Catalina 300 MPC 3000 User Manual
Contents
1. YY WS CNN CNN QS WS QN ouop 4015 11935 55014 JOJEM JO poursop 9 1 493 10 5 101 ssoJq our UJJSAS 0 oin y 59214 uou ot oouto SI USNJJ uouA 4019 110JS 655914 Ae dsrp 99 OJNV Sursso1d Aq 5 USNJA 1 493 OT uni dund 0 YO IMS jenuew pooj 251 L 493 Winterizing Warning Only use potable water antifreeze Propvlene Glycol Do not use automotive antifreeze Ethylene Glycol Step 1 With the system running use your product sampling valve to divert five gallons 20 liters into one or two containers e Step 2 Connect a hose using the garden hose barb fitting from your service kit to the service port of the fresh water flush module Lead the hose i2. 55 W 25 Normal Start Up Using the Auto Run Button Press Auto Run button once and the svstem will prime and run for 1 hour The dis play reads AUTO RUN then STARTING with a 30 second priming countdown timer After the prime the display reads AUTO RUN MODE with a countdown timer hour of run time 15 added up to 12 hours with each successive momentary press of the Auto Run button An hour can be added at any time The dis play shows the default readout unless there 1s an alarm condition Successive presses of the Alarm Display button will scroll through the displays starting with PRODUCT Upon auto shut down by the timer or by the optional tank full float switches the system will automatically fresh water flush and re flush every 5 days Pressing the Stop button stops the sequence at any time with no flushes Normal Operation For optimum performance Auto run the system as long as possible at one time Never let the system sit with salt water in it Never allow continuous air leaks in the intake Normal Shut Down If the system was started using the Auto Run button the system will shut off on 15 own when the selected run time 1s over and will auto flush every 5 days Pressing the Stop button at any time will shut off the system with no auto flush function The optional tank float switches will sh
3. 9 47 Active Circuits If Inlet Pressure gt Max Pressure 150psi for Newport Svstems Shutdown Audible Alarm HIGH PRESSURE Alarm LED lit If Stroke not sensed for 30 seconds RE STARTING Pump Off Pump2 On 2 00 l Countdown to 0 retrv previous mode RE STARTING 2 00 If still no stroke Pumpl Off Pump2 On l Countdown to 0 retrv previous mode If still no stroke SYSTEM STALLED Shutdown Audible Alarm Alarm LED lit If no Inlet 10 of vacuum sensed at vacuum switch CK SEA STRAINER Audible Alarm Error Occurred Alarm LED lit i Begin FWF Mode If problem corrects itself Audible alarm off Fresh Water FRESH WATER Flush FLUSH 5 00 FWF Mode Pump2 cycles On Off l Countdown to 0 Auxl CK SEA STRAINER Shutdown Shutdown Audible Alarm Alarm LED lit 48 Active Circuits If DC Input voltage too low Begin FWF Mode VOLTAGE TOO LOW To Shutdown If DC input voltage too high VOLTAGE TOO HIGH Begin FWF Mode To Shutdown If salinity probe bad SALINITY PROBE disconnected FAILED If blown fuse CHECK FUSE X Shutdown Where x represents number of blown fuse 1 5 If Tankl or Tank2 No display software registers that Tankl switch closed for 2 or Tank2 is full minutes If Tankl AND switch TANK S FULL closed for 2 minutes Depending on operating mode svstem mav at this point begin a fresh water flush begin storag
4. Composite cvlinder HP CVL CCA End cap O ring Cylinderendcap HP CYL EC N P Cylinder Ring HP CYL R Cylinder Assembly Piston with seal 1 2 SS tube Ma i bd MAS E l SY ARM 3 W gt _ Composite cylinder and base Cylinder Assembly Early Models
5. SPECTRA MPC 3000 salinity 5 SALINITV This mav not show anv lit bars on new svstem One bar ip represents 100 PPM System rejects water higher than 750 PPM Feedwater Pressure Pressure range 80 110 PSI A MERIT e 5 5 7 5 BAR A FEED WATER PSI 4 Filter Condition 5 PREFILTER Clean filters on first alarm as GOODBODDBREPLACE soon as convenient LPH PRODUCT _______ _ FEED WATER BAR 6 17 24 Dry Testing With Artificial Ocean If it is not possible to test run the system with the boat in the water testing may be accomplished with an artificial ocean Purchase enough aquarium salts to make 5 gallons 20 liters of salt water Make sure that the domestic water system 15 powered up and that there 1s water in the tank Confirm that the Charcoal filter 1s installed 1n the Fresh water flush module and that the domestic water line had been installed and all valves are open l Open Pressure Relief Valve Power up the control system Press both Auto Run and Stop to bypass the purge sequence If the motor starts stop imme diately and press the Auto run and stop button again until you get a message PURGE MODE BYPASSED Press the Auto Store button and allow the fresh water flush system to cycle through its timed op eration Cycle the auto store system 5 more times to purge all
6. CATALINA 300 INSTALLATION MANUAL B SPECTR WATERMACHING i B pA Gey WATERMAGHINES 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 09 20 04 Thank you for your purchase of a Spectra Catalina system Properly installed it will provide years of trouble free service Please pay attention to the installation instructions and the sys tem 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 pre vent 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 Catalina Installation Quick Start Important Details for Installer 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 for ward facing thru hull fitting installed Follow the wire gauge charts in the instructions Using larger wire than specified 1s ac ceptable 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
7. PL NP 1 8N gt 1 4 PLUG NYLON PL HP 1 4N 3 8 MALE NPTX1 2 TUBE SS FITT ST PL MTS 3 8X1 2S MEMBRANE END PLUG FT PV EP 1 4 DIVERSION VALVE 12V W O VB PL SLN 1 4D12VB 1 4 DIVERSION VALVE 24V W O VB PL SLN 1 4D24VB 1 4 PLASTIC CK VALVE M F PL CKV 1 4M F 1 4 NPTX1 4 TUBE FITTING ST 1 4 HEX PLUG NVLON PL MTS 1 4X1 4P PL HP 1 4N DIVERSION VALVE MANIFOLD SUB NP DVM SALINITV PROBE EL MPC SP 53 3 8 LOW PRESS TUBE PL NLT 3 8LP 3 4 MPT X 3 8 TUBE FITT ELL BERATEN RD _ 1 4 X 3 8 TUBE FITTING ELBOW PL MTE 1 4X3 8P 3 ANPTX1 2 HOSE BARB NYL ELL PL HBE 3 4X1 2 3 4 X 3 4 HOSE BARB ELBOW PL HBE 3 4X3 4 LOW PRESSURE FILTER HOUSING FT FTH 10L GARDEN HOSE CAP PL GHF GC 3 4 MPT X 3 4 HOSE BARB ELBOW PL HBE 3 4X3 4 3 4 3 WAY VALVE PL VLV 3W3 4 FRESH WATER FLUSH MODULE BRACKET FM NPC IM 50 MICRON FILTER ELEMENT FT FTC 50 3 4 NPT X 3 4 HOSE BARB ST PL HBS 3 4X3 4 S P S T ON OFF SWITCH EL SWT TK1 7 1 GGLE SWITCH BOOT SEAL I F SIT 4 CHARCOAL FILTER FT FTC CC SWT TSBHC d dean d Spe TERMINAL BLOCK 65A 2 CIRCUIT EL TM 65A2 PRESSURE SENSOR CABLE EL SSR PSH 50 DISPLAY CABLE EL MPC CBL50 STROKE SENSOR amp 15CABLE 8 15 SALINITV SENSOR BLE 15 EL MPC CBL15 54 STROKE SENSOR 1 5 CABLE EL MPC SC15 3 8 NP
8. lizer lamp module and ballast unit should mount vertically with the product water inlet at the bottom outlet at the top The ballast wires plug into the end of the bulb in the lamp module The ballast RED wire connects to STER terminal on the MPC board and the ballast BLACK wire connects to the GND terminal If the wires must be extended use minimum 16AWG wire External Buzzer s In addition to the external buzzer s installed at each remote control dis play panel a buzzer unit may be installed at the control box The buzzer RED wire connects to the BUZZ terminal on the MPC board and the buzzer BLACK wire connects to GND Tank Switch Operation The MPC controller can be set up to use your tank switches 1 two ways For normal operation using either Manual Run mode or Auto Run mode simply connect the switches to the Tankl and Tank2 connections on the MPC board If only one switch is to be used connect a jumper across the unused tank connection Note that the switch must be installed in a posi tion that will cause it to close short when the tank is full In Manual or Auto Run mode the system will stop producing water when both tank switches are closed perform a fresh water flush and shut down Jumpered for only 1 switch 1000000000 aA To Tank 1 Switch Tank 1 Connection Tank 2 Connection NORMALLY OPEN POSITION PHOTO SHOWS TANK FULL SWITCH REVERSE FOR TANK LOW SWITCH WIRE TO MPC
9. Each remote control display panel can accommodate an external alarm buzzer to provide audible alerts in the event of a fault or at the end of certain timed cycles Use only the buzzer units supplied by Spectra Watermakers as current on the LCD buzzer terminal 15 limited to 20 MA any excessive load may damage the controller or remote display panel Connect the buzzer RED wire to the terminal marked POSITIVE connect the buzzer BLACK wire to the terminal marked NEGATIVE on the back of the remote display panel There are currently two types of display options available Liquid Crystal Diode LCD dis play which is dark lettering on a backlit background or an optional Vacuum Florescent Display VFD which are bright characters on a dark background The VFD demands more power from the MPC controller and currently only one VFD can be run at a time You can run one and two LCD s or three LCD s at any time Pressure Sensors The pressure sensors mount on the prefilter housing to monitor svstem pressure and differential pressure across the filters Simplv route the wires and plug them into the respective color coded sensors If the wire leads for the sensors must be extended vou must use a minimum 18 AWG 3 conductor twisted and shielded marine grade wire Make a waterproof soldered splice connection to the new wire and seal the splice in waterproof heat shrink tubing The Water is inlet is plumbed to the left hand red
10. tue e 29 WY bel U T 32 33 SUBggested S 37 Membrane Pressure Vessel e tmc 38 Ttoubleshootune PtOCCOUTe 40 Spectra 3000 Operation ia 42 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 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 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 1n 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 1s 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
11. 4 9 16 116mm wide by 2 7 8 68mm high opening for the panel Locate in an area that 15 easily visible and easy to manipulate the buttons Use only Spectra approved remote cable The cable is not standard LAN cable or phone cord SPECTRA MACHINES 3000 Clark Pump Membrane Module The Clark pump membrane module comes complete with a mounting svstem Be sure to use the supplied washers on the rubber feet Use it as a template for drilling the mount holes Mount in anv position but leave access to the pressure relief valve on the Clark pump Install in an area that maintains a temperature below 120F 50C A cool location is preferable Keep this unit within the 15 4 5M reach of the wires from main feed pump module This unit 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 Membrane Pressure Vessel Mounting The Clark pump and membrane assembly has been pre assembled at the factory If it 15 neces sary to disassemble this module and mount the pressure vessel remotely use guidelines High pressure tube assembly in back of the manual Use only approved Spectra tubing for assem bly Diversion Valve and Salinitv Probe VERSIONS The diversion valve and salinitv probe is supplied as an assemblv Mount this assemblv near or on your pressure vessel The assemb
12. HP 10VSA Relief Valve HP TB BV Annular Ring O Rings Mount inside Valve Block SO HPP AR Valve Block HD CPS 5 162 75 5 16 2 3 4 SS bolts Reset button and O ring 47 End blockB SO HPP SP PS20 Piston O ring lt HP TB VSP VSP20 Spool piston HP TB SR Spacer ring s Valve block S Q SO HPP VB Valve bore O ring Spacer ring J Spool piston End block 2 SO HPP VP Valve spool Pilot port O rings SO HPP PLP lt D 507 _ Reversing Valve End Blocks x La AXE 57 Valve port seals SO HPP VP Pilot valve port seals SO HPP PLP Center block cylinder O rings SO HPP ECCB Pilot spool O rings 4 Mount inside block SO HPP PV HP CB PVS Pilot spool HP CB PPS Pilot valve pin SO HPP PS Pin seal O rings Rod lip seals Mount inside block SO HPP PR7 PR10 PR15 Check valve port O rings SO HPP CVP Check valve assembly Piston to rod O rings 2 Inside pistons Glass rod models only Center Block Piston rod HP CYL 3 4R 7 8R 1R Pilot orifice HP CB PO Center block Feed in Check valve SO HPP CVS O ring Check valve poppet HP CB CV Check valve spring 7 Check valve washer Check valve retainer HP CB CVR 58 1 2 SS S S compression L fittings E HP CYL SST lt 2 pus seal PL MTS 3 8X1 28 Y D
13. PCE FLOAT SWITCH SEE SIDE MOUNTED TANK SWITCH OPTION 20 Automatic operation Automatic operation for land based systems may be achieved by in stalling a low point tank switch and a high full tank switch Tank 2 switch 15 be the low point or system on and tank switch 1 will be the high point system off switch The system should then start when the tank low switch opens and shuts off when the tank one or high point switch closes The unit will perform a FW flush after the run cycle and default into the five day flush cycle How it Works Press and hold the Auto Run button for 5 seconds the display will read AUTO FILL MODE The system will begin operation and produce water filling the tank Eventu ally the water level will rise until it reaches the maximum switch at this time the display will read TANK S FULL the system will at this point stop producing water perform a fresh water flush and then go into a 5 day flush cycle storage mode The display will cycle TANK S FULL and FLUSH TIMER INTERVAL indicating the time remaining until the next flush occurs As you use the water in your tank the water level will drop until it reaches the minimum switch at this time the system will wake out of storage mode sensing that the minimum tank level has been reached and will begin to produce water again until the water reaches maximum 21 New Svstem Start Up and Testing Avoid run
14. before Diversion valve will open Press Low Mode Then press again And hold for 5 seconds Start 0 Stop Start Stop 1 RUN HIGH MODE RUN LOW MODE STARTING 1 30 GPH PRODUCT Pump2 Pvlv 1 Aux2 Ster When 30 seconds remaining Pump2 Off Pumpl On Pumpl Dvlv Auxl Aux2 Ster 44 RUN AUTO MODE Active Circuits Auto Run Mode 01 00 HOURS Pump2 Pvlv Auxl Aux2 Ster Note pressing Auto Run again will add time in 1 hour increments n STARTING riming 2 00 When 30 seconds remaining Pump2 Off Pumpl On Making RUN AUTO MODE Pumpl Pump2 Dvlv Water 0 59 HOURS Auxl Aux2 Ster Countdown to 0 Flush FRESH WATER Pump2 Cycles On Off FLUSH 5 00 Countdown to 0 FLUSH TIMER Storage Aux INTERVAL 19 59 Countdown to 0 Perform Flush Cvcle Repeats Note Pump2 Flush On Off times seconds as well as Storage Time hours are programmable via internal software Storage Auto STARTING Pump2 Fvlv Pvlv Aux Mode Store 5 30 FRESH WATER Flush FLUSH 5 00 FLUSH TIMER Storage INTERVAL 19 59 Countdown to 0 repeat Flush Cycle repeats Pump2 Cycles On Off Fvlv Aux Auxl 45 Press and hold Auto Fill Auto AUTO FILL MODE Mode Run gt 2 Pvlv 1 Aux2 Ster Active Circuits For 5 seconds STARTING 1 30 When 30 seconds remaining Pump2 Of
15. higher than normal readings for the conditions Other conditions can cause high pressure such as cold feed wa ter or clogged filters Low product flow is usually due to low voltage damaged feed pump or Clark pump Look for all other causes before cleaning the membrane Membrane life can be shortened by excessive cleaning There are two types of cleaners acid and alkaline The acid cleaner SC 3 will remove min eral scaling The alkaline cleaner SC 2 1s used to remove biological by products oil and dirt particles that get past the prefilters If membrane performance 15 reduced and they have not been pickled recently cleaning with both chemicals 1s recommended The acid cleaner should be used first If the membrane fails to respond to both cleanings this 1s an indication of another problem with the system or that it is time to replace the membrane Contact Spectra Watermakers before removing a membrane Membrane Cleaning For normal cleaning the SC 3 Acid Cleaning Compound 15 used first then the SC 2 Alkaline Cleaning Compound If known bio fouling 15 present the SC 2 may be used first Using hot wa ter 1f possible up to 120 45C 15 recommended as it greatly enhances the ability of the cleaners to do their jobs If the history of the system 1s unknown or has been left unpickled for an extended length of time and biological growth is present it is recommended that the system 1s cleaned with SC 2 using an alternate source of u
16. hose into the bucket Turn the service valve on the fresh water flush module 180 so the intake is now coming from the bucket e Step 5 Mix the storage chemical compound into the water in the bucket e Step 6 Make sure the pressure relief valve on the Clark pump is Open unpressurized e Step 7 Use the Feed Pump Manual switch on the MPC control box to turn on the feed pump Circulate the storage chemical in the system for approximately 10 minutes Turn off the switch when finished Clean Up e Remove the quick disconnect from the Clark pump brine dis charge and replace the original hose that leads to the thru hull You may at this point if you choose to pump the bucket dry by using the feed pump switch Stop when the bucket 15 empty e Turn the service valve 180 back to its original position and remove the service hose e Turn off the power to the system and the MPC control 30 31 jOUOP 493 1 26 XIN G 2081 AJLA 991AJ9S pue 0 osoq AAA JO 2 9509 IMAS NS SX KAAL v N 2 44 Ld Md Ml dll T MMMM dl Md T ll ddd dl MM Mb Ul dd ld MB pannoo tp 493 lt CS SS SS lt 2 U A 2 7 U WM MMMM Ma ad yoyonq 0 9SOU 99IAJOS YIM 998Jd91 pue SAOWIOY 27 93 W WSS
17. side of the assemblv as shown Water out on the right green side The filter assemblv be re oriented in the bracket if Water in Water out required Stroke Sensor The stroke sensor snaps into the side of the end block of the Clark pump If the wire leads for the sensor must be extended you must use a 3 conductor twisted and shielded marine grade wire Make a waterproof soldered splice connection to the new wire and seal the splice in waterproof heat shrink tubing Caution Make certain that no extra strands are free to make contact with other conductors or components Integrity of the sensor wiring 1 critical If the stroke sensor must be removed use a pen knife to find and depress the opposing clips holding the sensor to the block LN gt f Ste Diversion Valve and Salinitv VERSIONS The diversion valve and salinity probe is supplied as an assembly Locate the diversion valve wires and splice the remaining two conductor cables with the supplied butt splices These are heat shrink connectors so you can seal them after splicing Product Water to Tank Product Dump Line to the Brine S Discharge on Clark Pump salinity Probe Note Orientation Remove Plug and Install Adapter for Brine Dump See Parker assembly instruc tions next page a Fresh Water Flush Module Route the single two conductor har nesses to the fresh water flush module and splice the wires
18. to UL ABYC CE or applicable standards Component Placement Refer to the Plumbing Diagrams Strainer Mount the strainer in an accessible area close to the intake through hull 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 should be located between the intake strainer and the feed pump Module and as low as possible in the vessel It should be mounted with the filter housings vertical and accessible for changing filters Allow 2 below the filter housing for removal Do not install over electrical equipment Remove filter bowls for access to the screw holes in the mounting plate The unit contains a 50 Micron prefilter charcoal filter for the flush water flush solenoid and three way intake service valve Optional Zeta Guard The optional Zeta Guard Water treatment system should be in stalled between the fresh water flush module and feed pump to effectively treat all incoming water to the system Consult your Zeta handbook for specific directions Feed Pump Mount the feed pump module on a horizontal or vertical surface up to 4 above the waterline It 15 preferable to mount as low as possible If mounted on a vertical surface mount the pump head down The filter assembly is installed between the feed pump and the Clark pump membrane m
19. 11 on position Turn off manual switch on con trol box Feed pump runs with loud noise Intake blocked leakage in intake system Pump De Coupled Check thru hull valve Check sea strainer for leaks Check FWF module for leaks Check Accumulator for correct charge 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 sup ply breaker Check for voltage 12 or 24vDC at control box power input studs Try manual bypass switches if pumps run then control or Pumps run intermittently cycling on off System operating in flush mode DC models System will time out or manually stop with the Start Stop button Display activates but pump will not run loose or broken pump wire connection bad pump relay blown F3 or F5 fuse on MPC tanks are full Check wiring at terminal block inside MPC Test power relay replace Replace fuse mini automotive type ATM Check tanks system cannot be started 1f tanks are full System runs no product water delivered to water tanks GHP bar graph shows OK Good LED activated diversion valve inoperative wiring fault disconnected or broken prod uct tubing diversion valve plunger stuck Check wiring at diversion valve and inside control box Che
20. 3 gallons 12L per flush for the Catalina 300 The MPC 3000 control must be de powered DC power off after the system 15 put in storage pickled where a storage chemical or antifreeze 1s run through the system If you are separating the Clark pump membrane assembly please review the high pres sure tube assembly instructions Improper assembly will cause failure Run test then sea trial the complete system before assuming the system is tional If the boat is in fresh or dirty water see Dry testing the system 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 Please have the owner fill out the warranty card The warranty is void if it 15 not regis tered Table of Contents Installation Page Number Gerne T DONT 4 Installation ASICS i a ea E 5 COMPONENT EE 6 b l A 9 Parker Tube Fitting Assembly oe rete bis i ob eee 13 BIE cr MR 14 Operation New Systems Start Up and Testing 22 25 Normal Start Up Usine the Auto RUN ot bat ead TE deba 26 Automatic Fresh Water Flush Cycle an teret Rate Ra iua ead meas 24 Opera OIA nck e oed ase Uca tme dC t 28 Long Term Storage Procedures d
21. Store button will engage a flush and then the 5 day flush cycle The flush pump starts and the flush water solenoid opens for 5 minutes and then shuts down the display reads WATER FLUSH with a countdown timer and then will read FLUSH TIMER INTERVAL and the countdown timer will reflect the number of hours until the next flush e Pressing and holding the Auto Store button for 3 seconds will engage a time flush The system flushes as described above but will not re flush every 5 days Display will read FRESH WATER FLUSH with a countdown timer then the default display when fin ished e Pressing the Stop button will cancel the auto flush mode 2 Emergencv Operation n the event of an MPC control failure the system may be operated manually using the manual feed switch on the MPC control box e For manual start up switch on the feed pump using the feed pump switch Shut the unit down if the Clark pump does not cycle Shut down if air is continuously present in the intake line or if the feed pump 15 excessively noisy The automatic safety controls disabled in manual mode e Always discard the product water for the first few minutes of operation The initial prod uct water from the system may not be potable Taste the product water before sending to a tank In manual operation the salinity control 1s inoperative Product water is available either directly from the membrane product water out or at the divers
22. T QUICK DISCNT COUP 5 8 QUICK DISCNT FITT HOSE BODV BARB PL QDC BD3 8 PL QDC HB5 8 1 2 NPT X 3 8 TUBE FITTING Ss ACCUMULATOR TANK EL SWT VC MTE PL MTE 1 2X3 8P PLACE 1 2 NPT X 5 8 HOSE BARB NYL ST PL HBS 1 2X5 8 1 2 NPT X 1 8 FPT HI REDUCER NYLON PL BSH 1 2X1 8N 1 2 MPT X 3 4 HOSE BARB ST 1 2 CLOSE NIPPLE NY LON 1 4 MPT x 3 8 TUBE PL HBS 1 2X3 4 PL NP 1 2N FITTING ELBOW PL MTE 1 4X3 8P 1 2 FPT X 1 4 FPT GUAGE TEE PL TEE 1 2F1 4G 55 End block B HP TB VEB B Valve block HP TB VB End block A lind HP TB VEB A omposite cylinder and base Brine out PS HP CYL CCA Pressure relief valve HP TB BV Center block Y HP CB CB7 10 15 20 Feed in Stainless steel tube HP CYL SST Cylinder ring End Cap ors Clark Pump Front View HP CYL EC End block A Valve block End block B Reset button Not on all units HP TB RSB3 Ateet eo a Composite cylinder and base High pressure in i NN Test port Center block High pressure out Stainless steel tube Cylinder ring Clark Pump Back View End cap 56 5 16 3 1 4 SS AH Bolts HD CPS 5 16X3 Spool Assembly Sol Bid 3 Exploded View i Spool Seal E Quad Ring Seal w Spool Center Quad Ring Seal 5 2 Spool Seal Relief Valve O Ring Spool End Annular Rings P TB AR Spool Assemblv KIT
23. Voltage Too Low low Check charging voltage loose wires or poor connec Check power connections tions Re starting no signal from stroke sensor 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 Mic 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 41 spectra MPC 3000 Operation Guide This document 15 a basic outline of MPC 3000 operations It details what 1s seen on the LCD display during the various modes of operation FLUSH TIMER INTERVAL 128 88 3000 42 Power On Initial Startup Purge Mode Bypass Purge Mode Am OPEN PRESSURE on J RELIEF VALVE NOU Aut gt STARTING Start Stop Purging UD PURGING STORAGE SOLUTION 18 30 CLOSE PRESSURE RELIEF VALVE NOU Close pressure reli
24. air bubbles and con taminates For racing boats and high speed power boats above 15 knots a retractable snorkel type thru hull fitting 1s 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 wa terline 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 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 opera tion Wiring e Pay attention to wire size or system performance will be impaired e Perform wiring
25. ck product tubing Disassemble and clean diverion valve plunger or re place valve contact factory System runs no product water delivered to water tanks GPH bar graph shows OK reject LED activated high salinity of product wa ter causing system to reject water salinity probe out of calibra tion 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 40 Spectra Catalina Troubleshooting Procedures SYMPTOMS Error Messages PROBABLE CAUSE REMEDY 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 stroke sensor pump de coupled Close pressure relief valve Check thru hull Verify stroke sensor fully in serted in pump Check stroke sensor wiring at control box Replace stroke sensor Check accumulator for proper charge at startup System Air locked High Pressure blocked brine discharge Check brine discharge fouled membrane Clean membrane Voltage Too High battery voltage too high or Charge batteries
26. e compound used by the US Navy It is formulated to be com patible with the modern engineering plastics and composites in the Spectra pumps Do not use any substitute except propylene Glycol SC 1 Storage Compound has to be mixed at a ratio of 1 Spectra container to 3 gallons 121 of fresh water to have the proper solution An average of 2 gallons 8L of water is in a 300 system Caution Avoid contact with skin eyes or lungs with the storage chemical C om LP Ss Spectra stor Pd Nr E gt 4 Un dd m IQ tpl 2 O inc A ATI 710 Ntaine allons ofu hc gn 8 oz to 3 ga ater that is in the 57519 16 TY M dun tal for detailed proc 29 Storage Procedure Step 1 Flush the system twice Use the Auto Flush button on the LCD display once the first flush has been completed press Stop to cancel the 5 day interval timer then press Auto Flush again e Step 2 Remove the quick disconnect fitting from the brine discharge outlet of the Clark pump and replace with a quick disconnect from your service kit fitted to a hose and lead the hose to a 5 gallon bucket Step 3 Press Auto Flush again to fill the bucket with fresh unchlorinated water 1 gallon for 300 systems Step 4 Connect a hose using the garden hose barb fitting from your service kit to the service port of the fresh water flush module Lead the
27. e mode or shut down Refer to Operating Modes 49 If salinitv above tolerance If salinitv above tolerance for 20 minutes Shutdown Reject lamp lit 20 minute internal counter begins SALINITY HIGH FLUSH 5 00 SALINITY HIGH Active Circuits Dvlv Off Begin FWF Mode Audible Alarm Alarm LED lit Auxl 50 CATALINA MOTOR 12V EL MTR 1 6D12 CATALINA MOTOR 24V EL MTR 1 6D24 MPC BOX FM MPC MPCB tA 8 D SPECTRA my WATERMACHINES CATALINA FEED PUMP BRACKET FM CT PM CATALINA VANE PUMP 110 PL PMP 110MAG PRESSURE TRANSDUCER 150 PSI EL SSR 150 HIGH PRESS HOUSING BRACKET DUPLEX FT FHB 10HD 1 4 MPT X 1 4 ELBOW NYLON PL MFF 1 4X1 4 bw BARB ELL NYL PL HBE 3 4X5 8 HIGH PRESSURE FILTER HOUSING FT FTH 10H 5 lt 4 MPC CONTROL PANEL VFD EL MPC RMCDF HI REJECTION MEMBRANE 40 FT MB 40 3 4 16 ST X 1 2 TUBE FITT ELL SS PL MTE 3 4SX1 2 f PLATE BRACKET END FM PVB PBE RUBBER MOUNT HD RBP RM 3 8 MALE NPTX5 8 HOSE BARB ELL NYL PL HBE 3 8X5 8 PLATE BRACKET FM PVB PB 1 2 HIGH PRESSURE TUBE 3 8 LOW PRESS TUBE DAYCO PL NLT 3 8LP PL NLT 1 2HP 52 3 8 X 3 8 TUBE FITT ST PL MTS 3 8X3 8P 3 8 NPT X 1 4 TUBE FITT PL MTE 3 8X1 4 1 4 MPT X 3 8 TUBE FITTING ELBOW PL MTE 1 4X3 8P 1 8 FEMALE NPTX1 4 TUBE FITTING ELL PL FTE 1 8X1 4P 1 8 NPT NIPPLE NYLON
28. ed clear vinyl hose rated to 150 PSI 11 bar SUCTION HOSE HEIDE 111 ee ee ee 118 49 6 EE From the inlet thru hull to the flush module and from the flush module to the pump module inlet use the supplied clear 3 4 19mm spiral suc tion rated hose 10 Fresh Water Flush Module Run a feed line from the domestic cold pressure water svstem to the 1 2 hose barb on the fresh water flush assembiv This needs to be active when the boat is unattended for the fresh water flush svstem to function properlv The domestic fresh water pump must be able to deliver 2 5 gallons per minute at 25 PSI Connect the wiring harness and heat shrink butt splices Fresh Water In From Domestic pressure Svstem 1 27 12 7MM Hose Service Port For Water Out To Maintenance Feed Pump Module Sea Water In From Strainer Product Water tubing MPC 3000 Version Product water tubing is 1 4 6 3mm parker tubing pre plumbed from the membrane into the electric diversion valve The diversion valve will dump product water into the overboard brine stream until good quality is measured by the MPC 3000 control Product water is then di verted into the fresh water tank You will need to route the product water from the valve into the top of the tank Install a tee in the water fill or tap a pipe thread into an inspection port in the top of the tank Do not
29. ef valve and press Start Stop Start RUN HIGH MODE Stop Displayed for 10 secs STARTING Priming 2 00 PURGING PRODUCT 10 00 GPH PRODUCT Making Water T 22 PURGE BYPASSED Run Start Stop Simultaneously Active Circuits Off Aux1 On 2 Pvlv Auxl Aux2 When 30 seconds remaining Pump2 Off Pump On Pumpl Pump2 Auxl Aux2 Countdown to 0 00 Off Aux1 On Pump2 1 Auxl Aux2 Ster When 30 seconds remaining Pump2 Off Pumpl On Pumpl Pump2 Aux Aux2 Ster Pumpl Pump2 Dvlv Auxl Aux2 Ster 43 Manual Run Mode Start Stop Priming Making Water RUN HIGH MODE Displaved for 10 secs STARTING 2 00 GPH PRODUCT Active Circuits Pump2 Pvlv Auxl Aux2 Ster When 30 seconds remaining Pump2 Off Pumpl On Pumpl Pump2 Dvlv Aux Aux2 Ster Note on Diversion Valve Operation During a water making mode a 60 second salinity check is performed If salinity is within tolerance lt 700ppm for a continuous 60 seconds the Diversion valve will open and the good LED will be lit If salinity is out of tolerance the Diversion valve will close and the reject LED will be lit Salinity must drop below tolerance and remain within tolerance for a continuous 60 seconds
30. f Pumpl On AUTO FILL MODE Pumpl Pump2 Auxl Aux2 Ster Will produce water until Tankl switch closes Auto If Tank1 max Tank s Full Switch closes TANK S FULL Pump2 Fvlv Pvlv Auxl STARTING 5 30 TANK S FULL FRESH WATER Pump2 Cycles On Off FLUSH 5 00 Fvlv Aux Display will toggle Tank s Full to Fresh Water Flush every 5 seconds Countdown to 0 TANK S FULL FLUSH TIMER INTERVAL 119 59 Display will toggle Tank s Full to Flush Timer Interval every 5 seconds i Countdown to 0 If timer reaches 0 another fresh water flush will be performed If Tank2 min switch opens Timer will interrupt and unit will go back into Auto Fill Mode Production Mode 46 Run time Readouts Alarm Disp Pressing Alarm Disp at anv time during run cvcle will through the following readouts GPH PRODUCT 4 22 SALINITV LOW FEED WATER PSI 50 150 PREFILIER GOOD HOURS TOTAL 000000 Alarm Push and hold Disp Converts to Metric Metric gt Metric gt 15 LPH PRODUCT FEED WATER BAR 3
31. feed the water into a manifold or bottom of the tank Make sure there 1s no restriction in this plumbing to tank Valve Solenoid and Salinitv probe assembly adi MK 7 IN Diversion m 3 Quick Disconnect Fitting Brine Discharge Route the Brine discharge from the quick disconnect fitting to location above the waterline using the supplied 5 8 15 9MM hose Product water Parker Tube Fitting Assembly Procedure Tubing single grab ring for 1 4 amp 3 8 tube Use 2 grab rings for 1 2 tube Spacer NNNNNNNN N O ring Body 5 L TY R NNNNNNNNN ANA ANA 1 2 max NN A 44 rl INA MAN IIA MAN MAA SS AN AN ANN AN AN N AN AN NN Dissemble fitting components Step 1 Slip the O ring over the tube to hold the Spacer in place If the Grab Ring 1s pushed too far trim back the tube so about 1 4 of tube extends past the O ring 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 13 1 2 tube should not bottom out in the fitting to allow full compression of the O ring fit the tube into the body and loosely thread on the nut come out if pulled by hand If it does tighten the 1 4 3 8 1 2 Parker Tube Fitting Assembly DO NOT USE A WRENCH The tube should no
32. fter adding the jumper it may be necessary to cycle through the different LCD displays until the display reads salinity Procedure 1 Locate the Calibrate jumper location on the MPC 3000 Board Jump the terminals 2 Start the system and after the salinity stabilizes test the product water with a calibrated hand held tester 3 Locate the MPC calibration trimmer potentiometer on the board below the salinity probe jack Adjust until the display PPM matches the PPM reading from the hand held salinity monitor Turning the trim pot clockwise will lower the salinity reading and counter clockwise will raise it 4 Shut the system down and disconnect the jumper on MPC board If a hand held meter 15 not available you can remove the probe and dip it into a known calibrated solution This can be obtained from Spectra MPC 3000 CALIBRATION ADJUSTMENT CALIBRATION JUMPER CALIBRATION POT Li RD EST T RR BA CALIBRATE gt DL E 20 uM uro ji 36 Suggested Spares Short term cruising weekends etc We suggest a basic cruise kit Kit consists of 3 ea 50 micron 20micron and 5 micron filters and two SC 1 storage chemicals Cruising 2 to 6 months at time Two basic cruise kits One each replacement charcoal filter One replacement feed pump head Longer than 6 months Additional filters offshore cruising kit consisting of Clark pump seal
33. ge fitting and install the brine discharge service hose Flush the system until you get one gallon 4L in the bucket Proceed with step 6 and 7 above Note The product tube strainer and all associated hoses that are not subject to the glycol an tifreeze should be drained of fluid This may require compressed air 32 Maintenance General Periodicallv inspect the entire svstem 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 1s normal Wipe down any salt encrusted areas with a damp cloth The Seawater Strainer and 50 Micron Filter The sea water strainer s stainless steel element should be inspected removed and cleaned as needed A clogged strainer or 50 Micron filter will cause the MPC control to alarm Check Sea Strainer Be careful to ensure that the thru hull 15 closed before disassembly and the seal and element are in place before reassembly Put the screen up to a light for inspection When the system 15 put into storage remove rinse and reassemble dry to impede corrosion Check frequently during operation The 50 micron filter needs to be properly maintained to protect the feed pump Only use Spectra approved filters These may be cleaned several times before discarding The Prefilters service the prefilters as soon as possible after the first prefilter alarm sounds When the second alarm sounds the system will shut down to p
34. ht 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 90 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 The tube connectors can be disconnected and re tighten several times To reconnect insert the tube and ferrule into the body then hand tighten the nut Hold the body and tighten the nut with a wrench a little past where resistance 15 encountered When correct the nut should be tightened a little past where it was before disassembly Always check for leaks Index mark Straight thread Straight or 90 deg ET 3 8 pipe thread Figure 1 L Nut Ferrule Bodv Nut finger tight with thread showing Cut tube square UN Figure 2 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 y No threads showing Insert tube 0 9 until it stops Figure 3 IMPORTANT Hold fitting body with 13 16 wrench when tightening 39 Spectra Catalina Troubleshooting Procedures SYMPTOMS PROBABLE CAUSE REMEDY Feed pump runs constantly will not turn off Manual override switches
35. ion valve brine outlet You will have to bypass the diversion valve with the parker tubing Remove check valve Connect Product tube to and reconnect the Brine tube diversion valve to the check valve as shown Disconnect product fitting Activate manual switch ww XI 6 Q MANUAL 28 Long Term Storage Procedures Watermakers are best run continuously When not in use biological growth in the membrane is the leading cause of membrane fouling A warm environment will cause more growth than a cold environment The auto fresh water flush system will greatly reduce biological growth but may not stop it completely in certain conditions The 5 day re flush feature allows the system to be shut down without any service procedures for extended periods of time but it doesn t re place performing a storage procedure for long periods of non use If an optional Zeta Guard water treatment system 15 installed in the system the 5 day re flush will maintain the system as long as unchlorinated pressurized fresh water 1s provided System Storage or Pickling If the system is to be left unused for more than 2 weeks 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 Spectra s charcoal filter Charcoal filters last a maximum of 6 months once wetted Spectra SC 1 a special storag
36. ke sure the pressure relief valve on the Clark pump is Open unpressurized e Step 7 Use the Feed Pump Manual switch on the MPC control box to turn on the feed pump Circulate the storage chemical in the system for approximately 25 minutes Turn off the switch when finished Clean Up e Remove the quick disconnect from the Clark pump brine discharge and replace the origi nal hose that leads to the thru hull You may at this point if you choose to pump the bucket dry by using the feed pump switch Stop when the bucket 1s empty e Turn the service valve 180 back to its original position and remove the service hose 35 Salinitv Probe Calibration salinity is a measurement of TDS total dissolved solids in liquid these solids will conduct elec tricity to varying degrees special probe is used with two electrical contacts in it to determine the resistance to the flow of electricity in the liquid In the Spectra Watermakers systems the salinity probe 1s located just before the diversion valve at the output of the RO membrane This way we can look at the salinity level of the product water before deciding to either reject the water or accept it and divert it into the holding tank The salinity level in parts per million can be seen either through the salinity meter in the soft ware or a jumper can be added to the MPC board in the calibrate position where it can then be seen on the LCD display rather than a bar graph A
37. lve on the Clark pump must be open for this procedure or membrane damage may result Maximum pressure 50 psi A 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 aver age of two gallons 8L of water is already present inside a 300 system This water has to be figured into the mixture A 300 system will use 1 container of compound Cleaning Procedure Step 1 Flush the system twice Use the Auto Flush button on the MPC 3000 display once the first flush has been completed press Stop to cancel the 5 day interval timer then press Auto Flush again Step 2 Remove the quick disconnect fitting from the brine discharge outlet of the Clark pump and replace with a quick disconnect from your service kat fitted to a hose and lead the hose to a 5 gallon bucket e Step 3 Press Auto Flush again to fill the bucket with fresh unchlorinated water gallon 4L for 300 systems Press Stop when the bucket has reached the desired level Step 4 Connect a hose using the garden hose barb fitting from your service to the ser vice port of the fresh water flush module Lead the hose into the bucket Turn the service valve on the fresh water flush module 180 so the intake 15 now coming from the bucket Step 5 Mix the cleaning chemical compound into the water in the bucket e Step 6 Ma
38. ly should be oriented with the salinity probe down Make sure to install the watertight boot over the salinity probe Product Water to Product Dump Line to the Brine Discharge on Clark Pump salinity Probe Note Orientation Plumbing From the inlet thru hull to flush module and from flush module to pump module inlet use sup plied clear 3 4 19mm spiral suction rated hose Use the braided 5 8 hose on the discharge of the pump module The outlet of the filter assembly on the main module to the Clark pump as sembly 15 under pressure Use the supplied braided clear vinyl hose rated to 150 PSI 11 bar Install the supplied accumulator and gauge between the filter and the Clark pump per photos From Clark pump brine discharge connector use supplied 5 8 15 9mm clear braided vinyl hose 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 300 Svstems Piping Specification From the Clark pump brine discharge connector use the supplied 5 8 15 9mm _ clear braided vinyl hose if am Cn OR E E m ee dll aal Install the supplied accumulator and gauge between the filter assembly and Clark pump SPECTRA The outlet of the feed module to the Spectra high pressure pump assembly is under pressure Use the supplied braid
39. nchlorinated fresh water before the system 1s run under pressure A simple test can be performed to see if biological growth has occurred Before running the sys tem remove the prefilters and examine their condition If the housings are full of smelly discol ored water the system was not properly stored Install clean prefilters 1f 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 s discolored and smells bad perform an SC 2 cleaning with an alternate source of unchlori nated water before running the system pressurized If the brine 15 fairly clean the system be purged run normally and checked for performance Clean the membranes only if performance 15 reduced Heating the water is preferable One way to do this is to find a camp stove and use a large stainless steel pot to heat the solution in The cleaning solution throughout the system will heat as it circulates in and out of the pot An alternative 1s to heat the one or two gallons of initial water to 120 on the main stove before mixing the cleaner and circulating it into the system Periodi cally stop and reheat the solution Perform the cleaning procedures while the ship is in acceptable sea water for purging and testing 34 Note Procedures are the same for the SC 2 and SC 3 cleaners Warning The pressure relief va
40. ng 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 seal on an O ring and should be seated all the way in 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 38 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 a tube assembly after it is installed Refer to figure 1 If a fiting 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 15 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 tig
41. ning the system if the vessel 15 in contaminated water such as in a harbor or ca nal The system should be fully run tested before leaving port It 1s preferable to sacrifice a filter by running the system in turbid water rather than waiting to get offshore to discover a problem or deficiency in the installation 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 1 First Check That e Thru hull valve is open e Power is on If you have an AC system both the AC power and the DC control voltage to the unit needs to be on e Domestic fresh water system must be on 2 Open pressure relief valve 1 2 turn 3 Power up the system e Alarm will sound e Push the Alarm Display button to silence alarm 22 COM SPECTRA 4 Press Auto Run Button oe 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 no bubbles anywhere in the intake hoses and the feed pump should sound smooth after priming If the feed pump continues to sound rough find the reason before con tinuing Inspect the system for leaks PURGING STORAGE SOLUTION 19 3 Note If you must stop the purge sequence for any reason the control will default back t
42. nto the bucket Turn the service valve on the fresh water flush module 1807 so the intake 15 now coming from the bucket e Step3 Start the pump with the manual switch and flush the system with almost all of the product water leave about 2 cups or 1 2 Liter Step 4 Remove the quick disconnect fitting from the brine discharge outlet of the Clark pump and replace with a quick disconnect from your service kit fitted to a hose and lead the hose to a 5 gallon bucket Step 5 Pour one gallon 4L of Propylene Glycol into the bucket e Step 6 Make sure the pressure relief valve on the Clark pump is Open unpressurized Step 7 Use the on manual switch on the control box to turn on the feed pump Circulate the chemical in the system for approximately 10 15 minutes Turn off the switch when finished Clean Up e 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 1f you choose to pump the bucket dry by using the feed pump switch Stop when the bucket is empty e Turn the service valve 180 back to its original position and remove the service hose Alternative procedure If it 1s not possible to run the system you may use the fresh water flush system to get the required de chlorinated fresh water First shut the intake thru hull Confirm that the domestic fresh water system 1s on Flush the sys tem once Remove the brine dischar
43. o the beginning of the purging mode to protect your system If you wish you can by pass the purge sequence and initiate a normal start Pressing both Auto Run and Stop simultaneously anytime during the purge sequence will bypass the purge se quence and enable a normal start 5 After the purge sequence The control will alarm with the message Close pressure relief valve Close the valve and proceed by pressing Auto Run 6 The system 15 now running under pressure and making water The display will read purging product water This mode dumps the product water overboard for ten minutes in case there 15 any residual chemicals in the membrane Carefully inspect for leaks over the entire system Shut down the system and repair any leaks you find 7 The system 15 now in the operational mode You may start and run you system as you de sire You will not have to go through the purging mode unless you de power the system If you do you can bypass the purging mode by pushing Stop and Auto run buttons at the same time It 1s 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 but ton to effect a fresh water flush cycle 8 Check that the system 1s operating within its normal parameters Compare with the chart on the next page Product Flow Will produce 12 5 14 GPH 48 55LPH 3 _ _ EJ LLI jla
44. odule Mount vertically in a location with 2 below the filter bowls Locate where water spillage during filter change will not be a problem Plumb the water in on the left and water out on the right If you have an MPC control plug the color coded cables into the respective sensors There are two accumulator assemblies one 1s located in the feed pump module to facilitate the fresh water flushing process and the other is located between the feed pump module and the Clark pump pressure vessel unit Plumb the second as shown with the analog pressure gauge in one port The pressure 15 preset at the factory so adjust ment 15 necessary The MPC 3000 controller is the brain of your wa termaker system it is programmed to control and monitor your entire watermaker system No changes to the wiring should be necessary unless you wish to install additional options or lengthen any of the cables to suit your installation needs If this 1s the case please refer to the respective page in this manual for additional information on where to con nect additional devices as well as current and voltage limitations of the board ALWAYS mount this unit away from any possible water spray drips hose connections etc Keep the control box cover on at all times SPECTR WATER ACHT SPECTRA i WATERHEGBHIHES Remote Control Panel The remote control panel can be mounted anvwhere that s dry and convenient Cut a
45. of the storage chemicals out of the system Hook up your service hoses per the service diagram and photos Route them into a 5 gallon 20 Liter bucket Disconnect the product tube from the diversion valve and using another short piece of tube route the product water feed into the test bucket Turn the valve on the fresh water flush module from to Service Press auto flush one or two more times to get enough water into the bucket to properly mix your salt water Mix the salt until it goes into solution If you are using a hydrometer mix the water to be 34 000 PPM Close the pressure relief valve and start the system using the Auto Run But ton Run and test the system for as long as possible During the run test carefully inspect for leaks Check all of the system parameters to make sure the system 15 operating correctly Do not allow the water in the bucket to get above 120F 500 Store the system per the Storage instructions Outlet Service Port 1 77 Service Port Z lt 22 O 5 N SL NC iz WSS Sa J NS if H SS N INN _ 5 NY m
46. revent damage If cleaning and re using filter elements clean when the first segment appears on the filter condition bar graph on the LCD display To service the filters shut off the thru hull open the housings discard the old filters Clean out the housing bowls reassemble the housings with new 20 and 5 micron filter elements The 5 micron filter goes downstream from the 20 micron 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 O rings with silicone grease Oil Water Separator Optional To install oil water Removal capability remove the supplied 20 micron filter element in the duplex filter set and replace with the 20 micron oil water separator cartridge Replace this when the MPC alerts you with a Service Prefilter alarm The Charcoal Fresh Water Flush Filter Replace the charcoal filter element at least every 6 months 33 The Membranes The membranes need to be cleaned only when they have lost up to 15 of their capacity due to fouling or the product quality degrades The leading cause of fouling 1s from biologi cal growth that occurs when the system 15 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 bar graphs for
47. rminal block cover after making your connections Wire lengths are for a pair of wires from the source to the terminal block location Catalina 300 Systems 12V Fuse or circuit breaker 25A Use 10 Gauge wire 6MM to 10 Feet 3M Use 8 Gauge wire 10MM to 15 Feet 4 5M Use 6 Gauge wire 16MM to 20 Feet 6 1 M Use 4 Gauge wire 25MM to 35 Feet 10 6M For 24V systems you double the length of the pair of wires Use a 15A fuse or circuit breaker MPC Control and Wiring Harness Manual Control Switch Control Box Power Cable Filter Sensor Harness Pump Power harness With vacuum switch leads MPC Control Harness Fresh Water Flush harness Stroke Sensor Diversion Valve Wire _ a Salinitv Probe Cable Clark Pump Harness Route the pump feed terminal block near vour feed pump location Mount the terminal block and connect vour feed pump to the block Install the terminal block cover Connect the two push on connectors to the vacuum switch Route the control cable through the boat to the MPC displav location Be MPC 3000 REMOTE PANEL BACK SIDE careful not to damage the connector Plug this into the back of the control ALARM The displays must be mounted in a BUZZER protected location out of direct sunlight and away from spray or drip ping water a ea Commands to the system can be en POSITIVE NEGATIVE tered at panel Ll L CONNECT TO PC BOARD
48. s O rings tools and membrane cleaning chemicals One replacement strainer screen O ring for strainer screen O rings for filter housing Spectra Watermakers parts list Part Number SC I STORAGE CHEMICAL FT CHE SCI SC 2 CLEANER FT CHE SC2 SC 3 CLEANER FT CHE SC3 BASIC CRUISE KIT C KIT BCK C 5 MIC FILTER FT FTC 5 20 MIC FILTER FT FTC 20 50 MIC FILTER FT FTC 50 CHARCOAL FILTER FT FTC CC 6 STRAINER SCREEN FT STN 6S OIL WATER FILTER FT FTC OW FEED PUMP HEAD Contact Factorv with Model and Voltage 6 STRAINER O RING SO STN 6SS FILTER HOUSING O RING SO FHS 10H OFF SHORE KIT KIT OFFSH 20 MEMBRANE FT MB 20 40 MEMBRANE FT MB 40 Dal Membrane Pressure Vessel Relocation Use ONLX Davco Imperial Nvlo Seal 88 NSR 1 2 tubing for high pressure connections Pav attention to the direction and flow path of the tubing before disassembly Make sure that you re install the tubing 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 fac tory These fitting seal with an O ring and require no Teflon tape or pipe dope Loosen the back ing 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 15 better than a 90 degree fitti
49. t grab ring tabs Be careful not to cross thread the nut Step 4 Hand tighten the nut DO NOT OVER TIGHTEN Step 3 Gently Electrical Installation First locate and identifv the components that to be integrated into your system Review the MPC control and harness assembly to identify each of the leads and their function Make sure that the harness will reach each component of the Spectra watermaker system before it 1s installed It may be easier to relocate a component rather than extending the harness Locate the MPC control central to the system components to keep the wire runs short and direct The control harness assembly consists of the following Power feed in 4 1 2M Pump feed factory connected Pressure switch leads 6 1 8M Fresh water flush feed 15 4 5M MPC display cable 50 15 2M Stroke sensor Salinity probe and Diversion valve feed 15 4 5M Do not connect any power to the control until you have finished all connections and are ready to test the system The control 15 pre wired and requires only few connections to be made Pay particular atten tion to the main power wiring or system performance will be compromised Main Power feed should be connected to an uninterruptible power source and should be cir cuit protected with a fuse or circuit breaker Mount the main power terminal block in a dry location between the control and the power source to keep the wire run short as possible Install te
50. the MPC cable is long enough to reach from the display location to the main module Catalina 300 MPC shipping list Catalina Magnetic Drive Feed Pump Module High Pressure Clark Pump and Reverse Osmosis Membrane Module Fresh Water Flush Module e Duel filter assembly MPC 3000 control system with remote panel Catalina Installation Kit e service Hose Kit e 5 8 Hose 25 Catalina 300 shipping list e Catalina Feed Pump Module High Pressure Clark Pump and Reverse Osmosis Membrane Module Fresh Water Flush Module e Duel filter assembly e Analog Monitor Panel With Control Switches and control harness Catalina Installation Kit e service Hose Kit e 5 8 Hose 25 Installation Basics Thruhull Not Supplied Read the directions Avoid tight hose bends and excessive runs Use heavy gauge wire e Install feed pump as low as possible Use a dedicated thruhull with scoop type strainer y Flow Thru hulls It is mandatory that a dedicated 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 1s not acceptable and will void the warranty Sharing a thru hull can introduce unforeseen problems such as intermittent flow restriction
51. to the solenoid wires Heat the splice connectors for sealing Connection of Optional Accessories PRESSURE SENSOR 2 PRESSURE SENSOR 1 E PREFILTER OUTLET CLARK PUMP PREFILTER INLET 1 STROKE SENSOR CAUTION ENSURE THAT BARE SHIELD WIRES CAN NOT TOUCH COMPONENTS ON CIRCUIT BOARD Tank Switch 2 LCD CONTROL DISPLAY PANEL Tank Switch 1 CONNECT SHIELD TO THIS SCREW En 7 SENSORS inr SALINITY PROBE 11511212 oS Ae hhh ee ee EE E E SALINITY CALIBRATION ADJUSTMENT SCREW BATY E SAW 1 o 552 TET ABUZ GND PULV EWV GND 9 A GND OVLV PHP2 GND AUXI AUX2 GND STER OPTIONAL U V STERILIZER OPTIONAL EXTERNAL ALARM DC INPUT VOLTAGE FEED PUMP RELAY FRESH WATER FLUSH SOLENOID Soi OPTIONAL Z GUARD TO TEED SURE FRESH WATER FLUSH PUMP IF APPLICABLE DIVERSION VALVE 19 Connection of Optional Accessories Use of any external devices not approved by the factory may cause permanent damage to the controller and is not covered by the Spectra warranty Accessory outputs are limited to 2 amps maximum load Do not connect motors pumps etc to accessory outputs Optional Z Guard System Detailed instructions are included with the Z Guard kit Con nect to the Aux1 and GND terminals of the MPC board Ultraviolet Sterilizer Detailed instructions are included with the sterilizer kit The UV steri
52. ut off the system from any mode If the sys tem was started by the Auto Run button the system will flush and then re flush every 5 days If the system was started by the Start Stop button it will do a 1 time flush The display will read TANK S FULL Once one of the tank float switches opens the alarm and TANK S FULL display will cease on its own Note that if TANK S FULL is displayed the system cannot be restarted 26 Automatic Fresh Water Flush Cvcle Warning Proper understanding of the Spectra flush system and the vessel s fresh water system configuration 15 mandatory for extended automatic flush cycles The flush cycle must not be allowed to drain all the fresh water from the vessel or damage to the vessel s systems may occur e 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 300 requires 3 gallons 13 liters e Make sure that the pressure water supply is on and will stay on during the flush mode If this 1s not possible contact your certified dealer e 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 1f the valve 1s open The power for the system must remain on during the auto flush mode Turning off the power will disable the auto flush function and damage may occur Pressing the Auto
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