Spectra Watermakers Newport 700 Operating instructions

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Spectra Watermakers, Inc.
20 Mariposa Road, San Rafael, CA 94901
Phone [phone] Fax [phone]
E-mail: [email protected]
www.spectrawatermakers.com
O9/22/05 Rotoflow

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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 scoop type
forward facing 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. Each flush will use about 5 gallons (20L) for 700 and 1000
systems.
The MPC 3000 control must be de-powered (DC power off) after the system is put in
storage (pickled, where a storage chemical or antifreeze is 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 opera-
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 both be present for a “walk through” of the
installation and initial operation of the watermaker.
Please fill out the warranty card. This will insure that the factory can contact you in
case it should be necessary.
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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.
The Watermaker is equipped with overheat shutdown. The Feed Pump module must
be installed in a location where ambient temperature will not exceed 120F (50C).

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Table of Contents
Installation
Operation
Getting Started.....................................................................................................................7
Newport Schematic .............................................................................................................8
Installation Basics ...............................................................................................................9
Component Placement.......................................................................................................10
Plumbing ...........................................................................................................................14
Parker Tube Fitting Assembly Procedure .........................................................................17
Wiring................................................................................................................................19
MPC Tank Switch Wiring and operation……………………………………………….. 27
Checking the Flush Cycle .................................................................................................32
Membrane Pressure Vessel Relocation.............................................................................47
Z Brane Installation...........................................................................................................59
Page Number
New Systems Start Up and Testing...................................................................................28
Dry Testing........................................................................................................................31
Normal Start Up Using the Auto Run...............................................................................33
Automatic Fresh Water Flush Cycle.................................................................................34
Manual Operation..............................................................................................................35
Maintenance......................................................................................................................40
Service & Maintenance
Long Term Storage Procedures.........................................................................................36
Winterizing........................................................................................................................39
Maintenance......................................................................................................................40
Membrane Cleaning..........................................................................................................41
Salinity Probe Calibration.................................................................................................43
Vane Pump Replacement ..................................................................................................44
Suggested Spares...............................................................................................................46
Newport Troubleshooting Procedures, Service Bulletins.................................................48
Parts breakdown for all Newport systems………………………………………………..62

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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 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. Insure 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 main module.
Getting Started
Newport shipping list:
•Newport Feed Pump Module
•High Pressure Clark Pump and Reverse Osmosis Membrane Module
•Newport Fresh Water Flush Module
•Newport Installation Kit (k)
•Newport Service Kit
•1/2” High Pressure Tube (10’)
•3/8” Low Pressure Tube (15’)
•5/8” Hose (25’)
•3/4” Suction Hose (25’)

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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 thruhull 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 condi-
tions. 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 de-
bris can stop the system! Avoid getting teflon 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 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 Supplied.

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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 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 Z– Brane
The optional Z-Brane Water treatment system is permanently in-
stalled in the membrane pressure vessels and continuously helps
prevent biogrowth and fouling of the membrane system.
Feed Pump/Main Module
Fresh Water Flush Module
Mount the feed pump/main module on a horizontal or vertical sur-
face that can be up to 4’ (1.2M) above the waterline. It is prefer-
able to mount as low as possible. Locate in an area that allows easy
access to filters and a location that will not be a problem when
water spills during filter change. Keep future maintenance in mind
when choosing a location. The Feed Pump module has overheat
shutdown protection. It must be installed in a dry location where
temperatures will not exceed 120degrees F (50C).
Remove front covers to
access mounting holes in
the enclosure.

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The MPC Control Box may be demounted for
relocation up to 4’ (1.2M) from the pump module.
A long screwdriver will be required to
access the fasteners
The MPC Control Box
Filters may be relocated for bet-
ter access or to prevent splashing
water on sensitive equipment.
You may need additional 1/2”
Parker high pressure tubing.

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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. Mount in any 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.
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 “Membrane Pres-
sure Vessel Relocation” in the back of this manual. Use only approved tubing for assembly.
Clark Pump/Membrane Module
Membrane Pressure Vessel Mounting

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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” (68mm) high opening for the panel. Locate it
in an area that is easily visible and easy to manipulate
the buttons. Use only Spectra approved remote cable.
Do not connect power to the alarm buzzer terminals
on the back!
The cable is not standard LAN cable or phone cord.
Remote Control Panel

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From the inlet thru hull to the flush module and
from the flush module to pump module inlet
use the supplied clear 3/4 (19mm) spiral suc-
tion rated hose.
From the Clark pump brine discharge quick connec-
tor to the overboard thru hull use the supplied 5/8
(15.9mm) clear braided vinyl hose.
700/1000 System Tubing Schematic
Note! 700/1000 systems use Spectra high pres-
sure tubing with stainless fittings. See “Spectra
High Pressure Tube Fitting Assembly” for assem-
bly instructions.
Route the filter outlet
tubing with a “hinge
loop” allowing the pump
module cover and filter
housings to swing away
for pump maintenance
Plumbing

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Fresh Water Flush Module
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 2.5 gallons per minute at 25 PSI. Connect and heat shrink the flush
valve cable butt splices.
Fresh water from ship’s
cold pressure water system
From Sea Strainer
To Feed pump
module
From the inlet thru hull to the flush module and from flush module to the pump module inlet
use the 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 a pressure of 200 PSI (14.5 bar). Use the
supplied 1/2” (12.7mm) tubing. Follow the HP tube assembly instructions (p.47). From the
Clark pump brine discharge quick disconnect fitting use the 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.

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Product water
to tank
Diversion Valve Solenoid
Check Valve
Product water reject tube
Product water tube from
product manifold
Rotoflow flow meter
Salinity probe
Brine Discharge
Route the Brine discharge from the
quick disconnect fitting to location
above the waterline using the
supplied 5/8 (15.9MM) hose.
Quick Disconnect Fitting
Product Water tubing
700 1000 Systems
Product water tubing is 3/8”(9.5mm) on the 700/1000 models. See the Parker tube fitting
assembly diagram next page. Product water is pre-plumbed from the membrane into the
electric diversion valve. The diversion valve will reject product water into the overboard
brine stream until good quality is measured by the MPC-3000 control. Product water is then
diverted 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 feed the water into a manifold or bottom of the tank. Make sure there is no re-
striction in this plumbing.

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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

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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 fitting 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 is 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 tight 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 90º 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.
Make Sure these fittings are tight on initial assembly or they will fail!
The correct Torque is specification is 85 foot pounds
Tighten 1-2/3 turns (10 flats of the
nut) with a7/8" wrench after finger tight.
Use index mark as guide
Ferrule
Figure 2.
Insert tube 0.9" until it stops
Figure 3.
Figure 1.
Black high pressure tubing
Cut tube square
Nut
Index mark
IMPORTANT!
Hold fitting body with 13/16"
wrench when tightening
No threads showing
Nut finger tight with
1 thread showing
Body
Straight or 90 deg.
3/8" pipe thread
Straight thread

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Wiring 700/1000 24V DC Systems
DC Systems will have:
Fresh water flush cable, these wires have no polarity
A Power inlet harness with a terminal block,
A 75’(26 M) cable with connectors for the MPC-3000 control display,
Clark pump module harness consisting of the Rotoflow cable, salinity probe cable, and the
diversion valve (no polarity) cable.
The MPC-3000 Control box houses the Pulse Width Modulation motor speed control and
the MPC-3000 control board. On the motor speed control are two potentiometers used to set
the run, flush, and service speeds. The speed control has over-temperature shutdown pro-
tection. Do not install it in hot or poorly ventilated locations.
Fresh water flush cable
Power inlet terminal
block w/ cover
RED POSITIVE
YELLOW NEGATIVE 75’ (26M) cable with
connectors for the MPC-
3000 control display
Clark Pump Harness
Salinity probe cable
Diversion valve cable
Rotoflow cable
Manual Control
Switches
DC Speed Control
w/ speed adjusting
potentiometers.
MPC-3000 circuit
board

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Wiring 110 & 220 Volt AC Versions
AC Systems will Have:
Fresh water flush cable, these wires have no polarity
Two Power inlet harnesses with terminal blocks,
A 75’(26 M) cable with connectors for the MPC-3000 control display,
Clark Pump Module harness consisting of the Rotoflow cable, salinity probe cable, and the
diversion valve (no polarity) cable.
The MPC-3000 Control box houses the Variable Frequency motor Drive and the MPC-3000
control board. The VFD serves several functions. First it allows the machine to run with al-
most any AC frequency. Regardless of the input conditions the drive will hold a constant
motor speed. The motor controller output is three phase AC to the motor. The control will
“soft starts” the motor. This allows the watermaker to be run on a very small generator if
desired. The motor control also slows the motor to the flush and service speeds. The VFD
has over-temperature shutdown protection. Do not install it in hot or poorly ventilated
locations.
Manual Control
Switches
Variable Frequency Drive
(VFD) AC Versions
MPC– 3000 Controller
Feed Pump Power
AC Inlet
(3 wires)
DC inlet
(2 wires)
Clark Pump Harness:
Stroke sensor cable
Salinity probe cable
Diversion valve cable
Flush Valve cable
Display cable