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Katadyn Spectra Watermakers Catalina 340R Installation And Operating Manual

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Catalina 340R - Remote Manual
Installation and Operating Manual
Spectra Watermakers
Katadyn Desalination LLC.
2220 S. McDowell Blvd Ext. Petaluma, CA 94954
Phone: 415-526-2780 Fax: 415-526-2787
info@spectrawatermakers.com
www.spectrawatermakers.com
Updated February 2021

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  • Page 1 Catalina 340R - Remote Manual Installation and Operating Manual Spectra Watermakers Katadyn Desalination LLC. 2220 S. McDowell Blvd Ext. Petaluma, CA 94954 Phone: 415-526-2780 Fax: 415-526-2787 info@spectrawatermakers.com www.spectrawatermakers.com Updated February 2021...
  • Page 3 EXCITING EXTENDED WARRANTY OFFER! -Upgrade the standard 1-YEAR manufacturer warranty to 2-YEARS and LIFETIME on Clark Pump. Follow the below steps to submit for approval: 1. Have system installed & commissioned by Spectra Authorized FSP (full-service provider) 2. Fill out web-based Product Registration form (see back of owner’s manual for paper copy) 3.
  • Page 5 Thank you for your purchase of a Spectra Catalina 340R system. When properly installed and maintained, it will provide years of trouble-free service. Professional installation is strongly recommended. Like any piece of mechanical equipment, the system will require inspection and service, so plan ahead for service access and install “service loops” in cabling. If a dealer is installing the system for you, review the location of the components to ensure the installation will meet your approval upon completion.

  • Page 7: Table Of Contents

    Table of Contents Getting Started ........................9 Installation Basics ......................10 Components ........................11 Catalina Plumbing Schematic & Plumbing Detail .............. 13 Product Water Plumbing and Pressure Gauge Tube Installation ........15 Plumbing Detail ......................... 18 Tube Fitting Assembly Procedures ..................20 Electrical ..........................

  • Page 9: Getting Started

    Getting Started Unpack the system and inspect it for damage during shipping. Freight damage must be reported to the carrier 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 until you have found and identified all of the parts.

  • Page 10: Installation Basics

    Installation Basics Thru-hull Not Supplied. Important Installation Notes Avoid tight hose bends and excessive runs. • Use heavy gauge wire. • Seawater Flow Install feed pump module as low as possible. • Use a dedicated thru-hull with scoop type • strainer.

  • Page 11: Components

    Components Sea Strainer and Boost Pump Module: Mount close to the intake through-hull, below the waterline, in a location that can handle water spillage during service. The boost pump power cable will connect to the feed pump module. Fresh Water Flush Module: The fresh water flush module may be located in any convenient location near the feed pump module.
  • Page 12 Components Cont. 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 routing.

  • Page 13: Catalina Plumbing Schematic & Plumbing Detail

    Simplified Plumbing Layout Mount Controller in a dry location well above the waterline. Brine discharge thru hull (not included): place above waterline (Pressurized or tee into another Fresh Water) visible drain. Note: Brine discharge hose may Freshwater Storage Feed be connected to either side of tank Pump Module Clark Pump...
  • Page 14 Installation Notes...

  • Page 15: Product Water Plumbing And Pressure Gauge Tube Installation

    Product Water Plumbing and Pressure Gauge Tube Installation Product to tank: Route the product water from the valve into the top of a vented tank. Install a tee in the water fill or tap a Sampling Tap for testing pipe thread into an inspection port. the product water.
  • Page 16 Product Water Plumbing and Pressure Gauge Tube Orientation The black 1/4” tubing runs from the accumulator to the Feed Pressure Gauge. Locate an optimal location close to the Clark Pump for viewing and mounting the Product Water Flowmeter & Feed Pressure Gauge Panel and then cut the provided black 1/4”...

  • Page 18: Plumbing Detail

    Plumbing Detail From the intake seacock to the sea strainer/boost pump module, and from the sea strainer/boost pump module to the pre-filter housing on the feed pump module, use the 3/4-inch black, spiral- wound suction hose: Your system includes 25-feet of 1/2-inch vinyl hose with a Quick Connect fitting on one end and a 1/2-inch John Guest stem fitting on the other, both crimped on with ferrules.
  • Page 19 Plumbing Detail Cont. From the feed pump to the Clark Pump feed water inlet, use the remaining 1/2-inch vinyl hose, with the 1/2-inch John Guest stem fitting pre-fitted with a ferrule. Insert the pre-fitted end into the feed pump (Figure 1), and the 1/2” John Guest stem fitting and hose clamp from the installation kit for the Clark Pump feed water inlet (Figure 2).
  • Page 21 John Guest Super Speedfit Fittings...

  • Page 22: Electrical

    Electrical Catalina 340R systems are pre-fitted with waterproof connectors for electrical and signal cables. Each connector is different, 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, a 2- conductor boost pump cable, a 2–conductor fresh water flush solenoid cable, a Z-Ion power and signal cable, and a 25-foot (7.62M) cable for the Remote Manual Controller.
  • Page 23 Electrical Cont. Connect the yellow boost pump connector from the bottom of the feed pump housing to the corresponding connector routed from the boost pump. Mount the main power terminal block in a junction box or on a bulkhead adjacent to the feed pump module.
  • Page 24 Electrical Cont. The Catalina 340R has one port that can be viewed when looking down inside the Feed Pump Module. This port is labeled ‘Display’ but is actually for the Remote Manual Controller. The Remote Controller cable is a standard Cat 5e ethernet cable.

  • Page 25: Installing A Remote Controller

    Installing a Remote Controller Route the cable through the vessel in the most direct route possible. Avoid kinking the wire, or sharp corners where the wire can chafe through while the vessel is under way. Turn power OFF to the system. Connect the ethernet cable to back of the display in the open jack.

  • Page 26: Optional Tank Switch Installation

    Optional Tank Switch The customer supplied float 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 tinned wire or larger.
  • Page 27 Optional Tank Switch - Cont. Customer-Sourced Tank Full Switch Installing an optional tank full float switch at the top or the side of your water tank allows the watermaker to fill your ship’s water tank then automatically stop running. The user can then fresh water flush the system by hitting ’Stop’ and then ’FWF’...

  • Page 28: New Systems Start Up And Testing

    New System Start-Up and Testing Avoid running the Catalina system if the vessel is in contaminated water. The system should be fully tested before leaving port. If the location or weather prevents proper testing, refer to Dry Testing with an Artificial Ocean on page 29. Every new system is shipped from the factory with nontoxic, food-grade propylene glycol.

  • Page 29: Dry Testing With An Artificial Ocean

    Dry Testing with an Artificial Ocean If it is not possible to test run the system with the boat in the water, you may test the system with an artificial ocean. You will need 1.3 lbs. of non-iodized salt (rock salt, sea salt, or aquarium salt) to make a 5 gallons (33 grams of salt per liter) of water that is about 33,000 PPM salinity (average seawater salinity).

  • Page 30: Spectra Remote Manual Controller Guide

    Spectra Manual Remote Controller Guide If the system has been pickled, winterized, this is the first startup, or the condition of the system is unknown, go to NEW SYSTEM START-UP on page 28 or serious damage may occur. A fresh water flush should be performed after every use of the watermaker. The system will need to run for approximately half an hour to make enough fresh water for one flush.

  • Page 31: Freshwater Flush Calibration

    Freshwater Flush Calibration Flush Adjustments Adjustments for your Catalina 340R are typically calibrated from the factory to ensure that sea water is thoroughly flushed out of the watermaker using the least amount of fresh water. However, due to different lengths of hose runs, different rates of flow, and different pressures in shipboard fresh water systems, the flush duration should be optimized for your boat.

  • Page 32: Adjusting Fresh Water Flush Duration

    Adjusting Fresh Water Flush Duration 3. Check/Adjust the flush duration Run the watermaker for 10 minutes to fill the system with seawater, confirm that good product water is being sent to the tanks. Press the ‘Stop’ button. The system will stop. Press the ‘FWF’ button and the system will begin flushing.

  • Page 33: Normal Operation And Fresh Water Flush

    Normal Operation and Fresh Water Flush If the system has been pickled, stored, or contains cleaning compounds, use the New System Startup procedure. The system should be fully run tested before you leave port. If the location or weather prevents proper testing refer to “Testing with an Artificial Ocean.”...

  • Page 34: Maintenance

    Maintenance General Periodically inspect the entire system for leakage and chafing. Repair any leaks as soon as you find them. Some crystal formation around the Clark Pump blocks is normal. Wipe down any salt encrusted areas with a damp cloth. Watermakers are at their best when run regularly.
  • Page 35 Maintenance Cont. The Charcoal Fresh Water Flush Filter Replace the charcoal filter element at least every 6 months. This filter protects the membrane by removing chlorine from the flush water. Use only a Spectra-approved replacement. The Feed Pump and Clark Pump The feed pump and the Clark Pump require no routine maintenance except inspection for leaks.
  • Page 36 Maintenance Cont. Leaking Fittings The system has eight high pressure fittings, two on each cylinder on the Clark Pump, two on the pressure vessel end caps, and two 90-degree elbows on the back of the Clark Pump. As the compression fitting is tightened, it compresses a ferrule onto the stainless tubing, fixing the ferrule permanently to the tube and holding the compression nut captive.
  • Page 37 Maintenance Cont. Introduction to Spectra Chemicals We use four types of chemicals: SC-1, SC-2, SC-3, and propylene glycol antifreeze. SC-1 and propylene glycol are for system storage, while SC-2 and SC-3 are for membrane cleaning. Do not use sodium-bisulfate, citric acid, or any other storage chemical not supplied by Spectra. These chemicals, used to store other watermaker brands, will damage the Clark Pump, membrane end plugs, manifolds, and other components.

  • Page 38: Introduction To Spectra Chemicals

    Maintenance Cont. Introduction to Spectra Chemicals - Cont. Complete microbial protection requires a 25% solution of propylene glycol, so care must be taken that the solution remaining in the watermaker during long term storage is at least 25%, even if freeze protection is not required. For these reasons Spectra recommends that all pickling be carried out with a 60% or greater concentration.

  • Page 39: Storage Procedures

    Storage Procedure 1. Close the intake seacock. 2. Push the Fresh Water Flush (FWF) button to fresh water flush the system. Perform a second fresh water flush in the same way. 3. Remove the quick disconnect fitting from the brine discharge outlet of the Clark Pump, per photo below, and replace it with the quick disconnect brine discharge service hose.

  • Page 40: Winterizing With Propylene Glycol

    Winterizing with Propylene Glycol See description of propylene glycol formulations, and purging from system. 1. Close the intake seacock. 2. Push the Fresh Water Flush (FWF) button to fresh water flush the system. Perform a second fresh water flush in the same way. 3.

  • Page 41: Membrane Cleaning Procedure

    Membrane Cleaning Procedure Spectra cleaning compound (SC-2 or SC-3) must be mixed with fresh water at a ratio of 1 container of compound to 3 gallons (12L) of unchlorinated water. A Catalina 340R system requires one container of compound per cleaning. 1.

  • Page 42: Suggested Spares

    Suggested Spares for the Catalina 340R Short term cruising, weekends etc. A basic cruise kit A. This kit consists of six 5 micron filters and two packs of SC-1 storage chemical. Cruising 2 to 6 months at a time. Two basic cruise kits, one replacement charcoal filter, and one replacement feed pump head.

  • Page 43: Troubleshooting

    Troubleshooting Catalina Remote Manual Systems REMEDY PROBABLE CAUSE SYMPTOMS • While system is running, kink brine No product flow, good brine • Internal leak in Clark Pump hose to stop flow until pressure rises to discharge flow, 125psi (a few seconds), release hose Recovery percentage is 0 (See quickly, repeat no more than 10 times Flow Test)
  • Page 44 Troubleshooting Catalina Remote Manual Systems SYMPTOMS PROBABLE CAUSE REMEDY • Low product flow, more than 1 Motor receiving less than • Check wiring for voltage drop. Increase GPH Total flow down (see 12.5 VDC wire size if necessary flow test) •...
  • Page 45 Catalina 340R Fault Alarms SYMPTOMS PROBABLE CAUSE REMEDY High Pressure or Vacuum Switch Fault Light Illuminated • • Check brine discharge Blocked brine discharge • • Check static pressure Restriction in Clark Pump/ (pressure with system Membrane running and pressure relief valve open 1/2 turn) *Nominal Static Pressure on CT340 is 25-35psi...

  • Page 46: Catalina Flow Test

    Catalina 340R Flow Test The flow test is the most useful diagnostic test for system performance, and should be done before replacing or cleaning your membrane. Changes in production or water quality are normally caused by something other than the membrane, unless the system has been left unused for a long time.
  • Page 47 1. Product Flow: Product flow is expressed in Gallons Per Hour (GPH) or Liters Per Hour (LPH), by this equation: 3600 ÷ time in seconds x quantity of water in gallons or liters = GPH or LPH There are 3600 seconds in an hour. Example: It took 3 minutes and 35 seconds to collect 1 gallon of product water.

  • Page 48: Poor Water Quality

    Poor Product Water Quality With any product water quality issue, you must ensure accurate calibration if you are using a salinity meter. For general quality evaluation, your taste is always good enough. Membranes are not an exact science and two identical systems can have different product quality.

  • Page 49: Technical Bulletins

    Technical Bulletins The following pages include Spectra’s most commonly-used technical bulletins, covering tests, adjustments, troubleshooting, and common points of confusion. Many more technical bulletins are available on the Spectra website, www.spectrawatermakers.com. ACCUMULATOR PRESSURE Your Catalina 340R is supplied with a pressure accumulator tank (PL-ACC-TK) installed in the feed water line between the feed pump and the Clark Pump.
  • Page 50 PREFILTERS During normal operation, the feed water is filtered in two stages. First it passes through a fine mesh metal sea strainer, which protects the boost pump from foreign materials and sea creatures. After passing through the boost pump, the feed water passes the filter housings containing the 5 micron element, removing very fine particles that could damage the feed pump or Clark Pump and shorten membrane life.
  • Page 51 CHARCOAL FILTERS The charcoal filter element (FT-FTC-CC) removes chlorine from the fresh water flush water supply, as the RO membrane can only handle small amounts of chlorine without permanent damage. The charcoal filter used for the fresh water flush system will not plug up unless you have very dirty domestic water in your boat’s supply tank.

  • Page 54: Control Box Wiring

    Control Box Wiring Multiple Display Ports Switches for Relays 7-13 1. PWR IN+ 5. TANK SW 9. PWR RELAY+ 13. D.V.+ 2. PWR IN- 6. TANK SW 10. PWR RELAY- 14. D.V.- 3. PRS. SW 1+ 7. BOOST PUMP+ 11. FWF SPEED+ 15.

  • Page 56: Exploded Views And Part Numbers

    Exploded Views and Part Numbers High Pressure Module PL-TB-HPTPVUL Pump to Pressure Vessel PL-HP-1/8 Upper SS Tube Long 1/8NPT Nylon Hex Plug PL-MTS-3/8X1/2B FT-PV-40 3/8"NPTX1/2"Tube Fitt. St. 40” High Pressure Vessel SO-HPP-CT PL-TEE-1/2TJG PL-TB-HPTPVLL SUB-CT-Z-HPILHA Connector O-ring John Guest 1/2-inch swivel tee Pump to Pressure Vessel CT 340R Quick Disconnect Lower SS Tube Long...
  • Page 57 Part Numbers FT-FHB-3PCSHSS MOLDED FILTER PL-BSH-3/4X1/2N BRACKET 3/4" X 1/2" HEX BUSHING REDUCER PL-HBE-3/4X3/4 3/4” NPT X 3/4” HOSE PL-SWF-1/2X1/2 BARB ELL NYLON 1/2"NPT X 1/2” TUBE SWIVEL ELBOW FT-FTH-10L3PCS 3 PIECE 10” FILTER HOUSING PL-NLT-1/2LP 1/2" LOW PRESSURE TUBE EL-SWT-TG-DPDT TOGGLE SWITCH DP/DT EL-SWT-TSBHC...
  • Page 58 Part Numbers PL-STA-12TX38NJ 1/2” TUBE STEM x 3/8” NPT ADAPTER EL-SWT-PS120 PRESSURE SWITCH 120 PSI PL-TEE-1/2TJG 1/2” TUBE TEE JG PL-UNN-3/8x1/4N 3/8”FPT x 1/4” FPT COUPLING KIT-REM-RMC SPECTRA MANUAL NYLON REMOTE CNTRL. EL-SWT-PS200 PRESSURE SWITCH 200 PSI Hoses and Tubes Inlet/Flush Hose Assembly (SUB-CT-Z-HPIBHA): SUB-MD-PNLA380 REMOTE GAUGE PANEL ASSEMBLY...
  • Page 59 Part Numbers Boost Pump Module SUB-CT-Z-BPM PL-BHF-3/8TPIEJ 3/8” STEM ELBOW JG PL-BHF-3/8TSTJG EL-FP-BPLDC824 3/8” BULKHEAD FITTING JG 300-1000 BOOSTER PUMP DC 8-24 Volts PL-HBS-3/4X3/4 3/4” HOSE BARB NYL PL-CKV-1M3/4FWS 3/4” CHECK VALVE PL-FHB-1/2X3/4E 1/2"FPT X 3/4"Hose Barb Elbow NYLON SO-STN-6SS SEA STRAINER GASKET FT-STN-6 6”...
  • Page 60 Brine Discharge Quick Connect SUB-CT-Z-HPILHA CATALINA 340 HP INLET HOSE ASSEM. PL-QDC-HB5/8 5/8” Quick Disc. Fitting Hose Barb High Pressure Fittings SO-FT-STF SUB-MTS-3/8X1/2 3/4”-16 Straight Thread O-RING Nickel-Bronze High Pressure Straight Fitting PL-HWR-1/2FR 1/2” Stainless Ferrule SO-HPP-CT PL-MTE-3/4S1/2B Connector O-RING 3/4"-16 ST X 1/2"Tube Fitting PL-HWR-1/2HN Elbow Bronze...
  • Page 61 HP-TB-VEB-B HP-TB-VB HP-TB-VEB-A HP-CYL-CCA HP-TB-BV HP-CB-CB10 HP-CYL-SST HP-CYL-R HP-CYL-EC Not used...
  • Page 62 HD-CPS-5/16X3 SO-HPP-RV HP-TB-ARP KIT-HP-10VSA HP-TB-BV SO-HPP-AR1 HD-CPS-5/162.75 SO-HPP-SP HP-TB-VSP HP-TB-SR SO-HPP-VB SO-HPP-VP SO-HPP-PLP...
  • Page 63 Parts...
  • Page 64 Parts Parts HP-CYL-SST HP-CYL-PT PL-MTS-3/8X1/2B HP-CYL-CCA SO-HPP-ECCB HP-CYL-EC HP-CYL-R...
  • Page 65 You must examine the Product upon receipt and notify Katadyn Desalination LLC. if any item is damaged or missing within 30 days from the date of the delivery. Damage due to freight must be reported to Katadyn Desalination LLC. and to the freight carrier within 24 hours of delivery.
  • Page 66 SOLE WARRANTY THE PRODUCTS AND ARE IN LIEU OF AND EXCLUDE ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, ARISING BY OPERATION OF LAW OR PRODUCTS ARE SPECIFICALLY DESIGNED AND/OR MANUFACTURED BYMANUFACTURER FOR YOUR USE OR PURPOSE. WHAT WE WILL DO TO CORRECT PROBLEMS If You return the defective product during the warranty period and in accordance with the instructions contained herein, shipping prepaid, the Manufacturer shall, at its option and as Your exclusive remedy, repair, correct or replace the product at no charge if the product is found by the...
  • Page 67 Web-Based Format (Preferred option): spectrawarranty.formstack.com/forms/product_registration spectrawarranty.formstack.com/forms/spectra_install_commissioning_report Email: TechSupport@SpectraWatermakers.com Phone: +1(415) 526-2780 Address: Katadyn Desalination Technical Department 2220 S. McDowell Blvd Ext Petaluma, CA 94954 Please keep a copy of these reports for your records.
  • Page 69 Spectra Watermakers Installation Report (To be completed by authorized installer) The following checklist is designed to confirm that the watermaker installation meets Spectra standards. Fill out the checklist as completely as possible. Check any boxes that apply and note any concerns. Please document any discrepancies or concerns with photos. INLET □...
  • Page 71 Spectra Watermakers Commissioning Report – Page 1 (To be completed by authorized installer) The following checklist is designed to confirm that the watermaker installation meets Spectra standards and that the system is performing at specification. Fill out the below checks as completely as possible. Check any boxes that apply and note any concerns. PURGE □...
  • Page 72 Spectra Watermakers Commissioning Report – Page 2 OWNER EDUCATION Owner has been trained on the following: Know locations of □ Seacock/Thru-hull □ Sea strainer module □ Prefilter (and/or) Feed Pump Module □ Freshwater Flush Module □ High Pressure Module □ Clark Pump Pressure Relief valve □...

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