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. Do not place the components in inaccessible areas that will pre-
vent proper maintenance. If you are having a dealer install the system for you, review the
location of the components to make sure that the installation will meet your approval upon
completion.
Newport Installation Quick Start
Important Details for Installer
1.
The system must have a dedicated sea water inlet to guarantee a solid flow of water to
the system. The inlet should be as low in the boat as possible and with a scoop type for-
ward facing thru-hull fitting installed.
2. Both the Newport MkII Feed pump module and the Clark pump/Membrane module
must be installed in a well ventilated compartment where temperatures will not ex-
ceed 120F (48C). Many engine compartments exceed this temperature when under-
way. Warranty will be void if the installation does not meet this requirement.
3. Follow the wire gauge charts in the instructions! Using larger wire than specified is ac-
ceptable.
4. The MPC control must have DC power continuously to achieve the full benefits of the
fresh water flush system. The domestic fresh water pressure must be on and the fresh
water tank level maintained. Calculate 5 gallons (12L) per flush..
5. The MPC 5000 control must be de-powered (DC power off) after the system is put in
storage “pickled” where a storage chemical or antifreeze is run through the system.
6. If you are separating the Clark pump/membrane assembly, please review the high pres-
sure tube assembly instructions. Improper assembly will cause failure!
7. Run test, then “sea trial” the complete system before assuming the system is opera-
tional. If the boat is in fresh or dirty water, see “Dry testing the system.”
8. Spectra dealers are responsible for educating the vessel owners on the operation and
maintenance of the system. We request that you “walk through” the installation with
our customer.
9. Please have the owner fill out the warranty card. The warranty is void if it is not regis-
tered.
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Table of Contents
Part 1
Page Number
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
Normal Start Up Using the Auto Run ...........................................................................................................28
Automatic Fresh Water Flush Cycle .............................................................................................................29
Manual Operation..........................................................................................................................................31
Maintenance ..................................................................................................................................................36
Bulletins ........................................................................................................................................................44
Service & Maintenance
Long Term Storage Procedures.....................................................................................................................31
Winterizing....................................................................................................................................................34
Membrane Cleaning ......................................................................................................................................36
Salinity Probe Calibration .............................................................................................................................38
Suggested Spares...........................................................................................................................................39
Newport Troubleshooting Procedures, Service Bulletins..............................................................................42
Part 2 Controls
A-31 MK2 CONTROLS Operation Guide (Single Run Speed mode)……………………………………….5
Programming from the display……………………………………………………………………………....13
Tank Switch Operation and Installation …………………………………………………………………….16
Programming from a Computer……………………………………………………………………………...16
Software Installation…………………………………………………………………………………………17
Software Port Settings …………………………………………………………………………………...….18
Software Features …………………………………………………………………………………………...22
Computer Settings …………………………………………………………………………………………..25
Salinity Probe Calibration …………………………………………………………………………………..26
Detailed Controls Data……………………………………………………….……………………………...28
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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. The small installation parts are listed on the cellophane bags’ pick list.
We will not be held responsible for shortages and or freight damage that are not reported
within thirty days of the ship date.
Next, study the system layout diagram, component photos and descriptions before beginning
your installation. This will assist you in understanding the function of each component.
Layout the system. Before starting the installation identify the location where each module
and component will be placed. Insure that there is proper clearance around the components
for removal of filters and system service. Also check to make sure you have adequate tubing
and hose before starting so additional parts may be ordered. Check to see that the MPC cable
is long enough to reach from the display location to the feed pump module.
Newport MkII shipping list:
• Newport Feed Pump Module
• High Pressure Clark Pump and Reverse Osmosis Membrane Module
• MkII Fresh Water Flush Module
• MkII Installation Kit 400
• Boost Pump Module
• Newport Service Kit
• 1/2” braided hose (10’)
• 1/2” Black Nylon tube (10’)
• 5/8” Hose (25’)
• 3/4” Suction Hose (25’)
• 3/4” Braided Hose (10’)
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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” to 1” forward facing scoop type intake thru-hull and
seacock be installed. Install the intake for the system close to the middle and as far below
the water line as possible. Thru-hulls in the bow area are susceptible to air intake in rough
conditions. Sharing a thru-hull with another system is not acceptable and will void the war-
ranty. Sharing a thru-hull can introduce unforeseen problems such as intermittent flow re-
striction, air bubbles, and contaminates. For racing boats and high speed power boats above
15 knots a retractable snorkel-type thru-hull fitting is preferred to be able to pick up water
away from the hull.
Do not install the intake close to or downstream of a head discharge. Install as far below the
waterline and as close to center line as possible to avoid contamination and air induction.
The brine discharge through-hull should be mounted above the waterline, in or just above the
boot stripe to minimize water lift.
Double clamp all hose connections below the waterline.
Pipe Fitting Instruction
Plastic to plastic fittings should have 3 to 4 wraps of Teflon tape and will thread almost all
the way in.
Avoid getting dirt or debris into the piping or hoses during assembly. A small bit of de-
bris can stop the system! Avoid getting tape over the end of fittings that might get into the
system. To insure this does not happen, leave the very first thread uncoated.
Avoid restrictions or long runs on the entire inlet side of the plumbing from the thru hull to
the main feed pump module.
Prevent tight bends and excessive elbows. Any restrictions will hamper system performance.
Secure the piping away from moving objects such as engine belts and hatches. Prevent chafe
on the tubing as required. Test and inspect all piping and hose clamps after several hours of
operation.
Wiring
• Pay attention to wire size or system performance will be impaired.
• Perform wiring to UL, ABYC, CE or applicable standards.
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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” 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. It should be mounted with the filter hous-
ing vertical and accessible for changing filters. Allow 2” below the fil-
ter housing for removal. Do not install over electrical equipment. The
unit contains a charcoal filter for the flush water, flush solenoid and
flush water pressure regulator.
Boost Pump module
The boost pump module should be
mounted vertically with the service hose
connection at the top. The boost pump
must be installed below the water line to
ensure that it will prime.
Feed Pump Module
Mount the feed pump module on a horizontal or vertical sur-
face that can be up to 3’ (1.0M) above the waterline. It is
preferable to mount as low as possible. Locate in an area that
allows easy access to the filters and left hand side and where
water spills during filter changes will not be a problem. Keep
future maintenance in mind when choosing a location. The
feed pump has overheat protection and will not operate prop-
erly at ambient temperatures over 120F (48C).
Remove front cover
to access mounting
holes in the enclo-
sure.
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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. Water will be spilled during any repairs or if a
leak occurs.
Be sure you will have access to the pressure relief valve on the Clark pump.
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. You may
mount the Clark Pump in any position, even upside down.
Membrane Pressure Vessel Mounting
The Clark pump and membrane assembly has been pre-assembled at the factory. If it is nec-
essary to disassemble this module and mount the pressure vessel remotely use guidelines in
back of the manual. Use only approved tubing for assembly.
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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. Use only Spectra approved remote cable.
The cable is not standard LAN cable or phone cord.
Plumbing
From the inlet thru hull to the boost pump module and from the boost pump module to pump
module inlet use supplied clear 3/4 (19mm) spiral suction rated hose. The outlet of the filter
assembly on the main module to the Clark pump assembly is under pressure. Use the sup-
plied braided clear vinyl hose rated to 150 PSI (11 bar). From Clark pump brine discharge
connector use supplied 5/8 (15.9mm) clear braided vinyl hose.
On the feed pressure side use the supplied Parker 1/2 tube and fittings. Use two grab rings on
the 1/2 parker tubing. Refer to the parker assembly instructions.
!! Route all hoses and tubes to prevent kinks and restrictions. Se-
cure piping away from moving objects such as engine belts and
hatches. Prevent chafe on tubing as required. Test and inspect all
piping and hose clamps after several hours of operation.
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System Piping schematic
From the Clark pump brine dis-
charge connector use the supplied
5/8 (15.9mm) clear braided vinyl
hose to the brine overboard fitting.
Mount the pressure gauge in the
low pressure inlet gauge tee.
Use the 1/2 inch nylon
tubing between the
pump module Outlet
and the Clark Pump
Use the 1/2inch braided hose
between the Flush module and
the Feed Pump Module
Flush water from ship’s
pressure water system
25 psi (2bar) minimum
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.
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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.
Feed water inlet from boost
pump. Leave enough extra
length in this hose to allow the
front cover to be moved aside.
Flush water Inlet From Flush Module
Feed Water Inlet from Filters
Product Water Outlet to Tank
Feed Water Outlet to Clark Pump
Product Inlet from Membrane
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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. If the diversion valve is not energized the product goes back into the feed water.
Connect the product outlet on the membrane housing to the Product Inlet fitting on the pump
module manifold using the supplied 1/4 black nylon tubing.
Route the product water from the pump module manifold into the top of the tank. Install
a tee in the water tank fill or tap a pipe thread into an inspection port in the top of the
tank. Do not feed the water into a manifold or bottom of the tank. Make sure there is no
restriction in this plumbing.
If the length of product water tubing supplied with the watermaker is insufficient, use a larger
size hose. Product water flow restriction will cause reduced and power consumption in-
creased if product flow is restricted.
To Fresh Water Tank
Product tube from membrane
end cap to feed pump manifold
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Quick Disconnect Fitting
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. 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 1.5 gallons per minute (6lpm) at 25 PSI. Connect the wiring harness
and heat shrink butt splices.
To Flush water Inlet
on pump module
manifold
Fresh water from
boat’s pressure
water system
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Parker Tube Fitting Assembly Procedure
Spacer
Single grab ring for 1/4" & 3/8" tube
Use 2 grab rings for 1/2" tube
O-ring
Body
Nut
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". Slip the O-ring over the tube
to hold the Spacer in place. If the Grab Ring is pushed too far, trim back
the tube so about 1/4" of tube extends past the O-ring.
Step 3: Gently fit the tube into the body and loosely thread on the nut.
Be careful not to cross-thread the nut
1/2" tube should not bottom out in the fitting
to allow full compression of the O-ring
Step 4:
Hand tighten the nut. DO NOT OVER TIGHTEN!
DO NOT USE A WRENCH! The tube should not
come out if pulled by hand. If it does, tighten the
grab ring tabs.
1/4", 3/8", 1/2" Parker Tube Fitting Assembly
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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
50’ (15M) cable with
connectors for the MPC-
5000 control display
Power inlet harness with
terminal block
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Wiring (continued)
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. Plug this into the back of the control.
Connect the red and black Boost Pump wires to the corresponding red and black conductors in
the Boost Pump cable (red to red, black to black) using the supplied butt connectors, and heat
the connectors to waterproof them.
Check the wire size chart to select the proper size power feed to the main power harness. DC
power feeds should be uninterruptible to insure proper operation of the auto store feature.
Avoid house breaker panels that could be easily tripped.
Component Sizing:
• 12V Use a 30Amp breaker and size the wiring for 25 Amperes.
• 24V use a 15 Amp breaker and size the wire for 13 Amperes.
• Provide circuit protection at the source! Inadequate wiring will cause a loss of
system performance. DC power should be uninterruptible.
Note: If the specified circuit breaker sizes are unavailable use the next higher rating
but do not exceed the specification by more then 10%. All wiring to be done to
applicable ABYC, Marine UL or CE standards.
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WIRE SIZE CHART
Newport MkII 12V DC System Wiring
Wire Length FT.
Meters
AWG.
SQ MM
10
15
20
25
30
35
40
45
50
3
4.5
6.1
7.6
9.4
10.6
12
10
8
6
10
16
25
25
25
35
35
35
6
4
4
4
2
14
2
15
2
MkII 24V
Meters
3
AWG.
SQ MM
10
15
20
25
30
35
40
45
50
12
10
8
4
6
4.5
6.1
10
10
10
16
16
16
25
7.6
8
9.4
8
10.6
12
6
6
14
6
15
4
Wire length for a pair of wires is measured
from source circuit breaker or fuse to control
terminal block.
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MPC Remote Control Display Panels
There are currently two types of display options available: Liquid Crystal Diode (LCD)
display, which is dark lettering on a backlit background, or Vacuum Florescent Display
(VFD), which are bright characters on a dark background. The VFD display brightness
can be adjusted using the Programming Function detailed in Part 2 of this manual.
The displays must be mounted in a protected location, out of direct sunlight, and away from
spray or dripping water. Commands to the system can be entered at any panel.
The display panels connect with the supplied 50 foot modular-type cable to the MPC board
sockets marked “DISPLAYS.” Do not substitute a different type of cable! Contact the
factory if you need longer or additional cables.
Each remote control display panel can accommodate an external alarm buzzer to provide
audible alerts in the event of a fault or at the end of certain timed cycles. 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.
Connect the buzzer RED wire to the terminal marked +POSITIVE, connect the buzzer
BLACK wire to the terminal marked –NEGATIVE on the back of the remote display panel.
A buzzer may also be installed at the control box, current limit is 150mA.
This buzzer output terminal is 20mA
MAX current limit!
DO NOT CONNECT POWER TO
THESE TERMINALS
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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.
Connect to an uninterruptible 12 of 24Volt DC power source.
Ultraviolet Sterilizer: Detailed instructions are included with the sterilizer kit. The UV
sterilizer lamp module and ballast unit should mount vertically, with the product water inlet
at the bottom, outlet at the top. The ballast wires plug into the end of the bulb in the lamp
module. The ballast RED wire connects to “STER” terminal on the MPC board, and the bal-
last BLACK wire connects to the “GND” terminal. If the wires must be extended, use mini-
mum 16AWG wire.
External Buzzer(s): In addition to the external buzzer(s) installed at each remote control
display panel, a buzzer unit may be installed at the control box. The buzzer RED wire con-
nects to the “BUZZ” terminal on the MPC board, and the buzzer BLACK wire connects to
“GND.”
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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” and “Float Switch 2.” Float
Switch 1 is the tank full switch and Float Switch 2 is the tank empty switch.
If the unit is wired for both Autostart and Autostop, it can be put into AutoFill Mode by
pushing and holding the Auto Run switch on the MPC-5000 display. In this mode the water-
maker will start whenever the water level drops below the tank empty switch, so that it is
open (not conducting electricity). When the tank fills up and both the tank full switch and
the tank empty switch have remained closed for two minutes, the watermaker will shut down
and flush itself. The water maker will start back up when the water level drops below the
tank empty switch and it remains open for 2 minutes. This configuration allows for com-
pletely automatic operation. If the watermaker does not need to start up within five days it
will automatically do a fresh water flush. AutoFill mode can be ended by pushing the stop
button or the Autoflush button. If the watermaker is in Autorun mode it can be put into
Autofill mode without stopping it by holding down the Autorun button.
If the owner prefers to install the automatic shutoff feature without the automatic start up
option, only the tank full switch is used. A jumper must be placed between the tank empty
terminals (Float switch 2) in place of the tank empty switch, because the watermaker will
only shut down if both sets of terminals are closed. To use this mode the watermaker must
be started up with the Stop/start button or the Autorun button. After the unit starts up, then
press and hold the Autorun button until the display reads “Auto Fill Mode”. The water-
maker will fill the tank and automatically enter Autoflush mode.
It is possible to use the autofill feature with 2 tanks. A double throw electrical switch must
be installed in a convenient location. If only the single tank full switch is installed in each
tank connect the wire From the Float Switch 1 terminal “1” to the common on the switch and
run separate wires from the switch to each tank switch. The second wires can both be run to
the Float Switch 1 terminal 2. If you are using two switches in each tank you will need a
double pole double throw switch.
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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. If the location or
weather prevents proper testing refer to the section “Dry Testing.”
Warning! Damage may occur if the purge sequence is bypassed and the membrane is
pressurized with storage chemical in it.
1. First Check That:
• Thru-hull valve is open
• Service/ Run Auto/ Service switch in “Run Auto” Position
• Domestic fresh water pressure system must be on
2. Open pressure relief valve 1/2 turn !
3. Power up the system
• Alarm will sound -
• Push the Alarm /Display button to silence
alarm
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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. If the feed pump continues to sound rough, find the reason before con-
tinuing! Inspect the system for leaks.
Note: If you must stop the purge sequence for any reason, the control will default back to
the beginning of the purging mode to protect your system. If you wish you can
bypass the purge sequence and initiate a normal start. Pressing both “Auto Run”
and “Stop” simultaneously anytime during the purge sequence will bypass the purge
sequence and enable a normal start. In any case do not pressurize the system for
the first twenty minutes or more.
5. After the purge sequence. The control will alarm with the message “Close pressure relief
valve” - Close the valve and proceed by pressing “ Auto Run.”
6. The system is now running under pressure and making water. The display will read
“purging product water.” This mode sends the product water overboard for ten minutes
in case there are any residual chemicals in the membrane. Carefully inspect for leaks over
the entire system! Shut down the system and repair any leaks you find.
7. The system is now in the operational mode. You may start and run your system as you de-
sire. You will not have to go through the purging mode unless you “de-power” the system.
If you do, you can bypass the purging mode by pushing “Stop” and “Auto run” buttons
at the same time. It is best to use the Auto-Run and Auto-Store button to start and stop
the machine. If you shut down the system from the Stop button, then use the auto store
button to do a fresh water flush cycle.
8. Check that the system is operating within its normal parameters. Compare with the chart
on the next page
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Product Flow
Newport MkII Will produce 14 -16
GPH
(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.
Feedwater Pressure
Pressure range 90-115 PSI
(7-8 BAR)
Pressure will be higher in cold water and
lower in warm water. Extreme salinity
or temperature conditions may result in
operating pressures outside of the nomi-
nal range
Filter Condition Alarm occurs when
filters are partially clogged. When filters
are completely clogged system shuts
down and alarm sounds again
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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.
Make sure that the domestic water system is powered up and that there is water in the tank.
Confirm that the Charcoal filter is installed in the Fresh water flush module and that the domes-
tic water line had been installed and all valves are open.
1. Open Pressure Relief Valve.
2. Power up the control system.
3. Close the sea cock
4. Press both “Auto Run” and “Stop” to bypass the purge sequence. If the motor starts, stop
immediately and press the Auto run and stop button again until you get a message
PURGE MODE BYPASSED.
5. Press the Auto Store button and allow the fresh water flush system to cycle through its
timed operation. Cycle the auto store system 5 or more times to purge all of the storage
chemicals out of the system (20 minutes total purging). If you get a SERVICE PREFIL-
TER alarm, the flush water flow is not enough or the feed pump is running to fast. See the
instructions for “Flush Cycle Adjustment”.
6. Hook up your service hoses to the Clark Pump and the boost pump module. Route them
into a 5 gallon (20 Liter) bucket. Connect a piece of 1/4” product tubing to the product out-
let on the feed pump module.
7. Turn the valve on the boost pump module from “Run” to “Service.”
8. Press auto flush one or two more times to get enough water into the bucket to properly mix
your salt water. Close the pressure relief valve and start the system using the “Auto Run”
Button. Slowly begin adding salt. If you are using a hydrometer mix the water to be 30,000
PPM. If you have no way to measure the salinity, slowly add salt while running the ma-
chine until the feed pressure reaches 100psi (7bar).
9. Run and test the system for as long as possible. During the run test carefully inspect for
leaks. Check all of the system parameters to make sure the system is operating correctly.
Do not allow the water in the bucket to get above 120F (50C).
10. Store the system per the “Storage” instructions.
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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
“AUTO RUN MODE” then “STARTING” with a 30 second priming countdown timer. Af-
ter the prime, the display reads “AUTO RUN MODE” with a countdown timer. An hour of
run time is added, up to 12 hours, with each successive momentary press of the Auto Run
button. An hour can be added at any time. The display shows the default readout unless
there is an alarm condition. Successive presses of the Alarm/Display button will scroll
through the displays starting with “GPH PRODUCT.” Upon auto shut down by the timer or
by the optional tank full float switches, the system will automatically fresh water flush and
re-flush every 5 days.
•
•
Pressing the Stop button stops the sequence at any time with no flushes.
Normal Operation
For optimum performance, Auto run the system as long as possible at one time. Never let
the system sit with salt water in it. Never allow continuous air leaks in the intake.
Normal Shut Down
•
If the system was started using the Auto Run button, the system will shut off on its own
when the selected run time is over and will auto flush every 5 days.
•
•
Pressing the Stop button at any time will shut off the system with no auto flush function.
The optional tank float switches will shut off the system from any mode. If the system was
started by the Auto Run button the system will flush and then re-flush every 5 days. If the
system was started by the Start/Stop button it will do a 1 time flush. The display will read
“TANK/S FULL.” Once one of the tank float switches opens, the alarm and “TANK/S
FULL” display will cease on its own. Note that if “TANK/S FULL” is displayed, the sys-
tem cannot be restarted.
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Flush Cycle Adjustment
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.
First adjust the flush water pressure regulator. Remove the 1/2 inch vinyl flush water hose
where it attaches to the flush water inlet fitting at the feed pump module. Push the Auto store
button. Water will begin to flow out of the flush water tube. Using a graduated container, al-
low the water to flow into the container for exactly thirty seconds, then push the stop button. If
more than 3 quarts (3 liters) of water went into the bucket the pressure regulator is set too high,
if less the 2 quarts flow into the bucket the pressure is too low. Adjust the regulator by loosen-
ing the lock nut and turning the adjusting screw. Test again until the correct flow is achieved.
Reconnect the Flush water tube.
Pressure regulator
Decrease
Speed
switch
Increase speed
switch
Next adjust the feed pump flush speed. Mounted under the top of the Feed Pump Module,
under the MPC box, is a pump speed controller. On the board are two magnetic switches for
adjusting the pump motor rpm. The switches are narrow silver colored bars about 1/2” (1.5cm)
long. The Increase Speed switch is labeled S2 and is located near the upper right corner of the
board. The Decrease Speed switch is labeled S3 and is located to the right of the six cylindrical
capacitors. Each time a small magnet is placed near the switch while the pump is running, a
signal will be sent to the controller, changing the speed setting, and the pump will speed up or
slow down slightly.
Adjust the flush speed as follows. Push the Auto Store button. Push the Alarm display
button until the display reads PREFILTER GOOD REPLACE. The flush valve will open and
water will flow backwards through the filters and strainers. After about 30 seconds the back-
flush will end and the feed pump will come on, starting the forward flush of the Clark Pump
and membrane. After the feed pump starts, close the service valve, (handle crossways). If the
bar graph on the display begins to move toward REPLACE on the gauge the feed pump is try-
ing to pump more water than the Flush module can supply, and should be slowed down. Turn
the service valve to Service. Water should flow very slowly out of the service hose fitting. If
flow is more than a trickle, speed up the pump. Optimum flush speed will be the speed at
which slightly more water is coming from the flush module than the feed pump is pumping.
This setting will ensure that no sea water is drawn in during the flush, but fresh water is not be-
ing wasted overboard. Check the flush speed by
Adjust the Pump Off time and Pump On time. The flush begins and ends with the Pump
off. Pump off time should be set so that the feed pump comes on just as fresh water reaches the
sea cock. Pump on time should be adjusted so that the pump runs just long enough for Fresh
water to reach the brine overboard fitting, then stops. Pump On and Pump Off times can be ad-
justed from the laptop computer or the display. See the instructions in Section 2. Flush dura-
tion must be set the same as or higher than the total flush time (two pump off times plus one
pump on time).
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Automatic Store Cycle
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.
•
Make sure there is enough water in the fresh water supply system to supply the watermaker
for more than the expected time of operation in the “re-flush every 5 days” mode. The New-
port 400 MrkII units require about 6 gallons (24 liters) every 5 days.
•
•
•
•
Make sure that the pressure water supply is on and will stay on during the flush mode (If
this is not possible contact your certified dealer.).
Make sure that the pressure relief valve is closed. It should be closed if the system was just
used to make water. The auto flush may not operate if the valve is open.
The power for the system must remain on during the auto flush mode. Turning off the
power will disable the auto store function and damage may occur.
Pressing the Auto Store button momentarily will start a flush and then activate the
5 day flush cycle. The flush water solenoid will open and the display will read “FRESH
WATER FLUSH” with a countdown timer. After 30 seconds the feed pump will start, after
5-7 minutes the pump will stop while the flush valve remains open for another 30 seconds.
Them the display will read “FLUSH TIMER INTERVAL,” and the countdown timer will
reflect the number of hours until the next flush.
•
•
Pressing and holding the Auto Store button for 3 seconds will engage a 1 time
flush. The system flushes as described above but will not re-flush every 5 days. Display will
read “FRESH WATER FLUSH” with a countdown timer, then the default display when fin-
ished.
Pressing the Stop button will cancel the auto store mode and put the watermaker in
standby mode.
30
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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. The pressure sensors and salinity probe can also be
calibrated from the display. Complete instructions are found in Part 2 of this manual under
“Programming from the Display”. Be absolutely certain that the alarm is in error before defeat-
ing the automatic controls.
•
•
In the event of complete MPC control failure, the system may be operated manually by
using the manual run switch on the MPC control box and manually opening the diversion
valve.
For manual start up, switch on the feed pump by setting the feed pump switch to “RUN
MAN”. Shut the unit down if the Clark pump does not cycle, if air is continuously present
in the intake line or if the feed pump is excessively noisy. The automatic safety controls are
disabled in manual mode.
•
•
Always discard the product water for the first few minutes of operation. The initial product
water from the system may not be potable. Taste the product water before sending to a tank.
To get a water sample loosen the 1/4 inch product tube fitting at either the feed pump mod-
ule or the membrane outlet and collect a sample Check it with a handheld salinity meter or
taste it.
The diversion valve, an electrically operated three way valve which is normally energized
by the MPC controls to send water to the tank, will not open automatically in manual mode.
Instead, it must be opened using the mechanical override button on the valve. The valve is
located behind an access opening on the left side of the feed pump module. Push the man-
ual override button in and rotate 1/4 turn clockwise to open the valve.
31
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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. The 5 day re-flush feature allows the system
to be shut down without any service procedures for extended periods of time but it doesn't re-
place performing a storage procedure for long periods of non-use. If an optional “Zeta Guard”
water treatment system is installed in the system, the 5 day re-flush will maintain the system
as long as unchlorinated pressurized fresh water is provided.
System Storage or “Pickling”
If the system is to be left unused for more than 2 weeks, perform the following storage pro-
cedure. The procedure introduces a chemical compound into the system that prevents bio-
logical growth. This procedure requires de-chlorinated water which can be made with the
Spectra’s charcoal filter. Charcoal filters last a maximum of 6 months once wetted.
Spectra SC-1 a special storage compound used by the US Navy. It is formulated to be com-
patible with the modern engineering plastics and composites in the Spectra pumps. Do not
use any substitute except propylene Glycol, SC-1 Storage Compound has to be mixed at a
ratio of 1 Spectra container to 3 gallons (12L) of fresh water to have the proper solution.
An average of 2 gallons (8L) of water is in a NP Magdrive system. This water has to be
figured in to the mixture. A NP Magdrive system uses one SC-1 container.
Caution! Avoid contact with skin, eyes, or lungs with the storage chemical.
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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 pump, and replace with the quick disconnect hose from your service kit,
and lead the hose to a 5 gallon bucket.
Step 3: Set the Manual Operation switch on the Feed pump module to
“Service” to fill the bucket with 1 gallon of fresh unchlorinated water. Set the switch
back to “Run Auto” when the bucket has reached the desired level.
Step 4: Connect the hose, using the garden hose barb fitting from your service kit, to the
service port of the boost pump module. Lead the hose into the bucket. Turn the service
valve on the boost pump module 180°, so the intake is now coming from the bucket.
•
•
Step 5: Mix the storage chemical compound into the water in the bucket.
Step 6: Make sure the pressure relief valve on the Clark pump is Open
(unpressurized).
•
Step 7: Use the “Service” switch on the MPC control box to
turn on the feed pump. Circulate the storage chemical in
the system for approximately 10 minutes. Turn off the Pump
when finished.
Clean Up:
•
Remove the quick disconnect from the Clark pump brine discharge, and replace
the original hose that leads to the thru-hull. You may at this point, if you choose to, pump
the bucket dry by using the feed pump switch. Stop when the bucket is empty.
•
•
•
Turn the service valve 180° back to its original position, and remove the service hose.
Turn off the power to the system.
LEAVE THE PRESSURE RELIEF VALVE OPEN
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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. “Minus 50” antifreeze is already diluted to 25%. “Minus 100” is a 60%
solution. Purchase the strongest antifreeze available. Use enough to ensure that the system
contains at least a 25% solution even after dilution with the residual water inside the water-
maker.
•
Step 1: Flush the system for 12 minutes using the manual operation switch. Set the
switch to “Service.” The water maker will begin to flush itself. To stop the flush Set
the switch to “Run Auto”.
•
•
Step 2: Open pressure relief valve on the Clark pump.
Step 3: Pour the propylene glycol into a bucket. Follow the instructions on the con-
tainer.
•
•
Step 4: Connect the hose, using the garden hose barb fitting from your service kit, to
the service port of the boost pump module. Lead the hose into the bucket. Turn the
service valve on the boost pump module 180°, so the intake is now coming from the
bucket.
Step 5: Pump as much as possible of the water remaining inside the water maker overboard.
Set the switch on the pump module to “Service” to turn on the feed pump. Run the
feed pump until you see antifreeze begin to appear in the brine overboard hose. Set the
switch to “Run Auto” to stop the feed pump.
•
•
Step 6: Remove the quick disconnect fitting from the brine discharge outlet of the
Clark pump, and replace with the quick disconnect hose from your service kit, and
lead the hose to the bucket.
Step 7: Set the switch to “Service” to circulate the antifreeze for about ten minutes.
Switch to “Run Auto” to stop the pump.
Clean Up:
•
Remove the quick disconnect from the Clark pump brine discharge, and replace the
original hose that leads to the thru-hull. You may at this point, if you choose to,
pump the bucket dry by using the feed pump switch. Stop when the bucket is empty.
Turn the service valve 180° back to its original position, and remove the service hose.
Turn off the power to the system.
•
•
•
LEAVE THE PRESSURE RELIEF VALVE ON THE CLARK PUMP OPEN.
34
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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
as needed. A clogged strainer will cause the MPC control to alarm “Service Prefilters” Be
careful to ensure that the thru-hull is closed before disassembly and the seal and element
are in place before reassembly. Put the screen up to a light for inspection. When the system
is put into storage, remove, rinse, and reassemble dry to impede corrosion. Check frequently
during operation.
The Prefilters
•
Service the prefilters as soon as possible after the first prefilter alarm sounds. When the sec-
ond alarm sounds the system will shut down to prevent damage. If cleaning and re-using
filter elements, clean when the first segment appears on the filter condition bar graph on the
LCD display.
•
•
To service the filters shut off the thru-hull, open the housings, discard the old filters, Clean
out the housing bowls, reassemble the housings with new 20 and 5 micron filter elements.
The 5 micron filter goes downstream from the 20 micron. Leave dry until next startup.
Use only Spectra approved filters or you may void your warranty. The filters may be
cleaned several times by soaking them in a bucket. Occasionally, lightly lube the filter hous-
ing O-rings with silicone grease.
The Charcoal Fresh Water Flush Filter
•
Replace the charcoal filter element at least every 6 months.
35
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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 in marine use 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 condi-
tions, and from rust. Monitor the product salinity and feed pressure bar graphs for higher
than normal readings for the conditions. Other conditions can cause high pressure such as
cold feed water or clogged filters. Low product flow is usually due to low voltage, damaged
feed pump or Clark pump. Look for all other causes before cleaning the membrane. Mem-
brane life can be shortened by excessive cleaning.
•
There are two types of cleaners: acid and alkaline. The acid cleaner (SC-3) will remove min-
eral scaling. The alkaline cleaner (SC-2) is used to remove biological by-products, oil, and
dirt particles that get past the prefilters. If membrane performance is reduced and they have
not been pickled recently, cleaning with both chemicals is recommended. The acid cleaner
should be used first. 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. If known bio-fouling is present, the SC-2 may be used first. Using hot
water if possible, up to 120° (45C) is recommended as it greatly enhances the ability of the
cleaners to do their jobs.
If the history of the system is unknown or has been left “unpickled” for an extended length of
time and biological growth is present, it is recommended that the system is cleaned with SC-2,
using an alternate source of unchlorinated fresh water before the system is run under pressure.
A simple test can be performed to see if biological growth has occurred. Before running the
system, remove the prefilters and examine their condition If the housings are full of smelly dis-
colored water, the system was not properly stored. Install clean prefilters if they were bad. Next
check the membrane. Attach the brine discharge service hose and lead to a bucket. Open the
pressure relief valve one turn, and manually run the system for 30 seconds. Examine the brine
water: if it’s discolored and smells bad, perform an SC-2 cleaning with an alternate source of
unchlorinated water before running the system pressurized. If the brine is fairly clean, the sys-
tem can be purged, run normally, and checked for performance. Clean the membranes only if
performance is reduced.
Heating the water is preferable. One way to do this is to find a camp stove and use a large
stainless steel pot to heat the solution in. The cleaning solution throughout the system will heat
as it circulates in and out of the pot. An alternative is to heat the one or two gallons of initial
water to 120° on the main stove before mixing in the cleaner and circulating it into the system.
Periodically stop and reheat the solution.
Perform the cleaning procedures while the ship is in acceptable sea water for purging and testing.
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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. An average
of two gallons (8L) of water is already present inside a 400 system . This water has to be figured into
the mixture. A 400 system will use 1 container of compound. SC-2 and SC-3 are never mixed to-
gether. Do not use them for storage pickling solution.
Cleaning Procedure:
•
Step 1: Close the seacock. Flush the system twice. Use the “Auto Flush” button on the
MPC-5000 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
pump, and replace with a quick disconnect from your service kit, fitted to a hose, and lead
the hose to a bucket.
•
•
Step 3: Press “Auto Flush” again to fill the bucket with 1 gallon (4L) of fresh unchlorinated
water. Press “Stop” when the bucket has reached the desired level.
Step 4: Connect a hose, using the garden hose barb fitting from your service kit, to the ser-
vice port of the boost pump module. Lead the hose into the bucket. Turn the service valve
on the boost pump module 180°, so the intake is now coming from the bucket.
•
•
Step 5: Mix the cleaning chemical compound into the water in the bucket.
Step 6: Make sure the pressure relief valve on the Clark pump is Open
(unpressurized).
•
Step 7: Use the “Run Manual” switch on the MPC control box to turn on the feed pump.
Circulate the storage chemical in the system for approximately 25 minutes. Circulate the
chemical in the system for approximately 25 minutes. Allow to soak for several hours or
overnight if the solution is cold. Run the pump occasionally to agitate the solution. Set
both switches to Auto when finished.
•
•
Step 8: Turn off the control system (DC) power. Replace the brine over-
board hose. Remove the Inlet Service hose and turn the Service valve to the
Run position.
Step 9: To avoid damaging the membranes, Follow the “New System Startup” In-
structions to Purge the chemicals out of the System.
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Salinity Probe Calibration
Salinity is a measurement of dissolved solids in liquid: these solids will conduct electricity to
varying degrees. A special probe is used, with two electrical contacts in it, to determine the
resistance to the flow of electricity in the liquid. The higher the resistance, the lower the PPM
of dissolved solids.
In the MkII systems, the salinity probe is located in a port on the bottom of the pump module-
manifold. 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.
The salinity level in parts-per-million can be seen either through the salinity meter in the soft-
ware, or on the display.
The next step is to decide what medium to use as calibration solution. If a hand-held salinity
meter is available, you can simply take a reading of your product water while the unit is run-
ning, then calibrate our MPC board to match that reading. As long as you trust the accuracy of
your hand-held meter, this is all that is necessary.
The microprocessor calculates salinity from the signals sent back to it from the probe. The
salinity circuit can be adjusted from the Spectra software by adjusting the “Salinity Calibra-
tion” parameter, or from the display in the 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. Calibration consists of inserting our probe into the solution and setting
the calibration parameter to the required value.
To remove the salinity probe, unplug the telephone style cable from the probe. Use a wrench
to unscrew the probe from the manifold. Re-connect the salinity probe cable, and you are
ready to calibrate. Place the flat surface of the probe containing the two metal conductivity
contacts into the calibration solution being careful not to get the cable or jacks wet. Upon re-
installation, it is recommended to use Teflon tape on the salinity probe threads before re-
installing to prevent leaks. We also recommend putting some silicone grease inside the jack, to
prevent moisture from causing corrosion inside the jack.
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Suggested Spares
Short term cruising, weekends etc.
We suggest a basic cruise kit. Kit consists of 3 ea, 50 micron ,20micron, and 5 micron filters
and two SC-1 storage chemicals.
Cruising 2 to 6 months at a time.
Two basic cruise kits, One each replacement charcoal filter. One replacement feed pump head.
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
Part Number
Spectra Watermakers parts list:
SC-1 STORAGE CHEMICAL
SC-2 CLEANER
SC-3 CLEANER
BASIC CRUISE KIT B
5 MIC FILTER
KIT-CHEM-SC1
KIT-CHEM-SC2
KIT-CHEM-SC3
KIT-BCK-B
FT-FTC-5
20 MIC FILTER
FT-FTC-20
CHARCOAL FILTER
6” STRAINER SCREEN
FEED PUMP HEAD
6” STRAINER O-RING
FILTER HOUSING O-RING
OFF SHORE KIT
FT-FTC-CC
FT-STN-6S
PL-PMP-140MAG
SO-STN-6SS
SO-FHS-10H
KIT-OFFSH
FT-MB-40
40” MEMBRANE
39
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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. The high pressure fittings are typically pre-
installed at the factory. These fitting seal with an O-ring and require no Teflon tape or pipe
dope. Loosen the backing nut rotate the fitting and reseat the backing nut.
Follow the high pressure tube connection instructions on the next page. Connect the
tubes to one of the components, secure the tube runs, and then trim and connect to the other
component. A 90 degree bend in a tube is better than a 90 degree fitting. A tube, when
mounted, should have at least one gentle bend to allow for expansion. Do not connect a
tube straight between hard mounted fittings.
When connecting the tubes to their components, be sure to hold the fitting body with a
wrench during the final tightening. Of special note are the stainless steel tube fittings on
the membrane housing seal on an O-ring and should be seated all the way in. Hold the fit-
ting with a wrench while installing the tube.
The fittings on the Clark pump have an O-ring seal and can be re-oriented by backing out
the O-ring Stop nut. Rotate the fitting to align with the tube and tighten the nut just past
hand tight. Do Not over tighten!
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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. Have at least one shallow bend in a tube assembly after it is installed.
Refer to figure 1. If a fitting has been dissembled, reassemble as illustrated. The notch on the ferrule
must engage the inside of the nut properly for the nut to seat down fully. Once the tube is inserted the
ferrule and nut will naturally align.
Refer to figure 2. Insert tube fully into the fitting, it should go in 0.9”. Tighten the nut finger tight while
moving the tube around to prevent binding. One thread should be showing under the nut. Secure the tube
so it won’t back out when tightening.
Refer to figure 3. Use 13/16” wrench to hold a straight body fitting or a 3/4” wrench for a 90º body, and
a 7/8” wrench for the nut. Hold the body, recheck the tube insertion, then tighten the nut 1-1/4 turns. Use
the index mark on the nut as a guide. The threads should be completely covered by the nut.
Make Sure these fittings are tight on initial assembly or they will fail!
The correct Torque is specification is 85 foot pounds
Index mark
Straight or 90 deg.
3/8" pipe thread
Straight thread
Figure 1.
Figure 2.
Nut
Body
Ferrule
Nut finger tight with
1 thread showing
Cut tube square
Black high pressure tubing
Tighten 1-2/3 turns (10 flats of the
nut) with a7/8" wrench after finger tight.
Use index mark as guide
No threads showing
Figure 3.
Insert tube 0.9" until it stops
IMPORTANT!
Hold fitting body with 13/16"
wrench when tightening
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Spectra Watermakers Newport Troubleshooting Procedures
SYMPTOMS
PROBABLE CAUSE
REMEDY
Close Valve
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Spectra Watermakers Newport Troubleshooting Procedures
Error Messages
SYMPTOMS
PROBABLE CAUSE
REMEDY
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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. But
they do all kinds of fancy chemical injections and never shut the thing off. Most cruisers are
lucky to get five or six years out of one. You hear of the eight or ten year old membrane now
and then. The biggest killers of membranes are lack of use, chlorine damage, and improper
storage.
Don’t let membranes sit around with sea water or stale fresh water in them. Biological
growth will occur in the membrane. Here at the factory we frequently get back membranes
for inspection that reek of hydrogen sulfide (rotten eggs). This odor is produce by anaerobic
bacteria that live in an unused membrane, feeding on whatever animal or vegetable matter is
trapped in it from the plankton that gets through the system. Membranes badly fouled in
this way can seldom be saved. These bacteria are always present but are inhibited by the
oxygen in sea water while the unit is in frequent use, by scheduled fresh water flushes, or by
pickling. Keeping the prefilters clean is also important in preventing bio-fouling. If your
prefilters are allowed to become a breeding ground for bacteria (get smelly), the contamina-
tion will spread throughout the system. When we cut open a failed membrane we also find
mildew, another form of bio fouling, probably due to long term storage with no biocide or
stale biocide.
After many hours of water making mineral deposits will form and must be dissolved away
with an acid cleaner. Alkaline cleaners are used for bio-fouling. Cleaning chemicals, espe-
cially the alkaline, are not good for the membrane. Every time you clean the membrane it
shortens its life. Clean only when necessary, and avoid cleaning as a “diagnostic tool”.
Chlorine will destroy a membrane in minutes. It attacks the material that the membrane is
made from. Always use product water or water filtered slowly through a charcoal filter for
flushing and chemical treatments.
Oil simply plugs up the matrix of the membrane and clogs it up. We have brought back oil
fouled membranes with Joy soap (See MB-5 Cleaning with Detergent.)
For storage we recommend using propylene glycol potable water system antifreeze if avail-
able. It can safely be left in the system for one year and will keep things from freezing in
cold conditions. It is hard to find in warm climates, and takes up a lot of room on a small
boat, so our SC-1 is best for tropical cruising.
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
44
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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. If using shore water run it through a charcoal filter at a rate
of not more than 1.5 gallons (6 liters) per minute.
Fill a bucket with fresh water and mix in a couple squirts of the detergent. Run the system
depressurized with the watermaker drawing water from the bucket and discharging over-
board. When about half the water is gone from the bucket stop the unit and let the mem-
brane soak for a few minutes. Restart and pump the remaining solution overboard. Repeat
until the discharge appears clean.
After most of the oil is cleaned out you can put the brine discharge into the bucket and run
the system with the soapy water circulating as you would for the other cleaning chemicals.
Rinse the system with a bucket of fresh water or the fresh water flush cycle, then flush for
twenty minutes using sea water. Pressurize and test.
5/12/04
45
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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. Normally, during periods of disuse the MPC-5000 will
remain powered up so that it can do the five day flush cycles, and no storage solution will be
present. If the control power has been interrupted but the system is not filled with storage
solution, Purge Mode can be bypassed by tapping the two left hand buttons at the same time
until the display reads PURGE MODE BYPASSED. The buttons must be pushed at exactly
the same time. You can’t hold one down and then push the other. From Purge Mode By-
passed you can run the system in any mode. 4/20/04
46
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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
housings when the unit is shut down. Once all the available oxygen is consumed, anaerobic
bacteria begin to grow, causing the odor. If a unit being used frequently begins to make
smelly water, it will be the prefilters that are the source of the problem. This occurs in a
week or two in cold climates, but in less than one night in very warm waters like the Sea of
Cortes or Red Sea. These bacteria can spread throughout the watermaker, and begin to grow
on the membrane, causing poor water quality and high feed pressures.
Filling the system with fresh water after every use greatly slows this process, allowing the
automated spectra units to operate with less frequent prefilter changes, but units operated for
only an hour or so a day will probably need to have the filters changed due to odor before
they are dirty enough to restrict water flow. Prefilters can be cleaned. We recommend that
you have three sets in service, one in the unit, one set soaking overnight in a bucket of clean
fresh or salt water and one set drying for the next use. After shutting down the unit remove
the used prefilters and install the dry set. Leave the housings full of air until the next use.
On non-automated systems, open the pressure relief when starting if there is a lot of air in
the system until the air is cleared out through the brine overboard. The filters will get just as
clean when soaked in sea water, but dry much faster if soaked in fresh. Given gentle han-
dling, prefilters can be reused many times.
Bad smelling product water is usually caused by bad smelling feed water, but can also be
caused by a fouled membrane if the membrane has been left unpickled. If the unit makes
smelly but not salty water after a long idle period and the prefilters are new, the smell can be
eliminated by running the unit unpressurized for an hour or so to flush the membrane.
Odors in the product water can also be eliminated by adding a charcoal filter in the product
water line. Spectra offers a product water filter kit p/n KIT-FLT-CC.
8/17/04
47
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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.
During normal operation the feed water is filtered in two stages. First it enters a fine mesh
metal sea strainer then passes through a fifty micron pleated cellulose filter. These protect
the vane pump from damage due to abrasion from silt and hard shelled plankton found in the
feed water. After passing through the pump the feed water enters the filter housings contain-
ing 20 and 5 micron elements. These filters remove very fine particles which could damage
the Clark pump and which would shorten membrane life. Note: On Mark two systems there
is no 50 micron filter and the 20 and five are before the feed pump.
Cleaning schedules will vary widely depending on how and where the system is used. If
large amounts of feed water are run through the system in a relatively short period in bio-
logically fertile near shore waters, the prefilters will plug up, the pressure drop across the
filters will rise, product production and quality will drop, and the system will sense plugged
filters and give a service prefilters or check strainer alarm if so equipped. Plugged filters can
be cleaned several times by soaking in a bucket, towing behind the boat at moderate speeds,
or hosing them off.
When operated only an hour or two a day in inland or near shore waters, the trapped plank-
ton will begin to decay in the filters long before the elements plug up, and the bacteria in-
volved in the decay will cause a “rotten egg” smell in the product water. This decay will set
in overnight in tropical waters, or after a week or two in high latitudes. If handled gently
and changed regularly before they get too smelly, filters in this service can last through doz-
ens of cleanings.
In crystal clear blue water conditions the filters may need to be cleaned much less frequently.
The charcoal filter used in the fresh water flush system will not plug up unless you have
some incredibly dirty domestic water in your boat. About six months after installation the
charcoal filter element will lose its effectiveness at removing any membrane damaging chlo-
rine which may be present in domestic water. Charcoal filter elements must be replaced
every six months if there is ANY chance that chorine could be introduced into the flush wa-
ter. Charcoal filter elements cannot be cleaned.
To ensure that filter elements fit properly and remove chlorine effectively, they should be
purchased at factory authorized dealers. Our element part number is FT-FTC-XX. The last
two digits indicate the micron rating, e.g. FT-FTC-05 is for a 5 micron element. Charcoal
elements are FT-FTC-CC.
06/03/04
48
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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. The cheap ones in most cases will
only remove 60 or 70%. Also, there are aftermarket filters which are very close to, but not
exactly, the same dimensions that will not seal properly in the housing. The membrane can
only handle small amounts of chlorine for short periods without damage. The chlorine will
damage the bonding agent in the membrane in a very short time. So if you skimp on the char-
coal filter you will toast a $450.00 membrane on the first flush. The other factor is the flow
rate that the filter can handle. Because the chlorine is deactivated by a chemical reaction with
the charcoal, it must remain in contact with the charcoal for sufficient period of time for the
reaction to be complete. The filter we use can handle 1.5 gallons (6 litres) per minute flow,
and are good for 5000 gallons (12,000 litres) at 1.5 GPM, or six months, whichever comes
first. Regardless of the flow the charcoal loses its effectiveness after six months.
7/26/04
49
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Z-BRANE
OPERATION
MANUAL
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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. The Z-Brane will not prevent freezing so that in cold climates
Propylene Glycol is still required.
The Z-Brane system is integral with the watermaker unit and only requires continuous
12Vor 24V DC power to be operative. The installation of the Z-Brane only consists of
wiring the power supply to a continuous source The Z-brane power supply can tolerate
voltages between 10V and 28V DC.
Note: There is no reason to open the transformer enclosure. Do not ser-
vice this unit without disconnecting the power source! There may be
high voltage present.
It is recommended that the Z-Brane be connected to a discreet continuous power source.
The power must be on during the time that the system is operation and during the time the
Z-Brane is used for membrane storage. If the power is obtained from the MPC then the
MPC must be powered up at all times during storage. This may not be desirable.
Fuse the power at the source with a 5 amp fuse or circuit breaker.
Red is Positive (+) , Black is Ground (-)
Z-Brane Power Harness
51
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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. To achieve full effectiveness thoroughly fresh
water flush the watermaker several times before leaving the vessel.
The Z-Brane may be de-powered if the system is stored with chemicals or winterized with
Glycol.
Power on LED
High Voltage
connector
DO NOT DISCONNECT
OR SPLICE ANY OF THE
HIGH VOLTAGE WIRING!
Contact the factory if
modifications are required.
52
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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
HP-CYL-R
Clark Pump
Front View
End Cap
HP-CYL-EC
End block A
Valve block
End block B
Reset button
Composite cylinder
and base
Not on all unitsHP-TB-RSBT
Alternate brine out
High pressure in
Test port
Center block
High pressure out
Stainless steel tube
Cylinder ring
Clark Pump
Back View
End cap
53
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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
Reset button and O-ring
End block B
HD-CPS-5/162.75
Piston O-ring
Spool piston
SO-HPP-SP, PS20
HP-TB-VSP,VSP20
HP-TB-SR Spacer ring
Valve block
Valve bore O-ring
Spacer ring
Spool piston
SO-HPP-VB
Valve bore
O-ring
Brine port
End block A
O-ring
SO-HPP-VP
Valve spool
Pilot port O-rings
SO-HPP-PLP
Piston O-ring
Reversing Valve
End Blocks
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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
HP-CB-PPS
SO-HPP-PS
Pilot spool
Pilot valve pin
Pilot orifice
HP-CB-PO
Pin seal O-rings
Pin seals
HP-CB-PVPS
HP-CB-PVCR
Center block
Clip rings
Rod lip seals
Mount inside block
SO-HPP-PR7,
PR10,PR15
Feed in
Check valve port O-rings
SO-HPP-CVP
Check valve assembly
SO-HPP-CVS
Check valve
O-ring
Piston to rod O-rings (2)
Inside pistons Glass rod models only
HP-CB-CVS
Check valve seat
HP-CB-CV
Check valve poppet
Check valve spring
Check valve washer
HP-CB-SPR
Center Block
HP-CB-CVSW
HP-CB-CVR
Check valve retainer
55
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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
56
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10% CLARK PUMP PARTS LIST
PART
HP-CB-CB10
DESCRIPTION
CENTER BLOCK
USAGE
1
4
1
1
1
1
2
2
2
4
4
1
4
4
4
2
1
2
2
2
2
1
2
2
8
4
8
8
2
4
2
2
2
1
1
1
2
8
2
6
4
4
2
4
4
4
1
2
2
2
2
HP-CB-INS
CENTER BLOCK INSERT
VALVE BODY
HP-TB-VB
HP-TB-BV
BLEED VALVE
HP-TB-VEB-A1
HP-TB-VEB-A2
HP-CB-PVPS
HP-CB-PPS
VALVE END BLOCK A 1-1/4"
VALVE END BLOCK B 1-1/4"
PILOT VALVE PIN SEAL
PILOT VALVE PIN
HP-CB-PVCR
HP-CB-SPRP
HP-CB-CVSW
HP-CB-PVS
PILOT VALVE CLIP RING
CHECK VALVE SPRING PLASTIC (DELRIN)
CHECK VALVE SPRING WASHER
PILOT VALVE SPOOL
CHECK VALVE SEAT
CHECK VALVE RETAINER
CHECK VALVE
HP-CB-CVS
HP-CB-CVR
HP-CB-CV
HP-TB-AR
ANNULAR RING
HP-TB-10VSA
HP-TB-VSS
10% REV. VALVE SPOOLASSEMBLY
REV. VALVE SPOOL SEAL
REV. VALVE SPOOL PISTON
CYLINDER END CAP
END BLOCK PLUG
HP-TB-VSP
HP-CYL-EC
HP-TB-EBP
HP-CYL-7/8R
HP-CYL-PT
PISTON ROD
PISTON
HP-TB-SR
SPACER RING
HD-CPS-3/824175
HD-CPS-5/16X3
HD-CPS-5/162.75
HD-WSH-3/8X5/8S
HP-CYL-SST
PL-MTS-3/8X1/2S
HP-CYL-CC
3/8-24X1 3/4 CAP SCREW
5/16-18X3 1/4 CAP SCREW
5/16 X 2 3/4 CAP SCREW
3/8 X 5/8 O.D. SS FLAT WASHER
STAINLESS TUBE
3/8"NPT X 1/2"TUBE FITT ST SS.
COMPOSIT CYLINDER
COMPOSIT CYLINDER BASE
CYLINDER END RING
PILOT ORIFICE
HP-CYL-CCB
HP-CYL-R
PILOT ORIFICE
PL-HP-3/8N
GLASS FILLED BLACK NYLON PLUG 3/8'NPT
1/4 COUNTER SUNK HEX PLG.
3/4"MPT(ST) X 1/2" TUBE SS FITT. ELL.
PILOT PORTS
PL-HP-1/4BR
PL-MTE-3/4SX1/2
SO-HPP-PLP
SO-HPP-PS
SO-HPP-VP
SO-HPP-CVS
SO-HPP-CVP
SO-HPP-VB
SO-HPP-ECCB
SO-HPP-AR
SO-HPP-PV
SO-HPP-RV
SO-HPP-CT
SO-HPP-SP1
SO-HPP-Q
PIN SEALS
VALVE PORTS
CHK. VALVE SEATS
CHK. VALVE PORTS
VALVE BORE
END CAP & CENTER BLOCK
ANNULAR RING
PILOT VALVE
RELIEVE VALVE
CONNECTOR O-RING
SPOOL PISTON O-RING 1"
QUAD SEAL
SO-HPP-PR10
10%, 20% PISTON ROD
57
2/11/2005
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