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Spectra Watermakers CATALINA 300 MPC-5000 Installation & Owner's Manual

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CATALINA 300 MPC-5000
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
20 Feb,2006 MPC-5000
1

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Summary of Contents for Spectra Watermakers CATALINA 300 MPC-5000

  • Page 1 CATALINA 300 MPC-5000 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 20 Feb,2006 MPC-5000...
  • Page 3 Thank you for your purchase of a Spectra Catalina 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

    Table of Contents Installation Page Number Getting Started ........................7 Catalina Schematic ......................8 Installation Basics ........................9 Component Placement .......................10 Plumbing..........................13 Parker Tube Fitting Assembly Procedure ................16 Membrane Pressure Vessel Relocation................17 Wiring ..........................19 MPC Tank Switch Wiring and operation……………………………………………….. 25 Wiring Diagram .........................26 Z Brane Installation ......................53 Operation New Systems Start Up and Testing ...................27...

  • Page 7: Getting Started

    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 9: Installation Basics

    Installation Basics Thru-hull not supplied. Read the directions! • Avoid tight hose bends and excessive runs. • Use heavy gauge wire. • Install feed pump as low as possible. • Use a dedicated thru-hull with scoop-type strainer. • Flow Thru-hulls It is mandatory that a dedicated ”...

  • Page 10: Component Placement

    Component Placement Refer to the Plumbing Diagrams Strainer Mount the strainer in an accessible area close to the intake thru-hull that can handle water spillage during service. Extra care during as- sembly must be taken to avoid air leaks from the strainer. Use the supplied “quick block”...
  • Page 11 Clark Pump/Membrane Module 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. Mount in any position but leave access to the pressure relief valve on the Clark Pump. The membrane maximum temperature specification is 120 F.

  • Page 12: Plumbing

    Remote Control Panel The remote control panel can be mounted anywhere that is dry and convenient. Cut a 4 ” (116 mm) wide by ” (68 mm) high opening for the panel. Locate in an area that is easily visible and easy to manipulate the but- tons.
  • Page 13 System Piping Specification CLARK PUMP/MEMBRANE MODULE From the Clark Pump brine discharge connector use the supplied (15.9 mm) clear braided vinyl hose to the brine overboard fitting. The system from the pump module to the Clark Pump assembly is under pressure. Use the supplied braided clear vinyl hose rated to 150 PSI (11 bar).
  • Page 14 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. The boat’s fresh water system must be turned on for the fresh water flush system to function properly. The domestic fresh water pump must be able to deliver 2.5 gal- lons per minute at 25 psi.
  • Page 15 Product Water tubing Product water tubing is ” (6.3 mm) Parker tubing. See the Parker tube fitting assembly diagram next page. Product water is pre-plumbed from the membrane into the electric diver- sion valve. The diversion valve will reject product water into the overboard brine stream un- til good quality is measured by the MPC-5000 control.

  • Page 16: Parker Tube Fitting Assembly Procedure

    Parker Tube Fitting Assembly Procedure Spacer Single grab ring for 1/4" & 3/8" tube O-ring Use 2 grab rings for 1/2" tube Body Tubing Step 1: Dissemble fitting components 1/2" max 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".

  • Page 17: Membrane Pressure Vessel Relocation

    Membrane Pressure Vessel Relocation Use ONLY Dayco Imperial Nylo-Seal 88-NSR- 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 18 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 19: Wiring

    Wiring Identify the cables that are connected to the MPC-5000 Control System. Catalina Magdrive systems have a power inlet harness with a terminal block, fresh water flush cable, pressure sensor cable harness, and Clark Pump module harness consisting of the RotoFlow cable, salinity cable and the diversion valve solenoid leads.
  • Page 20 Wiring (continued) Mount the main power terminals on a bulkhead adjacent to the feed pump module. Make sure that this is a dry location well above bilge level and not subject to water spray. Route the control cable through the boat to the MPC display location. Be careful not to dam- age the connector.
  • Page 21 WIRE SIZE CHART Catalina Mag Drive 12V DC System Wire Length FT. Meters AWG. SQ MM 10.6 Mag Drive 24V Meters AWG. SQ MM 10.6 Wire length for a pair of wires is measured from source circuit breaker or fuse to control terminal block.
  • Page 22 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 23 Pressure Sensors Pressure sensors The pressure sensors are mounted on the filter housings to monitor system pressure and differential pressure across the filters. If the wire leads for the sensors must be extended, you must use a minimum 18 AWG 3 conductor twisted and shielded marine grade wire.
  • Page 24 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 limited to 2 amps maximum load! Do not connect motors, pumps, etc to accessory outputs. Optional Z-brane System: Detailed instructions are included with the Z-Brane kit.

  • Page 25: 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 27: New Systems Start Up And Testing

    New System Start-Up and Testing Avoid running the system if the vessel is in contaminated water, such as in a 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.
  • Page 28 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 29 Product Flow The Catalina Mag Drive will produce about 12.5 gallons per hour (48lph) NOTE: To toggle between GPH and liters, push and hold “Alarm/Disp” for 5 seconds. Salinity Salinity reads in parts per million. The sys- tem rejects water higher than 750 PPM. Anything below 500 is excellent.

  • Page 30: 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 aquarium salt to make 5 gallons (20 liters) of salt water. Make sure that the domestic water system is powered up and that there is water in the tank.

  • Page 31: Normal Start Up Using The Auto Run

    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 one hour. The •...

  • Page 32: Automatic Fresh Water Flush Cycle

    Automatic Fresh Water Flush Cycle Warning! Proper understanding of the Spectra flush system and the vessel’s fresh water sys- tem configuration is mandatory for extended automatic flush cycles. The flush cycle must not be allowed to drain all the fresh water from the vessel, or damage to the vessel’s systems may occur.

  • Page 33: Manual Operation

    In the event of a component failure resulting in a shut down due to a false alarm, the failed Manual Operation 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 34: 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 35 Storage Procedure: Step 1: Flush the system twice. Press the “Auto Flush” button on the LCD display, once the • first flush has been completed, press “Stop” to cancel the 5 day interval timer, then press “Auto Flush” again. Step 2: Remove the quick disconnect fitting from the brine discharge outlet of the Clark •...

  • Page 37: Winterizing

    Storage & 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 38: 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 crystal formation around the Clark Pump blocks is normal. Wipe down any salt encrusted areas with a damp cloth. The Seawater Strainer and 50 Micron Filter The sea water strainer’s stainless steel element should be inspected, removed, and •...

  • Page 39: 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 40 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 41: Salinity Probe Calibration

    The higher the resistance, the lower the PPM of dissolved solids. In the Spectra Watermakers systems, the salinity probe is located just before the diversion valve, at the output of the RO membrane. This way we can look at the salinity level of the product water before deciding to either reject the water or accept it and divert it into the hold- ing tank.

  • Page 42: Suggested Spares

    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: Part Number SC-1 STORAGE CHEMICAL KIT-CHEM-SC1...

  • Page 43: Catalina Troubleshooting Procedures, Service Bulletins

    Spectra Watermakers w/MPC Troubleshooting Procedures SYMPTOMS PROBABLE CAUSE REMEDY Feed pump runs constantly, Manual override switches Turn off manual switch on will not turn off in “on” position control box Feed pump runs with loud - Intake blocked - Check thru-hull valve...
  • Page 44 Spectra Watermakers Troubleshooting Procedures Error Messages SYMPTOMS PROBABLE CAUSE REMEDY “System Stalled” - Pressure relief valve open - Close pressure relief valve - Intake thru-hull closed - Check thru-hull (“system stalled” may alarm - Airlocked system - Verify stroke sensor fully in-...

  • Page 45: Bulletins

    Operation and Repair Bulletins The following documents are sections of our complete service bulletin set. These are available on our website at www.spectratermakers.com MB-2 MEMBRANE CARE Membrane life is affected by a large number of factors and is somewhat unpredictable. A big commercial plant running 24/7 will get 10 to 12 years out of a set of membranes.
  • Page 46 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 47 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 48 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 49 Most spectra watermakers are equipped with a fresh water flush module. This module in- cludes a 50 micron filter to filter out abrasive particles in the feed water that might damage the feed pump, a charcoal filter to remove any chlorine in the fresh water that might damage the membrane, an electrically operated valve and a check, or “one way”, valve.
  • Page 50 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 51 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 53: Z Brane Installation

    Z-BRANE OPERATION MANUAL...
  • Page 54 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 55 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 56: Parts Breakdown For All Catalina Magdrive Systems

    CATALINA MPC EL-SSR-PSH PART NUMBERS EL-SSR-150 PRESSURE SENSOR PRESSURE TRANSDUCER CABLE (150 PSI) PL-MFF-1/4X1/4 1/4"MPT X 1/4" FPT ELBOW PL-HBE-3/4X5/8 NYLON 3/4"MALE NPTX5/8"HOSE BARB ELL NYL. FT-FHB-10HD HIGH PRESS. HOUSING BRACKET DUPLEX FT-FTH-10H HIGH PRESSURE FILTER HOUSING PL-MTE-3/4X1/2P 3/4"MPT X 1/2" TUBE FITTING ELBOW PL-NP-3/4N 3/4"...
  • Page 57 MPC CONTROL PANEL (VFD) EL-MPC-RMCDFD MPC-CONTROL PANEL (LCD) EL-MPC-RMCD PL-MTE-3/4SX1/2 3/4"-16 X 1/2" SS TUBE FITT. ELBOW (BACK SIDE) BRACKET PLATE END FM-PB-PBE HI REJECTION MEMBRANE 40" FT-MB-40 (INSIDE HOUSING) 1/2" HIGH PRESSURE TUBE PL-HBE-3/8X5/8 (DAYCO) RUBBER MOUNT NYLON HOSE BARB PL-NLT-1/2HP HD-RBP-RM ELBOW...
  • Page 58 3/8"MPT X 3/8" TUBE FITT. ST. PL-MTS-3/8X3/8P 3/8"NPT X 1/4" TUBE FITT. ELL. PL-MTE-3/8X1/4 1/4"MPT X 3/8"TUBE FITTING ELBOW PL-MTE-1/4X3/8P 1/8"FEMALE NPTX1/4"TUBE FITTING PL-FTE-1/8X1/4P 1/8"NPT NIPPLE NYLON PL-NP-1/8N 3/8"MALE NPTX1/2"TUBE SS FITT.ST PL-MTS-3/8X1/2S MEMBRANE END PLUGFT-PV-EP Z-BRANE MEMBRANE END PLUG FT-PV-ZEP (Probe end) FT-PV-ZEPB (Ground End)
  • Page 59 3/8" LOW PRESS. TUBE PL-NLT-3/8LP 3/4" MPT X 3/8" TUBE FITT ELL 1/4"MPT X 3/8"TUBE FITTING ELBOW PL-MTE-3/4X3/8P PL-MTE-1/4X3/8P 3/4NPTX1/2"HOSE 3/4"MPT X 3/4" HOSE BARB NYL ELL BARB ELBOW PL-HBE-3/4X1/2 PL-HBE-3/4X3/4 LOW PRESSURE FILTER GARDEN HOSE CAP HOUSING PL-GHF-GC FT-FTH-10L 3/4"MPT X 3/4"...
  • Page 60 End block B HP-TB-VEB-B1 Valve block HP-TB-VB End block A Composite cylinder HP-TB-VEB-A1 and base Brine out HP-CYL-CCA Pressure relief valve HP-TB-BV Center block HP-CB-CB10 Feed in Stainless steel tube HP-CYL-SST Cylinder ring Clark Pump HP-CYL-R Front View End Cap HP-CYL-EC End block A Valve block...
  • Page 61 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 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,...
  • Page 62 Valve port seals SO-HPP-VP Pilot valve port seals SO-HPP-PLP Piston rod HP-CYL-7/8R Center block cylinder O-rings SO-HPP-ECCB Pilot spool O-rings (4) Mount inside block SO-HPP-PV HP-CB-PVS Pilot spool HP-CB-PPS Pilot valve pin Pilot orifice SO-HPP-PS Pin seal O-rings HP-CB-PO Pin seals HP-CB-PVPS Center block Clip rings...
  • Page 63 1/2" SS tube S.S compression Piston with seal HP-CYL-SST fittings HP-CYL-PT PL-MTS-3/8X1/2S Composite cylinder and base HP-CYL-CCA End cap O-ring SO-HPP-ECCB Cylinder end cap HP-CYL-EC Cylinder Ring HP-CYL-R Cylinder Assembly...

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