Spectra Watermakers Farallon 1800 User manual

Spectra Watermakers
Katadyn Desalination LLC.
2220 S. McDowell Blvd. Petaluma, CA 94954
Phone: [phone] Fax: [phone]
[e-mail]
www.spectrawatermakers.com
MPC 5000 from S/N 3840
Farallon 1800/2800
Installation and Operating Manual

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Table of Contents
Part 1
Installation
Operation
Getting Started..........................................................................................................................................5
Installation Basics .....................................................................................................................................6
Component Placement...............................................................................................................................7
Plumbing ................................................................................................................................................10
John Guest Fitting Assembly Procedure...................................................................................................15
Wiring ....................................................................................................................................................16
MPC Tank Switch Wiring and operation ................................................................................................. 20
Membrane Pressure Vessel Relocation ....................................................................................................38
Page Number
New Systems Start Up and Testing ..........................................................................................................21
Dry Testing .............................................................................................................................................24
Normal Start Up Using the Auto Run.......................................................................................................25
Adjusting the Flush Cycle........................................................................................................................26
Automatic Store Cycle.............................................................................................................................27
Manual Operation....................................................................................................................................28
Maintenance............................................................................................................................................32
Bulletins..................................................................................................................................................46
Long Term Storage Procedures................................................................................................................29
Winterizing .............................................................................................................................................31
Oil Changes.............................................................................................................................................33
Membrane Cleaning ................................................................................................................................34
Salinity Probe Calibration........................................................................................................................36
Suggested Spares...................................................................................................................................37
Troubleshooting Procedures, Service Bulletins.........................................................................................41
Service & Maintenance
Part 2
Controls
Begin after pg 53

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Farallon 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
acceptable.
The system must have 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 15 gallons (76L) per flush..
The system must be de-powered after the system is put in storage “pickled” where a storage
chemical or antifreeze is run through the system.
If you are separating the high pressure pump and membrane assembly please review the
high pressure hose assembly instructions. Improper assembly will cause failure! The
Control Box can also be remotely mounted, see instructions later in this manual.
Run, test, then “sea trial” the complete system before assuming the system is
operational. If the boat is in fresh or dirty water, see “Dry testing the system.” After
running 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 fill out the warranty card. The warranty is void if it is not registered.
1.
2.
3.
4.
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6.
7.
8.
Thank you for your purchase of a new Spectra Farallon system. When properly installed and
maintained it will provide years of trouble free service. Please pay attention to the installation
instructions and the system 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 prevent 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.
The Spectra-Pearson Pump module must be installed in a well ventilated compartment
where temperatures will not exceed 120F (48C). Many engine compartments exceed this
temperature when underway. Warranty will be void if the installation does not meet this
requirement.
9.

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Unpack the system and inspect it to make sure that it has not been damaged in shipment.
Refer to the shipping list for your system to make sure you have received all of the
components listed. Do not discard any packaging until you have found and identified all of
the parts. The small installation parts are listed on the cellophane bags’ pick list.
We will not be held responsible for shortages that are not reported within thirty days of the
ship date. Shipping damage must be reported within 30 days of receiving goods.
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. Check to see that the MPC cable
is long enough to reach from the display location to the feed pump module.
Farallon shipping list:
Spectra-Pearson Pump Module with remote mountable Control Box
Boost Pump
Pre-filter Module
Fresh Water Flush Module
Inlet and Brine Discharge Service Modules
Install Kit
Service Kit
25’ 5/8” Braided Nylon Brine Discharge Hose
10’ 3/4” Spiral Wound Reinforced Suction Hose
25’ 3/4” Braided Nylon Intake Hose
25’ 1/2” Parker Product Tubing
10’ 3/8” Low Pressure Tubing
Getting Started

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Installation Basics
 Read the directions!
 Avoid tight hose bends and excessive runs.
 Use heavy gauge wire.
 Boost Pump must be installed below waterline.
 Install Spectra-Pearson Pump as low and as close to the boost
pump as possible.
 Use a dedicated thru-hull with scoop type strainer.
Thru-hulls
It is mandatory that a minimum 1” diameter, dedicated, forward facing, scoop-type intake
thru-hull and seacock be installed. Install the intake for the system as close to the middle
and as far below the water line as possible. Thru-hulls in the bow area are susceptible to air
intake in rough conditions. Sharing a thru-hull with another system is not acceptable and
will void the warranty. Sharing a thru-hull can introduce unforeseen problems such as
intermittent flow restriction, air bubbles, and contaminates. For racing boats and high speed
power boats above 15 knots, a retractable snorkel-type thru-hull fitting is preferred to be able
to pick up water away from the hull.
Do not install the intake close to or downstream of a head discharge. Install as far below the
waterline and as close to center line as possible to avoid contamination and air induction.
The brine discharge 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 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.
Thruhull
Not Included.

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Component Placement
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.
Boost Pump
The boost pump module should be mounted horizontally.
The boost pump, and the entire intake hose leading to it,
MUST be installed below the water line to ensure that it
will prime.
Service Inlet Module
The service inlet module is mounted between the sea strainer and
the boost pump. It can be mounted in any orientation. Be sure that
once installed you will have access to the yellow valve handle on
top and the garden hose fitting on the side
The remote control panel can be mounted anywhere
that’s dry and convenient. Cut a 4-9/16” (116 mm) wide
by 2-7/8” (73mm) high opening for the panel. Locate in
an area that is easily visible and easy to manipulate the
buttons. Use only Spectra approved remote cable.
The cable is not standard LAN cable or phone cord.
Remote Control Panel

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The Charcoal Filter Housing may be located in any convenient
location near the Spectra-Pearson Pump Module. It should be
mounted with the filter housing vertical and accessible for
changing filters. Allow 2” below the filter 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.
Spectra-Pearson Pump and
Control Module
Charcoal Filter Housing
Mount the Spectra-Pearson Pump and
Control Module on a horizontal
surface no more than 3’ (1.0M) above
the waterline. It is preferable to mount
it as low as possible. Locate in an area
that allows the lid to be easily lifted
and is accessible for service and oil
changes. Keep future maintenance in mind when choosing a location. The membranes
can be damaged at ambient temperatures over 120F (48C). The Control Box can be
remotely mounted if space is limited. Call the factory if an extended control cable is
Pre-filters
The Pre-filters are located between the boost pump and
the High Pressure Module. They house the 20 and 5
micron filters. They should be mounted vertically so
that water doesn’t pour out of the filter bowls during
filter changes. Allow 2” below the filter housings for
removal. Do not install over electrical equipment.
Brine Discharge Service Module
The brine discharge service module is mounted between the brine
discharge outlet on the Spectra-Pearson Pump Module plumbing
manifold and the brine discharge thru-hull fitting. It can be mounted
in any orientation. Be sure that once installed you will have access
to the yellow valve handle on top and the garden hose fitting on the
side.

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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. 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 clearance to open the lid of the enclosure, and leave room to remove all
side and top panels for easy servicing..
The Spectra-Pearson Pump Module comes complete with a mounting system. Be sure to
mount the Module horizontally and securely bolt the Spectra-Pearson Pump Module to a shelf
or level surface.
The high pressure pump and membrane assembly has been pre-assembled at the factory. If it
is necessary to disassemble this unit and mount the pressure vessels remotely use the
guidelines on pg 39 of the manual. Use only approved hoses for assembly.
Spectra-Pearson Pump Module
Membrane Pressure Vessel Mounting

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Raw Water Plumbing
From the inlet thru hull through to the boost pump module use supplied clear 3/4” (19mm)
spiral suction rated hose.
The outlet of the Boost Pump is under pressure, use the supplied 3/4” (19mm) braided clear
vinyl hose rated to 150 PSI (11 bar) from the outlet of the Boost Pump through to the high
pressure pump inlet on the manifold.
From the brine discharge on the plumbing manifold to the brine discharge thru-hull use
supplied 5/8” (19mm) 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.
Air Purge Button

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From the inlet thru-hull up to the boost pump
module use the supplied clear 3/4 (19mm)
spiral suction rated hose.
System Piping schematic
Flush water from ship’s
pressure water system
25 psi (2bar) minimum
Use the 3/8” nylon tubing
between the Flush module and
the High Pressure Pump
Module
From the Boost Pump through
the 20 micron filter inlet out to
the plumbing manifold use the
3/4 inch braided hose.
Brine Discharge—Use 5/8”
braided hose from the manifold
through the Brine Discharge
Service Valve and to the brine
discharge thru-hull
Fresh Water out to
tanks. Use supplied
1/2” black Parker
tubing.
20micron 5 micron
Inlet Service
Module
Brine Service
Module
Air Purge Button
Air Purge Button

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Note! When plumbing the Farallon High Pressure Module route the feed
water so that the top and side covers may be opened without removing the
hoses or tubing.
Leave room on the left side for attaching tubing and
accessing the pump, motor and diversion valve.
Feed Water Inlet—From boost
pump
Brine Discharge—To above
the waterline Thru-Hull
Product Water Outlet—To
Ship’s Tanks
Fresh Water Flush Inlet—In
from the Fresh Water Flush
Module

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Product Water tubing
Product water tubing is 1/2” (9.5mm) Parker tubing. See the Parker tube fitting assembly
diagram on pg 14. Product water goes from the membrane into the pump module manifold
where it passes through the flow meter, the salinity probe 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.
Route the product water tube from the product water outlet fitting on the High Pressure 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.
A product sampling tap can be installed along the tank fill hose between the manifold and the
tank connection. If a sampling tap or filling manifold is to be installed on the product water
line, then an “open-before-close” type 3 way valve should be used to ensure that the product
water line is never accidentally pressurized.
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 output and increased power
consumption and can potentially damage the membrane.
1/2” Parker Tubing—
Product to Fresh
Water Tank

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Fresh Water Flush
Run a feed line from the domestic cold water pressure system to the 1/2 hose barb on the
fresh water flush assembly. This needs to be pressurized even when the boat is unattended
for the fresh water flush system to function properly. The domestic fresh water pump
must be able to deliver 2 gallons per minute (7.5lpm) at 25 PSI (1.5Bar).
Fresh water from
boat’s pressure
water system
To Flush water Inlet
on pump module
manifold
Air Purge
Button
Brine Discharge
Route the Brine discharge from hose
barb fitting to a location above the
waterline using the supplied 5/8”
braided nylon hose.

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John Guest Super Speedfit Fittings

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Wiring
PROVIDE CIRCUIT PROTECTION AT THE SOURCE!! Inadequate wiring will cause a loss
of system performance and could be a fire and/or shock hazard.
 110V: Use a 15Amp breaker and 12 AWG wire for 10.5 Amperes.
 220V use a 10 Amp breaker and 12 AWG wire for 5.5 Amperes.
 Amperage ratings assume a Pf of 60%. Actual measurements may vary.
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.
Wire Sizing
Farallon 1800
Farallon 2800
 220V use a 15 Amp breaker and 12 AWG wire for 7 Amperes.
 Amperage ratings assume a Pf of 60%. Actual measurements may vary.

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WIRING
Make sure that the Control Box is mounted in cool dry place, well above bilge level and not
subject to water spray.
Connect the remote display cable to the open display jack on the side of the electrical box.
Route the remote display control cable through the boat to the MPC remote display location. Be
careful not to damage the connector or get it wet. Plug this into the back of the remote display.
Connect DC power to the Batt + and Batt - posts on the MPC board, pictured above. DC power
feeds should be sized for 10 Amp maximum supply and be uninterruptible to insure proper
operation of the auto store feature. Avoid house breaker panels that could be easily tripped.
Connect the DC power cables directly to the battery positive and negative posts on the MPC
board.
Route the boost pump power cable to the Control Box from the boost pump. Do not get the
cable wet, and be careful not to damage the plug or conductors during installation. The boost
pump power cable plug is located inside the Spectra-Pearson Pump Module on the wall near the
top of the motor. Be sure to plug the boost pump into the corresponding socket on the Control
Box.
Display Jacks
Batt + Batt -
Boost Pump Plug
Backup Battery

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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 75 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.
5 1/4”
(13.3cm)
3 3/4”
(9.5cm)

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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.
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
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
display 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.”
Float Switches: The Spectra Farallon can have optional tank float switches installed for
complete automated operation. See detailed instruction on pg 20 for operation and
installation guidelines.

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Tank Switch Installation and Operation:
There are two sets of terminals on the MPC-5000 PCB that can be used in four
different configurations to automatically start and stop the watermaker, or to automatically
stop the watermaker when the tank(s) are full without the auto start feature. These terminals
are on the green ten pin connector on the MPC board and are labeled “Float Switch 1” and
“Float Switch 2.” Float Switch 1 is the tank full switch and Float Switch 2 is the tank empty
switch.
While the system is capable of completely automatic operation (starting when the low level
tank switch opens) we do not recommend it as a control failure could fill the boat with water.
That said if you are interested in completely automatic operation please contact technical
support for instructions.
If the owner prefers to utilize the automatic shutoff feature only the tank full switch is used.
A jumper must be placed between the tank empty terminals (Float switch 2) in place of the
tank empty switch, because the watermaker will only shut down if both sets of terminals are
closed. To use this mode the watermaker must be started up with the Auto Fill mode. The
watermaker will fill the tank and automatically enter Auto Store mode.
It is possible to use the auto fill feature with 2 tanks. A double throw electrical switch must
be installed in a convenient location. If only the single tank full switch is installed in each
tank connect the wire from the ‘Float Switch 1’ terminal “1” to the common on the switch
and run separate wires from the switch to each tank switch. The second wires can both be
run to the Float Switch 1 terminal 2. If you are using two switches in each tank you will
need a double pole double throw switch.
See wiring schematics beginning on pg. 45 for detailed drawings.