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Spectra Watermakers Newport 700 Installation & Owner's Manual

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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
O9/22/05 Rotoflow
1

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Summary of Contents for Spectra Watermakers Newport 700

  • Page 1 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 O9/22/05 Rotoflow...
  • 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

    Table of Contents Installation Page Number Getting Started........................7 Newport Schematic ......................8 Installation Basics ....................... 9 Component Placement....................... 10 Plumbing ........................... 14 Parker Tube Fitting Assembly Procedure ................. 17 Wiring..........................19 MPC Tank Switch Wiring and operation……………………………………………….. 27 Checking the Flush Cycle ....................32 Membrane Pressure Vessel Relocation ................

  • 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 Thruhull 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 thruhull with scoop type strainer. Flow Thru-hulls It is mandatory that a dedicated 3/4”...

  • Page 10: Component Placement

    Component Placement Refer to the Plumbing Diagrams 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”...
  • Page 11 Filters may be relocated for bet- ter access or to prevent splashing water on sensitive equipment. You may need additional 1/2” Parker high pressure tubing. The MPC Control Box The MPC Control Box may be demounted for relocation up to 4’ (1.2M) from the pump module. A long screwdriver will be required to access the fasteners...
  • Page 12 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.
  • Page 13 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 it in an area that is easily visible and easy to manipulate the buttons.

  • Page 14: Plumbing

    Plumbing 700/1000 System Tubing Schematic From the Clark pump brine discharge quick connec- tor to the overboard thru hull use the supplied 5/8 (15.9mm) clear braided vinyl hose. Route the filter outlet tubing with a “hinge loop” allowing the pump module cover and filter housings to swing away for pump maintenance...
  • Page 15 Fresh Water Flush Module 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 pressurized when the boat is unattended for the fresh water flush system to function properly. The domestic fresh water pump must be able to deliver 2.5 gallons per minute at 25 PSI.
  • Page 16 Product Water tubing 700 1000 Systems Product water tubing is 3/8”(9.5mm) on the 700/1000 models. See the Parker tube fitting assembly diagram next page. Product water is pre-plumbed from the membrane into the electric diversion valve. The diversion valve will reject product water into the overboard brine stream until good quality is measured by the MPC-3000 control.

  • Page 17: 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 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 700/1000 24V DC Systems DC Systems will have: Fresh water flush cable, these wires have no polarity A Power inlet harness with a terminal block, A 75’(26 M) cable with connectors for the MPC-3000 control display, Clark pump module harness consisting of the Rotoflow cable, salinity probe cable, and the diversion valve (no polarity) cable.
  • Page 20 Wiring 110 & 220 Volt AC Versions AC Systems will Have: Fresh water flush cable, these wires have no polarity Two Power inlet harnesses with terminal blocks, A 75’(26 M) cable with connectors for the MPC-3000 control display, Clark Pump Module harness consisting of the Rotoflow cable, salinity probe cable, and the diversion valve (no polarity) cable.
  • Page 21 Wiring (continued) Mount the main power terminals or junction box 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 damage the connector.
  • Page 22 24 volt DC System Wiring Wire length for a pair of wires is measured from source circuit breaker or fuse to control terminal block. Wire Run Length Wire Run meters AWG wire size Sq mm wire size Less than: 15 Less than: 5...
  • Page 23 Wire length for a pair of wires is measured 110 Volt AC System Motor Wiring from source circuit breaker to control box. Wire Length AWG wire size Square MM wire size To 25 feet 12 awg 3 sq mm (7.5M) 25 feet to 50 feet 10 awg 5 sq mm...
  • Page 24 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 25 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 18AWG 3 conductor twisted and shielded marine grade wire. Make both sensor wires close to the same length.
  • Page 26 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-Guard System: Detailed instructions are included with the Z-Guard kit.

  • Page 27: Mpc Tank Switch Wiring And Operation

    Tank Switch Installation and Operation: There are two sets of terminals on the MPC-3000 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 28: New Systems Start Up And Testing

    New System Start-Up and Testing The system should be fully run tested before leaving port. It is preferable to sacrifice a fil- ter by running the system in turbid water rather than waiting to get offshore to discover a problem or deficiency in the installation. Avoid running the system if the vessel is in con- taminated water, such as an industrial harbor or canal.
  • Page 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.
  • Page 30 The water maker will shut down automatically. Spectra watermakers MPC-3000 programming software and the Instruction book for its use can be found on our website under Data Sheets and Owner’s Manuals>MPC-3000 Controller. With this software you can connect your personal computer to the serial port on the MPC-3000 circuit board to check and adjust settings such as flush duration, Service Pre- filter setpoint, pressure sensor calibration, and others.

  • Page 31: 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 salts to make 5 gallons (20 liters) of salt water. Make sure that the domestic water system is pressurized and that there is at least 30 gallons (120 li- ters) of water in the tank.

  • Page 32: Checking The Flush Cycle

    Checking the Flush Cycle The length of time the flush cycle lasts, and the speed at which the feed pump runs, are preset to nominal values at the factory. After the installation is complete the flush cycle must be checked to ensure that no salt or brack- ish water remains in the system after the flush cycle is completed.

  • Page 33: Normal Start Up Using The Auto Run

    Normal Start Up Using the Auto Run Button Press 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 MODE” with a countdown timer.

  • Page 34: Automatic Fresh Water Flush Cycle

    Automatic Fresh Water Flush Cycle Warning! Proper understanding of the Spectra flush system and the vessel’s fresh water system 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 35: Manual Operation

    Manual Operation • In the event of an MPC control failure, the system may be operated manually using the switches on the feed pump module. For manual start up, set the switches to “Flush Auto” and “Run Manual. Shut • the unit down if the Clark pump does not cycle.

  • Page 36: 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 37 Storage Procedure: Step 1: Flush the system twice. Push the “Auto Flush” button on the MPC-3000 dis- • play, 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 •...
  • Page 38 • Push the “Auto Flush” button press “Stop” press “Auto Flush” again...

  • Page 39: 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 40: 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 •...

  • Page 41: 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 42 MEMBRANE 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. 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 43: Salinity Probe Calibration

    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 holding tank.

  • Page 44: Vane Pump Replacement

    Vane Pump Replacement Loosen the Compression nut on the feed wa- ter inlet tube at the 20 micron filter and dis- connect the tube. Remove the front cover of the pump control module. Leave filters attached. Loosen the hose clamp at the up- per end of the suction hose Loosen the V band clamp until the pump head can be removed.
  • Page 45 Loosen the hose clamp on the inlet hose and remove the hose from the fitting. Brass Tang Using two wrenches, loosen the compres- sion nut on the high pressure discharge fitting. Remove and set aside the hose To install the new pump, Install the supplied fittings into the pump body in the exact same positions as those on the old pump, using five wraps of Teflon tape.

  • Page 46: Suggested Spares

    Additional filters, offshore cruising kit consisting of Clark pump seals, O-rings, tools and membrane cleaning chemicals. One replacement strainer screen, O-ring for strainer screen, O-rings for filter housing Part Number Spectra Watermakers parts list: SC-2 ORGANIC CONTAMINATION CLEANER FT-CHE-SC2 SC-3 MINERAL SCALE CLEANER...

  • Page 47: 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 48: Newport Troubleshooting Procedures, Service Bulletins

    Spectra Watermakers Newport 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 49 Spectra Watermakers Newport 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 50 Operation and Repair Bulletins The following documents are sections of our complete service bulletin set. These are available on our website 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 51 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 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.
  • Page 52 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-3000 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 53 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 54 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 55 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 56 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 57 If you have the AC Tech Installation and Operation Manual that ships with replacement speed controllers the parameter menu section will be marked with the Spectra Watermakers factory presets for your unit. The manual is also available on the website at www.Spectrawatermakers.com...
  • Page 58 VP-5 DC SPEED CONTROL NP-700 & NP-1000 All current production Newport 700 & Newport 1000 model watermakers are equipped with a feed pump speed controller. The 24 Volt DC models use a Winland speed controller that has adjustable settings for Run Speed and Flush Speed.

  • Page 59: Z Brane Installation

    Z-BRANE OPERATION MANUAL...
  • Page 60 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 61 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 62: Parts Breakdown For All Newport Systems

    Pump Module Part Numbers EL-MTR-SPCAC110 3/4 SPEED CONTROLLER AC 110 EL-MTR-SPCAC220 3/4 SPEED CONTROLLER AC 220 EL-TM-30A4 TERMINAL BLOCK 30A 4 CIRCUITS FM-NPC-TC TOP COVER N.P. CHASSIS EL-BKR 15ADP (220VAC) EL-BKR-20ADP (110VAC) EL-BKR-32ADP (24 V DC) EL-SWT-TGS-SPST TOGGLE SWITCH SP/ST EL-SWT-TGSDPDT TOGGLE SWITCH DP/DT FM-NPC-FC...
  • Page 63 Pump Module Parts (cont) EL-MTR-3/4AC220 HP, 240 VAC, 3 PHASE, 56C SUB-NP-MNFC MOTOR NEWPORT INTAKE MANIFOLD EL-MTR-3/4D24 HP MOTOR (24V) PL-HBE-1/2X3/4 PL-PMP-PCA 1/2"MPT X 3/4" HOSE BARB ELBOW MOTOR COUPLING AND ADAPTOR EL-SWT-VC VACUUM SWITCH PL-PMP-VBC V-BAND CLAMP FOR PL-HS-3/4SH ROTARY VANE PUMP 3/4"...
  • Page 64 FT-PV-UTC PL-NLT-1/4LP PL-MTE-3/8X3/8P U-TUBE CONNECTOR 1/4" PRODUCT TUBE 3/8" MPT X 3/8" TUBE FITT. ELBOW PL-MTS-3/8NPTX1/2S 3/8"NPTX1/2"TUBE SS FITT. ST PL-MTE-3/8X1/2S HIGH PRESSURE ELBOW FM-PVB-PB PLATE BRACKET FT-PV-ER MEMBRANE RING FM-PVB-PBI PLATE BRACKET INTERMEDIATE FT-PV-ZEP FM-PVB-PBE Z BRANE END CAP A PLATE BRACKET EL-ZTG-1/2RD 8"...
  • Page 65 PL-SLN-1/4D12VB 1/4" DIVERSION VALVE 12V W/O VB PL-MTS-1/4X3/8P PL-SLN-1/4D24VB 1/4"MPT X 3/8" TUBE FITT. ST. 1/4" DIVERSION VALVE 24V W/O VB PL-MTE-3/8X3/8P 3/8" MPT X 3/8" TUBE FITT. ELBOW PL-CKV-1/4M-F PL-MTE-3/8X3/8P 1/4" PLASTIC CK VALVE PL-MTS-1/4X1/4P 3/8" MPT X 3/8" TUBE FITT. ELBOW (M-F) 1/4"...
  • Page 66 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 67 End block B HP-TB-VEB-B Valve block HP-TB-VB End block A Composite cylinder HP-TB-VEB-A and base Brine out HP-CYL-CCA Pressure relief valve HP-TB-BV Center block HP-CB-CB7,10,15,20 Feed in Stainless steel tube HP-CYL-SST Cylinder ring HP-CYL-R Front View End Cap HP-CYL-EC End block A Valve block End block B Reset button...
  • Page 68 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, PS20...
  • Page 69 Valve port seals SO-HPP-VP Pilot valve port seals SO-HPP-PLP Piston rod 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 70 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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