Table of Contents
Troubleshooting
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Summary of Contents for Spectra Watermakers Ventura 150T MPC
- Page 1 Ventura 150/200T MPC Installation and Operating Manual Spectra Watermakers Katadyn Desalination LLC. 2220 S. McDowell Blvd. Petaluma, CA 94954 Phone: 415-526-2780 Fax: 415-526-2787 techsupport@spectrawatermakers.com...
- Page 3 MPC Controller Quick Guide To bypass the Purge Mode, only if you are Program Mode allows checks and adjustments of sure there are no chemicals in the system, all system settings. Please consult your manual be- Press Auto Run and Stop, momentarily at fore making any adjustments.
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Page 5: Table Of Contents
Table of Contents Installation……………………………………………………………………………………………... Getting Started ........................ 9 Introduction ........................10 Installation Basics ......................11 Ventura Plumbing Schematic ..................12 Product Water plumbing ....................13 Tube Fitting Assembly Procedures ................. 14 Spectra High Pressure Fitting Instructions ..............15 Wiring ........................... 16 Salinity Probe Installation .................... - Page 6 Table of Contents continued... MPC-5000 Programming & Controls …………………………………………………………………..61 Introduction ........................63 MPC 5000 Operation Guide ..................64 Display Controls ......................65 Programming from the Display ..................68 Salinity Probe Calibration ....................71 Wiring Schematic ......................72 MPC 5000 PCB Fuses and Electrical Specifications............73 Exploded Views and Part Numbers ………………………………………………………….………...75...
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Page 7: Installation
Installation... -
Page 9: Getting Started
Getting Started Unpack the system and inspect it for damage during shipping. Freight damage must be report- ed to the carrier within 24 hours. Refer to the shipping list for your system to ensure you received all of the components listed. Do not discard any packaging until you have found and identified all of the parts. -
Page 10: Introduction
Introduction to the Ventura MPC The Ventura is the finest watermaker for small and midsized yachts. Properly installed and maintained it will supply years of reliable service. The MPC 5000 automatic control system adds programmability, automated operation, and system monitoring. Prudent operation is re- quired with any marine equipment. -
Page 11: Installation Basics
Installation Basics Thru-hull Read the directions! Not Supplied. Avoid tight hose bends and excessive runs. Use heavy gauge wire. Install feed pump module as low as possible. Use a dedicated thru-hull with scoop type strainer. ... -
Page 12: Ventura Plumbing Schematic
Ventura MPC Plumbing Brine Discharge thru-hull. Place above waterline or tee into an- other visible drain. Thru-hull not supplied Spectra Clark Pump. Mount in a cool location. May be oriented in any position and can be well above waterline. Leave access to the pressure relief valve. Do not mount over electrical equipment. -
Page 13: Product Water Plumbing
Product Water Plumbing The 1/4”(6mm) product water tubing is pre-plumbed from the membrane into the electric di- version valve. The diversion valve will reject product water into the overboard brine stream until MPC-5000 control determines the product water is below 750 PPM salinity. Once below 750 PPM, the MPC 5000 control opens the diversion valve and product water is diverted into the fresh water tank. -
Page 15: Spectra High Pressure Fitting Instructions
Spectra High Pressure Tube Fitting Assembly Instructions The Ventura Deluxe has eight high pressure fittings, two on each cylinder on the Clark Pump, two on the pressure vessel end caps, and two 90-degree elbows on the back of the Clark Pump. -
Page 16: Wiring
Wiring Mount the control box with 4 appropriate fasteners on a vertical surface, above components containing water, with the wire grommets down, and central to the other system components. Make sure the cables will reach all of the modules to avoid splices. The main power feed should come from an appropriately-sized fuse or breaker on the main DC panel. - Page 17 Wiring continued... Mount the terminal block from the feed pump and attach the pump power wires coming from the MPC control box. Both wire bundles are marked with green heat shrink tubing. Run the pressure sensor cables from the MPC control box to the filter housings.
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Page 18: Salinity Probe Installation
Wiring continued... Rotoflow and Diversion Valve: The Rotoflow meter measures product flow, and is supplied with a three-pin plug-in connector. Plug it in to the Rotoflow cable and seal the connection with the supplied heat shrink tubing. The diversion valve cable has two wires with no polarity, so they can be connected either way. -
Page 19: Mpc Tank Switch Wiring And Operation
MPC 5000 Tank Switch Installation and Operation By installing a float switch at the top of your water tank, the watermaker can shut itself down and fresh water flush itself when the tank is full. Automatic operation using a float switch could potentially flood a boat or run ship’s batteries completely dead, so it is imperative that you have a thorough understanding of the automatic operation, and your ship’s plumbing and electrical systems. - Page 20 Tank Switch Wiring: Tank full switch wired to Float Switch 1 ter- minals; jumper across Float Switch 2 terminals...
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Page 21: Optional Z-Ion And Z-Brane Membrane Protection Systems
Optional Z-Ion and Z-Brane Membrane Protection Systems The Z-Ion and Z-Brane, both developed by Spectra, are systems to protect the reverse osmosis membrane from fouling for extended periods without fresh water flushing or storage chemi- cals (pickling). The Z-Ion achieves this end by introducing a stream of metallic ions into the fresh water flush module, thus flooding the entire system with ions that prevent biological growth for up to thir- ty days. -
Page 22: Z-Ion Installation
Z-Ion Installation The Z-Ion replaces the fresh water flush module on the feed pump module, and will come in- stalled if you ordered your system with the optional Z-Ion. The Z-Ion filter bowl, like the nor- mal fresh water flush module, houses the charcoal filter, which must be replaced every six months. - Page 23 Z-Ion Operation This revolutionary adaptation of an ancient technology effectively and safely protects the mem- brane and filters on your Spectra Watermaker. Your system will be kept ready to operate with- out any additional flushing, external power sources, pickling chemicals, or complex procedures. The Z-Ion should be energized at all times, but will only consume power when water is running through it.
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Page 24: Z-Ion Testing
Testing the Z-Ion Normally no adjustment is necessary as the unit has been set up at the factory for your water- maker, however it is advisable to make sure the Z-Ion is working properly. Likewise, the fol- lowing test is the only way to know if the probes on the Z-Ion need replacement. There is no way to test for silver ions, but we can test for copper ions. -
Page 25: Z Brane Installation
Z-Brane Installation Spectra ships the high pressure module with the white Z-Brane anode removed from its socket to prevent shipping damage. Before the high pressure module (Clark Pump and membrane) is mounted the anode should be installed. The membrane housing has been capped with shipping plugs to keep the membranes clean and moist during shipping and storage. - Page 26 Z-Brane Wiring The Z-Brane system is integrated with the watermaker and only requires continuous 12V or 24V DC power to operate. WARNING! SHOCK HAZARD!: There is no reason to open the transformer enclosure. Do not service this unit unless it is disconnected from the power source! There may be high voltage present even after the transformer is de-powered! We recommend that the Z-Brane be connected to its own electrical circuit.
- Page 27 Z-Brane Operation During normal operation the Red LED should be on. Power needs to be supplied to the Z- Brane unit whenever you wish to prevent bio-fouling and scaling. We recommend flushing your watermaker with fresh water after each use, which will protect your membrane and also prevent corrosion in the feed water system.
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Page 29: Operation
Operation... -
Page 31: New Systems Start Up And Testing
New System Start-Up and Testing Avoid running the Ventura system if the vessel is in contaminated water. The system should be fully tested before leaving port. If the location or weather prevents proper testing, refer to Dry Testing with an Artificial Ocean on page 34. Warning! Damage may occur if the purge sequence is bypassed and the membrane is pressurized with storage chemical in it. - Page 32 New System Start-Up and Testing continued... The system will go into a starting mode and the feed pump will start shortly thereafter. The fresh water flush solenoid will open, allowing water from your pressurized fresh water system to help prime the pump. The system should prime within 30-90 seconds. Check the strainer and the brine discharge for water flow.
- Page 33 MPC Display Modes (Scroll through the modes with the Alarm Display key.) Product The Ventura 150 produces 6-6.5 Gallons Per Hour (GPH) or 26—27 Liters Per Hour (LPH) of product (fresh) water. The Ventura 200T produces 7.7-8.5 GPH (29—32LPH) Salinity Salinity readout displays the conductivity of the product water in parts per million (PPM).
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Page 34: Dry Testing With An Artificial Ocean
Dry Testing with an Artificial Ocean If it is not possible to test run the system with the boat in the water, you may test the system with an artificial ocean. You will need 1.3 lbs. of non-iodized salt (rock salt, sea salt, or aquarium salt) to make a 5 gallon (605 grams of salt per 20 liters) of water that is about 33,000 PPM salini- ty (average seawater salinity). -
Page 35: Normal Operation And Fresh Water Flush
Normal Operation and Fresh Water Flush If the system has been pickled or stored, use the New System Startup procedure on page 31. You should fresh water flush your watermaker after every use. Remember that you need to run the system almost a half hour to make enough fresh water for one flush. You may notice that the system output is higher when charging your batteries, as the watermaker is voltage sensitive. -
Page 36: Auto Store And Flush Cycle Adjustment
Auto Store Warning! Proper understanding of the Spectra flush system and the vessel’s fresh water system is mandatory for extended use of Auto Store. The flush cycles must not be allowed to drain all the fresh water from the tank or damage to the vessel’s systems and the watermaker may occur. As described in Normal Operation and Fresh Water Flush, on page 35, the Auto Store function flushes the watermaker at programmed intervals. -
Page 37: Alarm Override And Manual Operation
Alarm Override and Manual Operation In the event of a sensor failure resulting in a shut down due to a false alarm, the failed sen- sor can be overridden using the programming function on the display (pages 68-70). High Pres- sure, Service Prefilter, System Stalled (airlock), and Salinity Probe Failed can all be overridden and the system will still run automatically with all other functions intact. -
Page 39: Maintenance, Storage, And Troubleshooting
Maintenance, Storage, and Troubleshooting... -
Page 41: Suggested Spares
Suggested Spares for Ventura MPC Short term cruising, weekends etc. A basic cruise kit B. This kit consists of three 5 micron filters, three 20 micron filters, and SC- 1 storage chemical. Cruising 2 to 6 months at a time. Two basic cruise kits, one replacement charcoal filter, and one replacement feed pump head. -
Page 42: Maintenance
Maintenance General Periodically inspect the entire system for leakage and chafing. Repair any leaks as soon as you find them. Some crystal formation around the Clark Pump blocks is normal. Wipe down any salt encrusted areas with a damp cloth. Watermakers are at their best when run regularly. - Page 43 Maintenance continued... The Feed Pump and Clark Pump The feed pump and the Clark Pump require no routine maintenance except inspection for leaks. Tighten any hose clamps or fittings that show signs of leakage. The high pressure fittings threaded into the Clark Pump have O-ring seals with a straight thread. These should never leak and should never be over-tightened.
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Page 44: Introduction To Spectra Chemicals
Introduction to Spectra Chemicals We use four types of chemicals: SC-1, SC-2, SC-3, and propylene glycol antifreeze. SC-1 and propylene glycol are for system storage, while SC-2 and SC-3 are for membrane cleaning. Do not use metasodium-bisulfate, citric acid, or any other storage chemical not supplied by Spectra. - Page 45 Introduction to Spectra Chemicals continued... Complete microbial preservative protection requires a 25% solution of propylene glycol, so care must be taken that the solution remaining in the watermaker during long term storage is at least 25%, even if freeze protection is not required. For these reasons Spectra recommends that all pickling be carried out with a 60% or greater concentration.
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Page 46: Long Term Storage Procedures
Ventura MPC Storage Procedure 1. Turn the yellow service valve on the feed pump module to OFF (horizontal, see photo). 2. Push Auto Store to fresh water flush the system. Repeat, to flush the system twice. 3. Remove the cap on the service port on the feed pump module and install the inlet service hose from the service kit. -
Page 47: Winterizing With Propylene Glycol
Winterizing with Propylene Glycol See description of propylene glycol formulations, and flushing from system, on page 44-45. 1. Turn the yellow service valve on the feed pump module to OFF (horizontal, see photos). 2. Push Auto Store to fresh water flush the system. Repeat, to flush the system twice. 3. -
Page 48: Membrane Cleaning Procedure
Membrane Cleaning Procedures Spectra cleaning compound (SC-2 or SC-3) must be mixed with fresh water at a ratio of 1 container of compound to 3 gallons (12L) of unchlorinated water. An average of two gallons (8L) of water is already present inside a Ventura system, so this water must be figured into the mixture. -
Page 49: Troubleshooting
Troubleshooting Ventura MPC Systems REMEDY PROBABLE CAUSE SYMPTOMS Feed pump runs constant- Turn off manual switch on control Manual switch in ON ly, will not turn off position on control box Feed pump runs with loud Intake blocked Check thru-hull valve ... - Page 50 Ventura MPC Fault Alarms SYMPTOMS PROBABLE CAUSE REMEDY Pressure relief valve open Close pressure relief valve “System Stalled” Intake thru-hull closed Check thru-hull (“system stalled” may alarm Airlocked system Purge air when using the control pan- ...
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Page 51: Poor Water Quality
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 52: Ventura Flow Test
Ventura Flow Test The flow test is the most useful diagnostic test for system performance, and should be done be- fore replacing or cleaning your membrane. Changes in production or water quality are normally caused by something other than the membrane, unless the system has been left unused for a long time. - Page 53 1. Product Flow: Product flow is expressed in Gallons Per Hour (GPH) or Liters Per Hour (LPH), by this equation: 3600 ÷ time in seconds x quantity of water in gallons or liters=GPH or LPH There are 3600 seconds in an hour. Example: It took 3 minutes and 35 seconds to collect 1 gallon of product water.
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Page 54: Technical Bulletins
Technical Bulletins The following pages include Spectra’s most commonly used technical bulletins, covering tests, adjustments, troubleshooting, and common points of confusion. Many more technical bulle- tins are available on the Spectra website, www.spectrawatermakers.com. ACCUMULATOR PRESSURE Your Spectra watermaker is supplied with a pressure accumulator tank (PL-ACC-TK), which should be installed in the feed water line between the pre-filters and the Clark Pump. - Page 55 PREFILTERS During normal operation, the feed water is filtered in two stages. First it passes through a fine mesh metal sea strainer, which protects the feed pump from foreign materials and sea crea- tures. After passing through the feed pump, the feed water passes the filter housings contain- ing 20 and 5 micron elements, removing very fine particles that could damage the Clark Pump and shorten membrane life.
- Page 56 CHARCOAL FILTERS The charcoal filter element (FT-FTC-CC) removes chlorine from the fresh water flush water supply, as the RO membrane can only handle small amounts of chlorine without permanent damage. The charcoal filter used for the fresh water flush system will not plug up unless you have very dirty domestic water in your boat’s supply tank.
- Page 57 SHURFLO PUMP WON’T RUN If the pump has power to it but the pump won’t run, first check the pressure switch. The pres- sure switch (EL-FP-PS) is located on the wet end of the pump and has two red wires plugged into it (see photo, next page).
- Page 58 ADJUST SHURFLO PRESSURE SWITCH Shurflo feed pumps are equipped with a high pressure cutout switch (EL-FP-PS). This is the small black unit on the end of the wet end of the pump head (PL-PMP-SFPH) where the two red wires connect. If the pressure switch is not properly adjusted the pump may cut out each time the Clark pump cycles and the feed pressure spikes.
- Page 59 Performing a Fresh Water Flush with a Failed Salinity Probe In the event of a “Salinity Probe Failed” alarm on the remote display the alarm function can be defeated to allow the system to remain in the Auto Store mode until repairs can be facilitated. Access the program mode, as outlined on page 68, Programming from the Display.
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Page 61: Mpc-5000 Programming & Controls
MPC 5000 Programming and Controls... -
Page 63: Introduction
Introduction to the MPC 5000 Your new MPC 5000 with Battery Back-up is packed with features to make operating your Spectra Watermaker easy, intuitive, and automatic. All operating data for your watermaker is at your fingertips, including Feed Pressure, Filter Condition, Water Quality, Operating Mode, and Elapsed Time Counter. -
Page 64: Mpc 5000 Operation Guide
Spectra MPC 5000 Operation Guide This document outlines the MPC 5000 with Battery Backup operation. It details what is seen on the display, what outputs are active during run-time, and the functions of the different modes. Ventura systems use a single feed pump that runs at one speed, usually without a boost pump. -
Page 65: Display Controls
MPC 5000 Display Controls Auto Run: Pressing the Auto Run button in the top left corner of the display activates the MPC’s automated run sequence: The fresh water flush solenoid valve opens for 20 seconds to prime the feed pump. The display will begin to count down from 10, then feed pump will run. - Page 66 MPC 5000 Display Controls continued... Stop: Pressing the Stop button in the lower left corner of the MPC display will stop any cur- rent action. In standby mode pressing Stop will activate the manual run sequence: The fresh water flush solenoid valve opens for 20 seconds to prime the feed pump. The display counts down from 10, then feed pump will run.
- Page 67 The system will perform a single fresh water flush, then return to the default screen, dis- playing “Spectra Watermakers X-XX”. The system will remain in standby mode indefinitely until another key is pressed. Auto Store for 5 seconds:...
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Page 68: Programming From The Display
To enter Standby Mode, press the Stop button from any other mode. The display will read SPECTRA WATERMAKERS A-XX. To have the watemaker running during the programming pro- cess, start the machine using the run manual toggle switch on the control box. The watermak- er will run but the controls will be in standby mode. - Page 69 DISABLE PRESSURE: THIS IS A SAFETY SHUTDOWN. SELECT NO. Select YES only if you are getting a FALSE “High Pressure” alarm. DISABLE SALINITY: Factor default is NO. This function allows you to run the watermaker in the event of a salinity probe, probe cable, or salinity sensing circuit failure. If you get a “Salinity Probe Failed”...
- Page 70 INLET OFFSET: This parameter calibrates the pressure sensor on the inlet side of the black pre - filter housings. This sensor, and its cable, are usually marked with red heat shrink tubing. The num- ber on the left is the real time pressure reading and the number on the right is the offset. Factory default for Ventura models is 0.
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Page 71: Salinity Probe Calibration
Salinity Probe Calibration Salinity is a measurement of dissolved solids in liquid. These solids will conduct electricity to varying degrees. A probe with two electrical contacts determines the resistance to the flow of electricity in the liquid. The higher the resistance, the fewer the PPM (parts per million) of dis- solved solids. -
Page 73: Mpc 5000 Pcb Fuses And Electrical Specifications
MPC 5000 FUSES The CHECK FUSE alarm indicates that one of the seven fuses on the MPC-5000 Printed Circuit Board has blown. These fuses are the flat, color-coded, small ATM automotive style. The dis- play will indicate by number which fuse has blown, and the fuse bases are numbered on the board. -
Page 75: Exploded Views And Part Numbers
Exploded Views and Part Numbers... - Page 77 Pump to Pressure Vessel Part Numbers Upper SS Tube: PL-TB-HP-HPTVUS Front View Pump to Pressure Vessel Upper SS Tube: PL-TB-HP-HPTVUS Rubber Mount HD-RBP-RM Nickel-Bronze High Pressure Plastic Spacer Elbow HD-SPN-MKINS PL-MTE-3/4S1/2B Plate Bracket End Cap Pump to Pressure Vessel FM-PVB-PBE Lower SS Tube: PL-TB-HP-HPTPVLS Nickel-Bronze High Pressure...
- Page 78 Part Numbers 5/8 Quick Disc. Hose Barb PL-QDC-HB5/8 3/8 NPT Quick Disc. Body PL-QDC-BD3/8 Pressure Sensor 3/8”NPT X 5/8” Hose Barb El. EL-SSR-150 1/2” Female Tee PL-HBE-3/8X5/8 PL-TEE-1/2FN Filter Housing 1/2”NPT X 5/8 3/4”NPT X 5/8 Hose Barb El. Bracket Duplex Hose Barb FT-FHB-10HD 1/2”...
- Page 79 Part Numbers PL-MTE-3/8x1/4 PL-SLN-1/4D12 3/8”x1/2” TUBE FITT. 1/4" DIVERSION VALVE 12V/24V PL-CKV-1/4M-F 1/4" PLASTIC CK VALVE (M-F) SUB-NP-DVM PL-MTS-1/4X3/8P DIVERSION VALVE MAN- 1/4"MPT X 3/8" TUBE FITT. ST. IFOLD EL-MPC-SP4 PL-FTS-1/4X1/4P SALINITY PROBE 1/4"FPT X 1/4"TUBE FITT ST. REDUCING COUPLING EL-SSR-IFM PL-UNN-3/8X1/4N INLINE FLOW METER SENSOR...
- Page 80 Part Numbers Valve End Block B HP-TB-VEB-B 3/8”NPT Quick Disc. Coupling Body PL-QDC-BD3/8 5/8” Quick Disc. Fitting Hose Barb PL-QDC-HB5/8 3/8” Low Pressure Tube PL-NLT-3/8LP 3/4”-16 Straight Thread 1/4” Product Tube O-RING PL-NLT-1/4LP SO-FT-STF 1/2” Stainless Ferrule PL-HWR-1/2FR PL-MTE-3/4S1/2B Connector O-RING Stainless Fitting Hex Nut SO-HPP-CT PL-HWR-1/2HN...
- Page 81 Part Numbers 3/4”NPT X 1/2” Hose Barb Elbow PL-HBE-3/4X1/2 3/4” 3-Way Valve PL-VLV-3W3/4 1-Way Solenoid Valve 12V, 24V PL-SLN-1/4O12, 024 Cooling Fan 12V, 24V KIT-FK-12,24 Feed Pump Heat Sink EL-FP-FPHS Clear Filter Housing (Bowl & Cap) FT-FTH-10L3PCS Ventura Feed Pump Bracket Clear Filter Housing O-ring FM-VT-ITM SO-FHS-3PCS10...
- Page 82 HP-TB-VEB-B HP-TB-VB HP-TB-VEB-A HP-CYL-CCA HP-TB-BV HP-CB-CB7, HP-CYL-SST HP-CYL-R HP-CYL-EC Not used...
- Page 83 HD-CPS-5/16X3 SO-HPP-RV HP-TB-AR KIT-HP-10VSA HP-TB-BV SO-HPP-AR HD-CPS-5/162.75 SO-HPP-SP, PS20 HP-TB-VSP,VSP20 HP-TB-SR SO-HPP-VB SO-HPP-VP SO-HPP-PLP...
- Page 84 Parts HP-CYL-3/4R,...
- Page 85 Parts HP-CYL-SST HP-CYL-PT PL-MTS-3/8X1/2S HP-CYL-CCA SO-HPP-ECCB HP-CYL-EC HP-CYL-R...
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