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NEWPORT 400 Mk II INSTALLATION & OWNER`S MANUAL

1. 103SIH UOISIA9H Aules 0006 408086 aJnssad pad _ 6 dung xhu3 qut ETT O O OL 10 loued Adidsip 930 84 SW E i Q Aeidsip 20 2d Wi lt Joyoul dund 15008 m peadg 30 CJ gt J MOd End block B Valve block HP TB VB End block A C l HP TB VEB A1 o cylinder and base Brine out HP CYL CCA Pressure relief valve HP TB BV MS e am Center block 10 Stainless steel tube 5 SST inder ring End Ca Clark Pump Front View End block A Valve block End block B Composite cylinder and base 261 High pressure in Reset button Not on all units HP TB RSB Alternate brine out Test port B d a Center block le High pressure out b c Stainless steel tube Cylinder ri D Clark Pump Back View End cap 54 5 16 3 1 4 SS AH Bolts HD CPS 5 16X3 Relief Valve O Ring SO HPP RV Annular Rings HP TB AR Spool Assembly KIT HP 10VSA Relief Valve HP TB BV Annular Ring O Rings Mount inside Valve Block SO HPP AR Valve Block HD CPS 5 16275 5 16 2 3 4 SS bolts Reset button an
2. Z9 SPECTRA WATERMAKERS NEWPORT 400 MK II INSTALLATION amp OWNER S MANUAL Part 1 2 Installation Operation Maintenance Piri 2 099532 Programming and Controls Spectra Watermakers Inc 20 Mariposa Road San Rafael CA 94901 Phone 415 526 2780 Fax 415 526 2787 www spectrawatermakers com Feb 2012 mpc5000 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 1 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 forward facing scoop type thru hull fitting installed 2 Both the Newport MkII Feed pump module and the Clark Pump Membrane module must be installed in a well ventilated compartment where temperatures will not ex ceed 120F 48C Many engine compartments exceed this temperature when under way Warranty will be void if the in
3. e Display will read Open Pressure Relief Now Ensure that it is open SPECTRA URTERMBKERS A24 e Push the Alarm Display button to silence alarm 29 4 Press Auto Run Button 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 continuing Inspect the system for leaks PURGING STORAGE SOLUTION 19 38 Note If you must stop the purge sequence for any reason the control will default back to the beginning of the purging mode to protect your system If yu wish you can bypass the purge sequence and initiate a normal start Pressing both Auto Run 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 sends the product water overboard for ten minutes in case there are any residual chemicals 1 the membrane
4. Carefully inspect for leaks over the entire system Shut down the system and repair any leaks you find 7 The system 1s 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 and Auto Store button to start and stop the machine If you shut down the system from the Stop button then use the auto store button to do a fresh water flush cycle 8 Check that the system 15 operating within its normal parameters Compare with the chart on the next page 24 Product Flow Newport 400 MkII Will produce 14 16 GPH 54 60LPH Salinity Salinity reads parts per million Sys tem rejects water higher than 750 PPM Anything below 500 1s excellent Feed Water Pressure Pressure range 90 115 PSI 7 8 BAR Pressure will be higher in cold water and lower in warm water Extreme salinity ie or temperature conditions may result in eM operating pressures outside of nomi Lr nal range Filter Condition PREFILTER warns that filters are getting dirty et ofl Clean filters as soon as convenient Ifthe graph PREFILTER reaches full scale the machine will automati GOODMBOOGREPLACE cally slow down to Run Low speed If it reaches full scale again it will alarm Service Prefilters an
5. Pressure Relief Valve The membrane maximum temperature specification is 120F This module must be installed in an area that maintains a temperature below 120F 500 A cool location 15 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 The Clark pump membrane module comes 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 Note If your machine 1s equipped with the optional Z brane see the Z brane Installation and Operation section of this manual for instructions on installing the Z brane anodes into the membrane end plugs This should be done before installing the Clark Pump Membrane Module 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 is dry and convenient Cut a 4 9 16 116 mm wide by 2 7 8 68mm high opening for the panel Locat
6. Replace the machine will slow down When display reaches Replace a second time the alarm sounds and the system will shut down to prevent damage If cleaning and re using filter elements clean when the first segment ap pears 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 micron Leave dry until next startup Use only Spectra approved filters or you may void your warranty The filters may be cleaned up to 3 times with a soft brush and water in a bucket Occasionally lightly lube the O rings with silicone grease The Charcoal Fresh Water Flush Filter Replace the charcoal filter element at least every 6 months 34 The Membranes e The membranes need to be cleaned only when operating pressures have risen more than 10 or the product quality degrades The leading cause of fouling 1n marine use is from biological growth that occurs when the system 1s left unused without flushing or pickling Fouling from mineral scaling can happen during operation under certain sea water condi tions 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 water or clogged filters Low pro
7. i4 1 Lads 03 gt Sue xue 6 uondo YM HULL 7 uodo 0006 JdW Seu23iMs Xue pue yueL uondo 22 New System Start Up and Testing Use this procedure when starting a new watermaker for the first time and whenever the system contains preservative or cleaning compounds Avoid running the system if the vessel 15 in contaminated water such as in a dirty harbor or canal The system should be fully run tested before leaving port It is preferable to sacrifice a filter by running the system in turbid water rather than waiting to get offshore to discover a problem or deficiency in the installation If the location or weather prevents proper testing refer to the 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 e Thru hull valve is open e Run Manual Run Auto Flush Manual Switch in Run Auto Position Domestic fresh water pressure system must be on 2 Open pressure relief valve 1 2 turn 3 Power up the system to enter Purge Mode Note The watermaker will not run with the pressure relief valve open unless it is in Purge Instead it will restart twice and alarm System Stalled e Alarm will sound
8. 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 in the Z Brane section Connect 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 terminal 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 Float Switches Your MPC 5000 can be wired to operate with optional tank float switches for truly automated operation See the instructions and wiring schematics on the next page for additional details Order part number EL SWT SMLV and EL SWT LV for tank low and tank full switches 20 Tank Switch Installation and Operation There are two sets of terminals on the MPC 5000 PCB tha
9. 10 All wiring to be done to applicable ABYC Marine UL or CE standards 17 WIRE SIZE CHART Newport Mk II DC System Wiring Wire Length FT Meters AWG SQ MM Mk Il 12V 10 3 10 6 15 4 5 8 10 20 6 1 6 16 25 7 6 4 25 30 9 4 4 25 35 10 6 4 25 40 12 2 35 45 14 2 35 50 15 2 35 24V Meters AWG SQ MM 10 3 12 4 15 4 5 10 6 20 6 1 8 10 25 7 6 8 10 30 9 4 8 10 35 10 6 6 16 40 12 6 16 45 14 6 16 50 15 4 25 Wire length is measured from source circuit breaker or fuse to control termi nal block and back to the source again 18 MPC Remote Control Display Panels There are currently two types of display options available Liquid Crystal Diode LCD display which 15 dark lettering on a backlit background or Vacuum Florescent Display VFD which are bright characters on a dark background The VFD display brightness can be adjusted using the Programming Function detailed 1 Part 2 of this manual 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 REJECT 19 Connection of Optional Accessories Use of any external devices not approved by the factory may cause permanent damage
10. CCA Cylinder Ring HP CYL R Cylinder Assembly 10 CLARK PUMP PARTS LIST PART DESCRIPTION USAGE CENTER BLOCK CENTER BLOCK INSERT VALVE BODY BLEED VALVE VALVE END BLOCK 1 1 4 VALVE END BLOCK B 1 1 4 PILOT VALVE PIN SEAL PILOT VALVE PIN PILOT VALVE CLIP RING CHECK VALVE SPRING PLASTIC DELRIN CHECK VALVE SPRING WASHER PILOT VALVE SPOOL CHECK VALVE SEAT CHECK VALVE RETAINER CHECK VALVE ANNULAR RING 1096 REV VALVE SPOOLASSEMBLY REV VALVE SPOOL SEAL REV VALVE SPOOL PISTON CYLINDER END CAP END BLOCK PLUG PISTON ROD PISTON SPACER RING 3 8 24X1 3 4 CAP SCREW 5 16 18 3 1 4 CAP SCREW 5 16 X 2 3 4 CAP SCREW 3 8 X 5 8 O D SS FLAT WASHER STAINLESS TUBE 3 8 NPT X 1 2 TUBE FITT ST SS COMPOSIT CYLINDER COMPOSIT CYLINDER BASE CYLINDER END RING PILOT ORIFICE GLASS FILLED BLACK NYLON PLUG 3 8 NPT 1 4 COUNTER SUNK HEX PLG 3 4 MPT ST X 1 2 TUBE SS FITT ELL PILOT PORTS PIN SEALS VALVE PORTS CHK VALVE SEATS CHK VALVE PORTS VALVE BORE END CAP amp CENTER BLOCK ANNULAR RING PILOT VALVE RELIEVE VALVE CONNECTOR O RING SPOOL PISTON ORING 1 QUAD SEAL 10 20 PISTON ROD HP CB INS HP TB VB HP TB BV 5 5 HP CB PVCR HP CB CVSW HP CB PVS HP CB CVS HP CB CVR HP CB CV HP TB AR HP TB VSS HP CYL EC HP TB EBP HP CYL PT HP TB SR HD CPS 3 824175 HD CPS 5 16X3 5 5 162 75 HD WSH 3 8X5 8S HP CYL SST PL MTS 3 8X1
11. Capaci tive technology into the membrane pressure vessel Always active the Z Brane creates an 1 ronment that is unfriendly to bio film and bacteria The Z technology also assists in the preven tion 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 ANODE INSTALLATION Spectra Watermakers ship the High Pressure Module with the White Z brane electrodes s re moved from their socket s to prevent shipping damage Before the High Pressure Module is mounted the anodes should be installed The socket s have been plugged with plastic plugs to keep the membranes clean and moist dur ing shipping and storage Remove the clips that secure the plugs and remove the plugs Insert an anode into each socket It doesn t matter which anode goes in which socket Insert the anode until the groove 1s flush with the membrane end plug so the clip will slip into the groove Install the C clip screw to secure the clip C Clip and retaining screw Shipping Plug C Clip groove in Anode 50 WIRING The Z Brane system is integral with the watermaker unit and only requires continuous 12 Vor 24V DC power to be operative Note There is no reason to open the transformer enclosure Do not service this unit without
12. HOUSING 3 PCS 3 8 NPT X 1 4 TUBE FIT TING ELL PL MTE3 4S1 2B PL MTE1 4X1 4P 3 4 X 1 2 TUBE FITTING C 1 4 NPT X 1 4 FIT ELL BRONZE TING ELL NYL 59 PLATE BRACKET END PL MTE1 2X1 2P 1 2 NPT X 1 2 TUBE FIT TING ELL NYL PL MTS 1 2X1 2P 1 2 NPT X 1 2 TUBE FIT TING ST NYL 5 5 MICRON FILTER ELE MENT NEWPORT 400 MK II PL H P 1 2N PI ACC TK 1 2 HEX PLUG NY PL TEE1 2X1 2T ACCUMULATOR TANK LON 1 2 NPT X 1 2 TUBE y BRANCH TEE EN lt PL HP 3 8 gan 3 8 HEX PLUG NYLON i I lt a A 9 10 HIGH PRESSURE PUMP NE 10 FOR N P ASSM WE A Jp PL NLT 2HP 1 2 HIGH PRESSURE TUBE DAYCO PL MTS 1 2X1 2P PL TEE1 2F1 4G 1 2 NPT X 1 2 TUBE FIT 1 2 X 1 4 GUAGE TING ST NYL PLATE BRACKET TEE KIT HP MNTK SPECTRA MOUNT KIT 5 ASSEMBLY T PL HBE3 4X3 4 m 3 4 NPT X 3 4 HOSE BARB ELL NYLON EL MPGRMCD MPC REMOTE CONTROL LCD 20 20 MICRON FILTER ELEMENT PL MTS 3 8X1 2B PL NP 3 4N 3 8 NPT X 1 2 TUBE 3 4 NPT CLOSE NIPPLE FITTING ST BRZ NYLON SO HPP CT CONNECTOR O RING PL FTE1 8X1 4P 1 8 X 1 4 TUBE FIT TING ELL PL NP 1 8N 1 8 NPT CLOSE NIPPLE NYLON 60 NEWPORT 400 MK II PL MFE3 4X3 4 3 4 MPT X 3 4 FPT ELBOW FITT PL VLV 3 W3 4 3 4 3 WAY VALVE PL HBE3 4X3 4 3 4 NPT X 3 4 HOSE BARB ELL NYLON PL HS 3 4VN 3 4 VINYL HOS
13. 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 15 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 51 Operation During normal operation the Red LED should be Power needs to be supplied to the Z Brane unit at all times that you wish to have the bio fouling protection We recommend 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 15 stored with chemicals or winterized with Glycol Power on LED High Voltage connector Det DO NOT DISCONNECT OR SPLICE ANY OF THE HIGH VOLTAGE WIRING Contact the factory 1f modifications are required 52 d sjaxeuli9je e eds 290 9002 uoisi ey E Xy 03 ING Jaduunf pappe 9007 61 22g 105005 nab6ugu 9002 ll XW OOP
14. 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 sealing compound 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 1s 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 Of special note are the high pressure tube fittings on the membrane housing seal on an O ring and should be seated all the way in Hold the fitting 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 39 Spectra High Pressure Tube Fitting Assembly Use ONLY
15. pump module manifold where it passes through the flow meter the salinity sensor and the diversion valve Ifthe salinity 15 good the diversion valve energizes and the product goes to the tank from the manifold product outlet If the diversion valve 15 not energized the product goes back into the feed water Connect the product outlet on the membrane housing to the black Product Inlet fitting on the pump module manifold using the supplied 1 4 black nylon tubing Route the blue product water tube from the blue product water outlet fitting on the feed pump module manifold into the top of the tank Install a tee in the water tank 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 restriction in this plumbing If the length of product water tubing supplied with the watermaker is insufficient use a larger size hose Product water flow restriction will cause reduced and power consumption in creased if product flow is restricted Blue Product tube to Fresh Water Tank Product tube from membrane end cap to feed pump manifold 12 Brine Discharge Route the Brine discharge from the quick disconnect fitting to a location above the waterline using the supplied 5 8 hose 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 press
16. 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 1s trapped in it from the plankton that gets through the system Membranes badly fouled in this way can seldom be saved These bacteria are always present but are inhibited by the oxygen in sea water while the unit 1s 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 1001 Chlorine will destroy a membrane minutes It attacks the material that the membrane 15 made from Always use product water or water filter
17. showing Cut tube square Fi gure 2 Black high pressure tubing SS Tighten 1 2 3 turns 10 flats of nut with a7 8 wrench after finger tight Use index mark as guide B No threads showing ES Figure 3 Insert tube 0 9 until it stops MA IMPORTANT Hold fitting body with 13 16 wrench when tightening 40 Spectra Watermakers Newport Troubleshooting Procedures SYMPTOMS Feed pump runs constantly will not turn off Feed pump runs with loud noise No lights or display system does not operate Display activates but pump will not run System runs no product water delivered to water tanks GPH display shows OK Good LED activated System runs no product water delivered to water tanks GPH shows OK reject LED activated PROBABLE CAUSE Manual override switches in position Intake blocked Air in system Remote display not connected No power to control box loose or broken pump wire connection speed control overheat tanks are full diversion valve inoperative wiring fault disconnected or broken product tubing diversion valve faulty 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 REMEDY Turn off manual switch on control box Check thru hull valve Check sea straine
18. 1 2 VINYL HOSE TUBE DAYCO 62
19. 105 are produced an acetal copolymer or polypropylene locking system then holds the tube firmly in place O rinas are Nitrile rubber or EPDM without deforming it or restricting flow Collet are produced in acetal copolymer or polypropylene with stainless steel teeth O ring provides a leakproof seal The Collet gripper has stainless steel teeth which hold the tube firmly in position while the O ring provides a permanent leakproof seal Collet Cut the tube square and remove burrs and sharp edges Ensure the outside diameter is free of score marks For soft or thin walled grips the pipe lube we recommend the use of a tube insert To disconnect ensure the system is depressurized push the collet square against the fitting With the collet held in this position the tube can be removed Pull on the tube to check it is secure Test the system before use DC Wiring Identify cables that are connected to the Newport Control System Newport Mk II Systems have a Power Inlet harness with a terminal block a 2 conductor boost pump cable and a 50 15M cable for the MPC 5000 display A motor speed control sets the run speed and also slows the motor to the flush and service speeds Do not install it in hot or poorly ventilated locations and allow for access to the Motor Speed Control Boost pump cable 50 15M cable with Power inlet harness with connectors for the MPC terminal blo
20. 2S HP CYL CC HP CYL CCB HP CYL R PILOT ORIFICE PL HP 3 8N PL HP 1 4BR PL MTE 3 4SX1 2 O HPP PLP SO HPP PS O HPP VP SO HPP CVS O HPP CVP SO HPP VB O HPP ECCB SO HPP AR O HPP PV SO HPP RV O HPP CT SO HPP SP1 O HPP Q 2 11 2005 58 NEWPORT 400 MK II FT STN 6 6 STRAINER LARGE PL BSH 3 4X1 4N PL VLV 3 4PVC 3 4 X 1 4 HEX BUSH 3 A NPT X 3 4 FPT 1 WAY ING REDUCER NYL PVC VALVE FT FHW 3PCS BLUE COLLAR FILTER HOUSING WRENCH 1 4 1 4 1 4 NPT X 1 4 ELBOW FITTING NYL PL NP 1 4N 1 4 NPT CLOSE NIPPLE PL PRG 1 4P 1 4 WATER PRESSURE REGULATOR PL HBE3 4X1 2 PL HBS 1 4X1 2 3 4 NPT X 1 2 HOSE BARB 1 4 NPT X 1 2 HOSE BARB ST NYLON ELL NYLON FT FTH 10L3PCS 10 LOW PRESS FILTER HOUSING 3 PCS FM NPC SVBM NEWPORT II SERVICE amp BOOST MODULE CHARCOAL FILTER PL VLV 3W3 4 3 4 3 WAY VALVE PL F HB 3 4X3 4 3 4 X 3 4 HOSE BARB ST NYLON NEWPORT MARK IIA FILTER BRACKET PL GHEGC PL NP 1 2X3 8N GARDEN HOSE CAP 1 2 NPT X 3 8 NPT CLOSE amp NIPPLE NYL PL GHI WS EL MPC RMCD GARDEN HOSE WASHER MPC REMOTE CONTROL VINLY PL HBESFPA LCD amp SHURFLO PORT ADAPTOR PL GHE3 ANP 3 4 NPT X 3 A GHT NIPPLE PL SLN 1 4D12M 1 4 DIVERSION VALVE 12 PL MTE3 4X5 8P V MNF 3 A NPT X 5 8 TUBE FITT ELL PL MTE1 2X5 8P 1 2 NPT X 5 8 TUBE ELL FITTING FT FTH 10L3PCS 10 LOW PRESS FILTER PL MTE3 8X1 4JG
21. Compound SC 2 SC 3 must be mixed with fresh water at a ratio of con tainer of compound to 3 gallons 12L of unchlorinated water to have the proper solution An average of two gallons 8L of water is already present inside a 400 system This water has to be figured into the mixture A 400 system will use I container of compound SC 2 and SC 3 are never mixed to gether Do not use them for storage pickling solution Cleaning Procedure e Step 1 Close the seacock Flush the system twice Use the Auto Flush button on the MPC 5000 display once the first flush has been completed press Stop to cancel the 5 day interval timer then press Auto Flush again e Step 2 Remove the quick disconnect fitting from the brine discharge outlet of the Clark pump and replace with a quick disconnect from your service kit fitted to a hose and lead the hose to a bucket e Step 3 Press Auto Flush again to fill the bucket with 1 gallon 4L of fresh unchlorinated 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 boost pump module Lead the hose into the bucket Turn the service valve on the boost pump module 180 so the intake is now coming from the bucket e Step 5 Mix the cleaning chemical compound into the water the bucket e Step 6 Make sure the pressure relief valve on the Clark pu
22. 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 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 8 wrench for the nut Hold the body recheck the tube insertion then tighten the nut 1 1 4 turns Use the index mark on the nut as a guide The threads should be completely covered by the nut Make Sure these fittings are tight on initial assembly or they will fail The correct Torque is specification is 85 foot pounds Index mark Straight thread Straight or 90 deg 3 8 pipe thread D aw Nut Ferrule Body Nut finger tight with 1 thread
23. E 4 PL CLP 10SS 10 HOSE CLAMP EL FP BPLDC824 300 1000 BOOSTER PUMP DC 8 24V tt FM NPC SVBM NEWPORT II SERVICE amp BOOST MODULE 3 4 3 4 3 4 3 4 HOSE BARB ST NYLON PL NP 3 4X5 3 4 X 4 5 NIPPLE POLY PL SLN 1 4012VB 1 4 1 WAY SOLENOID 4 22 PULSE SWITCHING MOD ULE ASSEMBLY EL SSR ABS ABSOLUTE PRESSURE SENSOR PL FTE3 8X3 8P 3 8 FPT X 3 8 TUBE FITT ELL PL MTS 1 2X5 8P 1 2 NPT X 5 8 TUBE FIT EL MTR1 2HP12 TING ST 1 2HP MOTOR 12 2000 RPM 48YC TEFC OR EL MTR 1 2HP24 EL SSR IFM 1 2 MOTOR 24V 2000 INLINE FLOW SENSOR Reh aero AE PL MTS 1 2X1 2P 1 2 NPT X 1 2 TUBE FIT TINGST PL PMP 140MAG MAG DRIVE VANE PUMP 140 GPH C120 PL MTE3 8X1 2P 3 8 NPT X 1 2 TUBE FIT NEWPORT MK II INTAKE TING ELL NYL MANIFOLD PL FTE1 2X5 8P EL MPCSP4 1 2 FPT X 5 8 TUBE ELL SALINITY PROBE FITTING PL MTE3 8X3 8P PL NP 1 2X3 8N 3 8 NPT X 3 8 TUBE FITTING 1 2 NPT X 3 8 NPT CLOSE NIPPLE ELL NYL NYL 61 NEWPORT 400 MK EL SWT TG DPDT EL SWT TSBHC TOGGLE SWITCH DP DT TOGGLE SWITCH BOOT SEAL FM MPCMPCB MPC BOX EL MPCPCBDP MPC 5000 CIRCUIT BOARD PL HS 3 4VN PL HS 3 4SH 3 4 VINYL HOSE 3 4 REINFORCE SUCTION HOSE W 7 2 L EEE zz LY zs MAS PL HS 5 8V N 2 ni My MAN NY 5 8 VINYL HOSE we IN MS PL NLT 1 2 HP PL HS 1 2VN 1 2 HIGH PRESSURE
24. ERMAKERS CHARCOAL FILTERS The function of the charcoal filter element p n FT FTC CC is to remove any chlorine in the fresh water flush water supply It also removes any particulate matter The charcoal filter we use removes 99 7 of the chlorine Beware when buying other charcoal filters If they don t specify the percentage of chlorine removed don t use them The cheap ones in most cases will only remove 60 or 70 Also there are aftermarket filters which are very close to but not exactly the same dimensions that will not seal properly in the housing The membrane can only handle small amounts of chlorine for short periods without damage The chlorine will damage the bonding agent in the membrane in a very short time So if you skimp on the char coal filter you will toast a 450 00 membrane on the first flush The other factor 1s the flow rate that the filter can handle Because the chlorine 1s 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 5000 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 48 SPECTRA WATERMAKERS 7 BRANE OPERATION MANUAL The Z brane is a revolutionary product which incorporates Z Guard High Voltage
25. Module under the MPC box is a pump speed controller On the board are two magnetic switches for adjusting the pump mo tor rpm The switches are narrow silver colored bars about 1 2 1 5cm long The Increase Speed switch is labeled S2 and is located in the corner opposite the battery cables The Decrease Speed switch is labeled 53 and is located just above the battery cables and next to the 6 capacitors Each time a small magnet 15 placed near the switch while the pump 15 running a signal will be sent to the controller changing the speed setting and the pump will speed up or slow down slightly Adjust the flush speed as follows Push the Auto Store button Push the Alarm display button until the display reads PREFILTER GOOD REPLACE The flush valve will open and water will flow back wards through the filters and strainers After about 30 seconds the backflush will end and the feed pump will come on starting the forward flush of the Clark Pump and membrane After the feed pump starts close the service valve handle crossways or the thru hull If the bar graph on the display begins to move toward REPLACE on the gauge the feed pump is trying to pump more water than the Flush module can supply and should be slowed down Turn the service valve to Service Water should flow very slowly out ofthe garden hose fitting If flow is more than a trickle speed up the pump Optimum flush speed will be the speed at which slightly more water 1s coming from the flu
26. a maximum flow rate of 1 5 gallons per minute so the feed pump is operated at a reduced speed to avoid exceeding this flow rate If the ship s water system 15 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 5000 display gives a SER VICE PREFILTER alarm this means that the fresh wa ter supply is insufficient In this case it is very important to either increase the water supply or adjust the feed pump flush speed as shown in the System Startup instructions 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 itis 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 47 Z9 SPECTRA WAT
27. ank 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 DO NOT press and hold the Auto Run button as this will enter the Auto Fill Mode and the watermaker will not function properly The watermaker will then fill the tank and automatically enter the Auto flush mode fresh water flushing itself every 5 days until another command is given 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 you will need a double pole double throw switch NORMALLY OPEN POSITION PHOTO SHOWS TANK FULL SWITCH VERSE FOR TANK LOW SWITCH WIRE TO MPC 3000 PCB FLOAT SWITCH SEE 44 SIDE MOUNTED TANK SWITCH OPTION 21 1045 0005 0005 Dd 14 auda NO 4I 4 Wo NO mmm Pl sweden i LJ a EEUE
28. ck 5000 control display ue ___ MPC 5000 controller Inside Cover Manual Control Switch Motor Speed Control Behind the Prefilters Inside the Chassis 16 Wiring continued Mount the main power terminal block 1 a junction box or on a bulkhead adjacent to the feed pump module Make sure that this 1s a dry location well above bilge level and not subject to wa ter spray Route the control cable through the boat to the MPC display location Be careful not to damage the connector or get it wet Plug this into the back of the control Connect the red and black Boost Pump wires to the corresponding red and black conductors in the Boost Pump cable red to red black to black using the supplied butt connectors and heat the connectors to waterproof them 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 feature 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 e Provide circuit protection at the source Inadequate wiring will cause a loss of system performance DC power should be uninterruptible Note Ifthe specified circuit breaker sizes are unavailable use the next higher rating but do not exceed the specification by more then
29. cked blown fuse at circuit board clogged filters loose or defective pressure sensor wires REMEDY Close pressure relief valve Check thru hull Check flow meter wiring at con trol box Replace flow meter Check brine discharge Clean membrane Charge batteries Check charging voltage Check power connections See remedy above for system stalled Replace fuse mini automotive type ATM Look for cause Install new filters Check sensor wiring Salinity High high product water salinity Check for low feed pressure chlorine damage to mem Check for leaks at high pressure branes hoses defective salinity probe or Remove and clean probe con cable cable disconnected tacts check calibration Check cable connections Clean membrane 42 Operation and Repair Bulletins The following documents are sections of our complete service bulletin set These are available on our website ww w spectrawatermakers com MEMBRANE CARE Membrane life 1s affected by a large number of factors and 1s somewhat unpredictable A big commercial plant running 24 7 will get 10 to 12 years out ofa 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 1mproper storage Don t let membranes sit around with
30. 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 may be located in any convenient location near the Feed pump module It should be mounted with the filter hous ing vertical and accessible for changing filters Allow 2 below the fil ter housing for removal Do not install over electrical equipment The unit contains a charcoal filter for the flush water shut off valve and flush water pressure regulator Boost Pump module sg The boost pump module should be mounted vertically with the service hose connection at the top The boost pump MUST be installed below the water line to ec ensure that it will prime Feed Pump Module Mount the feed pump module on a horizontal or vertical sur face that can be up to 3 1 0M above the waterline It is preferable to mount as low as possible Locate in an area that allows easy access to the filters the left hand side and where water spills during filter changes will not be a problem Keep future maintenance in mind when choosing a location The feed pump has overheat protection and will not operate prop 4 erly at ambient temperatures over 120F 480 Remove front cover to access mounting holes in the enclosure Clark Pump Membrane Module
31. d Before running the system remove the prefilters and examine their condition If the housings are full of smelly dis colored water the system was not properly stored Install clean prefilters if they were bad Next check the membrane Attach the brine discharge service hose and lead to a bucket Open the pressure relief valve one turn and manually run the system for 30 seconds Examine the brine water if it s discolored and smells bad perform 522 cleaning with an alternate source of unchlorinated water before running the system pressurized If the brine is fairly clean the sys tem can be purged run normally and checked for performance Clean the membranes only if performance is reduced Heating the water 15 preferable One way to do this is to find a camp stove and use a large stainless steel pot to heat the solution in The cleaning solution throughout the system will heat as it circulates in and out of the pot An alternative is to heat the one or two gallons of initial water to 120 on the main stove before mixing in the cleaner and circulating it into the system Periodically stop and reheat the solution Perform the cleaning procedures while the ship is in acceptable sea water for purging and testing 35 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 Spectra Cleaning
32. d O ring Ay End block B E SO HPP sP Ps20 Piston O ring HP TB VSP VSP20 Spool piston HP TB SR Spacer ring Valve block 5 NS QN SO HPP VB Valve bore O ring CL n Valve bore Spacer ring A yw E e 9 2 O ring p 4 p V Spool piston sale SN Brine port End block A 4 lt 0 O ring SO HPP VP Valve spool NS 9 Pilot port O rings 5 dO EE End Blocks 55 Valve port seals SO HPP VP Pilot valve port seals SO HPP PLP Center block CHOSE O rings SO HPP ECC Pilot spool O rings 4 Mount inside block SO HPP PV HP CB PVS Pilot spool HP CB PPS Pilot valve pin SO HPP PS Pin seal O rings A HP CB PVPS Pin seals X HP CB PVCR Clip rings Rod lip seals Mount inside block SO HPP PR7 PR10 PR15 O SO HPP CVP Check valve assembly Piston to rod O rings 2 Inside pistons Glass rod models only Center Block 2221 2 H Feed in Check valve port O rings 09 Piston rod HP CYL 7 8R Pilot orifice HP CB PO Center block 2 we O ring Check valve seatHP CB CVS Check valve poppet HP CB CV Check valve spring Hp CB SPR 7 Check valve washer E Check valve retainer HP CB CVSW HP CB CVR 56 S S compressio 1 2 SS tube fittings PL MTS 3 8X1 28 HP CYL SST 0 Piston with seal Composite cylinder and base HP CYL
33. d shut off the watermaker CHINES MPC 3000 Spectra watermakers MPC 5000 programming instructions can be found in section 2 of this manual DO NOT ALTER THE FACTORY DEFAULT SETTINGS WITHOUT CONSULTING WITH A QUALIFIED TECHNICIAN FIRST Dry Testing With Artificial Ocean If itis not possible to test run the system with the boat in the water testing may be accomplished with an artificial ocean Purchase enough salt to make 5 gallons 20 liters of salt water Salt water 1s 32 000ppm or 3 salt by weight Make sure that the domestic water system 1s powered up and that there 1s water in the tank Confirm that the Charcoal filter 1s installed in the Fresh water flush module and that the domes tic water line had been installed and all valves are open a o an Open Pressure Relief Valve Power up the control system Close the sea cock Press both Auto Run and Stop to bypass the purge sequence If the motor starts press Stop immediately and press the Auto run and stop button again until you get a message PURGE MODE BYPASSED Press the Auto Store button and allow the fresh water flush system to cycle through its timed operation Perform 5 consecutive flushes to purge all of the storage chemicals out of the system 20 minutes total purging If you get a SERVICE PREFILTER alarm the flush water flow 1s not enough or the feed pump is running to fast See the instructions for Flush Cycle Adjustment Hook up your service hos
34. duct flow is usually due to low voltage damaged feed pump or Clark Pump issues 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 cleaner 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 1s 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 1s 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 Use hot water if possible up to 120 F 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 15 recommended that the system 15 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 occurre
35. e 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 e The power for the system must remain on during the auto flush mode Turning off the power will disable the auto store function and damage may occur e Pressing the Auto Store button momentarily will start a flush and then activate the 5 day flush cycle The flush water solenoid will open and the display will read FRESH WATER FLUSH with a countdown timer After 30 seconds the feed pump will start after 5 7 min utes the pump will stop while the flush valve remains open for another 30 seconds Them the display will read FLUSH TIMER INTERVAL and the countdown timer will reflect the number of hours until the next flush e 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 Display will read FRESH WATER FLUSH with a countdown timer then the default display when finished e Pressing the Stop button will cancel the auto store mode and put the watermaker in standby mode 29 Manual Operation In the event of a component failure resulting in a shut down due to a false alarm the failed component can be overridden using the Programming Function on the display High Pressure Service Prefilter System Stalled airlock and Salinity Probe Failed can be defea
36. e in an area that 1s easily visible and easy to manipulate the but tons Use only Spectra approved remote cable EJ MPC 3000 The cable is not standard LAN cable or phone cord Plumbing From the inlet thru hull to the boost pump module and from the boost pump 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 pres sure Use the supplied braided clear vinyl hose rated to 150 PSI 11 bar From Clark pump brine discharge connector use supplied 5 8 15 9mm clear braided vinyl hose On the feed pressure side use the supplied Parker 1 2 tube and fittings Use two grab rings on the 1 2 parker tubing Refer to the parker assembly instructions Route all hoses and tubes to prevent kinks and restrictions Secure 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 schematic From the Clark pump brine dis charge connector use the supplied 5 8 15 9mm clear braided vinyl hose to the brine overboard fitting Mount the pressure gauge in the low pressure inlet gauge tee Use the 1 2 inch nylon tubing between the feed pump module outlet and the Clark Pump inlet Use the 1 2inch braided hose between the Flush module and the Feed Pump Modu
37. e 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 ensure this does not happen leave the very first thread uncoated Avoid restrictions or long runs on the entire inlet side of the plumbing from the thru hull to the main feed pump module Prevent tight bends and excessive elbows Any restrictions will hamper system performance Secure the piping away from moving objects such as engine belts and hatches Prevent chafe on the tubing as required Test and inspect all piping and hose clamps after several hours of operation Wiring e Pay attention to wire size or system performance will be impaired e Perform wiring to UL ABYC CE or applicable standards Component Placement Refer to the Plumbing Diagrams Strainer Mount the strainer 1 an accessible area
38. e tubing and hose before starting so additional parts may be ordered if necessary Check to see that the MPC cable is long enough to reach from the display location to the feed pump module Newport MkII shipping list e Newport Feed Pump Module e High Pressure Clark Pump and Reverse Osmosis Membrane Module e MkII Fresh Water Flush Module e MkII Installation Kit e Boost Pump Module e Newport Service Kit e 1 2 braided hose 10 e 1 2 Black Nylon tube 10 5 8 Hose 25 e 3 4 Suction Hose 25 e 3 4 Braided Hose 10 Installation Basics Tie pall Not Supplied e Read the directions e Avoid tight hose bends and excessive runs e Use heavy gauge wire e Install feed pump as low as possible e Use a dedicated thru hull with scoop type strainer LM Flow Thru hulls It is mandatory that a dedicated 3 4 to 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 conditions Sharing a thru hull with another system is not acceptable and will void the war ranty Sharing a thru hull can introduce unforeseen problems such as intermittent flow re striction 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 abl
39. ed 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 1 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 1s 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 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 43 SPECTRA WATERMAKERS MEMBRANE CLEANING WITH DETERGENT If the membrane has been fouled with oil 1t 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 solu
40. es to the Clark Pump and the boost pump module Route them into a 5 gallon 20 Liter bucket Connect a piece of 1 4 product tubing to the product outlet on the feed pump module Turn the valve on the boost pump module from Run to Service Press auto flush one or two more times to get enough water into the bucket to properly mix your salt water Close the pressure relief valve and start the system using the Auto Run Button Slowly begin adding salt Slowly add 32mg of salt per liter of water 1n the bucket Confirm the solution concentration using a hydrometer if available If you have no way to measure the salinity slowly add salt while running the machine until the feed pressure reaches 100psi 7bar 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 1s operating correctly Do not allow the water in the bucket to get above 120F 500 10 Store the system per the Storage instructions 26 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 Press the 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 with a countdown timer An
41. everse 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 1s consumed anaerobic bacteria begin to grow causing the odor Ifa unit being used frequently begins to make smelly water it will be the prefilters that are the source of the problem This occurs ina 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 gently a limited num ber of times After shutting down the unit remove the used prefilters and install a clean set Leave the housings full of air until the ne
42. 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 I 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 Newport system This water has to be figured in to the mixture A Newport system uses one SC 1 container Caution Avoid contact with skin eyes or lungs with the storage chemical i on e Spectra St T7 T uem ja X N lt e s t E in Contain ns o li th clude er 8 02 to 3 gallo T Ope a jn the ler that is in the 575 for detailed pr 5 On u 31 Storage Procedure Clean Up Step 1 Flush the system twice Push the Auto Flush button on the 5000 display when 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 Push the Auto Store button to fill the bucket with 1 gallons of fresh unchlori nated water When the bucket has reached the desired level Push the Stop button Step 4 Connect the
43. hose using the garden hose barb fitting from your service kit to the service port of the boost pump module Lead the hose into the bucket Turn the service valve on the boost pump module 180 so the intake 1s 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 Set the switch on the pump module to Service System to turn on the feed pump Circulate the storage chemical in the system for approximately 10 minutes Set the switch to Run Auto when finished Remove the quick disconnect from the Clark pump brine dis charge and replace the original hose that leads to the thru hull You may at this point 1f 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 and the MPC control LEAVE THE PRESSURE RELIEF VALVE OPEN 32 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 witha temperature rating Minus 50 antifreeze is already diluted to 25 Minu
44. 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 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 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 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 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 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 sys tem ca
45. ion solution If a hand held salinity meter 15 available you can simply take a reading of your product water while the unit is run ning then calibrate our MPC board to match that reading As long as you trust the accuracy of your hand held meter this is all that is necessary The microprocessor calculates salinity from the signals sent back to it from the probe The salinity circuit can be adjusted from the Spectra software by adjusting the Salinity Calibra tion parameter or from the display in the Salinity Cal window Increase the calibration pa rameter to increase the salinity reading Conductivity calibration solutions are available from Spectra Watermakers 1f another method of calibration 1s necessary These solutions are pre made potassium chloride solutions with known salinity levels Calibration consists of inserting our probe into the solution and setting the calibration parameter to the required value To remove the salinity probe unplug the telephone style cable from the probe Use a wrench to unscrew the probe from the manifold Re connect the salinity probe cable and you are ready to calibrate Place the flat surface of the probe containing the two metal conductivity contacts into the calibration solution being careful not to get the cable or jacks wet Uponre installation it 15 recommended to use Teflon tape on the salinity probe threads before installing to prevent leaks We also recommend putting some silicone g
46. is located behind an access opening on the left side of the feed pump module Diversion Valve Push the manual override button in and rotate 1 4 turn clock Manual Override wise to open the valve NCC button Diversion valve manual override button 30 Long Term Storage Procedures Watermakers 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 Z Brane water treatment system is installed in the system the 5 day re flush will maintain the system as long as unchlorinated pressurized fresh water 1s provided System Storage or Pickling If the system 15 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 used by the US Navy It is
47. late the antifreeze for about ten minutes 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 Turn the 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 33 Maintenance General Periodically inspect the entire system 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 1s normal Wipe down any salt encrusted areas with a damp cloth The Seawater Strainer The sea water strainer s stainless steel element should be inspected removed and cleaned as needed A clogged strainer will cause the MPC control to alarm Service Prefilters Be careful to ensure that the thru hull is closed before disassembly and the seal and element 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 Prefilters Service the prefilters as soon as possible after the prefilter condition graph begins to rise If the filter condition graph gets all the way to
48. le tre saa dds Flush water from ship s pressure water system 25 psi 2bar minimum 9 o cm o 5 oO 9 c OOOO e P INE 4 Ay Je i e tay Sa fes Nost ZA e t D m wo m 4 4 v J pi NO From the Boost Pump to the 20 micron filter inlet us the 3 4 inch ID braided hose WEFFFFFFFFFFTTTITTYIITTY i mm he a uem T E m FREE bm A 3 E I Op US 7 lt gt gt gt dh ab dere ira Wieovi LUE F T hb bh 4 Lada From the inlet thru hull to the boost pump mod ule use the supplied clear 3 4 19mm spiral suction 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 Leave room on this side for attaching tubing and operat ing the manual button on the diver sion valve j Feed water inlet from boost pump Leave enough extra length in this hose to allow the front cover to be moved aside Flush water Inlet From Flush Module Feed Water Inlet from Filters Product Water Outlet to Tank Feed Water Outlet to Clark Pump Product Inlet from Membrane 11 Product Water tubing Product water tubing is 1 4 6 3mm Parker tubing See the Parker tube fitting assembly dia gram on pg 14 Product water goes from the membrane into the
49. mp is Open unpressurized e Step 7 Use the Run Manual switch on the MPC control box to turn on the feed pump Circulate the cleaning chemical in the system for approximately 25 minutes Allow to soak for several hours or overnight 1f the solution is cold Run the pump occasionally to agitate the solution Set the toggle switch to Auto when finished Step 8 Turn off the MPC control system DC power Replace the brine overboard hose Remove the Inlet Service hose and turn the Service valve to the Run position e Step 9 To avoid damaging the membranes Follow the New System Startup Instructions to Purge the chemicals out of the System 36 Salinity Probe Calibration Salinity 1s a measurement of dissolved solids in liquid these solids will conduct electricity to varying degrees A special probe 15 used with two electrical contacts it to determine the resistance to the flow of electricity in the liquid The higher the resistance the lower the PPM of dissolved solids In the MkII systems the salinity probe is located in a port on the bottom of the feed pump module plumbing manifold 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 on the display The next step is to decide what medium to use as calibrat
50. n 41 Ballet TS tse aap cance teense M 43 M aR MISLEUI EE 53 eae wna eae 54 Pare M quM UR AD ADT D UN 59 Part 2 Controls Section 2 Programming amp Controls Begins after pg 62 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 Ensure that there 1s proper clearance around the components for removal of filters and system service Also check to make sure you have adequat
51. ner Un mM MM DE 7 mae utero uno E MI M ME MM IE 10 Parker Tube Assembly Procede oro s uu epus e 14 Vott t5 UDCE SOC E M CM ME 15 MIL ioo cun E IE 16 MPC Tank Sw tie Wiring and iein e e QS 21 Membrane Pressure Vessel Relocation 39 aue TESTOTETCOTI Sus docere nee TCR 49 Operation New Systems start 6S0 T9 a reote dine 23 BSEC UL TROU TM IDEM RN 26 Normal Start Up Usina the Uto IU e a otesest oe tei d ee ta ah ed anced veftes 21 Automatic Fresk Water ous 28 Manual CVT AU euh oett bd b audierant aei dett 30 Service amp Maintenance one Termostordse Proce Gunes 31 A SH ai Vet a M E 33 ence terete tr werent 34 Membrane n o 35 Salinity Probe Calibrations _ 37 DUSPCSICLL 38 Newport Troubleshooting Procedures eitis perro oe
52. nnot be restarted 27 Flush Cycle Adjustment Before shipping from the factory the Newport watermaker flush cycle is set to factory default settings Af ter initial start up and annually thereafter the flush cycle should be checked The water going overboard at the end of the flush cycle should not taste salty 1000ppm If the water at the end of the flush is still salty or to minimize the use of fresh water during the flush cycle follow these instructions to optimize the cycle First adjust the flush water pressure regulator Remove the 1 2 inch vinyl flush water hose where it attaches to the flush water inlet fitting at the feed pump module Push the Auto store button Water will begin to flow out of the flush water tube Using a graduated container allow the water to flow into the con tainer for exactly thirty seconds then push the stop button If more than 3 quarts 3 liters of water went into the bucket the pressure regulator is set too high if less the 2 5 quarts went into the bucket the pressure is too low Adjust the regulator by loosening the lock nut and turning the adjusting screw Test again until the correct flow 1s achieved Reconnect the Flush water tube Pressure au hi 6 i 17 B 4 4 2465 7 Decrease Speed o Increase speed switch v switch i Next adjust the feed pump flush speed Mounted under the top of the Feed Pump
53. r for leaks Check module for leaks Re prime system restart 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 power input studs Try manual bypass switches if pumps run then control or display is defective Check wiring at terminal block inside MPC Improve cooling Check tanks system cannot be started 1f tanks are full Check wiring at diversion valve and inside control box Check product tubing Replace valve contact fac tory 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 750ppm for 1 hour contact factory Close Valve 41 Spectra Watermakers Newport Troubleshooting Procedures SYMPTOMS System stalled system stalled may alarm when using the control panel to run system for servicing with the pressure relief valve open use manual override switch instead High Pressure Voltage Too Low Re starting Check Fuse followed by fuse number Service Prefilter Error Messages PROBABLE CAUSE pressure relief valve open intake thru hull closed air locked system no signal from flow meter blocked brine discharge fouled membrane battery voltage too low loose wires or poor connec tions no signal from flow meter at startup System Air lo
54. rease inside the jack to prevent moisture from causing corrosion inside the jack NOTE If the system was manufactured after April 2008 the system will use 34 software or later This software revision requires a salinity probe that is hardwired at the probe end and cannot be disconnected Use caution when removing the probe so the cable 1s not damaged 37 Short term cruising weekends etc Suggested Spares We suggest a basic cruise kit Kit consists of 3 ea 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 mem brane 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 B 5 MIC FILTER 20 MIC FILTER CHARCOAL FILTER 6 STRAINER SCREEN FEED PUMP HEAD 6 STRAINER O RING FILTER HOUSING O RING OFF SHORE KIT 40 MEMBRANE Part Number 5 KIT CHEM SC2 KIT CHEM SC3 KIT BCK B FT FTC 5 FT FTC 20 FT FTC CC FT STN 68 PL PMP 140MAG SO STN 6SS SO FHS 3PCS10 KIT OFFSH FT MB 40 38 Membrane Pressure Vessel Relocation Use ONLY Dayco Imperial Nylo Seal 88 NSR 1 2 tubing for
55. s 100 15 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 twice Push the Auto Flush button on 5000 display when the first flush has been completed press Stop to cancel the 5 day interval timer then press Auto Flush again e 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 container e Step 4 Connect the service intake hose using the garden hose barb fitting from your service kit to the service port of the boost pump 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 Set the switch on the pump module to Service System to turn on the feed pump Pump as much of the water remaining inside the water maker overboard as possible 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 e Step 7 Set the switches to Service System and Flush Auto to circu
56. sh module than the feed pump is pumping This setting will ensure that no sea water is drawn in during the flush but fresh water 1s not being wasted overboard Adjust the Pump Off time and Pump On time The flush begins and ends with the Pump Off Time set ting Pump off time should be set so that the feed pump comes on just as fresh water reaches the sea cock Pump on time should be adjusted so that the pump runs just long enough for Fresh water to reach the brine overboard fitting then stops Pump On and Pump Off times can be adjusted from the laptop computer or the display See the instructions in Section 2 Flush duration must be set the same as or higher than the total flush time two pump off times plus one pump on time 28 Automatic Store Cycle Warning Proper understanding of the Spectra flush system and the vessel s fresh water sys tem configuration is mandatory for extended Auto Store cycles The flush cycles must not be allowed to drain all the fresh water from the vessel or damage to the vessel s systems may oc cur e Make sure there is enough water 1 the fresh water supply system to supply the watermaker for more than the expected time of operation in re flush every 5 days mode New port 400 MkII units require about 6 gallons 24 liters every 5 days e Make sure that the pressure water supply is on and will stay on during the flush mode If this 15 not possible contact your certified dealer
57. stallation does not meet this requirement 3 Follow the wire gauge charts in the instructions Using larger wire than specified 1s ac ceptable 4 If you are separating the Clark Pump membrane assembly please review the high pres sure tube assembly instructions Improper assembly will cause failure 5 Run test then sea trial the complete system before assuming the system 1s opera tional If the boat is in fresh or dirty water see Dry testing the system After testing make sure that the flush cycle operates properly The water going overboard at the end of the flush should not taste salty 1000ppm 6 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 5 gallons 12L per flush 7 The MPC 5000 control must be de powered DC power off after the system is put in storage 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 1s not regis tered Table of Contents Part 1 Installation Page Number IS TUTTO Cl tes lta 5 Tastallatton ES vena 6 Compo
58. t 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 5000 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 switch 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 1s 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 t
59. ted The other safety shutdowns will still be activated The pressure sensors and salinity probe can also be calibrated from the display Complete instructions are found in Part 2 of this manual under Programming from the Display Be absolutely certain that the alarm is in error before defeating the automatic controls e In the event of complete MPC control failure the system may be operated manually by using the manual run switch on the MPC control box and manually opening the diversion valve e For manual start up switch on the feed pump by setting the feed pump switch to RUN MAN Shut the unit down if the Clark pump does not cycle if air 1s continuously present in the intake line or if the feed pump 1s excessively noisy The automatic safety controls are disabled in manual mode e 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 MANIFOLD To get a water sample loosen the 1 4 inch product tube fitting at either the feed pump module or the membrane outlet and collect a sample Check it with a handheld salinity meter or taste it e The diversion valve an electrically operated three way valve which is normally energized by the MPC controls to send water to the tank will not open automatically in manual mode Instead it must be opened using the mechanical over ride button on the valve The valve
60. tion overboard Repeat until the discharge appears clean After most of the oil 15 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 44 Z9 SPECTRA WATERMAKERS PURGE MODE BYPASS Whenever the control power 12 or 24 volt DC has been shut off the system will prompt you through the purge mode when it is turned back on This 15 because the only time the MPC 5000 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 5000 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 1s 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 45 SPECTRA WATERMAKERS BAD SMELLING PRODUCT WATER The r
61. urized when the boat is unattended for the fresh water flush system to function properly The domestic fresh water pump must be able to deliver 1 5 gallons per minute 6lpm at 25 PSI To Flush water Inlet on pump module manifold Fresh water from boat s pressure water system 13 Parker Tube Fitting Assembly Procedure Spacer Single grab ring for 1 4 amp 3 8 tube Use 2 grab rings for 1 2 tube Nut O ring Body Tubi EUN UTD 24 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 Ifthe Grab Ring is pushed too far 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 14 John Guest Super Speedfit To make a connection the tube is simply pushed Jod ree Super Speedfit fittings are made up of three components in by hand the unique patented John Guest collet id fie 4 2
62. xt use Given gentle handling prefilters can be re used up to 3 times Bad smelling product water is usually caused by bad smelling feed water but can also be caused by a fouled membrane if the membrane has been left unpickled Ifthe 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 1 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 46 2 SPECTRA WATERMAKERS 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 All Newport 400 Mk II Spectra Watermakers are equipped with a fresh water flush module This module includes a charcoal filter to remove any chlorine in the fresh water that mi ght damage the membrane The electrically operated solenoid valve opens during the fresh wa ter flush allowing the boats pressurized water system to supply water to the system The charcoal filter has

NEWPORT 400 Mk II INSTALLATION & OWNER`S MANUAL

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NEWPORT 400 Mk II INSTALLATION &amp; OWNER`S MANUAL

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NEWPORT 400 Mk II INSTALLATION & OWNER`S MANUAL