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Summary of Contents for Katadyn Spectra Watermakers Cape Horn Extreme 330R-Remote
- Page 1 Cape Horn Extreme 330R-Remote Installation and Operating Manual Spectra Watermakers Katadyn Desalination LLC. 2220 S. McDowell Blvd Ext. Petaluma, CA 94954 Phone: 415-526-2780 www.spectrawatermakers.com Updated March 2025...
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Page 3: Table Of Contents
Table of Contents Getting Started ........................4 Installation …………………………………………………………………………………………………………..…..7 Introduction to the Cape Horn Extreme 330 ..............8 Installation Basics ........................ 9 Components ........................10 Cape Horn Extreme Plumbing Layout ................12 Product Water Plumbing and Pressure Gauge Tube Installation ........13 Cape Horn Extreme Remote System Wiring .............. -
Page 4: Getting Started
Getting Started and Manual Overview Description of the pictograms The following symbols will be used in the manual to highlight important indications and warnings: ATTENTION: This symbol indicates accident prevention 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. - Page 5 ATTENTION Important Information Safety Warning Cont. Study the system layout diagram, component photos, and descriptions before beginning installation. 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.
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Page 7: Installation
Installation... -
Page 8: Front View
Introduction to the Cape Horn Xtreme Remote Manual The Cape Horn Xtreme Remote Manual is designed to be efficient, simple, and durable. Properly installed and maintained it will supply years of reliable service. Prudent operation is required with any marine equipment. Always maintain enough reserve water to get safely into your next port. The Spectra Intensifier, known as the Clark Pump, was introduced in 1997 and has continually improved since. -
Page 9: Installation Basics
Installation Basics Thru-hull Important Installation Notes Not Supplied. • Avoid tight 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. -
Page 10: Components
Components Sea Strainer Mount close to the intake through-hull, in a location that can handle water spillage during service. Feed Pump Module A Mount the feed pump module on a vertical surface, no more than 3-feet (1.0M) above the waterline. It is preferable to mount as low as possible. - Page 11 Components - Cont. Remote Manual Control Box The remote manual control box should be mounted so the toggle switch can be accessed during trouble shooting or maintenance. It may need to be opened during commissioning in order to optimize the flush duration 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 option Z-Ion protection system.
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Page 12: Cape Horn Extreme Plumbing Layout
Cape Horn Xtreme 330R Plumbing Layout Water-sensitive Equipment. Note: Brine discharge may be connected to ei- ther side of Clark Pump Note: High Pressure Fittings may develop drip leaks in ship- ping. See Fitting instructions for detailed resolution Brine discharge thru hull (not included): place above waterline (Pressurized... -
Page 13: 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 the pipe thread into an inspection port. -
Page 14: Cape Horn Extreme Remote System Wiring
Cape Horn 330 Remote System Wiring Cape Horn Extreme 330 Remote Manual 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, two Pump Power cables, 2–conductor fresh water flush solenoid cable, a Z-Ion power and signal cable, and a 25-foot cable for the Remote Manual Controller. - Page 15 Cape Horn Remote Power Wiring DANGER: Installation • 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 junction box or on a bulkhead adjacent to the feed pump module.
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Page 16: Optional Z-Ion Protection System And Installation
Optional Z-Ion Protection System & Installation The Z-Ion, developed by Spectra, protects the entire system from fouling for extended periods without fresh water flushing or storage chemicals (pickling). The Z-Ion achieves this end by introducing a stream of metallic ions into the fresh water flush water, thus flooding the entire system with ions that prevent biological growth for up to thirty days. -
Page 17: Optional Tank Switch
Optional Tank Switch Customer-Supplied Tank Full Switch Installing an optional tank full float switch at the top 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 with by hitting ’Stop’ and then ’FWF’... - Page 18 Optional Tank Switch - Cont. 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.
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Page 19: New System Start Up
New System Start Up... -
Page 20: New System Startup And Testing Freshwater On Dock
New System Startup and Testing Freshwater on Dock 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 flush function. -
Page 21: New System Startup And Testing In Ocean
New System Startup and Testing in Ocean 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 flush function. -
Page 22: Operation
Operation... -
Page 23: 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 24: 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 25: Spectra Manual Remote 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 19 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 15 minutes to make enough fresh water for one flush. -
Page 26: Adjusting Freshwater Flush Duration
Adjusting Fresh Water Flush Duration The Cape Horn Freshwater Flush Duration is set to a factory default of 3 minutes, which is usually the right amount of time 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 can be optimized for your boat. -
Page 27: Suggested Spares
Suggested Spares Short term cruising, weekends, etc.: We suggest two treatments worth of preservative chemicals (either 2 bags of SC-1 or 2 gallons (8 liters) of Propylene Glycol). Six 5-micron filters and one Carbon filter. Cruising 2 to 6 months at a time: Twelve 5-micron filters, 2 Carbon filters, enough preservative chemicals for 4 treatments, one replacement feed pump head. -
Page 28: Maintenance, Storage & Troubleshooting
Maintenance, Storage, and Troubleshooting... -
Page 29: 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 30 Maintenance - Cont. Oil Water Separator (Optional) For oil/water separation, install the additional filter housing with its oil removal filter upstream of the 5 micron filter. Service at the same time as the 5 micron filter. The Charcoal Fresh Water Flush Filter Replace the charcoal filter element at least every 6 months.
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Page 31: Cape Horn Extreme Plumbing Diagram
Cape Horn Extreme 330R Plumbing Diagram... -
Page 32: Cape Horn Extreme Electrical Diagram
Cape Horn Extreme 330R Electrical Diagram 12V/24V... - Page 33 Cape Horn Extreme 330R 12V/24V...
- Page 34 Cape Horn Extreme 330R 12V/24V...
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Page 35: Cape Horn Extreme Electrical Specifications
Cape Horn Extreme 330R Electrical Specifications CAPE HORN EXTREME REMOTE 12V W/SHORT Power Supply Voltage: 12 VDC Bench Test: 13.7 V / 20 A Power Consumption: 275 W Efficiency: 18 Wh/gal CAPE HORN EXTREME REMOTE 12V W/LONG Power Supply Voltage: 12 VDC Bench Test: 13.6 V / 21.4 A Power Consumption: 292 W Efficiency: 19 Wh/gal... -
Page 36: Introduction To Spectra Chemicals
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. CAUTION: Do not use metasodium-bisulfate, citric acid, or any other storage chemical not supplied by Spectra. - Page 37 Introduction to Spectra Chemicals - Cont. Complete microbial preservative 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.
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Page 38: Cape Horn Storage Procedure
Cape Horn Remote Manual Storage Procedure NOTE: The Cape Horn contains about 2 gallons of water at any given time, so with 2 gallons in the bucket there will be a total of 4 gallons of solution. 1. Close the saltwater intake seacock. 2. -
Page 39: Winterizing With Propylene Glycol
Winterizing with Propylene Glycol See description of propylene glycol formulations, and flushing from system on page 36. 1. Close the saltwater intake seacock. 2. Push the Freshwater Flush button to perform a flush. Repeat a second flush. 3. Disconnect the brine discharge hose from the Clark Pump at quick disconnect. Replace with the vinyl brine discharge service hose* from your service kit. -
Page 40: Membrane Cleaning Procedure
Membrane Cleaning Procedures Spectra cleaning compound (SC-2 or SC-3) must be mixed with freshwater at a ratio of 1 container of compound to 3 gallons (12L) of non-chlorinated water. An average of two gallons (8L) of water is already present inside a Cape Horn 330 Extreme Remote Manual system, so this water must be figured into the mixture. -
Page 41: Flow Test
Flow Test for Dual ShurFlo Pumps (Cape Horn Extreme 330R) NOTE: 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 42 Flow Test - Cont. On the Cape Horn Xtreme, you should perform the tests using each pump alone, then using both pumps. To run one pump, simply unplug the other pump. Compare the results to the table in the New System Startup section. Minimum acceptable Product Recovery Rate = 8% Nominal Total Flow Rate = 2.7-2.8 G/M 1.
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Page 43: Troubleshooting
Troubleshooting Cape Horn Extreme 330 Remote Manual Systems SYMPTOMS PROBABLE CAUSE REMEDY Low product flow, more than 1 Motor receiving less than Check for voltage drop. Increase GPH, Total flow down (See Flow 12.5VDC. A 0.5 VDC decrease at wire size if necessary. Test.) the feed pump motor can equate Check Power Supply. - Page 44 Troubleshooting Cape Horn Extreme 330 Remote Manual Systems SYMPTOMS PROBABLE CAUSE REMEDY No Product flow, good brine dis- Internal leak in Clark Pump. While system is running kink brine charge flow. Recovery percentage hose to stop flow until feed pres- is 0 (See Flow Test) sure rises to 115 psi, release hose quickly, repeat no more than 10...
- Page 45 Troubleshooting Cape Horn Extreme 330 Remote Manual Systems SYMPTOMS PROBABLE CAUSE REMEDY Scaled or Fouled Membrane Clean membrane. Low Feed Pressure, Low Amper- Warm seawater or brackish water Normal Condition. PPM rises steadily while pressure Membrane needs to be replaced Consult dealer and replace mem- and production remain constant brane.
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Page 46: Spectra High Pressure Fitting Instructions
Spectra High Pressure Fitting Instructions Our systems have 8-12 high-pressure fittings, depending on the model. There are two fittings on each cylinder of the Clark Pump, two to six on the pressure vessel end caps, and two 90- degree elbows on the back of the Clark Pump. When tightening a compression fitting, it compresses a ferrule onto the stainless tubing, permanently fixing the ferrule to the tube and holding the compression nut captive. -
Page 47: Technical Bulletins
Technical Bulletins NOTE: The following pages include Spectra’s most commonly used technical bulletins, ad- dressing tests, adjustments, troubleshooting, and common points of confusion. Many more technical bulletins are available on the Spectra website, support.katadyngroup.com. DWYER FLOW METER SERVICE The mechanical flow meter, PL-FMT-10 (10 GPH range) or PL-FMT-20 (20 GPH range) can be opened for cleaning if it becomes difficult to read or if the little ball gets stuck. - Page 48 PREFILTERS It is important to remember that your Spectra Watermaker is designed to process clean, open- ocean seawater. Any departure from that standard for your seawater intake runs the risk of caus- ing excessive wear or damage to internal pump parts and/or the vulnerable reverse osmosis membrane.
- Page 49 PREFILTERS CONT. When operated for only an hour or two a day in inland or near-shore waters, the trapped plankton will begin to decay in the filter long before it plugs up. The decaying plankton and bacteria will cause a rotten egg smell in the product water. This decay will set in overnight in tropical waters, or after a week or two in higher latitudes.
- Page 50 SHURFLO PUMP WON’T RUN If the pump has power to it but the pump won’t run, first check the pressure switch. The pressure switch (EL-FP-PS) is located on the wet end of the pump and has two red wires plugged into it. DANGER: Jump the two red wires together and see if the pump runs.
- Page 51 ADJUST SHURFLO PRESSURE SWITCH Shurflo feed pumps are equipped with a high pressure cutout switch (EL-FP-PS). This is the small black unit on the end of the wet end of the pump head (PL-PMP-SFPH) where the two red wires connect. If the pressure switch is not properly adjusted the pump may cut out each time the Clark pump cycles and the feed pressure spikes.
- Page 52 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 53 Z-Ion Operation The Z-Ion should be energized at all times, but will only consume power when operating. Upon initial power-up the LED will flash red/green and then will turn solid green. Follow the instructions for Normal Operation and Fresh Water Flush. For treatment with the Z-Ion, the process is identical, only the Z-Ion will release silver and copper ions into the flush water when you turn on the generator with the on/off switch.
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Page 54: Parts Identification
Cape Horn Extreme Part Numbers Feed Pump Module A, with charcoal filter for fresh water flushes 1-Way Solenoid Valve 12V 3/4”NPT X 1/2” Hose PL-SLN-1/4O12SV Barb Elbow Fresh Water Flush Valve: PL-HBE-3/4X1/2 3/4”NPTX3/4”FPT PVC Valve Clear Filter Housing PL-VLV-3/4PVC (Bowl & Cap) FT-FTH-10L3PCS Filter Housing Seal 12 Volt: KIT-FK12... - Page 55 Cape Horn Extreme Part Numbers - Cont. Pump to Pressure Vessel Upper SS Tube Long 1/8NPT Nylon Hex Plug PL-TB-HPTPVUL 1/8"FPTX1/4"Tube Fitting Ell. PL-HP-1/8 PL-FTE-1/8X1/4P Pressure Vessel End Cap: FT-PV-EP1 3/8"NPTX1/2"Tube SS Fitt. St. PL-MTS-3/8X1/2S Pump to Pressure Vessel 40” High Pressure Vessel Lower SS Tube Long: FT-PV-40 Connector O-ring...
- Page 56 Cape Horn Extreme Part Numbers - Cont. Accumulator Tank PL-ACC-TK 1/2” X 1/4” Bushing Reducer PL-BSH-1/2X1/4N 1/2”NPT X 5/8 Hose Barb PL-HBS-1/2X5/8 1/2” Nipple PL-NP-1/2N Pump to Pressure Vessel Upper SS Tube: PL-TB-HPTPVUL 1/2” Female Tee PL-TEE-1/2FN PL-MTE-3/4SX1/2SL 3/4"-16S X 1/2""TUBE 90DEG. SS316L 1/4MPT X 1/4 TUBE Straight Fitting Plate Bracket End Cap...
- Page 57 HP-TB-VEB-B1 HP-TB-VB HP-TB-VEB-A1 HP-CYL-CCA HP-TB-BV HP-CB-CB7 HP-CYL-SST HP-CYL-R HP-CYL-EC Not used...
- Page 58 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 59 Parts HP-CYL-3/4R,...
- Page 60 Parts HP-CYL-SST HP-CYL-PT PL-MTS-3/8X1/2B SO-HPP-ECCB HP-CYL-CCA HP-CYL-EC HP-CYL-R...
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Page 62: Owner Resources & Warranty
Owner Resources & Warranty... -
Page 63: Product Registration , Installation & Commissioning Reports
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 64 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 De- salination LLC. and to the freight carrier within 24 hours of delivery.
- Page 65 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 SPE- CIFICALLY DESIGNED AND/OR MANUFACTURED BYMANUFACTURER FOR YOUR USE OR PUR- POSE. 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 reme- dy, repair, correct or replace the product at no charge if the product is found by the Manufacturer to...
- Page 66 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 67 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 68 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 69 Spectra Watermakers Commissioning Report – Page 2 OWNER EDUCATION Owner has been trained on the following: Know locations of □ Seacock/Thru-hull □ Sea strainer Module □ Feed Pump Modules A and B □ Prefilter □ High Pressure Module □ Clark Pump Pressure Relief Valve □...
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