catalina 300 deluxe installation & owner`s manual
Contents
1. 15 Membrane Pressure Vessel ttt radar etie eda a veste oU 16 Spectra High Pressure Tube Fitting Assembly 17 Mat Epiat aus 18 Winne Dia 20 Z Drane 39 Operation Up and Vesti Na a 21 Dry a 22 Adjust Fresh Water Fl sh Cycle sees Dopod a e esten 23 IN Gia 25 Manual E 25 MG A O 26 BUUS c 33 Service amp Maintenance Long Ternistorage Procedures met ibd boe na notet san 2 A A 29 Membrane CeT A 30 Spars tus 22 Parts Breakdown for all Catalina Deluxe 42 Getting Started Unpack the svstem and inspect it to make sure that it has not been damaged in shipment Refer to the shipping list for vour svstem to make sure vou have received all of the compo nents listed Do not discard anv packaging until vou have found and identified all of the parts The small installation parts are listed on the Installation Kit pick2. SPECTRA WATERMACDCHINES CATALINA 300 DELUXE INSTALLATION amp OWNER S MANUAL Spectra Watermakers Inc 20 Mariposa Road San Rafael CA 94901 Phone 415 526 2780 Fax 415 526 2787 E mail spectra spectrawatermakers com www spectrawatermakers com 10 21 05 NON MPC VERSION Thank you for your purchase of a Spectra Catalina system Properly installed it will provide years of trouble free service Please pay attention to the installation instructions and the sys tem layout Like any piece of mechanical equipment the system will require inspection and service from time to time Do not place the components in inaccessible areas that will pre vent proper maintenance If you are having a dealer install the system for you review the location of the components to make sure that the installation will meet your approval upon completion Catalina Installation Quick Start Important Details for Installer l The system must have a dedicated sea water inlet to guarantee a flow of water FREE OF AIR BUBBLES to the system The inlet should be as low in the boat as possible and with a scoop type forward facing thru hull fitting installed 2 Both the Catalina Mag Drive Feed pump module and the Clark pump Membrane mod ule must be installed in a well ventilated compartment where temperatures will not exceed 120F 48C Many engine compartments exceed this temperature when under way Warranty will be void if the installation does not
3. Prevent tight bends and excessive elbows Any restrictions will hamper system performance 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 after several hours of operation Wiring e Pay attention to wire size or system performance will be impaired e Perform wiring to UL ABYC CE or applicable standards Component Placement Refer to the Plumbing Diagrams Sea Strainer f Mount strainer 1 an accessible area close to the intake through hull that can handle water spillage during service Extra care during assembly must be taken to avoid air leaks from the strainer Use the supplied Quick Block cradle and wire tie for mounting Fresh Water Flush Module The fresh water flush module should be located between the intake strainer and the feed pump Module and as low as possible in the vessel It should be mounted with the filter housings vertical and accessible for changing filters Allow 2 below the filter housing for removal Do not install over electrical equipment Remove filter bowls for access to the screw holes in the mounting plate The unit contains a 50 Micron prefilter charcoal filter for the flush water flush solenoid and three way intake service valve Optional Z Brane The optional Z Brane Water treatment system is permanently in stalled in the membrane pressure vessels and continuously hel
4. 3 1 4 SS AH Bolts HD CPS 5 16X3 Relief Valve O Ring SO HPP RV Annular Rings HP TB AR Spool Assembly KIT HP IOVSA aye Annular Ring O Rings Mount inside Block Valve Block HD CPS 5 162 75 5 16 2 3 4 SS A H bolts mu 2 End block B yoo 2 HP TB VSP VSP20 Spool piston SS HP TB SR Spacerring Valve block _ SO HPP VB Valve bore O ring Spacer ring Spool piston End blockA 2 port D ring SO HPP VP Valve spool Pilot port O rings SO HPP PLP B 6 Reversing Valve End Blocks 47 Valve port seals SO HPP VP Pilot valve port seals SO HPP PLP Piston rod HP CYL 7 8R b Center block O rings X SO HPP ECC Pilot spool O rings 4 Mount inside block SO HPP PV HP CB PVS Pilot spool HP CB PPS Pilot valve pin SO HPP PS Pin seal O rings HP CB PVPS Pin seals HP CB PVCR Cliprings Pilot orifice HP CB PO Center block Rod lip seals E Mount inside block SO HPP PR7 PR10 PR15 Feed in Check valve port O rings SO HPP CVP Check valve assembly Bc AW Check valve SO HPP CVS Piston to rod O rings 2 4 IIA L O ring Inside pistons Glass rod models only Check valve seat HP CB CVS Center Block Check valve poppet HP CB CV Sl Check valve spring HP CB SPR 777 Check valve washer HP CB CVSW HP CB CVR 48 1 2
5. located here Product fitting Remove one of the 1 8 inch NPT prod uct port plugs from either end of the membrane housing and thread in the product fitting with Teflon tape sealant 14 Parker Tube Fitting Assembly Procedure Tubing 2 AN ANNA Single grab ring for 1 4 amp 3 8 tube Use 2 grab rings for 1 2 tube RAN KW SNO Spacer O ring Body AM AM AW ANA AN J NYS h ASSN NNN NNN SS AN AM AN AN SS SS AN AW AN AN N X Y N NN AN NN ANN 1 2 max PQQ PQQ POO ns N Dissemble fitting components Step 1 Slip the O ring over the tube to hold the Spacer place If the Grab Ring is pushed too far trim back the tube so about 1 4 of tube extends past the O ring Step 2 Install the Nut first then use the bevelled side of the Spacer to push the Grab Ring onto the tube no more than 1 2 fit the tube into the body and loosely thread on the nut Be careful not to cross thread the nut Step 3 Gently 1 2 tube should not bottom out in the fitting to allow full compression of the O ring The tube should not come out if pulled by hand If it does tighten the grab ring tabs Step 4 Hand tighten the nut DO NOT OVER TIGHTEN DO NOT USE A WRENCH 1 4 3 8 1 2 Parker Tube Fitting Assembly 15 Membrane Pressure Vessel Relocation Use ONLY Dayco Imperial Nylo Seal 88 NSR 1 2 tubing for hi
6. position e The boat s Pressure Water system is ON e Charcoal filter is Installed e Three way product valve is set to Sample diverting the product water away from the 2 1 Remove the warning tag and rub ber spacer from under the pressure relief valve knob and make sure the pressure relief valve is open 1 2 2 turn 3 Power up the system 4 Press the Flush button on the remote panel The feed pump will come on intermittently and the flush valve will open Priming the pump When water begins to come out the brine overboard thruhull Press the Flush Button again to end the flush cycle 5 Press the Start Stop button to start the watermaker The feed pump will come on continu ously Run the watermaker for 20 minutes with the pressure relief valve open to Purge the storage chemicals out of the membrane 6 After 20 minutes close the pressure relief valve Product water will begin to flow from the Sampling port The flow meter should show about 12 gph and the pressure gauge about 80psi spiking to about 90 Pressures will be lower in brackish water Check to see that the pressures are the same on each cycle Check for leaks 7 After 10 minutes check the flow meter for air bubbles in the product If there is air in the product after a few minutes operation you have an air leak in the suction side plumbing Sample the product water with your handheld meter If the water tastes good and the sa linitv is less than 500 ppm you can turn t
7. 6 16 40 12 6 16 45 14 6 16 50 15 4 25 19 SJO JLULIJJEM 202945 dn pours JOQWAS yas pobueu preoq pappy JOQWAS uas 5002 T JOP 5002 0 5002 UOIIADY Jenueui euiej1e ajqea JBMO4 o EHA THA 88 HI HSM peog O QUOD jENULLU EL1jEJED L g ued Fi i pou 5 usn J YIPAS ums WnNILA UJJIMS 1545 20 New Svstem Start Up and Testing Avoid running the system if the vessel is in contaminated water such as in a harbor or canal The system should be fully run tested before leaving port It is preferable to sacrifice a filter by running the system in turbid water rather than waiting to get offshore to discover a problem or deficiency in the installation If the location or weather prevents proper testing refer to the sec tion Dry Testing Warning Damage may occur if the purge sequence is bypassed and the membrane is pressurized with storage chemical in it 1 First Check That e Thru hull valve is open Local Remote Switch is in Remote
8. 7 2 Tt LL a Y 7 O 2 7f C ZZ ZG LL LELI AWL A 2 4 7 2 7 7 Y E 4 4 M j 1 f Naf ate S S xS SSL Qua i2 S 22 Adjust Fresh Water Flush Cvcle The Catalina 300 Deluxe Model is equipped with an automatic flush cycle which takes fresh water from the boat s pressure water system filters it through a charcoal filter to remove any damaging chemicals such as chlorine and pumps the filtered fresh water throughout the system to prevent biological growth and corrosion The flush timing 1s factory preset to default values Each installation will vary and the installer should check and adjust the timing to ensure that the water remaining in the system after the flush cycle is salt free while reducing the water used to a minimum e When flushing the watermaker immediately after making water be sure to Stop the Water maker and ALLOW THE FEED PRESSURE GAUGE TO DROP BELOW 40PSI be fore pushing the flush button Press the Flush button to start the flush cycle The feed pump will come on intermittently and the flush solenoid valve will open The flush will continue for a preset period and shut off automatically CATALINA 300 FLUSH TIMER ADJUSTMENT INSTRUCTIONS The Catalina 300 Deluxe watermak
9. FT FTC 05 is for a 5 micron element Charcoal elements are FT FTC CC 06 03 04 37 PF 2 CHARCOAL FILTERS The function of the charcoal filter element p n 15 to remove any chlorine in the fresh water flush water supply It also removes any particulate matter The charcoal filter we use removes 99 7 of the chlorine Beware when buying other charcoal filters If they don t specify the percentage of chlorine removed don t use them The cheap ones in most cases will only remove 60 or 70 Also there are aftermarket filters which are very close to but not exactly the same dimensions that will not seal properly in the housing The membrane can only handle small amounts of chlorine for short periods without damage The chlorine will damage the bonding agent in the membrane in a very short time So if you skimp on the char coal filter you will toast a 450 00 membrane on the first flush The other factor is the flow rate that the filter can handle Because the chlorine is deactivated by a chemical reaction with the charcoal it must remain contact with the charcoal for sufficient period of time for the reaction to be complete The filter we use can handle 1 5 gallons 6 litres per minute flow and are good for 3000 gallons 12 000 litres at 1 5 GPM or six months whichever comes first Regardless of the flow the charcoal loses its effectiveness after six months 7 26 04 38 SPECTRA 7 WATERMACHINES Z BRAN
10. Pressure Vessel Mounting The Clark Pump and membrane assembly has been pre assembled at the factory If 1t 1s neces sary to disassemble this module and mount the pressure vessel separately see the Membrane Pressure Vessel Relocation instructions in this manual This part of the system runs at 800psi SSbar Use only Spectra high pressure tubing and fittings Remote Control Panel The remote control panel can be mounted anywhere that is convenient Cut a 4 1 4 11cm wide by 4 3 4 12cm high opening for the panel Locate it in a protected area where it will be easy to read the gauges and operate the buttons The panel will have both fresh and salt water tubing connec tions and an electrical cable 10 Plumbing From the inlet thru hull to the flush module and from the flush module to the pump module inlet use supplied clear 3 4 19mm spiral suction rated hose The outlet of the filter assembly on the main module to the Clark pump assembly is under pres sure Use the supplied braided clear vinyl hose rated to 150 PSI 11 bar From the Clark pump brine discharge connector use supplied 5 8 15 9mm clear braided vinyl hose Route all hoses and tubes to prevent kinks and restrictions Se cure piping away from moving objects such as engine belts and hatches Prevent chafe on tubing as required Test and inspect all piping and hose clamps after several hours of operation 11 Salt Water Side Svstem Piping CLARK PU
11. SS tube S S compression XI fittings MELDE o EET d PL MTS 3 8X 1 25 At S NI Composite cvlinder HP CYL CCA End cap O ring Cylinder end cap HP CYL EC Cylinder Assembly
12. SWITCH TERMINAL STRIP COVER MAIN POWER FEED TERMINAL BLOCK CONTROL PANEL CABLE SHOWN WITH CABLE CONNECTED TO TERMINAL STRIP 18 Wiring Mount the main power feed terminal block on a bulkhead adjacent to the feed pump module Make sure that this is a drv location well above bilge level and not subject to water sprav Check the wire size chart to select the proper size power feed wires and run the cables from the breaker to the main power harness Install the cover Route the Flush solenoid cable to the fresh water flush module and splice the wires to the solenoid wires There is no polarity to the wires Heat the splice for sealing Connect the control cable to the Control Panel terminal strip The terminals are marked W B G amp R to correspond with the White Black Green amp Red wires in the cable Component Sizing e 12V Use a 25 Amp breaker and size the wiring for 20 Amperes e 24V Use a 15 Amp breaker and size the wire for 10 Amperes Note If the specified circuit breaker sizes are unavailable use the next higher rating but do not exceed the specification by more then 10 All wiring to be done to applicable ABYC Marine UL or CE standards Catalina Power Feed Wire Size Chart 12 volt Wire Meters AWG SQ MM Length FT 10 3 10 6 15 5 8 10 20 6 6 16 25 8 4 25 30 9 4 25 35 11 4 25 45 14 2 35 50 15 2 35 24V Wire Meters AWG SQ MM Length FT 10 3 12 4 15 5 10 6 20 6 8 10 25 8 8 10 30 9 8 10 35 11
13. accumulator is located inside the Feed pump module and should be precharged to 5psi 0 3bar FLUSH WATER INLET 13 Product Water and Pressure Gauge Piping Sampling Tap for discarding product at startup testing the product water Product to tank Route the product and for service procedures water from the valve into the top of Put enough tube on this port to reach the tank Install a tee in the water fill vour service pickling container or tap a pipe thread into an inspection port DO feed into a vent line manifold or the bottom of the tank Make sure that there is no restriction in this piping Product sampling valve Mount using the sup plied plastic straps as shown Note the handle points in the direction of the flow Use accumulator port to connect the pressure gauge Tubing must be pres sure rated to 150 PSI 10 BAR Use the supplied 1 4 black nylon tube or equivalent Product Flow Meter Use the supplied 1 4 black nylon tubing Plastic fittings should have 3 4 wraps of Teflon tape and For the product water tubing If more length will thread almost all the way in Leave the first pipe thread is needed than we supply use a larger size uncoated Avoid getting dirt or debris in the system during hose assembly Secure piping away from moving objects and protect from chafe Exercise care not to cross thread the fittings See the tube assembly instructions next page Product Ports are
14. bucket stop the unit and let the membrane soak for few minutes Restart and pump the remaining solution overboard Repeat until the discharge appears clean After most of the oil is cleaned out you can put the brine discharge into the bucket and run the system with the soapy water circulating as you would for the other cleaning chemicals Rinse the system with a bucket of fresh water or the fresh water flush cycle then flush for twenty minutes using sea water Pressurize and test 5 12 04 MISC 3 ACCUMULATOR PRESSURE All Spectra Watermakers except the 700 and 1000 series are supplied with a pressure accumula tor tank p n PL ACC TK to be installed in the feed water line between the feed pump and the Clark Pump In addition the 300 and some 400 series also have an accumulator mounted inside the fresh water flush module or the feed pump module The purpose of the feed line accumulator is to reduce the spikes in the feed pressure caused by the cycling of the Clark pump If the accumulator is not properly charged it can lead to prob lems with the pump pressure cutouts The accumulators have an air valve on top similar to those found on car tires This allows the internal air bladder of the accumulator to be pre charged The accumulator should be pumped up to about 65psi 4 5bar for best results Add air using a tire pump or air compressor You can experiment with the exact pressure that will give the best pulsation dampening on your installa
15. list Spectra Watermakers will not be held responsible for shortages and or freight damage that are not reported within thirtv davs of the ship date Next study the system layout diagram component photos and descriptions before beginning your installation This will assist you in understanding the function of each component Layout the system Before starting the installation identify the location where each module and component will be placed Insure that there 15 proper clearance around the components for removal of filters and system service Also check to make sure you have adequate tubing and hose before starting so additional parts may be ordered Check to see that the control ca ble is long enough to reach from the display location to the main module Catalina Deluxe shipping list e Catalina Magnetic Drive Feed Pump Module e High Pressure Clark Pump and Reverse Osmosis Membrane Module e Fresh Water Flush Module e Dual Filter Assembly e Catalina Installation Kit e Accumulator Gauge Assembly e Service Hose Kit 5 8 Hose 25 3 4 Suction Hose 25 Installation Basics Thru hull Not Supplied Read the directions e Avoid tight hose bends and excessive runs e Use heavy gauge wire e Install feed pump as low as possible e Use a dedicated thru hull with scoop type strainer Flow Thru hulls It is mandatory that a dedicated 3 4 to 1 forward facing scoop type intake thru hull a
16. relief valves can remain in the operating posi tion 24 Operation If the svstem contains preservative or cleaning chemicals follow the directions for New System Startup or Membrane damage will occur e Never let the system sit with salt water in it To avoid unnecessary consumption of flush water run the system for longer periods less frequently e Air in the feed water will damage the feed pump Check for air in the filters and lines and fix air leaks promptly If air may have gotten into the system due to filter changes or rough weather open the pressure relief before startup Normal Operation Set the sampling valve to the Sample position Press the Start Stop Button If the pressure relief valve is open allow the system to run until any air is cleared from the system Close the pressure relief valve The system will begin to make water After about two minutes taste or sample the product water If it is acceptable Turn the sampling valve to send water to the tank Note the Pressure Gauge Reading As the prefilters begin to plug up the pressure reading will rise If the pressure rises more than 5 psi 5 bar stop the ma chine and change the filters Note The operating pressure will vary with sea temperature and salt content Check the Clean Filter Operating Pressure each time you change the filters and when moving to areas with different water conditions If the machine must be stopped for any reason do not restart it until
17. strainer alarm if so equipped Plugged filters can be cleaned several times by soaking in a bucket towing behind the boat at moderate speeds or hosing them off When operated only an hour or two a day in inland or near shore waters the trapped plank ton will begin to decay in the filters long before the elements plug up and the bacteria in volved in the decay 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 high latitudes If handled gently and changed regularly before they get too smelly filters in this service can last through doz ens of cleanings In crystal clear blue water conditions the filters may need to be cleaned much less frequently The charcoal filter used in the fresh water flush system will not plug up unless you have some incredibly dirty domestic water in your boat About six months after installation the charcoal filter element will lose its effectiveness at removing any membrane damaging chlo rine which may be present in domestic water Charcoal filter elements must be replaced every six months if there is ANY chance that chorine could be introduced into the flush wa ter Charcoal filter elements cannot be cleaned To ensure that filter elements fit properly and remove chlorine effectively they should be purchased at factory authorized dealers Our element part number is FT FTC XX The last two digits indicate the micron rating e g
18. the eight or ten year old membrane now and then The biggest killers of membranes are lack of use chlorine damage and improper storage Don t let membranes sit around with sea water or stale fresh water in them Biological growth will occur in the membrane Here at the factory we frequently get back membranes for inspec tion that reek of hydrogen sulfide rotten eggs This odor is produce by anaerobic bacteria that live in an unused membrane feeding on whatever animal or vegetable matter is trapped in it from the plankton that gets through the system Membranes badly fouled in this way can sel dom be saved These bacteria are always present but are inhibited by the oxygen in sea water while the unit is in frequent use by scheduled fresh water flushes or by pickling Keeping the prefilters clean is also important in preventing bio fouling If your prefilters are allowed to be come a breeding ground for bacteria get smelly the contamination will spread throughout the system When we cut open a failed membrane we also find mildew another form of bio foul ing probably due to long term storage with no biocide or stale biocide After many hours of water making mineral deposits will form and must be dissolved away with an acid cleaner Alkaline cleaners are used for bio fouling Cleaning chemicals especially the alkaline are not good for the membrane Every time you clean the membrane it shortens its life Clean only when necessary and avoid
19. the feed pressure has dropped below 40 psi The feed pump is equipped with a magnetic drive coupling which will decouple and slip if started under load Excessive decoupling will damage the magnets Normal Shut Down Make sure the boat s pressure water system is energized Press the Start Stop button The watermaker will stop Allow the feed pressure to drop below 40 psi to prevent decoupling After the feed pressure has dropped Press the Flush Button The feed pump will begin to cycle on and off and the flush valve will open After the preset flush period is over the Unit will shutdown Flush the system every five days if it is not used to make wa ter to prevent membrane and feed pump damage Manual Operation The system can be operated locally from the feed pump module by setting the Run Local Run Remote Switch to Local Whenever there is power to the unit and the switch is in the Run Local position the Feed Pump will run Operate the system as you would in Auto operation Manual Flush The system can be flushed using the Run Local switch as follows Before shutting down use the sampling valve to make several gallons of product into a clean con tainer Connect the service hose to the service fitting and set the service valve to Service Start the feed pump and let it run until the water is almost gone Stop the feed pump before it sucks air Reset the service valve to Run and the system will be ready for the next use 25 Maintenance
20. E OP ERATION MANUAL The Z brane is a revolutionary product which incorporates the Z Guard High Voltage Capacitive technology into the membrane pressure vessel Always active the Z Brane creates an environment that is unfriendly to bio film and bacteria The Z technoalgy also assits in the prevention of scale formation on the membrane surfaces The Z Brane allows the system to be shut down or decommissioned for extended periods of time without chemicals or preservatives The Z Brane will not prevent freezing so that in cold climates Propylene Glycol is still required The Z Brane system is integral with the watermaker unit and only requires continuous 12Vor 24V DC power to be operative The installation of the Z Brane only consists of wiring the power supply to a continuous source The Z brane power supply can tolerate voltages between 10 and 28V DC Note There is no reason to open the transformer enclosure Do not ser vice this unit without disconnecting the power source There may be high voltage present It is recommended that the Z Brane be connected to a discreet continuous power source The power must be on during the time that the system is operation and during the time the Z Brane is used for membrane storage If the power is obtained from the MPC then the MPC must be powered up at all times during storage This may not be desirable Fuse the power at the source with a 5 amp fuse or circuit breaker Red is Positive Black is
21. F 2 SOLENOID VALVE PL SLN1 4D12 12 VOLT PL SLN1 4D24 24 VOLT 44 CATALINA DELUXE PARTS 3 8NPTX3 8 TUBE EL 3 8 NPT NYLON PLUG PL MTE 3 8X3 8P PL HP 3 8 3 8 LOW PRESSURE TUBE PL NLT 3 8LP FLUSH WATER ACCUMULATOR PL ACC TK VACUUM SWITCH EL SWT VC GUAGE TEE PL TEE 1 2F1 4G 1 2NPTX3 4 HOSE BARB PL HBS 1 2X3 4 1 4 NPT X 3 8 TUBE EL PL MTE 1 4X3 8P REDUCING NIPPLE 1 2X3 8 PL NP 1 2X3 8N CATALINA MOTOR EL MTR 16D12 LOCAL REMOTE SWITCH EL SWT TK1 CATALINA FEED PUMP BRACKET FM CT PM TERMINAL STRIP CATALINA VANE PUMP EL TM 30A2 PL PMP 110MAG CATALINA CONTROL PANEL ASSEMBLY KIT CT CTPAM RELAY EL RL 40A12 12 VOLT EL RL 40A24 24 VOLT TERMINAL STRIP EL TM 30A2 CIRCUIT BOARD SUB CT CTCBA TRA 45 End block B 1 Valve block HP TB VB m V cylinder Brine out 8 Pressure relief valve NIA HP TB BV amp Center block HP CB CB10 Feed in Stainless steel tube V HP CYL SST Cylinder ring End Ca HP CYLR Clark Pump Front View HP CYL EC End block A Valve block End block B Reset button Not on all unitsHP TB RSB I M cylinder Alternate brine out and base High pressure in Test port Center block High pressure out Stainless steel tube Cylinder ring Clark Pump Back View End cap 46 5 16
22. General Periodicallv inspect the entire svstem for leakage and chafe on the tubing and hoses Repair anv leaks as soon as possible Check for corrosion around the stainless steel fittings If anv rust ap pears remove clean and reassemble the fitting Rust 1s a sign of crevice corrosion inside the fit ting and must be dealt with promptly Some salt crystal formation around the Clark Bump blocks is normal Wash down any salt en crusted areas with a damp cloth Keep the watermaker clean dry and salt free The Seawater Strainer and 50 Micron Filter The sea water strainer s stainless steel element should be inspected removed and cleaned as needed A clogged strainer or 50 Micron filter will cause the controls to shut down the water maker Avoid letting the 50 micron get so dirty the unit shuts down automatically Be careful to ensure that the thru hull is closed before disassembly and the seal and element are in place before reassembly Put the screen up to a light for inspection When the system is put into storage remove rinse and reassemble dry to impede corrosion Check frequently during operation The 50 micron filter must be properly maintained to protect the feed pump Use only Spectra approved filters These may be cleaned several times before discarding The Prefilters Service the prefilters frequently As the prefilters get dirty energy consumption increases and production drops Careful monitoring of the feed pressure gau
23. Ground Z Brane Power Harness 40 Operation During normal operation the Red LED should be on Power needs to be supplied to the Z Brane unit at all times that you wish to have the biofouling and scale protection We recom mend that your watermaker be flushed after each use not only to protect the membrane but to prevent corrosion in the feed water system To achieve full effectiveness thoroughly fresh water flush the watermaker several times before leaving the vessel The Z Brane may be de powered if the system is stored with chemicals or winterized with Glycol Power on LED High Voltage connector DO NOT DISCONNECT OR SPLICE ANY OF THE HIGH VOLTAGE WIRING Contact the factory if modifications are required 41 CATALINA DELUXE PART NUMBERS PRODUCT WATER SAMPLING VALVE 1 PL VLV 3W1 4 1 4 TUBE X 1 4 T STRAIGHT FITTING 1 4INGH LOW PRESS TUBE PL NLT 1 4LP PL MTS 1 4X1 4P 1 4 TUBE X 1 4 MPT EL PL MTE 1 4X1 4P FLOW METER PL FMT 20 ACCUMULATOR PL ACC TK REMOTE SWITCH ASSEMBLY SUB CT SAM 1 2MPT X 5 8 HOSE BARB PL HBS 1 2X5 8 _ 1 8MPT X 1 4 TUBE E PL MTE 1 8X1 4P 1 2 TEE COMPLETE PANEL ASSY PL TEE 1 2FN 0 0 KIT CT CTPAM 1 2 NIPPLE PL NP 1 2N 1 4MPT X 1 4 TUBE STRAIGHT FITTING PL MTE 1 4X1 4 PRESSURE GUAGE PL PSG 2 5L 1 2 X 1 4 BUSHING 1 4FPT X 1 4 TUBE EL PL BSH 1 2X1 4N PL FTE 1 4X1 4P 5 8 IN VINVL
24. HOSE PL HS 5 8VN SUCTION HOSE PL HS 3 4SH PREFILTER HOUSING FT FTH 10L 5 MICRON FILTER CARTRIDGE 1 METTON HOSE T FTC 5F SEA STRAINER FT STN 5 STRAINER SCREEN FT STM 5S 42 CATALINA DELUXE PARTS 3 8 MALE NPTX1 2 TUBE SS FITT ST PL MTS 3 8X 1 2S MEMBRANE END PLUGFT PV EP A a ZBRANE MEMBRANE END PLUG FT PV ZEP Probe end 1 8 NPT NIPPLE FT PV ZEPB Ground End NYLON PL NP 1 8N 4 U ija NPTX1 4 TUBE FITTING PL FTE 1 8X1 4P PL MTE 3 4SX1 2 j BRACKET PLATE END 3 4 16 X 1 2 SS TUBE FITT ELBOW FM PB PBE HI REJECTION MEMBRANE 40 FT MB 40 INSIDE HOUSING 1 2 HIGH PRESSURE TUBE PL HBE 3 8X5 8 DAYCO NYLON HOSE BARB PL NLT 1 2HP ELBOW 7 BRACKET PLATE FM PVB PB 3 8 NPT QUICK DISCNT COUP 5 8 QUICK DISCNT FITT HOSE BODY BARB PL QDC BD3 8 PL QDC HB5 8 43 CATALINA DELUXE PARTS 3 8 LOW PRESS TUBE FITT ELL 1 4 MPT X 3 8 TUBE FITTING ELBOW a PL MTE 1 4X3 8P 3 4 MPT X 3 4 HOSE BARB ELBOW PL HBE 3 4X3 4 3 4 1 2 BARB NVL ELL PL HBE 3 4X1 2 GARDEN HOSE CAP PL GHF GC LOW PRESSURE FILTER HOUSING FT FTH 10L 3 4 3 WAY VALVE PL VLV 3W3 4 3 4 MPT X 3 4 HOSE BARB ELBOW PL HBE 3 4X3 4 FRESH WATER FLUSH MODULE BRACKET FM NPC IM 50 MIGRON FILTER ELEMENT FT FTC 50 CHARCOAL FILTER FT FTC CC 3 4 NPT X 3 4 HOSE BARB ST PL HBS 3 4X3 4 NOTE LOCATED INSIDE ARE 1 CHECK VALVE PL CKV 3 4F
25. MP MEMBRANE MODULE From the Clark Pump brine discharge connector use the supplied 5 8 15 9mm clear braided vinyl hose to the brine overboard fitting To prevent damage in shipping the quick disconnect is shipped attached to the module bracket Remove either one of the pipe plugs in the valve body and screw in the connector The system from the Pump module to the Clark pump assembly is under pres sure Use the supplied braided clear vinyl hose rated to 150 PSI 11 bar PREFILTER MODULE PRESSURE GAUGE Use the supplied 1 4 black nylon tubing FLUSH MODULE From the inlet thru hull to the flush module and from the flush module to the pump module inlet use the supplied clear 3 4 19mm spiral suc tion rated hose PUMP MODULE AST ror HOSE E SEA STRAINER e 4 aa L 8 PIX _ ad z s 5 b ee il 12 Fresh Water Flush Run a feed line from the domestic cold pressure water system to the 1 2 hose barb on the fresh water flush assembly The boat s fresh water system must be turned on for the fresh water flush system to function properly The domestic fresh water pump must be able to deliver 2 5 gal lons per minute at 25 psi Connect the flush solenoid cable by crimping and heat shrinking the butt splices The flush water
26. at the brine discharge then switch the brine discharge into the bucket and recycle the remaining solution until the glycol and water are completely mixed about ten minutes On some models you will have to shut down the unit to switch the brine discharge into the bucket The product water side of the system will not contain antifreeze and should be protected from freezing by blowing or draining it dry if necessary Turn off power to the system leaving the pressure relief valve open turn 39 OP 2 BAD SMELLING PRODUCT WATER The reverse osmosis membrane is permeable bv manv gases including hvdrogen sulfide the gas that causes rotten eggs to smell the way they do If there are bad odors in the feed water they will go through the membrane and the product water will be affected Usually the source of the odor is from the decay of planktonic creatures trapped in the sea strainer and prefilters These tiny oxygen loving creatures soon suffocate and die inside the prefilter housings when the unit is shut down Once all the available oxygen is consumed anaerobic bacteria begin to grow causing the odor If a unit being used frequently begins to make smelly water it will be the prefilters that are the source of the problem This occurs in a week or two in cold climates but in less than one night in very warm waters like the Sea of Cortes or Red Sea These bacteria can spread throughout the watermaker and begin to grow on the membrane causin
27. cleaning as a diagnostic tool Chlorine will destroy a membrane in minutes It attacks the material that the membrane 15 made from Always use product water or water filtered slowly through a charcoal filter for flushing and chemical treatments Oil simply plugs up the matrix of the membrane and clogs it up We have brought back oil fouled membranes with Joy soap See MB 5 Cleaning with Detergent For storage we recommend using propylene glycol potable water system antifreeze if available It can safely be left in the system for one year and will keep things from freezing in cold condi tions It is hard to find in warm climates and takes up a lot of room on a small boat so our SC Given good care a membrane will eventually just start to slowly fade away The feed pressure may rise and or the ppm go up Hardly ever will they just fail overnight 33 MB 5 MEMBRANE CLEANING WITH DETERGENT If the membrane has been fouled with oil it mav be possible to save it bv cleaning it with dish soap such as Joy Don t use anything that may contain bleach You will need quite a lot of chlorine free fresh water If using shore water run it through a charcoal filter at a rate of not more than 1 5 gallons 6 liters per minute Fill a bucket with fresh water and mix in a couple squirts of the detergent Run the system de pressurized with the watermaker drawing water from the bucket and discharging overboard When about half the water 15 gone from the
28. ct water line Spectra offers a product water filter kit p n KIT FLT CC More on this subject is available on our website at www spectrawatermakers com 8 17 04 36 PREFILTERS VANE PUMP SYSTEMS Five different filters are used on these Spectra Watermakers to make sure that no damaging foreign materials enter the system There are four filters in the system to clean the feed wa ter of abrasive materials while the system 15 1n operation and a fifth filter that prevents the entrance of chlorine during fresh water flushing During normal operation the feed water is filtered in two stages First it enters a fine mesh metal sea strainer then passes through a fifty micron pleated cellulose filter These protect the vane pump from damage due to abrasion from silt and hard shelled plankton found in the feed water After passing through the pump the feed water enters the filter housings contain ing 20 and 5 micron elements These filters remove very fine particles which could damage the Clark pump and which would shorten membrane life Cleaning schedules will vary widely depending on how and where the system is used If large amounts of feed water are run through the system in a relatively short period in bio logically fertile near shore waters the prefilters will plug up the pressure drop across the filters will rise product production and quality will drop and the system will sense plugged filters and give a service prefilters or check
29. d the hose into the bucket Turn the service valve on the fresh water flush module 180 so the intake 15 now coming from the bucket e Step 5 Mix the cleaning chemical compound into the water in the bucket e Step 6 Make sure the pressure relief valve on the Clark pump is Open unpressurized e Step 7 Use the Run Local switch to turn on the feed pump Circulate the storage chemi cal in the system for approximately 25 minutes Turn off the switch when finished Allow to soak for several hours or overnight if the solution is cold running the pump occasion ally to agitate the solution Set the switch to Remote when finished e Step 8 Replace the brine overboard hose Remove the Inlet Service hose and turn the Service valve to the Run position Step 9 To avoid damaging the membranes Follow the New System Startup In structions to Purge the chemicals out of the System 31 queeessseeesseecevseevesseevesseevesceceeeeeececeeeeceveeeeeveeceeceeeeeeeeeeecececeseeevecseeveseveveseveveeeveveeeeesseceeececeesceceeeceeeeeeeeeeeeeveeeececeeeeeceeeeeceeevesevesseevevseevesseeseecececseeecereceececeeeeeeeeeeeeeeeeecevecsceeesseeceeeesesseeveseeevesevesecseveeeeeeeceeeeeecececececeeceeecececececet Suggested Spares Short term cruising weekends etc We suggest a BASIC CRUISE KIT This kit consists of 3 ea 50 micron 20micron and 5 micron filters one charcoal filter and two jars of SC 1 storage chemical Cruis
30. eplace with the quick disconnect hose from your service kit Lead the hose to a 5 gallon bucket or container 3 Push Flush to run the feed pump until you have one gallon of fresh water in the bucket then push Flush again to end the flush cycle Mix 1 container of SC 1 storage compound with the water in the bucket Connect the inlet service hose using the garden hose barb fitting from your service kit to the service port of the fresh water flush module Lead the hose into the bucket Turn the ser vice valve on the fresh water flush module 180 so the intake 1s now coming from the bucket 6 Make sure the pressure relief valve on the Clark pump is Open unpressurized by turning 1 2 turn counterclockwise Pressure Relief Valve 7 Turn on the feed pump with the Start Stop Button or the Run Local Switch Circulate the storage chemical in the system for approximately 10 minutes Turn off the feed pump when fin ished Clean Up Remove the quick disconnect from the Clark pump brine discharge and replace the original hose that leads to the thru hull You may at this point if you choose to pump the bucket dry by using the Local Remote switch Stop when the bucket is nearly empty Turn the service valve 180 back to its original position and remove the service hose Close the seacock and drain and clean the strainer and any filters in the system Reassemble dry 28 Storage amp Winterizing Warning Use only potable wat
31. er antifreeze Propylene Glycol Do not use automotive antifreeze Ethylene Glycol SNL dq o 10 Inlet Service Hose Connection Flush the svstem with fresh water according to the Automatic Fresh Water Flush Instruc tions Connect your inlet service hose and place it in your service container or bucket Turn the service valve to the service position Pour 2 gallon 8L of Propylene Glycol 100 Antifreeze in the bucket Make sure that the pressure relief valve is open un pressurized Turn on the Feed Pump until antifreeze begins to appear at the brine discharge Stop the Pump Disconnect the Brine Overboard hose and Connect the Brine Service Hose Place the end of the brine Service Hose in the bucket Turn on the feed pump and re circulate the antifreeze for 20 minutes Stop the pump Reconnect the brine discharge hose Restart the pump until the bucket is empty Close the seawater intake and the service valve Drain the strainer and the hose leading to the inlet module Disconnect the product tubing and blow any residual water out of the tub ing with compressed air Open the pressure relief valye Service Valve 29 The Membrane e Membranes need to be cleaned only when feed pressures have risen 10 due to fouling or the product quality degrades The leading cause of fouling is from biological growth that occurs when the system 15 left unused without flushing or pickling Fouling from mineral scaling can happe
32. er is equipped with a timing circuit which controls the length of the fresh water flush cycle and the pump on and off timing Because the feed pump has only a single speed and the flow rate at this speed exceeds the flow capacity of the charcoal flush water filter the pump is pulsed on and off during the flush to limit the flush water flow to the approximately 1 5 gpm filter capacity The flush timer activates the flush solenoid valve continuously during the length of the flush cycle The flush module accumulator is used to even out the flow through the filter When the pump is running it draws water from both the accumulator and the charcoal filter When the pump is off water continues to flow from the boat s pressure water system through the charcoal filter and refills the accumulator The accu mulator should be pre charged to about 5psi 1 2bar The Flush timer circuit board also has as a safety shutdown circuit in case the vacuum switch senses a restriction in the suction lines causing the switch to open WIRING On the outside of the flush timer box is a Run Local Run Remote switch Inside the box are the Motor Relay the Flush Timer Circuit Board pcb and a terminal strip Power In put Control Panel and Flush Valve Solenoid cables are pre wired at the factory and need only be connected to the appropriate component The solenoid valve wires have no polarity The vacuum switch cable must be wired to the Normally Closed NC and Common C ter
33. g poor water quality and high feed pressures Filling the system with fresh water after every use greatly slows this process allowing the automated spectra units to operate with less frequent prefilter changes but units operated for only an hour or so a day will probably need to have the filters changed due to odor before they are dirty enough to restrict water flow Prefilters can be cleaned We recommend that you have three sets in service one in the unit one set soaking overnight in a bucket of clean fresh or salt water and one set drying for the next use After shutting down the unit remove the used prefilters and install the dry set Leave the housings full of air until the next use On non automated systems open the pressure relief when starting if there is a lot of air in the system until the air is cleared out through the brine overboard The filters will get just as clean when soaked in sea water but dry much faster if soaked in fresh Given gentle han dling prefilters can be reused many times Bad smelling product water is usually caused by bad smelling feed water but can also be caused by a fouled membrane if the membrane has been left unpickled If the unit makes smelly but not salty water after a long idle period and the prefilters are new the smell can be eliminated by running the unit unpressurized for an hour or so to flush the membrane Odors in the product water can also be eliminated by adding a charcoal filter in the produ
34. ge chemicals out of the sys tem 20 minutes total purging Hook up your service hoses per the service diagram and photos Route them into a 5 gallon 20 Liter bucket Set the diversion valve to the Sample position and route the product water into the test bucket Turn the valve on the fresh water flush module from to Service Press Flush one or two more times to get enough water into the bucket to properly mix your salt water Mix the salt until it goes into solution Mix in 30 grams of salt per liter of water If you are using a hydrometer mix the water to be 30 000 PPM Close the pressure relief valve and start the system using the Start Stop button or Run Local Switch Run and test the system for as long as possible During the run test carefully inspect for leaks Check all of the system parameters to make sure the system is operating correctly See previ ous page Do not allow the water in the bucket to get above 120F 50 Stop the watermaker using the Start Stop Button or Run Local Switch Allow the feed pres sure to drop below 40 psi before Initiating a flush or restarting the unit Outlet Service Port d Inlet Service Port de e VA i l A i
35. ge will allow you to see the pressure increase as the filters get dirty To service the filters shut off the thru hull open the housings Clean out the housing bowls reassemble the housings with new 20 and 5 micron filter elements The 5 micron filter goes downstream from the 20 micron Leave dry until next startup Use only Spectra approved filters or you may void your warranty The filters may be cleaned several times with a soft brush and water in a bucket Occasionally lightly lube the O rings with silicone grease Oil Water Separator Optional To install the capability to remove oil from the feed water replace the supplied 20 micron filter ele ment in the duplex filter set with the optional Oil Water Separator cartridge The Charcoal Fresh Water Flush Filter Replace the charcoal filter element at least every 6 months The activated charcoal loses its chlorine removing qualities after six months even if it is clean Chlorine will destroy the membrane 26 Long Term Storage Procedures Watermakers are best run continuously When not in use biological growth in the membrane is the leading cause of membrane fouling A warm environment will cause more growth than a cold environment The auto fresh water flush system will greatly reduce biological growth but may not stop it completely in certain conditions The 5 day re flush feature allows the system to be idle without any service procedures for extended periods of time but it doesn
36. gh pressure connections Pay attention to the direction and flow path of the tubing before disassembly Make sure that you reinstall the tubing in the same manner Rotate the 90 degree high pressure tube fittings on the Clark pump for ideal tube runs The high pressure fittings are typically pre installed at the factory The fittings on the Clark pump have an O ring seal and can be re oriented as follows Back out the O ring Stop nut Rotate the fitting to align with the tube and tighten the nut just past hand tight Do Not over tighten Follow the high pressure tube connection instructions on the next page Connect the tubes to one of the components secure the tube runs and then trim and connect to the other component A 90 degree bend in a tube is better than a 90 degree fitting A tube when mounted should have at least one gentle bend to allow for expansion Do not connect a tube straight between hard mounted fittings 16 Spectra High Pressure Tube Fitting Assembly Use ONLY Dayco Imperial Nylo Seal 88 NSR 1 2 tubing for high pressure connections Carefully fit and measure the tubing before cutting with a sharp razor knife or hose cutter and remove any burrs Minimum tubing bend radius is 6 Route tubing away from excessive heat sources and secure from vibration and chafe Have at least one shallow bend in a tube assembly after it is installed Refer to figure 1 If a fitting has been dissembled reassemble as illustrated The notch o
37. he sampling valve to the run position and begin filling your tank 8 When finished making water perform a fresh water flush according to the Automatic Fresh Water Flush Cycle Instructions and test the brine overboard water at the end of the flush cycle to insure that the water remaining in the machine is below 1000ppm salinity doesn t taste salty The feed pump and membrane will be damaged if allowed to sit idle while full of salt or brackish water If necessary the factory flush settings can be changed See Catalina 300 Flush Timer Adjustment Instructions 21 Dry Testing With Artificial Ocean If it is not possible to test run the system with the boat in the water testing may be accomplished with an artificial ocean Purchase enough aquarium salts to make 5 gallons 20 liters of salt water Res taurant salt can be used if necessary Make sure that the domestic water system is powered up and that there is at least 30 gallons 120liters of water in the tank Confirm that the Charcoal filter is installed in the Fresh water flush module and that the domestic water line had been installed and all valves are open 1 2 4 9 10 Store the system per the Storage instructions Open Pressure Relief Valve on the Clark Pump Power up the control system Press the Flush button and allow the fresh water flush system to cycle through its timed operation Cycle the auto store system 5 or more times to purge all of the stora
38. ing 2 to 6 months time Two basic cruise kits One each replacement charcoal filter element One replacement feed pump head Longer than 6 months Additional filters offshore cruising kit consisting of Clark pump seals O rings tools and mem brane cleaning chemicals One replacement strainer screen O ring for strainer screen O rings for filter housing Spectra Watermakers parts list Part Number SC 1 STORAGE CHEMICAL KIT CHEM SCI SC 2 CLEANER KIT CHEM SC2 SC 3 CLEANER KIT CHEM SC3 BASIC CRUISE KIT C KIT BCK C 5 MIC FILTER FT FTC 5 20 MIC FILTER FT FTC 20 50 MIC FILTER FT FTC 50 CHARCOAL FILTER FT FTC CC 5 STRAINER SCREEN FT STN 5S FILTER FT FTC OW FEED PUMP HEAD PL PMP 110MAG FEED PUMP BRUSHES KIT MTR BDMBK 5 STRAINER O RING SO STN 5SS FILTER HOUSING O RING SO FHS 10H SHORE KIT KIT OFFSH 20 MEMBRANE FT MB 20 FT MB 40 40 MEMBRANE 32 Operation and Repair Bulletins The following documents are sections of our complete service bulletin set These are available on our website Spectratermakers com MB 2 MEMBRANE CARE Membrane life is affected by a large number of factors and is somewhat unpredictable A big commercial plant running 24 7 will get 10 to 12 years out of a set of membranes But they do all kinds of fancy chemical injections and never shut the thing off Most cruisers are lucky to get five or six years out of one You hear of
39. meet this requirement 3 Follow the wire gauge charts in the instructions Using larger wire than specified is ac ceptable 4 To achieve the full benefits of the fresh water flush system the domestic fresh water pressure must be on and the fresh water tank level maintained Calculate 3 gallons 12L per flush 5 If you are separating the Clark pump membrane assembly please review the high pres sure tube assembly instructions Improper assembly will cause failure 6 Run test then sea trial the complete system before assuming the system is opera tional If the boat 1s 1n fresh or dirty water see Dry testing the system 7 Spectra dealers are responsible for educating the vessel owners on the operation and maintenance of the system Please arrange for a walk through of the installation be tween the owner and dealer 8 Because the one year Warranty begins when the unit is first installed or for new ves sels when the boat 1s launched and the Clark Pump is guaranteed for as long as the original owner has it it is important to fill out the warranty card naming the owner and the date of installation Table of Contents Installation Page Number Gerne NE 7 His talla non Senara 8 Component PACE He DE i mtr arene oe Oar Gen RS en aan mare MIN 9 e 11 Parker Tube Fitting Assembly Pro edute
40. minals of the Vacuum switch and to terminals 7 amp 10 on the circuit board The Feed Pump Negative yellow and Earth ground green leads should be connected directly to the Negative Yellow terminal on the terminal strip The Motor Positive red lead goes to the multi stack push on terminal on the Bosch relay Terminal 87 23 FLUSH TIMER ADJUSTMENT cont Flush timing is adjusted using the three potentiome ters on the pcb VRI TIME controls the total fresh water flush duration Factory default 5 minutes VR3 ON controls the length of time the pump runs during each pulse Default 3 sec VR2 OFF controls the amount of time between pulses Factory default 6 seconds Turning the pots clockwise increases the time Optimum flush timing is adjusted so that no sea water is drawn in during the flush and the flush ends just as the water going overboard drops to 1000 or quits tasting salty Close the sea cock Push the flush button Shorten the pump on time and or lengthen the pump off time so that the vacuum switch does not interrupt the flush If the vacuum switch opens this indicates that sea water would be drawn in if the sea cock were open When the ON OFF timing 15 optimized so that only fresh water 15 being drawn into the system shorten the flush duration as much as possible while insuring that all sea water has been flushed out and only fresh water remains in the system During a routine flush the seacock and pressure
41. n during operation under certain sea water conditions and from rust Monitor the product salinity and feed pressure bar graphs for higher than normal readings for the conditions Other conditions that can cause high pressure are cold feed water high salinity feed water and clogged filters Low product flow is more likely to be due to low voltage or poor feed or Clark pump performance Look for all other causes before cleaning the membrane Membrane life will be shortened by excessive cleaning e There are two types of cleaners acid and alkaline The acid cleaner SC 3 will remove min eral scaling The alkaline cleaner SC 2 1s used to remove biological by products oil and dirt particles that get past the prefilters If membrane performance 15 reduced and they have not been pickled recently cleaning with both chemicals is recommended The acid cleaner should be used first If the membrane fails to respond to both cleanings this is an indication of another problem with the system or that it is time to replace the membrane Contact Spectra Watermakers before removing a membrane Membrane Cleaning For normal cleaning the SC 3 Acid Cleaning Compound is used first then the SC 2 Alkaline Cleaning Compound If known bio fouling is present the SC 2 may be used first Using hot wa ter if possible up to 120 F 45 C is recommended as it greatly enhances the ability of the clean ers to do their jobs If the history of the system is unknown o
42. n the ferrule must engage the inside of the nut properly for the nut to seat down fully Once the tube is inserted the ferrule and nut will naturally align Refer to figure 2 Insert tube fully into the fitting it should go in 0 9 Tighten the nut finger tight while moving the tube around to prevent binding One thread should be showing under the nut Secure the tube so it won t back out when tightening Refer to figure 3 Use 13 16 wrench to hold a straight body fitting or a 3 4 wrench for a 90 body and a 7 8 wrench for the nut Hold the body recheck the tube insertion then tighten the nut 1 1 4 turns Use the index mark on the nut as a guide The threads should be completely covered by the nut Make Sure these fittings are tight on initial assembly or they will fail The correct Torque is specification is 85 foot pounds Index mark Straight thread Str aight or 90 deg Ne 3 8 pipe thread Figure 1 L Nut Ferrule Bodv Nut finger tight with 1 thread showing Cut tube square TN FI gure 2 Black high pressure tubing Tighten 1 2 3 turns 10 flats of the nut with a7 8 wrench after finger tight Use index mark as guide 2 No threads showing ES Figure 3 Insert tube 0 9 until it stops f IMPORTANT Hold fitting body with 13 16 wrench when tightening FLUSH SOLENOID CABLE CATALINA DELUXE WIRING FEED PUMP amp MOTOR CONTROL PANEL TERMINAL STRIP RUN MANUAL RUN LOCAL
43. nd seacock be installed Install the intake for the system close to the middle and as far below the water line as possible Thru hulls near the bow and stern are susceptible to air intake in rough conditions Sharing a thru hull with another system is not acceptable and will void the warranty Sharing a thru hull can introduce unforeseen problems such as intermittent flow restriction air bubbles and contaminates For racing boats and high speed power boats above 15 knots a retractable snorkel tvpe thru hull fitting is preferred to be able to pick up water away from the hull Do not install the intake close to or downstream of a head discharge Install as far below the waterline and as close to center line as possible to avoid contamination and air induction The brine discharge thru hull should be mounted above the waterline in or just above the boot stripe to minimize water lift Double clamp all hose connections below the waterline Pipe Fitting Instruction Plastic to plastic fittings should have 3 to 4 wraps of Teflon tape and will thread almost all the way in Avoid getting dirt or debris into the piping or hoses during assembly A small bit of de bris can stop the system Avoid getting tape over the end of fittings that might get into the system To insure this does not happen leave the very first thread uncoated Avoid restrictions or long runs on the entire inlet side of the plumbing from the thru hull to the main feed pump module
44. ps prevent biogrowth and fouling of the membrane system Feed Pump Main Module Mount the feed pump main module on a horizontal or vertical sur face that can be up to 3 1 0M above the waterline It 15 prefer able to mount it as low as possible Choose a location which will Local Remote Switch allow access to the manual switch for maintenance procedures The feed pump will not operate properly at am bient temperatures over 120F 48C The feed pump will be damaged or de stroyed if allowed to run dry Always ensure that there is water flow when the pump is run ning Feed Pump Clark Pump Membrane Module e ru Ly m Pressure Relief Valve The Clark pump membrane module comes complete with a mounting svstem Be sure to use the supplied washers on the rubber feet Use it as a template for drilling the mount holes Mount in anv position but leave access to the pressure relief valve on the Clark pump The membrane maximum temperature specification is 120F This module must be installed in an area that maintains a temperature below 120 F 50 C A cool location is preferable Keep this unit within the 15 4 5M reach of the wires from main feed pump module This unit may be placed as high in the boat as you desire Make sure that the area around and under the pump does not have any water sensitive equipment Water will be spilled during any repairs or if a leak occurs Membrane
45. r it has been left unpickled for an extended length of time and biological growth is present it is recommended that the system is cleaned with SC 2 using an alternate source of unchlorinated fresh water before the system is run under pressure A simple test can be performed to see if biological growth has occurred Before running the sys tem remove the prefilters and examine their condition If the housings are full of smelly discol ored water the system was not properly stored Install clean prefilters if they were bad Next check the membrane Attach the brine discharge service hose and lead to a bucket Open the pressure relief valve one turn and manually run the system for 30 seconds Examine the brine water if it s discolored and smells bad perform an SC 2 cleaning with an alternate source of unchlorinated water before running the system pressurized If the brine is fairly clean the system can be purged run normally and checked for performance Clean the membranes only if per formance is reduced Heating the water 15 preferable One way to do this is to find a camp stove and use a large stainless steel pot to heat the solution in The cleaning solution throughout the system will heat as it circulates in and out of the pot An alternative is to heat the one or two gallons of initial water to 120 on the main stove before mixing in the cleaner and circulating it into the system Periodi cally stop and reheat the solution Perform
46. t replace performing a storage procedure for long periods of non use If an optional Z Guard water treatment system 15 installed in the system the 5 day re flush will maintain the system as long as unchlorinated pressurized fresh water is provided System Storage or Pickling If the system is to be left unused for more than 2 weeks perform the following storage pro cedure The procedure introduces a chemical compound into the system that prevents bio logical growth This procedure requires de chlorinated water which can be made with the Spectra s charcoal filter Charcoal filters last a maximum of 6 months once wetted Spectra SC 1 a special storage compound also used by the US Navy It is formulated to be compatible with the modern engineered plastics and composites in the Spectra pumps Do not use any substitute except propylene Glycol SC 1 Storage Compound has to be mixed at a ratio of I Spectra container to 3 gallons 12L of fresh water to have the proper solu tion An average of 2 gallons 8L of water is in a Catalina system This water has to be figured in to the mixture A Catalina system uses one SC 1 container Caution Avoid contact with skin eyes or lungs with the storage chemical 21 Catalina Storage Procedure 1 Perform a fresh water flush as described in the Automatic Fresh Water Flush Instructions section 2 Remove the quick disconnect fitting from the brine discharge outlet of the Clark pump and r
47. the cleaning procedures while the ship is in acceptable sea water for purging and testing 30 Note Procedures are the same for the SC 2 and SC 3 cleaners Warning The pressure relief valve on the Clark pump must be open for this procedure or membrane damage mav result Maximum pressure 50 psi Spectra Cleaning Compound SC 2 or SC 3 must be mixed with fresh water at a ratio of I con tainer of compound to 3 gallons I2L of unchlorinated water to have the proper solution An aver age of two gallons 8L of water is already present inside a Catalina system This water has to be figured into the mixture A 300 system will use I container of compound SC 2 and SC 3 are never mixed together Do not use them for storage pickling solution Cleaning Procedure e Step 1 Flush the system twice Use the Flush button on the Panel When the first flush has been completed press Flush again e Step 2 Remove the quick disconnect fitting from the brine discharge outlet of the Clark pump and replace with a quick disconnect from your service kit fitted to a hose and lead the hose to a 5 gallon bucket e Step 3 Press Flush again to fill the bucket with 1 gallon 4L of fresh unchlorinated wa ter Press Flush again to stop the flush cycle when the bucket has reached the desired level e Step 4 Connect a hose using the garden hose barb fitting from your service kit to the ser vice port of the fresh water flush module Lea
48. tion The purpose of the fresh water flush accumulator is to allow a steady flow of 1 5 gallons per minute of flush water through the charcoal filter Because the feed pump on the 300 and 400 hundred series exceeds this maximum allowed flow rate the controller turns it on and off to reduce the overall flow rate The accumulator gives the water flowing through the charcoal fil ter somewhere to go while the feed pump is cycled off The flush water accumulator should be preloaded to 5 psi 35bar 9 27 04 34 WINTERIZING OR PICKLING W ANTIFREEZE WARNING Use oniv propvlene glvcol based drinking water svstem antifreeze Do not use ethvlene glvcol based automotive antifreeze which is toxic Propylene glycol can be used instead of Spectra SC 1 storage chemical for storage in any cli mate up to one year following this procedure Replace the prefilters with clean ones Flush the system with fresh water until the brine discharge water is below 1000 ppm or until the brine discharge does not taste salty Set up the system for pickling according to the directions for your model Place enough antifreeze in a bucket to fill your system This will be about two gallons for a 150 or 200 model three gallons for a 380 or 400 and larger systems will take more Run the system DEPRESSURIZED with the feed pump drawing from the bucket and the brine discharging overboard until the colored antifreeze solution begins to appear
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