Spectra Watermakers NEWPORT 400 Mk II Installation & Owner'S Manual Download Page 1

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NEWPOR

T 4

00 Mk II

INST

ALLA

TION & O

WNER’S

MANU

art 1……....Installa

tion, Oper

tion, Maintenance

art 2………………….. P

amming and Controls

Spectra Watermakers, I

nc.

20 Mariposa Road, San Ra

fael, CA 94901

Phone 415

- 526- 2780 Fax 415- 526- 2787

www.s

pectrawatermakers.com

Feb 2012 mpc5000

Summary of Contents for NEWPORT 400 Mk II

Page 1: ...ON OWNER S MANUAL Part 1 Installation Operation Maintenance Part 2 Programming and Controls Spectra Watermakers Inc 20 Mariposa Road San Rafael CA 94901 Phone 415 526 2780 Fax 415 526 2787 www spectrawatermakers com Feb 2012 mpc5000 ...

Page 2: ...2 ...

Page 3: ...rates properly The water going overboard at the end of the flush should not taste salty 1000ppm 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 Please have the owner fill out the warranty card The warranty is void if it is not regis tered 1 2 3 4 5 6 7 8 Thank you for ...

Page 4: ...nstallation Operation Page Number New Systems Start Up and Testing 23 Dry Testing 26 Normal Start Up Using the Auto Run 27 Automatic Fresh Water Flush Cycle 28 Manual Operation 30 Long Term Storage Procedures 31 Winterizing 33 Maintenance 34 Membrane Cleaning 35 Salinity Probe Calibration 37 Suggested Spares 38 Newport Troubleshooting Procedures 41 Bulletins 43 Wiring 53 Clark Pump 54 Parts List 5...

Page 5: ...derstanding the function of each component Layout the system Before starting the installation identify the location where each module and component will be placed Ensure 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 if necessary Check to see ...

Page 6: ...ter 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 debr...

Page 7: ...or the flush water shut off valve and flush water pressure regulator Feed Pump Module Fresh Water Flush 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 the left hand side and where water spills during filter changes will not be a ...

Page 8: ...he 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 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 Clark Pump Me...

Page 9: ... tube and fittings Use two grab rings on the 1 2 parker tubing Refer to the parker assembly instructions The remote control panel can be mounted anywhere that is 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 but tons Use only Spectra approved remote cable The cable is not standard LAN cable o...

Page 10: ...ne overboard fitting System Piping schematic Mount the pressure gauge in the low pressure inlet gauge tee Flush water from ship s pressure water system 25 psi 2bar minimum Use the 1 2 inch nylon tubing between the feed pump module outlet and the Clark Pump inlet Use the 1 2inch braided hose between the Flush module and the Feed Pump Module From the Boost Pump to the 20 micron filter inlet us the 3...

Page 11: ...et 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 Leave room on this side for attaching tubing and operat ing the manual button on the diver sion valve ...

Page 12: ...t Inlet fitting on the pump module manifold using the supplied 1 4 black nylon tubing Route the blue product water tube from the blue product water outlet fitting on the feed 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 ther...

Page 13: ...r 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 Brine Discharge Route the Brine discharge from the quick disconnect fitting to a location above the waterline using the supplied 5 8 hose Quick Disconnect Fitting Fresh water from boat s pressure water system To Flush water Inlet on pump module manifold ...

Page 14: ...or 1 4 3 8 tube 1 2 tube should not bottom out in the fitting to allow full compression of the O ring 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 1 4 3 8 1 2 Parker Tube Fitting Assembly Gently fit the tube into the body and loosely thread on the nut Be careful not to cross thread the nut grab ring tabs Step 4 S...

Page 15: ...15 John Guest Super Speedfit ...

Page 16: ...or speed control sets the run speed and also slows the motor to the flush and service speeds Do not install it in hot or poorly ventilated locations and allow for access to the Motor Speed Control Power inlet harness with terminal block 50 15M cable with connectors for the MPC 5000 control display Boost pump cable Motor Speed Control Behind the Prefilters Inside the Chassis MPC 5000 controller Ins...

Page 17: ...nd 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 ...

Page 18: ... 25 35 10 6 4 25 40 12 2 35 45 14 2 35 50 15 2 35 MkII 24V Meters AWG SQ MM 10 3 12 4 15 4 5 10 6 20 6 1 8 10 25 7 6 8 10 30 9 4 8 10 35 10 6 6 16 40 12 6 16 45 14 6 16 50 15 4 25 Mk II 12V Wire length is measured from source circuit breaker or fuse to control termi nal block and back to the source again WIRE SIZE CHART ...

Page 19: ... 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 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 b...

Page 20: ...nal 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 Option...

Page 21: ...resh 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...

Page 22: ...22 ...

Page 23: ...o Flush Manual 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 to enter Purge Mode Note The watermaker will not run with the pressure relief valve open unless it is in Purge Mode Instead it will restart twice and alarm System Stalled Alarm will sound Display will read Open Pressure Relief Now Ensure that it is ...

Page 24: ...t 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 ther...

Page 25: ...ons may result in operating pressures outside of the nomi nal range Filter Condition PREFILTER warns that filters are getting dirty Clean filters as soon as convenient If the graph reaches full scale the machine will automati cally slow down to Run Low speed If it reaches full scale again it will alarm Service Prefilters and shut off the watermaker Spectra watermakers MPC 5000 programming instruct...

Page 26: ...es total purging If you get a SERVICE PREFILTER 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 outlet on the feed pump module 7 Turn the valve on the boo...

Page 27: ...peration 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 o...

Page 28: ...h 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 back wards through the fil...

Page 29: ...o 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 Afte...

Page 30: ...lly 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 over ride button on the valve The valve is located behind an access opening on the left side of the feed pump module Push the manual override button in and rotate 1 4 turn clock wise to open the valve Manual...

Page 31: ...tem 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...

Page 32: ... 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 Set the switch on the pump module to Service System to turn on the feed pump Circulate the storage chemical in th...

Page 33: ... the service port of the boost pump module Lead the hose into the bucket Turn the service valve on the fresh water flush module 180 so the intake is now coming from the bucket Step 5 Set the switch on the pump module to Service System to turn on the feed pump Pump as much of the water remaining inside the water maker overboard as possible Run the feed pump until you see antifreeze begin to appear ...

Page 34: ...ut down to prevent damage If cleaning and re using filter elements clean when the first segment ap pears 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 ...

Page 35: ...hroughout 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 There are two types of cleaners aci...

Page 36: ...anual switch on the MPC control box to turn on the feed pump Circulate the cleaning 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 the toggle switch to Auto when finished Step 8 Turn off the MPC control system DC power Replace the brine overboard hose Remove the Inlet Ser...

Page 37: ... 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 Calibrat...

Page 38: ...sting of Clark pump seals O rings tools and mem brane cleaning chemicals One replacement strainer screen O ring for strainer screen O rings for filter housing Spectra Watermakers parts list SC 1 STORAGE CHEMICAL KIT CHEM SC1 SC 2 CLEANER KIT CHEM SC2 SC 3 CLEANER KIT CHEM SC3 BASIC CRUISE KIT B KIT BCK B 5 MIC FILTER FT FTC 5 20 MIC FILTER FT FTC 20 CHARCOAL FILTER FT FTC CC 6 STRAINER SCREEN FT S...

Page 39: ...age 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 w...

Page 40: ...ight 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 threa...

Page 41: ...not run loose or broken pump wire connection speed control overheat tanks are full Check wiring at terminal block inside MPC Improve cooling Check tanks system cannot be started if tanks are full System runs no product water delivered to water tanks GPH display shows OK Good LED activated diversion valve inoperative wiring fault disconnected or broken product tubing diversion valve faulty Check wi...

Page 42: ...rane Voltage Too Low battery voltage too low loose wires or poor connec tions Charge batteries Check charging voltage Check power connections Re starting no signal from flow meter at startup System Air locked See remedy above for system stalled Check Fuse followed by fuse number blown fuse at circuit board Replace fuse mini automotive type ATM Look for cause Service Prefilter clogged filters loose...

Page 43: ...tant 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 a...

Page 44: ...un 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 th...

Page 45: ...utes 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 BYPA...

Page 46: ...essures 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 gently a limited num ber of times After shu...

Page 47: ... drawn in to make up the difference This will cause the flush water to be brackish and ineffective in preserving the watermaker At initial startup the fresh water flush system should be tested by taking a sample of the brine discharge water just as the flush cycle is ending This water should not taste salty and should read less than 1000 ppm on a digital tds meter The flush cycle can also be teste...

Page 48: ...ing 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 charcoa...

Page 49: ...49 Z BRANE OPERATION MANUAL ...

Page 50: ...ol is still required ANODE INSTALLATION Spectra Watermakers ship the High Pressure Module with the White Z brane electrodes s re moved from their socket s to prevent shipping damage Before the High Pressure Module is mounted the anodes should be installed The socket s have been plugged with plastic plugs to keep the membranes clean and moist dur ing shipping and storage Remove the C clips that sec...

Page 51: ...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 ...

Page 52: ...t 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 DO NOT DISCONNECT OR SPLICE ANY OF THE HIGH VOLTAGE WIRING Contact the factory if modifications are required P...

Page 53: ...53 ...

Page 54: ...ite cylinder and base End block A End cap Cylinder ring Stainless steel tube End block B Valve block Alternate brine out Reset button Not on all units Test port Center block High pressure out Clark Pump Back View High pressure in Composite cylinder and base HP TB VEB B1 HP TB VB HP TB VEB A1 HP TB BV HP CB CB10 HP CYL SST HP CYL R HP CYL EC HP CYL CCA HP TB RSBT ...

Page 55: ...ve spool Spool piston End block A Piston O ring Valve bore O ring Spacer ring Valve block Brine port O ring Pilot port O rings Reversing Valve End Blocks 5 16 2 3 4 SS A H bolts Valve bore O ring Spool piston End block B Piston O ring HD CPS 5 16X3 KIT HP 10VSA HP TB AR SO HPP AR SO HPP RV HP TB BV HD CPS 5 162 75 SO HPP SP PS20 HP TB VSP VSP20 HP TB SR SO HPP VB SO HPP PLP SO HPP VP ...

Page 56: ...O rings Pilot spool O rings 4 Mount inside block Pilot valve pin Pin seal O rings Pilot spool Center block Check valve poppet Feed in Check valve spring Check valve seat Check valve retainer Check valve washer Check valve O ring Pilot orifice SO HPP VP SO HPP PLP SO HPP ECCB SO HPP PV HP CB PVS HP CB PPS SO HPP PS HP CB PVPS HP CB PVCR SO HPP PR7 PR10 PR15 SO HPP CVP HP CB PO SO HPP CVS HP CB CVS ...

Page 57: ...ssembly End cap O ring Cylinder Ring Cylinder end cap S S compression fittings 1 2 SS tube Piston with seal Composite cylinder and base PL MTS 3 8X1 2S HP CYL SST HP CYL CCA SO HPP ECCB HP CYL EC HP CYL R HP CYL PT ...

Page 58: ...1 HP CYL PT PISTON 2 HP TB SR SPACER RING 2 HD CPS 3 824175 3 8 24X1 3 4 CAP SCREW 8 HD CPS 5 16X3 5 16 18X3 1 4 CAP SCREW 4 HD CPS 5 162 75 5 16 X 2 3 4 CAP SCREW 8 HD WSH 3 8X5 8S 3 8 X 5 8 O D SS FLAT WASHER 8 HP CYL SST STAINLESS TUBE 2 PL MTS 3 8X1 2S 3 8 NPT X 1 2 TUBE FITT ST SS 4 HP CYL CC COMPOSIT CYLINDER 2 HP CYL CCB COMPOSIT CYLINDER BASE 2 HP CYL R CYLINDER END RING 2 PILOT ORIFICE PI...

Page 59: ...M NPC MKIIFBK NEWPORT MARK IIA FILTER BRACKET EL MPC RMCD MPC REMOTE CONTROL LCD PL MTE 3 4X5 8P 3 4 NPT X 5 8 TUBE FITT ELL FT FTH 10L3PCS 10 LOW PRESS FILTER HOUSING 3 PCS PL NP 1 2X3 8N 1 2 NPT X 3 8 NPT CLOSE NIPPLE NYL PL HBE SFPA SHURFLO PORT ADAPTOR PL MTE 1 2X5 8P 1 2 NPT X 5 8 TUBE ELL FITTING PL MTE 3 8X1 4JG 3 8 NPT X 1 4 TUBE FIT TING ELL PL MTE 3 4S1 2B 3 4 X 1 2 TUBE FITTING ELL BRON...

Page 60: ...HIGH PRESSURE PUMP 10 FOR N P ASSM PL NLT 1 2HP 1 2 HIGH PRESSURE TUBE DAYCO FM PVB PB PLATE BRACKET KIT HP MNTK SPECTRA MOUNT KIT ASSEMBLY PL HBE 3 4X3 4 3 4 NPT X 3 4 HOSE BARB ELL NYLON EL MPC RMCD MPC REMOTE CONTROL LCD FT FTC 20 20 MICRON FILTER ELEMENT FT FTC 5 5 MICRON FILTER ELE MENT PL FTE 1 8X1 4P 1 8 FPT X 1 4 TUBE FIT TING ELL PL NP 1 8N 1 8 NPT CLOSE NIPPLE NYLON PL HP 1 2N 1 2 HEX PL...

Page 61: ...SURE SENSOR PL MTS 1 2X5 8P 1 2 NPT X 5 8 TUBE FIT TING ST EL SSR IFM INLINE FLOW SENSOR PL MTS 1 2X1 2P 1 2 NPT X 1 2 TUBE FIT TING ST NYL SUB NP MK2 INT NEWPORT MK II INTAKE MANIFOLD EL MPC SP4 SALINITY PROBE PL MTE 3 8X3 8P 3 8 NPT X 3 8 TUBE FITTING ELL NYL PL FTE 1 2X5 8P 1 2 FPT X 5 8 TUBE ELL FITTING PL MTE 3 8X1 2P 3 8 NPT X 1 2 TUBE FIT TING ELL NYL PL PMP 140MAG MAG DRIVE VANE PUMP 140 G...

Page 62: ...TOGGLE SWITCH DP DT FM MPC MPCB MPC BOX EL SWT TSBHC TOGGLE SWITCH BOOT SEAL PL HS 1 2VN 1 2 VINYL HOSE PL NLT 1 2HP 1 2 HIGH PRESSURE TUBE DAYCO PL HS 3 4SH 3 4 REINFORCE SUCTION HOSE PL HS 3 4VN 3 4 VINYL HOSE PL HS 5 8VN 5 8 VINYL HOSE NEWPORT 400 MK II ...

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Spectra Watermakers NEWPORT 400 Mk II, Installation & Owner'S Manual

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