Spectra Watermakers NEWPORT 400 Mk II Operating instructions

1
NEWPORT 400 Mk II
INSTALLATION & OWNER’S
MANUAL
Part 1……....Installation, Operation, Maintenance
Part 2………………….. Programming and Controls
Spectra Watermakers, Inc.
20 Mariposa Road, San Rafael, CA 94901
Phone [phone] Fax [phone]
www.spectrawatermakers.com
Feb 2012 mpc5000

2

3
Newport 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 forward facing
scoop-type thru -hull fitting installed.
Follow the wire gauge charts in the instructions! Using larger wire than specified is 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 5 gallons (12L) per flush..
The MPC 5000 control must be de -powered (DC power off) after the system is put in
storage.
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 opera-
tional. If the boat is in fresh or dirty water, see “Dry testing the system.” After testing
make sure that the flush cycle operates properly. The water going overboard at the end
of the flush should not taste salty (<1000ppm)
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 is not regis-
tered.
1.
2.
3.
4.
5.
6.
7.
8.
Thank you for your purchase of a Spectra Newport system. Properly installed it will provide
years of trouble free service. Please pay attention to the installation instructions and the 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.
Both the Newport MkII Feed pump module and the Clark Pump/Membrane module
must be installed in a well ventilated compartment where temperatures will not ex-
ceed 120F (48C). Many engine compartments exceed this temperature when under-
way. Warranty will be void if the installation does not meet this requirement.
9.

4
Getting Started..................................................................................................................................................5
Installation Basics.............................................................................................................................................6
Component Placement......................................................................................................................................7
Plumbing ........................................................................................................................................................10
Parker Tube Fitting Assembly Procedure......................................................................................................14
John Guest Super Speedfit.............................................................................................................................15
Wiring.............................................................................................................................................................16
MPC Tank Switch Wiring and operation.......................................................................................................21
Membrane Pressure Vessel Relocation ..........................................................................................................39
Z Brane Installation........................................................................................................................................49
Table of Contents
Part 1
Installation
Operation
Page Number
New Systems Start Up and Testing................................................................................................................ 23
Dry Testing..................................................................................................................................................... 26
Normal Start Up Using the Auto Run ............................................................................................................27
Automatic Fresh Water Flush Cycle ..............................................................................................................28
Manual Operation...........................................................................................................................................30
Long Term Storage Procedures......................................................................................................................31
Winterizing..................................................................................................................................................... 33
Maintenance ...................................................................................................................................................34
Membrane Cleaning .......................................................................................................................................35
Salinity Probe Calibration..............................................................................................................................37
Suggested Spares............................................................................................................................................38
Newport Troubleshooting Procedures............................................................................................................ 41
Bulletins..........................................................................................................................................................43
Wiring.............................................................................................................................................................53
Clark Pump.....................................................................................................................................................54
Parts List.........................................................................................................................................................59
Service & Maintenance
Part 2 Controls
Section 2: Programming & Controls
Begins after pg 62

5
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 in understanding the function of each component.
Layout the system. Before starting the installation identify the location where each module
and component will be placed. Ensure that there is proper clearance around the components
for removal of filters and system service. Also, check to make sure you have adequate tubing
and hose before starting, so additional parts may be ordered if necessary. Check to see that
the MPC cable is long enough to reach from the display location to the feed pump module.
Newport MkII shipping list:
 Newport Feed Pump Module
 High Pressure Clark Pump and Reverse Osmosis Membrane Module
 MkII Fresh Water Flush Module
 MkII Installation Kit
 Boost Pump Module
 Newport Service Kit
 1/2” braided hose (10’)
 1/2” Black Nylon tube (10’)
 5/8” Hose (25’)
 3/4” Suction Hose (25’)
 3/4” Braided Hose (10’)
Getting Started

6
Installation Basics
 Read the directions!
 Avoid tight hose bends and excessive runs.
 Use heavy gauge wire.
 Install feed pump as low as possible.
 Use a dedicated thru -hull with scoop type strainer.
Thru-hulls
It is mandatory that a dedicated 3/4” to 1” forward facing scoop type intake thru -hull and
seacock be installed. Install the intake for the system close to the middle and as far below
the water line as possible. Thru-hulls in the bow area are susceptible to air intake in rough
conditions. Sharing a thru -hull with another system is not acceptable and will void the war-
ranty. Sharing a thru -hull can introduce unforeseen problems such as intermittent flow re-
striction, air bubbles, and contaminates. For racing boats and high speed power boats above
15 knots a retractable snorkel -type thru -hull fitting is preferred to be able to pick up water
away from the hull.
Do not install the intake close to or downstream of a head discharge. Install as far below the
waterline and as close to center line as possible to avoid contamination and air induction.
The brine discharge through -hull should be mounted above the waterline, in or just above the
boot stripe to minimize water lift.
Double clamp all hose connections below the waterline.
Pipe Fitting Instruction
Plastic to plastic fittings should have 3 to 4 wraps of Teflon tape and will thread almost all
the way in.
Avoid getting dirt or debris into the piping or hoses during assembly. A small bit of de-
bris can stop the system! Avoid getting tape over the end of fittings that might get into the
system. To ensure this does not happen, leave the very first thread uncoated.
Avoid restrictions or long runs on the entire inlet side of the plumbing from the thru hull to
the main feed pump module.
Prevent tight bends and excessive elbows. Any restrictions will hamper system performance.
Secure the piping away from moving objects such as engine belts and hatches. Prevent chafe
on the tubing as required. Test and inspect all piping and hose clamps after several hours of
operation.
Flow
Wiring
 Pay attention to wire size or system performance will be impaired.
 Perform wiring to UL, ABYC, CE or applicable standards.
Thru-hull
Not Supplied.

7
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.
The fresh water flush module may be located in any convenient location
near the Feed pump module. It should be mounted with the filter hous-
ing vertical and accessible for changing filters. Allow 2” below the fil-
ter housing for removal. Do not install over electrical equipment. The
unit contains a charcoal filter for the flush water, shut off valve, and
flush water pressure regulator.
Feed Pump Module
Fresh Water Flush Module
Mount the feed pump module on a horizontal or vertical sur-
face that can be up to 3’ (1.0M) above the waterline. It is
preferable to mount as low as possible. Locate in an area that
allows easy access to the filters, the left hand side, and where
water spills during filter changes will not be a problem. Keep
future maintenance in mind when choosing a location. The
feed pump has overheat protection and will not operate prop-
erly at ambient temperatures over 120F (48C).
Remove front cover to
access mounting holes
in the enclosure.
Boost Pump module
The boost pump module should be
mounted vertically with the service hose
connection at the top. The boost pump
MUST be installed below the water line to
ensure that it will prime.

8
The membrane maximum temperature specification is 120F. This module must be installed in
an area that maintains a temperature below 120F (50C). A cool location is preferable. It may
be placed as high in the boat as you desire. Make sure that the area around and under the pump
does not have any water sensitive equipment. Water will be spilled during any repairs or if a
leak occurs.
Be sure you will have access to the pressure relief valve on the Clark pump.
The Clark pump/membrane module comes complete with a mounting system. Be sure to use the
supplied washers on the rubber feet. Use it as a template for drilling the mount holes. You may
mount the Clark Pump in any position, even upside down.
The Clark pump and membrane assembly has been pre -assembled at the factory. If it is nec-
essary to disassemble this module and mount the pressure vessel remotely use guidelines in
back of the manual. Use only approved tubing for assembly.
Clark Pump/Membrane Module
Membrane Pressure Vessel Mounting
Note: If your machine is equipped with the optional Z -brane, see
the Z -brane Installation and Operation section of this manual for
instructions on installing the Z -brane anodes into the membrane
end plugs. This should be done before installing the Clark Pump/
Membrane Module.
Pressure Relief Valve

9
Plumbing
From the inlet thru hull to the boost pump module and from the boost pump module to pump
module inlet use supplied clear 3/4 (19mm) spiral suction rated hose.
The outlet of the filter assembly on the main module to the Clark pump assembly is under pres-
sure. Use the supplied braided clear vinyl hose rated to 150 PSI (11 bar).
From Clark pump brine discharge connector use supplied 5/8 (15.9mm) clear braided vinyl
hose.
On the feed pressure side use the supplied Parker 1/2 tube and fittings. Use two grab rings on
the 1/2 parker tubing. Refer to the parker assembly instructions.
The remote control panel can be mounted anywhere that
is dry and convenient. Cut a 4 -9/16” (116 mm) wide by
2-7/8” (68mm) high opening for the panel. Locate in an
area that is easily visible and easy to manipulate the but-
tons. Use only Spectra approved remote cable.
The cable is not standard LAN cable or phone cord.
Remote Control Panel
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.

10
From the inlet thru hull to the boost pump mod-
ule use the supplied clear 3/4 (19mm) spiral
suction rated hose.
From the Clark pump brine dis-
charge connector use the supplied
5/8 (15.9mm) clear braided vinyl
hose to the brine overboard fitting.
System Piping schematic
Mount the pressure gauge in the
low pressure inlet gauge tee.
Flush water from ship’s
pressure water system
25 psi (2bar) minimum
Use the 1/2 inch nylon
tubing between the
feed pump module
outlet and the Clark
Pump inlet
Use the 1/2inch braided hose
between the Flush module and
the Feed Pump Module
From the Boost Pump to the 20 micron filter
inlet us the 3/4 inch ID braided hose.

11
Note! When plumbing the Newport Pump Module route the feed water so
that the front cover may be opened without removing the hose or tubing.
Feed water inlet from boost
pump. Leave enough extra
length in this hose to allow the
front cover to be moved aside.
Flush water Inlet From Flush Module
Feed Water Inlet from Filters
Product Water Outlet to Tank
Feed Water Outlet to Clark Pump
Product Inlet from Membrane
Leave room on this
side for attaching
tubing and operat-
ing the manual
button on the diver-
sion valve.

12
Product Water tubing
Product water tubing is 1/4 “ (6.3mm) Parker tubing. See the Parker tube fitting assembly dia-
gram on pg 14. Product water goes from the membrane into the pump module manifold where
it passes through the flow meter, the salinity sensor and the diversion valve. If the salinity is
good the diversion valve energizes and the product goes to the tank from the manifold product
outlet. If the diversion valve is not energized the product goes back into the feed water.
Connect the product outlet on the membrane housing to the black Product Inlet fitting on the
pump module manifold using the supplied 1/4 black nylon tubing.
Route the blue product water tube from the blue product water outlet fitting on the feed pump
module manifold into the top of the tank. Install a tee in the water tank fill or tap a pipe thread
into an inspection port in the top of the tank. Do not feed the water into a manifold or bottom of
the tank. Make sure there is no restriction in this plumbing.
If the length of product water tubing supplied with the watermaker is insufficient, use a larger
size hose. Product water flow restriction will cause reduced and power consumption in-
creased if product flow is restricted.
Product tube from membrane
end cap to feed pump manifold
Blue Product tube to
Fresh Water Tank

13
Fresh Water Flush
Run a feed line from the domestic cold pressure water system to the 1/2 hose barb on the
fresh water flush assembly. This needs to be pressurized when the boat is unattended for
the fresh water flush system to function properly. The domestic fresh water pump must
be able to deliver 1.5 gallons per minute (6lpm) at 25 PSI.
Brine Discharge
Route the Brine discharge from the
quick disconnect fitting to a location
above the waterline using the
supplied 5/8” hose.
Quick Disconnect Fitting
Fresh water from
boat’s pressure
water system
To Flush water Inlet
on pump module
manifold

14
Install the Nut first then use the bevelled side of the Spacer to push the
Grab Ring onto the tube no more than 1/2". Slip the O-ring over the tube
to hold the Spacer in place. If the Grab Ring is pushed too far, trim back
the tube so about 1/4" of tube extends past the O-ring.
Use 2 grab rings for 1/2" tube
Single grab ring for 1/4" & 3/8" tube
1/2" tube should not bottom out in the fitting
to allow full compression of the O-ring
Hand tighten the nut. DO NOT OVER TIGHTEN!
DO NOT USE A WRENCH! The tube should not
come out if pulled by hand. If it does, tighten the
1/4", 3/8", 1/2" Parker Tube Fitting Assembly
Gently fit the tube into the body and loosely thread on the nut.
Be careful not to cross-thread the nut
grab ring tabs.
Step 4:
Step 3:
Step 1: Dissemble fitting components
O-ring
Step 2:
Body
Spacer
Tubing
1/2" max
Nut
Parker Tube Fitting Assembly Procedure

15
John Guest Super Speedfit

16
DC Wiring
Identify cables that are connected to the Newport Control System.
Newport Mk II Systems have a Power Inlet harness with a terminal block, a 2 conductor boost
pump cable, and a 50’ (15M) cable for the MPC -5000 display. A motor speed control sets the
run speed and also slows the motor to the flush and service speeds. Do not install it in hot or
poorly ventilated locations, and allow for access to the Motor Speed Control.
Power inlet harness with
terminal block
50’ (15M) cable with
connectors for the MPC-
5000 control display
Boost pump cable
Motor Speed Control
(Behind the Prefilters,
Inside the Chassis)
MPC-5000 controller
(Inside Cover)
Manual Control Switch

17
Wiring (continued)
Mount the main power terminal block in a junction box or on a bulkhead adjacent to the feed
pump module. Make sure that this is a dry location well above bilge level and not subject to wa-
ter spray.
Route the control cable through the boat to the MPC display location. Be careful not to damage
the connector or get it wet. Plug this into the back of the control.
Connect the red and black Boost Pump wires to the corresponding red and black conductors in
the Boost Pump cable (red to red, black to black) using the supplied butt connectors, and heat
the connectors to waterproof them.
Check the wire size chart to select the proper size power feed to the main power harness. DC
power feeds should be uninterruptible to insure proper operation of the auto store feature.
Avoid house breaker panels that could be easily tripped.
Component Sizing:
 12V Use a 30Amp breaker and size the wiring for 25 Amperes.
 24V use a 15 Amp breaker and size the wire for 13 Amperes.
 Provide circuit protection at the source! Inadequate wiring will cause a loss of
system performance. DC power should be uninterruptible.
Note: If the specified circuit breaker sizes are unavailable use the next higher rating
but do not exceed the specification by more then 10%. All wiring to be done to
applicable ABYC, Marine UL or CE standards.

18
Newport Mk II DC System Wiring
Wire Length FT. Meters AWG. SQ MM
10 3 10 6
15 4.5 8 10
20 6.1 6 16
25 7.6 4 25
30 9.4 4 25
35 10.6 4 25
40 12 2 35
45 14 2 35
50 15 2 35
MkII 24V Meters AWG. SQ MM
10 3 12 4
15 4.5 10 6
20 6.1 8 10
25 7.6 8 10
30 9.4 8 10
35 10.6 6 16
40 12 6 16
45 14 6 16
50 15 4 25
Mk II 12V
Wire length is measured from source circuit breaker or fuse to control termi-
nal block and back to the source again.
WIRE SIZE CHART

19
MPC Remote Control Display Panels
The displays must be mounted in a protected location, out of direct sunlight, and away from
spray or dripping water. Commands to the system can be entered at any panel.
The display panels connect with the supplied 50 foot modular -type cable to the MPC board
sockets marked “DISPLAYS.” Do not substitute a different type of cable! Contact the
factory if you need longer or additional cables.
There are currently two types of display options available: Liquid Crystal Diode (LCD)
display, which is dark lettering on a backlit background, or Vacuum Florescent Display
(VFD), which are bright characters on a dark background. The VFD display brightness
can be adjusted using the Programming Function detailed in Part 2 of this manual.

20
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 lim-
ited to 2 amps maximum load! Do not connect motors, pumps, etc to accessory outputs.
Ultraviolet Sterilizer: Detailed instructions are included with the sterilizer kit. The UV
sterilizer 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 bal-
last BLACK wire connects to the “GND” terminal. If the wires must be extended, use mini-
mum 16AWG wire.
External Buzzer(s): In addition to the external buzzer(s) installed at each remote control
display panel, a buzzer unit may be installed at the control box. The buzzer RED wire con-
nects to the “BUZZ” terminal on the MPC board, and the buzzer BLACK wire connects to
“GND.”
Optional Z-brane System: Detailed instructions are included in the Z -Brane section.
Connect to an uninterruptible 12 of 24Volt DC power source.
Float Switches: Your MPC 5000 can be wired to operate with optional tank float switches
for truly automated operation. See the instructions and wiring schematics on the next page
for additional details. Order part number EL -SWT-SMLV and EL -SWT-LV for tank low
and tank full switches.