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Newport 400 MPC 3000 Mag Drive User Manual

1. RRE M 13 Parker Tube Fitting Assembly Procedure iiec de rette Y He RUE 16 Wiin oet esce EL LEM 17 MPC Tank Switch Wiring and 222 23 Membrane Pressure Vessel RelocatiQn ee iebes un ge Pier oes a 40 Z Brane Installation eei ep e A a b EE iss ass 51 Operation New Systems Testing a n p s ua 24 Dry De ao cus nce elects acs 27 Normal Start Up Using the Auto Run eite ort I I restent 28 Automatic Fresh Water Flush Cycle 20 Manual asnu cu Eo 30 dak len adt tate ss 35 TOO OP OS a IN RR ea EUR ODE uu a 44 Service amp Maintenance Long Term Storage Procedures cinnsiot UTR sisted RISE a TERES d iiias 31 WW ADSI ZING EN 34 Membrane 36 Salinity Probe CaliDratton i ca dans ee T Ne ath 38 SUP SeSLeU Spares ee ooa d ed zea 39 Newport Troubleshooting Procedures Service
2. 42 Parts breakdown for all Newport Magdrive 2 54 Getting Started Unpack the system and inspect it to make sure that it has not been damaged in shipment Refer to the shipping list for your system to make sure you have received all of the compo nents listed Do not discard any packaging until you have found and identified all of the parts The small installation parts are listed on the cellophane bags pick list We will not be held responsible for shortages and or freight damage that are not reported within thirty days of the ship date Next study the system layout diagram component photos and descriptions before beginning your installation This will assist you in understanding the function of each component Layout the system Before starting the installation identify the location where each module and component will be placed Insure that there is proper clearance around the components for removal of filters and system service Also check to make sure you have adequate tubing and hose before starting so additional parts may be ordered Check to see that the MPC cable is long enough to reach from the display location to the main module Newport Mag Drive shipping list Newport Feed Pump Module High Pressure Clark Pump and Reverse Osmosis Membrane Module Newport Fresh Water Flush Module Newport Installation Kit 400 Newport Service Kit e 5 8
3. SPECTRA gt 5 NEWPORT MAGDRIVE INSTALLATION amp OWNER S MANUAL Spectra Watermakers Inc 20 Mariposa Road San Rafael CA 94901 Phone 415 526 2780 Fax 415 526 2787 E mail spectra spectrawatermakers com www spectrawatermakers com 9 15 05 Rotoflow Thank you for your purchase of a Spectra Newport system Properly installed it will provide years of trouble free service Please pay attention to the installation instructions and the sys tem layout Like any piece of mechanical equipment the system will require inspection and service from time to time Do not place the components in inaccessible areas that will pre vent proper maintenance If you are having a dealer install the system for you review the location of the components to make sure that the installation will meet your approval upon completion Newport Installation Quick Start Important Details for Installer The system must 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 with a scoop type for ward facing thru hull fitting installed 2 Both the Newport Mag Drive Feed pump module and the Clark pump Membrane mod ule must be installed in a well ventilated compartment where temperatures will not exceed 120F 48C Many engine compartments exceed this temperature when under way Warranty will be void if the installation does not meet this re
4. Press Auto Run button once and the system will prime and run for 1 hour The dis play 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 dis play shows the default readout unless there is an alarm condition Successive presses of the Alarm Display button will scroll through the displays starting with 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 5 days Pressing the Stop button stops the sequence at any time with no flushes Normal Operation For optimum performance Auto run the system as long as possible at one time Never let the system sit with salt water in it Never allow continuous air leaks in the intake Normal Shut Down e 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 every 5 days e Pressing the Stop button at any time will shut off the system with no auto flush function The optional tank float switches will shut off the system from any mode If the sys tem was started by the Auto Run button the system will flush and then re flush every
5. Newport Mag Drive 12V DC System Wire Length FT Meters AWG 10 3 10 15 4 5 8 20 6 1 6 25 7 6 4 30 9 4 4 35 10 6 4 40 12 2 45 14 2 50 15 2 Mag Drive 24V Meters AWG 10 3 12 15 4 5 10 20 6 1 8 25 7 6 8 30 9 4 8 35 10 6 6 40 12 6 45 14 6 50 15 4 Wire length for pair of wires is measured from source circuit breaker or fuse to control terminal block SQ MM 10 16 25 25 25 35 35 35 SQ MM 10 10 10 16 16 16 25 MPC Remote Control Display Panels There are currently two types of display options available Liquid Crystal Diode LCD display which is dark lettering on a backlit background or Vacuum Florescent Display VFD which are bright characters on a dark background The VFD demands more power from the MPC controller The displays must be mounted in a protected location out of direct sunlight and away from spray or dripping water Commands to the system can be entered at any panel The display panels connect with the supplied 50 foot modular type cable to the MPC board sockets marked DISPLAYS Do not substitute a different type of cable Contact the factory if you need longer or additional cables Each remote control display panel can accommodate an external alarm buzzer 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 LCD buzzer terminal is limited to 20 mA any excessive load
6. e Step 4 Connect the hose using the garden hose barb fitting from your service kit to the service port of the fresh water flush module Lead the hose into the bucket Turn the service valve on the fresh water flush module 180 so the intake is now coming from the bucket Step 5 Pump as much as possible of the water remaining inside the water maker overboard Set the switch on the pump module to Run Manual to turn on the feed pump Run the feed pump until you see antifreeze begin to appear in the brine overboard hose Set the switch to Run Auto to stop the feed pump e Step 6 Remove the quick disconnect fitting from the brine discharge outlet of the Clark pump and replace with the quick disconnect hose from your service kit and lead the hose to the bucket Step 7 Set the switch to Run Manual to circulate the antifreeze for about ten min utes Switch to Run Auto to stop the pump Clean Up e Remove the quick disconnect from the Clark pump brine discharge and replace the original hose that leads to the thru hull You may at this point if you choose to pump the bucket dry by using the feed pump switch Stop when the bucket is empty e Turnthe service valve 180 back to its original position and remove the service hose e Turn off the power to the system and the MPC control e LEAVE THE PRESSURE RELIEF VALVE ON THE CLARK PUMP OPEN 34 Maintenance General Periodically inspect the entire system
7. but can also be caused by a fouled membrane if the membrane has been left unpickled If the unit makes smelly but not salty water after a long idle period and the prefilters are new the smell can be eliminated by running the unit unpressurized for an hour or so to flush the membrane Odors in the product water can also be eliminated by adding a charcoal filter in the product water line Spectra offers a product water filter kit p n KIT FLT CC More on this subject is available on our website at www spectrawatermakers com 8 17 04 47 OP 4 FRESH WATER FLUSH The purpose of the fresh water flush is to replace the sea water in the watermaker with fresh water whenever the system is not operating The Auto Flush Mode changes the fresh water every five days if the system has been idle that long The watermaker will last longer and operate better if it is always kept filled with fresh water between uses Most spectra watermakers are equipped with a fresh water flush module This module in cludes a 50 micron filter to filter out abrasive particles in the feed water that might damage the feed pump a charcoal filter to remove any chlorine in the fresh water that might damage the membrane an electrically operated valve and a check or one way valve The electri cally operated solenoid valve opens during the fresh water flush allowing the boats pressur ized water system to supply water to the system The check valve prevents the fresh water
8. from going out backwards through the sea strainer and sea cock The charcoal filter has a maximum flow rate of 1 5 gallons per minute 6lpm so the feed pump 15 operated at a duced speed on some models or is cycled on and off on other models to avoid exceeding this flow rate If the ship s water system is unable to provide flush water at the required flow rate sea water will be drawn in to make up the difference This will cause the flush water to be brackish and ineffective in preserving the watermaker At initial startup the fresh water flush system should be tested by taking a sample of the brine discharge water just as the flush cycle is ending This water should not taste salty and should read less than 1000 ppm on a digital tds meter The flush cycle can also be tested by closing the sea cock during the flush cycle If the MPC 3000 display gives a CK SEA STRAINER alarm this means that the fresh water supply is insufficient Because the pre filters trap the plankton in the feed water they can be subject to going an aerobic or starting to smell like rotten eggs as the trapped plankton decay For this reason it is advisable to always put in clean elements if the unit is going to be left on Auto Flush Mode In daily or regular use the fresh water flush after each shutdown will help prevent this problem but in excessively warm or fertile waters the pre filters will need regular atten tion 7 26 04 48 PREFILTERS
9. trim back the tube so about 1 4 of tube extends past the O ring Step 3 Gently fit the tube into the body and loosely thread on the nut Be careful not to 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 NOT OVER TIGHTEN DO NOT USE A WRENCH The tube should not come out if pulled by hand If it does tighten the grab ring tabs 1 4 3 8 1 2 Parker Tube Fitting Assembly Wiring Identify cables that are connected to the Newport Control System Newport Magdrive Systems have a Power Inlet harness with a terminal block Fresh water flush harness and Clark pump module harness consisting of the Rotoflow cable salinity ca ble and the diversion valve solenoid leads A 50 15M cable with connectors is supplied for the MPC 3000 control display Fresh water flush harness Power inlet harness with terminal block p 50 15M cable with connectors for the MPC 3000 control display gt Diversion valve s p control feed Connector for Rotoflow sensor Clark pump module harness Wiring continued Mount the main power terminals or junction box on a bulkhead adjacent to the feed pump module Make sure that this is a dry location well above bilge level and not subject to water spray Route the control cable through the boat to the MPC display location Be careful not
10. 1 forward facing scoop type intake thru hull and seacock be installed Install the intake for the system close to the middle and as far below the water line as possible Thru hulls in the bow area are susceptible to air intake in rough condi tions Sharing a thru hull with another system is not acceptable and will void the warranty Sharing a thru hull can introduce unforeseen problems such as intermittent flow restriction air bubbles and contaminates For racing boats and high speed power boats above 15 knots a retractable snorkel 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 downstream of a head discharge Install as far below the waterline and as close to center line as possible to avoid contamination and air induction The brine discharge through hull should be mounted above the waterline in or just above the boot stripe to minimize water lift Double clamp all hose connections below the waterline Pipe Fitting Instruction Plastic to plastic fittings should have 3 to 4 wraps of Teflon tape and will thread almost all the way in Avoid getting dirt or debris into the piping or hoses during assembly A small bit of de bris can stop the system Avoid getting tape over the end of fittings that might get into the system To insure this does not happen leave the very first thread uncoated Avoid restrictions or long runs on the entire inlet side of the plumbing
11. 24 volt DC has been shut off the system will prompt you through the purge mode when it is turned back on This is because the only time the MPC 3000 should be turned off is after the system has been pickled Purge Mode prompts the operator to open the pressure relief and then runs seawater through the system for 20 minutes to clear away the chemicals Normally during periods of disuse the MPC 3000 will remain powered up so that it can do the five day flush cycles and no storage solution will be present If the control power has been interrupted but the system is not filled with storage solution Purge Mode can be bypassed by tapping the two left hand buttons at the same time until the display reads PURGE MODE BYPASSED The buttons must be pushed at exactly the same time You can t hold one down and then push the other From Purge Mode By passed you can run the system in any mode 4 20 04 WINTERIZING OR PICKLING W ANTIFREEZE WARNING Use only propylene glycol based drinking water system antifreeze Do not use ethylene glycol based automotive antifreeze which is toxic Propylene glycol can be used instead of Spectra SC 1 storage chemical for storage in any climate up to one year following this procedure Replace the prefilters with clean ones Flush the system with fresh water until the brine discharge water is below 1000 ppm or until the brine discharge does not taste salty 3 Setup the system for pickling according to the directi
12. 5 days If the system was started by the Start Stop button it will do a 1 time flush The display will read TANK S FULL Once one of the tank float switches opens the alarm and TANK S FULL display will cease on its own Note that if TANK S FULL is displayed the system cannot be restarted 28 Automatic Fresh Water Flush Cycle Warning Proper 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 be allowed to drain all the fresh water from the vessel or damage to the vessel s systems may occur Make sure there is enough water in the fresh water supply system to supply the water maker for more than the expected time of operation in the re flush every 5 days mode The 700 1000 units require 6 gallons 24 liters every 5 days Make sure that the pressure water supply is on and will stay on during the flush mode If this is not possible contact your certified dealer Make sure that the pressure relief valve is closed It should be closed if the system was just used to make water The auto flush may not operate if the valve is open The power for the system must remain on during the auto flush mode Turning off the power will disable the auto flush function and damage may occur Pressing the Auto Store button momentarily will start a flush and then activate the 5 day flush cycle The feed pump will star
13. FILTER 50 MIC FILTER CHARCOAL FILTER 6 STRAINER SCREEN OIL W ATER FILTER FEED PUMP HEAD 6 STRAINER O RING FILTER HOUSING O RING OFF SHORE KIT 20 MEMBRANE 40 MEMBRANE Part Number P N FT CHE SC1 FT CHE SC2 FT CHE SC3 KIT BCK C FT FTC 5 FT FTC 20 FT FTC 50 FT FTC CC FT STN 6S FT FTC OW PL PMP 140MAG SO STN 6SS SO FHS 10H KIT OFFSH FT MB 20 FT MB 40 39 Membrane Pressure Vessel Relocation Use ONLY Dayco Imperial Nylo Seal 88 NSR 1 2 tubing for high pressure connections Pay attention to the direction and flow path of the tubing before disassembly Make sure that you reinstall the tubing in the same manner Rotate the 90 degree high pressure tube fittings on the Clark pump for ideal tube runs The high pressure fittings are typically pre installed at the factory These fitting seal with an O ring and require no Teflon tape or pipe dope Loosen the backing nut rotate the fitting and reseat the backing nut Follow the high pressure tube connection instructions on the next page Connect the tubes to one of the components secure the tube runs and then trim and connect to the other component A 90 degree bend in a tube is better than a 90 degree fitting A tube when mounted should have at least one gentle bend to allow for expansion Do not connect a tube straight between hard mounted fittings When connecting the tubes to their components be sure to hold the fitting body with a wrench during the final tightening
14. Pump Back view End cap 58 5 16 3 1 4 SS AH Bolts HD CPS 5 16X3 Relief Valve O Ring SO HPP RV Annular Ring O Rings Mount inside Valve Block HPP AR Valve Block HD CPS 5 16275 5 16 2 3 4 SS bolts Reset button and O ring 3 End block B 3 so HPP sP Ps20 Piston O ring c A HP TB VSP VSP20 Spool piston HP TB SR Spacer ring ct an Valve block J SO HPP VB Valve bore O ring 4 Valve bore Spacer ring Ole End block A Brine port O ring SO HPP VP Valve spool Pilot port O rings SO HPP PLP 8 Reversing Valve v End Blocks 59 Valve port seals SO HPP VP Pilot valve port seals SO HPP PLP Piston rod HP CYL 7 8R Center block cylinder O rings SO HPP ECCB 5 R Pilot spool O rings 4 Mount inside block SO HPP PV D Q 2 HP CB PVS Pilot spool HP CB PPS Pilot valve pin SO HPP PS Pin seal O rings HP CB PVPS Pin seals Pilot orifice HP CB PO HP CB PVCR Clip rings Center block Rod lip seals Mount inside block SO HPP PR7 PR10 PR15 Feed in Check valve port O rings SO HPP CVP Check valve assembly Piston to rod O rings 2 Inside pistons Glass rod models only Center Block Check valve seat HP CB CVS Check valve SO HPP CVS A O ring Check valve poppet HP CB CV Check valve spring HP CB SPR Check valve washer Check valve retainer HP CB CVSW HP CB CVR 60 S S compre
15. ST SALINITY PROBE PL HBE 1 2X5 8 k 1 2 5 8 HOSE BARB r ELBOW PL CLP 8SS 8 HOSE CLAMP EL MTR SPCDC 3 4HP SPEED CONTROLLER 24V EL MTR SPCDC12 3 4 HP SPEED CONTROLLER 12V EL FN 12V 12 Volt Fan EL FN 24V 24 Volt Fan N Busse M PL UNN 3 8X1 4N LOW METER SENSO L4 REDUCING BUSHING 4 SUB NP MNF NEWPORT INTAKE MANIFOLD EL SWT VC VACUUM SWITCH EL MTR 1 6D12 12 Volt Motor EL MTR 1 6D24 24 Volt Motor PL HS 5 8SH 5 8 REINFORCE SUCTION HOSE PL HBS 3 8X5 8 3 8 MPT X 5 8 HOSE BARB STRAIGHT PL PMP140MAG Feed Pump Head z PL MTE 3 8X1 2P 3 8 MALE NPTX1 2 TUBE FITTING ELL 54 a E MPC CONTROL PANEL VFD EL MPC RMCDF RUBBER MOUNT HD RBP RM Z BRANE END CAP ASSY WITH ROD SUB ZG ZB 3 4 16 ST X 1 2 TUBE FITT ELL SS PL MTE 3 4SX1 2 Z BRANE POWER SUPPLY SUB ZG BSZBPS REJECTION MEMBRANE 40 FT MB 40 1 2 HIGH PRESSURE TUBE 1 2 LOW PRESS TUBE DAYCO PL NLT 1 2HP PL NLT 1 2LP 55 3 8 MPT X 3 8 TUBE FITT ST PL MTS 3 8X3 8P 3 8 NPT X 1 4 TUBE FITT ELL PL MTE 3 8X1 4 1 4 MPT X 3 8 TUBE FITTING ELBOW PL MTE 1 4X3 8P 1 8 FEMALE NPTX1 4 TUBE FITTIN ELL PL FTE 1 8X1 4P 1 8 NPT NIPPLE NYLON PL NP 1 8N 3 8 MALE NPTX1 2 TUBE SS FITT ST MEMBRANE END PLUGFT PV EP BIL MIS SBXU2S Z BRANE MEMBRANE END PLUG FT PV ZEP Probe end ACCUMULATOR PL ACC TK FT PV ZEPB Ground End 1 2 PLUG PL HP 1 2N TEE PL TEE 1 2X1 2T
16. and intake hoses Salinity High high product water salinity chlorine damage to mem branes defective salinity probe or cable cable disconnected Check for low feed pressure Check for leaks at high pressure hoses Remove and clean probe con tacts check calibration Check cable connections Clean membrane 43 Operation and Repair Bulletins The following documents are sections of our complete service bulletin set These are available on our website Spectratermakers com MB 2 MEMBRANE CARE Membrane life is affected by a large number of factors and is somewhat unpredictable A big commercial plant running 24 7 will get 10 to 12 years out of a set of membranes But they do all kinds of fancy chemical injections and never shut the thing off Most cruisers are lucky to get five or six years out of one You hear of the eight or ten year old membrane now and then The biggest killers of membranes are lack of use chlorine damage and improper storage Don t let membranes sit around with sea water or stale fresh water in them Biological growth will occur in the membrane Here at the factory we frequently get back membranes for inspection that reek of hydrogen sulfide rotten eggs This odor is produce by anaerobic bacteria that live in an unused membrane feeding on whatever animal or vegetable matter is trapped in it from the plankton that gets through the system Membranes badly fouled in this way can seldom be
17. may damage the controller or remote display panel Connect the buzzer RED wire to the terminal marked POSITIVE connect the buzzer BLACK wire to the terminal marked NEGATIVE on the back of the remote display panel A buzzer may also be installed at the control box current limit is 150mA 3000 REMOTE PANEL BACK SIDE This buzzer output terminal is 20mA MAX current limit DO NOT CONNECT POWER TO THESE TERMINALS ALARKA ELIZZEFI FLEITTFI L UUWIMELT TO PC HOARD Pressure Sensors The pressure sensors are mounted on the filter housings to monitor system pressure 5 A SPECTRA and differential pressure across the filters Nt If the wire leads for the sensors must be extended you must use a minimum 18AWG 3 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 Rotoflow Sensor The Rotoflow sensor measures the fresh product flow and sends a pulsed signal to the MPC 3000 control If no flow is sensed then the MPC will fault with the code SYSTEM STALLED Product water to tank E Check Rejected Product Product water from membranes Salinity Probe _ Rotoflow meter Diversion Valve Salinity Probe Rotoflow Assembly This assembly is located at the Clark pump Memb
18. saved These bacteria are always present but are inhibited by the oxygen in sea water while the unit is in frequent use by scheduled fresh water flushes or by pickling Keeping the prefilters clean is also important in preventing bio fouling If your prefilters are allowed to become a breeding ground for bacteria get smelly the contamina tion will spread throughout the system When we cut open a failed membrane we also find mildew another form of bio fouling probably due to long term storage with no biocide or stale biocide After many hours of water making mineral deposits will form and must be dissolved away with an acid cleaner Alkaline cleaners are used for bio fouling Cleaning chemicals espe cially the alkaline are not good for the membrane Every time you clean the membrane it shortens its life Clean only when necessary and avoid cleaning as a diagnostic tool Chlorine will destroy a membrane in minutes It attacks the material that the membrane is made from Always use product water or water filtered slowly through a charcoal filter for flushing and chemical treatments Oil simply plugs up the matrix of the membrane and clogs it up We have brought back oil fouled membranes with Joy soap See MB 5 Cleaning with Detergent For storage we recommend using propylene glycol potable water system antifreeze if avail able It can safely be left in the system for one year and will keep things from freezing in cold conditions It i
19. the chart on the next page Product Flow Newport Mag Drive Will produce 14 16 GPH 54 60LPH NOTE To toggle between GPH and Liters push and hold Alarm Disp for 5 seconds Salinity Salinity reads in parts per million Sys tem rejects water higher than 750 PPM Anything below 500 is excellent Nominal Feedwater Pressure Pressure range 90 115 PSI 7 8 BAR Pressure will be higher in cold water and lower in warm water Extreme sa linity or temperature conditions may result in operating pressures outside of the nominal range Filter Condition Alarm occurs when filters are partially clogged When filters are completely clogged system shuts down and alarm sounds again 26 Dry Testing With Artificial Ocean If it is not possible to test run the system with the boat in the water testing may be accomplished with an artificial ocean Purchase enough aquarium salts to make 5 gallons 20 liters of salt water Make sure that the domestic water system is powered up and that there is water in the tank Confirm that the Charcoal filter is installed in the Fresh water flush module and that the domestic water line had been installed and all valves are open 1 Open Pressure Relief Valve Power up the control system 3 Press both Auto Run and Stop to bypass the purge sequence If the motor starts stop imme diately and press the Auto run and stop button again until you get a message PURGE MODE BYPASSED 4 Pr
20. you will need double pole double throw switch 23 New System Start Up and Testing Avoid running the system if the vessel is in contaminated water such as in a harbor or ca nal The system should be fully run tested before leaving port It is preferable to sacrifice a filter by running the system in turbid water rather than waiting to get offshore to discover a problem or deficiency in the installation If the location or weather prevents proper testing refer to the section Dry Testing Warning Damage may occur if the purge sequence is bypassed and the membrane is pressurized with storage chemical in it 1 First Check That Thru hull valve is open Run Manual Run Auto Flush Manual Switch in Run Auto Position Domestic fresh water pressure system must be 2 Open pressure relief valve 1 2 turn 3 Power up the system e Alarm will sound Push the Alarm Display button to silence alarm 24 4 Press Auto Run Button m The system will go into a start 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 priming If the feed pump continues to sound rough find the reason before con tinuing Inspect the system for leaks Note If you must stop the purge sequence for any rea
21. 4 COUNTER SUNK HEX PLG 3 45 1 2 SO HPP PLP 3 4 MPT ST X 1 2 TUBE SS FITT ELL SO HPP PS SO HPP VP SO HPP CVS CHK VALVE SEATS SO HPP CVP CHK VALVE PORTS SO HPP VB VALVE BORE SO HPP ECCB END CAP amp CENTER BLOCK SO HPP AR SO HPP PV ANNULAR RING PILOT VALVE SO HPP RV RELIEVE VALVE SO HPP CT CONNECTOR O RING SO HPP SP1 SPOOL PISTON O RING 1 SO HPP Q QUAD SEAL 10 20 PISTON ROD 2 11 2005 62 63
22. 5 minutes Allow to soak for several hours or overnight if the solution is cold Run the pump occasionally to agitate the solution Set both switches to Auto when finished e Step 8 Turn off the control system DC power to reset the MPC 3000 controls Replace the brine overboard hose Remove the Inlet Service hose and turn the Service valve to the Run position Step 9 To avoid damaging the membranes Follow the New System Startup In structions to Purge the chemicals out of the System 37 Salinity Probe Calibration Salinity is a measurement of TDS total dissolved solids in liquid these solids will conduct elec tricity to varying degrees A special probe is used with two electrical contacts in it to determine the resistance to the flow of electricity in the liquid In the Spectra Watermakers systems the salinity probe is located just before the diversion valve at the output of the RO membrane This way we can look at the salinity level of the product water before deciding to either reject the water or accept it and divert it into the holding tank The salinity level in parts per million can be seen either through the salinity meter in the soft ware or a jumper can be added to the MPC board in the calibrate position where it can then be seen on the LCD display rather than a bar graph After adding the jumper it may be necessary to cycle through the different LCD displays until the display reads salinity Proc
23. 8 wrench for the nut Hold the body recheck the tube insertion then tighten the nut 1 1 4 turns Use the index mark on the nut as a guide The threads should be completely covered by the nut Make Sure these fittings are tight on initial assembly or they will fail The correct Torque is specification is 85 foot pounds yo X Straight T Straight or 90 deg 3 8 pipe Fa KW Ferrule Body Nut finger tight with P thread showing Cut tube square Figure 2 i Tighten 1 2 3 turns 10 flats of the nut with 7 8 wrench after finger tight Use index mark as guide yo No threads showing Figure 3 Insert tube 0 9 until it stops I IMPORTANT Hold fitting body with 13 16 wrench when tightening Spectra Watermakers Newport Troubleshooting Procedures SYMPTOMS PROBABLE CAUSE REMEDY Feed pump runs constantly will not turn off Manual override switches in on position Turn off manual switch on control box Feed pump runs with loud noise Intake blocked Air in system Check thru hull valve Check sea strainer for leaks Check FWF module for leaks Re prime system restart No lights or display system does not operate Remote display not connected No power to control box Check display cable connec tions at back of display and at control box Check and reset main DC supply breaker Check for voltage 12 or 24vDC at control box pow
24. ELBOW PL MTE 1 2X1 2P BRACKET PLATE END FM PB PBE HOSE BARB PL HBS 3 8X5 8 TUBE FITTING PL MTS 1 2X1 2P NIPPLE PL NP 1 2X3 8N TEE PL TEE 1 2FN 56 3 8 LOW PRESS TUBE PL NLT 3 8LP 4 2 ii 1 4 MPT X 3 8 TUBE FITTING ELBOW 4 PL MTE 1 4X3 8P 3 4NPTX1 2 HOSE BARB NYL ELL PL HBE 3 4X1 2 3 4 MPT X 3 4 HOSE BARB ELBOW PL HBE 3 4X3 4 LOW PRESSURE FILTER HOUSING FT FTH 10L GARDEN HOSE CAP PL GHF GC 3 4 MPT X 3 4 HOSE BARB ELBOW PL HBE 3 4X3 4 3 4 3 WAY VALVE PL VLV 3W3 4 FRESH WATER FLUSH MODULE BRACKET 50 MICRON FILTER ELEMENT CHARCOAL FILTER FT FTC 50 FT FTC CC 3 4 NPT X 3 4 HOSE BARB ST PL HBS 3 4X3 4 NOTE LOCATED INSIDE ARE 1 CHECK VALVE PL CKV 3 4F F 2 SOLENOID VALVE PL SLN1 4D12 12 VOLT PL SLN1 4D24 24 VOLT 3 8 NPT QUICK DISCNT COUP 5 8 QUICK DISCNT FITT HOSE BODY BARB PL QDC BD3 8 PL QDC HB5 8 57 End block B HP TB VEB B1 Valve block HP TB VB End block A ee cylinder Brine out Pressure relief valve HP TB BV 2 Center block 10 E Feed in Stainless steel tube HP CYL SST Cylinder ring no Clark Pump HP CYL EC End block A Valve block End block B Res tton Not ji UD ng B Composite cylinder and base Alternate brine out High pressure in Test port Center block High pressure out L Stainless steel tube Cylinder ring Clark
25. Hose 25 e 3 4 Suction Hose 25 Newport Schematic Da nat tha contra Cable cs e sni Factory supglied came DC Versians il eee rig prestune vessel consul HP maudis Pump pressure relic aive mesi be acoessible Brine discharge Location nel critical Poser brech ss sagene for 12v a breaks ad samene for Dy cee wire sire chard iratai pump re e ale pes ioa as peres Within Three feet 1 2M OT the watestine Bees inia piping 25 stertand direct passible avoid Sight besds and restrictions Strainer is optional EAR RR RAE R RR AAA AU US MOT GI RI GIG i C N M UR E RUE TOR Tm ORDER RE UR T RARE eS A w OOOO ii d dr dr d db qi h p OOOO a dp d to do t de YS A A A A A RR RET EDU UU RU UI RUD A UI I UU UK I AA UR RU ORI EIR T Fe I Install a dedicated 3 4 thru hull with a scoop type strainer Place the inlet a low as possible with scoop facing forward Avoid turbulent areas Installation Basics Thruhull Not Supplied Read the directions e Avoid tight hose bends and excessive runs Use heavy gauge wire Install feed pump as low as possible p Use a dedicated thruhull with scoop type strainer d Flow Thru hulls It is mandatory that a dedicated 3 4 to
26. Of special note are the stainless steel tube fittings on the membrane housing seal on an O ring and should be seated all the way in Hold the fit ting with a wrench while installing the tube The fittings on the Clark pump have an O ring seal and can be re oriented by backing out the O ring Stop nut Rotate the fitting to align with the tube and tighten the nut just past hand tight Do Not over tighten 40 Spectra High Pressure Tube Fitting Assembly Use ONLY Dayco Imperial Nylo Seal 88 NSR 1 2 tubing for high pressure connections Carefully fit and measure the tubing before cutting with a sharp razor knife or hose cutter and remove any burrs Minimum tubing bend radius is 6 Route tubing away from excessive heat sources and secure from vibration and chafe Have at least one shallow bend in a tube assembly after it is installed Refer to figure 1 If a fitting has been dissembled reassemble as illustrated The notch 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 a 90 body and a 7
27. VANE PUMP SYSTEMS Five different filters are used on these Spectra Watermakers to make sure that no damaging foreign materials enter the system There are four filters in the system to clean the feed wa ter of abrasive materials while the system is in operation and a fifth filter that prevents the entrance of chlorine during fresh water flushing During normal operation the feed water is filtered in two stages First it enters a fine mesh metal sea strainer then passes through a fifty micron pleated cellulose filter These protect the vane pump from damage due to abrasion from silt and hard shelled plankton found in the feed water After passing through the pump the feed water enters the filter housings contain ing 20 and 5 micron elements These filters remove very fine particles which could damage the Clark pump and which would shorten membrane life Cleaning schedules will vary widely depending on how and where the system is used If large amounts of feed water are run through the system in a relatively short period in bio logically fertile near shore waters the prefilters will plug up the pressure drop across the filters will rise product production and quality will drop and the system will sense plugged filters and give a service prefilters or check strainer alarm if so equipped Plugged filters can be cleaned several times by soaking in a bucket towing behind the boat at moderate speeds or hosing them off When operated only an hour o
28. Yms eNUeN USDIH UNA 1978M 59 8 ouo dogg MD peusiur USUM do1S 1191S sso1q oum puooes uiojs s YSN o USNJA OJNV ssod uou J99UB9 oj SI USNJJ UUM do1S 193S 68914 Ae dsrp GOT uo USNJ4 oin y Surssoyd Aq USNJA I 4936 SOJNUNU 0 10 uni dund Yms enueur uny dund os L 4936 33 Storage amp Winterizing Warning Use only potable water antifreeze Propylene Glycol Do not use automotive antifreeze Ethylene Glycol Propylene Glycol is an effective biocide and antifreeze only at concentrations above 25 Commercially available products range from 25 to 60 percent They are usually labeled with a temperature rating Minus 50 antifreeze is already diluted to 25 Minus 100 is a 60 solution Purchase the strongest antifreeze available Use enough to ensure that the system contains at least a 25 solution even after dilution with the residual water inside the water maker e Step 1 Flush the system for 12 minutes using the manual operation switch Set the switch to Flush Manual water maker will begin to flush itself To stop the flush Set the switch to Run Auto Step 2 Open pressure relief valve on the Clark pump e Step 3 Pour the propylene glycol into a bucket Follow the instructions on the con tainer
29. and scale protection We recom mend that your watermaker be flushed after each use not only to protect the membrane but to prevent corrosion in the feed water system To achieve full effectiveness thoroughly fresh water flush the watermaker several times before leaving the vessel The Z Brane may be de powered if the system is stored with chemicals or winterized with Glycol Power on LED High Voltage connector DO NOT DISCONNECT OR SPLICE ANY OF THE HIGH VOLTAGE WIRING Contact the factory if modifications are required 53 NEWPORT MAG Parts EL SWT TGSDPDT FM MPC MPCB S P S T ON OFF ON SWITCH EL SWT TSBHC MPC BOX TOGGLE SWITCH B SPECTRA SEAL w T EL SSR 150 j PRESSURE TRANSDUCER EL SSR PSH 150 PSI PRESSURE SENSOR PL MFF 1 4X1 4 CABLE 1 4 MPT X 1 4 ELBOW NYLON PL HBE 3 4X5 8 3 A MALE NPTX5 8 HOSE BARB ELL NYL PL CLP 8SS 8 HOSE CLAMP PL MTE 3 4X1 2P 3 4 MPT X 1 2 TUBE FITTING ELBOW FT FHB 10HD PL NP 3 4N FT FTH 10H HIGH PRESS HOUSING f BRACKET DUPLEX 3 4 CLOSE NIPPLE NYLON HIGH PRESSURE FILTER HOUSING PL SLN 1 4D12VB 1 4 DIVERSION VALVE 12V W O VB PL MTE 3 8X1 4P PL SLN 1 4D24VB 1 4 DIVERSION VALVE 24V W O VB 3 8 MPT X 1 4 TUBE FITT PL CKV 1 4M F ELBOW 1 4 PLASTIC CK VALVE M F i PL MTS 1 4X3 8P 1 4 MPT X 3 8 TUBE SUB NP DVM FITT ST DIVERSION VALVE MANIFOLD yooo __ PL FTS 3 8X1 4P EL MPC SP 3 8 FPT X 1 4 TUBE FITT
30. ed by the US Navy It is formulated to be com patible with the modern engineering plastics and composites in the Spectra pumps Do not use any substitute except propylene Glycol SC 1 Storage Compound has to be mixed at a ratio of 1 Spectra container to 3 gallons 12L of fresh water to have the proper solution An average of 2 gallons 8L of water is in a NP Magdrive system This water has to be figured in to the mixture A NP Magdrive system uses one SC 1 container Caution Avoid contact with skin eyes or lungs with the storage chemical ig raz 4 ut geen Il capers 1 palin 419 1 VOUT the 2 1 sal for aw i PPEP SS 31 Storage Procedure Step 1 Flush the system twice Press the Auto Flush button on the LCD display once the first flush has been completed press Stop to cancel the 5 day interval timer then press Auto Flush again Step 2 Remove the quick disconnect fitting from the brine discharge outlet of the Clark pump and replace with the quick disconnect hose from your service kit and lead the hose to a 5 gallon bucket Step 3 Set the Manual Operation switch on the Feed pump module to Flush Manual to fill the bucket with 1 gallon of fresh unchlorinated water Set the switch back to Run Auto when the bucket has reached the desired level Step 4 Connect the hose using the garden hose barb fitting from
31. edure 1 Locate the Calibrate jumper location on the MPC 3000 Board Jump the terminals 2 Start the system and after the salinity stabilizes test the product water with a calibrated hand held tester 3 Locate the MPC calibration trimmer potentiometer on the board below the salinity probe jack Adjust until the display PPM matches the PPM reading from the hand held salinity monitor Turning the trim pot clockwise will lower the salinity reading and counter clockwise will raise it 4 Shut the system down and disconnect the jumper on the MPC board If a hand held meter is not available you can remove the probe and dip it into a known calibrated solution This can be obtained from Spectra CALIBRATION ADIUSTMENT CALIBRATION JE MER 38 Short term cruising weekends etc Suggested Spares We suggest a basic cruise kit Kit consists of 3 ea 50 micron 20micron and 5 micron filters and two SC 1 storage chemicals Cruising 2 to 6 months at a time Two basic cruise kits One each replacement charcoal filter One replacement feed pump head Longer than 6 months Additional filters offshore cruising kit consisting of Clark pump seals O rings tools and membrane cleaning chemicals One replacement strainer screen O ring for strainer screen O rings for filter housing Spectra Watermakers parts list SC 1 STORAGE CHEMICAL SC 2 CLEANER SC 3 CLEANER BASIC CRUISE KIT C 5 MIC FILTER 20 MIC
32. er input studs Try manual bypass switches if pumps run then control or display is defective Pumps run intermittently cycling on off System operating in flush mode DC models System will time out or manually stop with the Start Stop button Display activates but pump will not run loose or broken pump wire connection bad pump relay blown F3 or F5 fuse on MPC tanks are full Check wiring at terminal block inside MPC Test power relay replace Replace fuse mini automo tive type ATM Check tanks system cannot be started if tanks are full System runs no product water delivered to water tanks GHP bar graph shows OK Good LED activated diversion valve inoperative wiring fault disconnected or broken product tubing diversion valve plunger Check wiring at diversion valve and inside control box Check product tubing Disassemble and clean diverion valve plunger or re place valve contact factory System runs no product water delivered to water tanks GPH bar graph shows OK reject LED activated high salinity of product water causing system to reject water salinity probe out of cali bration or defective bad cable chlorine damage to mem branes pressure relief valve open Check for low feed pressure close pressure relief valve Check for leaks at high pres sure hoses Test product water with hand held tester if over 500 for 1 hour con
33. er has to be figured into the mixture A 400 system will use 1 container of compound SC 2 and SC 3 are never mixed together Do not use them for storage pickling solution Cleaning Procedure e Step 1 Flush the system twice Use the Auto Flush button on the MPC 3000 display once the first flush has been completed press Stop to cancel the 5 day interval timer then press Auto Flush again Step 2 Remove the quick disconnect fitting from the brine discharge outlet of the Clark pump and replace with a quick disconnect from your service kit fitted to a hose and lead the hose to a 5 gallon bucket Step 3 Press Auto Flush again to fill the bucket with 1 gallon 4L of fresh unchlori nated water Press Stop when the bucket has reached the desired level e Step 4 Connect a hose using the garden hose barb fitting from your service kit to the ser vice port of the fresh water flush module Lead the hose into the bucket Turn the service valve on the fresh water flush module 180 so the intake is now coming from the bucket Step 5 Mix the cleaning chemical compound into the water in the bucket Step 6 Make sure the pressure relief valve on the Clark pump is Open unpressurized e Step 7 Use the Run Manual switch on the MPC control box to turn on the feed pump Circulate the storage chemical in the system for approximately 25 minutes Circulate the chemical in the system for approximately 2
34. ess the Auto Store button and allow the fresh water flush system to cycle through its timed op eration Cycle the auto store system 5 or more times to purge all of the storage chemicals out of the system 20 minutes total purging 5 Hook up your service hoses per the service diagram and photos Route them into a 5 gallon 20 Liter bucket Disconnect the product tube from the diversion valve and using another short piece of tube route the product water feed into the test bucket 6 Turn the valve on the fresh water flush module from Run to Service 7 Press auto flush one or two more times to get enough water into the bucket to properly mix your salt water Mix the salt until it goes into solution If you are using a hydrometer mix the water to be 30 000 PPM Close the pressure relief valve and start the system using the Auto Run But ton 8 Run and test the system for as long as possible During the run test carefully inspect for leaks Check all of the system parameters to make sure the system is operating correctly Do not allow the water in the bucket to get above 120F 50C 9 Store the system per the Storage instructions Outlet Service Port Hd 117227 DEZ Sui Inlet Service Port I Ehem 7 27 Normal Start Up Using the Auto Run Button If the system contains preservative or cleaning chemicals follow the directions for New System Startup or Membrane damage will occur
35. for leakage and chafe on the tubing and hoses Repair any leaks you find as soon as practical Some crystal formation around the Clark pump blocks is normal Wipe down any salt encrusted areas with a damp cloth The Seawater Strainer and 50 Micron Filter The sea water strainer s stainless steel element should be inspected removed and cleaned as needed A clogged strainer or 50 Micron filter will cause the MPC control to alarm Check Sea Strainer Be careful to ensure that the thru hull is closed before disassembly and the seal and element are in place before reassembly Put the screen up to a light for inspection When the system is put into storage remove rinse and reassemble dry to impede corrosion Check frequently during operation The 50 micron filter needs to be properly maintained to protect the feed pump Only use Spectra approved filters These may be cleaned several times before discarding The Prefilters Service the prefilters as soon as possible after the first prefilter alarm sounds When the second alarm sounds the system will shut down to prevent damage If cleaning and re using filter elements clean when the first segment appears on the filter condition bar graph on the LCD display To service the filters shut off the thru hull open the housings discard the old filters Clean out the housing bowls reassemble the housings with new 20 and 5 micron filter elements The 5 micron filter goes downstream from the 20 micro
36. from the thru hull to the main feed pump module Prevent tight bends and excessive elbows Any restrictions will hamper system performance Secure the piping away from moving objects such as engine belts and hatches Prevent chafe on the tubing as required Test and inspect all piping and hose clamps after several hours of operation Wiring Pay attention to wire size or system performance will be impaired Perform wiring to UL ABYC CE or applicable standards Component Placement L Refer to the Plumbing Diagrams Strainer 4 ROMS Mount the strainer in an accessible area close to the intake through hull that can handle water spillage during service Extra care during assembly must be taken to avoid air leaks from the strainer Use the supplied Quick Block and wire tie for mounting Fresh Water Flush Module The fresh water flush module should be located between the intake strainer and the feed pump Module and as low as possible in the vessel It should be mounted with the filter housings vertical and accessible for changing filters Allow 2 below the filter housing for removal Do not install over electrical equipment Remove filter bowls for access to the screw holes in the mounting plate The unit contains a 50 Micron prefilter charcoal filter for the flush water flush solenoid and three way intake service valve Optional Z Brane The optional Z Brane Water treatment system is permanently installed in the membrane press
37. ia begin to grow causing the odor If a unit being used frequently begins to make smelly water it will be the prefilters that are the source of the problem This occurs in a week or two in cold climates but in less than one night in very warm waters like the Sea of Cortes or Red Sea These bacteria can spread throughout the watermaker and begin to grow on the membrane causing poor water quality and high feed pressures Filling the system with fresh water after every use greatly slows this process allowing the automated spectra units to operate with less frequent prefilter changes but units operated for only an hour or so a day will probably need to have the filters changed due to odor before they are dirty enough to restrict water flow Prefilters can be cleaned We recommend that you have three sets in service one in the unit one set soaking overnight in a bucket of clean fresh or salt water and one set drying for the next use After shutting down the unit remove the used prefilters and install the dry set Leave the housings full of air until the next use On non automated systems open the pressure relief when starting if there is a lot of air in the system until the air is cleared out through the brine overboard The filters will get just as clean when soaked in sea water but dry much faster if soaked in fresh Given gentle han dling prefilters can be reused many times Bad smelling product water is usually caused by bad smelling feed water
38. ischarge service hose and lead to a bucket Open the pressure relief valve one turn and manually run the system for 30 seconds Examine the brine water if it s discolored and smells bad perform an SC 2 cleaning with an alternate source of unchlorinated water before running the system pressurized If the brine is fairly clean the system can be purged run normally and checked for performance Clean the membranes only if per formance is reduced Heating the water is preferable One way to do this is to find a camp stove and use a large stainless steel pot to heat the solution in The cleaning solution throughout the system will heat as it circulates in and out of the pot An alternative is to heat the one or two gallons of initial water to 120 on the main stove before mixing in the cleaner and circulating it into the system Periodi cally stop and reheat the solution Perform the cleaning procedures while the ship is in acceptable sea water for purging and testing 36 Note Procedures are the same for the SC 2 and SC 3 cleaners Warning The pressure relief valve on the Clark pump must be open for this procedure or membrane damage may result Maximum pressure 50 psi A Spectra Cleaning Compound SC 2 or SC 3 must be mixed with fresh water at a ratio of 1 con tainer of compound to 3 gallons 12L of unchlorinated water to have the proper solution An aver age of two gallons 8L of water is already present inside a 400 system This wat
39. iversion valve move the tube that goes to the tank from the diversion valve outlet to the membrane product water outlet as shown below Diversion valve outlet Membrane product outlet Automatic Tube to tank operation Membrane product outlet Manual operation Tube to tank Long Term Storage Procedures Watermakers are best run continuously When not in use biological growth in the membrane is the leading cause of membrane fouling A warm environment will cause more growth than a cold environment The auto fresh water flush system will greatly reduce biological growth but may not stop it completely in certain conditions The 5 day re flush feature allows the system to be shut down without any service procedures for extended periods of time but it doesn t re place performing a storage procedure for long periods of non use If an optional Zeta Guard water treatment system is installed in the system the 5 day re flush will maintain the system as long as unchlorinated pressurized fresh water is provided System Storage or Pickling If the system is to be left unused for more than 2 weeks perform the following storage pro cedure The procedure introduces a chemical compound into the system that prevents bio logical growth This procedure requires de chlorinated water which can be made with the Spectra s charcoal filter Charcoal filters last a maximum of 6 months once wetted Spectra SC 1 a special storage compound us
40. l on the MPC board and the bal last BLACK wire connects to the GND terminal If the wires must be extended use mini mum 16AWG 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 con nects to the BUZZ terminal on the MPC board and the buzzer BLACK wire connects to GND 22 Tank Switch Installation and Operation There are two sets of terminals on the MPC 3000 PCB that can be used in four dif ferent configurations to automatically start and stop the watermaker or to automatically stop the watermaker when the tank s are full without the auto start feature These terminals are on the green ten pin connector and are labeled Float Switch 1 and Float Switch 2 Float Switch 1 is the tank full switch and Float Switch 2 is the tank empty switch If the unit is wired for both Autostart and Autostop it can be put into AutoFill Mode by pushing and holding the Auto Run switch on the MPC 3000 display In this mode the water maker will start whenever the water level drops below the tank empty switch so that it is open not conducting electricity When the tank fills up and both the tank full switch and the tank empty switch have remained closed for two minutes the watermaker will shut down and flush itself The water maker will start back up when the water level drops below the tank empty swi
41. leaner SC 3 will remove min eral scaling The alkaline cleaner SC 2 is used to remove biological by products oil and dirt particles that get past the prefilters If membrane performance is reduced and they have not been pickled recently cleaning with both chemicals is recommended The acid cleaner should be used first If the membrane fails to respond to both cleanings this is an indication of another problem with the system or that it is time to replace the membrane Contact Spectra Watermakers before removing a membrane Membrane Cleaning For normal cleaning the SC 3 Acid Cleaning Compound is used first then the SC 2 Alkaline Cleaning Compound If known bio fouling is present the SC 2 may be used first Using hot wa ter if possible up to 120 45C is recommended as it greatly enhances the ability of the cleaners to do their 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 SC 2 using an alternate source of unchlorinated fresh water before the system is run under pressure A simple test can be performed to see if biological growth has occurred Before running the sys tem remove the prefilters and examine their condition If the housings are full of smelly discol ored water the system was not properly stored Install clean prefilters if they were bad Next check the membrane Attach the brine d
42. lorine in the fresh water flush water supply It also removes any particulate matter The charcoal filter we use removes 99 7 of the chlorine Beware when buying other charcoal filters If they don t specify the percentage of chlorine removed don t use them The cheap ones in most cases will only remove 60 or 70 Also there are aftermarket filters which are very close to but not exactly the same dimensions that will not seal properly in the housing The membrane can only handle small amounts of chlorine for short periods without damage The chlorine will damage the bonding agent in the membrane in a very short time So if you skimp on the char coal filter you will toast a 450 00 membrane on the first flush The other factor is the flow rate that the filter can handle Because the chlorine is deactivated by a chemical reaction with the charcoal it must remain in contact with the charcoal for sufficient period of time for the reaction to be complete The filter we use can handle 1 5 gallons 6 litres per minute flow and are good for 3000 gallons 12 000 litres at 1 5 GPM or six months whichever comes first Regardless of the flow the charcoal loses its effectiveness after six months 7 26 04 50 SPECTRA WATERMACHINES Z BRANE OPERATION MANUAL The Z brane is revolutionary product which incorporates the Z Guard High Voltage Capacitive technology into the membrane pressure vessel Always active the Z Brane creates an envir
43. n Leave dry until next startup Use only Spectra approved filters or you may void your warranty The filters may be cleaned several times with a soft brush and water in a bucket Occasionally lightly lube the O rings with silicone grease Oil Water Separator Optional To install oil water Removal capability remove the supplied 20 micron filter element in the duplex filter set and replace with the 20 micron oil water separator cartridge Replace this when the MPC alerts you with a Service Prefilter alarm The Charcoal Fresh Water Flush Filter Replace the charcoal filter element at least every 6 months 35 The Membranes The membranes need to be cleaned only when they have lost up to 15 of their capacity due to fouling or the product quality degrades The leading cause of fouling is from biologi cal 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 and feed pressure bar graphs for higher than normal readings for the conditions Other conditions can cause high pressure such as cold feed wa ter or clogged filters Low product flow is usually due to low voltage damaged feed pump or Clark pump Look for all other causes before cleaning the membrane Membrane life can be shortened by excessive cleaning e There are two types of cleaners acid and alkaline The acid c
44. ness and heat shrink butt splices N Product Water tubing Product water tubing is 1 4 6 3mm parker tubing See the Parker tube fitting assembly diagram next page Product water is pre plumbed from the membrane into the electric diver sion valve The diversion valve will reject product water into the overboard brine stream un til good quality is measured by the MPC 3000 control Product water is then diverted into the fresh water tank You will need to route the product water from the valve into the top of the tank Install a tee in the water fill or tap a pipe thread into an inspection port in the top of the tank Do not feed the water into a manifold or bottom of the tank Make sure there is no re striction in this plumbing Product water to tank Roto Flow Meter Salinity Probe Brine Discharge Quick Disconnect Fitting N Route the Brine discharge from the quick disconnect fitting to a location above the waterline using the supplied 5 8 15 9MM hose Parker Tube Fitting Assembly Procedure Spacer Single grab ring for 1 4 amp 3 8 tube Use 2 grab rings for 1 2 tube f Nut O ring Bodv Tubing Step 1 Dissemble fitting components Step 2 Install the Nut first then use the bevelled side of the Spacer to push the Grab Ring onto the tube no more than 1 2 Slip the O ring over the tube to hold the Spacer in place If the Grab Ring is pushed too far
45. onment that is unfriendly to bio film and bacteria The Z technoalgy also assits in the prevention of scale formation on the membrane surfaces The Z Brane allows the system to be shut down or decommissioned for extended periods of time without chemicals or preservatives The Z Brane will not prevent freezing so that in cold climates Propylene Glycol is still required The Z Brane system is integral with the watermaker unit and only requires continuous 12Vor 24V DC power to be operative The installation of the Z Brane only consists of wiring the power supply to a continuous source The Z brane power supply can tolerate voltages between 10V and 28V DC Note There is no reason to open the transformer enclosure Do not ser vice this unit without disconnecting the power source There may be high voltage present It is recommended that the Z Brane be connected to a discreet continuous power source The power must be on during the time that the system is operation and during the time the Z Brane is used for membrane storage If the power is obtained from the MPC then the MPC must be powered up at all times during storage This may not be desirable Fuse the power at the source with a 5 amp fuse or circuit breaker Red is Positive Black is Ground Z Brane Power Harness 52 Operation During normal operation the Red LED should be on Power needs to be supplied to the Z Brane unit at all times that you wish to have the biofouling
46. ons for your model 4 Place enough antifreeze in a bucket to fill your system This will be about two gallons for a 150 or 200 model three gallons for a 380 or 400 and larger systems will take more 5 Run the system DEPRESSURIZED with the feed pump drawing from the bucket and the brine discharging overboard until the colored antifreeze solution begins to appear at the brine discharge then switch the brine discharge into the bucket and recycle the remaining solution until the glycol and water are completely mixed about ten minutes On some models you will have to shut down the unit to switch the brine discharge into the bucket 6 The product water side of the system will not contain antifreeze and should be protected from freezing by blowing or draining it dry if necessary 7 Turn off power to the system leaving the pressure relief valve open turn Ne 5 25 04 46 OP 2 BAD SMELLING PRODUCT WATER The reverse osmosis membrane is permeable by many gases including hydrogen sulfide the gas that causes rotten eggs to smell the way they do If there are bad odors in the feed water they will go through the membrane and the product water will be affected Usually the source of the odor is from the decay of planktonic creatures trapped in the sea strainer and prefilters These tiny oxygen loving creatures soon suffocate and die inside the prefilter housings when the unit is shut down Once all the available oxygen is consumed anaerobic bacter
47. quirement 3 Follow the wire gauge charts in the instructions Using larger wire than specified is ac ceptable 4 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 Calculate 3 gallons 12L per flush 5 The MPC 3000 control must be de powered DC power off after the system is put in storage pickled where a storage chemical or antifreeze is run through the system 6 If you are separating the Clark pump membrane assembly please review the high pres sure tube assembly instructions Improper assembly will cause failure 7 Run test then sea trial the complete system before assuming the system is opera tional If the boat is in fresh or dirty water see Dry testing the system 8 Spectra dealers are responsible for educating the vessel owners on the operation and maintenance of the system We request that you walk through the installation with our customer 9 Please have the owner fill out the warranty card The warranty is void if it is not regis tered Table of Contents Installation Page Number G ttine Started u man a 7 Newport SChemati amp us asas nasua a a LA eks 8 I stallatione oo y S S a QR D qha 9 Component Placement m a Q M ae Sa Maa 10 PIU DINA
48. r two a day in inland or near shore waters the trapped plank ton will begin to decay in the filters long before the elements plug up and the bacteria in volved in the decay will cause a rotten egg smell in the product water This decay will set in overnight in tropical waters or after a week or two in high latitudes If handled gently and changed regularly before they get too smelly filters in this service can last through doz ens of cleanings In crystal clear blue water conditions the filters may need to be cleaned much less frequently The charcoal filter used in the fresh water flush system will not plug up unless you have some incredibly dirty domestic water in your boat About six months after installation the charcoal filter element will lose its effectiveness at removing any membrane damaging chlo rine which may be present in domestic water Charcoal filter elements must be replaced every six months if there is ANY chance that chorine could be introduced into the flush wa ter Charcoal filter elements cannot be cleaned To ensure that filter elements fit properly and remove chlorine effectively they should be purchased at factory authorized dealers Our element part number is FT FTC XX The last two digits indicate the micron rating e g FT FTC 05 is for a 5 micron element Charcoal elements are FT FTC CC 06 03 04 49 PF 2 CHARCOAL FILTERS The function of the charcoal filter element p n FT FTC CC is to remove any ch
49. rane module on Newport models The salinity probe should be removed and cleaned once a year if incorrect readings occur The probe wire is connected by a plug under the rubber boot at the sensor Both the diversion valve wires two conductor and the rotorflow sensor three conductor are to be spliced with the supplied butt connectors to their respective harness Heat the connectors to shrink Make sure the salinity probe is mounted in the position shown with the electrical cable plugged in at the bottom and the electrodes up Note There is no polarity or color code on the diversion valve wires The Rotoflow wires connect red to red Black to black and the brown to white 21 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 by the Spectra warranty Accessory outputs are lim ited to 2 amps maximum load Do not connect motors pumps etc to accessory outputs Optional Z brane System Detailed instructions are included with the Z Brane kit Con nect to an uninterruptible 12 of 24Volt DC power source 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 wires plug into the end of the bulb in the lamp module The ballast RED wire connects to STER termina
50. s complete with a mounting system Be sure to use the supplied washers on the rubber feet Use it as a template for drilling the mount holes You may mount the Clark Pump in any position even upside down The salinity probe must be mounted facing up or horizontally so that air bubbles cannot become trapped on the electrodes The di version valve probe assembly should be reoriented if necessary Membrane Pressure Vessel Mounting The Clark pump and membrane assembly has been pre assembled at the factory If it is nec essary to disassemble this module and mount the pressure vessel remotely use guidelines in back of the manual Use only approved tubing for assembly Remote Control Panel The remote control panel can be mounted anywhere that s dry and convenient Cut a 4 9 16 116 mm wide by 2 7 8 68mm high opening for the panel Locate in an area that is easily visible and easy to manipulate the buttons Use only Spectra approved remote cable The cable is not standard LAN cable or phone cord Plumbing From the inlet thru hull to flush module and from flush module to pump module inlet use supplied clear 3 4 19mm spiral suction rated hose The outlet of the filter assembly on the main module to the Clark pump assembly is under pressure Use the supplied braided clear vinyl hose rated to 150 PSI 11 bar From Clark pump brine discharge connector use sup plied 5 8 15 9mm clear braided vinyl hose Route all hoses and tube
51. s hard to find in warm climates and takes up a lot of room on a small boat so our SC 1 is best for tropical cruising 44 Given good care a membrane will eventually just start to slowly fade away The feed pres sure may rise and or the ppm go up Hardly ever will they just fail overnight 8 13 04 MB 5 MEMBRANE CLEANING WITH DETERGENT If the membrane has been fouled with oil it may be possible to save it by cleaning it with dish soap such as Joy Don t use anything that may contain bleach You will need quite a lot of chlorine free fresh water If using shore water run it through a charcoal filter at a rate of not more than 1 5 gallons 6 liters per minute Fill a bucket with fresh water and mix in a couple squirts of the detergent Run the system depressurized with the watermaker drawing water from the bucket and discharging over board When about half the water is gone from the bucket stop the unit and let the mem brane soak for a few minutes Restart and pump the remaining solution overboard Repeat until the discharge appears clean After most of the oil is cleaned out you can put the brine discharge into the bucket and run the system with the soapy water circulating as you would for the other cleaning chemicals Rinse the system with a bucket of fresh water or the fresh water flush cycle then flush for twenty minutes using sea water Pressurize and test 5 12 04 45 MPC 5 PURGE MODE BYPASS Whenever the control power 12 or
52. s to prevent kinks and restrictions Se cure piping away from moving objects such as engine belts and hatches Prevent chafe on tubing as required Test and inspect all piping and hose clamps after several hours of operation System Piping Specification From the Clark pump brine discharge connector use the supplied 5 8 15 9mm clear braided vinyl hose to the brine overboard fitting The outlet of the filter assembly on the main module to the Clark pump assembly is under pressure Use the supplied braided clear vinyl hose rated to 150 PSI 11 bar NA 2 2 JP PLO SSS SPS ORES i WEFEFFKSEFFFTTITTTYTT N 2 4 a tt eee I TION HOSE From the inlet thru hull to the flush module and from the flush module to the pump module inlet use the supplied clear 3 4 19mm spiral suc tion rated hose Note When plumbing the Newport Pump Module route the feed water so that the front cover may be opened without removing the hose or tubing Fresh Water Flush Run a feed line from the domestic cold pressure water system to the 1 2 hose barb on the fresh water flush assembly This needs to be active when the boat is unattended for the fresh water flush system to function properly The domestic fresh water pump must be able to deliver 2 5 gallons per minute at 25 PSI Connect the wiring har
53. son the control will default back to the beginning of the purging mode to protect your system If you wish you can bypass the purge sequence and initiate a normal start Pressing both Auto and Stop simultaneously anytime during the purge sequence will bypass the purge sequence and enable a normal start In any case do not pressurize the system for the first twenty minutes or more 5 After the purge sequence The control will alarm with the message Close pressure relief valve Close the valve and proceed by pressing Auto Run 6 The system is now running under pressure and making water The display will read purging product water This mode dumps the product water overboard for ten minutes in case there is any residual chemicals in the membrane Carefully inspect for leaks over the entire system Shut down the system and repair any leaks you find 7 The system is now in the operational mode You may start and run your system as you de sire You will not have to go through the purging mode unless you de power the system If you do you can bypass the purging mode by pushing Stop and Auto run buttons at the same time It is best to use the auto run button which defaults to the automatic fresh water rinse If you shut down the system from the stop button then use the auto store but ton to effect a fresh water flush cycle 8 Check that the system is operating within its normal parameters Compare with
54. ssion 1 2 SS tube fittings lt Pi CYL SS J iston with seal Cree S HP CYL PT PL MTS 3 8X 1 28 O AQ SO HPP ECCB End cap O ring Cylinder end cap HP CYL EC Cylinder Ring HP CYL R Cylinder Assembly 61 10 CLARK PUMP PARTS LIST PART DESCRIPTION USAGE CENTER BLOCK CENTER BLOCK INSERT VALVE BODY HP CB PVPS BLEED VALVE VALVE END BLOCK A 1 1 4 VALVE END BLOCK B 1 1 4 PILOT VALVE PIN SEAL HP CB PPS PILOT VALVE PIN HP CB PVCR HP CB CVSW PILOT VALVE CLIP RING CHECK VALVE SPRING PLASTIC DELRIN CHECK VALVE SPRING WASHER HP CB PVS PILOT VALVE SPOOL HP CB CVS CHECK VALVE SEAT CHECK VALVE RETAINER CHECK VALVE ANNULAR RING 1096 REV VALVE SPOOL REV VALVE SPOOL SEAL REV VALVE SPOOL PISTON CYLINDER END CAP HP CYL PT END BLOCK PLUG PISTON ROD PISTON HP TB SR SPACER RING HD CPS 3 824175 3 8 24X1 3 4 CAP SCREW HD CPS 5 16X3 5 16 18X3 1 4 CAP SCREW HD CPS 5 162 75 5 16 X 2 3 4 CAP SCREW HD WSH 3 8X5 8S 3 8 X 5 8 O D SS FLAT WASHER HP CYL SST PL MTS 3 8X1 28 STAINLESS TUBE 3 8 NPT X 1 2 TUBE FITT ST SS HP CYL CC COMPOSIT CYLINDER HP CYL CCB COMPOSIT CYLINDER BASE HP CYL R CYLINDER END RING PILOT ORIFICE PILOT ORIFICE PL HP 3 8N GLASS FILLED BLACK NYLON PLUG 3 8 NPT PL HP 1 4BR 1
55. t the flush water solenoid will open and the display will read FRESH WATER FLUSH with a countdown timer After 5 7 min utes the pump will stop the display will read FLUSH TIMER INTERVAL and the countdown timer will reflect the number of hours until the next flush Pressing and holding the Auto Store button for 3 seconds will engage 1 time flush The system flushes as described above but will not re flush every 5 days Dis play will read FRESH WATER FLUSH with a countdown timer then the default dis play when finished Pressing the Stop button will cancel the auto flush mode Manual Operation In the event of an MPC control failure the system may be operated manually by using the manual run switch on the MPC control box and bypassing the diversion valve For manual start up switch on the feed pump by setting the feed pump switch to RUN Shut the unit down if the Clark pump does not cycle if air is continuously sent in the intake line or if the feed pump is excessively noisy The automatic safety controls are disabled in manual mode Always discard the product water for the first few minutes of operation The initial prod uct water from the system may not be potable Taste the product water before sending to a tank In manual operation the salinity control and diversion valve are inoperative Product wa ter is available directly from the membrane product water outlet fitting To bypass the d
56. tact factory Close Valve 42 Spectra Watermakers Newport Troubleshooting Procedures SYMPTOMS Error Messages PROBABLE CAUSE REMEDY System stalled system stalled may alarm when using the control panel to run system for servicing with the pressure relief valve use manual override switch instead pressure relief valve open intake thru hull closed airlocked system no signal from stroke sensor Close pressure relief valve Check thru hull Verify stroke sensor fully in serted in pump Check stroke sensor wiring at control box Replace stroke sensor High Pressure blocked brine discharge Check brine discharge fouled membrane Clean membrane Voltage Too High battery voltage too high or Charge batteries Voltage Too Low low Check charging voltage loose wires or poor connec tions Check power connections Re starting no signal from stroke sensor at startup System Air locked See remedy above for system stalled Check Fuse followed by fuse number blown fuse at circuit board Replace fuse mini automotive type ATM Look for cause Service Prefilter clogged filters loose or defective pressure sensor wires Install new filters Check sensor wiring Ck Sea Strainer clogged strainer dirty 50 Micron prefilter Seacock closed Clean strainer screen change 50 Mic Check through hull
57. tch and it remains open for 2 minutes This configuration allows for com pletely automatic operation If the watermaker does not need to start up within five days it will automatically do a fresh water flush AutoFill mode can be ended by pushing the stop button or the Autoflush button If the watermaker is in Autorun mode it can be put into Autofill mode without stopping it by holding down the Autorun button If the owner prefers to install the automatic shutoff feature without the automatic start up option only the tank full switch is used A jumper must be placed between the tank empty terminals Float switch 2 in place of the tank empty switch because the watermaker will only shut down if both sets of terminals are closed To use this mode the watermaker must be started up with the Stop start button or the Autorun button After the unit starts up then press and hold the Autorun button until the display reads Auto Fill Mode The water maker will fill the tank and automatically enter Autoflush mode It is possible to use the autofill feature with 2 tanks A double throw electrical switch must be installed in a convenient location If only the single tank full switch is installed in each tank connect the wire From the Float Switch 1 terminal 1 to the common on the switch and run separate wires from the switch to each tank switch The second wires can both be run to the Float Switch 1 terminal 2 If you are using two switches in each tank
58. to dam age the connector Plug this into the back of the control Route the Clark pump harness to the Clark Pump membrane module location and plug in the rotoflow meter See photo page 15 Plug in the salinity sensor cable and install the plastic boot over the connection Locate the diversion valve wires and splice the remaining two conductor cables with the supplied butt splices The diversion valve wires have no polarity Heat shrink connectors or heat shrink tubing is supplied so you can seal the connections af ter splicing Route the single two conductor cable to the fresh water flush module and splice the wires to the solenoid wires There is no polarity to the wires Heat the splice for sealing Check the wire size chart to select the proper size power feed to the main power harness DC power feeds should be uninterruptible to insure proper operation of the auto store fea ture Avoid house breaker panels that could be easily tripped Component Sizing 12V Use 30Amp breaker and size the wiring for 25 Amperes e 24V use a 15 Amp breaker and size the wire for 13 Amperes Provide circuit protection at the source Inadequate wiring will cause a loss of system performance DC power should be uninterruptible Note If the specified circuit breaker sizes are unavailable use the next higher rating but do not exceed the specification by more then 10 All wiring to be done to applicable ABYC Marine UL or CE standards WIRE SIZE CHART
59. ure vessels and continuously helps prevent biogrowth and fouling of the membrane system Feed Pump Main Module Mount the feed pump main module on a horizontal or vertical sur face that can be up to 3 1 0M above the waterline It is prefer able to mount as low as possible Locate in an area that allows easy access to filters and a location that will not be a problem when water spills during filter change Keep future maintenance in mind when choosing a location The MPC control box can be removed from the main feed pump module and relocated if necessary The feed pump has overheat protection and will not operate properly at ambient temperatures over 120F 48C The MPC Control Box Remove front cover to access mounting holes in the enclo sure Filters may be relo cated You may need additional 1 2 Parker tubing Clark Pump Membrane Module The membrane maximum temperature specification is 120F This module must be installed in an area that maintains a temperature below 120 50 A cool location is preferable It may be placed as high in the boat as you desire Make sure that the area around and under the pump does not have any water sensitive equipment Water will be spilled during any repairs or if a leak occurs Be sure you will have access to the pressure relief valve on the Clark pump Keep this unit within the 15 4 5M reach of the wires from main feed pump module The Clark pump membrane module come
60. your service kit to the service port of the fresh water flush module Lead the hose into the bucket Turn the ser vice valve on the fresh water flush module 180 so the intake is now coming from the bucket Step 5 Mix the storage chemical Compound into the water in the bucket Step 6 Make sure the pressure relief valve on the Clark pump is Open unpressurized Step 7 Use the Run Manual switch on the MPC control box to turn on the feed pump Circulate the storage chemical in the system for approximately 10 minutes Turn off the Pump when finished Clean Up Remove the quick disconnect from the Clark pump brine discharge and replace the original hose that leads to the thru hull You may at this point if you choose to pump the bucket dry by using the feed pump switch Stop when the bucket is empty Turn the service valve 180 back to its original position and remove the service hose Turn off the power to the system LEAVE THE PRESSURE RELIEF VALVE OPEN 32 jSUOp 1 19 4936 Jexong T S XIN G 4936 FI 2081 991A19S pue peo Jo 1108 OOIAIOS 0 9SOU 991A19S 4936 jexonq o 8 pue SUQ LT 4936 uado st JINSSAJA ons IJEN

Newport 400 MPC 3000 Mag Drive User Manual

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