Spectra Watermakers MPC-5000 User Manual

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 [phone] Fax [phone] E-mail: [e-mail] www.spectrawatermakers.com

Rev. Feb-08-06

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Table of Contents

Section 1

Installation

Page Number

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
Operation
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 3 Detailed Controls Data……………………………………………….……….…...……..28

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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 reliability. 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	Front View
purchaser! It is built of modern non-corroding composites.		Pressure relief valve
Quick disconnect fitting to
facilitate maintenance.
Double rubber mounts to
absorb vibration

Rear view

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.

5

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

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

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	Installation Basics	Thruhull
		Not Supplied.
•	Read the directions!
• Avoid tight hose bends and excessive runs
• Use heavy gauge wire
•	Install feed pump as low as possible
• Use a dedicated thruhull with scoop type strainer		Flow

Thru-hulls

It is mandatory that a dedicated 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 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 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 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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Ventura 150 MPC Plumbing

Brine Discharge thru hull place above waterline or tee brine into another visible drain.

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.

Accumulator, Factory pre-charged. Install so that gauge is visible.

Fresh water flush inlet to charcoal filter. Plumb to pressure side of fresh water system.

Inlet pump module. Mount vertically as low as practical, no more than 4’ (1.1 M) above waterline and do not mount over electrical equipment.

Leave clearance below for filter change.

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.

20 and 5 micron filters. Do not mount over electrical equipment. Leave clearance underneath for filter change

Red In

Green Out

Sea Strainer, Mount with

Quick Block

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.

Water Flow

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Feed Pump Relocation

If you do not have adequate space to install the feed pump inlet module it is possible to remove 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 holding the pump to the module.

Cooling fan

Machine Screws

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

wire runs are longer.

Fig 1

Fig 2

Fig 3

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Product Water Plumbing

Product water tubing is 1/4”(6mm) on the Ventura 150 models. See the Parker tube fitting assembly 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 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.

Accepted Product

Water Outlet

Automatic Valve

Check Valve

Rejected product outlet

Product from membrane

RotoFlow Meter

Salinity Probe

Product Diversion Valve Manifold

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Product Tube Fitting Assembly

O-ring	Spacer
	Grab Ring
Body

Nut

Tubing

Step 1: Dissemble fitting components

1/2" max

Step 2: Install the Nut first then use the bevelled side of the Spacer to push the Grab Ring onto the tube no more than 1/2". Slip the O-ring over the tube to hold the Spacer in place. If the Grab Ring is pushed too far, trim back the tube so about 1/4" of tube extends past the O-ring.

Step 3: Gently fit the tube into the body and loosely thread on the nut.

Step 4: Push the tube into the body until it bottoms out then hand tighten the nut. DO NOT OVER TIGHTEN!

1/4" Tube Fitting Assembly

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Membrane Pressure Vessel Relocation

Use ONLY Dayco Imperial Nylo-Seal 88-NSR-1/2 tubing for high pressure connections. Pay attention to the direction and flow path of the tubing before disassembly. Make sure that you reinstall the tubing in the same manner. Rotate the 90 degree high pressure tube fittings on the Clark Pump for ideal tube runs. The high pressure fittings are typically preinstalled 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 installing the tube.

The fittings on the Clark pump have an O-ring seal and can be re-oriented by backing out the O-ring stop nut. Rotate the fitting to align with the tube and tighten the nut just past hand tight. Do not over tighten!

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Spectra High Pressure Tube Fitting Assembly

Use ONLY Dayco Imperial Nylo-Seal 88-NSR-1/2 tubing for high pressure connections.

Carefully fit and measure the tubing before cutting with a sharp razor knife or hose cutter and remove any burrs. Minimum tubing bend radius is 6”. Route tubing away from excessive heat sources and secure from vibration and chafe. Have at least one shallow bend in 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

Figure 1.

Figure 2.

Index mark	Straight thread	Straight or 90 deg.
		3/8" pipe thread

Nut Ferrule Body

Nut finger tight with 1 thread showing

Cut tube square

Black high pressure tubing

Tighten 1-2/3 turns (10 flats of the
nut) with a7/8" wrench after finger tight.
Use index mark as guide	No threads showing

Figure 3.

Insert tube 0.9" until it stops	IMPORTANT!
	Hold fitting body with 13/16"
	wrench when tighteninga

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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	Control cable 50’ (15.2M)		MPC-5000 display. Mount in
6’ (2M)	Protect connector while routing through		dry central location. Only con-
	the vessel.	Control Box	nect the MPC “plug in” cable.

Fresh water flush feed 15’ (4.5M) Splice to flush valve. Heat connectors to shrink.

Pump feed 4’(1.2M) may be	Main power feed. Install cover		Clark Pump harness, RotoFlow meter,
extended as required. Count	after terminating wires.		salinity probe, and diversion valve feed
additional length in wire siz-	Use a 15 amp breaker or fuse		15’ (4.5M). See next page.
ing. Wire fan in parallel.
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)		Total length for a pair of wires!
#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)

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Clark Pump Harness

Salinity Probe

Roto Flow meter.

Diversion

Valve.

To Roto Flow Meter

To Diversion Valve

To Salinity Probe

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.

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Tank Switch Installation and Operation:

There are two sets of terminals on the MPC-5000 PCB that can be used in four different configurations to automatically start and stop the watermaker, or to automatically stop the watermaker when the tank(s) are full without the auto start feature. These terminals are on the green ten pin connector and are labeled “Float Switch 1” and “Float Switch 2.” Float Switch 1 is the tank full switch and Float Switch 2 is the tank empty switch.

If the unit is wired for both Autostart and Autostop, it can be put into AutoFill Mode by pushing and holding the Auto Run switch on the MPC-5000 display. In this mode the 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 stopping it by holding down the Autorun button.

If the owner prefers to install the automatic shutoff feature without the automatic start up option, only the tank full switch is used. A jumper must be placed between the tank empty terminals (Float Switch 2) in place of the tank empty switch, because the watermaker will only shut down if both sets of terminals are closed. To use this mode the watermaker must be started up with the Stop/Start button or the Autorun button. After the unit starts up, then press and hold the Autorun button until the display reads “Auto Fill Mode”. The 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 separate wires from the switch to each tank switch. The second wires can both be run to the Float Switch 1 terminal 2. If you are using two switches in each tank, you will need a double pole double throw switch.

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.

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