Spectra Watermakers Ventura 150T MPC, Installation And Operating Manual

Page 1: ...tra Watermakers Katadyn Desalination LLC 2220 S McDowell Blvd Petaluma CA 94954 Phone 415 526 2780 Fax 415 526 2787 techsupport spectrawatermakers com Ventura 150 200T MPC Installation and Operating Manual ...

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Page 3: ...e to start or stop system If you stop the system by pressing stop the sys tem will not fresh water flush itself To bypass the Purge Mode only if you are sure there are no chemicals in the system Press Auto Run and Stop momentarily at the same time Alarm Display Push to silence alarm When system is running press to scroll though system readings In program mode push to scroll through the sys tem par...

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Page 5: ... 21 Z Ion Installation 22 Z Ion Testing 24 Z Brane Installation 25 Operation 29 New Systems Start Up and Testing 31 Dry Testing with an Artificial Ocean 34 Normal Operation and Fresh Water Flush 35 Auto Store and Flush Cycle Adjustment 36 Alarm Override and Manual Operation 37 Maintenance Storage and Troubleshooting 39 Suggested Spares 41 Maintenance 42 Introduction to Spectra Chemicals 44 Long Te...

Page 6: ...ing Controls 61 Introduction 63 MPC 5000 Operation Guide 64 Display Controls 65 Programming from the Display 68 Salinity Probe Calibration 71 Wiring Schematic 72 MPC 5000 PCB Fuses and Electrical Specifications 73 Exploded Views and Part Numbers 75 ...

Page 7: ...7 Installation ...

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Page 9: ... identify where each module and compo nent will be placed Ensure that there is enough clearance around the components for remov al of filters and system service Make sure you have adequate tubing and hose before starting Additional parts may be ordered THE VENTURA 200T IS DESIGNED FOR WARM WATER USE OPERATION IN WATERS BELOW 500 F 100 C MAY CAUSE HIGH OPERATING PRESSURES AND INCREASED WEAR ON THE ...

Page 10: ...Pressure Relief Valve 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 Module Includes the feed pump cooling fan charcoal filter flush valve service valve and service port The module has compact and streamlined plumbing The cooling fan is included for longevity Fresh Water Flu...

Page 11: ...ir bubbles contami nants and will void the warranty For racing boats and high speed boats traveling above 15 knots a retractable snorkel type thru hull fitting is preferred because it picks up water away from the hull The brine discharge thru hull should be mounted above the waterline along or just above the boot stripe to minimize water lift and back pressure Double clamp all hose connections bel...

Page 12: ...g 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 Note Salini ty probe must always be down to stay wet so you will need to reorient the diversion manifold if the module is mounted upside down Brine Discharge thru hull Place above waterline or tee into an othe...

Page 13: ...om the membrane into the electric di version valve The diversion valve will reject product water into the overboard brine stream until MPC 5000 control determines the product water is below 750 PPM salinity Once below 750 PPM the MPC 5000 control opens the diversion valve and product water is diverted into the fresh water tank For plumbing to the fresh water tank see the Parker tube fitting assem ...

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Page 15: ... rings on the 90 degree fittings on the back of the Clark Pump have captive nuts and washers which compress the O rings without turning the entire fitting If a tube fitting leaks it can sometimes be resealed by just tightening You must use two wrenches a 13 16 inch wrench to hold the base and a 7 8 inch wrench to turn the compres sion nut The 13 16 inch wrench will need to be thin so as not to int...

Page 16: ...feed Install cover after terminating wires Pump power feed 4 1 2M May be extended as required Count additional length in wire sizing 15 4 5M fresh wa ter flush solenoid cable Crimp onto to flush solenoid leads and heat shrink the connectors The wires have no polari ty Wire Size Guide for the Ventura 12V Protect with 15 Amp Fuse or Circuit Breaker 10 Gauge 5mm up to 15 feet 4 5M 8 Gauge 8mm up to 2...

Page 17: ...r flush cable to the fresh water flush solenoid Crimp the attached heat shrink butt connectors onto the two black wires coming from the solenoid There is no polarity The fresh water flush cable can be distinguished from the diversion valve cable both of which are gray cables with butt connectors on their individu al wires The diversion valve cable is run in a bun dle with the rotoflow cable while ...

Page 18: ...ting compound and cannot be removed Secure the salinity cable to the wiring bundle with the rotoflow and diversion valve wire har ness leaving enough loose cable for a service loop Plug the salinity probe connector into the jack marked Salinity on the MPC box Route the display cable from the display to the jack marked display Use only a Spectra approved cable The cable is not a standard LAN cable ...

Page 19: ...on the MPC circuit board labeled Float Switch 1 There is no polarity Float Switch 2 is for land based applications only and will be bridged with a jumper wire in marine installations See the wiring diagram on the next page Spectra uses two types of float switch the side mounted float switch EL SWT SMLV and the top mounted Tank Full Switch EL SWT LV Either may be used depending on the geometry of y...

Page 20: ...20 Tank Switch Wiring Tank full switch wired to Float Switch 1 ter minals jumper across Float Switch 2 terminals ...

Page 21: ...film and bacteria and assists in the preven tion of scale formation on the membrane surfaces After thoroughly fresh water flushing the system the Z Brane will protect an idle system indefinitely as long as the Z Brane is energized The Z Brane draws less than 1 Amp but storage with chemicals may be preferable for longer periods if battery power is an issue Neither the Z Ion nor the Z Brane will pre...

Page 22: ...r flexibility in mounting on the bulkhead above or adjacent to the feed pump module Plug the connector from the Z Ion generator bowl into the connector from the Z Ion control box Connect the power signal cable marked green from the Z Ion control box to the Z Ion control cable also marked green coming from the MPC box 1 5 GPM Flow regulator Manual shut off valve close when changing filters Solenoid...

Page 23: ...d the LED will flash green amber The cycle will continue until either the water flow stops or the adjustable timer times out factory set for 15 minutes If the voltage is out of range below 10V or above 56V the LED will flash red every two seconds and the unit will shut down Each fresh water flush with the Z Ion will protect your watermaker for up to 30 days after which the process must be repeated...

Page 24: ...he LED on the Z ION controller should flash as the unit cycles Close to the end of the flush cycle take a sample of the brine discharge If the brine discharge thru hull isn t accessible you will need take a sample from the brine outlet on the Clark Pump or use the brine discharge service hose Once you have obtained a sample first check it with a salinity meter to make sure the salinity is below 10...

Page 25: ...ist during shipping and storage Remove the C clips that secure the shipping plugs then remove the shipping plugs Insert an anode into the membrane until the groove is flush with the membrane end plug The C clip will then slip into the groove and the C clip screw will secure the clip C Clip and retaining screw with probe installed Shipping Plug remove to insert probe C Clip groove in Anode NOTE you...

Page 26: ...resent even after the transformer is de powered We recommend that the Z Brane be connected to its own electrical circuit The power must be on when the watermaker is in operation and when the Z Brane is used for membrane storage If the power is obtained from the MPC circuit board then the MPC must be powered up at all times during storage and this may not be ideal Fuse the power at the source with ...

Page 27: ... will protect your membrane and also prevent corrosion in the feed water system Thoroughly fresh water flush the water maker several times before leaving the vessel unattended for extended periods The Z Brane may be de powered if the system is pickled with chemicals or winterized with propylene glycol DO NOT DISCONNECT OR SPLICE ANY OF THE HIGH VOLTAGE WIRING Contact the factory if modifications a...

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Page 29: ...29 Operation ...

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Page 31: ... hose connections are tight The washer with the green tag under the pressure relief valve has been removed The pressure relief valve is open 1 2 turn The toggle switch on the MPC control box is set to the Auto position There are at least several gallons of water in your fresh water tank for priming New System Start Up and Testing Open 1 2 Turn when purging chemicals Remove Tag and Washer Power up ...

Page 32: ...lly inspect for leaks over the entire system Shut down the system and repair any leaks you find 3 The system is now operational and you may run your system as you desire When beginning to make water it is best to use the Auto Run button which defaults to the automatic fresh water flush after the unit is finished making water If you shut down the system by pressing the Stop button the system will n...

Page 33: ...ater in parts per million PPM Anything below 750 PPM is considered potable and will be diverted to the tanks Feed Pressure Ventura 150 feed water pressure range is 60 70 PSI 4 2 5 BAR Ventura 200T feed water pressure range is 80 90 PSI 5 5 6 2 BAR Filter Condition When filters become partially clogged the empty blocks on the bar graph on the MPC 5000 will gradually fill in If the filters become fu...

Page 34: ...e the storage chemicals 5 Connect the inlet and brine discharge service hoses per Figures 2 and 3 and route them into the 5 gallon 20 liter bucket Disconnect the product tube from the diver sion valve and using another small piece of tube route it into the bucket 6 Push the Auto Store button one or two more times to fill the bucket with fresh water from the brine discharge service hose hose attach...

Page 35: ...n 2 Push 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 3 Run the system until you have filled your tank or have made enough to meet your require ments for several days 4 After the system fresh water flushes and shuts down it will enter the Auto Store mode which will flush the system at programm...

Page 36: ...ill start the flush water solenoid will open and the display will read FRESH WATER FLUSH with a countdown timer After 3 minutes adjustable 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 5 seconds will engage a one time flush The display will read FRESH WATER F...

Page 37: ...utlet Alarm Override and Manual Operation Figure 2 Manual Operation Tube B connects diversion valve to tank Tube B connects membrane prod uct outlet direct ly to tank In the event of complete MPC control failure the system may be operated manually as follows Switch on the feed pump by setting the feed pump switch to RUN MAN The automatic safety controls are disabled in manual mode Shut the unit do...

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Page 39: ...39 Maintenance Storage and Troubleshooting ...

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Page 41: ...strainer screen replacement O ring for strainer screen and replacement O rings for the filter housings Spare feed pump or feed pump diaphragm Common Parts Item Part Number 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 STRAI...

Page 42: ...al If you use the system until it stops at a 10 PSI differential 75 BAR then the filters will have to be discarded Extremely dirty filters will harm system performance and may cause the feed pump to cut out from high pressure Leaving dirty filters in the machine during long idle periods will cause biological contamination To service the prefilters turn yellow service valve on feed pump module to O...

Page 43: ...ust Monitor the product salinity and feed pressure for higher than normal readings take environmental conditions into considera tion Cold feed water or clogged prefilters can cause high pressure Low product flow is usually due to low voltage a worn feed pump or worn Clark Pump Test to see if biological growth has occurred Before running the system remove the prefil ters and examine their condition...

Page 44: ...rage Proce dure on page 48 Spectra systems should be stored with propylene glycol if freezing is likely to occur Propylene glycol can be used instead of Spectra SC 1 storage chemical for storage in any climate and treatment is effective for one year Propylene glycol is a food grade antifreeze used to winter ize RV s boats and cabins Do not use ethylene glycol automotive antifreeze which is toxic a...

Page 45: ...to the level it was before storage with propylene glycol See the Cleaning Procedure on page 48 See Winterizing with Propylene Glycol on page 47 Cleaners Cleaning can be detrimental to the membrane and shorten its life Avoid unnecessary clean ing and 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...

Page 46: ...wise 7 Place the yellow service valve in the Service position pictured below 8 Turn on the feed pump using the manual con trol switch on the MPC 5000 Control Box The solution will be drawn from the bucket with the service hose and returned to the bucket from the brine discharge service hose Circu late the storage chemical in the system for ap proximately 10 minutes Turn off the feed pump Clean Up ...

Page 47: ... box until about a gallon of water has flowed from the brine discharge service hose or antifreeze appears Propylene gly col will look slightly different and feel more slippery than water Stop the pump Add more propylene glycol to the intake bucket if necessary 8 Lead the brine discharge service hose into the intake bucket of propylene glycol The service hose will now draw propylene glycol from the...

Page 48: ...allon of fresh water runs into the bucket from the brine discharge service hose Stop the system 5 Turn the yellow service valve to the SERVICE position 6 Make sure that the pressure relief valve on the Clark Pump is open un pressurized 7 Mix the cleaning chemical in the bucket If possible heat the solution to 120 deg F 49 deg C 8 Start the system using the manual switch on the MPC control box The ...

Page 49: ...ith hand held tester if over 500 PPM for 1 hour contact factory Close pressure relief valve No lights or display system does not operate Remote display not con nected Check display cable connections at back of display and at control box Check and reset main DC supply breaker Check for voltage 12 or 24 VDC at control box power input studs Try manual switch on MPC control box If pump runs then contr...

Page 50: ...e pressure relief valve Check thru hull Purge air Clean or replace Rotoflow meter Check brine discharge Clean membrane High Pressure Blocked brine discharge Fouled 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 Rotoflow meter at startup System stall...

Page 51: ...nt in flush water They must be of proper specification to be suitable See page 56 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 ab normal operating pressures If operating pressures are above normal then cl...

Page 52: ...ne discharge hose The feed pressure should rise to 125 PSI then the pump should shut off If the pump shuts off at a lower pressure see Adjust ShurFlo Pressure Switch on page 45 You will need a graduated bucket either a graduated pitcher or large measuring cup and a stop watch Before the flow test change all filters and clean the sea strainer Log the voltage at the feed pump at the same time Confir...

Page 53: ... 60 53 x 12 13 58 LPM 3 Recovery Rate Product Flow Total Flow Recovery Rate Example 6 5 GPH product flow 063 or 6 3 1 7 GPM total flow x 60 you must first multiply total flow by 60 to convert from GPM to GPH pressure relief valve open turn In order to make good quality product water you need the proper amount of feed water flow as in the table above Compare the product flow to the total feed flow ...

Page 54: ...ccumulator 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 problems with the Shurflo Pump pressure cutout switch see page 58 The accumulator has a Schrader air valve like a car tire which allows the internal air bladder of the accumulator to be pre charged The accumulator should be pumped up to about 65 ...

Page 55: ... waters the prefilters will plug up water production and quality will drop and the system pressure will change dramatically In blue water condi tions the pre filters may only need to be changed every week or two When operated for 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 The decaying plankton an...

Page 56: ... there are aftermarket filters which are very close to but not exactly the right dimensions and they will not seal in the housing If you skimp on the charcoal filter you risk damaging a 600 00 membrane on the first flush The other factor is the flow rate that the filter can handle Because the chlorine is adsorbed by the charcoal it must remain in contact with the charcoal for a sufficient period o...

Page 57: ...n 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 The overheat switch is unlikely to fail unless the motor has overheated Consider relocating the pump or im proving ventilation if the overheat protec...

Page 58: ...ssure spikes When this happens the production will drop and salinity will increase The points in the switch will fail quickly if set too low be cause of the constant arcing each time the Clark Pump shifts On the very center of the switch is a small 5 64 Allen screw While running the system close the brine discharge seacock or kink the discharge hose to block the flow Watch the pressure gauge and a...

Page 59: ...elf and then initiating the flush interval timer as outlined on page 38 Performing a Fresh Water Flush with a Failed Inlet Pressure Transducer In the event of a Service Prefilter alarm on the remote display that cannot be cleared by re placing the pre filters the alarm function can be defeated to allow the system to remain in the Auto Store mode until repairs can be facilitated Access the Program ...

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Page 61: ...61 MPC 5000 Programming and Controls ...

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Page 63: ...the operation of the system in real time to en sure a long and trouble free service life If an operating parameter changes the MPC can switch operating modes shut itself down or automatically store itself in order to protect your watermaker Your MPC control board can be calibrated and programmed from the remote display quickly and easily with only a few key strokes The Battery Back up feature allo...

Page 64: ...y without a boost pump These systems will have 2 identical pressure transducers mounted on the 20 and 5 mi cron filter housings to measure feed water pressure and filter condition Prior to starting your system for the first time remove the battery isolation tab located to the immediate left of the BATT post on the MPC board Ventura systems use software Version A 37 USB Type B Computer Connection J...

Page 65: ...l perform another fresh water flush and restart the flush interval timer The flush interval and flush cycle will repeat themselves until the user enters another com mand Auto Run Auto Store Pressing the Auto Store button in the top right corner of the display will acti vate the automated storage sequence This will automatically store the system performing a fresh water flush once every 1 30 days a...

Page 66: ...ut the system until another command is giv en After pressing Stop it is advisable to use the Auto Store button which will initiate a fresh water flush and restart the flush interval timer Stop Alarm Displ The Alarm Displ button has several functions depending on the current state of the system Alarm Active Pressing Alarm Displ will silence the alarm Pressing it again will reset the alarm if the un...

Page 67: ...d on pages 19 20 It is not advisable to operate your watermaker unattended Severe damage to the vessel watermaker or other equipment may result Auto Run for 5 seconds Auto Fill Mode Single Flush Pressing and holding the Auto Store button for 5 seconds will activate the single flush mode The system will perform a single fresh water flush then return to the default screen dis playing Spectra Waterma...

Page 68: ...ispl Scrolls through the various programming windows Stop Selects the digit in the Rotoflow meter calibration constant window to be changed Has no function in other windows Auto Run Changes the selected parameter down one unit per push Auto Store Changes the selected parameter up one unit with per push To Exit Program Mode Press and release the Stop and Alarm Displ buttons simultaneously The contr...

Page 69: ... system will alarm Service Prefilters and shutdown Fac tory default is 10 PSI PRESSURE LIMIT If the pressure at the feed pump discharge exceeds this set point the unit will shut down and alarm High Pressure The left hand number on the display is the real time feed pressure as read by the sensor marked green on the 5 micron filter housing The num ber on the right is the high pressure limit Factory ...

Page 70: ...et is the preferred method to eliminate this alarm BRIGHTNESS The brightness is not adjustable on LCD displays supplied with Ventura models but may be adjusted on Vacuum Fluorescent Displays Factory default is 0 FLUSH DURATION This parameter sets the length of the fresh water flush in minutes Factory default is 3 This should be the same as Pump On Time PUMP ON TIME Sets the length of time the feed...

Page 71: ...e salinity level in PPM can be seen through the remote display Using a hand held tester note the salinity in PPM of your product water after the unit has been running Be sure to calibrate the hand held salinity meter as per the manufacturer s in structions Access the Program Mode from the remote display simultaneously press and hold the Stop and Alarm Displ buttons for 4 seconds Press Alarm Displ ...

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Page 73: ...ut off the main power supplies Remove the lead wire that goes to the affected component from the terminal strip Using a digital ohmmeter check the circuits for dead shorts You should see about 10 ohms or more on the solenoid valve circuits On Ventura 150 and 200 systems using Shurflo feed pumps the pumps are run directly from the board The Shurflo pumps must be disconnected from the MPC printed ci...

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Page 75: ...75 Exploded Views and Part Numbers ...

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Page 77: ...s 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 Nickel Bronze High Pressure Elbow PL MTE 3 4S1 2B Nickel Bronze High Pressure Straight Fitting SUB MTS 3 8X1 2 PL MTE 3 4S1 2B Pump to Pressure Vessel Upper SS Tube PL TB HP HPTVUS Pump to Pressure Vessel Upper SS Tube PL TB HP HPTVUS Pump to Pressure Vessel Lower SS...

Page 78: ... Barb El 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 Gauge PL PSG LP2 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 ...

Page 79: ... PL HP 1 8 Part Numbers EL MPC SP4 SALINITY PROBE SUB NP DVM DIVERSION VALVE MAN IFOLD 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 4D12 1 4 DIVERSION VALVE 12V 24V PL FTS 1 4X1 4P 1 4 FPT X 1 4 TUBE FITT ST REDUCING COUPLING PL UNN 3 8X1 4N MPC CONTROL PANEL LCD EL MPC RMCD PL MTE 3 8x1 4 3 8 x1 2 TUBE FITT ELL ...

Page 80: ...5 8 Quick Disc Fitting Hose Barb PL QDC HB5 8 1 4 Product Tube PL NLT 1 4LP 3 8 Low Pressure Tube PL NLT 3 8LP Part Numbers 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 PL MTE 3 4S1 2B ...

Page 81: ...PL HBS 3 4X5 8 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 1 Way Solenoid Valve 12V 24V PL SLN 1 4O12 024 ...

Page 82: ...82 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 Not used ...

Page 83: ...83 HD CPS 5 16X3 KIT HP 10VSA HP TB AR SO HPP AR SO HPP RV HP TB BV HD CPS 5 162 75 SO HPP SP PS20 HP TB VSP VSP20 HP TB SR SO HPP VB SO HPP PLP SO HPP VP ...

Page 84: ...84 Parts HP CYL 3 4R ...

Page 85: ...85 PL MTS 3 8X1 2S HP CYL SST HP CYL CCA SO HPP ECCB HP CYL EC HP CYL R HP CYL PT Parts ...

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