Monday, July23, 2018

' Manual Power Survivor 40e En'

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Endurance Series
12 Volt 24 Volt
Thank you
for purchasing a Katadyn PowerSurvivor 40E watermaker It was built to rigorous 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 can be expected to
provide years of useful before installing or operating your watermaker take the short time needed to read this Users
Manual in its entirety That small investment of time will help assure many years of trouble free
operation from your system Weve worked hard to provide you with a reliable product that is
affordable compact simple to operate and easy to maintainthe rest is up to 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
Katadyn North America
9850 51st Avenue North
Minneapolis MN 55442
Phone 800 755 6701 or 763 746 3500
Fax 800 548 0406 or 763 746 3540
Website Customer Service Technical Support
800 755 6701 or 763 746 3500 Option 5
Collect Calls Accepted
Email suggest you keep a record of your Katadyn dealers name contact information and the serial number of
your watermaker in the space Name Number
Table of Description 2
Product 3
Energy Recovery 5
Installation 5
Installation DONTs 5
Plan Ahead for Manual Operation 6
Installation Procedures 6
Using your Watermaker 9
Powered 9
Manual 11
Special and 13
Pump 13
Prefilter Maintenance 14
Membrane Storage Biociding Cleaning 15
Seal Replacement 18
Flowchart 25
Glossary 25
Kits Accessories 30
Service Log 31
System Katadyn PowerSurvivor 40E watermaker system has several components Refer to the Figure A 1 in the Appendix for an overview of the components
of the system and Assembly 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 An oil bath gearbox drive assembly converts the rotary motion of the electric motor
to a powerful linear motion for driving the pump piston The pump pressurizes to approximately 800 psi pounds per square inch The high pressure
forces through a semipermeable membrane located in the membrane housing All of these have been integrated into a single compact piece of low quiet
operation and a small Assembly The prefilter assembly consists of one prefilter housing and a standard 30
micron prefilter element constructed of polyester fibers Two standard elements are included with
each system In some exceptional an optional second prefilter assembly with a 5
micron prefilter element may be needed see Kits Accessories The prefilter assembly is separate
from the pump which allows it to be installed in a convenient and accessible Two high quality plastic 3 way valves are supplied The prefilter 3 way
valve two input sources for the prefilter assembly and pump
Clean seawater during normal operation
An alternate intake line for inputting biocide or a cleaning solution
The product 3 way valve allows easy selection between the two required destinations for the A freshwater collection tank for normal
A convenient drain location for testing and discarding product freshwater
biocide and If you collect and discard the product freshwater at the same location manually directing the
output from the product freshwater hose may be the most practical approach In this case the
product 3 way valve need not be and Hardware Each PowerSurvivor 40E watermaker is shipped with hardware suf
ficient to perform a normal installation The 38 ID reinforced plastic hose is used for and reject brine The smaller 316 ID clear plastic hose is for
routing product are also hose clamps and mounting bracket hardware for the prefilter supplied Equipment Every installation represents a unique
challenge You or will have to provide
a reliable source of clean seawater for input to the prefilter 3 way valve
plumbing to an appropriate drain location for the reject brine water
a plumbing solution for your freshwater collection tank
Our Promise Every Katadyn PowerSurvivor 40E watermaker includes a three year and a long history of outstanding customer support Our reputation
for providing a with service when and where you need itis unequaled in the industry Of course
you may never need usbut if you do well be there
Product Requirements 4 amps 12 VDC 3 amps 24 316 Stainless Steel Pump Housing
Rate of Water Production 15 US galhr 56 litershr
15 138 VDC
Feed Water Flow Rate 15 US galhr 56 Weight 25 lbs 113 kg
Pump Height 6 152 cm
Pump Length 175 445 cm
Pump Width 16 405 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 draw Within a matter of hours the average current draw should
settle at the 3
Energy Recovery
The technology behind Katadyn reverse osmosis osmosis desalination was first developed over three decades ago It was a major break
through in desalting technology but the original process required a lot of power By recovering 90
of the energy lost in conventional reverse osmosis systems weve made small desalinators practical
so you can have freshwater when and where you need Reverse Osmosis lower left portion of Figure
2 shows the basic principle of
reverse osmosis saltwater is a semipermeable mem
brane at high 800 psi
pure water will pass through the
membrane but salts will not
The membrane acts as a barrier
to contaminants such as and bacteria from the pure water
When seawater is a membrane only 10
passes through as pure water In
a conventional system the
remaining waste brine stream
still under high pressure a pressure and 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 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 osmosis The waste brine stream contains up to 90 of the energy
expended By 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 pumps piston By balancing the opposing force
on the pistons front side the brine provides a power assist to the pumping operation Seawater can
then be pressurized with much less Watermakers Katadyn watermakers are simple affordable energy efficient and
easy to use and maintain The PowerSurvivor 40E represents the latest advancements in featuring an improved oil bath drive assembly an all 316
stainless steel pump body
and simplified construction for easier and less frequent Installation
Do it right the first time and reap the rewards
The PowerSurvivor 40E watermaker utilizes a low volume high pressure positive 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 may be installed in almost any location and most
important part of a good installation is proper planning Although the design and operat
ing requirements of the PowerSurvivor 40E allow much latitude for equipment location there are
several cautions and suggestions you should consider before proceeding with an
Installation DOs
When choosing a location for the watermaker assembly
5 Avoid areas with excessive heat Ambient temperatures above 105 F 40 C exceed the
ratings for the electric motor and excessive heat can damage or destroy the membrane
Note Most engine rooms get hotter than 105 F
5 Choose a dry area The motordrive assembly is not waterproof and can corrode
5 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
5 Find a location which allows comfortable access for routine inspection and servicing
In addition you should
5 Install the prefilter 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 makeplan it carefully
5 Provide a shutoff valve or seacock in the seawater intake line
5 Install a coarse strainer in the seawater intake line
5 We recommend using properly sized ring terminals and a terminal strip near the pump to
connect electric power This allows for easy testing removal and servicing when required
Installation DONTs
9 Dont use a thru hull installed high on your vessels 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
9 Dont locate the pump assembly above gear or materials that could be damaged if it leaked
9 Dont locate the pump assembly near to sleeping quarters bunks or other areas that are
normally quiet areas for yourself or crew members
Plan Ahead for Manual Operation
The PowerSurvivor 40E watermaker was never intended to be part of a vessels Abandon Its capability for manual operation is useful when normal ships
power is unavailable If
you perform a typical installation it is unlikely that you would have time to remove the abandoning ship Katadyn produces other desalinators that are
specifically designed to be
part of your survival equipment Please visit our website for information on the Survivor 35 and
Survivor 06 watermakers both of which are intended for inclusion in survival kits
Before finalizing your installation plans consider how you would manually operate your water
maker should the need arise You will require a source of seawater input and a place to drain the
reject brine as well as a product freshwater collection container Typically the watermaker will have
to be moved to a location convenient for manual pumping There are two common approaches such an arrangement
During your installation leave adequate service loops in the three hoses to allow the
watermaker to be moved to a nearby location convenient for manual operation This
arrangement eliminates the need to disconnect any of the hoses
Prepare a separate set of hoses to be used during manual operation This
approach allows the watermaker to be moved to any location for manual 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 every installation has custom aspects
the following general instructions should be
useful to the typical installer Refer to Figure A 1
in the Appendix for information on and system Install Pump After reading the comments
on the preceding pages decide on a location
for the main pumpdrive assembly It should be
mounted with the long axis of the in a horizontal position The purpose of
this requirement is to avoid two problems
If the pump develops a seawater leak
and is located directly above the drive
assembly the drive assembly andor
electric motor may be damaged Figure
3 left
If the drive assembly develops an oil leak and is located directly above the pump oil may
find its way into the pumping system and damage the membrane Figure 3 right
We recommend securely thru bolting the pumpdrive assembly to a sturdy bulkhead or corrosion resistant 14 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 Connect Electrical Power to Pump To provide 12 or 24 VDC
electric power to the mo
tor use a minimum of 16 gauge stranded copper
wire We recommend 14 gauge or larger wire
for distances over 5 6 feet Tinned wire is preferred for marine is available in most marine hardware 4 shows a typical electrical Mount Prefilter
Assembly and 3
Way Valve Lightly coat the male threads of
the middle port of the prefilter 3 way valve with a
non hardening paste type thread sealant to assure an airtight seal Note teflon
tape is not 1 Carefully thread the middle port of the prefilter 3 way valve into the IN port of the prefilter
housing Do not overtighten 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 prefilter assembly to a bulkhead
Orient it so the prefilter 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 prefilter housing to the bracket with the supplied screws One port of the
prefilter 3 way valve should project above the housing through the notch in the mounting
4 Install Seawater Intake Plumbing There are two common approaches to providing the
seawater intake circuit
Tee into an existing seawater intake eg engine cooling water or manual seawater pump
Install a dedicated thru hull for the of these should meet the following criteria
It should be at a low point on the vessels hull to minimize the chance of air intake during
heeling or rough conditions
The thru hull should be a minimum of 12 ID and possibly larger if it is a shared inlet
Note If there is the possibility that in the future you will want to upgrade to a higher
capacity unitor perhaps a second PowerSurvivor 40E to implement redundant systems
you should consider substituting 12 ID hoses and hose fittings during your initial
An easy to reach seacock should be installed on the thru hull immediately inside the hull
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 Because the flow rate and volume of seawater intake for the PowerSurvivor 40E are
both extremely low the pump can be adequately supplied by most pre existing inlets that operate at modest negative pressures such as the
cooling water inlet for an engine
or 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 Install Reject Brine Plumbing The reject brine water can be teed
into an existing scupper
or sink drain hose for draining overboard Use the 38 reinforced hose and supplied hose clamps
A tee of the correct size will have to be supplied a dedicated thru hull may be installed
at a 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 drain loca
tion and 2 a container for collecting good product no case should the product freshwater hose be permanently plumbed into the ships potable water
storage tanks 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 after biociding or chemical cleaning For that reason alone a
means must be provided for
disposing of unwanted product general we do not recommend that the output of product freshwater be routed directly into a ves
sels freshwater storage tanks 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 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 day tank which is isolated from the main storage tank Some method should be de
vised for testing the product freshwater quality at the beginning and at the end of each you are certain that the quality of the collected product
freshwater is acceptable it can to the main storage tank
Note The important concept is to always have a minimum quantity of known good potable
water available at all times either in your main storage tank or in the collection containers 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 route the product freshwater output of their watermakers many users simply run a single 316
ID 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 you prefer to have your product freshwater output routed to two separate locations for
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 Using your Watermaker
Watermakers like to be run often
Just like its predecessor the PowerSurvivor 35 the PowerSurvivor 40E watermaker can be operated
in either manual or powered mode This dual purpose feature of the watermaker 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 is easy to operate with little or no technical knowledge There are no to make or gauges to monitor By following the instructions
below and paying attention
to system maintenance you can expect years of trouble free operation
Powered Operation
Pre Run Checklist Before running your watermaker always check the following
5 Any valves in the seawater intake reject brine and product freshwater lines should be
5 Check for bad rotten egg smell from the water in the prefilter assembly Replace the
element and clean the housing as required Also check for foul water in any in line
coarse strainer
5 Assure that the product freshwater output is routed to a drain for 5 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
5 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 eg most dock water
silty waterwater contaminated by fine hard suspended particulates
putrid water red tides or any seawater that smells or looks contaminated
5 Make sure the cleaning valve lever on the pump is in the down or run position
It is important to remember that the watermaker is designed to process clean open ocean seawater
Any departure from that standard for your seawater intake runs the risk of causing excessive wear or
damage to internal pump parts andor the vulnerable reverse osmosis membrane or 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 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 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
Dont sail away without testing a new 9
Startup and Run Turn on the electric power to the watermaker If there is air in the seawater in
take plumbing the pump may require several minutes to draw up enough water to fill the housing pump and membrane housing Since the pump is self
priming there is no need to
prime the system prior to after the hoses and prefilter housing have filled with seawater reject brine water should from the pump When all air has
been forced out of the system which may take more product freshwater should begin to flow from the hose barb at the end of the
membrane housing Test and reject the product freshwater until the water quality is good quality water is flowing continuously direct the product
freshwater output to collection tank Continue to run until the desired quantity of water has been and Storage When the desired amount of water has
been produced the 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 ships po
table 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 biocide to pre
vent bacterial growth on the membrane
Note Bacterial growth is much more rapid in warm or tropical climates If using the watermaker
in a tropical environment we recommend a biocide treatment if the watermaker will not be run
again within the next three days
At the end of a watermaker run check the condition of water in the prefilter housing If there is evi
dence of trapped material clean the prefilter housing and install a clean prefilter Manual
operation of the PowerSurvivor 40E is
useful if the ships electric power supply fails Use
the following instructions to convert your water
maker to manual operation
1 Jog run the watermaker and stop it when the
piston has traveled the maximum distance
away from the pump toward the drive
2 If necessary disconnect the seawater intake
reject brine and product freshwater hoses
Figure 5 and move the watermaker to a
location convenient for manual operation
3 Slide the black rubber boot on the piston shaft
toward the pump to expose the coupling pin Pull
or tap out the coupling pin which connects the
pump piston shaft to the drive slider shaft Figure
6 The pin is a fairly loose fit and should come
out easily Be careful not to lose it
4 Using a 12 wrench remove the four hex 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 pump body Do not overtighten these nuts
6 Remove the clevis pin from the free end of the linkage attached to the handle assembly Line up
the holes in the handle linkage with the hole in the piston shaft Insert the clevis pin through the
linkage and the piston shaft and secure with a split ring Figure 8
7 Orient the hole in the handle located above the linkages between the holes in the handle
bracket Insert the second clevis pin through the holes and secure with the split ring Figure 9
8 If not already attached connect the seawater intake reject brine and product freshwater hoses
to be used for manual 11
9 Operate the pump handle back and forth through its
full range of travel in both directions Pump at a rate
of approximately one complete cycle every two
seconds one second in each direction This is about
the same rate at which the pump is driven by the
motor during powered operation Do not pump too
10 To return the watermaker to powered operation
reverse the above procedure When coupling the
pump piston shaft to the drive shaft align the hole in
the piston shaft with the mating hole in the drive shaft
insert the coupling pin and slide the rubber boot over the pin to hold it in place Then secure the
drive assembly to the pump with the four hex nuts Tighten the nuts evenly Do not Special
freshwater output volume will vary on the salinity and temperature of the
seawater being processed Figure 10 illustrates 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 not removed
during If you must regularly process such water consider installing a Silt
Reduction Kit see Kits 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
seawater 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 that cause
the red tide it can not remove all of the chemical pollutants caused by large scale biological
Therefore we do not recommend using the watermaker to process seawater when
a red tide is Maintenance and Service
A little love goes a long way
Weve worked hard to design a product that is simple to operate and maintain However to the few maintenance requirements of this equipment is
critically important This section of
the Owners Manual describes both the routine and the long term maintenance requirements of 40E
Much of our knowledge of maintenance requirements watermaker performance and 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 properly installed the main watermaker pump and drive assembly requires little attention You
should regularly inspect the equipment and check for any leakage of seawater or oil leaks from the
drive assembly Any leakage is a sign of a problem and should be certain that the watermaker remains dry
Exposure to saltwater can cause rapid corrosion
of the drive assembly andor damage to the
electric motor Keep all electrical dry and tight
After every 1000 hours of use
replace the seals in the pump See below After approximately 5000
hours of use have the electric motor inspected
for brush wear and commutator Piston Shaft Lubrication It is ex
tremely important to lubricate the pump piston
shaft periodically especially after cleaning the
membrane The piston shaft is visible at the side
of the drive assembly where the pump connects
to the drive see Figure 11 Jog run and stop it when the piston shaft is
at its point of farthest travel away from the pump ie towards the drive assembly Assure that is off and can not be started accidentally while you
work Clean the exposed piston shaft
with a clean rag and lubricate the shaft with non petroleum silicon
Prefilter 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 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 rather 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 are airtight especially the connections at the prefilter Be aware that a stable air gap at the top of the
prefilter housing is not uncommon and
doesnt necessarily mean that air is getting to the pump itself
Bad smelling Product Freshwater The purpose of the prefilter assembly is to trap in the intake seawater that are larger than 30
microns A coarse strainer if the same chore for contaminants of larger size In each case trapped material remains in
the prefilter housing or strainer bowl until removed
Much of the trapped material is organic plankton seaweeds and flotsam of all types After a
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 like rotten eggs
Two main factors affect the speed with which these products of organic decomposition a watermaker system 1 the ambient temperature and 2 the quantity
of trapped ma
terial We realize that many users of our equipment run their watermakers in near shore anchored The amount of trapped material is usually high in
such locations and the will require more frequent attention Moreover the high ambient temperatures in greatly accelerate the rate of such Users in
temperate climate areas or open ocean seawater during offshore passages are less likely to require the Maintenance At the end of each run
of your watermaker examine the 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 Warning If you purchase after
market filter elements be certain they
element and discard the water in the bowl Do not lose
are made from polyester fibers In
the large o ring at the top of the bowl
particular be wary of elements made of
2 Clean the inside surface of the prefilter bowl Inspect paper materials They look very similar
and clean the o ring at the top of the bowl Lubricate the but are designed for use with other
o ring and the threads of the prefilter housing with a types of water purification systems and
light coat of silicon grease are harmful to the membranes and high
3 Install a clean filter element and screw the prefilter bowl pressure pumps used in reverse osmosis
watermakers Be certain you purchase
back on securely
only polyester filters of 30 micron or
finer If the watermaker will not be used within the next three days treat it with biocide see Biocide
Treatment below
5 Tie a line through the center of the dirty filter element and if underway tow it behind the
vessel for a few minutes If the vessel is anchored hang the dirty filter over the side of the boat
so that it is underwater and jerk it up and down a few times to dislodge the 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
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 Storage Biociding Cleaning
The reverse osmosis membrane inside the membrane housing is an expensive and delicate compo
nent of your system When properly cared for it can be expected to last for several thousand hours
of use Improper use maintenance or handling can damage or destroy the membrane very Treatment The primary purpose of a bio
cide treatment is to kill biological growth and bacteria Warning Be sure to follow the
that are present inside the membrane It also functions flushing procedures described below to
as a membrane wetting agent for extended storage ensure that the biocide solution does not
Over time bacteria can multiply and adhere to the get into the freshwater surface thus gradually decreasing When the watermaker is not to be used
an extended period of time it should be biocided A biocide treatment is effective for year storage temperature 25C77F If longer storage is required
the biocide be repeated every year
In temperate climates the maximum period of time the watermaker should be stored is approximately one week
In hot or tropical climates should be biocided if it
will not be used within the next three
days Follow these directions to
perform a biocide treatment of Lift the lever on the cleaning valve
on the pump to place it in its clean
or up position see Figure 12
2 Fill a clean plastic container or
bucket with two quarts liters of clean water Freshwater but clean seawater may be
used if freshwater is not Never use chlorinated freshwater This may damage the
3 Mix two spoonful 20 grams or 1 by weight of dry Biocide chemical with the
water in the container and stir until completely dissolved
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 316 alter
nate intake hose with the strainer attached into the container of biocide solution
6 Turn on the watermaker and run it until almost all of the biocide has been drawn from the
container and foamy biocide 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 membrane freezes it must be slowly 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 biocide procedure with freshwater as soon as
possible Repeat the above procedure at least once a year if the watermaker is not being the Membrane We do not recommend casual or regular cleaning
of the membrane in the should only be done when needed Under normal when only open ocean seawater is being processed cleaning
the membrane should rarely or never be necessary Proper biocide Note Buildup of de
treatments prior to extended periods of non use will prevent biological posits and reduction in
growth on the membrane surface Under these conditions and with proper product freshwater flow
care a membrane can be used for years without requiring a cleaning usually take place
gradually over the membrane is only necessary if contaminants are deposited
periods of time Sudden
on and adhere to the membrane surface in sufficient amounts to affect
reduction or stopping of
the output of product freshwater Usually this condition also causes battery
product water output is
current to increase There are two main types of such deposits and a
rarely caused by a chemical cleaner is needed for each type
Organic caused by
processing brackish water or failure to properly store a membrane during
extended periods of non use Use Alkaline Cleaner
Mineral Scalecaused by mineral impurities in the intake water
supply Use Acid Cleaner
The only indication that a membrane might benefit from cleaning is a substantial reduction in the
quantity of product freshwater output all other factors being normal eg battery voltage 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 you have determined that your membrane needs cleaning and you know the
type of 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
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 Lift the lever on the cleaning valve on the pump to place it in its clean
or up position see
Figure 12
2 Discard any dirty seawater in the prefilter assembly Clean the housing and install a clean
3 Fill a clean plastic container or bucket with one gallon 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 Mix four spoonful 40 grams of either Acid Cleaner or Alkaline
Cleaner not both with the water in the container and stir until the cleaner is completely
dissolved The water should be warm but not over 120 F 49 C
5 Turn the lever on the prefilter 3 way valve to the alternate intake position Run the 316
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
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
9 Turn off the watermaker and allow the membrane to soak in the cleaning solution for 5 to 10
hours or overnight For severe fouling repeat steps 8 and 9 of this When the soaking is finished remove the reject brine hose from the cleaning
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 Continue to run the watermaker and recirculate the cleaning solution for another 30 to 60
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 strainer 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 biocide 17
Seal approximately every 1000 hours of use the watermaker should be partially 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 Kitsee
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 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
We recommend that you save old seals Most of them are still useable and could be kept in a kit for
emergency Before beginning to disassemble the watermaker read the following Have a Repair Seal Kit on hand Refer to the drawings in Figures A 2
A 3 and A 4
in the Appendix to identify the major components of the pump and the parts contained in the kit to
make sure none are missing Prepare a clean flat workspace with good lighting Have the and materials available for a complete Needed
piston seal installation tool small scissors
12 open end wrench 10x loupe or magnifier
58 open end wrench silicone grease
14 allen wrench included in Repair Seal Kit
medium flat blade screwdriver clean rags
small standard Before beginning disassembly run the watermaker and stop it when the piston shaft is at its
farthest point of travel away from the pump ie toward the drive assembly This provides
enough room for sliding the rubber boot toward the pump in Step 3
2 Disconnect the pump from the drive assembly by first removing the two hex nuts and 5
sockethead capscrews from the check valve plate using the 12 open end wrench and 14
allen wrench Also remove the two hex nuts securing the pump back plate to the drive assembly
See Figure R 1
3 Slide the black rubber boot on the
piston shaft toward the pump to
expose the drive shaft coupling
pin Use a small allen wrench or
similar tool to push the coupling
pin out of the drive shaft see
Figure 6 Be aware that the
coupling pin fits loosely in the
drive shaft and may fall out when
the rubber boot is removed Be
careful not to lose it Separate the
drive assembly from the pump
and set the drive assembly aside
4 Remove the two 3 socket head
capscrews using a 14 allen
wrench Separate the pump back
plate and piston assembly from
the pump body see Figure R 2
5 If the piston assembly remained
with the pump back plate when it
was removed pull the piston out
of the back plate and set it aside
If the piston stayed in the main
pump body pull it out of the
cylinder If the piston assembly is
difficult to remove from the pump
body insert a small allen wrench
or Phillips screwdriver through the
coupling pin hole This will
provide a t handle with a better
grip for extracting the piston assembly Be aware not to
damage the surface of the piston shaft
6 Remove the large o ring 8012588 from its groove in the
side of the pump back plate that faces the pump body
Remove the wiper block and spacer if present from the
pump back plate Use needle nosed pliers to pull the old
wiper block seal out of the wiper block See Figure R 3
Note This seal is usually damaged during removal Be sure
you have a replacement on hand before 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 Remove the remaining two 34 sockethead capscrews
from the check valve plate using a 14 allen wrench
Separate the check valve plate from the pump body If it
is difficult to remove try rotating the check valve plate
90 This provides a better grip for pulling the check
valve plate from the pump body
9 After the check valve plate has been separated from the
pump body the membrane tube plug will remain in
either the check valve plate or the pump end of the
membrane housing Use one of the following
procedures to remove it
A If the membrane tube plug remains in the membrane housing insert a hard thin edge
eg a dull pocket knife between the tube plug and the fiberglass molding of the
membrane housing Work the blade sideways to pry the tube plug out slightly until there is
enough of a gap between the tube plug body and the membrane housing to insert a flat
blade screwdriver Then use two screwdrivers on opposite sides of the tube plug to carefully
work it out of the membrane housing Avoid gouging or damaging the membrane housing
or the tube plug
B If the membrane tube plug remains in the check valve plate use a thin edge andor
flat blade screwdrivers on opposite sides of the membrane tube plug to carefully pry the
plug out of the check valve plate Avoid damaging the membrane tube plug
10 Disassemble the valves in the check valve
plate see Figure R 5 Use a 58 open
end wrench to unscrew the intake valve
seat Remove the intake poppet valve and
its spring If necessary use needle nosed
pliers to remove the poppet valve
retainer Then use the pliers to lift out the
reject poppet valve and its seat Grip the
x shaped ribs of the reject poppet valve
and pull straight up The seat will be
pulled out along with the valve After the
reject poppet valve and its seat have
been removed retrieve the reject poppet
valve spring from the bottom of the check
valve plate cavity
This completes the disassembly of all parts of the 40E 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 other deposits
on metal parts can be cleaned with a soft metal wire brush eg stainless steel or brass Do not use
polishes cleaning compounds containing abrasive materials or regular steel wire brushes refer to Figures A 3 and A 4 in the Appendix for full size
drawings and of
the components included in the Repair Seal Kit
In the following procedure for reassembling the watermaker it is assumed that all parts have been
cleaned and that all o rings seals and mating surfaces have been lightly lubricated with non
petroleum silicon grease supplied with the Repair Seal Kit References to the Repair Seal Kit will to RSK
Warning Use only non petroleum silicon 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 silicon etcsuch products
could also contain petroleum based components An ample supply of silicon grease is included
with each RSK
1 Make a note of the correct orientation of the old cup ring and PIP seal and then remove them
from the piston assembly Since these components are made of rather stiff rubber it is usually
easier to cut them off Use a small screwdriver to wedge under the cup seal and pry it up While
holding it up cut it with a small
pair of scissors Repeat this process
for the PIP ring
2 Refer to Figure R 6 during the
following procedure Place the
piston assembly on a flat stable
surface with the shaft pointing up
Slide the installation tool provided
in the RSK over the piston shaft
with the wide end down Lubricate
the new PIP ring cup seal and the
installation tool with silicon grease
With the grooved side facing up
slide the PIP ring down the
installation 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 ie the grooved
sides of the PIP ring and the cup seal should be facing
each other When finished with the remove the installation tool from the piston shaft
3 Lightly lubricate the cylinder in the pump body with
silicon grease Slide the finished piston assembly
shaft first into the pump body from the side of the
pump body that faces the check valve plate Install the
large o ring 8012588 into its groove in the pump
back plate and lower the pump back plate over the
piston shaft The side of the back plate with the large
o ring should be facing the pump body See Figure
4 Refer to Figure R 4 Slide one of the white backup washers over the piston shaft and press it into
its bore in the pump back plate Next slide one of the two black rubber piston shaft seals over
the piston shaft and work 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 tool used in Step 2 above over the piston shaft with the
narrow end facing the white bushing Use the installation tool to press the shaft washers seals
and bushing all the way into the bore When finished the outside end of the bushing should be
flush with the bore opening
5 Install a new wiper block seal into the wiper block The seal must be pressed into a groove inside
the bore in the middle of the wiper block with the narrower side of the seal facing outwards
Form the seal into an oval shape by squeezing it between your fingers and press one side of the
seal into the groove in the wiper block Once an edge of the seal is started into the groove
carefully work the rest of the seal into place After the seal has been installed slide the spacer if
present and wiper block onto the piston shaft The side of the wiper block from which the seal
was installed should be facing outward Refer to Figure R 3
6 Prepare the check valve plate for reassembly by installing the new poppet valves Note that both
the intake and reject poppet valves and valve springs are identical Refer to Figure R 5 during the
following procedure
A Lower a new poppet valve spring into the bottom of the bore in the check valve plate
Use your little finger or the eraser end of a pencil to press it into its seat It is designed to
be a light press fit and when installed correctly it should stay vertical in place during the
next step
B Use needle nosed pliers to carefully lower one of the new poppet valves into the bore
The poppet valve should rest on top of the spring with the poppets cross side facing up
C Lower the new reject valve seat into the bore and use a finger to press it down as far
as it will go Note that the hole in the middle of the valve seat has a beveled edge on one
side The side with the beveled edge must face downward ie it must face the poppet
valve When properly installed the valve seat should fit neatly over the poppet valve Test
the poppet valve by pressing it with the eraser end of a pencil It should move up and
down slightly and seat squarely in the valve seat
D Locate the small depression in the center of one end of the poppet valve retainer and
press the second valve spring into the depression It was designed as a light press fit and
should stay in place after being installed Then lower the poppet valve retainer into the
bore in the check valve plate with the spring facing upward
E Lower the second poppet valve into the bore in the check valve plate and rest it
carefully on top of the valve spring
F Remove the old o ring 8013015 from the intake valve seat and replace it with the
new one from the RSK Carefully screw the intake valve seat into the check valve plate and
tighten with a 58 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 Replace the two large o rings 8012947 and the two smaller o rings 8013006 on the
membrane tube plug with new o rings from the RSK Insert the small end of the membrane tube
plug into the exposed hole in the membrane element which should have been left installed in the
membrane housing and press the tube plug into the membrane housing as far as it will go The
ridge on the outside of the tube plug should be flush against the end of the membrane housing
8 Press the piston as far as it will go toward the pump back plate Install a new o ring 8012588
into its groove in the check valve plate
9 Press the check valve plate over the exposed end of the membrane tube plug If necessary rotate
the check valve plate to align it accurately with the pump body and install the 34 and the 3
sockethead capscrews Check that the
two large o rings 8012588 in the
check valve plate and the pump back
plate are still seated in their grooves
and then tighten the four capscrews
evenly with a 14 allen wrench
10 Slide the two 5 sockethead capscrews
through the holes in the check valve
plate and the back plate Slide the
rubber boot onto the piston shaft See
Figure R 8
11 Insert a small screwdriver or an allen
wrench through the hole in the piston
shaft and rotate the shaft to align its
hole with the hole in the slider shaft of the drive assembly When they are aligned slide the holes
in the drive assembly bracket over the studs projecting from the pump back plate Insert the
coupling pin through the aligned holes in the slider shaft and piston shaft Push the rubber boot
over the coupling pin to hold it in place
12 Install the four hex nuts on the studs
projecting from the pump back plate
through the drive assembly bracket
and tighten evenly with a 12
open end wrench and 14 allen
wrench Do not overtighten these
To replace the o rings beneath the
cleaning valve assembly refer to
Figure R 9 Unscrew the two
sockethead capscrews using a
532 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 capscrews This completes the procedure for reassembly of the
watermaker When operation is commenced again carefully inspect the watermaker for proper
operation and any leaks or other signs of incorrect
Use the flow chart below to diagnose and solve the most common problems associated with use of
the PowerSurvivor 40E watermaker The information in this chart is a distillation of the experience of
many users our field and customer support staff Use it first if you encounter a
problem If the problem persists our Customer Support department is ready to
A collection of useful information for the Katadyn watermaker owner
a chemical used to inhibit biological growth in the reverse osmosis membrane 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 a metric unit of measurement equal to one thousandth of a millimeter or one millionth of the process of diffusion between
two water sources through a resulting in both water sources striving to reach an equilibrium in the of
dissolved a slang term for the process of flushing the membrane with biocide solution see suitable for drinking especially water With regard
to a desalinator it is as water with 1500 ppm or lower of dissolved solids that is relatively free of parts per million Used as a measure of the
quantities of substances dissolved in a filter placed in a desalinator system to remove suspended solids from the feed water
before it reaches the high pressure pump and reverse osmosis Relief Valve a valve that relieves pressure in a system to prevent damage to In
the PowerSurvivor 40E the relief valve is set to open at 1000 psi to prevent damage
to the pump and Freshwater potable water produced by the reverse osmosis process
PSI pounds per square incha unit for measuring 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 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 33000 ppm of sodium a device such as an o ring used to prevent fluid leakage between two system the of some materials eg a
reverse osmosis membrane that
makes them relatively porous to some substances while blocking the passage of others Unlike semipermeable membranes usually operate at the molecular
or atomic level allowing much
finer filtering than simple mechanical filters
TDS Total Dissolved Solidsa type of measure commonly used to indicate the purity of expressed in ppms A standard TDS meter measures only the
electrical conductivity of the
water being tested Therefore it is only able to measure dissolved substances that are ionized in
solution eg sea salt In particular they do not indicate the presence of non ionized as bacteria viruses and many other soluble chemicals
Kits Maintenance Package
Part 8012607
An expanded cruise kit which includes all components of the Extended Cruise Kit plus a Kit This kit is strongly recommended for extended cruising
and variable water Reduction Kit
Part 8012859
This kit is intended to protect the high pressure pump and reverse osmosis membrane from 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 water
maker Also included is a 1 amp boost pump to ensure adequate intake flow to the Cruise Kit items needed for regular care and seasonal maintenance
andor storage Contains 1 Re
pair Seal Kit 1 container Acid Cleaner 2 containers Alkaline Cleaner 1 container
of Biocide and 6 30 micron prefilter Seal Kit 8012610
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 1000 hours of Storage Chemicals
Acid Cleaner 8 oz Part 8013608 1
Alkaline Cleaner 8 oz Part 8013615 1
Biocide 8 oz Part 8013609 1
Note You may order parts and kits through our retailers or from Katadyn North America directly
at 800 755 6701 If ordering directly youll need to provide detailed shipping instructions as well
as credit card QUESTIONS CALL 800 755 6701
Service Log
Date Used Biocide Cleaned Membrane Other Service
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 or exclusions may not apply to you
What Is Covered KATADYN warrants to the original purchaser that the PowerSurvivor enclosed with this Limited Warranty conforms to the and is
free from defects in workmanship and material for a period of three years from the date of If the original purchaser transfers the PowerSurvivor 40E
Watermaker to another person
this Limited Warranty will not be enforceable by the person to whom the product is We Will Do To Correct Problems Should your PowerSurvivor 40E
Watermaker during this period you must notify KATADYN at 9850 51st Avenue North 55442 or an authorized distributor or dealer of KATADYN You must
permit KATADYN or to make such examination and tests as KATADYN deems if requested to do so you will return the product to the factory at the
address set forth 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 40E Watermaker product for warranty service are your 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 Watermaker can be damaged by oil grease chlorine and certain other
organic or It must be cleaned carefully after use and requires periodic maintenance Failure to
observe the precautions listed in the Users Manual may constitute improper use or maintenance of
the product and causes this Limited Warranty not to apply This Limited Warranty does not 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
Katadyn North America
9850 51 Avenue MN 55442 USA
Phone 800 755 6701
Fax 800 548 0406
Katadyn Products Inc
Birkenweg 4
8304 Wallisellen
Phone 41 1 839 2111
Fax 41 1 830 7942
Print No 80126020

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The information on this web site has not been checked for accuracy. It is for entertainment purposes only and should be independently verified before using for any other reason. There are five sources. 1) Documents and manuals from a variety of sources. These have not been checked for accuracy and in many cases have not even been read by anyone associated with I have no idea of they are useful or accurate, I leave that to the reader. 2) Articles others have written and submitted. If you have questions on these, please contact the author. 3) Articles that represent my personal opinions. These are intended to promote thought and for entertainment. These are not intended to be fact, they are my opinions. 4) Small programs that generate result presented on a web page. Like any computer program, these may and in some cases do have errors. Almost all of these also make simplifying assumptions so they are not totally accurate even if there are no errors. Please verify all results. 5) Weather information is from numerious of sources and is presented automatically. It is not checked for accuracy either by anyone at or by the source which is typically the US Government. See the NOAA web site for their disclaimer. Finally, tide and current data on this site is from 2007 and 2008 data bases, which may contain even older data. Changes in harbors due to building or dredging change tides and currents and for that reason many of the locations presented are no longer supported by newer data bases. For example, there is very little tidal current data in newer data bases so current data is likely wrong to some extent. This data is NOT FOR NAVIGATION. See the XTide disclaimer for details. In addition, tide and current are influenced by storms, river flow, and other factors beyond the ability of any predictive program.