PowerSurvivorTM 160E Endurance Series 12-Volt & 24 Volt Watermakers OWNER`S MANUAL
Thank you… for purchasing a Katadyn PowerSurvivor 160E 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.
Table of Contents System Description .................................................................................................... 2 Product Specifications ............................................................................................... 3 Energy Recovery ........................................................................................................ 4 Installation...................................................................................................................
System Description The Katadyn PowerSurvivor 160E watermaker system has several components. Refer to the System Diagram (Figure A-1) in the Appendix for an overview of the components of the system and their interconnections. Motor/Drive/Pump & Membrane 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.
Product Specifications Power Requirements: Construction: Configuration: Rate of Water Production: Feed Water Flow Rate: Pump Weight: Pump Height: Pump Length: Pump Width: Membrane Housing Dimensions: Prefilter Housing Dimensions: 22 amps @ 12 VDC* 316 Stainless Steel Pump Housing Modular 6.7 U.S. gal./hr. (25.4 liters/hr.) ±15% @ 13.8 VDC 80 U.S. gal./hr. (300 liters/hr.) 36 lbs. (16.3 kg.) 6.2" (15.2 cm.) 17.5" (44.5 cm.) 13.5" (34.3 cm.) 25" x 3.5" (64 cm. x 8.9 cm.) 12" x 6" (30 cm. x 15 cm.
Reverse osmosis desalination was first developed over three decades ago. It was a major breakthrough in desalting technology, but the original process required a lot of power. By recovering 90% of the energy lost in conventional reverse osmosis systems, we’ve made small desalinators practical, so you can have freshwater when and where you need it. Conventional Reverse Osmosis Desalination The lower left portion of Figure 2 shows the basic principle of reverse osmosis desalination.
Installation Do it right the first time and reap the rewards The PowerSurvivor 160E 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. It can also draw water when mounted several feet above the waterline of a vessel. Thus, the watermaker may be installed in almost any location and orientation. The most important part of a good installation is proper planning.
Installation Procedures Although every installation has its custom aspects, the following general instructions should be useful to the typical installer. Refer to Figure A-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. It should be mounted with the pump and drive side by side horizontally.
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 chance of air intake during heeling or rough conditions. • The thru-hull should be a minimum of 1/2" I.D.
The preferred method for collecting product freshwater is to use portable jerry jugs or a 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.
• petroleum products, such as oil, fuel, thinners, paints, paint removers, etc. • water containing chlorine (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.
If you plan to run the watermaker again within a couple of days, it can simply be turned off. If you do not intend to use your watermaker again within a week, it should be treated with membrane preservative to prevent organic growth on the membrane. Note: Organic growth is much more rapid in warm or tropical climates.
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 maintenance requirements of the PowerSurvivor 160E.
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.
1. Unscrew the prefilter housing, remove the dirty Warning: If you purchase afterprefilter element, and discard the water in the market filter elements, be certain bowl. Do not lose the large o-ring at the top of they are made from polyester fibers. the bowl. In particular, be wary of elements 2. Clean the inside surface of the prefilter bowl. made of paper materials. They look Inspect and clean the o-ring at the top of the very similar, but are designed for bowl.
1. 2. 3. 4. 5. 6. 7. Turn the Clean/Run Valve lever on the pump to its “Clean” position (see Figure 8). Fill a clean plastic container or bucket with three quarts (approximately 3 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.
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 detect such a problem is by keeping an accurate log of product freshwater output at known battery voltages. Such a practice is highly recommended.
Seal Replacement After approximately every 500 hours of use, the watermaker should be partially disassembled, cleaned, and lubricated with non-petroleum silicon grease. At that time, the seals should be inspected and replaced, as required. The standard Repair Seal Kit (included in the Extended Cruising Kit—see Kits and Accessories) is available from Katadyn and most marine retail stores. It includes a complete set of replacement seals and other components for all userserviceable parts of the watermaker.
Disassembly: 1. Before beginning disassembly, run the watermaker and stop it when the piston shaft is at 2. 3. 4. 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. Use the 11/16" open-end wrench to disconnect the two highpressure hoses (coming from the membrane housing) from the tube connectors on the check valve plate and the valve assembly.
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. Finish removing the outlet adaptor (leave the tube fitting screwed into it), reject check valve retainer, valve spring and poppet valve from their bore in the outside 6. 7. 8. 18 surface of the check valve plate.
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.
3. With the o-ring side facing down (facing the valve seat), lower one of the poppet valves 4. 5. 6. 20 (they are both identical) into the bore for the reject check valve assembly. The poppet valve should be level and in the center of the valve seat at the bottom of the bore, with the narrow stem facing up. Lower a new valve spring over the stem of the poppet valve. Next, lower a valve retainer into the bore.
7. Refer to Figure R-8. Slide one backup washer over the piston shaft and down into the shaft bore in the pump back plate. Slide one of the shaft seals over the end of the piston shaft with its flared side (the side with an embedded o-ring) facing the pump back plate. Slide it down the shaft and gently work it into the shaft bore. In-stall the second shaft seal in exactly the same way, with its flared side also facing the pump back plate.
Troubleshooting Flowchart Use the flow chart below to diagnose and solve the most common problems associated with use of the PowerSurvivor 160E 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.
Appendix A collection of useful information for the Katadyn watermaker owner Glossary Membrane Preservative a chemical used to inhibit biological growth in the reverse osmosis membrane during storage or extended periods of non-use. Filter a device which removes suspended solids from a fluid stream. A filter is not the same as a reverse osmosis membrane. Micron a metric unit of measurement equal to one thousandth of a millimeter, or one millionth of a meter.
Diagrams 24
25
26
27
Kits & Accessories Preventive Maintenance Package Part # 8012514 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.
Service Log Date Preserved M b Cleaned Membrane Other Service 29
30
WARRANTY LIMITED WARRANTY FOR POWERSURVIVOR™ 160E WATERMAKER THIS LIMITED WARRANTY AND THE REMEDY PROVIDED HEREIN ARE EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS WARRANTIES AND, UNLESS STATED HEREIN, ANY STATEMENTS OR REPRESENTATIONS MADE BY OTHER PERSON OR FIRM ARE VOID. THE DURATION OF ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SHALL BE LIMITED TO THE DURATION OF THE EXPRESS LIMITED WARRANTY. NEITHER KATADYN NORTH AMERICA, INC.
Katadyn North America 6325 Sandburg Rd, Suite 400 Minneapolis MN 55427, USA Phone: 800-755-6701 Fax: 800-548-0406 www.katadyn.com marine@katadyn.com Katadyn Products Inc. Birkenweg 4 8304 Wallisellen Switzerland Phone: +41-1-839-2111 Fax: +41-1-830-7942 www.katadyn.ch info@katadyn.
