Katadyn Spectra Watermakers Catalina 340R Installation And Operating Manual Download Page 7

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Table of Contents

Getting Started

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Installation Basics

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Components

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Catalina Plumbing Schematic & Plumbing Detail

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Product Water Plumbing and Pressure Gauge Tube Installation

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Plumbing Detail

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Tube Fitting Assembly Procedures

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Electrical

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Installing A Remote Controller

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Optional Tank Switch Installation

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Operation

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New Systems Start Up and Testing

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Dry Testing with an Artificial Ocean

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Spectra Remote Manual Controller Guide

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Freshwater Flush Calibration

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Adjusting Fresh Water Flush Duration

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Normal Operation and Fresh Water Flush

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Nominal Operating Parameters

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Maintenance, Storage, and Troubleshooting

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Maintenance

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Introduction to Spectra Chemicals

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Storage Procedures

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Winterizing with Propylene Glycol

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Membrane Cleaning Procedure

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Suggested Spares

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Troubleshooting

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Catalina Flow Test

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Poor Water Quality

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Technical Bulletins

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Spectra Remote Manual Controls

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Wiring Schematic

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Control Box Wiring

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Exploded Views and Part Numbers

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Owner Resources

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Warranty, Product Registration

Installation & Commissioning Reports

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Summary of Contents for Spectra Watermakers Catalina 340R

Page 1: ...stallation and Operating Manual Spectra Watermakers Katadyn Desalination LLC 2220 S McDowell Blvd Ext Petaluma CA 94954 Phone 415 526 2780 Fax 415 526 2787 info spectrawatermakers com www spectrawatermakers com Updated February 2021 ...

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Page 3: ...XCITING EXTENDED WARRANTY OFFER Upgrade the standard 1 YEAR manufacturer warranty to 2 YEARS and LIFETIME on Clark Pump Follow the below steps to submit for approval 1 Have system installed commissioned by Spectra Authorized FSP full service provider 2 Fill out web based Product Registration form see back of owner s manual for paper copy 3 Complete web based install commissioning form see back of ...

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Page 5: ...y will be void if the installation does not meet this requirement 3 Follow the wire gauge charts in the instructions Using larger wire than specified is acceptable 4 If you are separating the Clark Pump membrane assembly please review the high pressure tube assembly instructions Improper assembly will cause failure 5 Run test then sea trial the complete system before assuming it is operational If ...

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Page 7: ...oller Guide 30 Freshwater Flush Calibration 31 Adjusting Fresh Water Flush Duration 32 Normal Operation and Fresh Water Flush 33 Nominal Operating Parameters 33 Maintenance Storage and Troubleshooting Maintenance 34 Introduction to Spectra Chemicals 38 Storage Procedures 39 Winterizing with Propylene Glycol 40 Membrane Cleaning Procedure 41 Suggested Spares 42 Troubleshooting 43 Catalina Flow Test...

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Page 9: ... 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 Getting Started Catalina 340R Shipping List Catalina Feed Pump Module 10 Clark Pump and Reverse Osmosis Membrane Module Boost Pump and Sea Strainer Module Fresh Water Flush Module or Optional Z Ion Upgrade Service Kit Remot...

Page 10: ...t and back pressure Double clamp all hose connections below the waterline Avoid restrictions or long runs on the entire inlet side of the 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 Test and inspect all piping and hose clamps after several hours of operation Pipe Fitting Inst...

Page 11: ... and Boost Pump Module Mount close to the intake through hull below the waterline in a location that can handle water spillage during service The boost pump power cable will connect to the feed pump module Fresh Water Flush Module The fresh water flush module may be located in any convenient location near the feed pump module It should be mounted with the filter housing vertical and accessible wit...

Page 12: ...airs or if a leak occurs Allow for easy access to the pressure relief valve The Clark pump and membrane module comes complete with a mounting system Be sure to use the supplied washers on the rubber feet Pressure Relief Valve Components Cont Clark Pump and Membrane Remote Manual Controller The remote control panel can be mounted anywhere dry and convenient Cut a 5 8 1 5 cm wide by 5 8 1 5 cm high ...

Page 13: ...kable Freshwater Brine Discharge Freshwater Flush Note Brine discharge hose may be connected to either side of Clark Pump Use the supplied 5 8 inch 15 9mm clear braided vinyl hose for all runs More hose may be ordered from Spectra or bought at a hardware or marine store Simplified Plumbing Layout Mount Controller in a dry location well above the waterline Flush water from ship s pressure water sys...

Page 14: ...14 Installation Notes ...

Page 15: ...the handle points in the direction of flow 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 pipe thread into an inspection port DO NOT feed the product into a vent line manifold or the bottom of the tank Make sure that there is no restriction in this piping Pressure in the product tubing must never exceed 5psi 3bar runnin...

Page 16: ...e are mounted in relation to the other sub assemblies The black 1 4 tubing runs from the accumulator to the Feed Pressure Gauge Locate an optimal location close to the Clark Pump for viewing and mounting the Product Water Flowmeter Feed Pressure Gauge Panel and then cut the provided black 1 4 tubing accordingly Take careful consideration where to mount the Product Sampling Valve so that the blue 1...

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Page 18: ...le to deliver 1 5 gallons per minute 6 LPM at 25 PSI 1 7 bar Note Never leave system unattended during a flush cycle Once cycle is complete system will still draw power in a standby state until user manually pushes the Stop button on the controller Attaching 1 2 inch vinyl hose to Z Ion fresh water flush module with the pre fitted Quick Connect fitting From the intake seacock to the sea strainer b...

Page 19: ...ting from the installation kit From the feed pump to the Clark Pump feed water inlet use the remaining 1 2 inch vinyl hose with the 1 2 inch John Guest stem fitting pre fitted with a ferrule Insert the pre fitted end into the feed pump Figure 1 and the 1 2 John Guest stem fitting and hose clamp from the installation kit for the Clark Pump feed water inlet Figure 2 Refer to John Guest assembly inst...

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Page 21: ...21 John Guest Super Speedfit Fittings ...

Page 22: ...oller The Catalina 340R has a power inlet harness with a terminal block and cover a boost pump power plug with a yellow band terminal block for the tank full switch and the optional tank level sensor and a short plug with a green band for the optional Z Ion Do not install it in hot or poorly ventilated locations Allow access to the motor speed control Electrical Run Auto Manual Service toggle swit...

Page 23: ... main power terminal block in a junction box or on a bulkhead adjacent to the feed pump module Make sure that this is a dry location well above bilge level and not subject to water spray Be sure to install the terminal block cover Check the wire size chart for appropriate wire sizes DC power feeds should be uninterruptible to insure proper operation of the auto store feature Avoid house breaker pa...

Page 24: ...be viewed when looking down inside the Feed Pump Module This port is labeled Display but is actually for the Remote Manual Controller The Remote Controller cable is a standard Cat 5e ethernet cable 25 7 62M cable with connectors for the Remote Manual Controller ...

Page 25: ...ng the wire or sharp corners where the wire can chafe through while the vessel is under way Turn power OFF to the system Connect the ethernet cable to back of the display in the open jack Connect the opposing end of the ethernet cable to the RJ45 port labeled DISPLAY in the feed pump module Remote Controller Plugin ...

Page 26: ... WARNING Optional Tank Switch The customer supplied float switch must be connected to the Terminals 5 6 labeled Tank Full within the Control Box that is mounted to the inside of the Feed Pump Module There is no polarity Remove the jumper Connect the wires to the terminals Use 18 2 tinned wire or larger Wire is not included in the installation kit Connect to Terminals 5 6 Note Remove only the jumpe...

Page 27: ... is full If you do not install the Tank Full switch in your tank you MUST MANUALLY STOP the system when your freshwater tank has been filled The system will not stop automatically Note The float may need to be flipped 180 degrees to work properly Many floats can be easily flipped by removing the clip opposite the wire Optional Tank Switch Cont Drill and Tap Drill and tap a 1 8 NPT port into the to...

Page 28: ...asher with the green tag under the pressure relief valve has been removed The pressure relief valve is open at least 1 2 turn The sampling valve is set to the sample position The brine line is able to freely discharge 3 Run the system without pressure for 60 minutes to purge the storage chemicals The pressure gauge should read less than 35 PSI If purging with freshwater the sampling tube may disch...

Page 29: ...e hose attached to Clark Pump Press Stop when the bucket is full 5 Mix the salt to the proper proportion or use an aquarium hydrometer to adjust the salinity level to a specific gravity of 1 025 6 Disconnect the quick release fitting from the pigtail coming from the charcoal filter housing outlet and connect the intake service hose per Figures 4 Route both service hoses into a 5 gallon 20 liter bu...

Page 30: ...he Fresh Water Flush FWF button floods the watermaker with fresh water from the vessel s domestic water tanks Opens solenoid valve to allow water to flow from tank instead of seawater from the thru hull Fresh Water Flush mode will end automatically after flush is complete approximately 3 minutes Stop Pressing the Stop button ends watermaker opera tion The Stop button must be pressed before beginni...

Page 31: ... Slowing down the pump during a Fresh Water Flush Inside the feed pump module next to the Control Box is the pump speed controller On the speed controller board are two magnetic reed switches for adjusting the pump motor speed The switches are narrow black bars 5 8 16mm long The increase speed switch is labeled S2 the decrease speed switch is labeled S3 Each time a small magnet is placed near the ...

Page 32: ... default of 3 minutes which is usually the right amount of time to ensure that seawater is thoroughly flushed out of the watermaker using the least amount of fresh water However due to different lengths of hose runs different rates of flow and different pressures in shipboard fresh water systems the flush duration can be optimized for your boat Set the Flush Duration with a small screwdriver so th...

Page 33: ...ing your water making session perform a freshwater flush Freshwater Flush You should freshwater flush your watermaker after EVERY use 1 Push the Freshwater Flush button on the remote panel 2 The freshwater flush solenoid will open and feed pump will come on allowing pressurized freshwater to flow through the system Pressure will drop on the gauge which indicates that the membrane is flooded with f...

Page 34: ...tion Prefilter Assembly Prefilter elements must be changed frequently The rate is solely dependent on the input water A 5 micron filter might last you a 4 6 weeks in clear open ocean seawater or be ruined in 45 minutes in a dirty harbor A vessel may be sailing through seemingly super clear water but cruise through a plankton bloom and the prefilter will be ruined Filters may be cleaned only up to ...

Page 35: ...ssure for higher than normal readings take environmental conditions into consideration Note Cold feed water or a higher salinity seawater source can cause high pressure Low product flow is usually due to low voltage a worn feed pump or worn Clark Pump Due to the unique design of your Spectra system low product water volume is typically not a membrane problem but frequently related to low voltage a...

Page 36: ... 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 by just tightening You must use two wrenches a 13 16 inch wrench to hold the base and a 7 8 inch wrench to turn the compression nut The 13 16 inch wrench will need to be thin so as not to interfere with the compression nut I...

Page 37: ... for Storage Procedure 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 winterize RV s boats and cabins Do not use ethylene glycol automotive antifreeze which is toxic and wi...

Page 38: ...xperience low product water quality cleaning with SC 2 usually removes all traces of propylene glycol and returns the salinity to the level it was before storage with propylene glycol See the Membrane Cleaning Procedure Cleaners Avoid unnecessary cleaning 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...

Page 39: ...ckwise 8 Turn on the feed pump by moving the manual control switch on the control box to SERVICE The solution will be drawn from the bucket with the service hose and returned to the bucket from the brine discharge service hose Circulate the storage chemical in the system for approximately 20 minutes Stop the feed pump by moving the switch back to the RUN AUTO position Clean Up Remove the brine dis...

Page 40: ...r Stop the pump by moving the switch back to RUN AUTO Add more propylene glycol to the intake bucket if necessary 7 Lead the brine discharge service hose into the intake bucket of propylene glycol Move the switch back to SERVICE The service hose will now draw propylene glycol solution from the bucket and the brine discharge service hose will return it Run the feed pump and circulate the propylene ...

Page 41: ...cket 5 Make sure that the pressure relief valve on the Clark Pump is open un pressurized 6 Mix the cleaning chemical in the bucket If possible heat the solution to 120 F 49 C 7 Move manual switch on the Feed Pump Module to SERVICE SYSTEM The intake service hose will draw solution from the bucket and the brine discharge service hose will return it Circulate the solution through the system in this m...

Page 42: ...gs tools and membrane cleaning chemicals One replacement strainer screen replacement O ring for strainer screen and replacement O rings for the filter housings Common Parts Item Part Number SC 1 STORAGE CHEMICAL KIT CHEM SC1 SC 2 CLEANER KIT CHEM SC2 SC 3 CLEANER KIT CHEM SC3 BASIC CRUISE KIT A KIT BCK A OFFSHORE REBUILD KIT KIT OFFSH 5 MICRON FILTER FT FTC 5 CHARCOAL FILTER FT FTC CC 6 STRAINER S...

Page 43: ...ater Brine or product flow path subject to back pressure Scaled or fouled membrane Normal condition Confirm by routing into a bucket to test Clean Membrane Feed Pump not running no noise No power at feed pump DC speed controller needs to be adjusted DC speed controller malfunction Check voltage at motor speed controller MTR leads Adjust speed controller per manual directions Replace speed controll...

Page 44: ... necessary Check voltage at speed controller If available turn on battery chargers Replace prefilter service strainer check all hose runs Confirm by using intake service hose and bucket of seawater to bypass Clean Thru hull Perform SC 3 Cleaning Note By design it is rare for a membrane to cause low total flow on Spectra systems Pump should be able to push 2 7 G M 90 100psi Replace pump head Asymme...

Page 45: ... Fault Light Illuminated High Pressure or Vacuum Switch Blocked brine discharge Restriction in Clark Pump Membrane Product line not vented causing back pressure Fouled membrane Vacuum switch faulty Boost Pressure Vacuum Switch Prefilter Sea Strainer clogged Intake restriction Boost Pump not receiving 24V or disconnected Vacuum switch faulty Install new prefilters Clear strainer Clear obstruction C...

Page 46: ...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 Log the voltage at the feed pump at the same time Confirm at least 12 5 Volts at the feed pump on 12 Volt DC systems Take two measurements and compare them with the table on the following page The first measurement is the product flow alone The second is ...

Page 47: ...ple 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 pressure relief valve open turn In order to make good quality product water you need the proper amount of feed water flow as in the tab...

Page 48: ...esent in flush water They must be of proper specification to be suitable See page 48 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 abnormal operating pressures If operating pressures are above normal then ...

Page 49: ...p 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 pressure spikes and system shut down 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 ...

Page 50: ...ter will plug up water production and quality will drop and the system pressure will change dramatically In blue water conditions the pre filter may only need to be changed every week or two 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 filters long before the elements plug up The decaying plankton and bacteria will cause...

Page 51: ... there are aftermarket filters which are very close to but not exactly the right dimensions and they will not seal in the housing If you skimp on the charcoal filter you risk damaging a 600 00 membrane on the first flush The other factor is the flow rate that the filter can handle Because the chlorine is adsorbed by the charcoal it must remain in contact with the charcoal for a sufficient period o...

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Page 53: ...P BOOST PUMP FW F FW F 30 86 87 85 15 AMP Fuse GND 12VDC SERVICE SYSTEM MANUAL RUN 5 AMP Fuse 4 5 6 Pressure Sw itch Boost Pump Plug 12V 30A Cube Relay White Wire Grommet 1 Grommet 2 Relay 5 Relay 4 Relay 2 Relay 3 Relay 1 TANK SW N C TANK SW N C PW R RELA Y PW R RELA Y FW F SPEED FW F SPEED DIV VLV DIV VLV Remote Control SPEED CONTROL MOT MOT BAT BAT FEED PUMP MOTOR HIGH PRESSURE SWITCH LOW PRESS...

Page 54: ...NK SW 9 PWR RELAY 13 D V 2 PWR IN 6 TANK SW 10 PWR RELAY 14 D V 3 PRS SW 1 7 BOOST PUMP 11 FWF SPEED 15 FWF 4 PRS SW 2 8 BOOST PUMP 12 FWF SPEED 16 FWF Multiple Display Ports Switches for Relays 7 13 Main Power Connection Terminal Block ...

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Page 56: ...yl hose PL HS 1 2VN 2 brass ferrules PL HF 75lDX1BR 2 1 2 inch hose barb tube adapters PL HBA 1 2Tx1 2 5 inches of 3 4 inch spiral wrap EL LT 3 4SW Hose clamps may be substituted for the brass ferrules which are crimped on FT PV ER Pressure Vessel End Ring PL SWF 1 8X1 4J 1 8 NPT to 1 4 Tube Parker Elbow PL ACC TK Accumulator Tank PL HP 1 2N 1 2 X 1 4 Hex Bushing Reducer PL SWF 1 2x1 2 1 2 NPT x 1...

Page 57: ... FT FTC 5 5 MICRON FILTER ELEMENT FT FTH 10L3PCS 3 PIECE 10 FILTER HOUSING PL HBE 3 4X3 4 3 4 NPT X 3 4 HOSE BARB ELL NYLON PL BSH 3 4X1 2N 3 4 X 1 2 HEX BUSHING REDUCER NYL FT FHB 3PCSHSS MOLDED FILTER BRACKET EL SWT TSBHC TOGGLE SWITCH BOOT SEAL EL SWT TG DPDT TOGGLE SWITCH DP DT PL SWF 1 2X1 2 1 2 NPT X 1 2 TUBE SWIVEL ELBOW PL NLT 1 2LP 1 2 LOW PRESSURE TUBE HD OTH 1 4TS1D 1 4 20 x 9 16 NYLON ...

Page 58: ...T Z HPIBHA PL HS 1 2VN 1 2 VINYL HOSE PL QDC 1 2HBDWV 1 2 HB QUICK DISCT BODY WITH VALVE PL HBA 1 2TX1 2 1 2 TUBE x 1 2 HB ADAPTER Brass ferrules for 1 2 inch hose PL HF 75lDX1BR Part Numbers KIT REM RMC SPECTRA MANUAL REMOTE CNTRL PL UNN 3 8x1 4N 3 8 FPT x 1 4 FPT COUPLING NYLON PL TEE 1 2TJG 1 2 TUBE TEE JG PL STA 12TX38NJ 1 2 TUBE STEM x 3 8 NPT ADAPTER EL SWT PS200 PRESSURE SWITCH 200 PSI EL S...

Page 59: ...USHING REDUCER NYLON PL NP 1 4N 1 4 NPT CLOSE NIPPLE NYLON Fresh Water Flush Module or Z Ion PL SLN 1 4O12SV 12V FRESH WATER FLUSH SOLENOID PL UNN 1 2N 1 2 FPT COUPLER NYLON PL QDC 1 2CP 1 2 NPT COLDER COUPLER FT FTH 10L3PCS 10 LOW PRESS FILTER HOUSING 3 PCS without Z ION PL FHB 1 2X3 4E 1 2 FPT X 3 4 Hose Barb Elbow NYLON EL FP BPLDC824 300 1000 BOOSTER PUMP DC 8 24 Volts PL BHF 3 8TPIEJ 3 8 STEM...

Page 60: ...SO FT STF 3 4 16 Straight Thread O RING SUB MTS 3 8X1 2 Nickel Bronze High Pressure Straight Fitting SUB CT Z HPILHA CATALINA 340 HP INLET HOSE ASSEM PL QDC HB5 8 5 8 Quick Disc Fitting Hose Barb Brine Discharge Quick Connect High Pressure Fittings PL MTE 3 4S1 2B 3 4 16 ST X 1 2 Tube Fitting Elbow Bronze ...

Page 61: ...61 HP TB VEB B HP TB VB HP TB VEB A HP TB BV HP CB CB10 HP CYL SST HP CYL R HP CYL EC HP CYL CCA Not used ...

Page 62: ...62 HD CPS 5 162 75 SO HPP SP HP TB VSP HP TB SR SO HPP VB SO HPP PLP SO HPP VP HD CPS 5 16X3 KIT HP 10VSA HP TB ARP SO HPP AR1 SO HPP RV HP TB BV 89 ...

Page 63: ...63 Parts 1 ...

Page 64: ...64 Parts PL MTS 3 8X1 2B HP CYL SST HP CYL CCA SO HPP ECCB HP CYL EC HP CYL R HP CYL PT Parts ...

Page 65: ...ed application the product warranty is provided for a period of year the Warranty Period after date of purchase if purchaser is installing system or date of commissioning if Spectra dealer is installing system You will be required to show written documentation supporting the date of purchase or date of commissioning If you are unable to provide documentation supporting the date of purchase or comm...

Page 66: ...uct All products being returned to the Manufacturer must have a return material authorization RMA number to be processed Any item returned to the Manufacturer without an RMA number will not be accepted by the Manufacturer Contact your Dealer or Customer Service to obtain an RMA number Once we have received Your returned product we will determine in our sole and absolute discretion whether Your cla...

Page 67: ...trawarranty formstack com forms product_registration spectrawarranty formstack com forms spectra_install_commissioning_report Email TechSupport SpectraWatermakers com Phone 1 415 526 2780 Address Katadyn Desalination Technical Department 2220 S McDowell Blvd Ext Petaluma CA 94954 USA Please keep a copy of these reports for your records Any commissioning install report and additional 12 month warra...

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Page 69: ... from boost pump module _____FT M HIGH PRESSURE MODULE and BRINE DISCHARGE Pressure relief valve is accessible Brine discharge has no obstructions and vents to atmosphere Notes ___________________________________________________________________ ________________________________________________________________________ PRODUCT WATER TUBING Product water flows into top of freshwater tank Freshwater ta...

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Page 71: ..._____________________________________________ ______________________________________________________________________ FRESHWATER FLUSH Freshwater Flush solenoid valve opens Feed Pump is not cavitating when system flushes with seacock closed When seacock is open what is the ppm of brine discharge at the end of the flush_______ Flush duration is ________Minutes Needed to change flush time Needed to c...

Page 72: ...when the system is on and when the system is off Understand the relationship between the boost pump and filter condition as well as feed pump health Note the filter condition change when boost pump cable is disconnected Be able to identify feed pump cavitation this is the sound the feed pump makes when the system is running and the seacock is closed momentarily Have seen how the service hoses and ...

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