Spectra Watermakers Newport 400 Installation And Owner's Manual

Spectra Watermakers Newport 400 Installation And Owner's Manual

Spectra watermakers water system installation manual

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NEWPORT 400 MPC-5000 MkII
INSTALLATION & OWNER'S
MANUAL
Part 1..........Installation, Operation, Maintenance
Part 2....................... Programming and Controls
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
1-28-07 mpc5000
1

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Summary of Contents for Spectra Watermakers Newport 400

  • Page 1 NEWPORT 400 MPC-5000 MkII INSTALLATION & OWNER’S MANUAL Part 1……...Installation, Operation, Maintenance Part 2………………….. Programming and Controls 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 1-28-07 mpc5000...
  • Page 3 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.
  • Page 5: Table Of Contents

    Installation Getting Started ... 7 Installation Basics ... 8 Component Placement ... 9 Plumbing ... 12 Parker Tube Fitting Assembly Procedure ... 16 Wiring ... 17 MPC Tank Switch Wiring and operation... 22 Membrane Pressure Vessel Relocation ... 40 Z Brane Installation... 51 Operation New Systems Start Up and Testing ...24 Dry Testing...27...
  • Page 7: 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.
  • Page 8: Installation Basics

    Read the directions! • Avoid tight hose bends and excessive runs. • Use heavy gauge wire. • Install feed pump as low as possible. • Use a dedicated thruhull with scoop type strainer. • Thru-hulls It is mandatory that a dedicated 3/4” to 1” forward facing scoop type intake thru-hull and seacock be installed.
  • Page 9: Component Placement

    Strainer 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 may be located in any convenient location near the Feed pump module.
  • Page 10 Clark Pump/Membrane Module Pressure Relief Valve The membrane maximum temperature specification is 120F. This module must be installed in an area that maintains a temperature below 120F (50C). 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.
  • Page 11: Plumbing

    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.
  • Page 12 System Piping schematic Use the 1/2 inch nylon tubing between the pump module Outlet and the Clark Pump From the Boost Pump to the 20 micron filter inlet us the 3/4 inch ID braided hose. From the inlet thru hull to the boost pump mod- ule use the supplied clear 3/4 (19mm) spiral suction rated hose.
  • Page 13: Programming From The Display

    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.
  • Page 14 Product Water tubing Product water tubing is 1/4 “ (6.3mm) parker tubing. See the Parker tube fitting assembly dia- gram next page. Product water goes from the membrane into the pump module manifold where it passes through the flow meter, the salinity sensor and the diversion valve. If the salinity is good the diversion valve energizes and the product goes to the tank from the manifold product outlet.
  • Page 15 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.
  • Page 16: Parker Tube Fitting Assembly Procedure

    Parker Tube Fitting Assembly Procedure O-ring Body 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.
  • Page 17: Wiring

    Identify cables that are connected to the Newport Control System. Newport MkII Systems have a Power Inlet harness with a terminal block, a 50’(15M) cable with connectors is supplied for the MPC-5000 control display and a two concuctor boost pump power cable. Boost pump cable Wiring 50’...
  • Page 18: Component Sizing

    Mount the main power terminal block in a junction box or 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 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.
  • Page 19 Newport MkII 12V DC System Wiring Wire Length FT. MkII 24V Wire length for a pair of wires is measured from source circuit breaker or fuse to control terminal block. WIRE SIZE CHART Meters AWG. 10.6 Meters AWG. 10.6 SQ MM SQ MM...
  • Page 20 Use only the buzzer units supplied by Spectra Watermakers, as current on the LCD buzzer terminal is limited to 20 mA, any excessive load may damage the controller or remote display panel.
  • Page 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 in the Z-Brane section.
  • Page 22: Mpc Tank Switch Wiring And Operation

    Tank Switch Installation and Operation: There are two sets of terminals on the MPC-5000 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”...
  • Page 24: New Systems Start Up And Testing

    New System Start-Up and Testing Avoid running the system if the vessel is in contaminated water, which might contain oil or high levels of bacteria. 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.
  • Page 25: Computer Settings

    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.
  • Page 26: Salinity Probe Calibration

    Product Flow Newport MkII Will produce 14 -16 (54-60LPH) NOTE: To toggle between Imperial (gallons) and Metric Units (Liters) push and hold Alarm/Disp for 5 sec- onds. Salinity Salinity reads in parts per million. Sys- tem rejects water higher than 750 PPM. Anything below 500 is excellent.
  • Page 27: Dry Testing

    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 salt to make 5 gallons (20 liters) of salt water. Salt water is 32,000ppm or 3% salt by weight.
  • Page 28: Normal Operation

    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 Auto Run button once and the system will prime and run for 1 hour. The display reads •...
  • Page 29: Automatic Fresh Water Flush Cycle

    Before shipping from the factory the Newport watermaker flush cycle is set to factory default settings. After initial start up, and annually thereafter, the flush cycle parameters must be ad- justed to ensure that the salt water is thoroughly flushed out of the machine while at the same time using the least amount of fresh water possible.
  • Page 30 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.
  • Page 31: 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 defeated. The other safety shutdowns will still be activated.
  • Page 32: Long Term Storage Procedures

    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.
  • Page 33: Storage Procedure

    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 •...
  • Page 34: 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.
  • Page 35: 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 is 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 •...
  • Page 36: Membrane Cleaning

    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.
  • Page 37: Cleaning Procedure

    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.
  • Page 38: Salinity Probe Calibration

    Salinity Cal window. Increase the calibration pa- rameter to increase the salinity reading. Conductivity calibration solutions are available from Spectra Watermakers if another method of calibration is necessary. These solutions are pre-made potassium chloride solutions with known salinity levels.
  • Page 39: Suggested Spares

    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...
  • Page 40: Membrane Pressure Vessel Relocation

    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.
  • Page 41 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.
  • Page 42: Newport Troubleshooting Procedures, Service Bulletins

    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”...
  • Page 43 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 High” “Voltage Too Low”...
  • Page 44: Bulletins

    Operation and Repair Bulletins The following documents are sections of our complete service bulletin set. These are available on our website Spectrawatermakers.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.
  • Page 45: Membrane Cleaning

    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.
  • Page 46 MPC-5 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 is 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.
  • Page 47 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...
  • Page 48 PF-1 PREFILTERS- VANE PUMP SYSTEMS Five different filters are used on these Spectra Watermakers to make sure that no damaging foreign materials enter the system. There are four filters in the system to clean the feed wa- ter of abrasive materials while the system is in operation, and a fifth filter that prevents the entrance of chlorine during fresh water flushing.
  • Page 49: Charcoal Filters

    PF-2 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.
  • Page 50 Z-BRANE OPERATION MANUAL...
  • Page 51: Z Brane Installation

    The Z-brane is a revolutionary product which incorporates the Z-Guard High Voltage Capacitive technology into the membrane pressure vessel. Always active, the Z-Brane creates an environment that is unfriendly to bio-film and bacteria. The Z technoalgy also assits in the prevention of scale formation on the membrane surfaces. The Z-Brane allows the system to be shut down or decommissioned for extended periods of time without chemicals or preservatives.
  • Page 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 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.
  • Page 53 End block B HP-TB-VEB-B1 Valve block HP-TB-VB End block A HP-TB-VEB-A1 Brine out Stainless steel tube HP-CYL-SST Cylinder ring HP-CYL-R End Cap HP-CYL-EC End block A Valve block End block B Reset button HP-TB-RSBT Not on all units Alternate brine out Stainless steel tube Cylinder ring End cap...
  • Page 54 5/16"-3 1/4" SS AH Bolts Annular Rings HP-TB-AR Spool Assembly KIT-HP-10VSA Valve bore O-ring SO-HPP-VB Spacer ring Spool piston End block A HD-CPS-5/16X3 Annular Ring O-Rings Mount inside Valve Block SO-HPP-AR 5/16"- 2 3/4" SS A.H. bolts HD-CPS-5/162.75 Reset button and O-ring End block B Piston O-ring SO-HPP-SP, PS20...
  • Page 55: Center Block

    Pilot valve port seals SO-HPP-PLP Center block cylinder O-rings SO-HPP-ECCB 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 Pin seals HP-CB-PVPS Clip rings HP-CB-PVCR Rod lip seals Mount inside block SO-HPP-PR7, PR10,PR15 Check valve port O-rings...
  • Page 56: Cylinder Assembly

    S.S compression fittings PL-MTS-3/8X1/2S End cap O-ring SO-HPP-ECCB Cylinder end cap HP-CYL-EC 1/2" SS tube HP-CYL-SST Composite cylinder and base HP-CYL-CCA Cylinder Ring HP-CYL-R Cylinder Assembly Piston with seal HP-CYL-PT...
  • Page 57 10% CLARK PUMP PARTS LIST PART HP-CB-CB10 CENTER BLOCK HP-CB-INS CENTER BLOCK INSERT HP-TB-VB VALVE BODY HP-TB-BV BLEED VALVE HP-TB-VEB-A1 VALVE END BLOCK A 1-1/4" HP-TB-VEB-A2 VALVE END BLOCK B 1-1/4" HP-CB-PVPS PILOT VALVE PIN SEAL HP-CB-PPS PILOT VALVE PIN HP-CB-PVCR PILOT VALVE CLIP RING HP-CB-SPRP...

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