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Monterrey 1000 User Manual

1. Membrane Array Product out L High pressure inlet 1 2 H P tube to top H P inlet san 3 8 Parker tubing 1 2 H P tube from bottom H P outlet ONES Product valve gt Salini Brine outlet Clark pump alinity contro 5 8 hose 1 2 Parker tubing Check valve Brine discharge service valve 5 micron 20 micron Pre filt Fresh water tank 6 re filters Intake service valve a Web reinforced 3 4 hose Check valve Flush solenoid valve _ Wire reinforced 3 4 Cleaning contaner intake hose C J S Feed pump j Charcoal filter WARNING Only use Spectra approved hose and tubing 2 3 8 Parker tubing Brine discharge Intake strainer PES NN Flush pump Intake Pressurized fresh water inlet gt 1 2 hose barb standard Monterey 1000 Plumbing Diagram page 37 Spectra High Pressure Tube Fitting Assembly Carefully fit and measure the tubing before cutt
2. LL a Ere e Monterey 1000 Callorsa Phone 415 112 3060 Fan 15 SEAT MAN BREAKERI CPER PUSH TD RESET ues g TA ponlier om e ee Pepe PPD d remind fenced cos gm ecc gp ITIN MAPA OPC PUS TOY ari Id Ep ILLE uuU Monterey DC Main Emergency Stop amp Manual Control Switches Long Term Storage Procedures Watermakers are best run continuously When not in use biological growth in the membrane is the leading cause of membrane fouling A warm environment will cause more growth than a cold environment The auto fresh water flush system will greatly reduce biological growth but will not stop it The 5 day re flush feature allows the system to be shut down without any service procedures for extended periods of time but it doesn t replace performing a storage procedure for long periods of non use If an optional Zeta Rod is installed in the system the 5 day re flush will maintain the system as long as unchlorinated pressurized fresh water is provided Storage Shutdown or Pickling If the system is to be left unused for more than 2 weeks perform the following pickling procedure The procedure introduces a chemical compound into the system that prevents biological growth Do not allow the system to empty the water tanks a good charcoa
3. The Membranes The membranes need to be cleaned only when they have lost up to 10 of their capacity due to fouling or the product quality degrades The leading cause of fouling is from biological growth that occurs when the system is left unused without flushing or pickling Fouling from mineral scaling can happen during operation under certain sea water conditions and from rust Monitor the product salinity bar graph for a higher than normal readings and the feed pressure gauge on the feed pump for higher than normal pressures for the conditions Other conditions can cause high pressure such as cold feed water or clogged pre filters Low product flow is usually due to low voltage poor feed pump clogged pre filter or a damaged Clark pump Look for all other causes before cleaning the membrane There are two types of cleaners acid and alkaline The acid cleaner SC 3 will remove mineral scaling The alkaline cleaner SC 2 is used to remove biological by products oil and dirt particles that get past the pre filters If membrane performance is reduced and has not been pickled recently cleaning with both chemicals is recommended The acid cleaner should be used first If the membrane fails to respond to both cleanings this is an indication of another problem with the system or that it is time to replace the membrane Contact Spectra Watermakers before removing a membrane page 22 Membrane Cleaning Procedures For normal cleaning the
4. Salinity high high salinity of product water causing system to reject water constantly product service valve in service position chlorine damage to membranes corroded salinity probe salinity probe cable disconnected or broken check for low feed pressure check for leaks at high pressure hoses verify service valves all in run position test product water with hand held tester if over 500 PPM clean or replace membrane remove and clean probe contacts check cable connections LIMITED WARRANTY Spectra Watermakers warrants to the original purchaser that all components except for the Clark Pump are free from any defects in material and or workmanship for a period of one year from the date of purchase Spectra Watermakers warrants to the original purchaser that the Clark Pump is free from any defects in material and or workmanship with a limited life time warranty from the date of purchase If any such defect is discovered and reported within the warranty period Spectra Watermakers will repair or replace the affected component free of charge subject to verification of the defect or malfunction upon inspection at Spectra Watermakers The customer is responsible for all costs incurred for removal shipping to and from our facility and reinstallation This warranty does not apply to malfunctions or physical damage resulting from abuse neglect accident alteration modification feed pump substi
5. terminals buzzer may also be installed at the control box See accessories below Feed Pump Wiring The feed pump wires connect to a power relay or solenoid inside the Power Control Box The terminals are marked The relay solenoid is controlled by PMP 1 GND output on the MPC circuit board e Follow the proper AC or DC wire size table if the pump is mounted remotely from the Power Control Box Ifa DC powered cooling fan is used it can also be connected to PMP 1 GND on the circuit board Use heat shrink tubing on all connections made outside of the control box Fresh Water Flush Pump Wiring fresh water flush pump connects to PMP 2 GND on the MPC circuit board e Follow the proper DC wire length table for the pump voltage Pressure Sensors e The pressure sensors mount on the pre filters housing to monitor the system pressure and differential pressure across the filters gt page 42 Electrical cont The sensors are extremely sensitive If the sensors are mounted remotely they must mount as close to the pre filters as possible as any length of hose or extra fittings between the filter and the sensor can cause errors in the readings due to plumbing drag through the system This can lead to the system constantly shutting down in a clogged pre filter condition See diagrams for assembly details The sensor connected to the inlet side of the filters must connect to
6. 120 volt AC system feed pump wiring WIRE LENGTH AWG wire size Square MM vire size To 25 feet 12 awg 3 sq mm 25 feet to 50 feet 10 awg 5 sq mm 50 feet to 75 feet 8 awg 8 sq mm 240 volt AC system feed pump wiring WIRE LENGTH AWG wire size Square MM vire size To 25 feet 14 awg 2 sq mm 25 feet to 50 feet 12 awg 3 sq mm 50 feet to 75 feet 10 awg 5 sq mm 24 volt DC feed pump and controller systems WIRE LENGTH AWG wire size Square MM vire size To 20 feet 12 awg 3 sq mm 20 feet to 30 feet 10 awg 5 sq mm 30 feet to 40 feet 8 awg 8 sq mm 40 feet to 50 feet 6 awg 13 sq mm 50 feet to 60 feet 4 awg 19 sq mm For large wires it may be advisable to use a terminal block or distribution posts near the control box to terminate the large cables then run smaller cables to the power inlet studs on the circuit board The wire leads for the stoke sensor and the pressure sensors are 6ft 2M long The control box must be located so that the wire leads can reach the sensors If the wire leads for the sensors must be extended see details below for proper wiring procedures The control box has three switches located on the cover One is an emergency shut off The other two directly power the feed pump and the flush pump for servicing the system as in pickling procedures cleaning the membrane or emergency override if the controller fails For normal operation both pump switches must be on AUTO Remote Control Display Panel s The system c
7. Fresh Water Flush System The fresh water flush solenoid valve wires connect to the terminals marked FW V and GND inside the control box Polarity is not critical The fresh water connection to the ships fresh water system must connect pressure side of the ships fresh water pump which can supply at least 2 gallons per minute for flushing operation The ships fresh water system must remain active during the auto store mode for automatic flushing to occur To confirm flushing listen for the ships water pressure pump to operate while the flush cycle is in process Insufficient flushing water supply can lead to a permanently damaged RO membrane and is not covered under the Spectra warranty Connection of Optional Accessories Use of any external devices not approved by the factory may cause permanent damage to the controller and is not covered under the Spectra warranty Accessory outputs are limited to 2 amps maximum load Do not connect motors pumps etc to accessory outputs ULTRAVIOLET STERILIZER Detailed instructions are included with the sterilizer kit The UV sterilizer lamp module and ballast unit should mount vertically with the product water inlet at the bottom outlet at the top The ballast unit wires plug into the end of the bulb in the lamp module The ballast unit power wires connect to the STER and GND terminals inside the control box Ballast RED wire connects to STER terminal an
8. SC 3 Acid Cleaning Compound is used first then the SC 2 Alkaline Cleaning Compound If known bio fouling is present the SC 2 may be used first Using hot water if possible 1209 is highly recommended as it greatly enhances the ability of the cleaners to do there jobs If the history of the system is unknown or has been left unpickled for an extended length of time and biological growth is present it is recommended that the system is cleaned with the SC 2 using an alternate source of unchlorinated fresh water before the system is run under pressure A simple test can be performed to see if biological growth has occurred Before running the system remove the pre filters and examine their condition If the housings are full of discolored smelly water the system was not properly stored Install clean pre filters if they were bad Next check the membrane Attach the brine discharge service hose and lead to a container Open the pressure relief valve 1 turn and turn the brine discharge service valve to the Service position Manually run the system for 30 seconds Examine the brine water if it s discolored and smells bad perform SC 2 cleaning with an alternate source of unchlorinated water before running the system pressurized If the brine is fairly clean the system can be purged run normally and checked for performance Clean the membranes only if performance is reduced Heating the water is preferable One way to do this is find a ca
9. beginning of the current operating purge mode to protect your system If you know it s OK you can bypass the purge sequence and enable a normal start Pressing both Auto Run and Start Stop simultaneously anytime during the purge sequence will bypass the purge sequence and enable a normal start Warning Damage may occur if the purge sequence is bypassed and the membrane is pressurized with storage chemical in it Caution Do not assume the system is operational without a complete run test at sea preferably in rough conditions Normal start up using the Auto Run button Press Auto Run button once and the system will prime and run for 1 hour The display reads AUTO RUN MODE then STARTING with a 30 second priming countdown timer After the prime the display reads AUTO RUN MODE with a countdown timer An hour of run time is added up to 12 hours with each successive momentary press of the Auto Run button An hour can be added at any time The display shows the default readout unless there is an alarm condition Successive presses of the Alarm Displ button will scroll through the displays starting with GPH PRODUCT Upon auto shut down by the timer or by the optional tank full float switches the system will automatically fresh water flush and re flush every five days Pressing the Stop Start button stops the system at any time with no flush sequence Normal start up using the Start Stop button Pressing the Start Stop button will
10. brine and product service hoses see instructions into the container and place all the service valves to the service position You are now using the water in the container as the ocean Start the system and let it run normally Taste the product water it should be good Now it can be directed to the tank or drinking water bottles The mini ocean will slowly drain from the container what s left getting saltier as it goes When there is about 1 10th of the water left switch the brine discharge back to the run position and dump it Repeat this until you have enough water to get where you need to go Don t let a poor performing watermaker stop you Where to Run Your Watermaker Ideally a watermaker wants to run in the cleanest water possible This is mostly for the life of the pre filters Running in turbid water typically doesn t hurt the system especially if the run time is short Many more problems are created by not testing a system because the boat was in a harbor with murky water than discovering a problem with the system 300 miles out to sea down wind A system must be tested in real seawater to prove anything If the water you are in is so bad that divers are melting before they can finish cleaning your boat s bottom you can make you own sea water with aquarium salts in a bucket All storage chemicals must be flushed from a system before it can be run from an ocean in a bucket Many people use their system in areas like the
11. components be sure to hold fitting body during the final tightening If other than the Spectra supplied high pressure tube and fittings are used they need to be at least 1 2 ID if hose 1 2 OD if tube with non ferrous 1 2 high pressure fitting s have a working pressure of at least 2000 psi page 29 General Plumbing cont Product Water Tubing product water lines 1 4 Parker tubing from each membrane to a collector then 3 8 Parker tubing to the system and tank Minimum tube bend radius is 4 inches Connections can be made to either end of the membrane housing Refer to the tube fitting assembly diagram Caution The product water flow should not be restricted in any way If the line gets blocked the pressure will build until the line fails Restricting the flow will reduce efficiency and may cause damage to the membrane e Connect to the water tank at or near the top The ideal spots are to tee into the tank vent line or the fill hose not tap into the bottom of the tank or a water feed manifold Air can be pulled through the membrane and affect the domestic water system e Connect the tank line to the product diversion valve inside the Frame See plumbing connection photo Leave enough length in the tank line so it can be removed from the diversion valve and attached to the product service valve on the face of the unit for emergency operation page 30 Component Placement
12. condition that could burst the tube Always verify the valves are in the proper position for the mode of operation desired before starting the system page 14 Operating Procedures New System Start Up and Testing Caution If possible avoid running the system if the vessel is in contaminated water such as in a harbor or canal That said we suggest that the system be fully run tested before leaving port We think that is preferable the sacrifice a filter by running in turbid water rather than waiting to get offshore to discover a problem or deficiency in the installation Another alternative is to test the system with an artificial ocean Open the pressure relief and flush the system by running the fresh water flush cycle 6 times with the pressure relief valve open and again 5 times with the pressure relief valve closed and the product water diverted This will flush the storage solution from the membrane The system can now be run using a clean source of sea water in the cleaning container Unchlorinated fresh water mixed with aquarium salt purchased from a pet store can be used Use the intake brine discharge and product service hoses to recirculate the salt water from the container First Check That Thru hull valve is open See caution about feed water condition above e Power is on If you have an AC system both AC power and the DC control voltage to the unit needs to be on e Service valves are in the run position S
13. flush mode Approximately 5 gallons of fresh water is used for flushing Emergency Operation In the event of a MPC control failure the system may be operated manually using the manual feed and flush pump switches on the MPC 3000 control box In manual operation the salinity control system is inoperative Product water is available through the product service valve If length permits the product tube to the tank may be removed from the diversion valve in the frame and connected to the product service valve s service port Always discard the product water for the first few minutes of operation The initial product water from the system may not be potable Taste the product water before sending to a tank For manual start up switch on the feed pump using the feed pump switch Monitor the feed pressure gauge on the feed pump for proper feed pressure Shut down the system immediately if the feed pressure is 240 psi or above and the Clark pump is not cycling Shut down if air is continuously present in the intake line or the feed pump is excessively noisy The automatic safety controls are disabled in manual mode For manual flushing switch on the flush pump using the flush pump switch Make sure the system is taking in fresh water by checking for operation of the ships pressure pump Run the flush pump a minimum of 4 minutes page 17 Service Valves in Service Position with Hoses Attached page 18 61 2 m
14. is supplied from a separate 12 or 24 volt source and wired directly to the circuit board Warning Do not connect AC or DC power to the control box until after all wiring connections are finished including remote panel connections Power Control Box Note If mounted remotely the control box must be mounted vertically on a bulkhead away from spray or dripping water The DC supply circuit must be rated to support a 20 amp continuous load for 12 volt systems or 10 amps continuous for 24 volt systems The AC supply circuit must be rated to support a 15 amp continuous load for 110 volt systems or 7 5 amps for 220 volt systems Use LARGE gauge feed wire rated as follows to avoid a voltage drop and related loss of performance Wire length in feet is measured from source circuit breaker to control box and back to source total length of supply wires 12 volt DC feed wire size for the MPC controller on AC systems WIRE LENGTH AWG wire size Square MM wire size To 20 feet 10 awg 5 sq mm 20 feet to 30 feet 8 awg 8 sq mm 30 feet to 40 feet 6 awg 13 sq mm 40 feet to 50 feet 4 awg 19 sq mm 50 feet to 60 feet 2 awg 32 sq mm 24 volt DC feed wire size for the MPC controller on AC systems WIRE LENGTH AWG wire size Square MM wire size To 20 feet 12 awg 3 sq mm 20 feet to 30 feet 10 awg 5 sq mm 30 feet to 40 feet 8 awg 8 sq mm 40 feet to 50 feet 6 awg 13 sq mm 50 feet to 60 feet 4 awg 19 sq mm 40 Electrical cont
15. on the slot provided As the retainer rings unscrew twist and pull the end cap to follow the ring out You will feel the O ring come out of the housing before the ring is off Do the same for the outlet end cap of the array Remove the interconnects before removing the rest of the end caps Inspect the end plugs and O rings for damage replace if necessary Push the membranes elements out of the housings by first pushing on the outlet ends If they resists try pushing on the other end If a membrane is going to be kept for any reason seal it in plastic before it dries out Do not open the new membrane packaging until ready to install To separate the housings first remove the end cap interconnects Loosen the bolts holding the plastic clamp haves together and remove the top clamps The tubes are now free Assembly Check that the new elements have brine seals on one end only and the seals are oriented the same way as the old membranes The seal lip should point outwards Lubricate the element brine seal and wet the whole inside of the housing Install a membrane starting at the outlet end of the housing by inserting the brine seal end first Use your fingers to compress the lip of the seal to get it started without folding over Push the membrane all the way into the housing so the brine seal is now at the inlet end of the housing Reinstall the ends and housings in reverse of the way they were disassembled Lube the cap O rings and the hous
16. prime and start the system in a manual mode Display defaults to the product gph meter The system will continue running until stopped by pressing the Start Stop again with no flush or by the optional tank full switches with a 1 time flush Normal operation For optimum performance run the system as long as possible then flush Never let the system sit with salt water in it Never allow continuous air leaks in the intake If pre filters are going to be cleaned do so when the first bar shows in the filter condition bar graph Normal shut down If the system was started using the Auto Run button the system will shut off on its own when the selected run time is over and will auto flush and re flush every 5 days Pressing the Start Stop button at any time will shut off the system with no auto flush function The optional tank full float switches will shut off the system from any mode If the system was started by the Auto Run button the system will flush and then re flush every 5 days If the system was started by the Start Stop button it will do a 1 time flush The display reads TANK S FULL Once one of the tank full float switches open the alarm and TANK S FULL display ceases on its own gt page 16 Operating Procedures cont Flushing Warning Proper operator understanding of the Spectra flush system and the vessel s fresh water system configuration is mandatory for extended automatic flush cycles The flush cycle must not
17. the set of terminals market INLET on the green plug and socket marked PRESSURE on the MPC circuit board The sensor on the outlet side of the filters must connect to the set of terminals marked OUTLET Connect the red wire to the white wire to and the black wire to If the wire leads for the sensors must be extended you must use a minimum 18AWG 8 sq mm three conductor twisted and shielded marine grade wire Make both sensor wires close to the same length Make a waterproof soldered splice connection to the new wire and seal the splice in waterproof heat shrink tubing Integrity of the sensor wiring is critical as any minute loss in the connections will be interpreted by the controller as a drop in pressure Be sure to carefully solder tin the bare strands of the wires before inserting them into the terminal plugs Caution Make certain that no extra strands are free to make contact with other conductors or components Ground the shield conductors to the chassis ground screw in the upper right hand corner of the circuit board Caution Make certain that the bare shield conductor cannot touch any components or other wires on the circuit board Stroke Sensor The stroke sensor snaps into the side of the end block of the Clark pump and the wires connect to the 1 set of terminals on the plug and socket marked STROKE SENSORS Connect red wire to P green wire to S and black wire
18. thing happens The fresh water wants to force itself through the membrane to dilute the salt water and the salt wants to migrate to fresh water side Osmotic pressure is created by the fresh water forcing itself into the salt water side where there isn t enough room for it With sea water osmotic pressure can build up to almost 400 pounds per square inch psi Reverse Osmosis RO happens when an artificial pressure higher that the osmotic pressure is applied to the sea water side This will force fresh water back through the membrane A little salt does go through but is highly diluted by the fresh water There is a rub however On the sea water side as the fresh water passes through the membrane the salts molecules crowd up against the membrane surface which starts to block the flow of fresh water To stop this a constant flow of new sea water must flow along the membrane surface to wash away the concentrating salts So to have reverse osmosis we must have sea water flowing at a pressure much higher than 400 psi along the membrane surface The spiral wound thin film composite membrane element that is in your pressure vessel was developed for this The Modern Marine Reverse Osmosis Watermaker A water maker system must deliver a filtered high pressure flow of seawater through the membrane That s it Some may have more bells and whistles than others but they all generate the high pressure flow The trick is to do it efficient
19. to If the wire leads for the sensor must be extended you must use a three conductor twisted marine grade wire Make a waterproof soldered splice connection to the new wire and seal the splice in waterproof heat shrink tubing Integrity of the sensor wiring is critical as any loss in the connections will be interpreted by the controller as a stall condition Be sure to carefully solder tin the bare strands of the wires before inserting them into the terminal plugs Caution Make certain that no extra strands are free to make contact with other conductors or components Diversion Valve and Salinity Probe The diversion valve solenoid amp salinity probe must be installed in a tee fitting in the product water tube between the product service valve and the ships fresh water tank The salinity sensor must be oriented with the wire pointing down to avoid any air bubbles from forming on the face of the sensor See diagrams for assembly detail The salinity probe wire plugs into the socket marked PROBE on the circuit board using the 6 foot modular type cable Do not substitute a different type of wire for the probe cable If you need a longer cable contact the factory Use the rubber boot to seal sensor to the cable after assembly is complete gt page 43 Electrical cont The diversion valve solenoid wires connect to the terminals marked D VLV and GND inside the control box Polarity is not critical
20. 10 high pressure tube 50 of 5 8 hose 25 of 1 4 product tubing Hose and tube fittings Hose clamps One container of SC 1 storage chemical Hand held salinity monitor Modular System Same components without the aluminum frame Options Basic Cruise Kit Includes three 20 micron filters three 5 micron filters and two SC 1 storage chemical containers Offshore Kit Includes Clark pump seals tools two SC 2 and 2 SC 3 cleaning chemical containers and overhaul instructions Spare Feed Pump Head Ultraviolet Product Sterilizer Additional Remote Panels page 5 Features The Spectra Monterey 1000 with the unique Spectra MPC 3000 automatic controller is the full featured flagship of the Spectra line It is ideal for large sailing and motor yachts Systems are available in modular or frame styles Using the proven Clark Pump the Spectra Monterey 1000 operates on a fresh water to power ratio that surpasses everything in the marine industry The AC or DC current power draw is so low a generator set is not always necessary The system makes an average of 42 gallons per hour on less than 3 4 horse power with about as much noise as a refrigerator Operating pressures are self regulating eliminating the need for adjustments even when operating in brackish waters The Spectra MPC 3000 automatic controller is the most advanced marine watermaker control system available The self regulating pressure feature of the Monterey allows it to be
21. Chesapeake where the water is murky and only have extra pre filter maintenance to deal with they ve done so for years If there is no other way to test the page 9 Living with a Watermaker cont system until the boat is in open water assume it s not going to work and plan the your trip accordingly Most of the time when a boat is being prepared for a cruise several systems must be sea trialed so leave enough time in your plans for this How to Store Your Watermaker This is one of the most confusing aspects of living with a watermaker You can t just turn it off and leave for a month or two without damaging it You might hear stories from people who do just that all the time and their watermaker is fine The strange thing is it might be true but for every one that gets away with it a hundred will eventually damage their systems The fact is membrane maintenance is a very inexact science You can read all the different watermaker manuals and will get a different version of how to maintain a membrane in each one All we can do is give you the benefit of our experience in this field with the hope that our version will give you the best performance with the least aggravation With that said what you need to do is pretty simple once you become familiar with it First don t let the system sit with salt water in it at all ever It has been a common belief that running a watermaker a couple of hours a day without flushing in between will m
22. Monterey Installation Quick Start Important Details for Installer and Owner It is imperative that the system have a dedicated sea water inlet to guarantee a solid flow of water to the system The inlet should be as low in the boat as possible and a scoop type forward facing through hull fitting installed Do not operate the system in rough conditions if the intake through hull is taking in air or damage may result Make sure to follow the wire gauge charts in the instructions Using larger wire than specified is acceptable The MPC control must have DC power continuously to achieve the full benefits of the fresh water flush system The domestic fresh water pressure must be on and the fresh water tank level maintained If these operational conditions present a problem consult factory The MPC control must be de powered after the system is put in storage or pickled where a storage chemical antifreeze is run through the system If you are remote mounting the membrane array please follow the high pressure tube assembly instructions These fittings must be tight Run test then sea trial the complete system before assuming the system is operational If the boat is in fresh or dirty water see Operation Procedures New System Start Up and Testing If you are a Spectra dealer we ask that you spend time with the vessels owner and operator so that they understand the operation and maintenance of the system Ple
23. Refer to the Dimension amp Plumbing Diagrams Main Pump and Control Frame Module The main pump module is designed to mount on a horizontal surface that can be up to 4 above the waterline Locate in an area that allows easy access to the face panel and the service hoses can reach a container placed in a spot where water spillage is acceptable Allow for a minimum of 2 of clearance on the sides and 12 over the top and at least 1 of clearance at the back Extra space over the top is preferred for easier internal access Use the unit itself as a template for drilling the mounting bolt holes Use quarter inch bolts or lag screws with washers If lag bolts are used they must thread into at least 1 of solid material Drill pilot holes for lags bolts Clark Pump modular systems Refer to the Clark Pump Mounting Diagram Bolt the mounting brackets to the base of the center block with the short 5 16 SS bolts and washers sandwiching the plastic washers in between the center block and the brackets The brackets will over hang from the front and back of the center block Moisten the rubber shock mounts and slip them into the bracket holes then install the plastic inserts The Clark Pump can be mounted on any horizontal surface that will support it s weight and is not subjected to excessive vibration Height above or below the water line is unrestricted Mounting on a vertical surface can be expedited by using the optional L mount
24. SC 1 storage chemical into the mixing container Warning Re check that the pressure relief valve is open or membrane damage may result Turn all the Service valves to the service position Start main feed pump manually using the manual switch on the MPC control box Run for 10 minutes to completely mix up the storage solution Light discoloring of the solution is acceptable After 10 minutes turn the brine discharge valve to the position When the container is empty shut off the system page 20 Long Term Storage Procedures cont Close the intake thru hull and turn the intake service valve back to the position Remove and clean the sea water strainer screen and pre filters Reassemble dry Turn off the DC power to the system Caution This is important so the system will perform an automatic storage solution purge cycle when the system is returned to service When returning the system to service after pickling check that the intake thru hull is open and the service valves are in the position and the charcoal flush filter is still good Turn on the system power and follow the instructions for a new or pickled system start up Winterizing Warning Use potable water antifreeze propylene glycol Do not use automotive antifreeze ethylene glycol Hardware stores in areas with freezing winters carry potable water system antifreeze or it may be ordered directly from Spectra Waterm
25. URE SENSOR COIFTPONAT FLOAT SWITCH MUST CLOSE WHEN TANK REACHES FULL OPTIONAL TANKA SWITCH IF JUMPER THESE TERMINAIS IF ONLY TANK SWITCH Is USED OPTIONAL INLET VACUUM STROKE SENSOR REMOTE PANEL OPTIONAL STERILIZE AUX 2 AUX 1 FLUSH PUMP DIVERSION VALVE UC INPUT DC INPUT FEED PUMP PLUMP AUX 3 FLUSH SOLENCOID VALVE OPTIONAL ALARM BLEEK Stroke Sensor Detail Pressure Sensor Detail Monterey MPC 3000 Control Wiring Connections page 46 Spectra Monterey Performance Specifications 120 240 volt systems Sea water temperature 77 degrees F 25 degrees C Feed flow Feed pressure High pressure Amperage Product 3 8 gpm 200 psi 750 psi 8 4 42 gph 24 Volt systems Sea water temperature 77 degrees F 10 degrees C Voltage Feed flow Feed pressure High pressure Amperage Product 27 6 3 8 gpm 200 psi 750 psi 24 42 gph Sea water salinity 35 000 parts per million TDS Salt rejection 99 0 99 4 Typical purity test lt 400 mhos 200 ppm 99 4 pure Performance Tolerance 10 Maximum Operating Temperature 113 degrees F 45 degrees C Dry weight 170 lbs page 47 osed Spectra Watermakers MPC 3000 troubleshooting procedures MECHANICAL FAULTS SYMPTOMS PROBABLE CAUSE REMEDY Feed pump runs constantly will not turn off manual
26. age 3 Table of Contents Shipping list Features Living With a Watermaker Component Description Clark Pump Diagram Operating Procedures Service Valve Position Photos DC Main Breaker amp Manual Control Switches Long Term Storage Maintenance Membrane Cleaning Procedures Membrane Element Replacement Installation Instructions Installation Basics General Plumbing Component Placement Component Dimensions Clark Pump Mounting Diagram Monterey Plumbing Block Diagram Plumbing Connection Photo Monterey Plumbing Layout Diagram High Pressure Tube Assembly Parker Tube Assembly Electrical Component Placement and Wiring Feed Pump and Control Power Connections MPC 3000 Circuit Board Wiring Specifications Troubleshooting Procedures Warranty page 4 page 5 page 6 page 7 page 11 page 12 page 15 page 18 page 19 page 20 page 22 page 23 page 25 page 26 page 28 page 29 page 31 page 33 page 34 page 35 page 36 page 37 page 38 page 39 page 40 page 45 page 46 page 47 page 48 page 50 Shipping List Frame System 1 Operation and Installation Manual 1 Main Module Aluminum Frame including Clark Pump Feed pump Membrane and Housing Array Automatic salinity control plumbing Automatic fresh water flush plumbing Flush pump 20 and 5 micron pre filter assembly with pressure sensors Manual override controls 1 MPC 3000 Remote Control Panel including Wiring harness 1 Installation Kit Including
27. aintain it The reality is sometime different Temperature and sea water variables may cause a slow degradation of the membrane So why not flush it every time Your Spectra system is set up to do this automatically if you like Next how long can you leave it flushed To be conservative we say up to 5 days After that it depends If the temperature is cool it could last much longer but if you already have bio fouling in the membrane the 5 day interval may be the maximum no matter what Now that you have decided to store or pickle your system what does that mean Just this you remove the salt water and replace it with fresh water mixed with a chemical that will stop biological growth In a little more detail you flush the system get some flush water in a bucket add the chemical to the bucket then mix the solution in the bucket with the flush water already in the system There are service valves built into your system just for this The instructions give the full details but the basic concept is simple When To Clean the Membrane The rule of thumb is if the system is performing 10 below what s normal for the conditions and is not caused by an electrical or mechanical problem clean the membrane Keeping a log of the system performance really helps in making this decision You look at operating pressure water quality power draw and production rate Higher than normal pressures for the conditions and or degradation of water qualit
28. akers Inc Follow the mixing instructions provided with the antifreeze Set up the domestic fresh water system so pressurized antifreeze is available to the Spectra flush system Open the pressure relief valve and start the auto flush and run until the antifreeze is visible in the pre filters then stop the flush with the Start Stop button Attach the intake service hose and move the intake service valve to service Place the intake service hose into a container holding at least 3 gallons of antifreeze and manually start the system Run the system until the antifreeze is gone then stop the system If the intake hose up to the flush module is to be flushed instead of using the intake service valve and hose remove the intake hose from the intake through hull and place it in the container of antifreeze Disconnect all of the product line connectors and blow through the tubes to purge of fresh water A portable air pressure tank filled at the gas station with a rubber tipped nozzle works well for this Close the intake thru hull On returning to service replace the charcoal flush filter page 21 Maintenance The Seawater Strainer The sea water strainer s stainless steel element should be inspected removed and cleaned as needed Be careful to ensure that the thru hull is closed before disassembly and the seal and element are in place on reassembly Put the screen up to the light for inspection When the system is put into s
29. alarm you Hand held meters must have a good battery and re calibrated periodically Built in ones have to have the probe cleaned and re calibrated also The basic problem with a TDS meter is it is reading the total impurities of the water your making This total is dictated by the feed water you happen to be floating in Salt is what you can taste the most Other minerals might not have a taste at all but will affect the meter Most of us have a higher quality more discerning TDS meter in our taste buds Product water readings below 500 ppm in standard sea water are considered OK by most peoples taste buds The rule of thumb is if the water is tasting OK to you and your crew it is OK no mater what the meter reads Product water quality will degrade slightly as the membrane ages But whether it is producing 150 ppm or 450 ppm it really doesn t matter if it tastes good Membranes rarely fail catastrophically but there are several circumstances that can degrade a membrane such as poor maintenance or exposure to oil and aggressive chemicals like chlorine Most of the time a good cleaning will improve quality and production to a satisfactory level If a poor membrane doesn t respond to cleaning don t go straight to hauling water or putting your dream cruise on hold A poor membrane usually will work fine if it processes brackish water Make water into the largest container you have then flush the system with some of it Put both the intake
30. alve into the cleaning container After 30 minutes check the feed pressure product flow and quality to determine if the membrane is functioning normally If the cleaning solution became very discolored during the cleaning process it is recommended to repeat the process If the first cleaning did not affect the membrane enough repeat the cleaning process using the other cleaner Always manually reject the product water for 30 minutes after cleaning e Ifthe membrane performance is still poor and no other problem can be found contact Spectra Watermakers for further assistance page 24 Membrane Element Replacement Do not remove the membrane from the housing unless absolutely necessary Troubleshoot for all other causes of poor performance and try the recommend procedures first Caution membranes must be stored wet with preservative to prevent permanent damage Disassembly Remove and move the membrane housing array to a work area that can handle water spillage Hold the body of the SS tube fittings when loosening the nuts Clean off any deposits on the ends with a stiff brush and fresh water Note which ends go where so they can be reinstalled the same way later There are two ways that the membranes can be replaced with the housing still in the clamps or with the housings separated With the housings still in the clamps loosen the ring on the array inlet end cap with a strap wrench or use a hard plastic or wood punch and a mallet
31. an accommodate up to 3 remote control display panels The displays must be mounted in a protected location out of direct sunlight and away from spray or dripping water Commands can be entered at any panel The display panels connect with the supplied 50 foot modular type cable to the control box sockets marked DISPLAYS on the MPC circuit board Do not substitute a different type of cable If you need longer cables contact the factory gt page 41 Electrical cont e Use care when pulling the modular cable through the ships wiring harness as the end plugs are easily damaged by excessive force Fold back 4 of wire and tape over the end plugs before pulling the cable to prevent damage If the cables are damaged during installation the system will not operate and the controller may also be damaged If in doubt use a new cable Each remote control display panel accommodate an external alarm buzzer MPC 3000 REMOTE PANEL BACK SIDE to provide audible alerts in the event of a fault or at the end of certain timed cycles Use only the buzzer units supplied by Spectra Watermakers as current on the buzzer circuit is limited to 20 milliamps any excessive load may damage the controller or remote display panel Connect the buzzer RED wire to terminal marked POSITIVE connect the buzzer BLACK wire to the terminal marked NEGATIVE on the eae back of the remote display panel Caution Do connect power to these
32. anty Sharing a thru hull can introduce unforeseen problems such as intermittent flow restriction air bubbles and contaminates For racing boats a retractable snorkel type thru hull fitting is preferred to be able to pick up water away from the hull Do not install the intake close to or down stream of a head discharge Install as far below the water line and as close to center line as possible to avoid contamination and air induction We recommend that a reputable boatyard install any underwater thru hulls The discharge thru hull should be mounted above the waterline in or just above the boot stripe to minimize water lift Having the discharge feed into a cockpit or sink drain will work but can make an unpleasant gurgle sound Double clamp all hose connections below the water line Pipe Fitting Instruction Metal pipe fittings that are to thread into plastic should be coated with at least 3 wraps of Teflon tape To avoid cracking the plastic tighten until only 1 2 to 2 3 of the threads are buried This may not seem tight but they will not and should not bottom out like a metal to metal connection Do not thread them in all the way as Metal to metal pipe connections should have 1 1 2 to 2 Teflon wraps only Plastic to plastic fittings should have 3 to 4 wraps and will thread almost all the way in Be very careful to avoid getting any tape over the end of the fitting that might get into the system To insure this does no
33. are to prevent possible salt water damage to surrounding equipment or surfaces Have the installer go over the complete system with you Using a Watermaker A good watermaker is a significant investment but if used properly will pay for itself and more First of all make sure that it really is functioning properly before going to sea new installation should be thoroughly sea trialed in rough conditions at all points of sail or speeds to make sure the intake flow is OK After that the system should always be run tested before leaving watermaker doesn t like to sit idle with salt water in it It wants to run The best way to use it is to run it until the tanks are full then flush it It can sit flushed for several days Your fresh water usage pattern can typically adapt to allow for a watermaker run every 3 to 5 days on average Use water The water you make and how you use it is the payback on your investment It s hard to break old habits of water conservation on board but really try Install a fresh water deck wash down system By keeping the salts off the boat and gear like you would in port after a day sail the watermaker will pay for itself in less maintenance costs and resale value of the ship By using more water for you and the crew the quality of life on board is greatly enhance One of the biggest benefits is the freedom it offers It is easy to carry enough fuel and food to last a month or more but with a limited water s
34. ase have the owner fill out the warranty card Please read the Installation Instructions page 1 1 2 02 2222 7764 MONTEREY 1000 OPERATION AND INSTALLATION Spectra Watermakers Inc 20 Mariposa Road San Rafael CA 94901 Phone 415 526 2780 415 526 2787 E mail spectra spectrawatermakers com www spectrawatermakers com Introduction Thank you for choosing a Spectra Watermaker It is our sincere wish for you to be completely satisfied with our product We have inspected and tested all of the components before shipping and are confident we have produced one of the finest products available Your long term satisfaction with this system will depend greatly on how the Spectra system is installed The unique performance is obtained not only by our new pressurization process but by careful attention to reducing flow restriction mechanical friction and electrical resistance of this is affected by the final installation and that is ultimately up to you By reading understanding and following this manual even if you are not doing the installation yourself you will be completely satisfied with your new Spectra system With years of experience installing and repairing many different kinds of watermakers we have seen nearly everything that can happen to marine watermakers This manual includes the summation of that knowledge tailored for the Spectra Watermakers Warning It is very important to read and foll
35. be allowed to drain all the fresh water from the vessel or damage to the vessel s fresh water pump may occur Adding a low pressure cutout switch on the vessel s fresh water pump is recommended if the vessel is to be left unattended during the Spectra re flush every 5 days program Make sure that there is enough water in the fresh water supply system to supply the watermaker for more than the expected time of operation in the re flush every 5 days mode Make sure that the pressure water supply is on and will stay on during the flush mode Make sure that the pressure relief valve is closed It should be if the system was just used to make water The auto flush may not operate if the valve is open The DC power for the MPC 3000 must remain on during the auto flush mode Turning off the DC power will disable the auto flush function and damage may occur Pressing the Auto Store button will engage a flush and then the every 5 day re flush The flush pump starts and the flush water solenoid opens for 3 5 minutes and then shuts down The display reads FLUSHING with countdown timer then AUTO FLUSH EVERY 5 DAYS when the flush is finished Pressing and holding the Auto Store button for 3 seconds will engage a 1 time flush The system flushes as described above but will not re flush every 5 days Display reads FLUSHING with countdown timer then the default display when finished Pressing the Start Stop button will cancel the auto
36. bracket For hanging from overhead use two of the L brackets Avoid mounting in the middle of a large unsupported flat surface that could amplify the sound of the pump shift The Clark Pump can be mounted in any position if it is hard mounted without using the brackets More noise may be transferred to the vessel Allow room in the front and back for access to the high pressure tubes and hose connections If the space behind the unit is restricted attach the high pressure tubes to the Clark Pump before final mounting The 90 degree fittings supplied are acceptable for the feed and high pressure tube connections to the unit and can be rotated up to 1 2 turn for easy tube runs Straight fittings can also be used The brine discharge hose connection to the reversing valve body should be straight if possible and can be connected to either end of the reversing valve Plug the unused port Make sure that the area around and under the pump does not have any water sensitive equipment Water will be spilled during any repairs or if a leak occurs Use the Clark Pump mounting hole guide to layout and drill for the fasteners 1 4 bolts and Nylock nuts are preferred but lag bolts are acceptable if they penetrate at least 1 into solid material Drill pilot holes for lags bolts Caution Tighten the fasteners until there is light pressure on the plastic inserts The plastic inserts will collapse if over tightened The 1 4 fender washer must be on top to
37. d ballast BLACK wire connects to GND terminal If the wires must be extended use minimum 16 AWG 1 sq mm wire EXTERNAL BUZZER S In addition to the external buzzer s installed at each remote control display panel a buzzer unit may be installed at the control box The buzzer RED wire connects to the BUZZ terminal and the buzzer BLACK wire connects to the GND terminal TANK FULL SWITCHES The system can accommodate 2 float switches in separate water tanks to automatically turn off the watermaker when both tanks reach the full level Tank Full Switch Notes The switches must be of the normally open type that close a contact when the tank is full Use at least 16A WG 1 sq mm 2 conductor marine grade twisted wire to connect the tank switches to the control box The tank full switches connect to the terminal plug inside the control box marked FLOAT SWITCHES 1 amp 2 See diagrams for wiring details If only 1 tank switch is used you must install a jumper between the unused set of terminals to make the system function properly page 44 E D POSITIVE INPUT CONNECTOR 3 DC NEGATIVE INPUT CONNECTOR 7 AC THOT BREAKER 20 AMPSQDIZV DCi ACIGROUNDI AC NEUTRAL 15 AMPS G 18 BREAKER 10 AMPSQAV n 4 BREAKER 7 5 AMPS igi 23997 AC Powered Feed Pump Connections page 45 PRESSURE SENSIE OROUNTE SALINITY PROBE INLET FRESSURE SENSOR OUTLET PRESS
38. ders and pistons that share a single rod through a center block A reversing valve controlled by a pilot valve actuated by the pistons allows the cylinders to alternate between driving and pressurizing Pressurization is achieved by the rod being driven into the other cylinder As the rod enters the cylinder it pushes the piston which circulates the water out through the membrane and back to the reversing valve The valve directs the water back into the same cylinder behind the piston creating a closed loop The rod displaces water as it enters the cylinder raising the pressure enough for reverse osmosis to occur in the membrane thus fresh water equal to the volume of the rod is produced on every stroke The driving cylinder has feed pressure pushing on the top of the piston which has ten times the surface area than the end of the rod The water under the piston brine is discharged overboard This gives the piston a 10 to 1 advantage over the rod allowing it to drive the rod into the pressurizing cylinder When the piston bottoms out on the center block it actuates the pilot valve and the process is instantly reversed High efficiency is achieved because there is no back stroke allowing one cylinder to always be under pressure The speed of this process is determined by the water flow from the feed pump The feed pump has a nearly constant flow rate at a given voltage so the production of fresh water is nearly constant only the pressures chan
39. ee photos on page 18 Domestic fresh water pressure system must be on OPEN PRESSURE RELIEF VALVE is displayed on the remote panel Locate the Clark pump and the pressure relief valve See drawing on page 12 e Open the pressure relief valve one turn counter clockwise Push the Start Stop or Auto Run button to start the system The control will prompt STARTING then PURGING STORAGE SOLOUTION Warning A system is always purged or serviced with the pressure relief valve open The control will go into an starting mode and the feed pump will start shortly after The system should prime within 60 90 seconds Check the strainer and the brine discharge for water flow There should be no bubbles anywhere in the intake hoses and the feed pump should sound smooth after the prime Ifthe feed pump continues to sound rough find the reason before continuing Then Inspect for leaks After 20 minutes the system will stop alarm and prompt CLOSE PRESSURE RELIEF VALVE e Close the pressure relief valve on the Clark pump and restart the system in Auto Run or with the Start Stop button manual mode The system will now start in a normal operating mode but will continue to divert the product for ten minutes Inspect for leaks again The system is now operating under pressure gt page 15 Operating Procedures cont Note If you must stop the purge sequence for any reason the control will default back to the
40. em with the Start Stop button Do not use tap water or chlorinated water Distilled or charcoal filtered water is acceptable if using the flush water is not an option Start heating the water gt page 23 Membrane Cleaning Procedures cont e With the system flushed and unchlorinated fresh water in the container thoroughly mix two containers of the chosen cleaning chemical into the mixing container Warning Re check that the pressure relief valve is open or membrane damage may result Turn all the valves to the service position Start the main feed pump manually using the manual switch on the MPC control box Do not use the remote control panel Run the system unpressurized for one hour while maintaining the solution at 120 F then turn off for one hour to let the membrane soak Don t forget to turn off the stove Run the system again for 1 hour while heating the solution then turn off for one hour Do not let the water get above 120 F Triple the run soak times if the water is not heated e Turn the brine discharge service valve to the Run position Restart the system the solution will now drain from the container e Place the intake service valve to the Run position Run the system unpressurized on sea water for at least 30 minutes to purge the cleaning solution e After purging close the pressure relief valve to pressurize the system Manually divert the product water with the product service v
41. fully inserted into pump check wires in control box and at sensor turn system on check for 5VDC between sensor RED amp GREEN wires on terminal plug if voltage is present controller is OK remove sensor from Clark pump see diagram for removal and place a strong magnet near sensor if green LED does not activate replace sensor contact factory Over pressure feed pressure too high blocked brine discharge feed pressure too high fouled membrane check all service valves in run position clean membrane see manual Voltage too high battery system voltage too high adjust charging system turn down settings Voltage too low battery system voltage too low loose supply wires or poor connections charge batteries check supply wires in control box and at electrical source for poor connections Restarting followed by countdown timer no signal from Clark pump stroke sensor see remedy above for system stalled see remedy above for stroke sensor Check fuse followed by fuse number blown fuse on circuit board replace fuse mini automotive type ATM look for cause Service pre filters pre filters clogged loose or defective pressure sensor wires install new filters check sensor wiring Service intake strainer clogged strainer intake blockage clean strainer screen check thru hull and intake hoses
42. ge with changes in sea water temperature and salinity see Membrane section A pressure relief valve is incorporated in the Clark Pump to depressurize the system for service Product out Brine out a Check Valves Function Diagram Feed Pressure page 11 Component Description cont Valve block End block A High pressure inletn or Accumulator port Composite cylinder and base Alternate brine outlet port Pressure relief valve P da Center block High pressure outlet Stainless steel tube Cylinder ring Clark Pump End cap Brine outlet port Composite cylinder Stroke sensor and base HP accumulator tank port or HP inlet port Center block Feed in Stainless steel tube Cylinder ring End Cap Clark Pump Back view page 12 Component Description cont Reverse Osmosis Membrane Elements and Pressure Vessel Array The RO membrane elements do the real work An element is made from membrane and separating layers attached and wrapped around a center catch tube then encased in fiberglass The ends of the windings are open allowing water to freely pass through from end to end An element is installed into a high pressure vessel that directs the pressurized salt water to flow through the element and lets the product fresh water that passes through the membrane escape from the center catch tube Threaded por
43. he water line A single self priming vane pump is all that drives the system No additional boost pump is needed or even helpful A separate small DC driven prime flush pump is used for the automatic flushing A 20 micron and 5 micron dual pre filter assembly is provided standard for maximum system life and reduced filter maintenance The system s noise level is exceptionally low and unobtrusive as compared to other systems of similar capacity and almost no vibration page 6 Living With a Watermaker Now that you own a watermaker what do you do with it Making good drinkable water for sure but there is more to it You may not think it now but your watermaker will probably become mission critical component for you Like your engine sails and safety gear you will not want to go to sea without it The following is to help you better understand the process of water making and making water reliably Theory of Reverse Osmosis Semi Permeable Membrane You may remember that term from some science class Each cell in our bodies is covered with one It s designed to be able to exchange desired chemicals in and out but reject unwanted ones Osmosis another science class term is a phenomenon where a solution with a high concentration of something lets say salt water and a solution with a low concentration of the same dissolved something fresh water happen to be separated by a semi permeable membrane a very strange
44. her cleaning them as the particles have been pushed too far into the filter material Get to know your system Listen to all the different sounds it makes as it s running normally Literally put your ear on the Clark pump and listen to its heart beat Get close to the feed pump and get to know it s tone Most problems with a watermaker have an associated change of sound If you can notice subtle changes in it s sound and feel it can go along way to stop a small problem before it becomes a big problem Fix any leak no matter how small right away especially if it s coming from a metal fitting If you can t see it use your finger to feel for wetness The extensive use of plastics and composites in the Spectra systems greatly reduce corrosion problems page 8 Living with Watermaker cont Just a reminder A watermaker system is bringing in a significant flow of seawater gt The flow is well below the capacity of a typical bilge pump when working properly A good test is to divert the full flow of the watermaker into the bilge and make sure your bilge pump system is up to the task It doesn t take much dirt in the bilge to completely stop a centrifugal bilge pump RO Product Water The water your system makes should be very good water Most people want to know how good it is A Total Dissolved Solids TDS meter reading in parts per million ppm is supplied with each system Unfortunately reading errors can occur that may
45. ined for the flush system to function 20 and 5 Micron Dual Pre filter Assembly The pre filters do the essential job of cleaning the sea water before it gets to the Clark Pump and R O membranes High quality replaceable pleated fiber filters are used Filter maintenance is crucial to the efficiency and life of the system Five micron filtered sea water is mandatory Do not use sub standard filters The 20 micron filter is plumbed in front of the 5 micron to reduce filter maintenance The system can be run on a single 5 micron pre filter if necessary The MPC 3000 monitors filter condition and will alarm when filter service is needed Analog Feed Pressure Gauge The dial type feed pressure gauge mounted on the output of the feed pump is used for system trouble shooting Higher than normal pressures indicates the need for pre filter service or a system blockage Service Valves The service valves are in the feed brine discharge and product lines to provide easy access for proper maintenance The service hoses attach to the panel face frame style or to the service valves directly modular systems and are lead to a cleaning container IMPORTANT The intake and discharge service valves will close off all the ports if the levers are moved to the Off or middle position The product service valve cannot close the ports when the lever is moved half way This precludes the possibility of blocking the product flow and causing an over pressure
46. ing with a sharp razor knife or hose cutter and remove any burrs Minimum tubing bend radius is 6 Route tubing away from excessive heat sources and secure from vibration and chafe Have at least one shallow bend in a tube assembly after it is installed Refer to figure 1 fitting has been dissembled reassemble as illustrated notch on the ferrule must engage the inside of the nut properly for the nut to seat down fully Once the tube is inserted the ferrule and nut will naturally align Refer to figure 2 Insert tube fully into the fitting it should go in 0 9 Tighten the nut finger tight while moving the tube around to prevent binding One thread should be showing under the nut Secure the tube so it won t back out when tightening Refer to figure 3 Use 13 16 wrench to hold a straight body fitting or a 3 4 wrench for 90 body and a 7 8 wrench for the nut Hold the body recheck the tube insertion then tighten the nut 1 2 3 turns 10 flats after a good finger tight Use the index mark on the nut as a guide The threads should be completely covered by the nut The tube connectors can be disconnected and re tighten several times To reconnect insert the tube and ferrule into the body then hand tighten the nut Hold the body and tighten the nut with a wrench a little past where resistance is encountered When correct the nut should be tightened a little past where it was before disassembly Always check for leaks I
47. ings with a very thin coating of silicone grease or soap and water Thread the end caps on until the o rings touch the housing Check that everything is straight and then continue to tighten the rings until they stop Leave the rings just loose so the end caps can be rotated for tube and interconnect assembly After the housing are assembled in the clamps reinstall the interconnect tubes Tighten the retainer rings after the whole assembly is assembled Do not over tighten the rings New membranes have a pickling solution and should be thoroughly flushed before use Follow the new system start up procedures Look for leaks at the end plugs If a large leak is present the large O ring around the end plug is not seated properly and the end plug will have to be removed and redone small leak at the tiny vent port by the SS fittings indicates a missing or damaged product tube O rings inside the end cap page 25 Installation Instructions Please follow the instructions carefully Any deviation from the following procedures must be approved in writing by Spectra Watermakers or the warranty may voided Spectra Watermakers are a new generation of marine watermakers with important differences from older designs Shopping List Materials needed in addition to the installation kit Refer to manual for wire size fuses or circuit breakers and type of fasteners e Fasteners Hardware for mounting components to desired surfaces e Marine grade
48. is used between the check valve flush water inlet tee and the intake of the feed pump In a modular installation keep this section as short as possible without any sharp bends Warning Any air leak in the intake plumbing will damage the feed pump Feed Pressure Tube e This is pre plumbed in the main module 1 2 Parker tubing and fittings are used between the feed pump pre filters and the Clark pump handle feed pressure up 10 260 psi proper assembly of the fittings is critical See tube fitting assembly instructions High Pressure Tubes For remote mounting of the membrane array be sure to follow the Clark Pump and Plumbing Diagrams for proper connection between the Clark Pump and the membranes Membrane water flow direction is marked on the housings Rotate the 90 degree high pressure tube fittings on the Clark Pump up to 1 2 turn for ideal tube runs The high pressure tubes are usually made in place Loosely route the tubes between the Clark pump and the membrane and cut long Minimum tube bend radius is 6 Follow the high pressure tube connection instructions Connect the tubes to one of the components secure the tube runs and then trim and connect to the other component A 90 degree bend in a hose is better than a 90 degree fitting A tube when mounted should have at least one gentle bend to allow for expansion Do not connect a tube straight between hard mounted fittings e When connecting the tubes to the
49. l filter is mandatory Charcoal filters last a maximum of 6 months once wetted Warning The Spectra SC 1 Storage compound is specially formulated to be used as a Spectra system preservative Sodium bisulfite or metabisulfite should not be used as a preservative in the Spectra systems Use of sodium bisulfite will attack materials used in the Spectra systems and void the warranty Warning The pressure relief valve on the Clark pump must be open for this procedure or membrane damage may result Maximum pressure 50 psi The SC 1 Storage Compound has to be mixed at a ratio of 2 Spectra containers to 6 gallons of fresh water to have the proper solution An average of 4 gallons a Monterey system This water has to be included in the mixture Caution Avoid contact with skin eyes or lungs with the storage chemical e Make sure the system has already flushed itself If unsure of the system status start the flush cycle with the MPC control Once flushed attach the service hoses to the face of the unit and direct them to a clean 3 gallon or larger plastic or SS mixing container e Turn only the brine discharge service valve to the Service position Re start the flush cycle and allow two gallons to flow into the container then turn press the Start Stop button Do not use tap water or any water that might have chlorine in it e With the system flushed and unchlorinated fresh water in the container thoroughly mix two containers of the
50. ly quietly and reliably Your Spectra system with its 21st century Clark Pump technology does it all There are several things that can hamper a system most caused by poor installation and or operator error and neglect With the system set up properly there has to be an unrestricted supply of seawater without air bubbles to the inlet of the system the sea water must be filtered to 5 microns the power wiring must be the right size with good connections the system should be flushed with fresh water after use if the system isn t going to be used for a while it has to be properly stored or pickled to stop bio fouling and or freezing which will damage the membrane and all service points placed in a convenient position Installing Your Watermaker The installer must read the manual even if he or she has installed other Spectra systems New information is constantly being added to our documentation A lot comes from customer input Pay special attention to the intake instructions they must be followed Even if you are not installing the watermaker yourself read through the whole introduction and operation sections of the manual before starting This will help you plan the layout of your watermaker page 7 Living with a Watermaker cont You are the one who will live with and service it make it as easy as possible to take care if it Caution Watermakers contain high pressure salt water A small leak can generate a water jet Take c
51. mp stove and use a large SS pot to heat the cleaning solution in The cleaning solution throughout the system will heat as it circulates in and out of the pot An alternative is to heat the one or two gallons of initial water in the cleaning container to 120 F on the main stove before mixing in the cleaner and circulating it into the system Periodically stop and reheat the solution Perform the cleaning procedures while the ship is in acceptable sea water for purging and testing Cleaning Procedures Note procedures are the same for the SC 3 and SC 2 cleaners A Spectra Cleaning Compound SC 2 or SC 3 must be mixed with fresh water at a ratio of 2 Spectra containers to 6 gallons to have the proper solution An average of 4 gallons are in a Monterey system This water has to be figured in the mixture SC 3 and SC 2 are never mixed together Do not use them for storage Warning The pressure relief valve on the Clark pump must be open for this procedure or membrane damage may result Maximum pressure 50 psi Note Triple the run soak times if the solution is not heated e Attach the service hoses to the pump valve module and direct them to the cleaning container Make sure the domestic water pressure system is on then start the automatic flush system When the flush cycle stops move only the brine discharge to the Service position and restart the flush cycle Allow two gallons of flush water to flow into the container then stop the syst
52. ndex mark Figure 1 KX J WZ Nut Cut tube square TN Fi gure 2 Black high pressure tubing _ gt gt Tighten 1 2 3 turns 10 flats with a 7 8 wrench after finger tight Use index mark as guide f No threads showing Figure 3 Insert tube 0 9 until it stops page 38 Single grab ring for 3 8 Double grab rings for 1 2 Nut Tabs Tubing Step 1 Dissemble fitting components 7 16 max Step 2 Slide nut grab ring s spacer and O ring onto the end of the tube Push on the O ring to slide the grab ring s and spacer back so the O ring is 7116 max 3 8 min from the end of the tube Grab ring s must be tight on the tube If not bend the tabs in to reduce the I D of the ring Step 3 Gently fit the tube into the body and loosely thread on the nut Be careful to not cross thread the nut 1 2 tube should not bottom out in the fitting to allow full compression of the O ring Step 4 Hand tighten the nut DO OVER TIGHTEN DO NOT USE WRENCH The tube should not come out if pulled by hand If it does tighten the grab ring tabs 3 8 amp 1 2 Parker Tube Fitting Assembly page 39 Electrical Component Placement Wiring Guidelines General On DC only powered systems the power for feed pump and the MPC controller is shared and pre wired inside the Power Control Box On AC systems power for the MPC controller
53. operated solely from the MPC 3000 remote panel even if the feed water changes from full sea water to even fresh water Unlike conventional systems no access to the system hardware for adjustments are necessary Standard features include a salinity control system with product diversion valve programmable automatic fresh water flush system and readouts for operating conditions It monitors all system parameters and will alarm if a fault is present and will stop the system if necessary Operated in the Auto Mode the MPC 3000 can be set for a desired run time then will automatically fresh water flush the system and re flush every five says The MPC 3000 controller is operated from the ships DC power supply even on AC systems allowing the system to operate in the auto re flush mode without having to start a generator The production of fresh water is stable through the system s normal operating sea water temperature and salinity range Only the working pressures change with the water conditions A conventional 1000 gallon per day unit running in 61 degree F water will only make 700 gallons per day The Spectra Monterey will still be producing 1000 gallons per day on a fraction of the power The frame design allows for easy installation All of the pumps pre filters automatic systems gauges controls and service valves are mounted in a lightweight frame The system s feed and flush pumps are self priming so they can be mounted up to 4 feet above t
54. override switches position turn off manual switch on control box Feed pump runs with loud noise Intake blocked check thru hull on check service valve in run position No lights or display system does not operate remote display not connected no power to control box check display cable connections at back of display and inside control box check and reset main DC supply breaker check for voltage 12 or 24VDC at control box power input studs try manual bypass switches if pumps run then control is defective or display is not connected to controller Pump runs intermittently cycling on amp off system operating in flush mode DC models system will time out or manually stop with the Start Stop button Display activates but pump does not run loose or broken pump wire connection bad pump relay bad flush timer DC models blown F3 or F5 fuse on circuit board check wiring at terminal block inside MPC test power relay replace test flush relay replace replace fuse mini automotive type ATM Display activates system runs no product water output no feed pressure pressure relief valve open intake service valve in service position check and close pressure relief valve verify all service valves in run position System runs no product water delivered to water tanks GPH bar graph shows OK good LED activated product
55. ow the instructions in this manual Unsatisfactory performance property damage or personal injury may occur if the installation and operating procedures are not completely understood and executed properly Caution If someone else is installing the watermaker for you review all aspects of the system with them before the installation begins Pay special attention to how easy it will be for you to service the system If you have any questions please contact us It is important the new system be checked by the owner operator for proper installation completely tested in seawater and thoroughly understood before leaving on a cruise Do not rely on the word of the installer that the system is fully operational watermakers will suffer damage if they are run then left to sit with salt water in them The Spectra MPC 3000 controller can automatically fresh water flush after use and even re flush every five days Do not let the auto flush feature drain the fresh water tank Damage to the fresh water pump may occur The system can also be long term stored if necessary by flushing with a storage pickling solution All the valves and plumbing necessary for servicing are included In conclusion having a reliable and adequate watermaker will improve the quality of life on board more than almost any other piece of equipment This manual is designed help you take full advantage of your new Spectra Watermaker You have indeed made the best choice p
56. prevent the mounting brackets from slipping out of the rubber mounts under adverse conditions Do not mount the Clark Pump in an area that is subject to sustained temperatures over 120 degrees F gt page 31 Component Placement cont Membrane Array Mounting If the membranes are to be removed from the Monterey frame mount the membrane and housing array near the system as close to the frame and in as cool a place as possible Mount the array using the four angle mounts The membrane housings are marked for water flow direction and can be mounted at an angle or vertical but the brine outlet end should be up to help purge air Route the high pressure tubing to and from the membrane housing as smoothly as possible Avoid clamping the tubes tightly to any surfaces for sound dampening Hanging the tubes away from a surface with wire ties so that they are neither tight nor completely loose is best Follow the high pressure tube fitting instructions on page 36 The product water collector can be connected to either end of the array Plug the unused product ports and re label Do not mount the membranes in an area that is subject to sustained temperatures over 120 degrees F Remote Control Panel The remote control panel can be mounted anywhere that s dry and convenient Cut a 4 9 16 wide by 2 7 8 high opening for the panel If the mounting area is finished wood tape the outside perimeter of the cutout and use a reverse tooth sa
57. ra Monterey Components Dimensions Drill for 1 4 bolts 1 4 lags 14 SM Screw 6 500 y Clark Pump Mounting Hole Layout Under Under Cylinder Cylinder 8 IMPORTANT Not a Template Front Lag or screw Bolt mounting mounting 2 1 4 SS Lag bolt or 1 4 SS Bolt 14 sheet metal screw Caution Do not over tighten the plastic inserts may crush 1 4 SS Fender Washer 1 4 SS Fender Washer Plastic Insert Plastic Insert AA u Rubber Grommet Aluminum brackets Plastic washers Bottom view Note Remove alluminum mounts before shipping the Clark Pump Clark Pump Mounting Modular Systems page 34 Pressurized fresh water from domestic water system to Shurflo flush pump 3 8 product tube T N Monterey 3500 Fresh water tank Charcoal filter NN osed SS discharge Removable service hoses Cleaning container Strainer Monterey Plumbing Block Diagram NOLLOANNOOD ONY YILVAMAVIS Td ANVI YALVAM HS3384 OL 110 LINCO YA OL LOO ANINA AINIVH LS JAVLNI LITH LEVA VHS page 36 High pressure outlet 5
58. rray please follow the high pressure tube assembly instructions These fittings must be tight Run test then sea trial the complete system before assuming the system is operational If the boat is in fresh or dirty water see Operation Procedures New System Start Up and Testing If you are a Spectra dealer we ask that you spend time with the vessels owner and operator so that they understand the operation and maintenance of the system Please have the owner fill out the warranty card page 27 Installation Basics The Spectra Watermakers are designed for energy efficiency All aspects of the system have been optimized for this goal therefore any changes in the basic layout or components will most likely reduce this efficiency The overall length of the feed discharge and high pressure hoses have little effect on performance but every hose bend or 90 degree fitting absorbs power Avoid adding 90 degree fittings Use gentle hose bends where possable A good installation will be a proper compromise between minimum hose and wire runs accessibility environment and esthetics Thru hulls It is recommended that a designated 3 4 to 1 intake thru hull and seacock be installed for the system as far below the water line as possible A protruding scoop type is mandatory Thru hulls in the bow area are susceptible to air intake in rough conditions Sharing a thru hull with another system is unacceptable and will void the warr
59. service valve in service position loose or broken diversion valve wires diversion valve plunger stuck verify service valves all in run position check wiring at terminal block inside the control box and at diversion valve disassemble amp clean diversion valve plunger or replace valve contact factory System runs no product water delivered to water tanks GPH bar graph shows OK reject LED stays activated high salinity of product water causing system to reject water constantly product service valve in service position chlorine damage to membranes check for low feed pressure check for leaks at high pressure hoses verify service valves all in run position test product water with hand held tester if constantly over 500 PPM for 1 hour clean or replace RO membrane contact factory 99 4 ERROR MESSAGES SYMPTOMS PROBABLE CAUSE REMEDY System stalled System stalled may alarm when using the remote panel to run the system for service with the pressure relief valve open Stop system and use the manual override switch on the MPC control box for system service flushing with pressure relief valve open intake thru hull closed air in system no signal from Clark pump stroke sensor LED not blinking loose or broken wires for sensor stroke sensor defective close pressure relief valve restart system check thru hull verify sensor
60. t happen leave the very first thread uncoated Male pipe tube fittings with an O ring under the body nut use 1 1 2 wraps of tape and thread into specially machined threaded ports until the nut just contacts the surface burying the O ring The membrane end caps and the Clark pump cylinder end caps are machined for O ring pipe fittings page 28 General Plumbing Several types of hose and tubing are incorporated into the Spectra systems to meet specific needs Care must be taken to use the proper type for each section of the plumbing system For a modular system the 90 degree high pressure SS tube fitting mounted in the high pressure out on the Clark Pump can be rotated up to 1 2 turn for better tube runs The high pressure inlet fitting and the SS accumulator tank can be swapped for better tube runs Double clamp all connections that are below the water line on the suction line to the feed pump Re tighten all hose clamps and check for leaks after the first few hours of running Use straight hose fittings and gentle turns in the hose where possible Minimum hose bend radius is 6 Tightly secure hoses with tie wraps to avoid chafe Suction Hose This is 3 4 wire reinforced clear nylon Route the hose smoothly from the intake thru hull to the strainer then the intake service valve This hose is designed for suction Do not use it in a pressure application web re enforced 3 4 hose that can handle the flush pressure
61. torage remove rinse and reassemble dry to impede corrosion Check frequently during operation The Micron Pre filters Service the pre filters as soon as possible after the first pre filter service alarm sounds When the second alarm sounds the system will shut down to prevent damage If cleaning and reusing filter elements clean when the first bar on the filter condition display comes on The easiest way to service the filters is to first shut off the thru hull open the housings discard the old filters remove the O rings to avoid loosing them and clean the housings Reinstall the O rings and reassemble the pre filters with new 20 and 5 micron filter elements The 5 micron filter goes down stream from the 20 micron Leave dry until the next start up Used pleated elements can be carefully cleaned if they are not too compacted Do not use full pressure from a garden hose or scrub with a hard brush on the pleats Gently spray the outside with water and then plug one end with your hand filling from the other end to flush from the inside Be careful to not distort the pleats Another way is to tow them behind the boat until clean 4 knots maximum Slip a line through the filter and tie a stopper knot Elements that show any signs of deterioration especially the 5 micron should be replaced Check for leaks on the first run after a filter service The Charcoal Fresh Water Flush Filter Replace the charcoal filter element at least every 6 months
62. ts are provided for hose connections in the end caps of the pressure housings The Monterey uses three membranes plumbed in series As high pressure salt water flows across the membrane layer fresh water is forced through the membrane and lead by a capillary layer to the catch tube The excess salt water flowing out of the membranes is saltier and is called brine No salts are collected in membranes Membrane element function is affected by sea water temperature and salinity The warmer or less salty the water the easier it is for the fresh water to pass through the membrane material This means that since the water production of the Spectra systems are nearly constant warmer water lowers the operating pressures The membranes are carefully sized to handle typical sea water temperatures and salinity keeping the pressures within limits set by the membrane manufacturers MPC 3000 System Control The Spectra MPC 3000 gives the operator complete control of the watermaker during normal operation through a remote touch pad control panel Four power outputs are available for optional devices such as an ultra violet sterilizer a Zeta Rod water pretreatment device etc Two inputs are available for optional tank full indicator float switches The system monitors and displays product flow product salinity feed pressure pre filter condition and total hours There are alarms for a stall condition high and low voltage high feed pressure contin
63. tution submersion shipping damage hoses and fittings not supplied by Spectra Watermakers improper membrane maintenance oil and chlorine damage use of sodium bisulfite or sodium metabisulfite or improper installation Consumables such as pre filter elements are not covered Spectra Watermakers under no circumstances shall be liable for any consequential damages arising out of or in any way connected with the failure of the product to perform as set forth herein This limited warranty is in lieu of any and all other expressed or implied warranties Spectra Watermakers reserves the right to make changes or improvements on its products without incurring the obligation to retrofit such changes or improvements on previously manufactured units If a possible warranty problem is detected please contact one of our service representatives before any disassembly for assistance and to receive a Return Authorization number if a component is to be returned for a warranty repair Proof of purchase return address and a Return Authorization number are required for all warranty repairs Ship to Spectra Watermakers 20 Mariposa Road San Rafael CA 94910 Phone 415 526 2780 Fax 526 2787 E mail spectra spectrawatermakers com page 50
64. uous high product salinity pressure differential across the pre filters and power interruption An intake line blockage sensor can be added If service is needed or a fault occurs audio and visual alarms will sound and the proper message will be displayed The system will automatically shut down if needed Power feed wires connect inside the enclosure The control module is powered by the ships DC system The feed pump may be a different voltage The MPC circuit board is housed in a control box with three switches located on the cover One is an emergency shut off The other two directly power the feed pump and the flush pump for servicing the system as in pickling procedures cleaning the membrane or emergency override if the controller fails For normal operation both pump switches must be on AUTO Feed Pump The feed pump is an 120V or 240V AC or 24 volt DC driven self priming stainless steel vane type with an adjustable pressure bypass The full bypass pressure is preset at 260 psi Partial bypass begins at approximately 220 psi The electronic high pressure cut out is set at 240 psi gt page 13 Component Description cont Flush Pump A 12 or 24 volt DC powered flush pump is used to fresh water flush the system at shut down It is also used to help the priming of the main feed pump at start up The ships domestic fresh water pressure is connected to the flush pump An adequate supply of pressurized fresh water must be mainta
65. upply the sailing itinerary is dictated by where you can get the next load of water With an unlimited supply a whole new set of choices emerge Once you get used to the benefits of a watermaker it is easy to think of it as a mission critical piece of equipment But it is a complex system with several components subject to failure though unlikely with proper maintenance Always carry enough water to make it to your destination without the watermaker The supply carried in reserve can be lessened as the passage goes to reduce weight but carry enough to get there Have enough spare filters and storage cleaning chemicals Periodically check the system performance especially the electrical supply at the system under load Electrical connections can go bad This is especially true for high load and charging circuits Inspect your charging system regularly With the Spectra there is very little to wear out as long as the system is properly maintained One of the most important components is the final 5 micron pre filter Do not scrimp there If there is any doubt as to the condition of the filter element replace it It s cheap insurance on your investment Any filters in front of the 5 micron filter are not critical as they don t have to be there for the system to work properly Just the 5 micron has to be good Filter elements are cleanable if they are cleaned before they start to resist the water flow If the filters get really packed up don t bot
66. w blade to prevent splintering Carefully run the remote cable between the panel and the main pump module Connect to one of the display sockets on the main circuit board inside the control module If access to the back of the panel is limited leave enough cable to be able to take the panel off for servicing Fold the extra cable back through the cut out and secure the panel with 4 screws Do not use non Spectra remote control cable The cable is not standard LAN cable There are terminals for an alarm buzzer on the back of the remote panel Caution Do not apply power to these terminals Fresh Water Flush Pump For remote mounting mount the flush pump close to the intake line for the feed pump ideally The pump inlet is connected to the ships pressure water supply The flush pump can be mounted vertical with the pump head down or horizontal The flush pump output connects to tee in the saltwater feed line as close to feed pump as possible The check valve must be install in the saltwater feed line upstream of where the flush pump tees into the feed line Strainer Mount the strainer close to the intake thru hull in an accessible area that can handle water spillage during service Extra care during assembly must be taken to avoid air leaks from the strainer while the system is running Air in the intake will damage the feed pump page 32 cc o8ed E Spect
67. wire connectors and wire ties with mounts 3 gallon minimum stainless steel or plastic mixing container e Fuses for AC and DC power connections Tools Required Wrench set to 7 8 e Adjustable wrench 3 8 drill drill index and a hole saw set e Jig saw or coping saw e Screwdrivers 5 16 nut driver for hose clamps not needed but helpful e Wire cutter Wire stripper e Electrical crimping tool for insulated connectors page 26 Monterey Installation Quick Start Important Details for Installer and Owner It is imperative that the system have a dedicated sea water inlet to guarantee a solid flow of water to the system The inlet should be as low in the boat as possible and a scoop type forward facing through hull fitting installed Do not operate the system in rough conditions if the intake through hull is taking in air or damage may result Make sure to follow the wire gauge charts in the instructions Using larger wire than specified is acceptable The MPC control must have DC power continuously to achive the full benefits of the fresh water flush system The domestic fresh water pressure must be on and the fresh water tank level maintained If these operational conditions present a problem consult factory The MPC control must be de powered after the system is put in storage or pickled where a storage chemical or antifreeze is run through the system If you are remote mounting the membrane a
68. y without a significant drop in feed and product flow rate are indicators As mentioned earlier the membrane will slowly degrade over time so cleaning can bring some performance back but not all Like a pre filter the idea is not to let a large build up of fouling occur before you try to clean the membrane which is hard or impossible to get off On the other hand cleaning itself is a bit hard on the membrane so you don t want to do it more than you have to Cleaning is similar to pickling except that you re circulate the chemical longer and try to heat it if you can Heating the cleaning chemical is something that has been largely ignored by the marine watermaker industry but is done routinely for commercial land based watermakers Heating the cleaning solution makes it work better just like with your laundry If you can t heat it just give the chemical more time to do it s job and hope for the best this has been the standard practice in the marine industry for years page 10 Component Description Note The Monterey frame components are pre plumbed and wired at the factory All installation plumbing connections are inside the frame Main power control power and remote panel wiring connections are made inside the power control module The Membrane array pre filter assembly and power control module may be removed and mounted remotely if necessary Clark Pump This is the heart of the system The Clark Pump uses two opposing cylin

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