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Table of Contents

System Description ....................................................................................................... 4

Product Specifications ................................................................................................... 5

Energy Recovery .......................................................................................................... 6

Installation ................................................................................................................... 7

Installation DOs ..................................................................................................................... 7

Installation DON’Ts ................................................................................................................ 7

Plan Ahead for Manual Operation ......................................................................................... 8

Installation Procedures ........................................................................................................... 8

Using your Watermaker ............................................................................................. 11

Powered Operation ............................................................................................................. 11

Manual Operation ............................................................................................................... 13

Special Conditions ............................................................................................................... 14

Maintenance and Service ............................................................................................ 15

Pump Maintenance .............................................................................................................. 15

Prefilter Maintenance ........................................................................................................... 16

Membrane Storage, Preserving & Cleaning ........................................................................... 17

Seal Replacement ................................................................................................................ 20

Drive Maintenance ............................................................................................................... 26

Troubleshooting Flowchart ................................................................................................... 28

Appendix ................................................................................................................... 29

Glossary ............................................................................................................................. 29

Diagrams ............................................................................................................................ 30

Kits & Accessories ................................................................................................................ 34

Service Log .......................................................................................................................... 35

WARRANTY ........................................................................................................................ 36

Содержание PowerSurvivor 40E

Страница 1: ...PowerSurvivorTM 40E 12 Volt 24 Volt Watermakers OWNER S MANUAL ...

Страница 2: ...oon 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 Se...

Страница 3: ...nstallation Procedures 8 Using your Watermaker 11 Powered Operation 11 Manual Operation 13 Special Conditions 14 Maintenance and Service 15 Pump Maintenance 15 Prefilter Maintenance 16 Membrane Storage Preserving Cleaning 17 Seal Replacement 20 Drive Maintenance 26 Troubleshooting Flowchart 28 Appendix 29 Glossary 29 Diagrams 30 Kits Accessories 34 Service Log 35 WARRANTY 36 ...

Страница 4: ...input sources for the prefilter assembly and pump Clean seawater during normal operation An alternate intake line for inputting membrane preservative or a cleaning solution The product 3 way valve allows easy selection between the two required destinations for the product freshwater A freshwater collection tank for normal operation A convenient drain location for testing and discarding product fre...

Страница 5: ...mp Weight 25 lbs 11 3 kg Pump Height 6 15 2 cm Pump Length 17 5 44 5 cm Pump Width 16 40 5 cm Prefilter Housing Dimensions 12 x 6 30 cm x 15 cm The electric current requirement is an average figure Instantaneous current will vary during a complete cycle of the pump Also upon initial installation you may experience modestly higher current draw Within a matter of hours the average current draw shoul...

Страница 6: ...nd is discharged overboard 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 wasted in conventional reverse osmosis The waste brin...

Страница 7: ...bly 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 Install the pre filter assembly in an easily accessible location It needs regular sometimes daily inspecti...

Страница 8: ...set of hoses to be used during manual operation recommended This approach allows the watermaker to be moved to any location for manual operation More than likely the plan you choose will be dictated by the location of the space available In any case consider how you would manually operate your watermaker before finalizing your installation plans Installation Procedures Although every installation ...

Страница 9: ...he mounting bracket 4 Install Seawater Intake Plumbing There are two common approaches to providing the seawater intake circuit Tee into an existing seawater intake e g engine cooling water or manual seawater pump inlet Install a dedicated thru hull for the watermaker Either of these configurations should meet the following criteria It should be at a low point on the vessel s hull to minimize the ...

Страница 10: ...re supply of freshwater in the storage tank could become contaminated by unpurified seawater This is especially important if you have only a single tank for storing potable water you will be making extended offshore passages and depending on your watermaker for your potable water supply The preferred method for collecting product freshwater is to use portable 5 or 6 gallon jerry jugs or a separate...

Страница 11: ...atermaker below about 11 VDC is hard on the electric motor and dramatically reduces the output of product freshwater 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 petroleum products such as oil fuel thinners paints paint removers etc chlorine treated water e g most dock water silty water water...

Страница 12: ...ater 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 ...

Страница 13: ...x nuts holding the pump body to the drive assembly Separate the drive assembly from the pump body and set the drive unit aside Remove the black rubber boot from the piston shaft 5 Align the holes in the handle bracket with the two pump bolts that are located above the piston shaft Figure 7 Slide the bracket over the bolts and secure it with two of the hex nuts that held the drive assembly to the p...

Страница 14: ... Silt or Sand can damage the membrane and internal pump components if not removed during pre filtration If you must regularly process such water consider installing a Silt Reduction Kit see Kits Accessories Foul Intake Seawater can seriously affect the quality of the product freshwater The watermaker membrane is designed to remove the impurities found in clean open ocean seawater Processing of sea...

Страница 15: ...ly 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 S...

Страница 16: ...ss 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 tha...

Страница 17: ...f use Improper use maintenance or handling can damage or destroy the membrane very quickly Membrane Preservative Treatment The primary 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 watermaker is not to be u...

Страница 18: ...rior 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 membrane 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 cau...

Страница 19: ... any solution coming from the reject brine hose for about 30 seconds Then run the reject brine water hose back into the container of cleaning solution to allow recirculation of the cleaner 8 Continue to run the watermaker for about 15 minutes to assure that the cleaning solution is well circulated through the pump and membrane 9 Turn off the watermaker and allow the membrane to soak in the cleanin...

Страница 20: ...re none are missing Prepare a clean flat workspace with good lighting Have the following tools and materials available for a complete rebuild Tools Needed piston seal installation tool small scissors 1 2 open end wrench 10x loupe or magnifier 5 8 open end wrench silicone grease included in Repair Seal Kit 1 4 allen wrench clean rags medium flat blade screwdriver small standard pliers Disassembly 1...

Страница 21: ... removing it 7 From the side of the pump back plate that contained the large o ring insert a round drift of slightly smaller diameter than the hole for the piston shaft Note a small socket on an extension or a wooden dowel makes a suitable drift Tap the drift with a mallet to drive the two backup washers two piston shaft seals and the piston shaft bushing out of the pump back body See Figure R 4 8...

Страница 22: ...10x magnifier or loupe to examine the seals o rings and other small parts Stubborn rust stains and other deposits on metal parts can be cleaned with a soft metal wire brush e g stainless steel or brass Do not use polishes cleaning compounds containing abrasive materials or regular steel wire brushes During reassembly refer to Figures A 3 and A 4 in the Appendix for full size drawings and identific...

Страница 23: ... it into the bore on top of the backup washer Note that the shaft seals are flared out on one side It is important that the flared wider side should be down facing the shaft bore Install the second piston shaft seal in exactly the same way It too should be installed with its flared side facing down Next install the second white backup washer and finally the white bushing Slide the installation too...

Страница 24: ... new one from the RSK Carefully screw the intake valve seat into the check valve plate and tighten with a 5 8 open end wrench Use the eraser end of a pencil or a small allen wrench to test the operation of the intake poppet valve The poppet valve should move down slightly and then spring back up against its seat 7 Replace the two large o rings 8012947 and the two smaller o rings 8013006 on the mem...

Страница 25: ...allen wrench Do not over tighten these fasteners 13 To replace the o rings beneath the cleaning valve assembly refer to Figure R 9 Unscrew the two socket head cap screws using a 5 32 allen wrench and remove the assembly from the pump body Remove old o rings 8012594 and 8012697 and replace them with new o rings from the RSK Replace the cleaning valve assembly on the pump body and install the two ca...

Страница 26: ...ue wrench if available Hammer Cape chisel Flat chisel or medium flat blade screwdriver Grease Disassembly Disconnect the drive assembly from the pump according to the instruction in section Seal Replacement Disassembly Remove the seven 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...

Страница 27: ...icate 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 an...

Страница 28: ...rvivor 40E watermaker The information in this chart is a distillation of the experience of many users our field representatives and customer support staff Use it first if you encounter a problem If the problem persists our Customer Support department is ready to help Internal problem with spool valve or cleaning valve Install new part ...

Страница 29: ...Survivor 40E the relief valve is set to open at 1000 psi to prevent damage to the pump and membrane Product Freshwater potable water produced by the reverse osmosis process PSI pounds per square inch a unit for measuring pressure Reverse Osmosis RO a reversal of the natural osmosis process between two fluids which occurs when water is forced under pressure through a semipermeable membrane It produ...

Страница 30: ...30 Diagrams ...

Страница 31: ...31 Kit Spool Valve 8018615 8016525 ...

Страница 32: ...32 ...

Страница 33: ...33 ...

Страница 34: ...ow to the watermaker Extended Cruise Kit Recommended Part 8012606 Includes items needed for regular care and seasonal maintenance and or storage Contains 1 Repair Seal Kit 1 container Acid Cleaner 2 containers Alkaline Cleaner 1 container of Membrane Preservative and 6 30 micron prefilter elements Repair Seal Kit Recommended Part 8012610 A set of all user serviceable seals and parts for the high p...

Страница 35: ...35 Service Log Date Preserved Membrane Cleaned Membrane Other Service ...

Страница 36: ...ill Do To Correct Problems Should your PowerSurvivor 40E 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 or its representatives to make such investigation examination and tests as KATADYN deems appropriate and if requested to do so you will return the pro...

Страница 37: ...inneapolis MN 55429 USA Phone 800 755 6701 Fax 800 548 0406 www katadyn com marine katadyn com Katadyn Products Inc Pfäffikerstrasse 37 8310 Kemptthal Switzerland Phone 41 44 839 2111 Fax 41 44 839 2199 www katadyn ch info katadyn ch Print No 8012602 6 ...

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