Katadyn PowerSurvivor 80E User manual

PowerSurvivorTM 80E
Endurance Series
12-Volt & 24 Volt
Watermakers
OWNER`S MANUAL

II

Thank you…
for purchasing a Katadyn PowerSurvivor 80E watermaker. It was built to rigorous
specifications, and designed to produce potable freshwater from clean seawater using
minimal power. It is simple to install and operate and, with reasonable care and
maintenance, will provide years of useful service.
Please…
before installing or operating your watermaker, take the short time needed to read this
User’s Manual in its entirety. This small investment of time will help assure many years of
trouble-free operation from your system. We’ve worked hard to provide you with a reliable
product that is affordable, compact, simple to operate and easy to maintain—the rest is up
to you.
Contact 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 www.katadyn.com.
Katadyn North America
6325 Sandburg Road, Suite 400
Minneapolis MN 55427
Phone: [phone] or 763-746-3500
Fax: [phone] or 763-746-3540
Website: www.katadyn.com
Customer Service / Technical Support:
800-755-6701 or 763-746-3500
(International Collect Calls Accepted)
Email: [email protected]
We suggest you keep a record of your Katadyn dealer’s name, contact information, and the serial
number of your watermaker in the space below:
Dealer Name:
_________________________________________________________________
Address:
_________________________________________________________________
Phone/Fax/Website:
_________________________________________________________________
Serial Number:
_________________________________________________________________
III

Table of Contents
System Discription......................................................................................................1
Product Specifications ...............................................................................................2
Energy Recovery.........................................................................................................3
Installation ...................................................................................................................4
Installation DOs ..................................................................................................4
Installation DON`Ts.............................................................................................4
Installation Procedures......................................................................................5
Using your Watermaker..............................................................................................7
Special Conditions .............................................................................................9
Maintenance and Service ......................................................................................... 10
Pump Maintenance........................................................................................... 10
Prefilter Maintenance........................................................................................ 11
Membrane Storage, Preserving & Cleaning ................................................... 12
Seal Replacement............................................................................................. 15
Troubleshooting Flowchart.............................................................................. 21
Appendix.................................................................................................................... 22
Glossary ............................................................................................................ 22
Diagrams ........................................................................................................... 23
Kits & Accessories ........................................................................................... 28
Service Log ....................................................................................................... 29
WARRANTY....................................................................................................... 31
IV

System Description
The Katadyn PowerSurvivor 80E watermaker system has several components. Refer to the
System Diagram (Figure A-1) in the Appendix for an overview of the components of the system
and their interconnections.
Motor/Drive/Pump & Membrane Housing: At the heart of the watermaker system
is a high-pressure, positive-displacement pump. The pump is powered by a reliable 12 (or 24)
VDC electric motor. An oil-bath gearbox (drive assembly) converts 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 inch) and forces
product freshwater through a semipermeable membrane located in the membrane housing. The
motor, gearbox and pump have been integrated into a single, compact piece of equipment—
with low power consumption, quiet operation and a small footprint. The membrane assembly is
a separate unit which allows it to be mounted in a convenient location.
Prefilter Assembly: The prefilter assembly consists of one prefilter housing and a
standard 30-micron prefilter element constructed of polyester fibers. Two standard elements
ship with each system. In some exceptional circumstances, an optional second prefilter
assembly with a 5-micron prefilter element may be needed (see Kits & Accessories). The
prefilter assembly is separate unit which allows it to be installed in a convenient and accessible
location.
Valves: Two high-quality plastic 3-way valves are supplied. The prefilter 3-way valve selects
between (1) seawater input for normal operation and (2) an alternate intake line for inputting
membrane preservative or a cleaning solution. The product 3-way valve allows easy routing of
product water to either (1) a freshwater collection tank for normal operation or (2) a drain
location for discarding during initial startup, testing, preservation or cleaning operations.
Hoses and Hardware: Each PowerSurvivor 80E watermaker is shipped with appropriate
hoses and hardware sufficient to perform a normal installation. This includes two high-pressure
hoses (3’ and 5’) for carrying pressurized seawater from the pump to the membrane housing
and reject brine water from the membrane housing back to the pump. The 1/2" I.D. reinforced
plastic hose is used for seawater intake and reject brine. The smaller, 1/4" I.D. clear plastic
hose is for routing product freshwater. There are also hose clamps and mounting bracket
hardware for the prefilter assembly and membrane housing, and a TDS (Total Dissolved Solids)
meter for testing and monitoring the quality of product freshwater.
Customer-supplied Equipment: Every installation represents a unique challenge!
You or your installer will need to provide:
1. a reliable source of clean seawater for input to the prefilter 3-way valve
2. plumbing to an appropriate drain location for the reject brine water
3. a plumbing solution for your freshwater collection tank
Our Promise: Every Katadyn PowerSurvivor 80E watermaker includes a three-year factory
warranty and a long history of outstanding customer support. Our reputation for providing a
quality product, along with service when and where you need it, is unequaled in the industry. Of
course, you may never need us—but, if you do, we’ll be there.
1

Product Specifications
Power Requirements: 8 amps @ 12 VDC; 5 amps @ 24
VDC*
Construction: 316 Stainless Steel Pump Housing
Configuration: Modular
Rate of Water Production: 3.4 U.S. gal./hr. (12.9 liters/hr.)
±15% @ 13.8 VDC
Feed Water Flow Rate: 34 U.S. gal./hr. (129 liters/hr.)
Pump Weight: 34 lbs. (15.4 kg.)
Pump Height: 6.2" (15.7 cm.)
Pump Length: 17.5" (44.5 cm.)
Pump Width: 13.5" (34.3 cm.)
Membrane Housing Dimensions: 31" x 2.5" (79 cm. x 6.4 cm.)
Prefilter Housing Dimensions: 12" x 6" (30 cm. x 15 cm.)
*The electric current requirement is an average figure. Instantaneous current will vary during a
complete cycle of the pump.
2

Energy Recovery
The technology behind Katadyn reverse osmosis watermakers
Reverse osmosis desalination was first developed over three decades ago. It was a major
breakthrough in desalting technology, but the original process required a lot of power. By
recovering 90% of the energy lost in conventional reverse osmosis systems, we’ve made small
desalinators practical, so you can have freshwater when and where you need it.
Conventional Reverse Osmosis Desalination
The lower left portion of Figure 2 shows the basic principle of reverse osmosis desalination.
When saltwater is forced through a
semipermeable membrane at high
enough pressure—typically 800
psi—pure 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
hem from the pure water.t
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 pressure-reducing 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 lost!
Energy Recovery Makes It Possible The upper right portion of Figure 2 illustrates
how Katadyn systems are configured to recover and effectively re-use the energy wasted in
conventional reverse osmosis. The waste brine stream contains up to 90% of the energy
expended. By recovering this energy, we are able to dramatically reduce the power needed to
esalt seawater.d
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 pump’s piston. By balancing the
opposing force on the piston’s front side, the brine provides a power assist to the pumping
operation. Seawater can then be pressurized with much less effort.
Katadyn Watermakers Katadyn watermakers are simple, energy efficient and easy to
use and maintain. The PowerSurvivor 80E incorporates the latest advances in watermaker
technology, featuring an improved oil-bath drive assembly, an all-316 stainless steel pump
body, and simplified construction for easier and less frequent maintenance.
3

Installation
Do it right the first time and reap the rewards
The PowerSurvivor 80E watermaker utilizes a low-volume, high-pressure, positive
displacement pump. Unlike the centrifugal pumps found in some systems, a positive
displacement pump is self-priming. It can also draw water when mounted several feet above
the waterline of a vessel. Thus, the watermaker may be installed in almost any location and
orientation.
The most important part of a good installation is proper planning. Although the design and
operating requirements of the PowerSurvivor 80E allow much latitude for equipment location,
there are several cautions and suggestions you should consider before proceeding with an
installation. Installation DOs
When choosing a location for the watermaker drive/pump or membrane assembly:
5Avoid 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!)
5Choose a dry area. The motor/drive assembly is not waterproof and can corrode.
5Choose 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!
5Find a location which allows comfortable access for routine inspection and servicing.
In addition, you should:
5Install the pre filter 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 make—
plan it carefully!
5Provide a shutoff valve or seacock in the seawater intake line.
5Install a coarse strainer in the seawater intake line.
5We 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 DON’Ts
9Don’t use a thru-hull installed high on your vessel’s 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.
9Don’t locate the pump assembly above gear or materials that could be damaged if it
leaked.
9Don’t locate the pump assembly near to sleeping quarters, bunks, or other areas that
are normally “quiet” areas for yourself or crew members.
4

Installation Procedures
Although every installation has its custom as-
pects, the following general instructions should be
useful to the typical installer. Refer to Figure A-1
(in the Appendix) for information on part identifica-
tion and system connections.
1. Install Pump: After reading the comments
on the preceding pages, decide on a location for
the pump and drive assembly. It should be
mounted with the pump and drive side by side
horizontally. The reason for 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 and/or
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 pump/drive assembly to a sturdy bulkhead or
platform, using corrosion-resistant 1/4" 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 motor.
2. Connect Electrical Power to
Pump: To provide 12 (or 24) VDC electric
power to the motor, use a minimum of 14
gauge / 12 VDC (16 gauge / 24 VDC)
stranded copper wire. We recommend 12
gauge / 12 VDC (14 gauge / 24 VDC) or
larger wire for distances over 20 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 Pre filter Assembly and
3-Way Valve: Lightly coat the male
threads of the middle port of the pre filter 3-
way valve with a non-hardening, paste-type
thread sealant (e.g., Permatex®) to assure an
airtight seal. (Note: Teflon tape is not
recommended.)
M
white
black
12 V or 24 V
Battery or Power
Source
red
black
-
+
Figure 4
Dimension of the cable:
14 gauge / 12 V
16 gauge / 24 V
Terminal
Strip
Fuse and Circuit
Breaker:
12 V = 15 A
24 V = 10 A
Basic Electrical Diagram
1. Carefully thread the middle port of the pre filter 3-way valve into the “IN” port of the pre
filter housing. Do not over tighten 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 pre filter assembly to a
bulkhead. Orient it so the pre filter 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 pre filter housing to the bracket with the supplied screws. One port
of the pre filter 3-way valve should project above the housing through the notch in the
mounting bracket.
5

4. Install Seawater Intake Plumbing: There are two common approaches to
providing the seawater intake circuit:
•Tee into an existing seawater intake (e.g., engine cooling water or manual seawater
pump inlet).
•Install a dedicated thru-hull for the watermaker.
Either of these configurations should meet the following criteria:
•It should be at a low point on the vessel’s hull, to minimize the chance of air intake
during heeling or rough conditions.
•The thru-hull should be a minimum of 1/2" I.D., and possibly larger if it is a shared inlet.
(Note: If there is the possibility that in the future you will want to upgrade by adding a
second PowerSurvivor 80E to implement redundant systems—you should consider
substituting 5/8" I.D. hoses and hose fittings during your initial installation).
•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 80E are
both extremely low, the pump can be adequately supplied by most pre-existing intakes—even
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 (in addition to the one at the thru-hull) to independently control the supply to the
watermaker.
5. Install Reject Brine Plumbing: The reject brine water can be teed into an existing
scupper or sink drain hose for draining overboard. Use the 1/2" reinforced hose and supplied
hose clamps. A tee of the correct size will have to be supplied. Alternatively, 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 container for collecting good product freshwater and (2) a drain location.
In no case should the product freshwater hose be permanently plumbed into the ship’s potable
water storage tank(s), 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, and especially after treating with membrane preservative or chemical cleaners. 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
vessel’s freshwater storage tank(s). 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 contaminated by unpurified seawater. This is especially important if:
•you have only a single tank for storing potable water.
•you will be making extended offshore passages and depend on your watermaker for
your potable water supply.
6