' Manual Power Survivor 40e En'
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for purchasing a Katadyn PowerSurvivor 40E 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 can be expected to provide years of useful service before installing or operating your watermaker take the short time needed to read this Users in its entirety That small investment of time will help assure many years of troublefree 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 you 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 tollfree phone numbers or visit our website at wwwkatadyncom Avenue North Minneapolis MN 55442 8007556701 or Option 5 International Collect Calls AcceptedWe suggest you keep a record of your Katadyn dealers name contact information and the serial number of your watermaker in the space below Dealer Name Address Serial Number System Installation DONTsanual your Watermaker9 Powered Operation Manual Operation Special and Service13 Pump Maintenance Prefilter Maintenance Membrane Storage Biociding Cleaning Seal Replacement Glossary Diagrams Kits Accessories Service Log 40E watermaker system has several components Refer to the System Figure A1 in the for an overview of the components of the system and their AssemblyAt the heart of the watermaker system is a highpressure pump The pump is powered by a reliable 12 or 24C electric motor An oilbath gearbox drive the rotary motion of the electric motor to a powerful reciprocating linear motion for driving the pump piston The pump pressurizes input seawater to approximately 800 psi pounds per square inchigh pressure forces product freshwater through a semipermeable membrane located in the membrane housing All of these main components have been integrated into a single compact piece of equipmentwith low power The prefilter assembly consists of one prefilter housing and a standard prefilter element constructed of fibers Two standard elements are included with each system In some exceptional circumstances an optional second prefilter assembly with a prefilter element may be needed see Kits AccessoriesThe prefilter assembly is separate from the pump which allows it to be installed in a convenient and accessible location Two highquality plastic 3way valves are supplied The prefilter 3way valve selects between two input sources for the and pump Clean seawater during normal operation An alternate intake line for inputting biocide or a cleaning solution The product 3way 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 freshwater biocide and cleaners 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 Hoses and 40E watermaker is shipped with hardware sufficient to perform a normal installation The 38 ID reinforced plastic hose is used for seawater intake and reject brine The smaller 316 ID clear plastic hose is for routing product freshwater acket hardware for the prefilter assembly EquipmentEvery installation represents a unique challenge You or your installer will have to provide a reliable source of clean seawater for input to the prefilter 3way valve plumbing to an appropriate drain location for the reject brine water a plumbing solution for 40E watermaker includes a threeyear factory warranty and a long history of outstanding customer support Our reputation for providing a quality productalong with service when and where you need itis unequaled in the industry Of course 4 amps 12 VDC 3 amps 24 VDC 316 Stainless Steel Pump Housing 15 US galhr 56 litershr 15 138 VDC 15 US galhr 56 litershr 25 lbs 113 kg 6 152 cm 175 445 cm 16 405 cm 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 should settle at the above specification Energy Recovery 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 weve 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 shows the basic principle of reverse osmosis desalination When saltwater is forced through a semipermeable membrane at high enough 800 psipure water will pass through the membrane but salts will not The membrane acts as a barrier to contaminants such as salts viruses and bacteria separating them from the pure water When seawater is forced against a membrane only 10 passes through as pure water In a conventional system the remaining waste brine stream still under high pressure passes through a valve 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 is Energy Recovery Makes It PossibleThe upper right portion of Figure 2 illustrates how Katadyn systems are configured to recover and effectively reuse the energy wasted in conventional reverse osmosis The waste brine stream contains up to 90 of the energy expended By recovering this energy we are able to dramatically reduce the power needed to desalt seawater To do this we developed and patented a high pressure energyrecovery pump It recycles the highpressure 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 effort Katadyn watermakers are simple affordable energy efficient and easy to use and maintain The PowerSurvivor 40E represents the latest advancements in watermaker technology featuring an improved oilbath drive assembly an all316 stainless steel pump body and simplified construction for easier and less frequent maintenance PowerSurvivor 40E watermaker utilizes a lowvolume highpressure positive displacement pump Unlike the centrifugal pumps found in some systems a positive displacement pump is selfpriming It can also draw water when mounted several feet above the waterline of a vessel Thus the watermaker may be installed in any location and orientation The most important part of a good installation is proper planning Although the design and operating 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 When choosing a location for the watermaker assembly Avoid areas with excessive heat Ambient temperatures above 105 40 Ceed the ratings for the electric motor and excessive heat can damage or destroy the membrane Most engine rooms get hotter than 105 FChoose a dry area The motordrive assembly is not waterproof and can corrode Choose an area free of fuel vapors The electric motor is not vaporproof and should not be operated if explosive or flammable materials are presentccess for routine inspection and servicing In addition you should Install the prefilter assembly in an easily accessible location It needs regular sometimes spection and maintenance For ease of routine maintenance the choice for this ant decision you will makeplan it carefully Provide a shutoff valve or seacock in the seawater intake line Install a coarse strainer in the seawater intake line We recommend using properlysized ring terminals and a terminal strip near the pump to connect electric power This allows for easy testing removal and servicing when required Dont use a thruhull 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 thruhull to be out of the water allowing air into the intake system A rolling Dont locate the pump assembly above gear or materials that could be damaged if it leaked Dont locate the pump assembly near to sleeping quarters bunks or other areas that are normally quiet areas for yourself or crew members PowerSurvivor 40E watermaker was never intended to be part of a vessels Abandon Ship equipment 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 watermaker when 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 watermaker 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 to implementing 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 approach allows the watermaker to be moved 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 Although every installation has custom aspects the following general instructions should be useful to the typical installer Refer to Figure A1 on parts identification and system connections 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 membrane housing 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 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 We recommend securely thrubolting the pumpdrive assembly to a sturdy bulkhead or platform using 14 fasteners with flat washers See Figure A1ick a location that allows ample space for routing the required hoses and electrical wires to the pump and motor To provide 12 or 24tor use a minimum of 16gauge stranded copper wire We recommend or larger for distances over 56 feet Tinned stranded copper wire is preferred for marine installations and is available in most marine hardware stores Figure 4 shows a typical electrical power configuration 3 Mount Prefilter Assembly and 3Lightly coat the male threads of the middle port of the prefilter 3way valve with a nonhardening pastetype thread sealant eg airtight seal teflon Carefully thread the middle port of the prefilter 3way valve into the IN port of the prefilter housing Do not overtighten this connection When assembled correctly the long axis of the 3way valve should be vertical See Fasten the supplied rightangled 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 thrubolted with hardware Screw the top of the prefilter housing to the bracket with the supplied screws One port of the prefilter 3way valve should project above the housing through the notch in the mounting 4 Install Seawater Intake PlumbingThere are two common approaches to providing the seawater intake circuit Tee into an existing seawater intake engine cooling water or manual seawater pump ould meet the following criteria It should be at a low point on the vessels hull to minimize the chance of air intake during The thruhull should be a minimum of 12 ID and possibly larger if it is a shared inlet 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 systemsyou should consider substituting 12 ID hoses and hose fittings during your initial An easytoreach seacock should be installed on the thruhull 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 are both extremely low the pump can be adequately supplied by most preexisting intakeseven inlets that operate at modest negative pressures such as the cooling water inlet for an engine or generator When teeing into an existing seawater supply we recommend installing a separate seacock or valve dependently control the supply to the watermaker 5 Install Reject Brine PlumbingThe 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 Alternatively a dedicated thruhull may be installed at a convenient location In this case we recomm6 Install Product Freshwater PlumbingYour product freshwater plumbing design should allow for both saving and discarding of product freshwater This normally requires 1 drain location and 2a container for colleIn no case should the product freshwater hose be permanently plumbed into the ships potable water storage tanksing a way to reject the product freshwater when necessary Note that product freshwater should be rejected during the first few minutes after startup and especially after biociding or chemical cleaning For that reason alone a means must be provided for disposing of unwanted product freshwater In general we do not recommend that the output of product freshwater be routed directly into a vessels freshwater storage tanksany reason the watermaker should fail during operation there is a good chance that the entire supply of freshwater in the storage tank could become contaminated by unpurified seawater This is especially important if you will be making extended offshore passages and depending on your watermaker for your The preferred method for collecting product freshwater is to use portable 5 or 6gallon 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 The important concept is to always have a minimum quantity of knowngood potable water available at all times either in your main storage tank or in the collection containersThe 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 knowngood potable water on board in one or both To 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 Should you prefer to have your product freshwater output routed to two separate locations for and collection the watermaker system includes a product 3way valve for use in your for a routing diagram Watermakers like to be run often Just like its predecessor the PowerSurvivor 35 the watermaker can be operated in either manual or mode This dualpurpose feature of the watermaker has its roots in our original products which were designed as 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 complicated adjustments to make or gauges to monitor By following the instructions below and paying attention to system maintenance you can expect years of troublefree operation Before running your watermaker always check the following Any valves in the seawater intake reject brine and product freshwater lines should be Check for bad rotten eggter in the prefilter assembly Replace the element and clean the housing as required Also check for foul water in any inline coarse strainer Assure that the product freshwater output is routed to a drain for 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 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 water eg most dock water silty waterwater contaminated by putrid water red tides or any seawater that smells or looks contaminated 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 openocean seawaterAny 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 producing 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 seepagesstill the chance of such things happening is normally small On the other hand regularly running a watermaker in an enclosed marina or harbor runs a much higher risk of harmful contamination If you need to test a new installation while in a marina or harbor monitor the water quality around your vessel carefully while testing Most of the time you should be able to run the watermaker safely for enough time to check out the system Dont sail away without testing a new installation Turn on the electric power to the watermaker If there is air in the seawater intake plumbing the pump may require several minutes to draw up enough water to fill the hoses prefilter housing pump and membrane housing Since the pump is selfpriming there is no need to prime the system prior to running Shortly after the hoses and prefilter housing have filled with seawater reject brine water should start discharging from the pump When all air has been forced out of the system which may take several minutes moreproduct 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 acceptable When good quality water is flowing continuously direct the product freshwater output to your freshwater collection tank Continue to run until the desired quantity of water has been produced Shutdown and StorageWhen 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 ships potable water storage tank If you plan to run the watermaker again within a couple of days it can simply be turned off If you do not intend to use your watermaker again within a week it should be treated with biocide to prevent bacterial growth on the membrane 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 At the end of a watermaker run check the condition of water in the prefilter housing If there is evidence of trapped material clean the prefilter housing and install a clean prefilter element Manual operation of the is useful if the ships electric power supply fails Use the following instructions to convert your watermaker to manual operation Jog run the watermaker and stop it when the piston has traveled the maximum distance away from the pump toward the drive assembly If necessary disconnect the seawater intake reject brine and product freshwater hoses Figure 5e watermaker to a location convenient for manual operation 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 ose fit and should come Using a 12 wrench remove the four hex nuts holding the pump body to the drive assembly from the pump body and set the drive unit aside Remove the black rubber boot from the piston shaft Align the holes in the handle bracket with the two pump bolts that are located above the piston Figure 7Slide 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 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 Orient the hole in the handle located above the the holes in the handle bracket Insert the second clevis pin through the holes and secure with the split ring If not already attached connect the seawater intake reject brine and product freshwater hoses to be used for manual operation 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 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 overtighten Product freshwater output volume will vary somewhat depending on the salinity and temperature of the seawater being processed Figure 10 illustrates the relationship between feed water temperature and the quantity of product water Factors which are known to affect output or performance include High Salinity will decrease output slightly and lead to a modest increase in current draw Effectively the pump must work harder to remove a larger percentage of dissolved solids from the seawater Cold Water will have an effect similar to that of Silt or Sand can damage the membrane and internal pump components if not removed during prefiltration If you must regularly process such water consider installing a Silt ts 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 remove those impurities and 2may damage or destroy the membrane See Maintenance and Service 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 Note on Red TidesIn 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 microorganisms which turns the seawater red Occasionally a red tide is accompanied by the death of local fish and other sea life which can cause serious local pollution of the seawater Although the watermaker membrane can remove the microorganisms that cause the red tide it can remove of the chemical pollutants caused by largescale biological decomposition Therefore we do not recommend using the watermaker to process seawater when a red tide is present Maintenance and Service Weve 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 describes both the routine and the longterm maintenance requirements of the PowerSurvivor 40EMuch of our knowledge of maintenance requirements watermaker performance and potential problems is a result of feedback from actual users over many years Following these instructions will help keep your product freshwater quality good and your watermaker running troublefree Once 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 correctedMake 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 connections After every 1000 hours replace the seals in the pump See Seal belowximately 5000 hours of use have the electric motor inspected for brush wear and commutator condition Pump Piston Shaft Lubrication It is extremely important to lubricate the pump piston ally 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 11watermaker and stop it when the piston shaft is at its point of farthest travel away from the pump ie towards the drive assemblysure that the started accidentally while you work Clean the exposed piston shaft with a clean rag and lubricate the shaft 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 1ducing diminished or no freshwater output or 2producing badsmelling product freshwater Here is what happens No Freshwater OutputThe most common cause of diminished or no product freshwater output is air entering the seawater intake system at some point The pump volume is small and the pressure required to press water through the membrane is rather high about 800 psiir 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 assembly 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 Product FreshwaterThe purpose of the prefilter assembly is to trap any particulates in the intake seawater that are larger than 30 microns A coarse strainer if installed performs the same chore for contaminants of larger size In each case trapped material remains in the prefilter housing or strainer bowluntil 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 bestknown 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 will contaminate a watermaker system 1the ambient temperature and 2quantity of trapped material We realize that many users of our equipment run their watermakers in nearshore situations while anchored The amount of trapped material is usually high in such locations and the prefilter assembly will require more frequent attention Moreover the high ambient temperatures in tropical locations greatly accelerate the rate of such decomposition Users in temperate climate areas or users processing openocean seawater during offshore passages are less likely to require the same At the of each run of your watermaker examine the prefilter assembly and the coarse strainer if material If anything is visible perform the following procedure Unscrew the prefilter housing remove the dirty prefilter element and discard the water in the bowl Do not lose the large oring at the top of the bowl Clean the inside surface of the prefilter bowl Inspect and clean the oring at the top of the bowl Lubricate the oring and the threads of the prefilter housing with a light coat of silicon grease Install a clean filter element and screw the prefilter bowl If you purchase aftermarket filter elements be certain they are made from fibers In particular be wary of elements made of paper materials They look very similar but are designed for use with other types of water purification systems and are harmful to the membranes and high pressure pumps used in reverse osmosis watermakers Be certain you purchase only polyester filters of 30micron or finerIf the watermaker will not be used within the next three days treat it with biocide see Biocide Treatment below 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 velter over the side of the boat so that it is underwater and jerk it up and odge the contaminants Dry the filter element thoroughly preferably in the sun Then store it for use as a clean filter the next time the prefilter assembly is serviced 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 The reverse osmosis membrane inside the membrane housing is an expensive and delicate component 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 quickly The primary purpose of a biocide treatment is to kill biological growth and bacteria that are present inside the membrane It also functions as a membrane wetting agent for extended storage Over time bacteria can multiply and adhere to the membrane surface thus gradually decreasing its effectiveness When the watermaker is not to be used for an extended period of time it should be biocided A biocide treatment is effective for approximately storage temperature 25C77FIf longer storage is required the biocide treatment repeated every yearIn temperate climates the maximum period of time the watermaker should be stored without biociding is approximately one week In hot or tropical climates the watermaker should be biocided if it will not be used within the next three days Follow these directions toperform a of your watermaker Lift the lever on the cleaning valve on the pump to place it in its clean Figure 12 Fill a clean plastic container or bucket with two quarts approximately 2 liters clean water Freshwater is preferable but clean seawater may be used if freshwater is not available CautionNever use chlorinated freshwater This may damage the membrane sure to follow the flushing procedures described below to ensure that the biocide solution does not get into the freshwater supply Mix two spoonful approximately 20 grams or 1 by weightBiocide chemical with the water in the container and stir until completely dissolved Use your product 3way valve or move the product water output hosethat any water flowing from the product freshwat Turn the lever on the prefilter 3way valve to the alternate intake position Run the 316 alternate intake hose with the strainer attached into the container of biocide solution 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 If the membrane freezes it must be slowly and termaker may be used again 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 operated Cleaning the MembraneWe do not recommend casual or regular cleaning of the reverse osmosis membrane in the watermakerit should only be done when needed Under normal use conditions when only openocean seawater is being processed cleaning the membrane should rarely or neveressary Proper biocide treatments prior to extended periods of nonuse will prevent biological growth on the membrane surface Under these conditions and with proper 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 causes battery current to increase There are two main types of such deposits and a different chemical cleaner is needed for each type processing brackish water or failure to properly store a membrane during extended periods of nonuse Use caused by mineral impurities in the intake water 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 salinity seawater temperatureThe best way to detect such a problem is by keeping an accurate log of product freshwater output at known battery volt highly recommended If you have determined that your membrane needs cleaning and you know the type of deposits mineral or organicthe appropriate cleaner If you do not know the nature of the deposits try Alkaline Cleaner and check for improvement in product freshwater output If output remains poor repeat the cleaning process using the Acid CleanerNever 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 cleaners Buildup of deposits and reduction in product freshwater flow usually take place gradually over extended periods of time Sudden reduction or stopping of product water output is rarely caused by a dirty membrane Lift the lever on the cleaning valve on the pump to place it in its clean or up position see Discard any dirty seawater in the prefilter assembly Clean the housing and install a clean Fill a clean plastic container or bucket with is preferable but clean seawater may be used if freshwater is not available CautionNever use chlorinated freshwater This may damage the membrane Mix four spoonful approximately 40 gramsAcid Cleaner or Alkaline in the container and stir until the cleaner is completely dissolved The water should be warm but not over 120 F 49 C Turn the lever on the prefilter 3way valve to the alternate intake position Run the 316 alternate intake hose with the strainer attached into the container of cleaning solution Disconnect the reject brine water hose from its drain or use a separate length of hoseroute the reject brine water back into the container of cleaning solution during the following 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 Continue to run the watermaker for about 15 minutes to assure that the cleaning solution is well circulated through the pump and membrane Turn off the watermaker and allow the membrane to soak in the cleaning solution for 5 to 10 repeat steps 8 and 9 of this procedure When the soaking is finished remove the reject brine hose from the cleaning solution container and run the watermaker again Discard the first pulses of the reject brine water When the reject brine flow becomes cleaner return the reject brine hose to the cleaning solution container for recirculation Continue to run the watermaker and recirculate the cleaning solution for another 30 to 60 minutes When cleaning is complete turn off the watermaker Reconnect the reject brine hose to its normal drain location Remove the alternate intake hose and strainer from the cleaning solution and place them into a container of clean warm If freshwater is not available clean seawater may be used if its temperature is above 68 F 20 CTurn 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 climatesit should now be treated with the biocide solution After approximately every 1000 hours of use the watermaker should be partially disassembled cleaned and lubricated with nonpetroleum 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 from Katadyn and most marine retail stores It includes a complete set of replacement seals and other components for all parts of the watermaker It is unlikely that you will have to replace all of the seals contained in the kit at every servicing The dynamic seals work harder and wear faster than others and will need to be replaced more often We recommend that you save old seals Most of them are still useable and could be kept in a kit for emergency repairs Preparation Before beginning to disassemble the watermaker read the following instructions completely Have a Repair Seal Kit on hand Refer to the drawings in and 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 following tools and materials available for a complete rebuild piston seal installation tool small scissors 12 openend wrench 10x loupe or magnifier 58 openend wrench silicone grease 14 allen wrench included in Repair Seal Kit medium flat blade screwdriver clean rags small standard pliers 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 assemblyis provides enough room for sliding the rubber boot toward the pump in Step 3 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 openend wrench and 14 allen wrench Also remove the two hex nuts securing the pump back plate to the drive assembly Figure R1 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 6that 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 Remove the two 3 sockethead capscrews using a 14 allen wrench Separate the pump back plate and piston assembly from the pump body see Figure R2 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 thandle with a better grip for extracting the piston assemblyBe aware not to damage the surface of the piston shaft Remove the large oring 8012588its 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 needlenosed pliers to pull the old wiper block seal out of the wiper block See Figure R3 This seal is usually damaged during removal Be sure you have a replacement on hand before removing it From the side of the pump back plate that contained the large oring insert a round drift of slightly smaller diameter than the hole for the piston shaft a small socket on an extension or a wooden dowel makes a suitable driftTap 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 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 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 If the membrane tube plug remains in the membrane housing insert a hard thin edge eg a dull pocket knifeetween 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 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 Disassemble the valves in the check valve Figure R5end wrench to unscrew the intake valve seat Remove the intake poppet valve and its spring If necessary use needlenosed pliers to remove the poppet valve retainer Then use the pliers to lift out the reject poppet valve and its seat Grip the xshaped 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 Katadyn PowerSurvivor 40E you begin reassembly of the watermakrags At this time all parts should be carefully inspected for wear or damage Use a 10x magnifier or loupe to examine the seals orings and other small parts Stubborn rust stains and other deposits on metal parts can be cleaned with a softmetal wire brush eg stainless steel or brass Do use polishes cleaning compounds containing abrasive materials or regular steel wire brushes During reassembly refer to Figures A3 and in the for fullsize drawings and identification 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 orings seals and mating surfaces have been lightly lubricated with nonpetroleum silicon grease supplied with the Repair Seal Kitnces to the Repair Seal Kit will be Use only nonpetroleum 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 petroleumbased components An ample supply of silicon grease is included RSK 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 holding it up cut it with a small pair of scissors Repeat this process Refer to Figure R6 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 iston 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 installation remove the installation tool from the piston shaft 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 oring 8012588ve in the pump back plate and lower the pump back plate over the piston shaft The side of the back plate with the large oring should be facing the pump body See Figure Refer to Figure R4 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 widerside 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 abovee 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 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 wiper block onto the piston shaft The side of the wiper block from which the seal was installed should be facing outward Refer to 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 during the following procedure 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 Use needlenosed 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 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 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 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 Lower the second poppet valve into the bore in the check valve plate and rest it carefully on top of the valve spring Remove the old oring 8013015m the intake valve seat and replace it with the new one from the 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 seat Replace the two large orings 8012947d the two smaller orings 8013006 membrane tube plug with new orings from the 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 housingtube 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 Press the piston as far as it will go toward the pump back plate Install a new oring 8012588into its groove in the check valve plate 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 orings 8012588check 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 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 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 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 openend wrench and 14 allen Do not overtighten these fasteners To replace the orings beneath the cleaning valve assembly refer to Figure R9 Unscrew the two sockethead capscrews using a 532 allen wrench and remove the assembly from the pump body Remove old orings 8012594and 8012697and replace them with new orings from the 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 assembly Use the flow chart below to diagnose and solve the most common problems associated with use of 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 help A collection of useful information for the Katadyn watermaker owner a chemical used to inhibit biological growth in the reverse osmosis membrane during storage or extended periods of nonuse a device which removes suspended solids from a fluid stream A filter is the same as a reverse osmosis membrane a metric unit of measurement equal to one thousandth of a millimeter or one millionth of a meter the process of diffusion between two water sources through a semipermeable membrane resulting in both water sources striving to reach an equilibrium in the concentrations of dissolved substances a slang term for the process of flushing the membrane with biocide solution see Biocide suitable for drinking especially water With regard to a desalinator it is generally defined as water with 1500 ppm or lower of dissolved solids that is relatively free of harmful microorganisms parts per million Used as a measure of the quantities of substances dissolved in water 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 membrane Pressure Relief Valve a valve that relieves pressure in a system to prevent damage to system components In the PowerSurvivor 40E the relief valve is set to open at 1000 psi to prevent damage to the pump and membrane potable water produced by the reverse osmosis process pounds per square incha 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 produces a measure of the amount of salts minerals and other dissolved solids contained in a water source Salinity see TDSms the common name for the chemical sodium chloride Openocean seawater is about 3 dissolved salt or about 33000 ppm of sodium chloride a device such as an oringt fluid leakage between two system components Semipermeable the characteristic of some materials eg a reverse osmosis membrane makes them relatively porous to some substances while blocking the passage of others Unlike normal filters semipermeable membranes usually operate at the molecular or atomic level allowing much finer filtering than simple mechanical filters Total Dissolved Solidsa type of measure commonly used to indicate the purity of water usually 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 indicate the presence of nonionized substances such as bacteria viruses and many other soluble chemicals 26 Diagrams 27 28 29 Part 8012607 An expanded cruise kit which includes all components of the Extended Cruise Kit plus a Silt This kit is strongly recommended for extended cruising and variable water condiPart 8012859 This kit is intended to protect the high pressure pump and reverse osmosis membrane from excessive exposure to silt and other suspended particulates It should be used in brackish water shallow water inland waterways areas of glacial runoff and other similar situations The Silt Reduction Kitincludes a 5micron prefilter which follows the standard 30micron filter supplied with the watermaker Also included is a 1amp boost pump to ensure adequate intake flow to the watermaker Part 8012606 Includes items needed for regular care and seasonal maintenance andor storage Contains 1pair Seal Kit 1Acid Cleanerand 6micron prefilter elements Part 8012610 A set of all seals and parts for the high pressure pump This kit also includes replacement gear oil for the drive assembly A Repair Seal Kit should be installed after each approximately 1000 hours of use Part 8013608 1Alkaline Cleaner 8 oz Part 8013615 1 Part 8013609 1 You may order parts and kits through our retailers or from Katadyn North America directly at 8007556701 If ordering directly youll need to provide detailed shipping instructions as well as credit card information Date Used Biocide Cleaned Membrane Other Service LIMITED WARRANTY FOR POWERSURVIVOR 40E 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 MADE BY OTHER PERSON OR FIRM ARE VOID THE DURATION OF ANY IMPLIED WARRANTIES OF OR FITNESS FOR A PARTICULAR PURPOSE SHALL BE LIMITED TO THE DURATION OF THE EXPRESS LIMITED WARRANTY NEITHER KATADYN NORTH AMERICA INC KATADYNILIATES SHALL BE LIABLE CONSEQUENTIAL OR SPECIAL LOSSES OR DAMAGES RESULTING FROM THE USE OR INABILITY TO USE THE POWERSURVIVOR 40E WATERMAKER WHETHER RESULTING FROM BREACH OF WARRANTY OR ANY OTHER LEGAL THEORY This Limited Warranty gives you specific legal rights and you may also have other rights which vary from State to State Some States do not allow limitations on how long an implied warranty lasts or do not allow the exclusion or limitation of incidental or consequential damages so the above limitations or exclusions may not apply to you What Is CoveredKATADYN warrants to the original purchaser that the PowerSurvivor 40E Watermaker enclosed with this Limited Warranty conforms to the manufacturers specifications and is free from defects in workmanship and material for a period of three years from the date of original purchase If the original purchaser transfers the PowerSurvivor 40E Watermaker to another person this Limited Warranty will not be enforceable by the person to whom the product is transferred What We Will Do To Correct Problems Should your PowerSurvivor 40E Watermaker prove defective during this period you must notify KATADYN at 9850 51st Avenue North Minneapolis MN 55442 or an authorized distributor or dealer of KATADYN You must permit KATADYN or its to make such investigation examination and tests as KATADYN deems appropriate and if requested to do so you will return the product to the factory at the address set forth above KATADYNs 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 responsibility What Is Not Covered This Limited Warranty is contingent upon proper use and maintenance of the product it does not cover products that have been improperly shipped or improperly installed or that have been misused abused neglected or improperly maintained cleaned or stored or that have been serviced other than by an authorized KATADYN distributor or dealer The PowerSurvivor 40E Watermaker can be damaged by oil grease chlorine and certain other organic or inorganic substances It must be cleaned carefully after use and requires periodic maintenance Failure to observe the precautions listed in the Users Manual may constitute improper use or maintenance of the product and causes this Limited Warranty not to apply This Limited Warranty does not cover products from which the KATADYN label or logo or the rating label or serial number has been removed This Warranty does not extend to normal wear or to replacement items including but not pump seals and Orings st Avenue North Minneapolis MN 55442 USA wwwkatadyncom Katadyn Products Inc Birkenweg 4 Phone 4118392111 infokatadynch Print No 80126020 v C2h1hz0uqqOhTu EF HHEFa aHHEF a FHHEFa a aHHEFa fHHEFa aaHH E D ZQX DY QX MDY QX DY EhD EEadPQXEDYCcbB ECDCCe ia D QXDzzYYFFaHKS XYXY EDEDEeE j Bhja RyE TXYaDRy E I c a a CC5vAp AE PXaYddbQXdd EDYKTX FH FHYYCXddadQX FH F20T1UVF30T1UV 40E Endurance Series 12Volt 24 Volt Watermakers OWNERS MANUAL
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