Spectra Watermakers Cape Horn Extreme 330R User manual

Cape Horn Extreme 330R-Remote
Installation and Operating Manual
Spectra Watermakers
Katadyn Desalinaon LLC.
2220 S. McDowell Blvd Ext. Petaluma, CA 94954
Phone: [phone]
www.spectrawatermakers.com
Updated March 2023

2
• Scan QR Code to Visit Spectra Manuals Page.
• Select System, then download the User Manual.
• Reference Commissioning Checklist for important
installaon requirements.
• Review Installaon Basics secon of Owner’s Manual
to ensure warranty compliance.
Spectra Watermakers - User Manual Online Access
hp://katadyngroup.ladesk.com/206595-Spectra-Manuals

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Table of Contents
Geng Started.................................................................................................................... 4
Installaon…………………………………………………………………………………………………………..…..7
Introducon to the Cape Horn Extreme 330...................................................................... 8
Installaon Basics................................................................................................................ 9
Components...................................................................................................................... 10
Cape Horn Extreme Plumbing Layout............................................................................... 12
Product Water Plumbing and Pressure Gauge Tube Installaon..................................... 13
Cape Horn Extreme Remote System Wiring .................................................................... 14
Oponal Z-Ion Protecon System and Installaon........................................................... 16
Oponal Tank Switch ........................................................................................................ 17
New System Start Up ........................................................................................................ 19
New System Start up and Tesng Freshwater on Dock.................................................... 20
New System Start up and Tesng in Ocean...................................................................... 21
Operaon…………………………………………………………………………………………….………………...22
Normal Operaon and Fresh Water Flush........................................................................ 23
Dry Tesng with an Arcial Ocean.................................................................................. 24
Spectra Manual Remote Controller Guide ....................................................................... 25
Adjusng Freshwater Flush Duraon ............................................................................... 26
Suggested Spares .............................................................................................................. 27
Maintenance, Storage & Troubleshoong……………………………………………..28
Maintenance..................................................................................................................... 29
Cape Horn Extreme Plumbing Diagram ............................................................................ 31
Cape Horn Extreme Electrical Diagram............................................................................. 32
Introducon to Spectra Chemicals ................................................................................... 35
Cape Horn Storage Procedure .......................................................................................... 37
Winterizing with Propylene Glycol ................................................................................... 38
Membrane Cleaning Procedure........................................................................................ 39
Flow Test........................................................................................................................... 40
Troubleshoong ............................................................................................................... 42
Technical Bullens………………………………………………………………………………………………………..45
Parts Idencaon .......................................................................................................... 53
Owner Resources & Warranty................................................................................. 61
Product Registraon, Installaon & Commissioning Reports.......................................... 62

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Descripon of the pictograms
The following symbols will be used in the manual to highlight important indicaons and warnings:
ATTENTION:
This symbol indicates accident prevenon for the
operator and / or for any exposed persons.
CAUTION:
This symbol indicates that there is the possibility of
damaging the system and / or its components.
DANGER:
This symbol indicates a shock hazard or exposure to risk.
NOTE:
This symbol indicates useful informaon.
Getting Started and Manual Overview
ATTENTION
Important Informaon Safety Warnings
To safeguard the operator's safety and to avoid possible damage to the machine, before carrying out
any operaon on the machine, it is essenal to read carefully all the instrucons manual. Check
periodically that no leaks are present. Avoid installing the plant where a leak may cause damage and/or
jeopardize the safety of the vessel.
Unpack the system and inspect it for damage during shipping. Freight damage must be reported within
24 hours. Refer to the shipping list for your system to ensure you received all of the components listed.
Do not discard any packaging unl you have found and idened all of the parts. The small installaon
parts are listed on the kit list.
Be aware of the cauon and warning signage on the system. If box is labeled “Heavy”,
please use two people when moving.

5
ATTENTION
Important Informaon Safety Warning Cont.
Study the system layout diagram, component photos, and descripons before beginning
installaon.
CAUTION: We will not be held responsible for shortages and or freight damage that are not
reported within thirty days of the ship date.
Lay out the system. Before starng the installaon idenfy where each module and
component will be placed. Insure that there is enough clearance around the components for
removal of lters and system service. Make sure you have adequate tubing and hose before
starng. Addional parts may be ordered.
DANGER/CAUTION:
Do not use system in ports or polluted seaways.
Cape Horn Extreme 330 Remote Manual Shipping List:
ATTENTION: Please read any warning labels in packaged materials which may include SDS
sheets and further documents.
•Cape Horn 330 Remote Manual kit (includes Control Box and Remote Control)
•Accumulator Assembly
• Flowmeter and Pressure Gauge Assembly
•High pressure Clark Pump with membrane pressure vessel
•Black high pressure prelter with 5 micron lter
•Feed Pump Module Assembly with fresh water ush module
• Remote Manual install kit with black product water tubing
•Service kit
•Two lengths 5/8” Hose (25’)
Oponal: Z-Ion Copper Ionizaon Flush System Upgrade

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7
Installation

8
Service Port
The Cape Horn Xtreme Remote Manual is designed to be ecient, simple, and durable. Properly
installed and maintained it will supply years of reliable service. Prudent operaon is required with
any marine equipment. Always maintain enough reserve water to get safely into your next port.
The Spectra Intensier, known as the Clark Pump, was introduced in 1997 and has connually
improved since. It is built of modern non-corrosive composites and comes with a 40” (101.6 CM)
high rejecon membrane. The Clark Pump and membrane module are pre-mounted and plumbed
together as a single unit to save me and add reliability.
Front View Pressure Relief Valve
Double rubber mounts
to absorb vibraon
Feed Pump Module A:
Includes primary feed pump, switch, cooling fan,
charcoal lter, ush valve, service valve, and service
port. The module has compact and streamlined
plumbing. The cooling fan increases longevity.
Service
Valve
Cooling
Fan
Motor
Shuro
pump
head
NOTE: If your system came with the oponal Z-Ion, the Z-Ion unit will replace the charcoal
lter housing. The photo above, and all subsequent photos of the Feed Pump Module, will
look slightly dierent.
Charcoal Filter and
Housing
On/O Switch
Feed Pump Module B:
Includes secondary feed pump (same
as in module A), 5 micron lter hous-
ing, and power switch.
5 Micron Filter
and Housing
Introduction to the Cape Horn Xtreme Remote Manual
1-Way Solenoid Valve 12V
PL-SLN-1/4O12SV

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Installation Basics
• Avoid ght hose bends and excessive runs.
• Use heavy gauge wire.
• Install feed pump module as low as possible.
• Use a dedicated thru-hull with scoop type strainer.
• Do not mount components over electrical devices.
Seawater Flow
Thru-hull
Not Supplied.
Thru-hull Locaon: The system must be connected to a dedicated 1/2” to 3/4” forward facing
scoop-type intake thru-hull and seacock.
Install the thru-hull intake as far below the waterline and as close to centerline as possible to
avoid contaminaon and air entering the system. Do not install the intake close to, or
downstream of, a head discharge, behind the keel, stabilizer ns, or other underwater xtures.
Thru-hulls in the bow area are suscepble to air intake in rough condions. Sharing a thru-hull
can introduce unforeseen problems such as intermient ow restricons, air bubbles,
contaminants, and will void the warranty. For racing boats and high speed boats traveling
above 15 knots, a retractable snorkel-type thru-hull ng is preferred because it picks up
water away from the hull.
The brine discharge thru-hull should be mounted above the waterline, along or just above the
boot stripe, to minimize water li and back pressure.
Avoid restricons or long runs on the enre inlet side of the plumbing from the thru-hull to
the feed pump module.
Secure the piping away from moving objects such as engine belts and hatches. Prevent chafe
on the tubing as required. Test and inspect all piping and hose clamps aer several hours of
operaon.
Pipe Fing Instrucons: To seal plasc-to-plasc ngs, wrap 6 to 8 layers of Teon tape
over their threads. Hold the ng in your le hand and ghtly wrap the threads clockwise.
For smoother assembly, do not tape the rst (starng) threads.
Wiring
• Pay aenon to wire size or system performance will be impaired
• Perform wiring to UL, ABYC, CE or applicable standards
Important Installation Notes
CAUTION: Avoid geng dirt or debris into the piping or hoses during assembly. A small bit
of debris can stop the system!

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Components
Sea Strainer Mount close to the intake through-hull, in a
locaon that can handle water spillage during service.
Feed Pump Module B
5 Micron Prelter Bowl Locate in an area that allows easy access as
this will be the most frequently serviced module while cruising.
Mount vercally and leave room below bowl for lter changes.
CAUTION: Do not mount above water-sensive equipment.
Feed Pump Module A
Mount the feed pump module on a vercal surface, no more
than 3-feet (1.0M) above the waterline. It is preferable to
mount as low as possible. Locate in an area that allows easy
access to the charcoal lter, and the service valve. Keep
future maintenance in mind when choosing a locaon, and do
not mount above water-sensive equipment.
NOTE: IF INSTALLING THE Z±ION, SEE Z±ION INSTALLATION
INSTRUCTIONS FOR MORE DETAILS.

11
Components - Cont.
Double rubber mounts
to absorb vibraon
NOTE: This module must be installed in an area that maintains a temperature below 113°F
(45°C). It may be placed as high in the boat as you desire, and mounted in any posion, even
upside down. Make sure that the area around and under the pump does not have any water
sensive equipment, as water will be spilled during any repairs or if a leak occurs. Allow for
easy access to the pressure relief valve.
The Clark pump and membrane module comes complete with a mounng system. Be sure to
use the supplied washers on the rubber feet.
Pressure Relief Valve
Clark
Remote Manual Controller
The remote control panel can be mounted anywhere dry and
convenient. Cut a 5/8” (1.5 cm) wide by 5/8”” (1.5 cm) high
opening for the display port. The display needs minimum 2 1/2”
deep clearance for the cable. Take care not to damage the plugs
on the ends of the cable when roung. The recommended
display cable is a standard Cat 5e ethernet cable.
NOTE: Use only a Spectra approved cable. 4”/ 10.15 cm Depth: .6”/1.5 cm
2.15”
5.5 cm
Remote Manual Control Box
The remote manual control box should be mounted so the toggle
switch can be accessed during trouble shoong or maintenance.
It may need to be opened during commissioning in order to
opmize the ush duraon for the given install. The Remote box
has an RJ 45 display jack, two pump power pigtails, a power inlet
terminal block, a freshwater solenoid pigtail (blue) and a green
pigtail for the opon Z-Ion protecon system.

12
ShurFlo
Pump
Charcoal
filter
Freshwater Storage
(Inside Boat)
(Outside Boat)
Feed
Water
Inlet
Feed
Pump Module B
Brine discharge thru
hull (not included):
place above waterline
or tee into another
visible drain.
(Pressurized
Fresh Water**)
Ocean Feedwater
Legend:
Drinkable Freshwater
Brine Discharge
Freshwater Flush
Note: Brine discharge
may be connected to ei-
ther side of Clark Pump
Use the supplied 5/8-inch
(15.9mm) clear braided vinyl
hose for all runs. More hose may
be ordered from Spectra, or
bought at a hardware or marine
store.
Cape Horn Xtreme 330R Plumbing Layout
Water-sensive Equipment.
**Fresh water from ship’s pressure
water system 30 psi (2bar)
minimum. 50 psi (3.5bar) maximum.
Target should be 1.5 gal/min.
Feed
Pump Module A
Note: High Pressure Fittings
may develop drip leaks in ship-
ping. See Fitting instructions for
detailed resolution

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Back view of instrument panel
Use accumulator port to connect the
pressure gauge with the supplied 1/4”
black nylon tubing. Tubing must be
pressure rated to 150 PSI (10 BAR).
Product Flow Meter
Pressure Gauge
Product Water Plumbing and Pressure Gauge Tube Installation
Product Sampling Valve: Mount using the
supplied plasc straps.
Note: the handle points in the direcon of
ow.
Product to tank: Route the product water
from the valve into the top of a vented
tank. Install a tee in the water ll or tap a
pipe thread into an inspecon port.
CAUTION: DO NOT! feed the product into
a vent line, manifold, or the boom of the
tank. Make sure that there is no
restricon in this piping. Pressure in the
product tubing must never exceed 5psi
(.3bar), running or stopped, or the
membrane will be permanently damaged.
Sampling Tap for tesng the
product water.
Use the supplied 1/4”
black tubing for the
product water plumbing.
Product output ng.

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Cape Horn 330 Remote System Wiring
Cape Horn Extreme 330 Remote Manual systems are pre-ed with waterproof connectors for
electrical and signal cables. Each connector is dierent, so it is impossible to connect them incorrectly,
and the connectors are color-coded. The system has a power inlet harness with a terminal block and
cover, two Pump Power cables, 2–conductor fresh water ush solenoid cable, a Z-Ion power and signal
cable, and a 25-foot cable for the Remote Manual Controller.
Do not install it in hot or poorly venlated locaons.
Power Inlet Harness with
terminal block
*See Cape Horn Remote
Power Wiring (Page 15)
Display Port,
*see components cont.
(Page 11) for
installaon
*Manual Remote Controller
guide (Page 25) for funcon
Standard Fresh Water
Flush connector (Blue)
Z-ION Connector (with green
band).
*Only used with oponal Z-
Ion Connector
*see Zion Operaon and In-
stall (Page 16) for more
details.
Run Manual/Run Auto - Toggle Switch
*Spectra Manual Remote Operaon Guide
(Page 25)
Feed Pump B Power Cable
Feed Pump A Power Cable

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Cape Horn Remote Power Wiring
DANGER:
Installaon
• Connect wires using supplied terminal blocks.
• Use marine grade breakers and avoid house breaker panels that could be
accidentally tripped.
• Mount the main power terminal block in a juncon box or on a bulkhead
adjacent to the feed pump module.
• Make sure that this is a dry locaon well above bilge level and not subject
to water spray.
• Be sure to install the terminal block cover
• Conrm the voltage and polarity before wiring to the unit
• Gauge wire so the appropriate voltage is provided to the system. Use a Digital Mulmeter to
ensure the voltage at the power terminal block is at the nominal specicaons for the system.
• DC power feeds should be uninterrupble to ensure proper operaon.
• If the specied circuit breaker sizes are unavailable, use the next higher rang but do not
exceed the specicaon by more than 10%.
• Upon successful power up the remote display will turn on and a freshwater ush may
engage.
Warning
• All wiring and over current protecon must be done to applicable ABYC, Marine UL, or CE
standards.
• Check for exposed wiring throughout enre installaon before supplying voltage to unit.
Do not apply voltage to the unit that exceeds 14.6V / 29.2V to 12V / 24V models.
Serious damage to the electrical system may occur.
System performance is voltage specific.
12 Volt Models 24 Volt Models
Nominal Producon Voltage 13.5V DC 27V DC
Nominal Producon Amperage 19 Amps 11 Amps
Max Amperage 20 Amps 11 Amps
Recommended Breaker Size 25 Amp 15 Amp
Applying less than 10.4V / 20.8V to 12V / 24V Models will impact functions of
control system
Applying less than 12.8V / 25.6V to 12V / 24V Models will increase rate of wear
on system motor and pump.

16
Connector for generator bowl (green)
Generator bowl with
charcoal lter in bowl
Generator bowl
connector
Z-Ion control box: Mount
in a visible locaon near
the feed pump module.
Optional Z-Ion Protection System & Installation
The Z-Ion, developed by Spectra, protects the enre system from fouling for extended periods
without fresh water ushing or storage chemicals (pickling).
The Z-Ion achieves this end by introducing a stream of metallic ions into the fresh water ush
water, thus ooding the enre system with ions that prevent biological growth for up to thirty
days. If you are going to let your system sit idle for longer than thirty days, you will sll need to
treat it with SC-1 storage chemical or propylene glycol.
The Z-Ion will not prevent freezing, so in freezing climates pickling with propylene glycol is sll
required. Even with the Z-Ion there may sll be cases when you need to pickle your system
with SC-1 storage chemical or propylene glycol, so we recommend you carry one of these
products at all mes.
Installation
For a detailed overview of the Z-ION installaon, see below.

17
Customer-Supplied Tank Full Switch
Installing an oponal tank full oat switch at the top of your water tank
allows the watermaker to ll your ship’s water tank then automacally stop
running. The user can then fresh water ush with by hing ’Stop’ and then
’FWF’ on the Remote Controller.
Your watermaker does not come with the top-mounted Tank Full Switch (EL
-SWT-LV). However, this part can easily be sourced from your local dealer or
Full Service Provider if you wish for your system to automacally stop once
your freshwater tank is full.
If you do not install the Tank Full switch in your tank, you MUST MANUALLY STOP the system
when your freshwater tank has been lled. The system will not stop automacally.
NOTE: The oat may need to be ipped 180 degrees to work properly. Many oats can be
easily ipped by removing the clip opposite the wire.
Optional Tank Switch
Drill and Tap
Drill and tap a 1/8” NPT port into the top of the fresh water tank that is being lled by the
watermaker. This can be installed on a tank access cover, or directly into the water tank. If
installing on an access cover, be sure to leave a service loop on the oat switch wiring to allow
removal of the tank access cover.

18
Watermakers should never be run unaended.
Tank Full
If a tank switch has been installed, the
“Running” and “Stopped” lights will be
illuminated when the tank is full and the
system will stop.
Your watermaker should never be le running unaended.
Optional Tank Switch - Cont.
The customer supplied oat switch must be connected to the Terminals 5 & 6 labeled Tank
Full within the Control Box that is mounted to the inside of the Feed Pump Module. There is
no polarity. Remove the jumper. Connect the wires to the terminals.
Use 18/2 nned wire or larger. Wire is not included in the installaon kit.
Connect to
Terminals 5 & 6
Note: Remove only the jumper in terminals 5 & 6.

19
New System Start Up

20
Every new system is shipped from the factory with nontoxic, food-grade propylene glycol. Propylene
glycol, Spectra Chemicals, or anything other than seawater or freshwater must be purged from the
system with the pressure relief valve open at least 1/2 turn. You can purge your system with seawater or
freshwater via the Spectra’s freshwater ush funcon. The system must be purged for a minimum of 60
minutes, or unl at least 40 gallons (151.42 liters) of water have moved through the system.
CAUTION: Damage will occur if the purge process is not properly followed and the membrane is
pressurized with chemicals in it. Check that no hoses are kinked or restricng ow.
Follow this procedure for starng a new system the rst me, and aer a system has been stored or
cleaned with chemicals.
First check that:
• All of your hose connecons are ght.
• The green warning tag and washer have been removed from under the pressure relief valve.
• The pressure relief valve is open at least 1/2 turn.
• The sampling valve is set to the sample posion.
• The brine line is able to freely discharge
*For purging with seawater see next page.
New System Startup and Testing Freshwater on Dock
Open 1/2 Turn
Remove Tag and Washer Sampling Tap to Sample
To Sample To Tanks
In
For a purge using the freshwater ush:
1) Ensure The vessel’s pressurized water system is on
2) Locate the potenometer screw on the circuit board (pictured on pg. 34) and turn this all the way
clockwise to increase the ush duraon to 10 minutes.
3) Flush 6 mes in succession will achieve a 60 minute purge.
4) Remember to turn the ush potenometer screw back close to its original posion aer this is com-
plete. Only proceed to step 5 on purging with seawater: (Close the pressure relief valve. Turn on Pump B.
The pressure should rise to 90-100 PSI. If pressure does not rise Feed Pump A may need to be turned on and o
in order to prime both pumps. Water should begin to ow out of the sampling tube. If the ship is located in
brackish or fresh water the pressure will be lower) for the product purge once you can run the system in
seawater. In the interim, ensure the system is ushed with freshwater weekly or preserved with bio-
cide.