English Manual Katadyn PowerSurvivor 80E
Contents
1. DYN AKING WATER DRINKING WATER PowerSurvivor 80E 12 Volt amp 24 Volt Watermakers OWNER S MANUAL Thank you for purchasing a Katadyn PowerSurvivor 80E 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 will 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 This 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 4830 Azelia Avenue North Minneapolis MN 55429 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 We sugg2. gt Intake Check 2012830 Valve Seat with o ring installed 8012977 Valve Assembly Poppet Valve with o ring installed 8012978 Spring 8013120 Valve Retainer en 8012609 K 5 16 18 Coupling Rubber Capsctrew Pin Boot 8013388 8013394 Check Valve Plate 8012770 Tube Fitting 18012777 Reject Check I long Valve Assembly 8013381 Wiper Block Seal Main Pump 3012776 Components Pump Wiper Back Block Pump Pump Plate 012779 N Back Spacer 6 8012904 Body O ring 8012444 Check Shaft N Burning 8012797 Backup Washer ZT 8012967 Piston Shaft Seals Backup 3013013 8012967 8012775 rir Riog 8012830 Relief Valve Factory preset Piston Do nos aadjust ssembiy Figure A 2 29 Poppet Valve Seat Poppet Valve O ring with O ring installed with O ring installed 8013008 8012977 8012978 Qty 1 Qty 2 Qty 2 0 438 0 070 Cup Seal PIP Ring 8012775 8012796 Qty 1 1 1 500 0 312 1 500 0 188 O ring 8012830 Wiper Block Seal 2 8012776 2 688 0 094 1 0 750 0 210 6 Figure 3 NOTE Some dimensions are approximate 30 O ring 8012444 Qty 1 0 875 0 094 gt j Backup Washer white nylon 8012967 Qty 2 0 750 0 125 gt lt Po
3. 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 or repair Startup 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 prefilter 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 Test and Run When all air has been forced out of the system
4. 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 when the electric power is turned on Is reject brine water being discharged Is normal volume of good product water being produced Is the watermaker running without any seawater leaks Enjoy your watermaker It s working normally Is 12 or 24 VDC available at the motor connections Remove coupling pin from piston shaft Does motor run now Are seawater intake and reject brine seacocks open Is the prefilter 3 way valve in the normal run position Is the cleaning valve in its normal run position Bypass intake system run hose from bucket of clean seawater directly to intake hose barb Does product water flow now Is seawater leaking from around the piston shaft Damaged or defective piston shaft or piston shaft seals Replace defective parts 26 Main battery switch off Circuit breaker off or tripped Blown fuse Electric motor or gcarbox defective Return to factory Piston is scized or pump damaged Disassemble repair amp lubricate Open intake and reject scacocks Turn prefilter 3 way valve to normal run position Defective poppet valve or spring Install new Repair Seal Kit Move the cleaning valve lever to the run position Internal problem wit
5. does not scratch the surface Inspect the parts for any damage and wear In case of damage or excessive wear install a new drive service kit Art no 8019114 Reassembly Push the small pin in the housing until it is flush with the outer side aligned Figure R 12 Figure R 13 Lubricate the needles of the needle bearing with grease Put the sleeve with the bronze bushing first onto the slider It is not necessary to lubricate as the bronze bushing is oil impregnated Push the wiper over the edge while turning the sleeve Turn the hole of the sleeve to the side where the needle bearing is not flush with the connection rod Align it with the cross holes of the slider Place the needle bearing of the connection rod with the jutting side first onto the eccentric Align the hole in the sleeve with the pin in the housing and push it back to the housing Place the housing front back to the drive assembly Insert the bolts and tighten it with 25 Nm Connect the drive to the power source and check if the drive runs smooth If it does not run smooth disassemble the drive again and correct the fault Assemble the drive unit to the pump according to the instruction in section Seal Replacement Reassembly 25 Troubleshooting Flowchart Use the flow chart below to diagnose and solve the most common problems associated with use of the PowerSurvivor 80E watermaker The information in this chart is a distillation of the experience of
6. farthest travel away from the pump i e towards the drive assembly Assure that the watermaker is off and cannot be started accidentally while you work Clean the exposed piston shaft with a clean rag and lubricate the shaft with non petroleum silicone lubricant Warning The PowerSurvivor 80E motor should be turned off and disconnected from its source of power before attempting to lubricate the piston shaft Never put your Figure 7 fingers into the area of the piston shaft while the motor is running This could result in serious Injury 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 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 ar
7. maintenance requirements of the PowerSurvivor 80E 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 watermaker pump and drive assembly require little attention You should regularly inspect the equipment and check for any leakage of seawater or oil leaks from the drive assembly Any leakage of oil or seawater is a sign of a problem and should be corrected Make certain that the watermaker remains dry Exposure to saltwater can cause corrosion of the drive assembly and or 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 1000 hours of use grease and inspect the eccentric drive parts After approximately 5000 hours of use have the electric motor inspected for brush wear and commutator condition Pump Piston Shaft Lubrication It is important to lubricate the pump piston shaft periodically especially after cleaning the membrane The piston shalt is visible at the side of the drive assembly where the pump connects to the drive see Figure 7 Jog run the watermaker and stop it when the piston shaft is at its point of
8. 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 2 Connect Electrical Power to Pump To provide 12 or 24 VDC electric power to the motor use minimum of 14 gauge 2 5 12 VDC 16 gauge 1 5 mm 24 VDC stranded copper wire We recommend 12 gauge 4 12 VDC 14 gauge 2 5 mm 24 VDC or larger wire for distances over 20 feet 6 m 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 Basic Electrical Diagram Fuse and Circuit Breaker 12V 15A DAV 10A Terminal Strip Dimension of the cable 14 gauge 2 5 mm 12 V 16 gauge 1 5 mm 24 V 12V or24V Battery or Power Source Figure 4 with non hardening paste type thread sealant e g Loctite 5331 Permatexe to assure an airtight seal Note Teflon tape is not recommended 1 Carefully thread the middle port of the pre filter 3 way valve into the IN port of
9. 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 80E 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 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 ppms Salt the common name for the chemical sodium chloride Open ocean seawater is about 3 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 type of measure commonly used to indicate the purity of water usually expressed in ppms A standard TDS meter measures on
10. to the alternate intake position Run 1 4 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 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 housing 9 Turn off the watermaker and allow the membranes 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 strain
11. Katadyn Products Inc Pf ffikerstrasse 37 8310 Kemptthal Switzerland Phone 41 44 839 2111 Fax 41 44 839 2199 www katadyn ch info katadyn ch Print No 8012864 6 36
12. UENTIAL OR SPECIAL LOSSES OR DAMAGES RESULTING FROM THE USE OR INABILITY TO USE THE POWERSURVIVOR 80E 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 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 80E 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 80E 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 80E Watermaker prove defective during this period you must notify KATADYN at 4830 Azelia Avenue North Minneapolis MN 55429 or an authorized distributor or dealer of KATADYN You must permit KATADYN 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 abo
13. an expect years of trouble free operation Pre Run Checklist Before running your watermaker always check the following Check for bad rotten egg smell from the water in the prefilter assembly Replace the element and clean Seawater the housing as required Also check for foul water in any in line coarse strainer Any valves in the seawater intake reject brine and product freshwater lines should be open The prefilter 3 way valve should be in the position to intake seawater Assure that the product freshwater output is routed to Figure 5 a drain for testing discarding MI Make sure the clean run valve lever on the pump is in the run position See Figure 5 VI 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 MI 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 10 petroleum products such as oil fuel thinners paints paint removers etc chlorine treated water for example most dockside water silty water water contaminated by fine hard suspended particulates putrid water red tides or any seawater that smells or looks contaminated It is important to remember that the watermaker is designed to process clean open ocean seawater
14. back plate to the drive assembly Then pull the pump away from the drive assembly to expose as much of Hex Nut piston shaft as possible Slide the black 4 plc typ Rubber Boot rubber boot on the piston shaft toward the x pump to expose the shaft coupling pin Assembly Use a small screwdriver or allen wrench to push the coupling pin out of the shaft Note the coupling pin is a loose fit and may fall out on its own Do not lose it Separate the pump from the drive assembly and set the drive assembly aside 7 KG in a safe place Slide the black rubber Check Valve boot off the piston shaft Move the pump x Plate to a clean work surface for further 2 Flange Intake Hose disassembly See Figure R 2 i 4 Remove plastic intake hose barb from the check valve plate While the pump is still bolted together use the 7 8 open end wrench to just loosen the tube fitting in the check valve plate Then use the 1 4 allen wrench to remove the six socket head flange bolts that hold the check valve plate to the pump body Separate the check valve plate from the pump body and remove the large o ring 8012830 seal between them See Figure R 2 5 Disassemble the two check valve assemblies Use the needle nose pliers to lift the intake valve retainer valve spring and poppet valve out of their bore in the inside surface of the check valve plate Remove the
15. ded Under normal use conditions when only open ocean seawater is being processed cleaning the membranes should rarely or never be necessary Proper membrane Note Buildup 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 without requiring a cleaning Cleaning the membranes is only necessary if contaminants are deposited on and adhere to the membrane surface in sufficient amounts to affect the output of product freshwater Usually this condition also causes battery current to increase There are two main types of such deposits and different chemical cleaner is needed for each type of deposits and reduction in product freshwater flow usually take place gradually over extended periods of time Sudden reduction or stopping of product water output is rarely caused by a dirty membrane Organic Growth usually caused by processing brackish water or failure to properly store a membrane during extended periods of non use Use Cleaner e Mineral Scale caused by mineral impurities in the intake water supply Use Acid Cleaner The only indication that the membranes 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 de
16. e airtight especially the connections at the prefilter assembly Note Be aware that a stable air gap at the top of the prefilter housing while operating is not uncommon and doesn t necessarily mean that air is getting to the pump itself Bad smelling Product Freshwater The 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 and or strainer bowl until removed Much of the trapped material is organic plankton seaweeds and flotsam of all types After 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 prefi
17. e side of the boat so that it is underwater and jerk shake it up and down a few times to dislodge the contaminants 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 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 filter elements of 30 micron or finer size 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 Preservative purpose of a membrane preservative treatment is to keep membrane moist and reduce biological growth on the membrane surface Over time biological matter can adhere to the membrane surface thus gradually decreasing its effectiveness When the wa
18. e unit 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 e 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 freshwater collection tank for normal operation e A convenient drain location for testing and discarding product freshwater membrane preservative and cleaners Hoses and Hardware Each PowerSurvivor 80E watermaker is shipped with appropriate hoses and hardware sufficient to perform a normal installation This includes two high pressure hoses 3 and 5 for carrying pressurized seawater from the pump to the membrane housing and reject brine water from the membrane housing back to the pump The 1 2 I D reinforced plastic hose is used for seawater intake and reject brine The smaller 1 4 1 0 clear plastic hose is for routing product freshwater There are also hose clamps and mounting bracket hardware for the prefilter assembly and membrane housing and a TDS Total Dissolved Solids meter for testing and monitoring the quality of product freshwater Customer supplied Equipment Every installation represents a unique challenge You or your installer will need t
19. ed in conventional reverse osmosis The waste brine stream contains up to 90 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 energy efficient and easy to use and maintain The PowerSurvivor 80E incorporates the latest advances in watermaker technology featuring an improved grease lubricated 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 80E watermaker utilizes a low volume high pressure positive displacement pump Unlike the centrifugal pumps found in some systems a positive displacement pump is self priming This pump s powerful performance enables the delivery of seawater even if the desalinator is mounted several feet above waterline We still however recommend the use of an additional pump available in the silt reduction kit for assembly and use of the desalinator above waterline or when a longer hose is r
20. equired The most important part of a good installation is proper planning Although the design and operat ing requirements of the PowerSurvivor 80E 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 or membrane assembly VI Avoid areas with excessive heat Ambient temperatures above 105 F 40 exceed the ratings for the electric motor and excessive heat can damage or destroy the membrane Note Most engine rooms get hotter than 105 LI MI Choose a dry area The motor drive assembly is not waterproof and can corrode 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 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 the single most important decision you will make plan it carefully Provide a shutoff valve or seacock in the seawater intake line Install a coarse strainer in the seawater intake line S K K We recommend using properly sized ring terminals and a terminal strip near the pump
21. er 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 a week three days in warm climates it should now 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 silicone grease At that time the seals should 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 Seals will wear faster in watermakers that are operated in silty or high salinity water 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 c
22. est 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 4 Product Specifications 5 ROCOV OIG rare ee inne 7 Installation ee 7 DON TS anne 7 Installation Procedures ccccccccsssssssssssesssssssscsscsecsessessessesssssssussecsucsucsecsessesseessssssussessecsucsecsesseeseeseeseeseseeaes 8 Using your aan ae 10 Special Condi ONS M 12 Maintenance and 13 PUmMB Ma nlenance a 13 Prefilter 14 Membrane Storage Preserving amp 15 Seal 18 Drive 24 Troubleshooting Flowchart 26 2 E 27 GOSSA 27 28 KiS Se ACCESS ONES 33 SEIVICE L0G n
23. h spool valve or cleaning valve Install new part Air ingress in intake system Check fittings and connections Damaged or defective seal or o ring Install Repair Seal Damaged pump body part Return to factory Appendix A collection of useful information for the Katadyn watermaker owner Glossary Membrane Preservative chemical used to inhibit biological growth in the reverse osmosis membrane during storage or extended periods of non use Filter device which removes suspended solids from a fluid stream A filter is not the same as a reverse osmosis membrane Micron metric unit of measurement equal to one thousandth of a millimeter or one millionth of meter Osmosis the process of diffusion between two water sources through 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 filter placed in desalinator system to remove suspended solids from the feed water before it reaches the high pressure
24. iston ee assembly through its hole in the pump back plate and slide it as NANDA Zi shaft far as it will go toward the pump Op back plate as shown in Figure Pump Back R 7 Install the two o rings Plate 8012830 and 8012444 in their grooves in the pump back DIS plate Make sure the relief valve Q Figure R 7 spring is installed in the pump body Bring the pump back plate and pump body together carefully first guiding the piston into the cylinder in the pump body and then pressing the back plate as close as possible to the pump body Install the four sockethead flange bolts and tighten snugly approximately 120 140 in lbs Refer to Figure R 8 Slide one backup washer over the piston shaft and down into the shaft bore in the pump back Wiper Block plate Slide one of the Figure R 8 Seal shaft seals over the end Spacer of the piston shaft with if present its flared side the side Shaft Seals with an embedded o 08 Wi ring facing the pump EIER ad Block back plate Slide it Bushing down the shaft and lt Backup gently work it into the Piston Washers shaft bore In stall the N Shaft second shaft seal in exactly the same way with its flared side also facing the pump back plate Work it into the shaft bore and press both seals in until the back of the second seal is about flush with the top of the shaft bore Next slide on the second backup washer followed by
25. ivor Caution Never use chlorinated freshwater This may damage the membrane 3 Prepare the membrane preservative solution according to the instruction on the Membrane Preservative container 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 5 Turn the lever on the prefilter 3 way valve to the alternate intake position Run the 1 4 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 membranes freeze they 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 preserving 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 membranes in the watermaker it should only be done when nee
26. lter assembly will require more frequent attention Moreover the high ambient temperatures in tropical locations greatly accelerate the rate of the decomposition process The following maintenance routine for the prefilter assembly is appropriate for a worst case scenario using the watermaker in a near shore location in the tropics Users in temperate climate areas or users processing open ocean seawater during offshore passages are not as likely to require 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 silicone grease 14 3 Install a clean filter element and screw the prefilter bowl back on securely If the watermaker will not be used within the next three days treat it with membrane preservative see Membrane Storage below Tie a line through the center of the dirty filter ele ment and if underway tow it behind the vessel for a few minutes If the vessel is anchored hang the dirty filter over th
27. lve bore with the spring facing the poppet valve Make sure the tube fitting still has an o ring installed and then screw it into the reject check valve hole and tighten securely with the 7 8 open end wrench Test your installation by inserting a small screwdriver into the hole for the reject check valve on the side of the check valve plate opposite the tube fitting The reject poppet valve should move up and down slighily Screw the plastic intake hose barb into the check valve plate See Figure R 2 Then working from the other side of the check valve plate install a new poppet valve valve spring and valve retainer using the same procedure as was used for the reject check valve assembly Lubricate a new o ring 8012830 with silicone grease and install it into its groove in the pump side of the check valve plate Taking care that the intake check valve O ring components do not fall out of their bore 8012850 bring the check valve plate and the pump check Valve body together align them and install the six socket head flange bolts to hold the assembly together Tighten these fasteners snugly If a torque wrench is available tighten to approximately 120 140 in Ibs Use pencil eraser or small screwdriver to test the action of the intake poppet valve See Figure R 6 Figure R 4 Pump Body 21 Lubricate the inside of the ring O ring cylinder in the pump body with silicone grease Insert the p
28. ly 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 indicate the presence of non ionized substances such as bacteria viruses and many other soluble chemicals 27 Diagrams Figure 1 Fasteners supplied by customer Drive Assembly System Diagram High Pressure Steel Tubing 1 2 I D Hoses Hose LA Membrane Housing To Drain or Membrane Manual Fill Test Mounting Clamps Prefilter 3 Way Valve Product 3 Way Freshwater _ Valve Collection Supplied Customer Prefilter 1 4 1 0 Assembly Seacock or Shutoff Valve supplied by 1 4 1 0 customer To Seawater Hose Intake Source vy nn EN Alternate 2 rine are Intake Line Seawater HH overboard for membrane Intake HER Go drain preservative and cleaner Line Seawater solutions Strainer j supplied by customer Strainer 28 Spool Valve 8018615 Pump Body Pump Assembly Exploded Parts Valve Spring 8013120 Valve Retainer View Poppet Valve with o ring installed 8012609 8012976 Valve Seat with o ring installed 801 8977 O ring a
29. n 34 WARRANTY 35 System Description The Katadyn PowerSurvivor 80E 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 amp Membrane Housing 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 A grease lubricated 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 and forces product freshwater through a semipermeable membrane located in the membrane housing The motor gearbox and pump have been integrated into a single compact piece of equipment with low power consumption quiet operation and a small footprint The membrane assembly is a separate unit which allows it to be mounted in a convenient location Prefilter Assembly The prefilter assembly consists of one prefilter housing and a standard 30 micron prefilter element constructed of polyester fibers Two standard elements ship 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 separat
30. n tool and onto the piston Repeat this process for the cup seal Note that the grooved side of the cup seal 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 To install the check valve components refer to Figure R 3 Locate the two new check valve seats in the RSK Observe that the hole in the center of each valve seat has a beveled edge on one side Use your finger to press a valve seat into the bore for the reject check valve assembly The seat should be pressed all the way in with the beveled side of the valve facing outward that is against the end of your finger Use the same technique to install the other valve seat in the bore for the intake check valve assembly It should be installed with the beveled edge of the valve seat facing outward or against your finger With its cross side facing down facing the valve seat lower a new poppet valve into the bore for the reject check valve The poppet valve should be level and in the center of the valve seat at the bottom of the bore Observe that one end of the valve retainers has a shallow hole that is the same diameter as the valve spring Press a new spring into the hole in one of the retainers When installed correctly the spring should stay in the valve retainer when it is inverted Lower the spring and valve retainer into the reject check va
31. o 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 plumbing solution for your freshwater collection tank Our Promise Every Katadyn PowerSurvivor 80E watermaker includes a three year factory warranty and a long history of outstanding customer support Product Specifications Power Requirements 8 amps 12 VDC 5 amps 24 VDC Construction 316 Stainless Steel Pump Housing Configuration Modular Rate of Water Production 3 4 U S gal hr 12 9 liters hr 15 13 8 VDC Feed Water Flow Rate 34 U S gal hr 129 liters hr Pump Weight 34 165 15 4 kg Pump Height 6 2 15 7 cm Pump Length 17 5 44 5 Pump Width 135 34 3 cm Membrane Housing Dimensions 31 x 2 5 79 cm x 6 4 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 Seawater Intake Reject Brine 8 A wen Allow 7 for hose bend Product Freshwater Output The technology behind Katadyn reverse osmosis watermakers Reverse osmosis desalination was first developed in the mid 1950 s It was a major breakthrough in desalting technology but the original process required a lot of power By recovering 90 of the energy lo
32. ompletely Have a Repair Seal Kit on hand Before commencing work refer to the full size drawings in Figures A 3 and 4 in the Appendix to identify the parts contained in the kit and 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 needle nosed pliers 1 2 open end wrench small standard pliers 11 16 open end wrench small scissors 7 8 open end wrench soft mallet 1 4 allen wrench 10x loupe or magnifier medium flat blade screwdrivr silicone grease included in Repair Seal Kit clean rags 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 toward the drive assembly This provides enough room for sliding the rubber boot back toward the pump in Step 3 Figure 1 2 Use the 11 16 open end wrench to disconnect the two high pressure hoses coming the membrane housing A pighp from the tube connectors on the check gt valve plate and the valve assembly CxS Loosen the hose clamps and remove i i 5 _Intake the reinforced plastic seawater intake 8 and reject brine hoses See Figure R 1 pressure I hose 3 Use the 1 2 open end wrench to _7 Reject Brine remove the four hex nuts securing the pump
33. 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 watermaking 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 the 1 4 I D clear plastic 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 The ease of operation of our watermakers 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 can be operated 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 c
34. ppet Valve Spring 8013120 Qty 2 Piston Shaft Bushing 8012797 Qty 1 0 750 0 034 Piston Shaft Seal 8013013 Qty 2 0 750 0 125 gt lt Repair Seal Kit also includes Silicone Lubricant Piston Seal Installation Tool 8012812 Figure A 4 VI V NOILVUGIA dWNd 594 89 AlWald SNISNOH 3NVAAWIW 5010 YSHSVM ANY MINDS JO JOV1d NI SNISNOH GV4H N33M 134 3DVdS HONI 74 MOTIV MINOS LON OQ 1 HLIM LNNOW ONISNOH SINNOW ANVAEWAW NOILVITVISNI dddOdd AN 32 Kits amp Accessories Preventive Maintenance Package Part 8012905 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 8012895 Includes items needed for regular ca
35. r 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 de composition 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 s Manual describes both the routine and the long term
36. re 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 8012889 A set of all user serviceable seals and parts for the high pressure pump This kit also includes re placement gear oil for the drive assembly A Repair Seal Kit should be installed after each approximately 1000 hours of use Cleaning amp Storage Chemicals Acid Cleaner 8 oz 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 Inc directly at 800 755 6701 If ordering directly be sure to include detailed shipping instructions as well as credit card information QUESTIONS CALL 800 755 6701 or 763 746 3500 33 34 LIMITED WARRANTY FOR POWERSURVIVOR 80E 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 WARRANTY NEITHER KATADYN NORTH AMERICA INC KATADYN NOR ITS AFFILIATES SHALL BE LIABLE FOR ANY INCIDENTAL CONSEQ
37. st 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 desalination When saltwater is forced through a semi r permeable membrane enough pressure typically 800 psi pure water will pass through the membrane but salts will not The Katadyn Improved High pressure Technology membrane acts as a barrier to Redirected waste brine contaminants such as salts viruses provides o poWwarassist fo the back side and bacteria separating them from I _ f Se on of pump piston the pure water When seawater is forced against a membrane only 10 passes through sure as pure water In a conventional press GEE 1 rn reducing system the remaining waste brine brine ejected ee stream still under high pressure passes through a pressure reducing Conventional membrane valve and is discharged overboard RO Technology Figure 2 For every gallon of pure water made up to ten gallons of seawater must be pressurized Therefore 90 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 wast
38. t in place Install the four hex nuts on the studs projecting through the flange on the drive unit and tighten them securely Refer to Figure R 1 and install the two high pressure hoses the seawater intake hose and the reject brine hoses to the pump assembly Tighten the hoses clamps on the two reinforced plastic hoses This completes the procedure for reassembly of the watermaker When opera tion is commenced again carefully check for any leaks or other signs of incorrect assembly 23 Drive Maintenance After approximately every 1000 hours of use or when there is a suspect that salt water has entered the housing the eccentric drive should be opened for inspection cleaning and lubrication Tools Needed a allen wrench Torque wrench if available Hammer Cape chisel Flat chisel or medium flat blade screwdriver Grease Figure R 10 Disassembly Disconnect the drive assembly from the pump according to the instruction in section Seal Replacement Disassembly Remove the seven 4 hex bolts from the eccentric drive assembly Remove the housing front from the drive assembly You can use a cape chisel and a hammer to hit from the pump flange side into the groove 24 Remove the connecting rod with slider assembly from the eccentric Use flat chisel to lift the connecting rod Slide the slider out of the sleeve Clean the parts with dry cloth The slider can be cleaned with a soft scotch brite that
39. tect 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 membranes need 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 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 16 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 1 Turn the clean run valve lever on the pump to its clean position see Figure 8 2 Discard any dirty seawater in the prefilter assembly Clean the housing and install a clean element 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 Prepare the cleaning solution according to the instruction on the cleaner container Do not mix Acid Cleaner and Alkaline Cleaner Stir until the cleaner is completely dissolved The water should be warm but not over 120 49 5 Turn the lever on the prefilter 3 way valve
40. ter turning off the system Otherwise the possibility exists that hose failure for example could cause the 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 11 Special Conditions Product freshwater output volume will vary depending on the salinity and temperature of the seawater being processed Figure 6 illustrates the relationship between feed water temperature and the quantity of product water Factors which are known to affect output or performance include High Salinity will decrease output slightly and lead to a modest increase in current draw Effectively the pump must work harder to remove a larger percentage of dissolved solids from the seawater Cold Water will have an effect similar to that of high salinity Silt or Sand can damage the membrane and internal pump components if removed during prefiltration If you must regularly process such water consider installing a Silt Reduction Kit see Kits amp Accessories Temperature vs Output Capacity 120 Range of Membrane and Salinity Variations 100 80 50 40 40 60 80 1 Feedwater Temperature F Figure 6 Foul Intake Seawater can seriously effect the quality of the product freshwater The watermaker membrane is designed to remove the impurities found in clean open ocean seawate
41. termaker 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 lt 25 C 77 F If longer storage is required the membrane preservative treatment should be repeated every year Membrane Storage Preserving amp Cleaning The two reverse osmosis membrane elements inside the membrane housing are expensive and delicate components of your system When properly cared for they can be expected to last for several thousand hours of use However improper use maintenance or handling can damage or destroy them very quickly Treatment The primary Assembly Reject Figure 8 Warning Be sure to follow the flushing procedures described below to ensure that the membrane preservative solution does not get into the freshwater supply 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 15 1 Turn the Clean Run Valve lever on the pump to its Clean position see Figure 8 2 Fill a clean plastic container or bucket with two quarts approximately 2 liters of clean water preferably freshwater from the PowerSurv
42. the Appendix for the location of parts and seals 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 the following procedure references to the Repair Seal Kit will be abbreviated to RSK It will be assumed that all o rings seals and mating surfaces have been lightly lubricated with non petroleum silicone grease supplied with the RSK Warning Use only non petroleum silicone 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 silicone etc such products could also contain petroleum based components An ample supply of silicone grease is included with each RSK I Refer to Figure R 5 during the following procedure Place the piston assembly on a flat stable surface p Installation Piston Shaft Tool Installation Tool SS with the shaft pointing 2 i EA NE D Slide the er installation tool provided in the RSK PIP Ring Pisten Assembly over the piston shaft Cup Seal Ring slide over the with the wide end Installation Tool and onto the piston down Lubricate the Figure R 5 new PIP ring cup seal and the installation 20 tool with silicone grease With the grooved side facing up slide the ring down the installatio
43. the pre filter housing Do 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 Ideally it should be lower than the pump intake to allow air bubbles to pass easily 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 e into an existing seawater intake e g engine cooling water or manual seawater pump inlet e Install a dedicated thru hull for the watermaker Either of these configurations should meet the following criteria should be at a low point on vessel s hull to minimize the chance of air intake during heeling or rough conditions e thru hull should be a minimum of 1 2 I D and possibly larger if it is a shared inlet Note If there is the possibility that in the future you will want to upgrade by adding a second PowerSurvivor 80E to implement redundant systems you should consider substituting 5 8 1 D hoses and hose fittings d
44. the white plastic piston shaft bushing Finally slide the piston installation tool onto the piston shaft small end first and use it to push the backup washers piston shaft seals and bushing all the way into the shaft bore until the outside face of the bushing is flush with the top of the shaft bore Remove the piston installation tool If it was present when you disassembled the pump install the thin plastic spacer washer Press a new wiper block seal into the groove in the center of the wiper block Squeeze the seal into an oval and start one edge into the groove Then work the rest of the seal in until it seats evenly inside the wiper block bore Slide the wiper block onto the piston shaft and press it down into the cavity in the pump back plate The side of the wiper block from which the seal was installed should face outward Slide the black rubber boot onto the piston shaft Its flat side should face the pump 22 Place the assembled pump next to the drive unit and check the alignment of the coupling pin hole in the end of the piston shaft Insert an allen wrench or small screwdriver through the coupling pin hole and use it to rotate the shaft until it will align with the hole in the slider shaft of the drive assembly Bring the drive assembly and pump together carefully and when the holes in the piston shaft and the slider shaft are aligned press the coupling pin through the holes and slide the rubber boot over the coupling pin to hold i
45. to connect electric power This allows for easy testing removal and servicing when required Installation DON Ts Don t use 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 yourself or crew members Although every installation has its custom aspects the following general instructions should be useful to the typical installer Refer to Figure 1 in the Appendix for information on part identification and system connections 1 Install Pump After reading the comments on the preceding pages decide on a location for the pump and drive assembly II should be mounted with the pump and drive side by side horizontally The reason for this requirement is to avoid two problems f 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 Installation Procedures Incorrect Pump Orientations If the drive assembly develops an oil leak and is located directly above the
46. tube fitting reject check valve retainer valve spring and poppet valve from their bore in the outside surface of the check valve plate To remove the valve Figure R 2 Check Valve Figure R 3 Valve Seat Reject Check Plate Valve Assembly Poppet Valve Valve Spri Valve Valve Spring A Poppet Valve Valve Seat gt Valve Retainer N amp O N Intake Check Valve Assembly with o ring installed seats use an allen wrench or similar flat ended tool to push each valve seat out of its bore working from the opposite side of the bore from which the rest of the valve assembly was removed See Figure R 3 6 Separate the pump back plate from the pump body by first using the 1 4 allen wrench to re move the four socket head flange bolts that hold them together It is unlikely that the two parts will separate easily Insert the wide end of the piston seal installation tool into the pump body cylinder from the check valve side of the pump body until it contacts the exposed end of the piston Use a soft mallet to tap the small end of the installation tool and drive the piston and pump back plate away from the pump body When the back plate has separated from the pump body pull the piston out of the back body and remove the two old o rings 8012830 and 8012444 Be careful not to lose the large relief valve spring that is exposed when the pump parts separate 19 7 Remo
47. uct 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 ves sel 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 have only a single tank for storing potable water e will be making extended offshore passages and depend on your watermaker for your potable water supply The preferred method for collecting product freshwater is to use portable jerry jugs or separate day tank which is isolated from the main storage tank Some method should be devised for testing 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
48. uring your initial installation An easy to reach seacock should be installed on the thru hull immediately inside the hull e A coarse seawater strainer is strongly recommended It should be easy to reach and clean The easiest and most commonly used approach is to tee into an existing seawater intake system Be cause the flow rate and volume of seawater intake for the PowerSurvivor 80E 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 1 2 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 convenient location In this case we recommend that a seacock be installed at the 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 container for collecting good product freshwater and 2 a drain location In no case should the prod
49. ve 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 80E Watermaker product for warranty service are your responsibility What Is Not Covered This Limited Warranty is 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 80E 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 35 Katadyn North America 4830 Azelia Avenue North Minneapolis MN 55429 USA Phone 800 755 6701 Fax 800 548 0406 www katadyn com marine katadyn com
50. ve the old ring and cup seal from the piston One method to accomplish this is to wedge a small screwdriver underneath the cup seal and pry it up far enough that it can be cut with a pair of small scissors or a razor blade Repeat the process for the PIP ring 8 Remove the wiper block from the pump back plate and use a pair of Wiper Block needle nose pliers to pull the old wiper block seal out of the wiper block Remove the spacer washer if present Working from the side of the back plate that faces the pump Spacer if present Backup Washers body use a flat ended tool or a N Piston Shaft 11819 small socket on an extension to N Seals 59 press out the two backup washers u ushing two piston shaft seals and shaft Figure R 4 bushing from the back plate Refer to Figure R 4 This completes the disassembly of all user serviceable parts of the Katadyn PowerSurvivor watermaker 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 deposits on metal parts may 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 Refer to the exploded drawing of the pump in Figure A 2 in
51. which may take several minutes more product freshwater should begin to flow from the hose barb at the end of the membrane housing It is normal for product water to be unpotable for a short time after startup Reject the initial product water and use the TDS meter and or taste test to monitor the quality until it is acceptable This will usually take about 5 10 minutes 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 Y 9 preservative to prevent organic growth on membrane Note Organic growth is much more rapid in warm tropical climates If using the watermaker in a tropical environment we recommend a membrane preservative treatment if the watermaker will not be run again within the next three days Before doing repairs or maintenance work on a PowerSurvivor close the seawater inlet valve af
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