Cape Horn Extreme 330R-Remote
Installation and Operating Manual
Spectra Watermakers
Katadyn Desalinaon LLC.
2220 S. McDowell Blvd Ext. Petaluma, CA 94954
Phone: 415-526-2780
www.spectrawatermakers.com
Updated January 2024
2
3
Table of Contents
Geng Started .................................................................................................................... 4
Installaon…………………………………………………………………………………………………………..…..7
Introducon to the Cape Horn Extreme 330 ...................................................................... 8
Installaon Basics ................................................................................................................ 9
Components ...................................................................................................................... 10
Cape Horn Extreme Plumbing Layout ............................................................................... 12
Product Water Plumbing and Pressure Gauge Tube Installaon ..................................... 13
Cape Horn Extreme Remote System Wiring .................................................................... 14
Oponal Z-Ion Protecon System and Installaon ........................................................... 16
Oponal Tank Switch ........................................................................................................ 17
New System Start Up ........................................................................................................ 19
New System Start up and Tesng Freshwater on Dock .................................................... 20
New System Start up and Tesng in Ocean ...................................................................... 21
Operaon…………………………………………………………………………………………….………………...22
Normal Operaon and Fresh Water Flush ........................................................................ 23
Dry Tesng with an Arcial Ocean .................................................................................. 24
Spectra Manual Remote Controller Guide ....................................................................... 25
Adjusng Freshwater Flush Duraon ............................................................................... 26
Suggested Spares .............................................................................................................. 27
Maintenance, Storage & Troubleshoong……………………………………………..28
Maintenance ..................................................................................................................... 29
Cape Horn Extreme Plumbing Diagram ............................................................................ 31
Cape Horn Extreme Electrical Diagram ............................................................................. 32
Cape Horn Extreme Electrical Specicaons....................................................................35
Introducon to Spectra Chemicals ................................................................................... 36
Cape Horn Storage Procedure .......................................................................................... 38
Winterizing with Propylene Glycol ................................................................................... 39
Membrane Cleaning Procedure ........................................................................................ 40
Flow Test ........................................................................................................................... 41
Troubleshoong ............................................................................................................... 43
Technical Bullens………………………………………………………………………………………………………..46
Parts Idencaon .......................................................................................................... 54
Owner Resources & Warranty ................................................................................. 62
Product Registraon, Installaon & Commissioning Reports .......................................... 63
4
Descripon of the pictograms
The following symbols will be used in the manual to highlight important indicaons and warnings:
ATTENTION:
This symbol indicates accident prevenon for the
operator and / or for any exposed persons.
CAUTION:
This symbol indicates that there is the possibility of
damaging the system and / or its components.
DANGER:
This symbol indicates a shock hazard or exposure to risk.
NOTE:
This symbol indicates useful informaon.
Getting Started and Manual Overview
ATTENTION
Important Informaon Safety Warnings
To safeguard the operator's safety and to avoid possible damage to the machine, before carrying out
any operaon on the machine, it is essenal to read carefully all the instrucons manual. Check
periodically that no leaks are present. Avoid installing the plant where a leak may cause damage and/or
jeopardize the safety of the vessel.
Unpack the system and inspect it for damage during shipping. Freight damage must be reported within
24 hours. Refer to the shipping list for your system to ensure you received all of the components listed.
Do not discard any packaging unl you have found and idened all of the parts. The small installaon
parts are listed on the kit list.
Be aware of the cauon and warning signage on the system. If box is labeled “Heavy”,
please use two people when moving.
5
ATTENTION
Important Informaon Safety Warning Cont.
Study the system layout diagram, component photos, and descripons before beginning
installaon.
CAUTION: We will not be held responsible for shortages and or freight damage that are not
reported within thirty days of the ship date.
Lay out the system. Before starng the installaon idenfy where each module and
component will be placed. Insure that there is enough clearance around the components for
removal of lters and system service. Make sure you have adequate tubing and hose before
starng. Addional parts may be ordered.
DANGER/CAUTION:
Do not use system in ports or polluted seaways.
Cape Horn Extreme 330 Remote Manual Shipping List:
ATTENTION: Please read any warning labels in packaged materials which may include SDS
sheets and further documents.
• Cape Horn 330 Remote Manual kit (includes Control Box and Remote Control)
• Accumulator Assembly
• Flowmeter and Pressure Gauge Assembly
• High pressure Clark Pump with membrane pressure vessel
• Black high pressure prelter with 5 micron lter
• Feed Pump Module Assembly with fresh water ush module
• Remote Manual install kit with black product water tubing
• Service kit
• Two lengths 5/8” Hose (25’)
Oponal: Z-Ion Copper Ionizaon Flush System Upgrade
6
7
Installation
8
Service Port
The Cape Horn Xtreme Remote Manual is designed to be ecient, simple, and durable. Properly
installed and maintained it will supply years of reliable service. Prudent operaon is required with
any marine equipment. Always maintain enough reserve water to get safely into your next port.
The Spectra Intensier, known as the Clark Pump, was introduced in 1997 and has connually
improved since. It is built of modern non-corrosive composites and comes with a 40” (101.6 CM)
high rejecon membrane. The Clark Pump and membrane module are pre-mounted and plumbed
together as a single unit to save me and add reliability.
Front View
Pressure Relief Valve
Double rubber mounts
to absorb vibraon
Feed Pump Module A:
Includes primary feed pump, switch, cooling fan,
charcoal lter, ush valve, service valve, and service
port. The module has compact and streamlined
plumbing. The cooling fan increases longevity.
Service
Valve
Cooling
Fan
Motor
Shuro
pump
head
NOTE: If your system came with the oponal Z-Ion, the Z-Ion unit will replace the charcoal
lter housing. The photo above, and all subsequent photos of the Feed Pump Module, will
look slightly dierent.
Charcoal Filter and
Housing
On/O Switch
Feed Pump Module B:
Includes secondary feed pump (same
as in module A), 5 micron lter hous-
ing, and power switch.
5 Micron Filter
and Housing
Introduction to the Cape Horn Xtreme Remote Manual
1-Way Solenoid Valve 12V
PL-SLN-1/4O12SV
9
Installation Basics
• Avoid ght hose bends and excessive runs.
• Use heavy gauge wire.
• Install feed pump module as low as possible.
• Use a dedicated thru-hull with scoop type strainer.
• Do not mount components over electrical devices.
Seawater Flow
Thru-hull
Not Supplied.
Thru-hull Locaon: The system must be connected to a dedicated 1/2” to 3/4” forward facing
scoop-type intake thru-hull and seacock.
Install the thru-hull intake as far below the waterline and as close to centerline as possible to
avoid contaminaon and air entering the system. Do not install the intake close to, or
downstream of, a head discharge, behind the keel, stabilizer ns, or other underwater xtures.
Thru-hulls in the bow area are suscepble to air intake in rough condions. Sharing a thru-hull
can introduce unforeseen problems such as intermient ow restricons, air bubbles,
contaminants, and will void the warranty. For racing boats and high speed boats traveling
above 15 knots, a retractable snorkel-type thru-hull ng is preferred because it picks up
water away from the hull.
The brine discharge thru-hull should be mounted above the waterline, along or just above the
boot stripe, to minimize water li and back pressure.
Avoid restricons or long runs on the enre inlet side of the plumbing from the thru-hull to
the feed pump module.
Secure the piping away from moving objects such as engine belts and hatches. Prevent chafe
on the tubing as required. Test and inspect all piping and hose clamps aer several hours of
operaon.
Pipe Fing Instrucons: To seal plasc-to-plasc ngs, wrap 6 to 8 layers of Teon tape
over their threads. Hold the ng in your le hand and ghtly wrap the threads clockwise.
For smoother assembly, do not tape the rst (starng) threads.
Wiring
• Pay aenon to wire size or system performance will be impaired
• Perform wiring to UL, ABYC, CE or applicable standards
Important Installation Notes
CAUTION: Avoid geng dirt or debris into the piping or hoses during assembly. A small bit
of debris can stop the system!
10
Components
Sea Strainer Mount close to the intake through-hull, in a
locaon that can handle water spillage during service.
Feed Pump Module B
5 Micron Prelter Bowl Locate in an area that allows easy access as
this will be the most frequently serviced module while cruising.
Mount vercally and leave room below bowl for lter changes.
CAUTION: Do not mount above water-sensive equipment.
Feed Pump Module A
Mount the feed pump module on a vercal surface, no more
than 3-feet (1.0M) above the waterline. It is preferable to
mount as low as possible. Locate in an area that allows easy
access to the charcoal lter, and the service valve. Keep
future maintenance in mind when choosing a locaon, and do
not mount above water-sensive equipment.
NOTE: IF INSTALLING THE Z±ION, SEE Z±ION INSTALLATION
INSTRUCTIONS FOR MORE DETAILS.
11
Components - Cont.
Double rubber mounts
to absorb vibraon
NOTE: This module must be installed in an area that maintains a temperature below 113°F
(45°C). It may be placed as high in the boat as you desire, and mounted in any posion, even
upside down. Make sure that the area around and under the pump does not have any water
sensive equipment, as water will be spilled during any repairs or if a leak occurs. Allow for
easy access to the pressure relief valve.
The Clark pump and membrane module comes complete with a mounng system. Be sure to
use the supplied washers on the rubber feet.
Pressure Relief Valve
Clark
Remote Manual Controller
The remote control panel can be mounted anywhere dry and
convenient. Cut a 5/8” (1.5 cm) wide by 5/8”” (1.5 cm) high
opening for the display port. The display needs minimum 2 1/2”
deep clearance for the cable. Take care not to damage the plugs
on the ends of the cable when roung. The recommended
display cable is a standard Cat 5e ethernet cable.
NOTE: Use only a Spectra approved cable.
4”/ 10.15 cm Depth: .6”/1.5 cm
2.15”
5.5 cm
Remote Manual Control Box
The remote manual control box should be mounted so the toggle
switch can be accessed during trouble shoong or maintenance.
It may need to be opened during commissioning in order to
opmize the ush duraon 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 opon Z-Ion protecon system.
12
ShurFlo
Pump
Charcoal
filter
Freshwater Storage
(Inside Boat)
(Outside Boat)
Feed
Water
Inlet
Feed
Pump Module B
Brine discharge thru
hull (not included):
place above waterline
or tee into another
visible drain.
(Pressurized
Fresh Water**)
Ocean Feedwater
Legend:
Drinkable Freshwater
Brine Discharge
Freshwater Flush
Note: Brine discharge
may be connected to ei-
ther side of Clark Pump
Use the supplied 5/8-inch
(15.9mm) clear braided vinyl
hose for all runs. More hose may
be ordered from Spectra, or
bought at a hardware or marine
store.
Cape Horn Xtreme 330R Plumbing Layout
Water-sensive Equipment.
**Fresh water from ship’s pressure
water system 30 psi (2bar)
minimum. 50 psi (3.5bar) maximum.
Target should be 1.5 gal/min.
Feed
Pump Module A
Note: High Pressure Fittings
may develop drip leaks in ship-
ping. See Fitting instructions for
detailed resolution
13
Back view of instrument panel
Use accumulator port to connect the
pressure gauge with the supplied 1/4”
black nylon tubing. Tubing must be
pressure rated to 150 PSI (10 BAR).
Product Flow Meter
Pressure Gauge
Product Water Plumbing and Pressure Gauge Tube Installation
Product Sampling Valve: Mount using the
supplied plasc straps.
Note: the handle points in the direcon of
ow.
Product to tank: Route the product water
from the valve into the top of a vented
tank. Install a tee in the water ll or tap a
pipe thread into an inspecon port.
CAUTION: DO NOT! feed the product into
a vent line, manifold, or the boom of the
tank. Make sure that there is no
restricon in this piping. Pressure in the
product tubing must never exceed 5psi
(.3bar), running or stopped, or the
membrane will be permanently damaged.
Sampling Tap for tesng the
product water.
Use the supplied 1/4”
black tubing for the
product water plumbing.
Product output ng.
14
Cape Horn 330 Remote System Wiring
Cape Horn Extreme 330 Remote Manual systems are pre-ed with waterproof connectors for
electrical and signal cables. Each connector is dierent, so it is impossible to connect them incorrectly,
and the connectors are color-coded. The system has a power inlet harness with a terminal block and
cover, two Pump Power cables, 2–conductor fresh water ush solenoid cable, a Z-Ion power and signal
cable, and a 25-foot cable for the Remote Manual Controller.
Do not install it in hot or poorly venlated locaons.
Power Inlet Harness with
terminal block
*See Cape Horn Remote
Power Wiring (Page 15)
Display Port,
*see components cont.
(Page 11) for
installaon
*Manual Remote Controller
guide (Page 25) for funcon
Standard Fresh Water
Flush connector (Blue)
Z-ION Connector (with green
band).
*Only used with oponal Z-
Ion Connector
*see Zion Operaon and In-
stall (Page 16) for more
details.
Run Manual/Run Auto - Toggle Switch
*Spectra Manual Remote Operaon Guide
(Page 25)
Feed Pump B Power Cable
Feed Pump A Power Cable
15
Cape Horn Remote Power Wiring
DANGER:
Installaon
• 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 juncon box or on a bulkhead
adjacent to the feed pump module.
• Make sure that this is a dry locaon well above bilge level and not subject
to water spray.
• Be sure to install the terminal block cover
• Conrm the voltage and polarity before wiring to the unit
• Gauge wire so the appropriate voltage is provided to the system. Use a Digital Mulmeter to
ensure the voltage at the power terminal block is at the nominal specicaons for the system.
• DC power feeds should be uninterrupble to ensure proper operaon.
• If the specied circuit breaker sizes are unavailable, use the next higher rang but do not
exceed the specicaon by more than 10%.
• Upon successful power up the remote display will turn on and a freshwater ush may
engage.
Warning
• All wiring and over current protecon must be done to applicable ABYC, Marine UL, or CE
standards.
• Check for exposed wiring throughout enre installaon before supplying voltage to unit.
Do not apply voltage to the unit that exceeds 14.6V / 29.2V to 12V / 24V models.
Serious damage to the electrical system may occur.
System performance is voltage specific.
12 Volt Models 24 Volt Models
Nominal Producon Voltage 13.5V DC 27V DC
Nominal Producon Amperage 19 Amps 11 Amps
Max Amperage 20 Amps 11 Amps
Recommended Breaker Size 25 Amp 15 Amp
Applying less than 10.4V / 20.8V to 12V / 24V Models will impact functions of
control system
Applying less than 12.8V / 25.6V to 12V / 24V Models will increase rate of wear
on system motor and pump.
16
Connector for generator bowl (green)
Generator bowl with
charcoal lter in bowl
Generator bowl
connector
Z-Ion control box: Mount
in a visible locaon near
the feed pump module.
Optional Z-Ion Protection System & Installation
The Z-Ion, developed by Spectra, protects the enre system from fouling for extended periods
without fresh water ushing or storage chemicals (pickling).
The Z-Ion achieves this end by introducing a stream of metallic ions into the fresh water ush
water, thus ooding the enre system with ions that prevent biological growth for up to thirty
days. If you are going to let your system sit idle for longer than thirty days, you will sll need to
treat it with SC-1 storage chemical or propylene glycol.
The Z-Ion will not prevent freezing, so in freezing climates pickling with propylene glycol is sll
required. Even with the Z-Ion there may sll be cases when you need to pickle your system
with SC-1 storage chemical or propylene glycol, so we recommend you carry one of these
products at all mes.
Installation
For a detailed overview of the Z-ION installaon, see below.
17
Customer-Supplied Tank Full Switch
Installing an oponal tank full oat switch at the top of your water tank
allows the watermaker to ll your ship’s water tank then automacally stop
running. The user can then fresh water ush with by hing ’Stop’ and then
’FWF’ on the Remote Controller.
Your watermaker does not come with the top-mounted Tank Full Switch (EL
-SWT-LV). However, this part can easily be sourced from your local dealer or
Full Service Provider if you wish for your system to automacally stop once
your freshwater tank is full.
If you do not install the Tank Full switch in your tank, you MUST MANUALLY STOP the system
when your freshwater tank has been lled. The system will not stop automacally.
NOTE: The oat may need to be ipped 180 degrees to work properly. Many oats can be
easily ipped by removing the clip opposite the wire.
Optional Tank Switch
Drill and Tap
Drill and tap a 1/8” NPT port into the top of the fresh water tank that is being lled by the
watermaker. This can be installed on a tank access cover, or directly into the water tank. If
installing on an access cover, be sure to leave a service loop on the oat switch wiring to allow
removal of the tank access cover.
18
Watermakers should never be run unaended.
Tank Full
If a tank switch has been installed, the
“Running” and “Stopped” lights will be
illuminated when the tank is full and the
system will stop.
Your watermaker should never be le running unaended.
Optional Tank Switch - Cont.
The customer supplied oat switch must be connected to the Terminals 5 & 6 labeled Tank
Full within the Control Box that is mounted to the inside of the Feed Pump Module. There is
no polarity. Remove the jumper. Connect the wires to the terminals.
Use 18/2 nned wire or larger. Wire is not included in the installaon kit.
Connect to
Terminals 5 & 6
Note: Remove only the jumper in terminals 5 & 6.
19
New System Start Up
20
Every new system is shipped from the factory with nontoxic, food-grade propylene glycol. Propylene
glycol, Spectra Chemicals, or anything other than seawater or freshwater must be purged from the
system with the pressure relief valve open at least 1/2 turn. You can purge your system with seawater or
freshwater via the Spectra’s freshwater ush funcon. The system must be purged for a minimum of 60
minutes, or unl at least 40 gallons (151.42 liters) of water have moved through the system.
CAUTION: Damage will occur if the purge process is not properly followed and the membrane is
pressurized with chemicals in it. Check that no hoses are kinked or restricng ow.
Follow this procedure for starng a new system the rst me, and aer a system has been stored or
cleaned with chemicals.
First check that:
• All of your hose connecons are ght.
• The green warning tag and washer have been removed from under the pressure relief valve.
• The pressure relief valve is open at least 1/2 turn.
• The sampling valve is set to the sample posion.
• The brine line is able to freely discharge
*For purging with seawater see next page.
New System Startup and Testing Freshwater on Dock
Open 1/2 Turn
Remove Tag and Washer Sampling Tap to Sample
To Sample
To Tanks
In
For a purge using the freshwater ush:
1) Ensure The vessel’s pressurized water system is on
2) Locate the potenometer screw on the circuit board (pictured on pg. 34) and turn this all the way
clockwise to increase the ush duraon to 10 minutes.
3) Flush 6 mes in succession will achieve a 60 minute purge.
4) Remember to turn the ush potenometer screw back close to its original posion aer this is com-
plete. Only proceed to step 5 on purging with seawater: (Close the pressure relief valve. Turn on Pump B.
The pressure should rise to 90-100 PSI. If pressure does not rise Feed Pump A may need to be turned on and o
in order to prime both pumps. Water should begin to ow out of the sampling tube. If the ship is located in
brackish or fresh water the pressure will be lower) for the product purge once you can run the system in
seawater. In the interim, ensure the system is ushed with freshwater weekly or preserved with bio-
cide.
21
1) Move to an area free of contaminated water, such as in a polluted harbor or canal.
2) Make sure the inlet thru hull/seacock is open.
3) Turn on Feed Pump A and check to make sure water is coming out of the brine discharge (thru-hull
above water).
4) Run the system without pressure for 60 minutes to purge the storage chemicals. The pressure gauge
should read less than 3 5 PSI. If purging with freshwater the sampling tube may discharge water.
5) Close the pressure relief valve. Turn on Pump B. The pressure should rise to 90-100 PSI. If pressure
does not rise Feed Pump A may need to be turned on and o in order to prime both pumps. Water
should begin to ow out of the sampling tube. If the ship is located in brackish or fresh water the pres-
sure will be lower.
6) Depending on storage and environmental condions the system may need to have addional purg-
ing me. If the product water does not taste pure or sample below 500 ppm, purge or run the sys-
tem for up to 6 addional hours.
7) The system may be run with only one feed pump at a me or with both pumps simultaneously.
Water quality may improve slightly when running with both pumps, as product salinity decreases with
higher feed pressure.
For a purge with seawater :
New System Startup and Testing in Ocean
Open 1/2 Turn
Remove Tag and Washer Sampling Tap to Sample
To Sample
To Tanks
In
Every new system is shipped from the factory with nontoxic, food-grade propylene glycol.
Propylene glycol, Spectra Chemicals, or anything other than seawater or freshwater must be
purged from the system with the pressure relief valve open at least 1/2 turn. You can purge
your system with seawater or freshwater via the Spectra’s freshwater ush funcon. The sys-
tem must be purged for a minimum of 60 minutes, or unl at least 40 gallons (151.42 liters)
of water have moved through the system.
CAUTION: Damage will occur if the purge process is not properly followed and the mem-
brane is pressurized with chemicals in it. Check that no hoses are kinked or restricng ow.
Follow this procedure for starng a new system the rst me, and aer a system has been
stored or cleaned with chemicals.
First check that:
• All of your hose connecons are ght.
• The green warning tag and washer have been removed from under the pressure relief
valve.
• The pressure relief valve is open at least 1/2 turn.
• The sampling valve is set to the sample posion.
The brine line is able to freely discharge
22
Operation
23
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 locaon or weather prevents
proper tesng refer to “Tesng with an Arcial Ocean.”
THE VENTURA 200T IS DESIGNED FOR WARM WATER USE. OPERATION IN WATER BELOW 50 DEG F (10
DEG C) MAY CAUSE HIGH OPERATING PRESSURES AND INCREASED WEAR
1. Check that the thru-hull inlet is open.
2. Turn the product sample valve to the SAMPLE posion.
3. Turn the yellow service valve handle on the feed pump module to RUN.
4. Start the system by pushing ‘Start’ and check for ow by inspecng the brine discharge and checking
for pressure on your analogue gauge. If there is no ow, open the pressure relief valve on the Clark
Pump to prime the system and bleed the air out of the feed pump.
5. Aer 5 minutes, check the product water with your handheld salinity tester. When it is below 750
PPM, divert the product into your tank by rotang the product sample valve handle 90 degrees.
6. Run the system unl you have lled your tank or have made enough to meet your requirements.
7. Following your water making session, perform a freshwater ush.
Freshwater Flush (You should freshwater ush your watermaker aer EVERY use.)
1. Push the Freshwater Flush buon on the remote panel.
2. The freshwater ush solenoid will open and feed pump will come on, allowing pressurized freshwater
to ow through the system. Pressure will drop on the gauge, which indicates that the membrane is
ooded with fresh water.
3. Aer a proper ush, the ppm of the brine discharge should be below 1000ppm.
You may now leave the system unaended for up to ve days (30 with the Z-Ion) without further aen-
on.
Remember that you need to run the system almost a half an hour to make enough water for a ush. You
may noce that the system output is higher while charging your baeries, as the machine is voltage
sensitive.
Analogue Gauge
Panel
Remote Panel
3-Way Product
Sampling Valve
To Sample
To Tanks
AMPS
Feed Static *
Feed Flow Product Flow
Watts/
Gallon
12V MAX 24V MAX Pressure Pressure Flow MIN MIN Flow Flow MIN MIN Nom Max
PSI bar PSI GPM LPM GPM LPM GPH LPH GPH LPH
Both
Pumps ≈ 19 20 ≈ 10 11 90-100 6.3-7 30-35 2.8 10.6 2.7 10.2 15 56.7 14.3 54.1 16 18.4
Nominal Parameters
For Spec Producon:
12V Systems: Run at 13.2 VDC min
24V Systems Run at 26.4 VDC min
24
If it is not possible to test run the system with the boat in the water, you may test the system with an
arcial 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).
Make sure the domesc water system is powered up and the boat’s tank has at least 60 gallons (230
Liters) of water to purge the storage chemicals from the system. Conrm that the charcoal lter is
installed in the feed pump module, and the domesc water line is connected. If freshwater system
is not available & system is sll pickled, alter beginning procedure to feed unchlorinated water
through the service port to purge out storage chemical.
1. Open the pressure relief valve on the Clark Pump. Remove the green tag and spacer, if sll
aached.
2. Press the Freshwater Flush buon to run a full ush cycle. If there are storage chemicals in
the system, ush for addional me to purge out chemicals. SC-1 minimum 20 minutes purge,
Propylene Glycol minimum 60 minutes purge.
3. Connect the black spiraled intake service hose** to the service port on feed pump module,
then connect the vinyl brine discharge service hose* to the quick disconnect ng on Clark
Pump. Refer to the photos below. Route both hoses into the 5 gallon (20 Liter) container. Turn
the product sample valve to the sample posion, and route the product into the bucket.
4. Using the remote panel, select Freshwater Flush. Run unl the bucket is lled.
5. Turn the yellow valve to SERVICE.
6. Mix salt with the freshwater to the proper proporon or use an aquarium hydrometer to adjust the
salinity level.
7. Push the Start buon to run the system.
8. Allow the system to prime and then close the pressure relief valve. The system should build pressure
shortly and start making water, with the brine and product water recombining in the bucket to be
cycled again. This will gradually heat the water. Do not let the water temperature exceed 120 deg. F
(49 deg. C).
9. Run the system under pressure, checking for proper operaon and leaks. Aer tesng the system, re-
install the brine discharge hose, product tube, and freshwater hose from the strainer. You can now
ush the system by pressing the Freshwater Flush buon.
**Intake service hose con-
nected and yellow service
valve handle to SERVICE
*Connecng brine discharge
service hose at quick disconnect
Service valve OFF, in FLUSH
posion
**Black spiraled rein-
forced intake service
hose
*Vinyl Brine Discharge Service
Hose
Remote panel
Dry Testing with an Artificial Ocean
25
Start
Pressing the ‘Start’ buon begins
watermaker operaon.
If the system has been pickled, winterized, this is the rst startup, or the condion of the system is
unknown, go to NEW SYSTEM START-UP on page 19 or serious damage may occur.
A fresh water ush should be performed aer every use of the watermaker. The system will need to
run for approximately 15 minutes to make enough fresh water for one ush.
Fresh Water Flush (FWF)
Pressing the ‘Fresh Water Flush’ buon oods the watermaker with fresh water
from the vessel’s domesc water tanks. Opens solenoid valve to allow water to
ow from tank instead of seawater from the thru-hull. Fresh Water Flush mode
will end automacally aer ush is complete, approximately 3 minutes.
Stop
Pressing the “Stop” buon ends watermaker
operaon. The “Stop” buon must be pressed
before beginning a Fresh Water Flush.
Spectra Manual Remote Controller Guide
Run Manual Operaon
The remote manual circuit board, its funcons and protecons, can be bypassed all together
by engaging the toggle switch to “Run Manual”. When the switch is engaged both motors will
receive power and will only cease to run when the switch is turned back the to Auto Posion,
tank oat switch will not disengage the system.
Running the system without a display is possible, however, it is not recommended unless
alternate measures are taken to freshwater ush the system aer every use. Such as running
dechlorinated (or product) water through the system via the service port.
26
Adjusting Fresh Water Flush Duration
The Cape Horn Freshwater Flush Duraon is set to a factory default of 3 minutes, which is
usually the right amount of me to ensure that sea water is thoroughly ushed out of the
watermaker using the least amount of fresh water. However, due to dierent lengths of hose
runs, dierent rates of ow, and dierent pressures in shipboard fresh water systems, the
ush duraon can be opmized for your boat.
Set the Flush Duraon with a small screwdriver so that the fresh water ush comes to an end
just as the salinity of the brine discharge drops below 1000 PPM, or no longer tastes brackish.
Since the ush duraon can only be adjusted in round minutes, you may want to lessen the
duraon to 2 minutes, to save water, or increase to 4 or more minutes to ensure a thorough
ush.
Also, the charcoal lter is rated for 1.5 GPM (6 LPM): If the system pushes more than 1.5 GPM
through the charcoal lter (4.5 gallons in 3 minutes), a ow regulator can be added.
27
Suggested Spares
Short term cruising, weekends, etc.:
We suggest two treatments worth of preservave chemicals (either 2 bags of SC-1 or 2
gallons (8 liters) of Propylene Glycol). Six 5-micron lters and one Carbon lter.
Cruising 2 to 6 months at a me:
Twelve 5-micron lters, 2 Carbon lters, enough preservave chemicals for 4 treatments,
one replacement feed pump head.
CAUTION: Longer than 6 months:
Addional lters, Oshore Cruising Kit consisng of Clark Pump seals, O-rings, tools, and
membrane cleaning chemicals. One replacement strainer screen, O-ring for strainer screen,
O-rings for lter housings. Addional feed pump heads and/or feed pump diaphragms.
Common Parts Part Number
SC-1 STORAGE CHEMICAL KIT-CHEM-SC1
SC-2 CLEANER KIT-CHEM-SC2
SC-3 CLEANER KIT-CHEM-SC3
BASIC CRUISE A KIT-BCK-A
OFFSHORE REBUILD KIT KIT-OFFSH
5 MICRON FILTER FT-FTC-5
CHARCOAL FILTER FT-FTC-CC
5” STRAINER SCREEN FT-STN-5S
OIL/WATER FILTER FT-FTC-OW
FEED PUMP EL-FP-12V or 24V
FEED PUMP HEAD PL-PMP-SFPH
FEED PUMP DIAPHRAGM EL-FP-DP
5” STRAINER O-RING SO-STN-5SS
FILTER HOUSING O-RING SO-FHS-10H
CHARCOAL FILTER HOUSING O-RING SO-FHS-3PCS10
All sales are made through Spectra’s network of dealers/full service providers. Contact your
local full service provider for addional suggesons and support.
28
Maintenance, Storage, and
Troubleshooting
29
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. Biological fouling in the membrane is more
likely when a watermaker sits idle. A warm environment will cause more growth than a cold
environment. A fresh water flush every five days will greatly reduce biological growth but may
not stop it completely. You can also protect your watermaker with the optional Z-Brane or Z-Ion
systems: Both protect the membrane from bio-fouling without the use of storage chemicals.
DANGER/ATTENTION: For maintenance, always disconnect from power source rst.
The Seawater Strainer
The seawater strainer’s stainless steel element should be inspected, removed, and cleaned as
needed.
ATTENTION: Ensure that the thru-hull is closed before disassembly and the gasket is in place
before reassembly. When the system is put into storage, remove the strainer, rinse with fresh
water, and reassemble dry to impede corrosion. Check frequently during operation.
The Prefilter
Service the prefilter on a regular basis. If the system is installed as shown on the plumbing
schematic, the pressure will fall on the remote gauge as the prefilter becomes dirty. Extremely
dirty filters will harm system performance and may cause the feed pump to cut out from high
pressure. Leaving dirty filters in the machine during long idle periods will cause biological
contamination. Please review prefilter bulletin to page 48. prior to running your system.
NOTE: Prelter elements must be changed frequently. The rate is solely dependent on the input
water. A 5-micron lter might last you a 4-6 weeks in clear open ocean seawater, or be ruined in
minutes in a dirty harbor. Spectra does not advise to aempt to clean dirty prelters. Prelters
are a consumable item and should be changed for new when in queson.
To service the lter close the thru-hull, open the prelter housing, remove the old lter, clean
out the housing bowl, and reassemble the housing with a new 5 micron lter element. Leave dry
unl next startup.
NOTE: Use only Spectra-approved lters or you may void your warranty. Occasionally, lightly
lubricate the O-rings with silicone grease.
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. This filter protects the membrane
by removing chlorine from the flush water. Use only a Spectra-approved replacement.
The Feed Pumps and Clark Pump
The feed pumps and the Clark Pump require no routine maintenance except inspection for
leaks. Tighten any hose clamps or fittings that show signs of leakage. The high pressure fittings
threaded into the Clark Pump have O-ring seals with a straight thread. These should never leak
and should never be over-tightened. If one of the tube nuts starts to leak, it can be un-
threaded, sealed with a bit of silicone grease or oil, and tightened with two wrenches very
tightly.
The Membrane
Always perform a flow test before cleaning your membrane. Cleaning with chemicals shortens
the lifespan of membranes, so only clean if you are certain it is warranted. The leading cause
of fouling is biological growth that forms when the system is left unused without flushing or
pickling. Fouling from mineral scaling can happen during operation under certain seawater
conditions, and from rust. Monitor the product salinity and feed pressure for higher than
normal readings, and take environmental conditions into consideration:
• Cold feed water or clogged filters can cause high pressure.
• Low product flow is usually due to low voltage, a worn feed pump, or a worn Clark Pump.
Test to see if biological growth has occurred: Before running the system, remove the prelter
and examine its condion. If the lter housing is full of smelly, discolored water, the system
was not properly stored. Install a clean prelter.
Next, check the membrane. Aach the brine discharge service hose and lead it into a bucket.
Open the pressure relief valve half a turn, and manually run the system for 30 seconds (metal
toggle switch on feed pump module). Examine the brine water: If it is discolored and smells
bad, perform an SC-2 cleaning with unchlorinated water before running the system
pressurized. If the brine is fairly clean, follow the New System Startup procedure and run
normally. Check for performance. Clean the membranes only if performance is reduced.
NOTE: See the Cleaning Procedure (pg. 39) for complete instructions.
31
Cape Horn Extreme 330R Plumbing Diagram
32
Cape Horn Extreme 330R
Electrical Diagram
12V/24V
33
Cape Horn Extreme 330R 12V/24V
34
Cape Horn Extreme 330R 12V/24V
35
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
CAPE HORN EXTREME REMOTE 24V W/LONG
Power Supply Voltage: 24 VDC
Bench Test: 27.2 V / 10 A
Power Consumption: 273 W
Efficiency: 18 Wh/gal
36
Introduction to Spectra Chemicals
We use four types of chemicals: SC-1, SC-2, SC-3, and propylene glycol anfreeze. 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. These chemicals, used to store other watermaker brands, are very acidic
and will damage the Clark Pump and void the warranty.
CAUTION: Never use any chemicals with the system pressurized! Always open the pressure
relief valve 1/2 turn. Always follow the instrucons for purging the chemicals as shown in the
New System Startup secon.
Storage
SC-1 prevents biological growth when your system is idle. It should not be used as a cleaning
chemical, nor will it protect your system from freezing. A bag of SC-1 is mixed with 1 to 3
gallons of product or dechlorinated fresh water in a bucket and circulated through the system
for 10 minutes. This treatment will protect the system for six months, aer which the SC-1
treatment must be repeated. To use SC-1, follow the instrucons for Storage Procedure.
Spectra systems should be stored with propylene glycol if freezing is likely to occur. Propylene
glycol can be used instead of Spectra SC-1 storage chemical for storage in any climate, and
treatment is eecve for one year. Propylene glycol is a food-grade anfreeze used to
winterize RV’s, boats, and cabins. Do not use ethylene glycol automove anfreeze, which is
toxic and will damage the system.
The propylene glycol formulaons sold in marine and RV stores are usually diluted with water.
The water remaining in the watermaker before the storage procedure will further dilute the
anfreeze, reducing the microbial protecon and increasing the temperature at which the
mixture will freeze.
Anfreeze labeled “Minus Fiy” is a 25% soluon and will begin to form an icy slush at about
15°F (-10°C) and will only provide burst protecon to about 0°F (-18°C). Aer a further 50%
percent diluon by water remaining in the watermaker, “Minus Fiy” anfreeze will only
protect from bursng down to about 25°F (-4°C). Therefore if low temperature freezing
protecon is required a 60% or stronger anfreeze should be used. 60% soluons are labeled
“Minus 100” and will provide burst protecon to -15°F (-27°C) even aer a y percent
diluon with residual water. “Minus 200” formulaons are pure propylene glycol.
37
Introduction to Spectra Chemicals - Cont.
Complete microbial preservave protecon requires a 25% soluon of propylene glycol, so
care must be taken that the soluon remaining in the watermaker during long term storage is
at least 25%, even if freeze protecon is not required. For these reasons Spectra recommends
that all pickling be carried out with a 60% or greater concentraon.
NOTE: See Winterizing with Propylene Glycol on page 39.
Propylene glycol can be dicult to ush from a membrane, especially aer extended storage
periods. This results in high salinity water (high PPM) and residual avor in the product water.
We recommend ushing the system WITH THE PRESSURE RELIEF VALVE OPEN for 4-6 hours
aer storage with propylene glycol—the longer the beer. If, aer extended ushing, you sll
experience low product water quality, cleaning with SC-2 usually removes all traces of
propylene glycol and returns the salinity to the level it was before storage with propylene
glycol.
Cleaners
Cleaning can be detrimental to the membrane and shorten its life. Avoid unnecessary
cleaning, and avoid cleaning as a diagnosc tool.
SC-2 s an alkaline cleaner used to remove light oil, grime, and biological growth. It is most
eecve if heated to 120°F (49°C), which is dicult on a boat. In most cases the water quality
will increase in PPM (salinity) aer an SC-2 cleaning. Aer a few hours it should recover to
near the level it produced before the cleaning.
SC-3 is an acid cleaner used to remove mineral and scale deposits. In most cases this is used
rst and if there is no improvement, go on to the SC-2. SC-3 will in most cases lower the
product PPM and overall pressures. Scaling is a slow process that may take several months or
years. SC-3 is less harmful to the membrane and will almost always improve the performance
of an older membrane.
For cleaning with either SC-2 or SC-3, see the Membrane Cleaning Procedure on page 40.
38
NOTE: The Cape Horn contains about 2 gallons of water at any given me, so with 2 gallons in the bucket there
will be a total of 4 gallons of soluon.
1. Close the saltwater intake seacock.
2. Push the Freshwater Flush buon to perform a ush. Repeat a second ush.
3. Disconnect the brine discharge hose from the Clark Pump at quick disconnect. Replace with the vinyl brine
service hose* from your service kit. Lead the service hose into a 5 gallon bucket.
4. Push Freshwater Flush again and stop the feed pump when the bucket has lled with one gallon of non-
chlorinated freshwater (or ll a bucket with a gallon of dislled).
5. Mix one 8 oz. container of SC-1 storage compound with the water in the bucket. It will not dissolve
completely, which is normal, and any undissolved parcles will be caught by the prelter.
6. Connect black spiraled reinforced service hose** to the service port (garden hose style ng) above the
yellow valve on the feed pump module and lead the hose into the soluon in the bucket, creang a closed
loop. Turn the yellow service valve to SERVICE.
7. CAUTION: Ensure the pressure relief valve on the Clark pump is OPEN (unpressurized), 1/2
turn counterclockwise OR THE MEMBRANE WILL BE DAMAGED.
8. Turn on the feed pump using manual toggle switch***. The system will draw soluon from
the bucket and return it via the brine discharge hose. Circulate the storage soluon through
the system for 20 minutes. Turn o the feed pump when nished.
Clean Up:
1. Remove the brine service hose from the Clark Pump brine discharge using quick disconnect, and replace with
the original hose that leads to the discharge thru-hull.
2. Pump the bucket dry using the manual toggle switch, turn o when empty.
3. Turn the yellow service valve back to RUN. Remove the intake service hose, and replace the cap.
4. Close the seacock, drain then clean the sea strainer and prelters. Reassemble dry with new lters. Leave the
pressure relief valve open, since the next me you run the system you will need to purge the storage
chemicals with the system unpressurized.
Your system is now protected from biological growth for 6 months.
Cape Horn Remote Manual Storage Procedure
**Intake service hose con-
nected and yellow service
valve handle to SERVICE
*Connecng brine discharge
service hose at quick disconnect
Service valve OFF, in FLUSH
posion
***Manual toggle switch
**Black spiraled
reinforced intake
service hose
*Vinyl Brine Discharge Service
Hose
39
See descripon of propylene glycol formulaons, and ushing from system on page 36.
1. Close the saltwater intake seacock.
2. Push the Freshwater Flush buon to perform a ush. Repeat a second ush.
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. Lead hose into a 5 gallon bucket.
4. Push Freshwater Flush and stop with one gallon of freshwater in the bucket (or use dislled).
5. There are two gallons of water in the watermaker, so add potable water anfreeze to the bucket per the
label instrucons based on the protecon level needed.
6. Connect black spiraled intake reinforced service hose** to the service port (garden hose style ng) above
the yellow valve on the feed pump module and lead the hose into the soluon in the
bucket, creang a closed loop. Turn the yellow service valve handle to SERVICE.
7. CAUTION: Ensure the pressure relief valve on the Clark Pump is OPEN 1/2 turn
(unpressurized).
8. If a stronger concentraon of anfreeze is required you can discard the rst one or two
gallons of water from the discharge line before placing it into the bucket to recirculate. Add
more propylene glycol to the intake bucket if necessary. Turn on the feed pump using the manual toggle
switch*** and the pump will draw propylene glycol from the bucket, and the brine discharge service hose
will return it, creang a closed loop. Run the feed pump and circulate the anfreeze for approximately 20
minutes. Stop the feed pump by moving the toggle switch back to ‘RUN AUTO’.
Clean Up:
1. Remove the brine discharge service hose from the Clark Pump, and replace with the original brine discharge
hose that leads to the thru-hull. You may now pump the bucket dry by engaging the toggle switch again. Stop
when the bucket is empty, switching back to ‘RUN AUTO’.
2. Turn the yellow service valve handle to OFF. Disconnect the intake service hose and replace cap.
3. Drain the seawater strainer and the hose leading to the feed pump module. Disconnect the product tubing
from the membrane housing and blow residual water out of the tubing. Empty the charcoal lter housing
and ush water lines.
Your system is now protected from biological growth and freezing for 12 months.
Winterizing with Propylene Glycol
**Intake service hose connected
and yellow service valve handle
to SERVICE
*Connecting brine discharge
service hose at quick disconnect
Service valve OFF, in FLUSH
position
***Manual toggle switch
**Black spiraled
reinforced intake service
hose
*Vinyl Brine Discharge
Service Hose
40
Spectra cleaning compound (SC-2 or SC-3) must be mixed with freshwater at a rao 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
gured into the mixture. A Cape Horn 330R system requires one container of compound per
cleaning.
1. Turn the yellow service valve on the feed pump module to OFF (horizontal, see photo*).
2. Push Freshwater Flush to ush the system. Repeat, to ush the system twice.
3. Remove the cap on the service port on the feed pump module and install the black spiraled reinforced
intake service hose** from the service kit. Remove the quick disconnect ng from the brine discharge
outlet of the Clark Pump, and replace it with the vinyl brine discharge service hose***. Lead both hoses
into a 5 gallon (20 liter) bucket.
4. Push the Freshwater Flush buon and run the feed pump unl one gallon of fresh water runs into the
bucket from the brine discharge service hose (or ll with a gallon of dislled water). Stop the system.
5. Turn the yellow service valve to the SERVICE posion.
6. CAUTION: Make sure that the pressure relief valve on the Clark Pump is open (unpressurized).
7. Mix the SC-2 or SC-3 cleaning chemical in the bucket with the freshwater. If possible (for maximum
eecveness), heat the soluon to approximately 120°F(49°C).
8. Start the system using the manual toggle switch**** on the control box. The intake service hose will
draw soluon from the bucket and the brine discharge service hose will return it. Circulate the soluon
through the system in this manner for 45 minutes.
9. Stop the pump. Replace the brine discharge overboard hose and run the pump unl the bucket is empty.
Stop the pump and turn the yellow service valve back to the RUN posion. Restart the pump and run for
20 minutes to ush the chemicals out of the system (DO NOT CLOSE the pressure relief valve!)
10. Move the manual toggle switch on the Control Box to RUN AUTO.
The system may now be restarted, ushed, or stored.
Membrane Cleaning Procedures
**Intake service hose con-
nected and yellow service
valve handle to SERVICE
***Connecting brine discharge
service hose at quick disconnect
*Service valve OFF, in FLUSH
position
****Manual toggle
switch
**Black spiraled
reinforced intake service
hose
***Vinyl Brine Discharge
Service Hose
41
Flow Test for Dual ShurFlo Pumps (Cape Horn Extreme 330R)
NOTE: The ow test is the most useful diagnosc test for system performance, and should be
done before replacing or cleaning your membrane. Changes in producon or water quality are
normally caused by something other than the membrane, unless the system has been le
unused for a long me.
Before the ow test, change the prelter and clean the sea strainer. Carefully check for water or
air leaks, as air in the system will cause low producon and errac salinity. Look for air bubbles
in the product ow meter, feed water hoses, and brine overboard hose.
Run the system and watch the pressures very closely. If the feed pressure to the Clark Pump is
asymmetrical from one stroke to another, this could be part of the problem. A dierence of a
few PSI is acceptable, but anything over that is an issue. If the pump is asymmetrical, Clark
Pump repairs should be done before connuing with these tests.
If no asymmetry is noted, connue with this test.
You will need a graduated bucket, either a graduated pitcher or large measuring cup (or any
container of a known volume), and a stopwatch. Before the flow test, change all filters and
clean the sea strainer. Carefully check for water or air leaks, as air in the system will cause low
production and erratic salinity. Observe the feed pressure and ensure that the Clark Pump
cycles symmetrically. Log the voltage at the feed pumps at the same time. Confirm at least 12.5
Volts at the feed pump on 12-Volt DC systems; 25 volts on 24-Volt DC systems.
Take two measurements and compare them with the table in the New System Startup section.
The first measurement is the product flow alone. The second is the product flow combined with
the brine discharge flow to get the total flow or feed flow. You may take these measurements
by two methods:
1. Time the product flow into a graduated pitcher, then divert both the product flow and brine
discharge together into a bucket to measure total flow.
OR
2. Divert the product flow into the pitcher while diverting the brine discharge into the bucket.
Time the flow of both. After calculating the product flow, pour the pitcher of product into the
bucket of brine to measure total flow.
The ratio of product flow to total flow gives us the recovery rate, expressed as a percentage. If
the percentage is below the minimum it indicates an internal leak in the Clark Pump. A Cape
Horn system uses a 10% recovery pump, where 8% is the minimum acceptable recovery rate.
42
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. 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.
3600 ÷ 215 x 1 = 16.74 GPH (3 minutes, 35 seconds is 215 seconds)
Example: It took 2 minutes and 25 seconds to collect 2.5 liters of product water.
3600 ÷ 145 x 2.5 = 62.07 LPH (2 minutes, 25 seconds is 145 seconds)
2. Total Flow or Feed Flow: Feed flow or total flow (brine + product) is expressed in Gallons
Per Minute (GPM) or Liters Per Minute (LPM) , by this equation:
60 ÷ time in seconds x quantity of water in gallons or liters = GPM or LPM
Example: It took 1 minute and thirty-seven seconds to collect 5 gallons of total flow.
60 ÷ 97 x 5 = 3.09 GPM (1 minute, 37 seconds is 97 seconds)
Example: It took 53 seconds to collect 12 liters of total flow.
60 ÷ 53 x 12 = 13.58 LPM
3. Recovery Rate: Recovery Rate = (Product Flow/Total Flow) x 100
Example: 14.5 GPH product flow = .089 x 100 = 8.9%
2.7 GPM total flow x 60
(you must first multiply total flow by 60 to convert from GPM to GPH)
In order to make good water, you need the proper amount of feed water ow. Each pump
alone should produce 1.5 gallons per minute (5.7 LPM) of brine discharge PLUS product water
(Total Flow = Product + Brine). Running on both pumps the ow should be 2.7 GPM (10 LPM).
Compare the product ow to the total feed ow. Product ow should be between 8% and 9%
of total ow for a Cape Horn Xtreme. If product percentage is low, you may have an internal
leak in the Clark Pump and it probably needs to be rebuilt.
For every
1
/
10
th
of a GPM feed water ow loss, we will lose about
1
/
2
gallon (1.89 liter) per hour
of product ow and the salinity will go up approximately 100 PPM.
Low feed ow combined with low system pressures is most frequently due to worn Shuro
pump heads (PL-PMP-SFPH) or low input voltage.
Flow Test - Cont.
43
Troubleshooting Cape Horn Extreme 330 Remote Manual Systems
SYMPTOMS PROBABLE CAUSE REMEDY
Low product ow, more than 1
GPH, Total ow down (See Flow
Test.)
Motor receiving less than
12.5VDC. A 0.5 VDC decrease at
the feed pump motor can equate
to a loss of 0.5 gallons (1.89 liters)
product per hour. If possible, run
diagnosc tests when the system
is geng at least 13.2 VDC.
Check for voltage drop. Increase
wire size if necessary.
Check Power Supply.
If available, turn on baery
chargers.
Blockage or restricon in the sys-
tem.
Replace prelter, service strainer,
and check all hose runs.
Thru-hull blockage Conrm by using intake service
hose and bucket of seawater to
bypass thru-hull
Clean thru-hull.
Mineral scaling
Perform SC-3 Cleaning. Note:
By design, it is rare for the mem-
brane to cause low total ow on
Spectra Systems.
Pump or Motor worn Conrm by aempng pressure
test (See Tech Bullen). Strong
pumps with good power should
reach 125 psi within 3 seconds.
Replace pump head.
Low product ow, Recovery per-
centage below minimum nominal
value (See Flow Test)
Pressure Relief Valve open
parally
Close pressure relief valve.
Internal leak in Clark Pump Complete service is recommend-
ed. Contact Dealer or see Clark
Pump rebuild manual.
Install Oshore Kit.
Asymmetrical pressure and ow
readings between pump shis
–
When one shi has 0 pressure
Internal leak in Clark Pump.
While system is running kink brine
hose to stop ow unl feed pres-
sure rises to 115 psi, release hose
quickly, repeat no more than 10
mes.
Inspect Clark Pump Check Valves.
Asymmetrical pressure and ow
readings between pump shis-
more than a few psi
Scored Clark Pump annular rings
and reversing valve spool
Replace.
Scored Clark Pump piston rod and
lip seals
Conrm by opening test port on
back of pump. If constant ow,
replace seals and circular sand
(240 grit) or replace piston rod.
Scored Clark Pump Cylinder(s)
Hone, circular sand (240 grit) or
replace.
Display acvates, but pump will not
run
Loose or broken pump wire con-
necon
Tanks are full (if equipped with
tank switch). If full, Run & Stop
LED should be lit.
Check wiring at terminal block
inside control box
Check tanks– system cannot be
started if tanks are full.
44
Troubleshooting Cape Horn Extreme 330 Remote Manual Systems
SYMPTOMS PROBABLE CAUSE REMEDY
No Product ow, good brine dis-
charge ow. Recovery percentage
is 0 (See Flow Test)
Internal leak in Clark Pump. While system is running kink brine
hose to stop ow unl feed pres-
sure rises to 115 psi, release hose
quickly, repeat no more than 10
mes.
Inspect Clark Pump Check Valves.
Complete service is recommend-
ed. Contact Dealer or see Clark
Pump rebuild manual. Install O-
shore Kit.
Feed Pump not running, no noise
No Power At feed pump
Check voltage at feed pump.
Pressure switch failed.
Adjust or bypass. To bypass, turn
o power and pull o the 2 cables
with push-on terminals and con-
nect them together with a piece
of electrical cable pushed into
each terminal. Do not run the
pump for long, just to diagnose
failure.
Feed pump runs intermiently
cycling on/o
Overpressure switch on Feed
pump opening
Adjust or replace switch.
Feed Pump runs with loud noise
Intake blocked Check Through Hull.
Air in system
Check sea strainer for leaks.
Check freshwater ush module
for leaks.
Re-prime system (restart).
Feed Pump turns on but no pres-
sure
Feed Pump air locked
Open pressure relief valve to
bleed the air then close to start
Pressure relief valve open
Close pressure relief valve.
Feed Pump Starts but shuts down
on high pressure
Prelter excessively clogged
Change prelter.
Closed valve or blockage in ow Check ow path for closed valve
or kink in hose.
High Feed Pressure, High Amper-
age, and Product ow down up to
15%
Colder or more saline seawater
Normal Condion.
Brine or product ow observing
back pressure
Conrm by running both into a
bucket.
45
Troubleshooting Cape Horn Extreme 330 Remote Manual Systems
SYMPTOMS PROBABLE CAUSE REMEDY
Scaled or Fouled Membrane
Clean membrane.
Low Feed Pressure, Low Amper-
age
Warm seawater or brackish water
Normal Condion.
PPM rises steadily while pressure
and producon remain constant
Membrane needs to be replaced Consult dealer and replace mem-
brane.
Feed ow or Clark Pump problem
Low product ow, recovery per-
centage or feed pressure can lead
to drop in product water quality,
perform Flow Test and address
ow issue.
Membrane was fouled or dam-
aged
Clean membrane or consult deal-
er about membrane damage
when product ow and pressure
are at spec levels but water tastes
salty.
Fouled Prelters
Freshwater ush procedure needs
to be tested and adjusted.
Replace lters or run watermaker
for an extended period of me to
rinse.
PPM High TDS meter needs calibraon
Feed Flow or Clark Pump Problem
Membrane fouled or damaged
Fouled Prelters
Recalibrate TDS meter or taste test
water unl it can be replaced
Low product ow, recovery percent-
age, or feed pressure can lead to drop
in product water quality. Perform
Flow Test & address ow issue.
Clean membrane or consult dealer
about membrane damage.
If system ow (product plus brine) is
to specicaon, the membrane is
clean, the product ows are con-
sistent with the system ow, and the
water quality is sll not acceptable,
then replacement of the membrane is
indicated. By design, high ppm typi-
cally has to do with something other
than the membrane itself.
Freshwater ush procedure needs to
be tested and adjusted. PPM of brine
discharge must be below 1000ppm at
end of ush cycle.
Replace lters or run watermaker for
an extended period of me with pres-
sure relief valve open to rinse.
46
Technical Bulletins
Spectra High Pressure Fitting Instructions
The Cape Horn Xtreme has eight high pressure ngs, 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 ng is ghtened, it compresses a ferrule onto the stainless
tubing, xing the ferrule permanently to the tube and holding the compression nut capve.
The body of the ng seals to the underlying component with an O-ring. On the Clark Pump
cylinders and the end caps this O-ring is compressed by ghtening the enre ng. The O-
rings on the 90-degree ngs on the back of the Clark Pump have capve nuts and washers,
which compress the O-rings without turning the enre ng.
If a tube ng leaks it can somemes be resealed by just ghtening. You must use two
wrenches, a 13/16-inch wrench to hold the base, and a 7/8-inch wrench to turn the
compression nut. The 13/16-inch wrench will need to be thin so as not to interfere with the
compression nut. If this doesn’t work, disassemble the ng, grease liberally with silicone
grease (the ferrule and the threads) and re-ghten rmly.
The base O-rings should be gently compressed to achieve a good seal, and may be damaged
by overghtening.
Stainless Fing Hex Nut
Connector O-ring
Nickel-Bronze High Pressure Elbow
Nickel-Bronze High Pressure Straight Fing
Ferrule
47
Technical Bulletins
NOTE: The following pages include Spectra’s most commonly used technical bullens, ad-
dressing tests, adjustments, troubleshoong, and common points of confusion. Many more
technical bullens are available on the Spectra website, support.katadyngroup.com.
DWYER FLOW METER SERVICE
The mechanical ow meter, PL-FMT-10 (10 GPH range) or PL-FMT-20 (20 GPH range) can be
opened for cleaning if it becomes dicult to read or if the lile ball gets stuck.
The ow meter will come completely apart for cleaning. First remove the meter from the pan-
el. Remove the four small screws that hold the stainless steel bracket in place. Carefully wedge
out the steel bracket. Above where the bracket was removed, there is a clear plasc slide-out.
Use a at bladed screwdriver to pull it out carefully. Once it is out, insert your athead into the
space it was removed from and gently nudge upwards to remove the top piece. Invert the ow
meter and catch the ball as it falls out. You can use tooth paste or plasc window polish to
polish the inside using a small bole brush, or simply a q-p. Clean the ball and give it a few
coats of wax. If the O-rings are damaged or the unit has been leaking, install new O-rings using
a lile silicone grease to ease assembly. These are standard O-rings and should be available at
most larger auto parts or bearing stores. Reassemble in reverse.
ACCUMULATOR PRESSURE
Your Spectra watermaker is supplied with a pressure accumulator tank (PL-ACC-TK), which
should be installed in the feed water line between the prelters and the Clark Pump.
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
problems with the Shuro pump pressure cutout switches.
NOTE: The accumulator has a Schrader air valve, like a car re, which allows the internal air
bladder of the accumulator to be pre-charged. The accumulator should be pumped up to
about 65 psi (4.5 bar) for best results. Add air using a re pump or air compressor. You can ex-
periment with the exact pressure that will give the best pulsaon dampening on your installa-
on.
Connecons to feed water
hose, between Shuro
pump and Clark Pump
Schrader Valve
48
ATTENTION:
A Cape Horn Xtreme system uses two dierent lters to prevent damaging foreign materials from en-
tering the system. A single 5 micron lter cleans the feed water of abrasive materials while the system
is in operaon; an addional carbon lter prevents the entrance of chlorine during fresh water ush-
ing.
During normal operaon, the feed water is ltered in two stages. First it passes through a ne mesh
metal sea strainer, which protects the feed pump from foreign materials and sea creatures. Aer pass-
ing through the feed pump, the feed water passes the lter housing containing 5 micron element, re-
moving very ne parcles that could damage the Clark Pump and shorten membrane life.
Replacement schedules will vary widely depending on how and where the system is used. If large
amounts of feed water are run through the system over a relavely short period of me in biologically
ferle near-shore waters, the prelter will plug up, water producon and quality will drop, and the sys-
tem pressure will change dramacally. If the pressure gauge was installed aer the prelters, as pic-
tured on the plumbing schemac, the pressure will decrease as the lter becomes more clogged.
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. Addional preltraon consideraons and/or extremely frequent prelter replace-
ments may be required in any deviaon from open-ocean seawater. Your local service provider or
installer may have specic recommendaons based on their experience with water condions
unique to your region.
Observe the seawater around your vessel. Is it clean enough to use for your seawater intake? There
are several things to avoid feeding to your watermaker:
• petroleum products, such as oil, fuel, thinners, paints, paint removers, etc.
• chlorine-treated water; e.g., most “dock” water
• silty water — water contaminated by ne, hard, suspended parculates
• putrid water, “red des”, or any seawater that smells or looks contaminated
• harbor/marina water that you cannot see through or that shows visible signs of
contaminate (neighboring boats docked nearby may be discharging contaminaon!
Sewage, chemicals, etc.)
Judging the quality of seawater input always involves a certain calculated risk. We know of water-
maker systems that have been destroyed far oshore by intaking fresh whale excrement or oil con-
taminants from natural seepages. The chance of such things happening is normally small but should
be considered. On the other hand, regularly running a watermaker in an enclosed marina or har-
bor runs a much higher risk of harmful contaminaon. If you need to test a new installaon while
in a marina or harbor, monitor the water quality around your vessel carefully while tesng. Oen
mes you should be able to run the watermaker safely for enough me to briey check out the sys-
tem if you are mindful of external feed condions. If this is not possible, an arcial ocean is a use-
ful alternave (see Page 24 for arcial ocean tesng/instrucons). Don’t sail away without tesng
a new installaon or repair!
PREFILTERS
49
CHARCOAL FILTERS
ATTENTION:
The charcoal lter element (FT-FTC-CC) removes chlorine from the fresh water ush water
supply. The RO membrane can only handle small amounts of chlorine without permanent
damage. If the fresh water ush water contains chlorine, the membrane will be exposed to it
for days and will produce high salinity water.
The charcoal lter used for the fresh water ush system will not plug up unless you have very
dirty domesc water in your boat’s supply tank. About six months aer installaon the char-
coal lter element will lose its eecveness and must be replaced. This is purely a funcon of
me.
The charcoal lter we supply removes 99.7% of the chlorine. Beware when buying other char-
coal lters. If they don’t specify the percentage of chlorine removed, don’t use them. Cheap
ones may remove only 60% or 70%. Also, there are aermarket lters which are very close to,
but not exactly the same dimensions, and will not seal properly in the housing. If you skimp
on the charcoal lter you risk damaging a $600.00 membrane on the rst ush. The other fac-
tor is the ow rate that the lter can handle. Because the chlorine is adsorbed by the char-
coal, it must remain in contact with the charcoal for a sucient period of me for the all of
the chlorine molecules to be captured. The lters we use can handle 1.5 gallons (6 liters) per
minute ow, and are good for 3000 gallons
(12,000 liters) at 1.5 GPM, or six months, which-
ever comes rst. Regard- less of the ow, the char-
coal loses its eecve- ness aer six months.
Charcoal lter, Spectra part number FT-FTC-CC
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 lter long before it plugs up. The decaying plankton and
bacteria will cause a roen egg smell in the product water. This decay will set in overnight in
tropical waters, or aer a week or two in higher latudes. In crystal clear blue water condi-
ons, the lters may need to be cleaned much less frequently.
If handled gently and changed regularly before they get too smelly, lters can be cleaned and
reused several mes.
Our lter element part number is FT-FTC-XX.
The last digits indicate the micron rang, e.g. FT-FTC-5 is for a 5 micron element:
50
SHURFLO PUMP WON’T RUN
If the pump has power to it but the pump won’t run, rst 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. You can safely run the
system with the pressure switch jumped, just keep an eye on the pressure gauge and don’t let
system pressure exceed 110 PSI. Replace the switch when a spare is available. The pressure
switch should never open unless there is a problem with the system or it is incorrectly
adjusted. Check the accumulator pressure, the operang feed pressure, and the switch cut-out
seng.
If the pump will not run with the pressure switch jumped then it is most likely a problem with
the brushes or overheat protecon switch inside the motor. The motor will come completely
apart by removing the two screws on the end of the motor. Remove the rear cover and paper
insulator. Pull out the plasc brush holder. The thermal switch is located on one of the brush
leads. With an ohmmeter, check for connuity through the switch. If it is open, you can make
temporary repairs by wiring around it, being careful that your new wiring doesn’t chafe on the
moving parts, nor resist the springs that push the brushes on to the commutator. The overheat
switch is unlikely to fail unless the motor has overheated and shut down. Consider relocang
the pump or improving venlaon if the overheat protecon has failed.
If any corrosion is apparent the brushes may be scking. Once apart clean all the carbon dust
from all the parts. Clean the commutator with light sandpaper. Make sure to clean the small
grooves on the commutator with a small sharp tool to remove the carbon in between the
segments. Adjust the springs on the brush holders so the brushes slide smoothly in and out. If
the bearings are rough and binding, remove the rubber dust cover and clean the best you can,
grease them, and work them free by hand. Don't service the bearing unless absolutely
necessary. Reassemble in reverse order. You can hold the carbon brushes back with papers
clips inserted through the slots in the brush holder so they don't hang up on the bearing during
assembly. Make sure the corrugated bearing shim doesn't push out, if it does, push it back into
place.
51
ADJUST SHURFLO PRESSURE SWITCH
Shuro 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
me the Clark pump cycles and the feed pressure spikes. When this happens the producon
will drop and salinity will increase. The points in the switch will fail quickly if set too low
because of the constant arcing each me the Clark Pump shis.
On the very center of the switch is a small 5/64” Allen screw. While running the system close
the brine discharge seacock or kink the discharge hose, to block the ow. Watch the pressure
gauge and adjust the pressure switch to shut o at 125 psi. Turn the Allen screw clockwise to
increase the cut o set point.
Pressure Switch
Adjusng Screw
52
Poor Product Water Quality
With any product water quality issue, you must ensure accurate calibraon if you are using a
salinity meter. For general quality evaluaon, your taste is always good enough.
Membranes are not an exact science and two idencal systems can have dierent product
quality. World health standards deem water of up to 1000 PPM of total dissolved solids
acceptable for drinking consumpon. We consider any thing below 750 PPM acceptable but
not ideal, and anything below 500 PPM excellent. Factors that could aect water quality are
addressed below.
LOW SYSTEM FLOW OR PRESSURE will equate to lower product quality (higher PPM).
Cape Horn Xtreme systems will produce slightly beer quality water running two
pumps, as this will create higher pressure and lower salinity. Worn feed pump heads
or ow restricons will cause lower feed pressure and higher salinity.
DAMAGE TO THE MEMBRANE by chlorine contaminaon. Flushing the system with
chlorinated water will irreparably damage the membrane. Charcoal lters are used to
absorb any chlorine which might be present in ush water. They must be of proper
specicaon to be suitable. There is no test for chlorine damage except the process
of eliminaon of other causes.
DANGER:
DIRTY OR SCALED membranes. A dirty (foreign material), scaled (mineral deposits), or
contaminated (bacterial growth) membrane can result in poor water quality and
abnormal operang pressures. If operang pressures are above normal, then cleaning
is indicated. If the system pressures are within operang normal range, cleaning may
have lile result. Avoid cleaning as a diagnosc tool. Low water quality aer storage
with propylene glycol can usually be remedied by extended ushing or an SC-2
cleaning.
MECHANICAL LEAKAGE within the membrane pressure vessel. This is an unlikely but
possible cause of poor water quality. A pinched or damaged O-ring within the
pressure vessel, a scratch on the product tube on the membrane, a scratch within
one of the end caps, or a seal fouled by contaminaon could allow sea water into the
product water.
NOTE: If system ow (product plus brine) is 2.7 GPM or above (1.6 GPM running one feed
pump), the membrane is clean, the product ows are consistent with the system ow and the
water quality is sll not acceptable, then replacement of the membrane is indicated.
53
The Z-Ion should be energized at all mes, but will only consume power when operang. Upon
inial power-up the LED will ash red/green and then will turn solid green.
Follow the instrucons for Normal Operaon and Fresh Water Flush. For treatment with the
Z-Ion, the process is idencal, only the Z-Ion will release silver and copper ions into the ush
water when you turn on the generator with the on/o switch. Turn on the ion generator at the
same me that you open the ush valve.
The operaon cycle begins and the LED will ash green/amber. The cycle will connue unl you
turn o the ion generator or the adjustable mer mes out (factory set for 15 minutes).
Turn o the ion generator at same me that you close the ush valve. If you forget to turn o
the ion generator, the Z-Ion will me out aer 15 minutes, so no harm will be done to the unit.
If the voltage is out of range, below 10V or above 56V, the LED will ash red every two seconds
and the unit will shut down.
Each fresh water ush with the Z-Ion will protect your watermaker for up to 30 days, aer
which the process must be repeated.
Aer 720 cycles the service light on the front of the control box will light up, indicang that the
probes on your Z-Ion may be wearing down, and should be tested. The service light is just a
reminder, and the Z-Ion will go on funconing while it is lit.
NOTE To reset the service counter, touch two magnets, at the same me, to the two red reed
switches on the Z-Ion circuit board, labeled Switch 1 and Switch 2 below.
Z-Ion Operation
Switch 1
Switch 2
Pin 1
Figure 1
Pin 7
Z-Ion Operaon – LED Status Lights & Pinout Info
• Power-up indicaon – Fast red/green ash for a few seconds
• Ready/Idle – Solid green
• Generang (during a ush) – The LED will quickly ash at a pro-
grammed interval (factory set to 17 seconds between ashes) The
ash color with alternate between green and amber and will be o in
between voltage spikes. The color change symbolizes the polarity al-
ternang from posive to negave.
• Bad power – Fast red ash followed by shut down
• High temperature – Fast red ash
• Service/Cycle Counter Limit - Slow red ash
There are 7 pins on the phoenix connector from le to right in Figure 1.
Pin 1 Supply Voltage-
Baery ( + )
Pin 2 Ground
Pin 3 Trigger
Pin 4 Auxiliary Output 1
Pin 5 Auxiliary Output 2
Pin 6 To Zion generator (bowl). No polarity.
Pin 7 To Zion generator (bowl). No polarity.
54
Fan
12 Volt: KIT-FK12
24 Volt: KIT-FK24
Shuro Pump Assy
(no fan)
12V: KIT-FP-SF12
24V: KIT-FP-SF24
Feed Pump Head:
PL-PMP-SFPH
Pressure Switch
EL-FP-PS
Cape Horn Extreme Part Numbers
Feed Pump Module A, with
charcoal lter for fresh water ushes
Fresh Water Flush Valve:
3/4”NPTX3/4”FPT
PVC Valve
PL-VLV-3/4PVC
Clear Filter Housing
(Bowl & Cap)
FT-FTH-10L3PCS
Filter Housing Seal
SO-FHS-3PCS10
3/4”NPT X 1/2” Hose
Barb Elbow
PL-HBE-3/4X1/2
3/4”NPTX5/8” Hose Barb
PL-HBS-3/4X5/8
Charcoal Filter Cartridge
FT-FTC-CC
1/4” 3-Way Valve
PL-VLV-3W1/4
3/4” Clamp
PL-CLP-3/4CAR
1/4”NPTX1/4”Tube Fing
PL-MTS-1/4X1/4J
1/4”NPTX1/4” Tube Fing El.
PL-MTE-1/4X1/4J
1/4”NPTX1/4”Tube Fing
PL-MTS-1/4X1/4J
1/8MPT X 1/4
TUBE EL
PL-MTE-1/8X1/4J
Pressure Gauge
PL-PSG-LP2.5
1/4FPT X 1/4 TUBE EL
PL-FTE-1/4X1/4P
Product Flow Meter
PL-FMT-20
3/4” 3-Way Service Valve
PL-VLV-3W3/4
1-Way Solenoid Valve 12V
PL-SLN-1/4O12SV
SPECTRA PANEL ASSEMBLY 400
GPD
SUB-MD-PNLA380
55
1/8"FPTX1/4"Tube Fing Ell.
PL-FTE-1/8X1/4P
Pump to Pressure Vessel
Lower SS Tube Long:
PL-TB-HPTPVLL
40” High Pressure Vessel
FT-PV-40
3/8"NPTX1/2"Tube SS Fi. St.
PL-MTS-3/8X1/2S
Connector O-ring
SO-HPP-CT
Pressure Vessel Ring
FT-PV-ER
Pressure Vessel
End Cap:
FT-PV-EP1
1/8NPT Nylon Hex Plug
PL-HP-1/8
High Pressure Filter Housing
Complete Assembly
FT-FTH-10H
3/4”NPT X 5/8” Hose Barb Ell
PL-HBE-3/4X5/8
5 Micron Filter Cartridge
FT-FTC-5
Cape Horn Intake Module
FM-VT-ITM
#8 Hose Clamp
PL-CLP-8SS
Cooling Fan Kit
KIT-FK-12, 24
Heat Sink
EL-FP-FPHS
3/8”NPT X 5/8”
Hose Barb Ell
PL-HBE-3/8X5/8
Sea Strainer (Complete Assembly)
FT-STN-5
Strainer Seal
SO-STN-5SS
Strainer Screen
FT-STN-5S
Pump to Pressure Vessel
Upper SS Tube Long
PL-TB-HPTPVUL
Feed Pump Assembly
(Complete Pump With Heat Sink)
KIT-FP-SF12 or 24
Pump Head Assembly With Pressure Switch
PL-PMP-SFPH
Pressure Switch
EL-FP-PS
Shuro Pressure Switch
KIT-FP-SFSK
3/4"MPT X 5/8"HB
PL-TEE-3/4M5/8B
Feed Pump Module B:
Cape Horn Extreme Part Numbers - Cont.
56
Rear View
Plate Bracket
FM-PVB-PB
Rubber Mount
HD-RBP-RM
Plasc Spacer
HD-SPN-MKINS
Plate Bracket End Cap
FM-PVB-PBE
Pressure Vessel End Cap
FT-PV-EP
Pressure Vessel End Ring
FT-PV-ER
Nickel-Bronze High Pressure Elbow
PL-MTE-3/4S1/2B
Nickel-Bronze High
Pressure Straight Fing
SUB-MTS-3/8X1/2
Pump to Pressure Vessel
Upper SS Tube:
PL-TB-HP-HPTVUS
Pump to Pressure Vessel
Lower SS Tube:
PL-TB-HP-HPTPVLS
Stainless Fing Hex Nut
PL-HWR-1/2HN
1/2” Stainless Ferrule
PL-HWR-1/2FR
Connector O-RING
SO-HPP-CT
3/4”-16 Straight Thread
O-RING
SO-FT-STF
Nickel-bronze high pres-
sure 90 degree ng
PL-MTE-3/4S1/2B
Accumulator Tank
PL-ACC-TK
1/2” X 1/4” Bushing Reducer
PL-BSH-1/2X1/4N
1/2” Nipple
PL-NP-1/2N
1/2” Female Tee
PL-TEE-1/2FN
1/2”NPT X 5/8
Hose Barb
PL-HBS-1/2X5/8
1/4MPT X 1/4 TUBE
Straight Fing
PL-MTE-1/4X1/4
Cape Horn Extreme Part Numbers - Cont.
57
HP-TB-VEB-B
HP-TB-VB
HP-TB-VEB-A
HP-TB-BV
HP-CB-CB7
HP-CYL-SST
HP-CYL-R
HP-CYL-EC
HP-CYL-CCA
Not used
58
HD-CPS-5/16X3
KIT-HP-10VSA
HP-TB-ARP
SO-HPP-AR1
SO-HPP-RV
HP-TB-BV
HD-CPS-5/162.75
SO-HPP-SP
HP-TB-VSP
HP-TB-SR
SO-HPP-VB
SO-HPP-PLP
SO-HPP-VP
59
Parts
HP-CYL-3/4R,
60
PL-MTS-3/8X1/2B
HP-CYL-SST
HP-CYL-CCA SO-HPP-ECCB
HP-CYL-EC
HP-CYL-R
HP-CYL-PT
Parts
61
62
Owner Resources
&
Warranty
63
Spectra Product Registraon Form
(To be completed by end user/owner)
hps://spectrawarranty.formstack.com/forms/product_registraon
Spectra Watermakers Commissioning Report
(To be completed by authorized installer)
hps://spectrawarranty.formstack.com/forms/spectra_install_commissioning_report
Note: Oer & warranty criteria eecve 1/1/2021. For purchases made in the EU, please see ‘Expanded Warranty’ secon of
warranty policy in back of the manual for EU specic coverage.
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 Registraon form (see back of owner’s manual for paper copy)
3. Complete web-based install/commissioning form (see back of owner’s manual for paper copy)
4. Upon sasfactory review of required submissions, your 4-digit system serial number will
receive an extra year of warranty coverage, and lifeme coverage on the Clark Pump!
See ‘Extended Warranty’ secon of owner’s manual for full coverage details.
64
SPECTRA WATERMAKERS LIMITED LIFETIME WARRANTY
THIS LIMITED WARRANTY APPLIES TO THE ORIGINAL OWNER OF THE WATERMAKER AND IS NOT TRANSFERRABLE
For warranty information regarding products sold within the European Union please contact eu-
rope@spectrawatermakers.com.
This limited product warranty is provided by Katadyn Desalination LLC, a Business Unit of the Katadyn
Group. (“Manufacturer” of “We” or “Our”) to the original, consumer owner of the product (“You” or
“Your”) with which this limited product warranty is provided (the “Product.”)
The Manufacturer warrants to You that the product will be free from defects in material and workmanship
under normal use and regular service and maintenance, subject to the exclusions described below, for a period
of year (the “Warranty Period”) after date of installation, or 15 months after the shipment date, whichever
comes first. This warranty will be extended for an additional 12-month period when the product is installed
and commissioned by a Katadyn Desalination Authorized Installer. A Spectra Watermakers Commissioning
Report must also be returned and approved by the factory. The Spectra Clark Pump has a Limited Lifetime
Warranty on Marine systems to the original consumer owner of the product, not inclusive of repair or re-
placement parts due to wear over time. If the Spectra Clark Pump is used in a Landbased application, the prod-
uct warranty is provided for a period of year (the “Warranty Period”) after date of purchase (if purchaser is
installing system) or date of commissioning (if Spectra dealer is installing system).
You will be required to show written documentation supporting the date of purchase or date of commission-
ing. If you are unable to provide documentation supporting the date of purchase or commissioning, the war-
ranty period shall be based on the product’s date code and will be determined by the Manufacturer’s sole
and absolute discretion.
WHAT IS COVERED
Katadyn Desalination LLC. warrants, for the period defined above, that the Product will be free from defects
in materials and/or workmanship and will conform to Manufacturers published specifications if installed
and maintained in accordance with the Manufacturers Instructions.
WHAT IS NOT COVERED
The Warranty does not include service, repair, or replacement to correct damage caused by improper installa-
tion, maintenance, improper connection with water systems, external electrical fault, accident, alteration, mis-
use, abuse, neglect, negligence, (other than Manufacturer’s), acts of God, failure to install or maintain the
product in accordance with the Manufacturers instructions.
DAMAGED OR MISSING PRODUCT
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.
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
be a valid warranty claim, in Manufacturer’s sole discretion. Replacement product may be refur-
bished and/or different models but will be functionally equivalent to the product or hardware being
replaced. Product repaired or replaced during the warranty period shall be covered by the foregoing
warranty for the remainder of the original warranty period or ninety (90) days from the date of ship-
ment or purchase, whichever is longer. Contact your Dealer or the Manufacturer’s Customer Service
at 415-526-2780 to obtain a returns materials authorization (RMA #).
HOW TO MAKE A WARRANTY CLAIM
If You discover any warranty related issues after 30 days, or You have questions concerning Your
product or how to determine when service is needed, please contact your local dealer or contact the
Manufacturer’s Technical Support at 415-526-2780 or email the Manufacturer at techsup-
port@spectrawatermakers.com. The following information must be provided as part of Your warranty
claim: your name, address, phone number, Your products’ model number, Your product’s 4-digit serial
number, and if necessary, upon request, written confirmation of the date shown on Your purchase re-
ceipt and the purchase price paid for the product. All products being returned to the Manufacturer must
have a return material authorization (RMA) number to be processed. Any item returned to the Manu-
facturer without an RMA number will not be accepted by the Manufacturer Contact your Dealer or
Customer Service to obtain an RMA number. Once we have received Your returned product, we will
determine, in our sole and absolute discretion, whether Your claim is covered by, or excluded from,
this limited warranty. Repairs or modifications made to the product by other than the Manufacturer will
nullify this limited warranty. Coverage under this limited warranty is conditioned at all times
upon the original purchaser’s compliance with these required notification and repair procedures.
LIMITATION OF LIABILITY TO THE FULLEST EXTENT PERMITTED BY LAW, IN NO EVENT, SHALL
MANUFACTURER OR ITS AUTHORIZED SERVICE REPRESENTATIVES BE LIABLE FOR ANY INCI-
DENTAL, SPECIAL, INDIRECT, OR CONSEQUENTIAL DAMAGES, INCLUDING ANY ECONOMIC
LOSS, WHETHER RESULTING FROMNONPERFORMANCE, USE, MISUSE OR INABILITY TO USE
THE PRODUCT OR THE MANUFACTURER'S OR ITS AUTHORIZED SERVICE REPRESENTATIVE’S
NEGLIGENCE. THE MANUFACTURER SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY DELAY
IN PERFORMANCE AND, IN NO EVENT, REGARDLESS OF THE FORM OF THE CLAIM OR CAUSE OF
ACTION (WHETHER BASED IN CONTRACT, INFRINGEMENT, NEGLIGENCE, STRICT LIABILITY,
OTHER TORT OR OTHERWISE), SHALL MANUFACTURER’S LIABILITY TO YOU EXCEED THE
PRICE PAID BY THE ORIGINAL OWNER FOR THE MANUFACTURER’S PRODUCT.
The term “consequential” damages shall include, but not be limited to, loss of anticipated profits, busi-
ness interruption, loss of use or revenue, the cost of capital or loss or damage to property or equipment.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so the
above limitation may not apply to you. This limited warranty gives you specific legal rights, and you may
also have may other rights which vary from State to State.
66
Spectra Product Registration Form
Registration (To be completed by owner)
Boat model or type (i.e. Leopard 44, Beneteau 55' powerboat, catamaran, powercat, 42’ sailboat…)
______________________________________________________________________________
What type of boating will you be doing and what will the watermaker primarily be used for:
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Submission for Approval:
Please submit this document along with the Installaon and Commissioning Reports to Spectra
Watermakers for approval. Submissions can be submied online, scanned and emailed, or mailed directly
to the factory. Spectra Watermakers Technical Support will email the original owner and the authorized dis-
tributor with the status of submission.
Web-Based Format (Preferred opon):
spectrawarranty.formstack.com/forms/product_registraon
spectrawarranty.formstack.com/forms/spectra_install_commissioning_report
Email: TechSupport@SpectraWatermakers.com
Phone: +1(415) 526-2780
Address: Katadyn Desalinaon
Technical Department
2220 S. McDowell Blvd Ext
Petaluma, CA 94954
USA
Please keep a copy of these reports for your records.
Any commissioning/install report (and additional 12 month warranty) may be rejected at the
sole discretion of Spectra Watermakers if the system is not installed correctly.
System Details:
Model ________________________ Date of install: ______________________________
4-digit S/N___________ Clark Pump S/N: _____________ Voltage_______
Dealer/distributor:____________________ Boat Location:___________ max speed:______
Original Owner Details:
Name:_________________________________ Phone Number:________________________
Email Address:________________________________________________________________
Address (Optional):____________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
CUT HERE
67
Spectra Watermakers Installation Report
(To be completed by authorized installer)
INLET
□ Inlet Seacock is below waterline
□ Inlet Seacock is dedicated
□ Inlet Seacock is shared
□ Inlet Thru-Hull forward facing scoop
□ Has strainer
□ Has diving snorkel
□ Sea chest
□ Other
Thru Hull Size: ____________IN/CM
Approximate location on vessel and notes:_____________________________________
_______________________________________________________________________
FEED PUMP MODULE A
□ Feed pump module is mounted upright
□ Clearance for filter cartridge changes
□ Intake hoses are free of kinks
□ Pressurized domestic water is connected to carbon filter
Distance from waterline: ________FT/M above/below the waterline
FEED PUMP MODULE B
□ Feed pump module is mounted upright
□ Clearance for filter cartridge changes
□ Intake hoses are free of kinks
Distance from waterline: ________FT/M above/below the waterline
HIGH PRESSURE MODULE and BRINE DISCHARGE
□ Pressure relief valve is accessible
□ Brine discharge has no obstructions and vents to atmosphere
Notes:___________________________________________________________________
________________________________________________________________________
PRODUCT WATER TUBING
□ Product water flows into top of freshwater tank
□ Freshwater tank is vented
Notes:___________________________________________________________________
_________________________________________________________________________
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.
INSTALLATION SIGN OFF
Technician’s Name: __________________________________________ Date: _____________
Technician’s Signature: __________________________________________________________
Distributor/Dealer_______________________________________________________________
CUT HERE
68
Spectra Watermakers Commissioning Report – Page 1
(To be completed by authorized installer)
Fill out the below checks as completely as possible. Check any boxes that apply and note any concerns.
PURGE
□ Storage Chemicals have been purged with PRV open
Length of purge: _______Minutes
□ Diversion Valve is up, in reject position
□ Filter condition has been calibrated
□ “Run Manual” switch engages full speed
□ “Service” switch engages flush speed
RUN HIGH MODE CHECKS
Product Flow: _____________ GPH/LPH
Confirmed Product Flow Rate ___________GPH/LPH
□ Technician Flow meter. Brand________________
□ Hand Measurement _______Gal/Liters in _____SEC/MIN
Product Quality: __________ PPM
□ Confirmed product quality with handheld TDS meter
Feed Pressure: __________ PSI/BAR
Boost Pressure (with clean prefilters): ________PSI/BAR
Brine Flow Rate: _______________ GPM/LPM
Measurement taken with:
□ Technician Flow meter. Brand_________________
□ Hand Measurement: _______Gal/Liters in _____SEC/MIN
□ Boost Pump runs
□ Output and motor speed decrease when low mode is engaged
Notes:__________________________________________________________
______________________________________________________________________
FRESHWATER FLUSH
□ Freshwater Flush solenoid valve opens
□ Feed Pump is not cavitating when system flushes with seacock closed
Ship's pressurized freshwater pump flow & pressure rating ________ GPM/LPM ________ PSI/BAR
When seacock is open, what is the ppm of brine discharge at the end of the flush_______
Flush duration is ________Minutes
□ Needed to change flush time
□ Needed to change speed of feed pump during flush
Notes:__________________________________________________________
______________________________________________________________________
*If the system does not have a dedicated forward-facing scoop type thru-hull or will be on a vessel that
moves faster than 15 knots the system needs to complete the following sea trial checks. Spectra
Watermakers reserves the right to require a sea trial from any customer before approving a
commissioning report.
SEA TRIAL
□ Watermaker will flush while underway
□ Watermaker will start while underway
While the vessel is underway moving _______KNOTS/MPH/KPH the watermaker is producing
_______ GPH/LPH at ______PPM
The following checklist is designed to confirm that the watermaker installation meets Spectra
standards and that the system is performing at specification.
CUT HERE
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
□ Product water inlet to Freshwater Tank
□ Sampling Tap
□ Brine Discharge location
□ Service hoses and storage chemicals
□ User Manual
□ How to power the watermaker off and on at the main breaker.
□ How to run the watermaker.
□ How to freshwater flush and the importance of freshwater flushing.
□ Knows each pump can make water individually.
□ Knows when the ships domestic freshwater pump is on.
□ Knows which prefilter cartridges to use and how to change them.
□ Knows how to service the sea strainer module.
□ Knows where the carbon block filter is and is familiar with (6 months) service frequency.
□ Have visually seen the overboard brine discharge (Should know when the system is pumping water).
□ Knows how to sample the product water.
□ Understand when the Clark Pump is under pressure and cycling.
□ Have seen how the service hoses and bucket are used to circulate seawater or freshwater through
the system.
Notes:____________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
COMMISSIONING REPORT SIGN OFF
Technician’s Name: ____________________________________________________________
Technician’s Signature: _________________________________________________________
Owner’s Name________________________________________________________________
Owner’s Signature_____________________________________________________________
CUT HERE
70
