Katadyn EK-4 User manual

ELECTRO-KATADYN INSTRUCTION MANUAL
EK-4
EK-24

Katadyn Page 1
1Table of Contents
1Table of Contents ............................................................................................................................... 1
2Silver Ionization: What are the benefits? ............................................................................................. 3
3Effect of Silver Ions on Bacteria Cells.................................................................................................... 4
4General Safety Instructions.................................................................................................................. 5
5Quick Reference Control Cabinet......................................................................................................... 6
6Quick Reference Layout of the EK-4 activator........................................................................................ 7
7Quick Reference Layout of the EK-24 activator ...................................................................................... 8
8Technical data ................................................................................................................................... 9
8.1 Operating data.................................................................................................................................. 9
8.2 Environmental data .......................................................................................................................... 10
9General details ................................................................................................................................ 11
10 Operating Panel .............................................................................................................................. 12
10.1 Start Screen..................................................................................................................................... 12
10.2 Overview Screen.............................................................................................................................. 13
10.3 Setting Screen.................................................................................................................................. 14
10.4 Alarm Screen .................................................................................................................................. 16
10.5 Alarm History and Trend Screen........................................................................................................ 17
11 Commissioning of the Electro-Katadyn System EK-4 / EK-24................................................................ 18
11.1 Basic components: ........................................................................................................................... 18
11.2 Environmental conditions .................................................................................................................. 18
11.3 Short installing guide of the EK System............................................................................................... 18
11.4 Mount the anodes to the activator EK-X/24 ........................................................................................ 19
11.5 Insert the anode into the EK-4 activator .............................................................................................. 20
11.6 Water inlet and outlet / drainage...................................................................................................... 21
11.7 Starting the Water Flow.................................................................................................................... 22
11.8 Electrical connection......................................................................................................................... 23
11.9 Starting the Electrical Control System ................................................................................................. 23
11.10 Current/Dosage adjusting of the EK................................................................................................... 23
11.11 Local Setpoint .................................................................................................................................. 24
11.11.1 Remote Setpoint............................................................................................................................... 24
11.11.2 Dosage control ................................................................................................................................ 24
11.12 Start/Stop silver ion (Ag+) production................................................................................................ 25
11.12.1 Start/Stop Local............................................................................................................................... 25
11.12.2 Start/Stop Remote............................................................................................................................ 25
12 Installation options of EK systems....................................................................................................... 26
12.1 Sample System Layout bypass ........................................................................................................... 26
12.2 Sample System Layout marine ........................................................................................................... 26

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12.3 Sample System Layout without bypass using direct flow marine ............................................................ 26
12.4 Sample P&I Layout bypass with automatic valves and flow measurement ............................................... 27
13 The conductivity of the water ............................................................................................................. 28
14 Monitoring and Maintenance ............................................................................................................ 29
14.1 Basic Maintenance........................................................................................................................... 29
14.2 Checking the Effect........................................................................................................................... 29
14.3 Cleaning the Electrode System........................................................................................................... 29
15 Troubleshooting ............................................................................................................................... 31
15.1 Flow Low......................................................................................................................................... 31
15.2 Voltage High................................................................................................................................... 31
15.3 Voltage Low .................................................................................................................................... 31
15.4 Temperature High ............................................................................................................................ 31
15.5 Overvoltage .................................................................................................................................... 31
15.6 Short Circuit .................................................................................................................................... 32
15.7 Communication Error ....................................................................................................................... 32
16 Packaging and Transport.................................................................................................................. 33
17 Appendix........................................................................................................................................ 34
17.1 Spare Parts for Electro Katadyn EK-4 ................................................................................................. 34
17.2 Spare Parts for Electro Katadyn EK 2-6/24 ........................................................................................ 34
17.3 Dimensions EK 4.............................................................................................................................. 35
17.4 Dimensions EK 24............................................................................................................................ 36
17.5 Electrical connection......................................................................................................................... 37
17.6 Electrical connection Activator Anode/Cathode .................................................................................. 39
17.6.1 EK-4 ............................................................................................................................................... 39
17.6.2 EK-24 ............................................................................................................................................. 40
18 CE declaration of conformity............................................................................................................. 41

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2Silver Ionization: What are the benefits?
Silver has been used for centuries as a way to prevent or reduce bacterial growth. In ancient times cultures
discovered that water stored in silver pots had a longer useable life than other types of pots. Today silver
is used in a variety of bacteria-reducing & preservation applications from clothing to water purification.
The Electro Katadyn (EK) system uses electrical modulation of the catalytic process to introduce silver ions
into water flowing through the system. Based on Faraday’s law and system design, as parts per million
amount of silver ions are introduced into the water. At various concentrations, this ion-enriched water
preserves drinking water, is used for rinse and disinfection of food equipment, or in hot water systems to
prevent Legionella growth.
Silver ionization offers additional benefits in simplicity, maintenance and eco-friendly processes.
Compared to liquid or gas chemical treatment, ionization offers a much simpler process. Depending on
the application and volume required, the EK system can be piped into a bypass or direct line to deliver the
ions. It does not require separate chemical pumping, dose control and contact tanks to ensure safety. The
Electro-Katadyn system use of Silver anodes means operators aren’t constantly adding new chemical
mixtures to the process and reduces the chances of under- or overdosing the water in normal operation.
This reduces the complexity and logistics required to support the chemicals as well as any additional safety
protocol equipment.
The Katadyn EK silver ionization system is easy to maintain. Anode changes are simple mechanical
replacements requiring no electrical or special materials handling by site operators.
Katadyn anodes are a fraction of the volume of liquid or gas containers used by other treatment methods.
The small size of the anodes reduces the freight costs and carbon footprint, handling and packaging
required for operating the system. The overall system has a much smaller footprint also reducing the
associated capital costs for space for the client.
The EK 24 systems offer users two types of solutions:
Normal water treatment (conductivity > 100 µSiemens) for preservation, legionella or cleaning
applications are covered by the standard EK x-24 units.
Customers with low conductivity water (conductivity 10 to 100 µSiemens), typically marine or Food and
Beverage production, can benefit from the EK x-24 LC units.

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3Effect of Silver Ions on Bacteria Cells
The bactericidal action of silver (Ag+) is known as the “Katadyn” effect, a fusion of “catalytic” (: and
“oligodynamic.” It means the destruction of micro-organisms by catalysis, using very small amounts of
dissolved silver (oligos = small; dynamis = force).
A typical bacteria cell has the following key components:
•Cell wall & membrane:
Provides protection and controls the
movement of substances into
and out
of the cell
•Chromosomes:
Contain DNA used in reproduction
•Cytoplasm:
Contains water, proteins and
enzymes
that help in cellular growth metabolism
Silver ions (Ag+) have a high affinity towards sulphur as well as phosphorous and easily get attached to thiol
(-SH) groups, which are sulphur containing organic compounds found in proteins and enzymes.
The positively charged silver ions (AG+) affect the bacteria cells in the following ways:
a. Bonding to thiol groups in the protein of the membrane wall, causing pores in the membrane
walls that allow more silver ions in
b. Bonding to thiol groups in the cytoplasm proteins and enzymes, thus inhibiting them from
supporting the cells basic support and growth functions
c. Disrupting the hydrogen bonding within DNA strands and denaturing the DNA
A description of influences of silver in drinking water can be found in the following publications “Guidelines
for drinking-water quality, 2nd. Ed. Vol. 2 Health criteria and other supporting information” published by
WHO (Geneva, 1996).
Disruption of
DNA reproduction
Silver ions (Ag+)
Destruction of cell membrane
Inhibition of enzymes

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4General Safety Instructions
ATTENTION!
Indicates a potentially dangerous situation.
Failure to observe this notice may cause slight or severe
personal injury and property damage.
ELECTRIC SHOCK!
Warning of dangerous electrical voltage.
Failure to observe this notice may result in serious
Injury or death.
Before working with the EK system, it is imperative that the instruction manual be read and
understood. Installation, commissioning, operation and maintenance of the EK system may be
carried out only by authorized personnel.
When working with an EK system, it is highly recommended that cut resistant gloves be worn.
The disposal of scrap electronic and electrical goods, including silver anodes, as household
waste is not permitted. Please dispose of this scrap material as per local regulations and with
properly accredited waste management companies.
Before working on the control cabinet or activator, be certain to pull out the power plug and
wait at least 5 minutes until all components have discharged.
NOTE
Useful application notes for the operator and service personal
Please read the instruction manual before carrying out any work for the installation, operation
and maintenance of the EK system.
IMPORTANT

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5Quick Reference Control Cabinet
1. Control panel (touch screen)
2. Mains connection with fuse
3. Mains Switch
4. Cable ingress
1
3
2
4

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6Quick Reference Layout of the EK-4 activator
1. Low power cable for electrolysis (connected to control box)
2. Protection cap
3. Water outlet needle valve G3/4“ with probe valve
4. Activator body (acts as cathode)
5. Mounting clamps (must be electrical isolated)
6. Plastic isolation adapter G3/4“ (Important to isolate the activator)
7. Water inlet ball valve G3/4“
8. Flow Switch G3/4“ (monitoring of water flow)
9. Drain port G3/4
1
3
4
7
6
6
8
2
5
9

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7Quick Reference Layout of the EK-24 activator
1. Low power cable for the electrolysis (screwed connection below metal cap)
2. Header with anodes and cathode system
3. Water outlet needle valve G1“ with probe valve
4. Activator body
5. Water inlet ball valve G1“
6. Flow Switch G1“
7. Drain port G1“
3
4
6
1
5
2
7

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8Technical data
8.1 Operating data
Electro Katadyn
Type of device
EK-4
EK 2-24
EK 3-24
EK 4-24
EK 6-24
Application
Drinking water 0.02ppm
20m
3
/h
40 m
3
/h
60 m
3
/h
80 m
3
/h
120 m
3
/h
Cleaning Rinse water 0.5ppm 0.8 m3/h 1.6 m3/h 2.4 m3/h 3.2 m3/h 4.8 m3/h
Disinfected Cleaning water 1.0ppm
0.4 m
3
/h
0.8 m
3
/h
1.2 m
3
/h
1.6 m
3
/h
2.4 m
3
/h
Lifetime of the anode (est.)
20'000 m
3
(at 0.01 ppm Ag)
10'000 m
3
(at 0.02 ppm Ag)
Conductivity drinking water
100 to 500 µS/cm
Conductivity low
3 to 99 µS/cm
Chloride (Cl)
Max. 25 ppm
Organics (KMnO4)
Max. 10 ppm
Activator housing
No. of anodes of Type E1
1
2
3
4
6
Material of the body
1.4301 / 316S
Nominal pressure (bar)
6 / PN6
Weight (without water) kg
5.8
15.8
16.2
16.6
17.3
Dimensions
Height mm
500
605
Diameter mm
64
140
Connections (inlet / outlet)
G 3/4"
G 1"
Mounting position
Vertical
Control Cabinet
Dimensions mm (w x h x d)
300 x 400 x 155
Weight kg
9.8
Electrical supply
230/120V 50/60Hz
Nominal power
40W
Protection class
IP64
Remote Interface (see attachment 17.5)
6 Remote relay output:
4 Remote Input :
2 Analog Input:
Potential free relay contacts (max.240VAC/2A/24VDC)
Contact closed 24VDC from cabinet
0-10VDC

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8.2 Environmental data
Electro Katadyn
Type of device
EK-4
EK 2-24
EK 3-24
EK 4-24
EK 6-24
Environment
Ambient operating temperature 5 to 40°C
Ambient operating humidity 10 - 85% non-condensing
Storage and transportation temperature -25 to 55°C
Max. altitude
3000 m above sea level
Aggressive environment to be avoided
Shock and vibration low vibration environment

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9General details
Maintenance manual
NOTE
The system must be installed, operated and maintained in accordance with this instruction
manual. In our experience, the information and instructions contained in the manual will
guarantee maximum operational safety for the system. The instruction manual is to be
retained for future reference.
Warranty claims
All rights to claim for damage under warranty will be invalidated:
•if safety, operating, maintenance and repair instructions are not observed,
•if any work on the system is carried out improperly, and unsuitable equipment is used,
•if the EK system, or individual components thereof, are used for purposes which do not comply with
the specification and application
•if unauthorized changes are made to the EK system,
•if original Katadyn replacement parts are not used,
•if work is carried out, particularly on the control box, by untrained and unauthorized personnel.
Copyright
The contents of this document are the intellectual property of Katadyn Group,
Kemptthal, Switzerland. It may not be adapted by the user of the EK system
for his own manufacture, nor on behalf of a Third Party, even under
exceptional circumstances, without our written approval. The instruction
manual, or parts thereof, may not be reproduced in any way, nor made
available to a Third Party.

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10 Operating Panel
NOTE
Do not use any metallic or sharp objects to operate the touch screen.
Avoid excessive pressure when operating the touch screen.
All necessary control operation can be carried out through the Operating Panel Touch Screen.
10.1 Start Screen
After switching on the Control Cabinet, the Katadyn “Start” Screen will appear.
By touching the Katadyn Logo, the “Overview” Screen will appear.

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10.2 Overview Screen
Alarm indication:
Appears when an alarm occurs
Change to the «Alarm» Screen
Hour counter
ON/OFF Switch
Flow indication:
Only available with the option «Flow measurement»
EK is running
Voltage measurement
Current indication
Adjust Setpoint in 10
mA steps
Setpoint adjustment:
Increase or decrease the
Setpoint numerical
(mA or ppm)
Change to the «Settings» Screen
Setpoint indication
Local/Remote
Control indication
Local/Remote
Switches on the Screen “Overview”
Switch ON the EK System locally
The controller will ramp up the actual value to the Setpoint.
Switch OFF Locally the EK System.
Increases the Setpoint in 10mA steps up
Decreases the Setpoint in 10mA steps down
Numerical current (mA) Setpoint input.
If the option “Flow measurement” is activated and the control is set to
ppm, then the required dose* in ppm can be set over the numerical
input.
Change from “Overview” screen to “Setting” screen
*Dose control is calculated by the law of Faraday: 1mA= 4mg Ag+/hr

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NOTE
Dose control is based on flow measurement, and the law of Faraday and will
help to achieve a flow independent silver concentration in the process flow.
Measurements in regular intervals have to be conducted to ensure the correct
dosage.
10.3 Setting Screen
Change back to the Screen «Overview»
Switch between:
Control Remote/Local
Adjust Language
Switch controller between mA/ppm:
ppm only possible with the option
«Flow measurement»
Change to the Screen
«Service»
Restricted Screen, Password
required
Change to the Screen «Alarm History»
Change to the Screen «Alarm»
Switch between:
Setpoint Remote/Local
Change to the «Trend» Screen ( Volt vs Time)
Switches on the Screen “Setting”
Change to the screen “Service”
Access only for Katadyn authorized personal.
Change to the screen “Overview.”
Setpoint switch Local / Remote
Control switch Local / Remote
Change from current (mA) to dose control (ppm).
ppm control only with option “Flow measurement” possible.
Language selection (GE, EN, FR)
Change to the screen “Alarm”

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Change to the screen “Alarm History”
Change to the screen “Trend”

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10.4 Alarm Screen
Change back to th e Screen «Overview»
Reset Alarm’s
Alarm’s
Alarms
Flow Low Flow rate through EK below 0.5 m^3/h
Voltage High Voltage on the Activator is above 21.5 V DC.
Voltage Low Voltage on the Activator is below 0.25 V DC.
Temperature High Cabinet temperature (internal) is above 45°C
Overvoltage Electrical circuit to the Activator is open
Short Circuit
Short circuit inside of the Activator or the wiring
to the Activator
Communication Error Connection between PLC and HMI is faulty
Switches on the Screen “Alarm”
Change to the screen “Overview.”
Acknowledge all Alarms.
Red LED will disappear when no alarms are pending

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10.5 Alarm History and Trend Screen
Change to the «Settings» Screen
Last 10 Alarm’s
Change to the «Settings» Screen
Activator Voltage

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11 Commissioning of the Electro-Katadyn System EK-4 / EK-24
11.1 Basic components:
−Control Cabinet
−Activator with electrode system
−Flow Switch
The bypass piping (main pipe) is not part of the Katadyn scope of supply. The bypass (“part-stream”)
principle is applied to keep the head loss low and is used in the case of larger flow volumes. The partial
flow diverted through the Electro-Katadyn System receives silver ions in proportionately higher
concentration. The silver dose needed is reached by subsequent mixing of the water in the common pipe
downstream of the Electro-Katadyn. Based on empirical data the following values serve as a guide for
expected flows through the EK:
EK 4: 0.5 m3/h
EK 2-6/24:
2.0m3/h
11.2 Environmental conditions
Check if the mounting position corresponds to the environmental data in chapter 8.2 Environmental data
11.3 Short installing guide of the EK System
•Mount the Activator body to a suitable place
•Mount the Control Cabinet close to the activator body (activator cable length 1.2m)
•Connect the inlet piping to the inlet of the activator (G3/4” EK-4, G1” EK-X/24)
•Connect the outlet piping to the outlet piping of the activator (G3/4” EK-4, G1” EK-X/24)
•Connect the drain piping to the drain outlet of the activator (G3/4” EK-4, G1” EK-X/24)
•Wiring the Flow Switch, activator head, the Mains supply and all other optional instruments to the
Control Cabinet (see connection drawings 17.5 Electrical connection / 17.6 Electrical connection
Activator Anode/Cathode).
•Remove screws from activator head.
•Remove activator head
oIf silver anodes and cathodes are not installed, install them according chapter 11.4 Mount
the anodes to the activator
•Check that sealing ring is properly placed on activator head
•Replace activator head on Activator body and screw in the screws (max 4Nm torque)
•Pressurize the whole system and check for leaks.

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11.4 Mount the anodes to the activator EK-X/24
Before working on the control cabinet or activator, be certain to unplug it
from the power socket and wait at least 5 minutes until all components have
discharged.
•Screw in all the anodes on the activator head in following order
o2 Anodes
o3 anodes
o4 anodes
o6 anodes
•Insert the outer cathode over the anodes and place it flush against the activator head
•Ensure the guide pins are properly aligned with the guide holes in the outer cathode
Make sure, the anodes and the cathodes are mounted accordingly (shown the anode-/cathode-
combination of a Type EK 6/24)
View of the inside of the
outer cathode without central
cathode and anode installed
View of the inside of the outer
cathode with central cathode
and anodes installed