NEWPORT 400 MPC-5000 MkII INSTALLATION & OWNER’S MANUAL
Part 1……....Installation, Operation, Maintenance
Part 2………………….. Programming and Controls
Spectra Watermakers, Inc.
20 Mariposa Road, San Rafael, CA 94901 Phone 415-526-2780 Fax 415-526-2787 E-mail: spectra@spectrawatermakers.com www.spectrawatermakers.com
1-28-07 mpc5000
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Thank you for your purchase of a Spectra Newport system. Properly installed it will provide years of trouble free service. Please pay attention to the installation instructions and the system layout. Like any piece of mechanical equipment the system will require inspection and service from time to time. Do not place the components in inaccessible areas that will prevent proper maintenance. If you are having a dealer install the system for you, review the location of the components to make sure that the installation will meet your approval upon completion.
Newport Installation Quick Start
Important Details for Installer
1.The system must have a dedicated sea water inlet to guarantee a solid flow of water to the system. The inlet should be as low in the boat as possible and with a scoop type forward facing thru-hull fitting installed.
2.Both the Newport MkII Feed pump module and the Clark pump/Membrane module must be installed in a well ventilated compartment where temperatures will not exceed 120F (48C). Many engine compartments exceed this temperature when underway. Warranty will be void if the installation does not meet this requirement.
3.Follow the wire gauge charts in the instructions! Using larger wire than specified is acceptable.
4.The MPC control must have DC power continuously to achieve the full benefits of the fresh water flush system. The domestic fresh water pressure must be on and the fresh water tank level maintained. Calculate 5 gallons (12L) per flush..
5.The MPC 5000 control must be de-powered (DC power off) after the system is put in storage “pickled” where a storage chemical or antifreeze is run through the system.
6.If you are separating the Clark pump/membrane assembly, please review the high pressure tube assembly instructions. Improper assembly will cause failure!
7.Run test, then “sea trial” the complete system before assuming the system is operational. If the boat is in fresh or dirty water, see “Dry testing the system.”
8.Spectra dealers are responsible for educating the vessel owners on the operation and maintenance of the system. We request that you “walk through” the installation with our customer.
9.Please have the owner fill out the warranty card. The warranty is void if it is not registered.
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Table of Contents
Part 1
Installation
Page Number
Getting Started ................................................................................................................................................ |
7 |
Installation Basics ........................................................................................................................................... |
8 |
Component Placement .................................................................................................................................... |
9 |
Plumbing....................................................................................................................................................... |
12 |
Parker Tube Fitting Assembly Procedure ..................................................................................................... |
16 |
Wiring ........................................................................................................................................................... |
17 |
MPC Tank Switch Wiring and operation...................................................................................................... |
22 |
Membrane Pressure Vessel Relocation......................................................................................................... |
40 |
Z Brane Installation....................................................................................................................................... |
51 |
Operation |
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New Systems Start Up and Testing............................................................................................................... |
24 |
Dry Testing.................................................................................................................................................... |
27 |
Normal Start Up Using the Auto Run ........................................................................................................... |
28 |
Automatic Fresh Water Flush Cycle ............................................................................................................. |
29 |
Manual Operation.......................................................................................................................................... |
31 |
Maintenance .................................................................................................................................................. |
36 |
Bulletins ........................................................................................................................................................ |
44 |
Service & Maintenance |
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Long Term Storage Procedures..................................................................................................................... |
31 |
Winterizing.................................................................................................................................................... |
34 |
Membrane Cleaning ...................................................................................................................................... |
36 |
Salinity Probe Calibration ............................................................................................................................. |
38 |
Suggested Spares........................................................................................................................................... |
39 |
Newport Troubleshooting Procedures, Service Bulletins.............................................................................. |
42 |
Part 2 Controls |
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A-31 MK2 CONTROLS Operation Guide (Single Run Speed mode)……………………………………….5 |
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Programming from the display……………………………………………………………………………....13 |
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Tank Switch Operation and Installation …………………………………………………………………….16 |
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Programming from a Computer……………………………………………………………………………...16 |
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Software Installation…………………………………………………………………………………………17 |
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Software Port Settings …………………………………………………………………………………...….18 |
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Software Features …………………………………………………………………………………………...22 |
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Computer Settings …………………………………………………………………………………………..25 |
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Salinity Probe Calibration …………………………………………………………………………………..26 |
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Detailed Controls Data……………………………………………………….……………………………...28 |
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Getting Started
Unpack the system and inspect it to make sure that it has not been damaged in shipment.
Refer to the shipping list for your system to make sure you have received all of the components listed. Do not discard any packaging until you have found and identified all of the parts. The small installation parts are listed on the cellophane bags’ pick list.
We will not be held responsible for shortages and or freight damage that are not reported within thirty days of the ship date.
Next, study the system layout diagram, component photos and descriptions before beginning your installation. This will assist you in understanding the function of each component.
Layout the system. Before starting the installation identify the location where each module and component will be placed. Insure that there is proper clearance around the components for removal of filters and system service. Also check to make sure you have adequate tubing and hose before starting so additional parts may be ordered. Check to see that the MPC cable is long enough to reach from the display location to the feed pump module.
Newport MkII shipping list:
•Newport Feed Pump Module
•High Pressure Clark Pump and Reverse Osmosis Membrane Module
•MkII Fresh Water Flush Module
•MkII Installation Kit 400
•Boost Pump Module
•Newport Service Kit
•1/2” braided hose (10’)
•1/2” Black Nylon tube (10’)
•5/8” Hose (25’)
•3/4” Suction Hose (25’)
•3/4” Braided Hose (10’)
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Installation Basics
•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
Thruhull
Not Supplied.
Flow
It is mandatory that a dedicated 3/4” to 1” forward facing scoop type intake thru-hull and seacock be installed. Install the intake for the system close to the middle and as far below the water line as possible. Thru-hulls in the bow area are susceptible to air intake in rough conditions. Sharing a thru-hull with another system is not acceptable and will void the 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 through-hull should be mounted above the waterline, in or just above the boot stripe to minimize water lift.
Double clamp all hose connections below the waterline.
Pipe Fitting Instruction
Plastic to plastic fittings should have 3 to 4 wraps of Teflon tape and will thread almost all the way in.
Avoid getting dirt or debris into the piping or hoses during assembly. A small bit of debris can stop the system! Avoid getting tape over the end of fittings that might get into the system. To insure this does not happen, leave the very first thread uncoated.
Avoid restrictions or long runs on the entire inlet side of the plumbing from the thru hull to the main feed pump module.
Prevent tight bends and excessive elbows. Any restrictions will hamper system performance. Secure the piping away from moving objects such as engine belts and hatches. Prevent chafe on the tubing as required. Test and inspect all piping and hose clamps after several hours of operation.
Wiring
•Pay attention to wire size or system performance will be impaired.
•Perform wiring to UL, ABYC, CE or applicable standards.
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Component Placement
Strainer |
Refer to the Plumbing Diagrams |
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Mount the strainer in an accessible area close to the intake throughhull that can handle water spillage during service. Extra care during assembly must be taken to avoid air leaks from the strainer. Use the supplied “Quick Block” and wire tie for mounting.
Fresh Water Flush Module
The fresh water flush module may be located in any convenient location near the Feed pump module. It should be mounted with the filter housing vertical and accessible for changing filters. Allow 2” below the filter housing for removal. Do not install over electrical equipment. The unit contains a charcoal filter for the flush water, flush solenoid and flush water pressure regulator.
Boost Pump module
The boost pump module should be mounted vertically with the service hose connection at the top. The boost pump must be installed below the water line to ensure that it will prime.
Feed Pump Module
Mount the feed pump module on a horizontal or vertical surface that can be up to 3’ (1.0M) above the waterline. It is preferable to mount as low as possible. Locate in an area that allows easy access to the filters and left hand side and where water spills during filter changes will not be a problem. Keep future maintenance in mind when choosing a location. The feed pump has overheat protection and will not operate properly at ambient temperatures over 120F (48C).
Remove front cover to access mounting holes in the enclosure.
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Clark Pump/Membrane Module
Pressure Relief Valve
The membrane maximum temperature specification is 120F. This module must be installed in an area that maintains a temperature below 120F (50C). A cool location is preferable. It may be placed as high in the boat as you desire. Make sure that the area around and under the pump does not have any water sensitive equipment. Water will be spilled during any repairs or if a leak occurs.
Be sure you will have access to the pressure relief valve on the Clark pump.
The Clark pump/membrane module comes complete with a mounting system. Be sure to use the supplied washers on the rubber feet. Use it as a template for drilling the mount holes. You may mount the Clark Pump in any position, even upside down.
Membrane Pressure Vessel Mounting
The Clark pump and membrane assembly has been pre-assembled at the factory. If it is necessary to disassemble this module and mount the pressure vessel remotely use guidelines in back of the manual. Use only approved tubing for assembly.
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Remote Control Panel
The remote control panel can be mounted anywhere that’s dry and convenient. Cut a 4-9/16” (116 mm) wide by 2-7/8” (68mm) high opening for the panel. Locate in an area that is easily visible and easy to manipulate the buttons. Use only Spectra approved remote cable.
The cable is not standard LAN cable or phone cord.
Plumbing
From the inlet thru hull to the boost pump module and from the boost pump module to pump module inlet use supplied clear 3/4 (19mm) spiral suction rated hose. The outlet of the filter assembly on the main module to the Clark pump assembly is under pressure. Use the supplied braided clear vinyl hose rated to 150 PSI (11 bar). From Clark pump brine discharge connector use supplied 5/8 (15.9mm) clear braided vinyl hose.
On the feed pressure side use the supplied Parker 1/2 tube and fittings. Use two grab rings on the 1/2 parker tubing. Refer to the parker assembly instructions.
!! Route all hoses and tubes to prevent kinks and restrictions. Secure piping away from moving objects such as engine belts and hatches. Prevent chafe on tubing as required. Test and inspect all piping and hose clamps after several hours of operation.
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System Piping schematic
Use the 1/2 inch nylon tubing between the pump module Outlet and the Clark Pump
Flush water from ship’s pressure water system 25 psi (2bar) minimum
From the Clark pump brine discharge connector use the supplied 5/8 (15.9mm) clear braided vinyl hose to the brine overboard fitting.
Mount the pressure gauge in the low pressure inlet gauge tee.
Use the 1/2inch braided hose between the Flush module and the Feed Pump Module
From the Boost Pump to the 20 micron filter inlet us the 3/4 inch ID braided hose.
From the inlet thru hull to the boost pump module use the supplied clear 3/4 (19mm) spiral suction rated hose.
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Note! When plumbing the Newport Pump Module route the feed water so that the front cover may be opened without removing the hose or tubing.
Leave room on this side for attaching tubing and operating the manual button on the diversion valve.
Feed water inlet from boost pump. Leave enough extra length in this hose to allow the front cover to be moved aside.
Flush water Inlet From Flush Module 
Feed Water Inlet from Filters 
Product Water Outlet to Tank 
Feed Water Outlet to Clark Pump
Product Inlet from Membrane
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Product Water tubing
Product water tubing is 1/4 “ (6.3mm) parker tubing. See the Parker tube fitting assembly diagram next page. Product water goes from the membrane into the pump module manifold where it passes through the flow meter, the salinity sensor and the diversion valve. If the salinity is good the diversion valve energizes and the product goes to the tank from the manifold product outlet. If the diversion valve is not energized the product goes back into the feed water.
Connect the product outlet on the membrane housing to the Product Inlet fitting on the pump module manifold using the supplied 1/4 black nylon tubing.
Route the product water from the pump module manifold into the top of the tank. Install a tee in the water tank fill or tap a pipe thread into an inspection port in the top of the tank. Do not feed the water into a manifold or bottom of the tank. Make sure there is no restriction in this plumbing.
If the length of product water tubing supplied with the watermaker is insufficient, use a larger size hose. Product water flow restriction will cause reduced and power consumption increased if product flow is restricted.
To Fresh Water Tank
Product tube from membrane end cap to feed pump manifold
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Brine Discharge
Route the Brine discharge from the quick disconnect fitting to a location above the waterline using the supplied 5/8 hose.
Fresh Water Flush
Quick Disconnect Fitting
Run a feed line from the domestic cold pressure water system to the 1/2 hose barb on the fresh water flush assembly. This needs to be pressurized when the boat is unattended for the fresh water flush system to function properly. The domestic fresh water pump must be able to deliver 1.5 gallons per minute (6lpm) at 25 PSI. Connect the wiring harness and heat shrink butt splices.
To Flush water Inlet on pump module manifold
Fresh water from boat’s pressure water system
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Parker Tube Fitting Assembly Procedure
Spacer |
Single grab ring for 1/4" & 3/8" tube |
O-ring |
Use 2 grab rings for 1/2" tube |
Body |
Nut |
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Tubing |
Step 1: Dissemble fitting components
1/2" max
Step 2: Install the Nut first then use the bevelled side of the Spacer to push the Grab Ring onto the tube no more than 1/2". Slip the O-ring over the tube to hold the Spacer in place. If the Grab Ring is pushed too far, trim back the tube so about 1/4" of tube extends past the O-ring.
Step 3: Gently fit the tube into the body and loosely thread on the nut. Be careful not to cross-thread the nut
1/2" tube should not bottom out in the fitting to allow full compression of the O-ring
Step 4: Hand tighten the nut. DO NOT OVER TIGHTEN! DO NOT USE A WRENCH! The tube should not come out if pulled by hand. If it does, tighten the grab ring tabs.
1/4", 3/8", 1/2" Parker Tube Fitting Assembly
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Wiring
Identify cables that are connected to the Newport Control System.
Newport MkII Systems have a Power Inlet harness with a terminal block, a 50’(15M) cable with connectors is supplied for the MPC-5000 control display and a two concuctor boost pump power cable.
Boost pump cable |
50’ (15M) cable with |
Power inlet harness with |
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connectors for the MPC- |
terminal block |
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5000 control display |
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Wiring (continued)
Mount the main power terminal block in a junction box or on a bulkhead adjacent to the feed pump module. Make sure that this is a dry location well above bilge level and not subject to water spray.
Route the control cable through the boat to the MPC display location. Be careful not to damage the connector or get it wet. Plug this into the back of the control.
Connect the red and black Boost Pump wires to the corresponding red and black conductors in the Boost Pump cable (red to red, black to black) using the supplied butt connectors, and heat the connectors to waterproof them.
Check the wire size chart to select the proper size power feed to the main power harness. DC power feeds should be uninterruptible to insure proper operation of the auto store feature. Avoid house breaker panels that could be easily tripped.
Component Sizing:
•12V Use a 30Amp breaker and size the wiring for 25 Amperes.
•24V use a 15 Amp breaker and size the wire for 13 Amperes.
•Provide circuit protection at the source! Inadequate wiring will cause a loss of system performance. DC power should be uninterruptible.
Note: If the specified circuit breaker sizes are unavailable use the next higher rating but do not exceed the specification by more then 10%. All wiring to be done to applicable ABYC, Marine UL or CE standards.
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