Spectra Watermakers CABO 10,000 User manual

Spectra Watermakers
Katadyn Desalination LLC.
2220 S. McDowell Blvd. Petaluma, CA 94954
Phone: [phone] Fax: [phone]
[e-mail]
www.spectrawatermakers.com
Updated March 2019
CABO 10,000
With SP-20 Pearson Pump Technology
Installation and Operating Manual

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Table of Contents
Getting Started 5
Introduction 6
Installation and Setup 8
Plumbing and Controls 7
Plumbing Schematic 10
PageInstallation Instructions
Care and Maintenance
Maintenance 14
Long Term Storage 15
Winterizing 16
Membranes 17
Clean-in-Place Procedures 18
Troubleshooting 19
Operation
Initial Start-up 11
Normal Operation 13
Monitoring the System 17
Wiring Diagram 21
Specifications 24
Pump Breakdown 25
Reference

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5
Thank you for trusting Spectra Watermakers for your water purification needs. The
Spectra Cabo-10,000 comes equipped with the revolutionary Spectra Pearson Pump,
a unique high pressure pump with integrated energy recovery that allows users to
purify up to 420 gallons of seawater per hour on as little as 3 Kilowatts. If properly
installed and cared for, your system will provide you with years of high quality, potable,
fresh water.
Please take a moment to review this manual before
operating the machine and if you have any questions
Contact: [e-mail]
Parts List:
Any shipping damage must be reported to the carrier within 24 hours of receipt,
so please inspect the contents of your shipment to ensure that all parts have
arrived undamaged. It is the responsibility of the receiver to report any missing
or damaged parts to Spectra within one week of taking delivery. Spectra is not
responsible for claims made outside this one week window .
Cabo 10,000 Watermaker
5 Micron Pre-filter Housing Assembly
Power cable
Installation manual
Operators Log
Getting Started

6
The Spectra Cabo-10,000 watermaker is designed for use in seagoing vessels or
platforms. Feed water must be supplied to the system a minimum of 20 gpm (76lpm)
at ≈20psi (1.4 Bar) pressure. The machine separates the feed water into two
streams; product and brine. The brine stream contains the dissolved solids removed
from the product water. Brine flow may be as high as 13 gpm (50L/min) and should be
discharged above the waterline. The system requires a small amount of back pressure
on the brine stream so plumb the discharge accordingly. Long runs in solid tubing will
require a vacuum break so as to not create any suction at the brine discharge.
Cabo 10,000 frame is constructed of powder coated 304 stainless steel and must be
positively fixed in place. includes the Spectra Pearson Pump, Motor and Belt drive
system coupled to three 8” x 40” seawater membranes. All high pressure connections
between the membranes and the pump come pre-assembled and tested. The high
pressure hoses use 1” JIC 37 deg. flare fittings.
20” Pre-filter Housings are two 5 micron filter
housings plumbed in parallel. The filter housing
lids have a spring loaded “purge” button to
released air from the filters. Do not install the
filters above any electrical devices as some water
will be spilled when changing the filters or purging
air.
Note that filter housings should always be
tightened hand tight, do not use the wrench. If the
housing leaks when hand tightened then the o-
ring needs to be cleaned and greased (silicone
grease only). A small amount of silicone grease
on the threads will also help the housing to seal by
hand tightening.
Boost Pump assembly is to be
installed below the water line in
seagoing vessels. The pump will fail if
there is any suction on the inlet so be
sure the pump is completely flooded at
all times. Land based systems will be
supplied with Jet pump (that have a
suction head limit of 10 ft.) or a well
pump based on the specific customer
requirements.
Introduction to your System

7
The basic system layout and controls are shown in the picture below
Control Box The molded FRP watertight box contains the speed control and the
safety control circuits. This module should be kept away from any water source or
where it could get sprayed or wet. Do not operate the machine with the control box
open. Should the need arise to open the electrical box after installation, use caution as
there is live AC in the box.
Note; For smooth and safe operation always open the pressure relief valve prior
to starting or stopping the watermaker. The pressure relief valve is always open
when there are chemicals in the system, failure to do so will damage the
membranes.
Front View Pressure Relief
Valve
1” Feed port/valve
Feed and Membrane
pressure gauges
1” Brine port/valve
Feed & Product flow gauges
3/4” Pressurized Fresh water in
3/4” Product water
Introduction to your System, cont….

8
Installation and Setup
Mounting and Service access: Your Cabo system is designed to be mounted on a
level surface and properly fixed in place. There are cleats supplied with the system for
mounting or holes can be drilled through the frame to bolt it into place.
Be sure to allow for service access to the unit, we recommend:
A minimum of 40” (1m) to the right of the unit so membranes can be changed.
A minimum of 24” (60cm) on the front and above the unit.
Cables and Hoses: Route all hoses and power cables in the most direct route
possible and do not allow hoses to kink or make excessive bends. Hoses should be
supported to take any load off the fittings to reduce leaks caused by vibration. Protect
all cables and hoses against chafing and size all wiring according to industry
standards and local regulations. There is a 10 ft. length of SOJ power cord included
(but not connected) and a strain relief built into box.
CAUTION: Undersized or improperly terminated cabling can result in serious
injury or death. Always follow best industry practices when sizing, terminating,
and routing cables and hoses.
Feed Water Pump: The Supplied Jet pump should
be installed per the manufacturers recommendations.
It is pre-wired and has a plug connector in the
bottom of the feed pump control box.
An AcTech speed control for the feed pump is located in
the box on the left side of the unit. There is a three
position switch on the right side of the box that is; Off , full
speed or variable speed. The black knob above the
switch will adjust the pump speed when the switch is in
the variable speed position. Full speed in intended for
back-flushing the media filters.

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INSTALLATION - Control System
Manual systems have simple
controls, momentary buttons for
priming the filters, start and stop.
The Prime button is a
momentary switch for the feed
pump (run variable speed
setting).
The Start button does just that.
You need to hold the button
down until the Pearson Pump
comes up to full speed.
The Stop button will stop the
system.
The service switch will run the Pearson Pump only (no feed pump) on service speed
(about 1/2 speed or 10 gpm) for fresh water flushing, cleaning or pickling.
After the system is purged, use the brine discharge
valve to restrict the flow so the Brine Discharge
Gauge reads 20 psig (absolute pressure gauge).
There must be a vacuum break on the brine
discharge line and 3 to 5 psi of back pressure on the
brine discharge to allow for smooth pump operation.
The valves in the Pearson Pump are opened and
closed by small pressure differences and this back
pressure aids the pump function. A feed pressure
adjust may be necessary after the brine discharge
pressure is set.

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Simplified Plumbing Layout
Feed Water
Inlet High Pressure to
Membranes
High Pressure
Return
Membrane Array
Boost
Pump
Optional
Media
filter
Feed
Water
Flow
Gauge
Filter
Array Flush
Valve
Pearson Energy
Recovery Pump
Pressurized Fresh
water from tank
Fresh water tank
Product water
to tank
Charcoal
filter
Fresh
Water
Pump

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New System Startup and Testing (Purging storage chemicals)
Use this procedure when starting a new system for the first time, when the last known
state of the system is unknown, or whenever the system contains Preservative or
cleaning chemicals.
Warning! Damage will occur if the purge sequence is bypassed and
the membrane is pressurized with storage chemical in it.
Note: Remove the tape over the Crankcase vent hole and check the oil level
before operating the watermaker. Check the dip-stick to confirm the oil level is correct in
the crankcase. Spectra recommends 76 Super Synthetic Blend SAE 5W-30 (ILSAC GF-5).
Caution; Never operate the system with the belt guard removed or the control
boxes open as serious injury could occur.
1. First Check That:
Feed water is available at the Feed
Water Inlet (see page 7). Confirm
both service valves are in the run
position as seen in the picture at
right.
Brine discharge is connected and
there are no restrictions on the line.
The brine discharge will contain a
small amount of propylene glycol (potable
antifreeze) until the purge cycle is
completed .
Power is supplied to the control box
The crankcase oil level has been checked
Pressure Relief Valve is OPEN one full turn
2. Turn on main power switch (breaker) on control box.
Boost pump switch to variable speed
Adjust Feed Pump knob so there is 20 psi showing on the feed
pressure gauge
Purge filters of air
3. Start the watermaker using the Service Switch on the control box.
Bleed air from filters during startup. The unit will be running as the
service speed which is about 10 gpm of feed flow.
Check the brine discharge for water flow. There should be no bubbles
anywhere in the intake hoses and the Pearson Pump should run
smoothly after priming (some knocking during start-up is normal). If
the pump continues to sound rough, find the reason before continuing!
Inspect the system for leaks.

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New System Startup and Testing, cont...
4. Check again that air is purged from filters (buttons on top of filter housings).
5. Confirm there is water flowing from the brine discharge and Carefully inspect for
leaks over the entire system! Shut down the system and repair any leaks you
find.
6. Allow the system to complete a 30 to 60 minute purge cycle to insure all chemicals
are eliminated from system (longer is always better).
7. After the purge cycle is complete, stop the system. Re-start by pressing the run
button holding it down until the pump comes up to speed. Be sure the fed pump is
running and adjust the speed if necessary so there is 20 psi showing on the feed
pressure gauge.
8. Close the brine discharge valve slightly so the gauge shows 20 psi (absolute) of
back pressure. A small amount of back pressure is necessary to allow the pump to
operate at peak performance.
9. Close the pressure relief valve.
11.Allow the system to run for an hour or so while you check for leaks.
Note that knocking in the system indicated either incorrect feed pressure or
suction on the brine discharge. If the brine discharge gauge is reading less than
15 psig** or the feed pressure is less than 20 psi then an adjustment is required.
** This is an absolute pressure gauge that should be reading atmospheric
pressure of ≈ 15psig when the system is off.
Log Book
It is highly recommended you keep an accurate daily log (or at least weekly) of the
operating conditions. If any of the parameters change it may indicate that chemical
treatments or mechanical repairs are required. This is one of the best tools available
for troubleshooting any problems in the future.
An increase in membrane pressure may indicate membrane fouling.
A decrease in product water quality (higher ppm) may indicate membrane damage.
A decrease in product water production may indicate Pearson pump damage or
wear.

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Normal Operation
If the system is not running and you do not know how it was shut down it is best to
assume it needs to be purged. Running the system on feed water with the pressure
relief valve for 20-30 minutes will clear the system of anything that would harm the
membranes.
As a general rule always open the pressure relief valve prior to either starting or
stopping the system. When the system is stopped let the membrane pressure drop to
zero before restarting.
When in doubt open the pressure relief valve.
Over the lifespan of the system is will become important to understand the systems
past performance. Many troubleshooting questions start with “how has the system
been running in the past” so keeping a log of performance will be very helpful.
Log Book
It is highly recommended you keep an accurate daily log (or at least weekly) of the
operating conditions. If any of the parameters change it may indicate that chemical
treatments or mechanical repairs are required. This is one of the best tools available
for troubleshooting any problems in the future.
An increase in membrane pressure may indicate membrane fouling.
A decrease in product water quality (higher ppm) may indicate membrane damage.
A decrease in product water production may indicate Pearson pump damage or
wear.

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Maintenance
The 20 and 5 Micron Filters
A clogged filter will cause the controls to shut down the watermaker. Avoid letting the filters
get so dirty the unit shuts down automatically and check the Prefilter pressure drop frequently
during operation. Knowing the pressure drop across the filters is the best way to monitor filter
loading. If you only let the pressure drop get to 5 psi you can carefully rinse the filters, let them
dry and then reuse them. They will not last as long as when they are new but you can “clean”
them about 3 times.
After a filter change it may be necessary to expel the air from the feed line using the purge
buttons, located on top of the filter housings.
When the system is put into storage, remove, rinse, and re-install new dry filters to impede
corrosion and fouling. Check frequently during operation.
The filters must be properly maintained to protect the Spectra Pearson Pump. Use only
Spectra approved filters.
Use silicone grease on the o-ring to ensure a proper seal between the filter bowl and lid. Do
not use a petroleum based product, such as petroleum jelly or mineral oil, as it will
permanently damage the filter housing bowl.
The Crankcase
Change the crankcase oil every 5000 hours or if it begins to darken in color or become milky.
Milky oil indicates seal failure so replace seals if this happens. Use high quality synthetic
motor oil. SAE 5W-30 or equivalent is recommended in most climates.
General
Periodically inspect the entire system for leaks and chafe on the tubing and hoses. Repair
any leaks as soon as possible. Check for corrosion around the fittings. If any rust appears,
remove, clean, and reassemble the fitting. Rust is a sign of crevice corrosion inside the fitting
and must be dealt with promptly.
Some salt crystal formation around the Spectra Pearson Pump mating surfaces is normal.
Wash down any salt encrusted areas with a damp cloth. Keep the watermaker clean, dry, and
salt free.
The Spectra Pearson Pump should have the plunger seals replaced annually, every 2,500
hours of operation, or when leaks are present, whichever comes first.
Belt Tension
The belt alignment and tension have been pre-set at the factory prior to shipping. Check both
tension and alignment weekly for signs of wear or slipping. You should just be able to twist the
belt 90 degrees when it is properly tensioned.
Replace the belt immediately if it looks worn or damaged, or if it cannot be properly tensioned.

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Long Term Storage
If the machine will not be used for more than seven days it should be placed in Auto
store mode or treated with preservative. Spectra Watermakers SC-1 powdered
preservative may be used if there is no danger of freezing. Do not use other brands
of preservative, they will damage the equipment! If there is danger of freezing
Propylene Glycol potable water antifreeze should be used instead of Spectra
Watermakers SC-1. The Pressure Relief Knob on the Spectra Pearson Pump
must be open while preservatives or cleaning compounds are present!
If SC-1 chemical is to be used: You will need 1 bag of SC-1, 5 gal. (38L) of chlorine
free water, and the system must have already been thoroughly flushed with fresh
water. The feed water supply must be shut off.
Mix the bag of SC-1 storage chemical into a bucket of the unchlorinated water, stir until
well dissolved. Warm water will allow the SC-1 to dissolve more quickly.
Attach the service hoses, place the open ends of the
hoses in the bucket and turn both the service valves to
SERVICE (valves in picture shown in run position)
Use the Service switch on the control panel to run the
pump and the preservative will begin to circulate.
Circulate the solution for about 20 minutes.
Turn the Service switch to off, remove the brine hose
from the bucket and put it to a drain.
Turn the Service switch to on again and pump the
remaining solution out of the bucket to the drain. Turn
off the Service switch before the bucket is drained.
Turn both service valves to off (vertical) so no water
will circulate through the system. These valves will
need to be turned to the Run position so the system is
ready go through the Purge Cycle (see New System
Start up) when it is time to use the watermaker again.
Leave the pressure relief knob open. The watermaker can now be stored for up to
six months. If the machine has not been used for six months the preservative
procedure should be repeated.

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Storing with Antifreeze
(Winterizing)
You will need approximately 8 US gal (30L) of Propylene Glycol potable water
antifreeze*. The system must have been fresh water flushed thoroughly.
Open the Pressure Relief Knob on the Pearson Pump.
Attach the service hoses, place the open ends of
the hoses in the bucket and turn both the service
valves to SERVICE (valves in picture shown in run
position)
Use the Service toggle switch on the front of the
control panel to run the pump.
Circulate the antifreeze for 20 minutes.
Turn both the service valves to the off position
(vertical)
Leave the pressure relief knob open.
The prefilter housings should be drained and new
filters installed.
*USE THE MOST CONCENTRATED FORMULA
PROPYLENE GLYCOL AVAILABLE, –100
FORMULA OR HIGHER CONCENTRATION.
We recommend a sign be placed on the frame
above the feedwater inlet and the brine discharge connections so the next
person knows what is required to restart the watermaker.

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Membrane Cleaning
For normal cleaning, the SC-3 Acid Cleaning Compound is used first, then the SC-2
Alkaline Cleaning Compound, if necessary. If known bio-fouling is present, the SC-2
may be used first. Using warm water if possible, up to 120°F (50ºC) is recommended
as it greatly enhances the ability of the cleaners to do their jobs.
Note: Procedures are the same for the SC-2 and SC-3 cleaners
Warning! The pressure relief valve on the Spectra Pearson Pump must be open
for this procedure or membrane damage may result.
Spectra Cleaning Compounds (SC-2 or SC-3) must be mixed with unchlorinated fresh
water at a ratio of two containers (16oz. Total) of compound to 10 gallons (45L) of
water to have the proper solution. An LB 10,000 system has about 8 gallons of water
inside it (after being flushed with fresh water so with about two gallons of water in a 5
gallon bucket you will use two containers (16oz) either of compound.
SC-2 and SC-3 are never mixed together. Do not use them for storage pickling solution.
 There are two types of cleaners: acid and alkaline. The acid cleaner (SC-3) will
remove mineral scaling. The alkaline cleaner (SC-2) is used to remove biological by
-products, oil, and dirt particles that get past the pre-filters. The acid cleaner should
be used first. If the membrane fails to respond to both cleanings, this is an
indication of another problem with the system, or that it is time to replace the
membrane. Contact Spectra Watermakers before removing a membrane.
 Membranes need to be cleaned only when feed pressures have risen 10% or
production has dropped 10% due to fouling, or the product quality degrades.
Causes of fouling are: Biological growth that occurs when the system is left unused
without flushing or pickling, and mineral scaling if the feed water contains
carbonates, sulfates, silicates or other sparingly soluble salts. Colloidal particles
can also clog the membrane. Monitor the product salinity and feed pressure for
higher than normal readings for the conditions. Look for all other causes before
cleaning the membrane, i.e. feed water temperature and salinity, pump speed,
hose restrictions, membrane life can be shortened by unnecessary cleaning.
The Membranes
MEMBRANE MAINTENANCE

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Cleaning Procedure:
You will need 10 gal (38 L) of chlorine free water and the system must have already
been thoroughly flushed. Mix the bag of Spectra Watermakers cleaning chemical into
the water and stir until well dissolved. Some chemical may remain out of solution in
the bucket, this is normal.
Open the Pressure Relief Valve on the Pearson Pump.
You will need 1 bag of the cleaning chemical to be used, 10 gal. (38L) of chlorine free
water, and the system must have already been thoroughly flushed. The feed water
supply must be shut off.
Mix the bag of Spectra Watermakers cleaning chemical into a bucket of the
unchlorinated water, stir until well dissolved.
Attach the service hoses, place the open ends of
the hoses in the bucket and turn both the service
valves to SERVICE (valves in picture shown in run
position)
Use the Service toggle switch on the front of the
control panel to run the pump.
Circulate cleaning chemicals for up to 6 hours
depending on the level of fouling present (contact
Tech Support for advise on cleaning).
Turn both the service valves to the off position
(vertical)
Leave the pressure relief knob open.
The prefilter housings should be drained and new
filters installed.
Leave the pressure relief knob open. The watermaker can now be stored for up to
six months. If the machine has not been used for six months the preservative
procedure should be repeated.
MAINTENANCE, cont….

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TROUBLESHOOTING
Symptom Cause Resolution
Pump Knocks Loudly Incorrect Boost Pressure
Inadequate Feed Water
Supply
Suction on brine discharge
Increase or Decrease boost
pressure as appropriate
Check Pre-filtration for
blockages
Check Supply Pump for
proper operation and
adequate flow through pre-
filtration system
A vacuum break (air gap) or
a small restriction on the
brine discharge (2-5 psi)
can reduce knocking
Belt Skipping Teeth on
Gear-End
Belt Too Loose
Motor Turning Wrong
Direction
Tighten Belt
Run motor in reverse
direction by swapping T1
and T2 on VFD Output
terminals (AC Systems
Only)
Permeate Flow Decreasing Permeate Flow Meter Not
Calibrated
Worn High Pressure Seals
Worn Damper Piston Seal
Worn Piston Seals
High Membrane Pressure
Calibrate permeate flow
meter
Replace seals
Replace Damper Piston and
Seal
Replace Pistons and Seals
Check membrane pressure
against nominal system
parameters.
Recovery Ratio Increasing Worn Pistons
Permeate Flow Meter Not
Calibrated
Replace Pistons and seals
Calibrate permeate flow
meter

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TROUBLESHOOTING
Symptom
High Power Consumption
(Decreased Energy Efficiency)
Pump will not run from
Connect control inputs
Alarms - Check Pre-Filter
Alarms - Check Pre-Filter
Cannot properly adjust Clean
Pressure setting
Pump Won’t Run
Cause
High Membrane
Pressure
Low Boost Pressure
Motor Problems
Water in crankcase
No Power to Control
Box
Speed control fault
Bad Switch/Broken
Wire
Clogged Pre-Filters
“Clean Pressure” on
Connect setting
incorrect
Insufficient Boost
Pressure
Motor Problem
VFD Problem
Resolution
Check membrane pressure
against nominal system
parameters
Check Supply Pump for proper
operation and adequate flow
through pre-filtration system
Test motor, replace if necessary
Change oil
Check All Breakers and
Confirm Voltage at Connect
board
Speed control display should
change when running.
Replace Switch and Re-terminate
wires
Replace Filters
Adjust “Clean Pressure”
setting on Connect (see
Programming from Display)
Adjust Boost Pump Pressure and
address any pressure drop in
intake line
Check AcTech VFD for error
codes, display should change if
manual run or service switch is
used
Check all wiring
Check VFD for error codes