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Spectra Watermakers LB-20000 Installation And Operating Manual

Containerized watermakers with spectra connect
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LB-20,000 Containerized Watermakers
with Spectra Connect
Installa on and Opera ng Manual
Spectra Watermakers
Katadyn Desalination LLC.
2220 S. McDowell Blvd. Petaluma, CA 94954
Phone: 415-526-2780 Fax: 415-526-2787
techsupport@spectrawatermakers.com
www.spectrawatermakers.com
Updated March 7, 2018

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  • Page 1 LB-20,000 Containerized Watermakers with Spectra Connect Installa on and Opera ng Manual Spectra Watermakers Katadyn Desalination LLC. 2220 S. McDowell Blvd. Petaluma, CA 94954 Phone: 415-526-2780 Fax: 415-526-2787 techsupport@spectrawatermakers.com www.spectrawatermakers.com Updated March 7, 2018...
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  • Page 3: Table Of Contents

    Table of Contents Installation Page Number Quick Start…………………………………….…………… 5 Getting Started …………………………………………….. 6 Introduction to the System………………………………… 7 Installation…………………………………………………… 13 Tank Switch Installation …………………………………… 16 Tank Level Sensor Installation…………………………… 17 Networking…………………………………….…………… 18 Operation New Systems Start Up and Testing………………………. 20 Sensor Calibration…………………………………………...
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  • Page 5: Quick Start

    Spectra Connect Quick Start Guide When you first power up the system, you will get a warning message, asking if the sys- tem has been stored with chemicals. If the system has been pickled, winterized, this is the first startup, or the condition of the system is unknown, go to COMMIS- SIONING or serious damage may occur.

  • Page 6: Getting Started

    Please read through the complete manual before starting your installation. The system is easy to operate and maintain as long as it is installed and calibrated correctly. Spectra Watermakers Land Based Desalination Systems are shipped pre-tested and pickled with propylene glycol for shipment. The system is ready for installation with the options speci- fied with your order.

  • Page 7: Introduction To The System

    Introduction to the system The large control box contains the:  Spectra Connect control panel  Main circuit breaker for the system  The Run Manual, Run Auto and Service switch.  Start and stop buttons for manual operation The small control box is for the feed/boost pump and includes;...
  • Page 8 The Valve and Gauge panel Both of the watermakers are identical and are capable of fully automatic operation or can be run manually. In manual mode the system is still protected from loss of feed pressure and ex- cess membrane pressure, which are the two main things that can cause a fault. Note that the valves (yellow handles) are shown in the off position.
  • Page 9 Introduction to the system Feed/boost pumps The two Boost pumps pressurize water from the feed tank connected to the container. There is a basket strainer on each pump that can be checked through the clear window on the top of the unit. Note that these pumps must be full of water before starting.
  • Page 10 Introduction to the system Cartridge Pre-Filters Each system uses two 4x20” 5 micron filters as the final stage of filtration before going to the Pearson Pump and the seawater membranes. There is a button on top of each housing to bleed air out of the housing after changing filters.
  • Page 11 Introduction to the system Input / Output Manifold The ports that allow the plumbing connections to go in and out of the container are lo- cated at the floor level. The bottom two ports are feed water to the boost pumps. The next two are chlorinated product water out to the storage tank (on the left) and pressurized chlorinated water back from the storage tank.
  • Page 12 Simplified Plumbing Layout Drain manifold SP-20 Energy Recovery Pump Pressure Relief Valve Boost Media Cartridge Pump filter Filter Feed Flush Array Water Valve Flow Gauge Feed High Pressure to High Pressure Water Membranes Return Inlet Pressurized Fresh water from tank Product Charcoal water...

  • Page 13: Installation

    INSTALLATION Recommended Site Layout It is always preferable to draw feed water from a Borehole or Beach Well. Drawing water directly from the open ocean creates additional maintenance requirements, as pipes, pumps and the filtration system are exposed to sea life. All of this is avoided by using the local geology as a barrier to sea life.
  • Page 14 INSTALLATION, continued... Site requirements for container The container weighs a little under 20,000 lbs (9090 kg.) and should be mounted on a concrete pad in accord- ance with local regulations. The ideal installation has a gentle slope that allows water drain out the door and drain holes. The far end of the container needs to be elevated 5-6”...
  • Page 15 INSTALLATION, continued... The Fresh Water Flush is a 1” NPT (pipe thread) fitting. Connect the pressurized fresh water supply from the potable water delivery system to this connection. The potable water system must supply 5 gpm (20lpm) of po- table water at 30psi (2 Bar) to fresh water flush the sys- tems.

  • Page 16: Tank Switch Installation

    Tank Switch Installation Optional Tank Switches There are two types of tank float switches available depending on your installation re- quirements. Often making an assembly as pictured below (right) is a good solution as there is only a single penetration and it can be above the high water level. Typical float valve tree that is attached to the inside of the tank with a bulkhead fitting...

  • Page 17: Tank Level Sensor Installation

    Optional Tank Level Sensor Installation The optional Tank Level sensor allows even greater control of your fresh water storage systems. This unique level monitoring system requires no holes to be drilled into your tank while measuring tank volume with greater accuracy than a standard resistive float. Turn off the freshwater supply pump, close the fresh water supply valve at the water tank, then bleed off the pressure by opening a tap in the galley or head sink.

  • Page 18: Networking

    Networking Your Spectra Connect is equipped with state of the art networking options to allow the maximum user control in a wide variety of installations. The instructions below will help you get the most out of your Spectra Connect. Note: Your Spectra Connect is only available when your device is connected to the same local network as the Spectra Connect control board.
  • Page 19 Connecting to an existing Network, continued… 6. Connect your computer, tablet or smart phone to the local network your Spectra Connect is plugged into; Wired Connection: simply plug your computer’s ethernet port directly into the router or switch where you connected the watermaker. Wireless Connection: make sure your device is connected to the same local wireless network as the Spectra Connect (LAN).

  • Page 20: New Systems Start Up And Testing

    New System Start-Up and Testing Use this procedure when the system contains preservative or cleaning chemi- cals. Warning! Damage will occur if the system is not purged of the storage chemicals before pressurizing the system. Maintenance note; Get into the habit of recording the pressures and flow rates of the system in the Log Book.
  • Page 21 New System Start-Up and Testing continued... 2. Confirm there is water to the feed pumps, the pumps must be full of water (primed) before starting or damage to the seals will result. See boost pump manual for priming in- structions, if required. ...
  • Page 22 New System Start-Up and Testing continued... 4. Confirm the inlet valve and the brine discharge valves are in the RUN position  The Brine Discharge valve handle should point up  The Feed water valve handle should point down 5. Open the oilers on the SP20 crankcase and allow 5—6 drops of oil to lubricate the pump plungers.
  • Page 23 New System Start-Up and Testing continued... 8. Note that the Boost (feed) Pres- sure sensor and gauge are after the feed valve so it will only read when the feed valve is open. The Boost Pressure should be about 20 psi (1.4 Bar) during opera- tion.
  • Page 24 New System Start-Up and Testing continued... 11. After the purge sequence the display will alarm with the message “Close pressure relief valve.” Remove the tag and the rubber washer under the knob for the valve and close it. Proceed by pressing Ok to re- sume the last part of the Purge Cycle which will di- rect product water to the drain.
  • Page 25 New System Start-Up and Testing continued... Setup Instructions on Chlorine Injection System The chlorine injection system is activated when the di- version valve is directing product water to the storage tank(s). Priming the system Fill the Chlorine injection tank halfway with water and with the watermaker(s) running set both the stroke and frequency to 100%.

  • Page 26: Sensor Calibration

    Sensor Calibration Many of the settings on your system have been pre-calibrated during standard factory testing, however, there are a few settings that will vary based on the installation condi- tions. If the system has just been installed you must calibrate the Pre-filter Con- dition graph before proceeding.
  • Page 27 Tank Level Sensor Calibration (with optional transducer installed) Installing the optional tank level sensor (KIT-SC-TNKSS) will allow the control to dis- play tank levels in up to two tanks. Follow the steps below to enter the calibration se- quence for the optional Tank Level Sensor(s). The tank needs to be full to proceed with the calibration process and you need to measure the approximate height of the tank.
  • Page 28 Salinity Calibration The Salinity probe has been calibrated at the factory during testing and is not normally required during commissioning. If the product quality is not reading accurately, follow calibration steps. A handheld salinity meter (or other reliable device) is required to perform this calibra- tion as you need to confirm the salinity of the product water.
  • Page 29 Product Flow Calibration The Product Flow sensor has been calibrated at the factory during testing and isn’t normally required during commissioning. If the product flow is not reading accurately, confirm the product flow rate by following the Product Flow calibration steps. 1.

  • Page 30: Normal Operation

    Normal Operation If the system has been pickled or stored with chemicals, use the New System Startup procedure. Your system will fresh water flush after every use. Remember that you need to run the system approximately half an hour to make enough fresh water for one flush. 1.
  • Page 31 Normal Operation continued... 6. The system will now begin the start sequence and will count down to the pump starting. Pressing ‘Stop’ will stop the sequence and bring you back to the Main Menu. Once the Boost Pressure reaches the minimum threshold, the system starts oper- ating and you will be taken directly to the Main Dashboard which shows the current status.
  • Page 32 Normal Operation continued... 10. When the Run Cycle completes, the system will start the Fresh Water Flush cycle. If you stop the system (interrupting the run cycle) the system will also start a flush cy- cle. The system must be FRESH WATER FLUSHED AFTER EACH USE, or serious damage can occur.

  • Page 33: Manual Operation

    Manual Operation Each of the watermakers will operate as a manual system (no automation), protected by a low pressure switch for the feed and a high pressure switch for membrane pres- sure. The system will not stay running until the feed pressure is over 10psi, and if it drops below 10psi and it will shut down.
  • Page 34 Manual Operation continued…. 4. Turn the Main Breaker on. Main Breaker Boost pump Run Switches 5. Confirm the boost pumps are full of water. The feed tank level should allow the pump baskets to fill by just “cracking” the seal on the lid.
  • Page 35 Manual Operation continued…. 8. Turn the toggle switch to Run Manual toggle switch- Push and hold the start button to start the main pump. Run Switch Start Button Diversion Valve Product Flow Gauge  Confirm the boost (feed) pressure is 20psi and adjust the boost (feed) pump Speed control if necessary.
  • Page 36 Manual Operation continued…. Fresh Water flushing—To flush the system;  Open the pressure relief valve and Stop the watermaker  close the feed valve  Confirm the Brine discharge valve is pointing up (to drain)  Open the Flush valve Brine discharge valve Brine discharge...

  • Page 37: Other Operating Modes

    Other Operating Modes Auto Fill Mode If using the Tank Low and Tank Full switches, and both are enabled in the system settings, then your Start Menu will allow the system to be operated in Auto Fill mode. In Auto Fill Mode the Spectra Connect will automatically fill your water tank, stop itself, fresh water flush, return to auto store mode with the flush interval timer running and then turn itself on again to fill the tank as soon as the water level drops below the Tank Low Switch with no additional user commands.

  • Page 38: Auto Store

    Auto Store Warning! Proper understanding of the Spectra flush system and the fresh water sys- tem is mandatory for extended use of Auto Store. The Auto Store function flushes the system at programmed intervals. As long as the system is flushed with fresh water every 5 days you need not store the system with chemicals.

  • Page 39: Long Term Storage Procedures

    Long Term Storage Procedures Desalination systems are best run frequently as biological growth in the membrane is the leading cause of membrane fouling. A warm environment will cause faster growth than a cold environment. The fresh water flush system will greatly reduce biological growth but may not stop it completely in certain conditions.
  • Page 40 Long Term Storage Procedures Storage Procedure: SC-1 powdered preservative (good for 6 months): 1. Fill a bucket with 4 gallons (15 l) of fresh unchlorinated water, leaving at least 4” (10cm) to the top of the bucket. Mix 2 lbs (1kg) SC-1 storage chemical compound into the water in the bucket.

  • Page 41: Maintenance

    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 salt crystal formation around the Spectra-Pearson Pump blocks is normal. Wipe down any salt encrusted areas with a damp cloth.
  • Page 42 MAINTENANCE, continued... SP-20 pump The oil in the SP-20 pump crankcase should be changed every 5000 hours or if it be- comes dirty, or contaminated with water (milky). As with all high pressure pumps the seals in the Pearson Pump need to be replaced from time to time. Inspect the pump daily for leaks at the high and low pressure fittings, and at the mating surface between the black manifold layers and the blue crankcase.
  • Page 43 MAINTENANCE, continued... Seal / Ceramic Oilers The Pearson Pump comes with drip oilers which are used to extend the service life of the seals. Allow the system to run for at least one hour before allowing the seal oilers to drip. Use the same gearcase oil as used in the Pearson Pump crankcase.
  • Page 44 MAINTENANCE, continued... The Chlorine Injection System will require filling every 1-2 weeks based on the de- fault settings as described on page 25. The level of residual chlorine required based on local conditions and should be moni- tored at least weekly. Normally chlorination of 0.5 to 1 ppm after 1 hour (in the tank) is adequate., however if the containers used to transport the water are of questionable cleanliness it may be a good idea to increase the chlorination level and/or set up a cleaning/sanitation station for containers.
  • Page 45 MAINTENANCE, continued... The Membranes 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 is from biological growth that occurs when the system is left unused without flushing or pickling. Fouling from mineral scaling can happen during operation under certain sea water conditions, and from rust.

  • Page 46: Membrane Cleaning Procedures

    Membrane Cleaning Procedures The Procedure is the same for SC-2 and SC-3 1. Fill a bucket with 4 gallons (15 l) of fresh unchlorinated water, leaving at least 4” to the top of the bucket. Mix 2 lbs. (1kg) cleaning chemical compound into the water in the bucket. 2.

  • Page 47: Oil Changes

    Oil Changes GEARCASE LUBE OIL Use only Spectra PP-CC-CCO, or source ISO 68 petroleum oil locally Spectra-Pearson Pump crankcase. Do not overfill the crankcase with oil. Check oil condition and level frequently and it should be changed every 5000 hours of operation or annually, whichever comes first.

  • Page 48: Tube Fitting Information

    Black Parker tube fittings...
  • Page 49 John Guest Super Speedfit Fittings...

  • Page 50: Troubleshooting Procedures

    Troubleshooting Spectra Connect Alarms Symptom Cause Resolution Pump Knocks Loudly Incorrect Boost Pressure Increase or Decrease boost pressure as appropriate Check Pre-filtration for blockages Inadequate Feed Water Supply Check Supply Pump for proper op- eration and adequate flow through pre-filtration system Belt Skipping Teeth on Gear-End Belt Too Loose Tighten Belt...
  • Page 51 Troubleshooting Spectra Connect Alarms REMEDY PROBABLE CAUSE SYMPTOMS   Pump runs constantly, will Toggle switch on control Turn switch on control box to not turn off box to RUN MAN or SER- RUN AUTO  VICE Replace Speed Control ...

  • Page 52: Calibration

    Troubleshooting Spectra Connect Alarms SYMPTOMS PROBABLE CAUSE REMEDY   Pressure relief valve open Close pressure relief valve “System Stalled”   Intake thru-hull closed Check thru-hull alarm is caused ty the roto-   Airlocked system Purge air flow not reading properly, if ...
  • Page 53 Troubleshooting Spectra Connect REMEDY PROBABLE CAUSE SYMPTOMS   Connect the control board to a Control board not connect- Device IP in Support Menu router or switch according to ed to router or switch reads ‘NIL’  the Networking instructions Control board not receiving ...

  • Page 54: Spectra Connect Settings

    Spectra Connect Settings Your new Spectra Connect is designed to make your watermaker easier than ever to operate, maintain and enjoy. This section will guide you through some of the more ad- vanced settings options available. Always use caution when changing any factory default settings, as serious dam- age can occur.

  • Page 55: User Settings

    Spectra Connect Settings continued... User Settings LCD Brightness: Set brightness of the hardwired display(s) from 10—100% System Units: Change from US Standard units to Metric Factory Reset: Resets any changed parameters a user has made back to the factory de- faults for that configuration.

  • Page 56: Dealer Access Settings

    Dealer Access Point—Settings Dealer Access Settings It is highly recommended that users consult with a factory trained technician before altering any settings behind the ‘Dealer Access Point’. Changing this settings without understanding the full effect of each change can void the warranty of your system, and cause irreparable damage. If any settings are inadvertently changed, they can be reverted back to the defaults by using the ‘Factory Reset’...
  • Page 57 Dealer Access Point—Settings continued... Dealer Access Settings It is highly recommended that users consult with a factory trained technician before altering any settings behind the ‘Dealer Access Point’. Changing this settings without understanding the full effect of each change can void the warranty of your system, and cause irreparable damage. If any settings are inadvertently changed, they can be reverted back to the defaults by using the ‘Factory Reset’...
  • Page 58 Dealer Access Point—Settings continued... Dealer Access Settings It is highly recommended that users consult with a factory trained technician before altering any settings behind the ‘Dealer Access Point’. Changing this settings without understanding the full effect of each change can void the warranty of your system, and cause irreparable damage. If any settings are inadvertently changed, they can be reverted back to the defaults by using the ‘Factory Reset’...

  • Page 59: Fault Explanations

    Handling Spectra Connect Alarms or Faults Faults are (potentially hazardous) conditions that might occur during running of your watermaker. The control board has the ability to monitor these faults in real time and take necessary actions to prevent damaging your equipment. HIGH PRESSURE FAULT High pressure fault is triggered if Outlet pressure (Feed/Membrane pressure) >...

  • Page 60: Bulletins

    Poor Product Water Quality With any product water quality issue, you must ensure accurate calibration if you are using a salinity meter. For general quality evaluation, your taste is always good enough. Membranes are not an exact science and two identical systems can have different product quality.

  • Page 61: Wiring Schematics

    Operation and Repair Bulletins The following documents are sections of our complete service bulletin set available on our website Spectrawatermakers.com. Technical Support, - Service Bulletins. MB-2 MEMBRANE CARE Membrane life is affected by a large number of factors and is somewhat unpredictable, however five or six years of use is typical.
  • Page 62 MB-5 MEMBRANE CLEANING WITH DETERGENT If the membrane has been fouled with oil it may be possible to save it by cleaning with dish soap such as Joy, but do not use anything that contains bleach. You will need a lot of chlorine free fresh water.
  • Page 63 BAD SMELLING PRODUCT WATER The reverse osmosis membrane is permeable by many gases including hydrogen sul- fide, the gas that causes rotten egg smell. 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 plankton trapped in the sea strainer and pre- filters These tiny oxygen loving creatures soon suffocate and die inside the pre-filter...

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