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Spectra Watermakers VENTURA 150 MPC-5000, Owner'S Manual

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Spectra Watermakers VENTURA 150 MPC-5000 Owner'S Manual Download Page 43

43 

Z-BRANE 

OPERATION  

MANUAL 

Spectra Watermakers Inc. 

20 Mariposa Rd., San Rafael, CA 94901 

Phone 415-526-2780   Fax 415-526-2787 
Email: [email protected] 

Http://www.spectrawatermakers.com 

Current manuals/Z-Brane 12/10/04 

Summary of Contents for VENTURA 150 MPC-5000

Page 1: ... 1 Installation Operation Maintenance Section 2 Controls Programming Spectra Watermakers Inc 20 Mariposa Road San Rafael CA 94901 Phone 415 526 2780 Fax 415 526 2787 E mail spectra spectrawatermakers com www spectrawatermakers com Rev Feb 08 06 ...

Page 2: ...2 ...

Page 3: ...uto Run 22 Flushing 23 Manual Operation 24 Maintenance 28 Service Maintenance Long Term Storage Procedures 25 Winterizing 27 Maintenance 28 Membrane Cleaning 29 Suggested Spares 31 Troubleshooting Procedures Service Bulletins 33 Part Numbers 46 Section 2 Programming Controls A 31 MK1 CONTROLS Operation Guide Single Run Speed mode 5 Programming from the display 13 Tank Switch Operation and Installa...

Page 4: ...4 ...

Page 5: ...ntensifier known as the Clark Pump was introduced in 1997 and has continually im proved since It holds a lifetime warranty for the original purchaser It is built of modern non corroding composites Front View Rear view Pressure relief valve Quick disconnect fitting to facilitate maintenance Double rubber mounts to absorb vibration The Clark Pump membrane module Pre mounted and plumbed together as a...

Page 6: ...nding 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 tub ing and hose before starting so additional parts may be ordered Getting Started Ventura MPC Shi...

Page 7: ...enter line as possible to avoid contamination and air induction The brine discharge thru 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 debri...

Page 8: ...coated Avoid getting dirt or debris in the system during assembly Avoid tight bends and elbows Secure piping away from moving objects and protect from chafe Fresh water flush inlet to charcoal filter Plumb to pressure side of fresh water system Spectra Clark Pump Mount in a cool location May be oriented in any position and can be well above waterline Leave access to the pressure relief valve Do no...

Page 9: ...h no fasteners Remove the 4 machine screws hold ing the pump to the module Feed Pump Relocation Cooling fan Heat sink With the pump on a flat surface Remove the three screws that hold the pump head on See Fig1 Re orient the pump head 120 degrees See Fig2 Reinstall the screws and tighten firmly See Fig3 Now the feed pump may be installed where you wish Do not install with the pump head over the mot...

Page 10: ... is 1 4 6mm on the Ventura 150 models See the Parker tube fitting as sembly diagram next page Product water is pre plumbed from the membrane into the electric diversion valve The diversion valve will reject product water into the overboard brine stream until good quality is measured by the MPC 5000 control Product water is then diverted into the fresh water tank Product Diversion Valve Manifold Ro...

Page 11: ...he 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 4 Step 3 Step 2 Step 1 Dissemble fitting components Body O ring Spacer 1 2 max Grab Ring Nut Tubing Product Tube Fitting Assembly ...

Page 12: ...nents 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 ...

Page 13: ...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 14: ...nect the MPC plug in cable Main power feed Install cover after terminating wires Use a 15 amp breaker or fuse Pump feed 4 1 2M may be extended as required Count additional length in wire siz ing Wire fan in parallel Fresh water flush feed 15 4 5M Splice to flush valve Heat connectors to shrink Wire Size Guide for Ventura 150 12V Protect with 15 Amp Fuse or Circuit Breaker 10 Gauge 6mm to 15 feet 4...

Page 15: ...nnection with the supplied heat shrink tubing The salinity probe uses a telephone style jack and plug Plug it in and slide the black plastic boot over the sensor to waterproof the connection The diversion valve cable has two conductors There is no polarity Crimp the supplied heat shrink butt connectors to the diversion valve leads and heat them to seal To Roto Flow Meter To Diversion Valve To Sali...

Page 16: ...lush button If the watermaker is in Autorun mode it can be put into Autofill mode without stop ping it by holding down the Autorun button If the owner prefers to install the automatic shutoff feature without the automatic start up op tion only the tank full switch is used A jumper must be placed between the tank empty ter minals Float Switch 2 in place of the tank empty switch because the watermak...

Page 17: ...17 ...

Page 18: ...hose connections are tight The green tag with the spacer under the pressre relief valve has been removed The pressure relief valve is open 1 2 turn The switch on the MPC control box is set to the Auto position First check that Ventura MPC New System Start Up and Testing Open 1 2 Turn when Purging Chemicals Remove Tag and Washer Power up the system by turning on the cir cuit breaker A message on th...

Page 19: ...he membrane 1 After the purge sequence the control will alarm with the message Close pressure relief valve Close the valve and proceed by pressing Auto Run 2 The system is now running under pressure and making water The display will read purging product water This mode dumps the product water overboard for ten min utes in case there is any residual chemicals in the membrane Carefully inspect for l...

Page 20: ... new system Each square represents 100 ppm System re jects water higher than 750 PPM LED lights Reject Good indicate product mode Feed Water Pressure range 60 70 PSI 4 2 5 BAR Filter Condition When filters become partially clogged the MPC 5000 will alarm Service Prefilters If the filters become fully clogged all squares highlighted the unit will shut off automati cally ...

Page 21: ... the photo and route them into the 5 gallon 20 liter container Turn your product sample valve if installed to the sample posi tion If no sampling valve is installed temporarily route the product to tank tube into the bucket 6 Push the Auto Store button and fill the bucket with fresh water from the brine discharge Stop the system when it is full 7 Rotate the yellow service valve to the service posi...

Page 22: ...the Stop button is pressed 5 You may stop the system at any time with the Stop button but if you do it will not flush itself or go into Auto Flush mode You may now leave the system unattended for up to five days without further attention We recommend operating the system for longer periods and effecting a fresh water flush rather than running the machine every day and not flushing the system Remem...

Page 23: ...a countdown timer After 5 7 min utes the pump will stop 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 Dis play will read FRESH WATER FLUSH with a countdown timer then t...

Page 24: ...t fitting To shut down manually set the switch Auto If the system is to be left idle for more than a day it should be given a fresh water flush To manually flush collect 3 gallons of product water in a bucket Connect the service hose to the service connection on the pump module Place the service valve in SERVICE posi tion and start the feed pump with the manual switch Run the feed pump until the b...

Page 25: ...e than five days 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 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 compatible with the m...

Page 26: ...re the pressure relief valve on the Clark pump is OPEN un pressurized by turning 1 2 turn counterclockwise 7 Place the service valve in Service position 8 Turn on the feed pump You can use the man ual switch on the MPC 5000 control box Circu late the storage chemical in the system for ap proximately 10 minutes Turn off the feed pump when finished Clean Up Remove the quick disconnect from the Clark...

Page 27: ...col in the bucket 7 Make sure that the pressure relief valve is OPEN un pressurized 8 Turn on the feed pump with the manual switch on the MPC control box until antifreeze appears in the brine overboard hose 9 Stop the pump Reconnect the brine service hose Start the pump and re circulate the re maining antifreeze for a few minutes 10 Close the seawater intake and the service valve Drain the straine...

Page 28: ...ccasionally lightly lube the filter housing O ring with silicone grease Replace the charcoal filter element at least every 6 months This filter protects the membrane by removing chlorine from the fresh flush water Use only a Spectra replace ment Oil Water Separator Optional To install oil water separator capability remove the 20 micron filter from the dual filter hous ing and replace with the oil ...

Page 29: ...ter 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 test ing or follow the flushing purging and testing procedure given in the Dry Testing with Artificial Ocean instructions There are two types of cleaners acid and alkaline The...

Page 30: ...ne discharge hose and start the pump until the bucket is empty Stop the pump and rotate the service valve back to the run position Restart the pump and run for 20 minutes to flush the chemicals out of the system DO NOT CLOSE the pressure relief valve 8 The system may now be restarted to make water flushed or stored Service valve in off position Open the pressure relief valve Service hose connected...

Page 31: ... membrane cleaning chemicals One replacement strainer screen O ring for strainer screen O rings for filter housing Spectra Watermakers recommended spare parts SC 1 STORAGE CHEMICAL KIT CHEM SC1 SC 2 CLEANER KIT CHEM SC2 SC 3 CLEANER KIT CHEM SC3 BASIC CRUISE B KIT BCK B OFFSHORE REBUILD KIT KIT OFFSH 5 MICRON FILTER FT FTC 5 20 MICRON FILTER FT FTC 20 CHARCOAL FILTER FT FTC CC 5 STRAINER SCREEN FT...

Page 32: ...mp will not run loose or broken pump wire connection bad pump relay tanks are full Check wiring at terminal block inside MPC Test power relay replace Check tanks system cannot be started if tanks are full System runs no product water delivered to water tanks GPH bar graph shows OK Good LED activated diversion valve inoperative wiring fault disconnected or broken product tubing valve plunger stuck ...

Page 33: ...ose wires or poor connec tions Charge batteries Check charging voltage Check power connections Re starting no signal from flow meter at startup System stalled 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 or defective pressure sensor wires Install new fi...

Page 34: ...op similar to those found on car tires This allows the internal air bladder of the accumulator to be precharged The accumulator should be pumped up to about 65psi 4 5bar for best re sults Add air using a tire pump or air compressor You can experiment with the exact pres sure that will give the best pulsation dampening on your installation The purpose of the fresh water flush accumulator is to allo...

Page 35: ... 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 t...

Page 36: ...s good for one year See Wintering or Pickling With Antifreeze for instructions on this procedure NOTE Do not use metasodium bisulfate the standard chemical used to store most watermak ers This chemical will damage the Clark pump and void the warranty CLEANERS Cleaning can be detrimental to the membrane and shorten its life Avoid unnec essary cleaning Avoid cleaning as a diagnostic tool SC 2 is an ...

Page 37: ...e feed pump is operated at a reduced speed on some models or is cycled on and off on other models to avoid exceeding this flow rate If the ship s water system is unable to provide flush water at the required flow rate sea water will be 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 fl...

Page 38: ...o equipped Plugged filters can be cleaned several times by soaking in a bucket towing behind the boat at moderate speeds or cleaning with a hose When operated only an hour or two a day in inland or near shore waters the trapped plankton will begin to decay in the filters long before the elements plug up and the bacteria involved in the decay will cause a rotten egg smell in the product water This ...

Page 39: ... the switch If it is open you can make temporary repairs by wiring around it being careful that your new wiring doesn t chafe on the moving parts nor resist the springs that push the brushes on to the commutator If any corrosion is apparent the brushes may be sticking Once apart clean all the carbon dust from all the parts Clean the commutator with light sand paper Make sure to clean the small gro...

Page 40: ...se of the constant arcing from cutting out each time the Clark pump shifts For all systems except the Gulfstream the feed pump pressure switches should be set to shut off at 125 psi 8 5 bar as follows On the very center of the switch is a small 5 64 allen screw Run the system on pump one and close the brine discharge valve 1 2 way 90 deg to block the flow Watch the pressure gauge and adjust the pr...

Page 41: ...eparably damage the membrane Charcoal filters are used to absorb any chlorine which might be present in flush water They must be of proper specification to be suitable There is no test for chlorine damage except the process of elimination of other causes DIRTY OR SCALED membranes A dirty foreign material scaled mineral deposits or contaminated bacterial growth membrane can result in poor water qua...

Page 42: ...nd the pump should shut off Repeat with pump 2 If the pumps shut off at a lower pres sure see SF 2 Adjust ShurFlo Pressure Switch bulletin 1 Log the pressure on pump 1 pump 2 and both Log the product GPH LPH at the same time 2 Log the voltage at the feed pumps at the same time Confirm at least 12 5 volts at the pumps You may have to run the engine or battery charger 3 Measure the total flow rate o...

Page 43: ...OPERATION MANUAL Spectra Watermakers Inc 20 Mariposa Rd San Rafael CA 94901 Phone 415 526 2780 Fax 415 526 2787 Email spectra spectrawatermakers com Http www spectrawatermakers com Current manuals Z Brane 12 10 04 ...

Page 44: ... 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 B...

Page 45: ...se 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 DO NOT DISCONNECT OR SPLICE ANY OF THE HIGH VOLTAGE WIRING Contact the factory if modifications are requi...

Page 46: ...HD SPN MKINS Plate Bracket End Cap FM PVB PBE Clear Filter Housing Bowl Cap FT FTH 10L Clear Filter Housing O ring SO FHS 10H 3 4 NPT X 1 2 Hose Barb Elbow PL HBE 3 4X1 2 1 Way Solenoid Valve 12V PL SLN 1 4O12 3 4 NPTX5 8 Hose Barb PL HBS 3 4X5 8 Pressure Vessel End Cap FT PV EP Pressure Vessel End Ring FT PV ER 1 2 High Pressure Tube PL NLT 1 2HP Part Numbers ...

Page 47: ...1 4 Pressure Sensor EL SSR 150 Filter Housing Bracket Duplex FT FHB 10HD 3 4 Nipple PL NP 3 4N High Pressure Filter Housing Lid Bowl FT FTH 10H Filter Housing O ring SO FHS 10 Accumulator Tank PL ACC TK Pressure Guage PL PSG LP1 5 1 2 X 1 8 Bushing Reducer PL BSH 1 2X1 8N 1 2 Nipple PL NP 1 2N 1 2 Female Tee PL TEE 1 2FN 1 2 NPT X 5 8 Hose Barb PL HBS 1 2X5 8 3 8 NPT X 5 8 Hose Barb El PL HBE 3 8X...

Page 48: ...X1 4P 1 8 Hex Plug PL HP 1 8 Part Numbers EL MPC SP SALINITY PROBE SUB NP DVM DIVERSION VALVE MANIFOLD PL MTS 1 4X3 8P 1 4 MPT X 3 8 TUBE FITT ST EL SSR IFM INLINE FLOW METER SENSOR PL CKV 1 4M F 1 4 PLASTIC CK VALVE M F PL SLN 1 4D12VB 1 4 DIVERSION VALVE 12V W O VB PL FTS 3 8X1 4P 3 8 FPT X 1 4 TUBE FITT ST REDUCING COUPLING PL UNN 3 8X1 4N MPC CONTROL PANEL VFD EL MPC RMCDFD ...

Page 49: ...Disc Fitting Hose Barb PL QDC HB5 8 1 2 High Pressure Tube PL NLT 1 2HP 1 4 Product Tube PL NLT 1 4LP 3 8 Low Pressure Tube PL NLT 3 8LP Stainless Fitting Hex Nut PL HWR 1 2HN 1 2 Stainless Ferrule PL HWR 1 2FR Connector O ring SO HPP CT 3 4 16 Straight Thread O ring SO FT STF Part Numbers ...

Page 50: ...Fan 12V 24V KIT FK 12 24 Feed Pump Heat Sink EL FP FPHS Ventura Feed Pump Bracket FM VT ITM Feed Pump 12V 24V EL FP 12V 24V 3 8 NPT X 5 8 Hose Barb El PL HBE 3 8X5 8 Pump Head Assembly W Press Switch PL PMP SFPH Feed Pump Pressure Switch EL FP PS Part Numbers ...

Page 51: ...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 Back View High pressure out Clark Pump High pressure in Composite cylinder and base HP TB VEB B HP TB VB HP TB VEB A HP TB BV HP CB CB7 HP CYL SST HP CYL R HP CYL EC HP CYL CCA Parts Not used ...

Page 52: ...lief Valve O Ring Reset button and O ring Spacer ring Valve 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 Spool piston Valve bore O ring 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 VS...

Page 53: ...ings 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 O ring Check valve retainer Check valve washer Pilot orifice Piston rod HP CYL 3 4R 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 S...

Page 54: ...mbly End cap O ring Cylinder end cap Cylinder Ring 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 Parts ...

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