Spectra Watermakers Ventura 150 Mpc 5000 Users Manual

MPC-5000 to the manual 481bf3ea-6033-0694-51dd-791d71363a8c

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VENTURA 150 MPC-5000

OWNER’S MANUAL

Section 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

Table of Contents

Section 1

Installation

Operation

Introduction ......................................................................................................................... 5

Getting Started..................................................................................................................... 6

Installation Basics ............................................................................................................... 7

Ventura Plumbing Schematic.............................................................................................. 8

Feed Pump Relocation ........................................................................................................ 9

Product Water plumbing ................................................................................................... 10

Tube Fitting Assembly Procedures ................................................................................... 11

Wiring................................................................................................................................ 14

MPC Tank Switch Wiring and operation……………………………………………….. 16

Z Brane Installation........................................................................................................... 43

Page Number

New Systems Start Up and Testing................................................................................... 17

Dry Testing........................................................................................................................ 21

Normal Start Up Using the Auto 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 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

Introduction to the Ventura 150 MPC

The Ventura represents the finest watermaker for small and midsized yachts available today. The Spectra

Clark Pump is matched to a 21” high rejection membrane. Properly installed and maintained it will supply

years of reliable service. The MPC-5000 control provides the ultimate in operational convenience and reli-

ability. Note that prudent operation is required with any marine equipment. Always maintain enough reserve

water to get safely into your next port.

The Spectra High Pressure Intensifier, 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 single unit.

Saves time and adds reliability.

Ventura feed pump inlet module.

Includes the feed pump, cooling fan, charcoal filter for the flushing

system, manual flush valve, service valve and service port . Compact

and streamlined plumbing. Feed pump may be removed and relocated

if necessary. Cooling fan is included for long life.

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 kit list.

Warning! We will not be held responsible for shortages and/or freight damage that are

not reported within thirty days of the ship date.

Study the system plumbing and wiring diagrams 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 tub-

ing and hose before starting so additional parts may be ordered.

Getting Started

Ventura MPC Shipping List

• High Pressure Clark Pump and reverse osmosis membrane module.

• Feed pump inlet module with automatic fresh water flush system.

• Accumulator tank

• Seawater strainer

• MPC 3000 control with harnesses

• MPC 3000 display panel.

• Dual filter assembly with pressure sensors

• Installation Fittings Kit

• Service Hose kit

• 5/8” Hose (25’) 2 ea

• 1/4 product tubing (25’)

• Filter wrench

• Teflon pipe tape

Installation Basics

• 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

Thru-hulls

It is mandatory that a dedicated 1/2” to 3/4” 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 condi-

tions. Sharing a thru-hull with another system is not acceptable and will void the warranty.

Sharing a thru-hull can introduce unforeseen problems such as intermittent flow restriction,

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 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 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.

Flow

Wiring

• Pay attention to wire size or system performance will be impaired

• Perform wiring to UL, ABYC, CE or applicable standards

Thruhull

Not Supplied.

Water Flow

Sea Strainer, Mount with

Quick Block

Ventura 150 MPC Plumbing

Inlet pump module. Mount vertically as low as prac-

tical, no more than 4’ (1.1 M) above waterline and do

not mount over electrical equipment.

Leave clearance below for filter change.

20 and 5 micron filters. Do not mount

over electrical equipment. Leave clear-

ance underneath for filter change

Accumulator, Factory

pre-charged. Install so

that gauge is visible.

Plastic fittings should have 3-4 wraps of Teflon

tape and will thread almost all the way in. Leave

the first pipe thread uncoated. 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 not mount over electrical equipment. Use supplied

spacers and washers for the vibration mounts.

Brine Discharge thru hull place

above waterline or tee brine into

another visible drain.

1/2” or 3/4” scoop strainer thru-hull and seacock for

watermaker only. Mount low, in a clear flow and away

from head discharge. Thru-hull is owner supplied.

Red In Green Out

If you do not have adequate space to install the feed pump inlet module it is possible to re-

move and relocate the feed pump. Before you install the module, disconnect the hose that

connects the feed pump to the module plumbing. Remove the cooling fan and the heat sink

from the pump. Both are friction fits with 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 motor in-

case of leaks. Wire size may have to be increased if

wire runs are longer.

Fig 1

Fig 2 Fig 3

Machine Screws

Product to tank.

Route the product water into the top of the tank, or a tee in the

water tank fill hose.

DO NOT! feed into a vent line, a manifold or the bottom of the

tank. Make sure that there is no restriction in this piping.

Product Water Plumbing

Salinity Probe

Automatic Valve

Product water tubing 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

RotoFlow Meter

Accepted Product

Water Outlet

Check Valve

Rejected product outlet

Product from membrane

Gently fit the tube into the body and loosely thread on the nut.

Push the tube into the body until it bottoms out then hand tighten the nut.

DO NOT OVER TIGHTEN!

1/4" Tube Fittin

Assembl

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 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

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 fittings 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 which seal with an O-ring and should be seated all the way in, but need

only to be snug, not tight as with tapered threads. Hold the fitting with a wrench while in-

stalling 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!

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 the 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

Tighten 1-2/3 turns (10 flats of the

nut) with a7/8" wrench after finger tight.

Use index mark as guide

Ferrule

Figure 2.

Insert tube 0.9" until it stops

Figure 3.

Figure 1.

Black high pressure tubing

Cut tube square

Nut

Index mark

IMPORTANT!

Hold fitting body with 13/16"

wrench when tightening

No threads showing

Nut finger tight with

1 thread showing

Body

Straight or 90 deg.

3/8" pipe thread

Straight thread

MPC-5000 Wiring

Mount the control box on a vertical surface with the wire grommets down, central to the

other system components. Make sure the cables will reach all of the modules to avoid

splices.

Filter Sensor harness

6’ (2M)

Control cable 50’ (15.2M)

Protect connector while routing through

the vessel. Control Box

Clark Pump harness, RotoFlow meter,

salinity probe, and diversion valve feed

15’ (4.5M). See next page.

MPC-5000 display. Mount in

dry central location. Only con-

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 (4.5M)

# 8 Gauge (10 mm) to 25 feet (7.5M)

#6 Gauge (16mm) to 35 feet (10.6M)

Wire Size Guide for the Ventura 150 24V

Protect with 7 Amp Fuse or Circuit Breaker

#12 Gauge(4mm) to 10 feet (3M)

#10 Gauge (6mm) to 25 feet (7.6M)

#8 Gauge (10mm) to 35 feet (10.6M)

Total length for a pair of wires!

Clark Pump Harness

Diversion

Valve.

Salinity Probe

Roto Flow meter.

The RotoFlow meter measures product flow. It is supplied with a three pin plug-in connector.

Plug it in to the RotoFlow cable and seal the connection 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 Salinity Probe

Tank Switch Installation and Operation:

There are two sets of terminals on the MPC-5000 PCB that can be used in four different con-

figurations to automatically start and stop the watermaker, or to automatically stop the water-

maker 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 push-

ing and holding the Auto Run switch on the MPC-5000 display. In this mode the watermaker

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 watermaker 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 completely 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 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 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 watermaker 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 Float Switch 1 terminal “1” to the common on the switch and run sepa-

rate 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.

Note: If the Automatic startup is enabled the watermaker may start at any time. Because no

one may be available to check for oil in the water around the boat, it is recommended that an

oil-water separator, part number FT-FTC-OW be installed in place of the 20 micron filter.

Avoid running the Ventura system if the vessel is in contaminated water, such as in a harbor

or canal. The system should be fully tested before leaving port. 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.

• Thru-hull inlet valve is open and the brine discharge valve is open.

• All of your 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 the display will

read Open Pressure Relief Valve Now

Push the “Auto Run” Button. The feed

pump will start and the message

“Purging Storage Solution” will appear.

Note: See Part 2 for instructions on dimming the display and programming from the display

3. The system is now in the operational mode. You may start and run your system as you

desire. You will not have to go through the purging mode unless you “de-power” the sys-

tem. 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” button which defaults to the

automatic fresh water rinse. If you shut down the system from the “Stop” button then use

the “Auto Store” button to effect a fresh water flush cycle.

Note: You can bypass the purge sequence and initiate a normal start at any time by

Pressing both “Auto Run” and “Stop” simultaneously. This will bypass the

purge sequence and enable a normal start.

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.

Do not bypass the purge mode unless you are sure that the chemicals are

purged from the system or you will permanently damage the 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 leaks

over the entire system! Shut down the system and repair any leaks you find.

4. Check that the system is operating within its normal parameters. Compare with the chart

on the next page.

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 few bubbles anywhere in the intake hoses and the feed pump should

sound smooth after priming. After confirming that the system is primed, inspect for leaks.

Note: The reject light will be on whenever the

product water is being rejected or not being made.

When the product water is below 750 PPM the

green (Good) light will show that water is going

to the tank.

Product

The Ventura will produce 6- 6.5 GPH (26-27 LPH)

MPC Display Modes

Scroll through the modes with the alarm display key.

Salinity

This may not show any lit bars on a 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.

Ventura MPC Dry Testing With Artificial Ocean

If it is not possible to test run the system with the boat in the water, testing may be accom-

plished with an artificial ocean. Purchase enough aquarium salt to make 5 gallons (20 liters)

of salt water.

Make sure that the domestic water system is powered up and that there is water in the tank.

Confirm that the charcoal filter is installed in the fresh water flush module and that the domestic

water line had been installed and all valves are open.

1. Open Pressure Relief Valve on the Clark Pump. Remove the green tag and spacer!

2. Close the yellow service valve on the inlet module. This will be the center location.

3. Power up the control. Bypass the purge mode by pushing “Auto Run” and “Stop” simulta-

neously.

4. Push the “Auto Store” button and allow it to run a flush cycle. Do this five times to purge

the storage chemicals.

5. Hook up your inlet and brine discharge service hoses per 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 position.

8. Mix the salt to the proper proportion or use an aquarium hydrometer to adjust the salinity

level.

9. Push the “Auto Run” button, allow the system to prime and then close the pressure relief

valve. The system should build pressure and after several minutes start making water.

10. Run the system under pressure and check for proper operation and leaks.

After testing the system, stop and replace the brine discharge hose. Restart and drain the bucket.

You can now store the system by using the above procedure for adding fresh water to the

bucket and pickling the system, or using the “Auto Store” system.

Valve in closed position

Valve in service position

Inlet service hose connected

Connecting the brine

discharge service hose

Ventura MPC Operation

Normal operation

If the system has been pickled or stored, use the “New System Startup” procedure.

1. Check to see that the inlet seacock is open.

2. Push the “Auto Run” one or more times. The machine will run for one hour for each

time the button is pushed, then shut off and automatically do a fresh water flush. If you

receive a “System Stalled” error code, there is no flow in the system. Open the pressure

relief valve on the Clark Pump and bleed the air out of the feed pump.

3. Run the system until you have filled your tank or have made enough to meet your re-

quirements for several days.

4. When the unit shuts down it will enter the “Auto Store” mode, which will flush the unit

every five days unless you run it to make water, the unit is de-powered, or 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. Remember that you

need to run the system almost a half hour to make the flushing water. You may notice that

the system output is higher while charging your batteries as the machine is voltage sensitive.

Storage mode. The timer counts down in hours until the next flush cycle.

Warning! Understanding automatic fresh water flush system is essential for it to be effec-

tive.

1. Make sure that the system has continuous power. Shutting down power will reset control.

2. Make sure that the potable water system is “on” and that there is adequate water in the

tank for the extended period.

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 water-

maker for more than the expected time of operation in the “re-flush every 5 days” mode.

The Ventura 150 requires about 2.5 gallons (10 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 feed pump will start, the flush water solenoid will open and

the display will read “FRESH WATER FLUSH” with 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 the default dis-

play when finished.

• Pressing the Stop button will cancel the auto store mode.

Flush Cycle Adjustment

Before shipping from the factory the Ventura 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. Check the flush by closing the sea cock.

If the system alarms “Check sea strainer” insufficient water is being supplied from the vessels

fresh water system. If the fresh water supply is insufficient sea water will be drawn in to make

up the difference and the system will not be properly flushed. After checking the flush water

flow adjust the “Flush Duration” from the Programming Function on the display. Set the Flush

duration so that the Flush comes to an end just as the salinity of the water going overboard

drops below 1000 ppm or no longer tastes brackish.

In the event of complete MPC control failure, the system may be operated manually using

the switch on the feed pump module.

• For manual start up, set the switch to “Manual”. Shut the unit down if the Clark Pump does

not cycle. In manual operation, the salinity control is inoperative and the diversion valve

will not operate. Instead, product water must be taken directly from the membrane product

water outlet. The automatic safety controls are disabled in manual mode.

• Bypass the diversion valve as follows:

• Disconnect the 1/4 inch tube “A” that runs between the membrane product outlet and

the RotoFlow meter at the membrane outlet fitting. Product water will run out of the

fitting.

• Taste the product water before sending it to a tank. Always discard the product water

for the first few minutes of operation. The initial product water from the system may not

be potable.

• Disconnect the product-to-tank tube from the diversion valve manifold outlet and con-

nect it to the membrane product outlet 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 bucket is

empty and turn the service valve back to “RUN”.

Manual Operation

Tube “A”

Tube to tank

Membrane

product outlet

Automatic

Operation

Manual

Operation

Tube “A”

Tube to tank

Diversion valve

manifold outlet

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 shutdown will still be activated. The pressure sensors and salinity probe can also be cali-

brated 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.

Long Term Storage Procedures

Watermakers are best run continuously. When not in use, biological growth in the mem-

brane is the leading cause of membrane fouling. A warm environment will cause more

growth than a cold environment. The fresh water flush system will greatly reduce biologi-

cal growth but may not stop it completely in certain conditions. If an optional “Zeta Guard”

or Z-Brane water treatment system is installed in the system, then three to five day flushing

intervals will maintain the system as long as fresh water is provided and the charcoal filter

maintained.

System Storage or “Pickling”

If the system is to be left unused for more 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 modern engineering plastics and composites in the Spectra pumps.

Do not use any substitute except propylene Glycol, If you chose to use glycol follow the

winterizing instructions. 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 for short term stor-

age (under two months use 1/2 of a container)

Caution! Avoid contact with skin, eyes, or lungs with the storage chemical.

Ventura MPC Storage Procedure

1. Shut the service valve by moving it to the middle position.

2. Perform two fresh water flushes by pushing the “Auto Store” button .

3. Remove the cap on the service port on the feed pump module and install the service hose

from your kit. Remove the quick disconnect fitting from the brine discharge outlet of the

Clark Pump, and replace with a quick disconnect service hose from your service kit.

Lead the hoses to a 5 gallon bucket or container.

4. Push the “Auto Store” button and run the feed pump until you have one gallon of fresh

water in the bucket. Stop the system.

5. Mix 1 container of SC-1 storage compound with the water in the bucket.

6. Make sure 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 Pump brine discharge, and replace the original

hose that leads to the thru-hull. You may at this point, if you choose, 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.

Close the seacock and drain and clean the strainer and any filters in the system. Reassemble

dry.

Service valve Off Service hose connected

Service valve in service position

Brine disconnect fitting

Winterizing

1. Close yellow service valve, push “Auto Store” to flush the system.

2. Connect the inlet service hose and the brine discharge service hose. Place them in the

service container or bucket.

3. Push “Auto Store” and run until there is 1 gallon (4L) of fresh water in the bucket, then

stop the system.

4. Reconnect the brine overboard hose to the Clark Pump

5. Turn the service valve to the “Service” position.

6. Pour 2 gallons (8L) of Propylene Glycol 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 strainer and the hose leading to

the inlet module.

11. Disconnect the product to tank tube and blow the water out of it with compressed air.

Valve in off position Open the pressure relief valve

Valve in service position Connecting brine discharge hose

Maintenance

The Seawater Strainer

The sea water strainer’s stainless steel element should be inspected, removed, and cleaned as

needed. Be careful to ensure that the thru-hull is closed before disassembly and the gasket is

in place before reassembly. When the system is put into storage, remove, rinse, and reassem-

ble dry to impede corrosion. Check frequently during operation.

The Prefilters

• Service the pre-filters on a regular basis. The MPC will alarm when the filters reach a 5

PSI (.35 BAR) pressure drop. You may clean and reuse the filters at this level. If you con-

tinue to use the system until it stops at 10 PSI (.75 BAR) then the filters will have to be

discarded.

• To service the filters, shut off the service valve, open the housing, and discard the old fil-

ters. Clean out the housing bowl and reassemble the housings with new 5 and 20 micron

filter elements. Leave dry until next startup.

• Use only Spectra approved filters or you may void your warranty. The filters may be

cleaned several times with a soft brush and water in a bucket. Occasionally, 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 water separator element.

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 Charcoal Fresh Water Flush Filter

The Feed Pump and Clark Pump

The feed pump and the Clark Pump require no routine maintenance except inspection for

leaks. Tighten any hose clamps or fittings the show signs of leakage. The high pressure

stainless steel fittings threaded into the Clark Pump have o-ring seals with a straight thread.

These should never leak and should never be over tightened. If one of the tube nuts starts to

leak it can be un-threaded, sealed with a bit of silicone grease or silicone seal, and, using two

wrenches, tightened very tight.

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 it has been left “unpickled” for an extended length of time

and biological growth is present, it is recommended that the system be 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 prefil-

ters and examine their condition. If the housings are full of smelly discolored water, the system was

not properly stored. Install clean prefilters if they were bad. Next, check the membrane. Detach the

brine discharge 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 is 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 system can be purged, run normally, and checked for performance. Clean the

membranes only if performance is reduced.

Heating the water is preferable. 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 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 acid cleaner (SC-3) will remove mineral scal-

ing. 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 is recommended. The acid cleaner should be used first. If the problem persists after the acid

cleaning, do the alkaline cleaning. If the membrane fails to respond to both cleanings, this is an indica-

tion of another problem with the system, or that it is time to replace the membrane. Contact Spectra

Watermakers before removing a membrane.

The membranes need to be cleaned only when operating pressures have risen 10% due to fouling, or

when the product quality degrades. The leading cause of fouling 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 conditions, and from rust. Monitor the product salinity and

feed pressure for higher than normal readings for the existing conditions. Other conditions can cause

high pressure such as cold feed water or clogged filters. Low product flow is usually due to low volt-

age, damaged feed pump or Clark Pump. Look for all other causes before cleaning the membrane.

Membrane life can be shortened by excessive cleaning.

The Membranes

Cleaning Procedure:

1. Close the service valve and push “Auto Store” to effect a fresh water flush.

2. Connect your inlet service hose and the brine discharge service hose. Push “Auto Store”

again and allow to run until there is 1 gallon (4L) of water in the bucket. Stop the system.

3. Turn the service valve to the service position.

4. Make sure that the pressure relief valve is open (un-pressurized).

5. Mix the cleaning chemical in the bucket.

6. Start the system with the manual switch on the MPC control box and circulate the chemi-

cal through the system for the required time.

7. Stop the pump, replace the brine 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

ump 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 Connecting brine discharge hose

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 av-

erage of two gallons (8L) of water is already present inside a Ventura 150 system . This water has

to be figured into the mixture. A Ventura 150 system will use one container of compound.

Suggested Spares Ventura MPC

Short term cruising, weekends etc.

A basic cruise kit B. This kit consists of three 5 micron filters, three 20 micron filters, and

SC-1 storage chemicals.

Cruising 2 to 6 months at a time.

Two basic cruise kits, one replacement charcoal filter, and one replacement feed pump head.

Longer than 6 months

Additional filters, offshore cruising kit consisting of Clark Pump seals, O-rings, tools and

membrane cleaning chemicals. One replacement strainer screen, O-ring for strainer screen,

O-rings for filter housing,

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-STN-5S

OIL/WATER FILTER FT-FTC-OW

FEED PUMP HEAD PL-PMP-SFPH

5” STRAINER O-RING SO-STN-5SS

FILTER HOUSING O-RING SO-FHS-10H

20” MEMBRANE FT-MB-20

SALINITY PROBE EL-MPC-SP

SALINITY PROBE CABLE EL-MPC-SC15

Part Number

Feed pump runs constantly,

will not turn off

Manual override switch in

“on” position

Turn off manual switch on

control box

SYMPTOMS PROBABLE CAUSE REMEDY

Ventura MPC Troubleshooting Procedures

No lights or display, system

does not operate

- Remote display not connected

- No power to control box

- Check display cable connec-

tions at back of display and at

control box

- Check and reset main DC

supply breaker

- Check for voltage (12 or

24vDC) at control box power

input studs

- Try manual bypass switches;

if pumps run, then control or

display is defective

Feed pump runs with loud

noise

- Intake blocked

- Air in system

- Check thru-hull valve

- Check sea strainer for leaks

- Check FWF module for leaks

- Re-prime system (restart)

Pumps run intermittently,

cycling on/off

Overpressure switch opening - Adjust or replace switch

Display activates, but pump

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

- Check wiring at diversion

valve and inside control box

- Check product tubing

- Disassemble and clean diver-

sion valve plunger or replace

valve (contact factory)

System runs, no product

water delivered to water

tanks, GPH bar graph

shows OK, “reject” LED

activated

- high salinity of product

water, causing system to

reject water

- salinity probe out of cali-

bration or defective, bad

cable

- chlorine damage to mem-

branes

- pressure relief valve open

- Check for low feed pressure,

close pressure relief valve

- Check for leaks at high pres-

sure hoses

- Test product water with hand-

held tester– if over 500ppm

for 1 hour, contact factory

Close Valve

SYMPTOMS PROBABLE CAUSE REMEDY

Ventura MPC Troubleshooting Procedures

Error Messages

“System stalled”

(“system stalled” may alarm

when using the control panel

to run system for servicing

with the pressure relief valve

open– use manual override

switch instead)

- pressure relief valve open

- intake thru-hull closed

- airlocked system

- no signal from RotoFlow

meter

- Close pressure relief valve

- Check thru-hull

- Verify stroke sensor fully in-

serted in pump

- Check stroke sensor wiring at

control box

- Replace flow meter

“High Pressure” - blocked brine discharge

- fouled membrane

- Check brine discharge

- Clean membrane

“Voltage Too High”

“Voltage Too Low”

- battery voltage too high or

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 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 filters

- Check sensor wiring

“Ck Sea Strainer” - clogged strainer

- dirty 50 Micron prefilter

- Seacock closed

- Clean strainer screen; change 50

micron filter; check through-hull

and intake hoses

“Salinity High” - high product water salinity

- chlorine damage to mem-

branes

- defective salinity probe or

cable, cable disconnected

- Check for low feed pressure

- Check for leaks at high pressure

hoses

- Remove and clean probe con-

tacts check calibration.

- Check cable connections

- Clean membrane

ACCUMULATOR PRESSURE

All Spectra Watermakers, except the Newport 700 and 1000 series, are supplied with a pres-

sure accumulator tank (part no. PL-ACC-TK) to be installed in the feed water line between the

prefilters and the Clark Pump. In addition, the Catalina 300 and Newport 400 series also have

an accumulator mounted inside the fresh water flush module.

The purpose of the feed line accumulator is to reduce the spikes in the feed pressure caused by

the cycling of the Clark pump. If the accumulator is not properly charged it can lead to prob-

lems with the ShurFlo pump pressure cutout switches. The accumulators have an air valve on

top 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 allow a steady flow of 1.5 gallons per

minute of flush water through the charcoal filter. Because the feed pump on the 300 and 400

hundred series exceeds this maximum allowed flow rate, the controller turns it on and off, to

reduce the overall flow rate. The accumulator gives the water flowing through the charcoal

filter somewhere to go while the feed pump is cycled off. The flush water accumulator should

be preloaded to 5 psi (.35bar).

9/27/04

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 pre-

filters 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 the 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 auto-

mated Spectra units to operate with less frequent prefilter changes. 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 sys-

tems, 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 handling, 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 wa-

ter line. Spectra offers a product water filter kit (part no. KIT-FLT-CC).

More on this subject is available on our website at www.spectrawatermakers.com.

8/17/04

OP-3 CHEMICALS 101

Spectra systems use four types of chemicals: SC-1, SC-2, SC-3, and propylene glycol anti-

freeze.

NOTE: Never use any chemicals with the system pressurized! Always open the pressure relief

valve 1/2 turn. Always purge a system containing chemicals for at least 20 minutes unpressur-

ized before pressurizing and making water.

The SC-1 is for storage only. It is no longer used as a cleaning chemical. To prepare the sys-

tem for storage, first do a fresh water flush until the brine discharge is below 1000 ppm or does

not taste salty. Mix one jar of SC-1 with 1 to 2 gallons of product or de-chlorinated fresh water

in a bucket and circulate UNPRESSURIZED with the fresh water in the system for 10 minutes,

then discard. The system should be re-pickled every six months in warm conditions, and every

eight months in cooler conditions.

The Spectra systems should be stored with propylene glycol if freezing could occur. This is the

food grade antifreeze used to winterize RVs, boats and cabins. This works very well for storing

in warm climates and is 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 alkaline cleaner used to remove light oil, grime and biological growth. It is most

effective if heated to 120 oF On a boat this is not easy to do. If not heated, circulate for 2 hours

and let set for several hours and re-circulate for one hour and discard. In most cases the water

quality will increase in PPM after an SC-2 cleaning. After a few hours it should recover to near

the PPM it produced before the cleaning.

SC-3 is an acid cleaner used to remove mineral and scale deposits. This is used in the same way

as the SC-2. In most cases this is used first, and if no results are achieved, proceed with the SC-

2. SC-3 will in most cases lower the product PPM and over all pressures. Scaling is a slow

process that may take several months or years. SC-3 is less harmful to the membrane and will

almost always improve the performance of an older membrane.

7/19/04

OP-4 FRESH WATER FLUSH

The purpose of the fresh water flush is to replace the sea water in the watermaker with fresh

water whenever the system is not operating. The “Auto Flush Mode” on the MPC 3000

changes the fresh water every five days if the system has been idle that long. The watermaker

will last longer and operate better if it is always kept filled with fresh water between uses.

Most spectra watermakers are equipped with a fresh water flush module. This module in-

cludes a 50 micron filter to filter out abrasive particles in the feed water that might damage the

feed pump, a charcoal filter to remove any chlorine in the fresh water that might damage the

membrane, an electrically operated valve and a check, or “one way”, valve. The electrically

operated solenoid valve opens during the fresh water flush allowing the boats pressurized wa-

ter system to supply water to the system. The check valve prevents the fresh water from going

out backwards through the sea strainer and sea cock. The charcoal filter has a maximum flow

rate of 1.5 gallons per minute (6lpm) so the 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 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 tested by closing the sea cock during the flush cycle. If the MPC-

5000 display gives a CK SEA STRAINER alarm this means that the fresh water supply is in-

sufficient.

Because the pre-filters trap the plankton in the feed water they can be subject to “going an-

aerobic” or starting to smell like rotten eggs, as the trapped plankton decay. For this reason it

is advisable to always put in clean elements if the unit is going to be left on Auto Flush Mode.

In daily or regular use the fresh water flush after each shutdown will help prevent this prob-

lem, but in excessively warm or fertile waters the pre-filters will need regular attention.

7/26/04

PF-3 PREFILTERS– ShurFlo

Up to four different filters are used on all Spectra Systems using ShurFlo feed pumps to en-

sure that no damaging foreign materials enter the system. There are 2 or 3 filters in the system

to clean the feed water of abrasive materials while the system is in operation, and an addi-

tional filter to prevent 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. This protects the feed pump from damage due to foreign materials and lar-

ger sea creatures. After passing through the pump the feed water enters the filter housings

containing 20 and 5 micron elements. These filters remove very fine particles which could

damage the Clark Pump and shorten membrane life. Some units have only the 5 micron filter.

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 biologically

fertile near shore waters, the prefilters will plug up, the pressure drop across the filters will

rise, 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

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 decay will set in overnight

in tropical waters, or after a week or two in high latitudes. If handled gently and changed regu-

larly before they get too smelly, filters in this service can last through dozens 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 chlorine 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 water.

To ensure that filter elements fit properly and remove chlorine effectively, they should be pur-

chased 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 ele-

ments are FT-FTC-CC.

06/03/04

SF-1 SHURFLO PUMP WON’T RUN

If the pump has power to it (the fan runs), but the pump won’t run, the first thing to check is

the pressure switch. The pressure switch, p/n EL-FP-PS, is located on the wet end of the

pump and has two red wires plugged into it. Jump the two red wires together and see if the

pump runs. You can safely run the system with the pressure switch jumped, just keep an eye

on the pressure gauge and don’t let system pressure exceed 110 psi. Replace the switch when

a spare is available.

If the pump will not run with the pressure switch jumped then it is most likely a problem with

the brushes or overheat protection switch inside the motor. The motor will come completely

apart by removing the two screws on the end of the motor. Remove the rear cover and paper

insulator. Pull out the plastic brush holder. The thermal switch is located on one of the brush

leads. With an ohmmeter, check for continuity through 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

grooves on the commutator with a small sharp tool to remove the carbon in between the seg-

ments. Adjust the springs on the brush holders so the brushes slide smoothly in and out. If

the bearings are rough and binding, remove the rubber dust cover and clean the best you

can, grease them, and work it free by hand. Don't service the bearing unless absolutely neces-

sary. Reassemble in reverse order. You can hold the carbon brushes back with papers clips

inserted through the slots in the brush holder so they don't hang up on the bearing during as-

sembly. Make sure the corrugated bearing shim doesn't push out, if it does, push it back into

place.

This will at least keep you going until the motor can be replaced if necessary.

6/03/04

SF-2 ADJUST SHURFLO PRESSURE SWITCH

The ShurFlo feed pumps are equipped with a high pressure cut out switch (part no. EL-FP-

PS). This is the small black unit on the end of the wetted end of the pump head (part no. PL-

PMP-SFPH) where the two red wires connect. If the pressure switch is not properly adjusted

the pump may cut out each time the Clark Pump cycles and the feed pressure spikes. When

this happens, the production will drop and an unusual noise will be heard when operating with

two pumps, but the system will function normally during one pump operation on either pump.

The points in the switch will fail fairly quickly if set too low because 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 pressure switch to shut off at 125

psi. Repeat for pump two. Turn the allen screw clockwise to increase the cut off set point.

Gulfstream models could experience seal failures in the manifold if pressurized too high. For

this reason, the pump should be removed from the system and the switch adjusted using a

separate pressure gauge. If replacing a feed pump or pump head for a Gulfstream model ar-

range to preset the switch before installation.

8/05/04

HS LF-1 POOR PRODUCT QUALITY

With any product water quality issue, you need to check the calibration of the salinity tester

that you are using before proceeding.

Membranes are not an exact science and two identical systems can have a different product

quality result. World health standards deem water of up to 1000 PPM of total dissolved solids

acceptable for drinking consumption. We consider any thing below 700 PPM acceptable but

not ideal, and anything below 500 PPM excellent. Factors that could affect water quality are

addressed below.

LOW SYSTEM FLOW OR PRESSURE will equate to lower product quality (higher

PPM). A 200-C system running at 70 psi will deliver product water in the 400- 500

PPM range, while the 380-C systems with twice the flow and operating at 100 psi into

the same size membrane, will produce 200-300 PPM water. Ventura 150 systems,

which have a higher feed to output pressure ratio (See MISC-4 nominal pressures), as

well as a higher feed flow/membrane area ratio, will produce water in the 150-200

PPM range. These improvements in product quality come at the expense of energy

efficiency.

DAMAGE TO THE MEMBRANE by chlorine contamination. Flushing the system with

chlorinated water will irreparably 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 quality and abnor-

mal operating pressures. If operating pressures are above normal, then cleaning is indi-

cated. If the system pressures are within operating normal range, cleaning may have

little result. Cleaning is no better for a membrane than it is for your clothes. Avoid

cleaning as a diagnostic tool.

MECHANICAL LEAKAGE within the membrane pressure vessel. This is an unlikely but

possible cause of poor water quality with old style Codeline pressure vessels (white)

that we have used in the past. The Spectra pressure vessel has a double O-ring arrange-

ment that includes a telltale hole between them so that any salt water leaking past an

O-ring will drip into the boat and not go into the product water.

If system flow (product plus brine) is 1.5 GPM or above on one pump, the membrane is clean,

the product flows are consistent with the system flow and the water quality is still not accept-

able, then replacement of the membrane is indicated. See “HS-LF2 Flow Check” for instruc-

tions on checking flow rates

7/6/14

HS LF-2 FLOW TEST/ SHURFLO

Before the test, change all filters and clean the strainer. Make sure that there are no leaks.

Check for air leaks, as air in the system will cause low production and erratic salinity. Look

for air bubbles in the product flow meter, feed pump discharge hose, and brine overboard

hose.

Run the system and watch the pressures very closely. Make sure that on each shift everything

is even from side to side. If the feed pressure to the Clark pump is different (asymmetrical) on

one stroke than on the other this could be part of the problem. A difference of a few PSI is ac-

ceptable, but anything over that is an issue. If the pump is asymmetrical Clark pump repairs

should be done before continuing with these tests. Ask for CP-5 Clark Pump Checkout in-

structions. If no asymmetry is noted, please do this test.

NOTE: On Ventura 150 and 200 models with only one feed pump, disregard the instructions

concerning “pump two” and “both”

Make sure the ShurFlo overpressure cutout switches (part no. PL-PMP-SFPH) are set to 125

psi. With pump 1 running, close the brine service valve. The feed pressure should rise to 125

psi and 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 of the system. Run the system making water and divert BOTH

the brine discharge AND product water into a bucket. Time how long it takes to make a

given amount of water. Repeat with pump 2 and both pumps.

In order to make good water, you need the proper amount of feed water flow. Each pump

alone should produce 1.5 gallons per minute (5.7 lpm). Running on both pumps the flow

should be 2.7 gpm (10 lpm).

Compare the product flow to the total feed flow. Product flow should be 7% of total flow for

a 150, and 9.5% of total flow for a 200 or 380 model. If product percentage is low, you may

have an internal leak in the Clark pump.

For every 1/10th of a gallon per minute of feed water flow loss, we will lose about 1/2 gallon

per hour of product flow and the salinity will go up 100ppm. Low feed flow combined with

low system pressures, (see “Misc-4: Nominal Pressures”), is most frequently due to worn

ShurFlo pump heads (part no. PL-PMP-SFPH).

9/24/04

Z-BRANE

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

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

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.

DO NOT DISCONNECT

OR SPLICE ANY OF THE

HIGH VOLTAGE WIRING!

Contact the factory if

modifications are required.

Power on LED

High Voltage

connector

Front View

Rear View

3/8 NPT Quick Disc. Body

PL-QDC-BD3/8

5/8 Quick Disc. Hose Barb

PL-QDC-HB5/8

Plate Bracket

FM-PVB-PB

Rubber Mount

HD-RBP-RM

Plastic Spacer

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

Sea Strainer (Lid & Bowl& Screen)

FT-STN-5

Sea Strainer Screen

FT-STN-5S

Sea Strainer O-ring

SO-STN-5SS

1-Way Solenoid Valve 12V,

PL-SLN-1/4O12,

1/4”NPT X 5/8” Hose Barb El.

PL-HBE-1/4X5/8

3/4”NPT X 5/8 Hose Barb El.

PL-HBE-3/4X5/8

1/4” Street El.

PL-MFF-1/4X1/4

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-3/8X5/8

Charcoal Filter Cartridge

FT-FTC-CC

Part Numbers

3/4”-16 ST X 1/2”

Tube Fitting El.

PL-MTE-3/4SX1/2

3/8”NPTX3/8”Tube Fitting

PL-MTS-3/8X3/8P

3/8”NPT X 1/2” Tube Fitting SS.

PL-MTS-3/8X1/2S

1/8”FPT X 1/2”

Tube Fitting El.

PL-FTE-1/8X1/4P

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

Valve End Block B

HP-TB-VEB-B

3/8”NPT Quick Disc. Coupling Body

PL-QDC-BD3/8

5/8” Quick 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

Fig 1

Fig 2 Fig 3

3/4” 3-Way Valve

PL-VLV-3W3/4

Cooling 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

End block B

End Cap

Cylinder ring

Stainless steel tube

End block A

Brine out

Valve block

Pressure relief valve

Center block

Front View

Feed in

Clark Pump

Composite 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

5/16"-3 1/4" SS AH Bolts

Spool Seal

Spool End

Spool Assembly

Annular Rings

Spool Center

Quad Ring Seal

Exploded View

Spool Assembly

Spool Seal

Quad Ring Seal

Spool End

Valve Block

Relief Valve

Mount inside Valve Block

Annular Ring O-Rings

Relief 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,VSP20

HP-TB-SR

SO-HPP-VB

SO-HPP-PLP

SO-HPP-VP

Pilot valve port seals

Valve port seals

Pin seals

Center Block

Check valve port O-rings

Piston to rod O-rings (2)

Inside pistons Glass rod models only

Rod lip seals

Mount inside block

Clip rings

Check valve assembly

Center block cylinder 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

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

SO-HPP-CVS

HP-CB-CVS

HP-CB-CV

HP-CB-CVR

Parts

Cylinder Assembly

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

Spectra Watermakers Ventura 150 Mpc 5000 Users Manual

MPC-5000 to the manual 481bf3ea-6033-0694-51dd-791d71363a8c

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