water away from the hull The brine discharge thru hull should be above the waterline along or just above the boot stripe to minimize water lift and back pressure Double clamp all hose connections below the waterline Avoid restrictions or long hose runs along the intake plumbing from the thru hull to the feed pump module Secure the piping away from moving objects such as engine belts and hatches Prevent chafe on the tubing as required After several hours of operation inspect all piping and hose clamps for leaks Pipe Fitting Instructions To seal plastic to plastic fittings wrap 6 to 8 layers of Teflon tape around the threads Hold the fitting in your left hand and tightly wrap the threads clockwise For smoother assembly do not tape the first starting threads Wiring e Pay attention to wire size or system performance will be impaired e Perform wiring to UL ABYC CE or applicable standards Cape Horn Ktreme Plumbing Note Brine discharge may be connected to either side of Clark Pump _ Brine discharge thru hull not included place above water line or tee into another visible drain Spectra Clark Pump and Pressure Vessel Membrane Mount in a cool location below 120 deg F 49 deg C May be ori ented in any position and can be well above waterline Leave access to the pres sure relief valve Do not mount over elec trical equi
31. filters or you may void your warranty The filters may be cleaned up to three times with a soft brush and water in a bucket hung overboard overnight or dragged behind your vessel underway Drying in the sun helps remove odors Occasionally lightly lube the filter housing O ring with silicone grease Oil Water Separator Optional For oil water separation install the additional filter housing with its oil removal filter upstream of the 5 micron filter Service at the same time as the 5 micron filter The Charcoal Fresh Water Flush Filter Replace the charcoal filter element at least every 6 months This filter protects the membrane by removing chlorine from the flush water Use only a Spectra approved replacement See page 44 The Feed Pumps and Clark Pump The feed pumps and the Clark Pump require no routine maintenance except inspection for leaks Tighten anv hose clamps or fittings that show signs of leakage The high pressure fittings threaded into the Clark Pump have O ring seals with a straight thread These should never leak and should never be over tightened If one of the tube nuts starts to leak it can be un threaded sealed with a bit of silicone grease or oil and tightened with two wrenches verv tightly see page 12 The Membrane Alwavs perform a flow test page 39 before cleaning vour membrane Cleaning with chemicals shortens the lifespan of membranes so only clean if you are certain it is warranted The lead ing cause of
32. ge chemi cals pickling The Z lon achieves this end by introducing a stream of metallic ions into the fresh water flush module thus flooding the entire svstem with ions that prevent biological growth for up to thir tv davs If vou are going to let vour svstem sit idle for longer than thirtv davs treatment with SC 1 storage chemical or propylene glycol is still required The Z Brane applies zeta potential high voltage capacitive current to the membrane pressure vessel creating an unfriendly environment for bio film and bacteria and assists in the preven tion of scale formation on the membrane surfaces After thoroughly fresh water flushing the system the Z Brane will protect an idle system indefinitely as long as the Z Brane is energized The Z Brane draws less than 1 Amp but storage with chemicals may be preferable for longer periods if battery power is an issue Neither the Z lon nor the Z Brane will prevent freezing so in freezing climates pickling with propylene glycol is still required Even with the Z lon or Z Brane there may still be cases where you need to pickle your system with SC 1 storage chemical or propylene glycol so we recom mend you carry one of these products at all times If your system was ordered with either of these systems they will require only some basic wir ing and commissioning laid out in the following pages If you didn t order you system with the Z lon or Z Brane either can be retrofitted to any Spec
33. hed or damaged O ring within the pressure vessel a scratch on the product tube on the membrane a scratch within one of the end caps or a seal fouled bv contamination could allow sea water into the product water If svstem flow product plus brine is 2 7 GPM or above 1 6 GPM running one feed pump the membrane is clean the product flows are consistent with the svstem flow and the water qualitv is still not acceptable then replacement of the membrane is indicated 47 Cape Horn Xtreme Part Numbers Feed Pump Module A with 3 A NPTX 1 2 Hose charcoal filter for fresh water Barb Elbow 1 3 4 1 2 flushes Fresh Water Flush Valve 3 4 NPTX3 4 FPT PVC Valve Clear Filter Housing PL VLV 3 4PVC Bowl amp Cap FT FTH 10L3PCS Fan 12 Volt KIT FK12 24 Volt KIT FK24 Filter Housing Seal SO FHS 3PCS10 Shurflo Pump Assy no fan 12V KIT FP SF12 24V KIT FP SF24 Charcoal Filter Cartridge not shown FT FTC CC 3 4 3 Way Service Valve PL VLV 3W3 4 Feed Pump Head PL PMP SFPH 3 4 NPTX5 8 Hose Barb Pressure Switch PL HBS 3 4X5 8 EL FP PS 1 8MPT X 1 4 TUBE EL PL MTE 1 8X1 4P 1 4 3 Wav Valve TID A PL VLV 3W1 4 1 4 NPTX1 4 Tube Fitting 4 PL MTS 1 4X1 4P 1 4 NPTX1 4 Tube Fitting El qe TE BB mn 3 4 Clamp PL CLP 3 4CAR Product Flovv Meter 1 4 NPTX1 4 Tube Fitting PL FMT 20 7775 PL MTS 1 4X1 4P 1 4 1 4 EL 1
34. in ways to wire the system Method 1 is the standard installation and preferable in most cases Method 1 Two Pairs of Wires from Distribution Panel to Feed Pumps Route two pairs of wires as in the diagram below from two fuses or breakers on the main distri bution panel With switches or breakers on the distribution panel this method allows you to con trol the pumps remotely which is helpful if the system is difficult to reach You may also control the system from the switches on the individual feed pumps during maintenance Refer to wire guides below Wire length is the sum of the length of the positive and negative wires Example In a 12 Volt system 7 feet of duplex wire two wires in a protective cover is needed to connect the DC electrical panel to each feed pump module 7 7 14 the round trip length so you would use 12 Gauge 6mm wire for each feed pump Connect wires using supplied terminal blocks then seal connectors Voltage drop will impair per formance of the system k loc P E Le 1114 sr ja V Main Electrical Panel Positive buss Feed Pumps A on off switch on each pump 15 amp breakers 12VDC 7 amp 24VDC Feed Pump wiring Red is Positive Black Yellow is Ground Negtive buss To Battery Wire size guide for 12 Volt system with
35. k of the Clark Pump As the compression fitting is tightened it compresses a ferrule onto the stainless tubing fixing the ferrule permanentiv to the tube and holding the compression nut captive The bodv of the fitting seals to the underlving component with an O ring On the Clark Pump cvlinders and the end caps this O ring is compressed by tightening the entire fitting The O rings on the 90 degree fittings on the back of the Clark Pump have captive nuts and washers which compress the O rings without turning the entire fitting If a tube fitting leaks it can sometimes be resealed bv just tightening Vou must use two wrenches a 13 16 inch wrench to hold the base and a 7 8 inch wrench to turn the compres sion nut The 13 16 inch wrench will need to be thin so as not to interfere with the compres sion nut If this doesn t work disassemble the fitting grease liberallv with silicone grease the ferrule and the threads and re tighten firmiv The base O rings should be gentiv compressed to achieve a good seal and mav be damaged bv overtightening Connector O ring Ferrule Stainless Fitting Hex Nut Nickel Bronze High Pressure Elbow Nickel Bronze High Pressure Straight Fitting Cape Horn Ktreme Wiring The Cape Horn Ktreme has two feed pumps which may be operated independentiv For maxi mum production both pumps are run at the same time To save power or to reduce operating pressures the system is run on a single pump There are two ma
36. lark Pump 39 40 Flow Test continued On the Cape Horn Xtreme you should perform the tests using each pump alone then using both pumps Compare the results to the table on page 26 1 Product Flow Product flow is expressed in Gallons Per Hour GPH or Liters Per Hour LPH bv this equation 3600 time in seconds x quantity of water in gallons or liters GPH or LPH There are 3600 seconds in an hour Example It took 3 minutes and 35 seconds to collect 1 gallon of product water 3600 215 x 1 16 74 GPH 3 minutes 35 seconds is 215 seconds Example It took 2 minutes and 25 seconds to collect 2 5 liters of product water 3600 145 x 2 5 62 07 LPH 2 minutes 25 seconds is 145 seconds 2 Total Flow or Feed Flow Feed flow or total flow brine product is expressed in Gallons Per Minute GPM or Liters Per Minute LPM by this equation 60 time in seconds x quantity of water in gallons or liters GPM or LPM Example It took 1 minute and thirty seven seconds to collect 5 gallons of total flow 60 97x5 3 09 GPM 1 minute 37 seconds is 97 seconds Example It took 53 seconds to collect 12 liters of total flow 60 53 x 12 13 58 LPM 3 Recovery Rate Product Flow Total Flow Recovery Rate Example 6 5 GPH product flow 063 or 6 3 1 7 GPM total flow x 60 you must first multiply total flow by 60 to convert from GPM to GPH In order to make good water you need the proper amount of feed water flow Ea
37. ly Step 1 Mark from end of tube the length of insertion See table below Cut the tube squarely and remove any burrs Insertion Insertion Length Length with without Tube Tube Support Support in in Parts are easilv replaced O Rings are standard size and univer sallv available For applications requiring other than Nitrile O Rings consult your Fast amp Tite distributor Use Fast 8 Tite fittings with Parker Parflex tubing or other plastic glass or metal tubing for low pressure or vacuum lines up to the pressure limits shown below Fast 8 Tite fittings meet FDA and NSF 51 requirements for food contact Working Pressures for Fast Tite Fittings Air Oil Water Pressure in PSI Tube O D in Up to 75 F 76 to 125 F 126 to 175 F Ratings are based on use with copper tubing and in all cases represent the maximum recommended working pressure of the fitting only Working pressures vs temperatures of other types of tubing may limit the tube and fitting assembly to pressures lower than shown above Consult factory for recommendations on applications other than shown above Temperature Range Black White Polypropylene O F 18 C to 212 F 100 C White Nylon 40 F 40 C to 200 F 93 C Step 3 Loosen nut on fitting until three threads are visible Fittings for glass tubes must be disassembled and the grab ring removed Step 4 Moisten end of th
38. mav be de powered if the svstem is pickled with chemicals or winterized with propylene glycol Power on LED High Voltage connector DO NOT DISCONNECT OR SPLICE ANY OF THE HIGH VOLTAGE WIR ING Contact the factory if modifications are required Operation 24 New System Startup Avoid running the watermaker if the vessel is in contaminated water such as in a polluted harbor or canal The svstem should be fullv run tested before vou leave port If the location or weather prevents proper testing refer to the manual section Testing with an Artificial Ocean on page 27 Warning Damage will occur if the purge sequence is bypassed and the membrane is pressur ized with storage chemical in it 1 First check that To Sample To Tanks e Thru hull inlet valve and brine discharge valve are open e All of your hose connections are tight e The green warning tag and spacer has been removed from under the pressure relief valve e The pressure relief valve is open 1 2 turn e The sampling valve is set to the sample position Remove Tag and Washer 2 Turn on feed pump module A Check to make sure water is coming out of the brine discharge thru hull above water Shut down module A and repeat this procedure with module B 3 Turn on both feed pump modules and run the system WITHOUT PRES SURE for 20 minutes to purge the storage chemicals If the system has been stored with propylene glycol purge the system for 4 6 hou
39. module has compact and power switch and streamlined plumbing The cooling fan increases longevitv Note If vour svstem came with the optional Z lon the Z lon unit will replace the charcoal filter housing in Feed Pump Module A The photo above and all subsequent photos of feed pump module A will look slightly different See page 16 for Z lon installation and instruc tions Thru hull e Read the directions Not Supplied e Avoid tight hose bends and excessive runs e Use heavy gauge wire e Install feed pump modules as low as possible Use a dedicated thru hull with scoop type strainer e Do not mount components over electrical devices e Avoid getting dirt or debris into the piping or hoses during assembly A small bit of debris can stop the system Seawater Flow Thru hull Location The system must be connected to a dedicated 1 2 to 3 4 forward facing scoop type intake thru hull and seacock Install the thru hull intake as far below the waterline and as close to centerline as possible to pre vent air or contamination from entering the system Do not install the intake close to or down stream of a head discharge keel stabilizer fins or other underwater fixtures Thru hulls near the bow are susceptible to air intake in rough conditions Sharing a thru hull can cause flow restrictions intake of air bubbles or contaminants and will void the warranty For rac ing boats and high speed boats traveling above 15 knots a r
40. nerator bowl and flow sensor connected to control box Z lon Power Connections Turn the main DC breaker off or remove the main power fuse to the watermaker Locate the DC Bus Bar for the watermaker or any other DC power source as shown below Connect the DC power leads from the Z lon Control Box to the Incoming DC Bus Bar Pay attention to polarity e Connect Red fuse to DC e Yellow or black to DC e Replace protective cover Z lon Fuse holder Install ina dry location with easy access 17 Z lon Operation This revolutionary adaptation of an ancient technology effectively and safely protects the mem brane and filters on your Spectra Watermaker Your system will be kept ready to operate with out any additional flushing external power sources pickling chemicals or complex procedures The Z lon should be energized at all times but will only consume power when water is running through it Upon initial power up the LED will flash red green and then will turn solid green Follow the instructions on page 28 for Normal Operation and Fresh Water Flush For treatment with the Z lon the process is identical only the Z lon will release silver and copper ions into the flush water When fresh water flows the operation cycle begins and the LED will flash green amber The cycle will continue until either the water flow stops or the adjustable timer times out factory set for 15 minutes If the voltage is out of range
41. ning solution is cold 8 Stop the pump replace the brine discharge hose and run the pump until the bucket is empty Stop the feed pump and turn the yellow service valve to RUN Follow the instructions for a New System Startup pages 25 26 KEEP PRESSURE RELIEF VALVE OPEN to flush out the cleaning chemicals Feed Pump Module Valves in flush position Opening the pressure relief valve Flush Valve B Service Valve OFF Flush Valve CLOSED Service Hose ATTACHED Service Valve to SERVICE SPECTRA WATERMAKERS Flow Test for Dual ShurFlo Pumps Cape Horn Xtreme The flow test is the most useful diagnostic test for svstem performance and should be done be fore replacing or cleaning vour membrane Changes in production or water qualitv are normallv caused by something other than the membrane unless the system has been left unused for a long time Before the flow test change the pre filter and clean the sea strainer Carefullv check for water or air leaks as air in the svstem will cause low production and erratic salinitv Look for air bub bles in the product flow meter feed water hoses and brine overboard hose Run the svstem and watch the pressures verv closelv If the feed pressure to the Clark Pump is asvmmetrical from one stroke to another this could be part of the problem A difference of a few PSI is acceptable but anything over that is an issue If the pump is asymmetrical Clark
42. p until the container is filled with fresh water Stop the pump and close the grey flush valve 8 Turn the yellow valve on feed pump module A to SERVICE 9 Mix the salt to the proper proportion or use an aquarium hydrometer to adjust the specific gravity to 1 025 10 Start the feed pump allow to prime then close the pressure relief valve on the Clark Pump The system should build pressure and start making water 12 Run the system under pressure and check for proper operation and leaks After testing the system stop the feed pump Remove the inlet service hose and replace the brine discharge hose Turn yellow service valve to RUN Perform a fresh water flush next page A fresh water flush will hold the system for 5 days If you don t use the system in 5 days we recommend the storage procedures on pages 36 or 37 Valves in flush position Open the pressure relief valve on Flush Valve Clark Pump 1 2 turn OPEN 2 Service Intake Port Service Valve OFF Flush Valve CLOSED Service Hose ATTACHED Service Valve to SERVICE 27 28 Normal Operation and Fresh Water Flush If the svstem has been pickled stored or contains cleaning compounds use the New Svstem Startup procedure on page 25 Make sure the inlet thru hull is open Product Sample Turn the product sample valve to the SAMPLE position Valve Turn vellow service valve on feed pump module A to RUN Start the feed pump metal toggle switch on feed p
43. pment Use supplied spacers and washers for the vibration mounts Accumulator Tank Dampens pulsations in feed line Fresh water from boat s Feed Pump Module B Same instructions as Feed Pump Module A pressure water svstem Feed Pump Module A Mount verticallv as low as practical no more than 3 feet above water line and not over electri cal equipment or any thing that will be dam aged by water Leave at least 2 inches of clear ance below for filter changes A TEN RS x Use the supplied 5 8 inch 15 9mm clear braided vinyl hose for all runs More hose may be or dered from Spectra or bought at a hardware or marine store Sea Strainer Mount with sup 22 plied Quick Block and wire tie Intake thru hull Product Water Plumbing and Pressure Gauge Tube Installation Product to tank Route the product water from the valve into the top of a vented tank Install a tee in the water fill or tap a Sampling Tap for testing pipe thread into an inspection port L il r the product water m x b i DO NOTI feed the product into a vent 4 EEN bo x line manifold or the bottom of the tank MA VARA I Make sure that there is no restriction in A S this piping Pressure in the product tubing 22 must never exceed 5psi 3bar running or stopped or the membrane will be per manently damaged Product Sampling Valve Mount using the sup plied plastic straps as shown Note the
44. r SC 3 see the Membrane Cleaning Procedure on page 38 35 36 Storage Procedure NOTE When storing with SC 1 you only need to use one feed pump to circulate the storage solution through the watermaker but vou should brieflv alternate pumps to ensure that the SC 1 solution is circulated throughout the svstem The watermaker will contain about 2 gallons 8 liters of water so starting with one gallon in the bucket there will be about 3 gallons 12 liters of solution Make sure the pressure relief valve on the Clark pump is Open unpressurized 1 2 turn counter clockwise OR THE MEMBRANE WILL BE DAMAGED 1 Performa fresh water flush page 28 Turn off the feed pump and close the grev fresh water flush valve Leave the vellow service valve OFF 2 Disconnect the brine discharge hose from the Clark Pump and replace with the brine service hose from vour service kit Lead the brine service hose into a bucket 3 Doanother fresh water flush and run the feed pump until vou have one gallon 4 liters of fresh water in the bucket Turn off the feed pump and close the grev fresh water flush valve 4 Mix one container of SC 1 storage compound with the water in the bucket It will not dissolve com pletelv which is normal and any particles will be caught by the filter 5 Connect the intake service hose to the service port on feed pump module A and lead the hose into the solution in the bucket Turn the vellow service valve to SERVICE The s
45. r anv thing below 750 PPM acceptable but not ideal and anvthing below 500 PPM excellent Factors that could affect water qualitv are addressed below LOW SYSTEM FLOW OR PRESSURE will equate to lower product quality higher PPM Cape Horn Xtreme systems will produce slightly better quality water running two pumps as this will create higher pressure and lower salinity Worn feed pump heads or flow restrictions will cause lower feed pressure and higher salinity DAMAGE TO THE MEMBRANE by chlorine contamination Flushing the system with chlo rinated water will irreparably damage the membrane Charcoal filters are used to ab sorb any chlorine which might be present in flush water They must be of proper specification to be suitable There is no test for chlorine damage except the process of elimination of other causes DIRTY OR SCALED membranes A dirty foreign material scaled mineral deposits or contaminated bacterial growth membrane can result in poor water quality and ab normal operating pressures If operating pressures are above normal then cleaning is indicated If the system pressures are within operating normal range cleaning may have little result Avoid cleaning as a diagnostic tool Low water quality after storage with propylene glycol can usually be remedied by extended flushing or an SC 2 clean ing MECHANICAL LEAKAGE within the membrane pressure vessel This is an unlikelv but pos sible cause of poor water guality A pinc
46. rane Warm sea water or brackish water Check valve leaking Failed annular ring Shaft Seal leaking Remedy Adjust or replace switch see pages 45 46 Check thru hull valve Check sea strainer for leaks Check fresh water flush module for leaks Re prime system restart Open pressure relief valve to bleed the air then close to start Close valve Change filter Check flow path for closed valve or kink in hose Service pre filter and strainer Close Valve Perform flow test pages 39 40 Replace Pump Head Normal condition Clean membrane Normal Condition Contact dealer or see the Clark Pump repair manual 41 42 SPECTRA WATERMAKERS Technical Bulletins The following pages include Spectra s most commonly used technical bulletins addressing tests adjustments troubleshooting and common points of confusion DWYER FLOW METER SERVICE The mechanical flow meter PL FMT 10 10 GPH range or PL FMT 20 20 GPH range can be opened for cleaning if it becomes difficult to read or if the little ball gets stuck The flow meter will come completely apart for cleaning First remove the meter from the pan el Remove the four small screws that hold the stainless steel bracket in place Carefully pry off the bracket On the very top of the meter is a clear plastic slide off cover over an Allen screw Use a flat bladed screwdriver to push the cover off Holding the meter upright remove the Al len
47. rs See pages 34 35 4 Close the pressure relief valve The pressure should rise to 90 100 PSI 6 2 7 bar Water should flow out of the sampling tube If the vessel is located in brackish or fresh water the pressure will be lower 5 Allow the system to run for 10 minutes then test the product with your hand held salinity tester When the product is below 750 PPM it is consid ered potable and can be diverted to the tank 25 6 idi 126 n u sdulnd ujoq is BE 4 JONPOJ4 poo 7779797 SJJJOWELJEA JEUILION g 40 y duund uns NOA JBUJ9UM JIOHEWI J US9aOp y dund auo 3snf suluuns UIUM sdund 00 Jo auo UNI 0 4 U12 UM pue WIJSAS ay UNI UIUM Suipioap usum uondu nsuo 31aua pue Amuenb uon npoud sduund y JO lil SDINJAS v JIIUEJEQ jim NO asn JEJNHII JO DSINOI y 189 9 8 ISd SZT 9AOQE salnssald paaj YUM WIJSAS y IJEJIAO 0 5 ag a4nssald Zune A dO ISEJJIUI JIM Japjoo SE BINSSIJA LUIISAS BINPIJ o dwind auo snf uni o Aless u aq eu 11 sasunzesadw a 2 ul aJnssaJd JIUBIU YUM SOSEIJ29P JU1jes JonpoJd se sduund yJog Yum BUIUUNI usum JJUBIJS Ao duul Aew Ayjenb J91EM Ajsnosuejjnuis sdund y10q YAM Jo au e Je dund auo juo YUM uni aq AewW WIJSAS 9 paonunuood dnie16 UIJSAS M N 26 Testing with an Artificial Ocean If it is not possible to test run the system with the boat in the w
48. switch inside the motor The motor will come completelv apart bv removing the two screws on the end of the motor Remove the rear cover and paper insulator Pull out the plastic brush holder The thermal switch is located on one of the brush leads With an ohmmeter check for continuitv through the switch If it is open you can make temporary repairs by wiring around it being careful that your new wiring doesn t chafe on the moving parts nor resist the springs that push the brushes on to the commutator The overheat switch is unlikely to fail unless the motor has overheated and shut down Consider relocating the pump or improving ventilation if the overheat protection has failed If any corrosion is apparent the brushes may be sticking Once apart clean all the carbon dust from all the parts Clean the commutator with light sandpaper Make sure to clean the small grooves on the commutator with a small sharp tool to remove the carbon in between the seg ments Adjust the springs on the brush holders so the brushes slide smoothly in and out If the bearings are rough and binding remove the rubber dust cover and clean the best you can grease them and work them free by hand Don t service the bearing unless absolutely neces sary Reassemble in reverse order You can hold the carbon brushes back with papers clips in serted through the slots in the brush holder so they don t hang up on the bearing during as sembly Make sure the corrugated bearing shim do
49. ump module to ON and check for flow by inspecting the brine discharge or checking for pressure on your analogue gauge If there is no flow open the pressure relief valve on the Clark Pump and bleed the air out of the feed pumps by running them one at a time 5 Close the pressure relief valve After 5 minutes check the product water with your hand held salinitv tester When it is below 750 PPM divert the product into vour tank by rotating the product sample valve handle 90 degrees Panel 6 Run the system until you have filled your tank or made enough to meet your require ments US Fresh Water Flush 1 Turnthe yellow service valve to OFF Open the grey flush valve on filter housing at top of feed pump module A 2 Flush for three minutes alternating between pumps to circulate fresh water through the entire system Pressure will drop on the gauge which indicates that the membrane is flooded with fresh water Stop the feed pumps 3 Return the yellow service valve to RUN Close the grey flush valve You may now leave the system unattended for up to five days 30 days with the Z lon without further attention Remember that you need to run the system almost a half an hour to make enough water for a fresh water flush You may notice that the system output is higher while charging your batteries as the ma chine is voltage sensitive Feed Pump Module A with valves Feed Pump Module A with valves in the RUN Position in the FLUS
50. v Biological fouling in the membrane is more likely when a watermaker sits idle A warm environment will cause more growth than a cold en vironment A fresh water flush every five days will greatly reduce biological growth but may not stop it completely You can also protect your watermaker with the optional Z Brane or Z lon sys tems Both protect the membrane from bio fouling without the use of storage chemicals The Seawater Strainer The seawater strainer s stainless steel element should be inspected removed and cleaned as needed Ensure that the thru hull is closed before disassembly and the gasket is in place before reassembly When the system is put into storage remove the strainer rinse with fresh water and reassemble dry to impede corrosion Check frequently during operation The Pre filter Service the pre filter on a regular basis If the system is installed as shown on pages 9 and 10 the pressure will fall on the remote gauge as the pre filter becomes dirty Extremely dirty filters will harm system performance and may cause the feed pump to cut out from high pressure Leaving dirty filters in the machine during long idle periods will cause biological contamination To service the pre filter turn yellow service valve on feed pump module A to OFF open the housing and remove the old filter Clean out the housing bowl reassemble the housing with a new 5 micron filter element Leave dry until next startup Use only Spectra approved
51. vstem will now draw the solution from the bucket and return it via the brine discharge service hose 6 Turnonafeed pump and circulate the storage chemical through the svstem for approximatelv 10 minutes alternating feed pumps Turn off the feed pumps Clean Up Remove the brine discharge service hose and replace the brine discharge hose leading to the thru hull Turn the vellow service valve back to RUN and remove the intake service hose Close the seacock drain and clean the sea strainer and pre filter Reassemble drv with a new filter Vour svstem is now protected for the next six months Feed Pump Module Valves in flush position PENING ME pressure tella rama ma er On Clark Pump 1 2 turn US alve JISTA zz ES 31 g N MST p P Service Valve OFF Connecting brine discharge hose Flush Valve gt gt gt 21 5 CLOSED Service Hose ATTACHED Service Valve to SERVICE 10 Winterizing with Propylene Glycol Fresh water flush the watermaker page 28 Turn off the feed pumps Close the grev flush valve located on feed pump module A Connect the inlet service hose to the service intake on feed pump module A and lead it into a bucket Turn the vellow service valve to the SERVICE position Connect the brine discharge service hose to the quick disconnect on the side of the Clark Pump and lead it into a second container Pour 1 gallon 4L of propvlene glycol of appropriate
52. w Wire length is the sum of the length of the positive and negative wires Example In a 12 Volt system 7 feet of duplex wire two wires in a protective cover is needed to connect the DC electrical panel to the terminal block for the feed pump modules 7 7 14 the round trip length so you would use 10 Gauge 6mm wire Connect wires using supplied terminal block then seal connectors Voltage drop will impair per formance of the system AI Main DC Electrical Panel Feed Pump Wiring Red is positive Black or vellow is negative Fuses for each pump along positive wire Feed Pumps on off switch on each pump o o To Battery VVire Size Guide for 12 Volt system for a single pair VVire Size Guide for 24 Volt system for a single pair Of vvires to Cape Horn Xtreme Of vvires to Cape Horn Xtreme Protect individual feed pumps vvith 15 Amp fuses Protect individual feed pumps vvith 7 5 Amp fuses H10 Gauge 6mm up to 15 feet 4 5M 12 Gauge 4mm up to 10 feet 3M HS Gauge 10mm up to 25 feet 7 5M H10 Gauge 6mm up to 25 feet 7 6M 6 Gauge 16mm up to 35 feet 10 6M 8 Gauge 10mm up to 35 feet 10 6M 14 PS SPECTRA WATERMAKERS Optional Z lon and Z Brane Membrane Protection Svstems The Z lon and Z Brane both developed bv Spectra are svstems to protect the reverse osmosis membrane from fouling for extended periods without fresh water flushing or stora
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