Spectra VENTURA TROPICAL 200 DELUXE User manual

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VENTURA TROPICAL 200 DELUXE
INSTALLATION & OWNER’S MANUAL
Spectra Watermakers, Inc.
20 Mariposa Road, San Rafael, CA 94901
Phone [phone] Fax [phone]
E-mail: [email protected]
www.spectrawatermakers.com
Rev 09/20/05 f: masterdoc/ventura deluxe

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Table of Contents
Installation
Operation
Getting Started.....................................................................................................................5
Introduction .........................................................................................................................6
Salt Side Piping Schematic..................................................................................................7
Product Piping Schematic....................................................................................................8
1/4 Inch tube Fitting Instructions.........................................................................................9
Membrane Housing Relocation.........................................................................................10
Wiring Diagram.................................................................................................................12
Feed Pump Relocation.......................................................................................................13
Z Brane Installation...........................................................................................................33
Page Number
New Systems Start Up and Testing...................................................................................14
Dry Testing........................................................................................................................15
Normal Operation .............................................................................................................16
Maintenance.......................................................................................................................20
Service & Maintenance
Long Term Storage Procedures.........................................................................................17
Winterizing........................................................................................................................19
Membrane Cleaning ..........................................................................................................21
Suggested Spares...............................................................................................................23
Catalina Troubleshooting Procedures, Service Bulletins..................................................24
Parts breakdown for VT-200 Deluxe systems...................................................................36

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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 kit list.
Warning! We will not be held responsible for shortages and or freight damage that are not
reported within thirty days of the ship date.
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.
Getting Started
Ventura Deluxe Shipping List
?High Pressure Clark Pump and Reverse Osmosis Membrane Module.
?Feed pump inlet module with fresh water flush system.
?Accumulator Tank
?Seawater strainer
?Monitor Gauge panel
?Installation Fittings Kit
?Service Hose kit
?Hand held Salinity monitor
?5/8” Hose (50’)
?1/4 product tubing (25’)

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Introduction to the Ventura Tropical 200 Deluxe
The Ventura represents the finest watermaker for small and midsized yachts available today.
The Spectra Clark Pump is matched to a 21” high rejection membrane. Properly installed and
maintained it will supply years of reliable service. Prudent operational is required with any
marine equipment. Always maintain enough reserve water to get safely into your next port.
The Spectra Intensifier, known as the Clark
Pump, was introduced in 1997 and has continu-
ally improved since. It holds a lifetime warranty
for the original purchaser! It is built of modern
non-corrosive composites. Front View
Rear View
Pressure relief valve
Quick disconnect fitting to
facilitate maintenance.
Double rubber mounts
for to absorb vibration
The Clark Pump Membrane Module. Pre-
mounted and plumbed together as a single
unit. Saves time and adds reliability.
Ventura feed pump inlet module.
Includes the feed pump, cooling fan, charcoal filter for the
flushing system, manual flush valve, service valve and ser-
vice port . Compact and streamlined plumbing. Feed pump
may be removed and relocated if necessary. Cooling fan is
included for long life.

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Bow of Vessel Water Flow
Sea Strainer, Mount with
Quick Block
Ventura Tropical 200 Deluxe Plumbing
Inlet pump module. Mount vertically as
low as practical, no more than 4’ (1.1 M)
above waterline and not over electrical
equipment.
Leave clearance below for filter change.
5 micron filter. Do
not mount over
electrical equipment.
Leave clearance be-
low for filter change.
Accumulator, Factory pre-charged.
Install and plumb as shown.
Plastic fittings should have 3-4 wraps of Teflon
tape and will thread almost all the way in. Leave
the first pipe thread uncoated. Avoid getting dirt
or debris in the system during assembly. Avoid
tight bends and elbows. Secure piping away from
moving objects and protect from chafe.
Fresh water flush inlet to charcoal filter.
Plumb to fresh water system.
Spectra Clark Pump. Mount in a cool location. May be
oriented in any position and can be well above waterline.
Leave access to the pressure relief valve. Do not mount
over electrical equipment. Use supplied spacers and wash-
ers for the vibration mounts.
Pressure
Relief Valve
Brine Discharge thru hull place
above waterline or tee brine into
another visible drain.
1/2” or 3/4 scoop strainer thru hull and seacock for water maker only. Mount low, in
a clear flow and away from head discharge. Thru hull is shipyard supplied.

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Remove one of the product port plugs (from either end) and
thread in the product fitting with Teflon tape sealant.
Back view of instrument panel.
Use accumulator port to connect the pressure
gauge. Use the supplied 1/4” black nylon tub-
ing. If other tubing is used it must be pressure
rated to 150 PSI (10 BAR)
Product Flow meter
Pressure Gauge
Product Water and Pressure Gauge Tube Installation
Product sampling valve. Mount using the sup-
plied plastic straps as shown.
Note: the handle is pointing in the direction of the
flow.
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.
Product to tank.
DO NOT! feed the product into a vent
line, manifold or the bottom of the tank.
Make sure that there is no restriction in
this piping. Pressure in the product
tubing must never exceed 5psi (.3bar)
at any time, (running or stopped) or the
membrane will be permanently dam-
aged.
Sampling Tap for testing the product
water or for service procedures.
Put enough tube on this port to reach
your service (pickling) container.
Plastic fittings should have 3-4 wraps of Teflon tape and
will thread almost all the way in. Leave the first pipe thread
uncoated. Avoid getting dirt or debris in the system during
assembly. Secure piping away from moving objects and
protect from chafe. Exercise care not to cross thread the
fittings. See the tube assembly instructions next page.
Product fitting
Product Ports are
located here
Use the supplied 1/4”
black nylon tubing for
the product plumbing

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Gently fit the tube into the body and loosely thread on the nut.
Push the tube into the body until it bottoms out then hand tighten the nut.
DO NOT OVER TIGHTEN!
1/4" Tube Fitting Assembly
Grab Ring
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.
Step 4:
Step 3:
Step 1: Dissemble fitting components
O-ring
Step 2:
Body
Spacer
Tubing
1/2" max
Nut

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Membrane Pressure Vessel Relocation
Use ONLY Dayco Imperial Nylo-Seal 88-NSR-1/2 tubing for high pressure connections.
Pay attention to the direction and flow path of the tubing before disassembly. Make sure
that you reinstall the tubing in the same manner. Rotate the 90 degree high pressure tube
fittings on the Clark Pump for ideal tube runs. The high pressure fittings are typically pre-
installed at the factory. These fittings seal with an O-ring and require no Teflon tape or pipe
dope. Loosen the backing nut, rotate the fitting, and reseat the backing nut.
Follow the high pressure tube connection instructions on the next page. Connect the
tubes to one of the components, secure the tube runs, and then trim and connect to the other
component. A 90 degree bend in a tube is better than a 90 degree fitting. A tube, when
mounted, should have at least one gentle bend to allow for expansion. Do not connect a
tube straight between hard mounted fittings.
When connecting the tubes to their components, be sure to hold the fitting body with a
wrench during the final tightening. Of special note are the stainless steel tube fittings on the
membrane housing which seal on an O-ring and should be seated all the way in. Hold the
fitting with a wrench while installing the tube.
The fittings on the Clark Pump have an O-ring seal and can be reoriented by backing out
the O-ring stop nut. Rotate the fitting to align with the tube and tighten the nut just past
hand tight. DO NOT over tighten!

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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 the 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 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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Ventura Tropical 200 Wiring Diagram
Route a heavy pair of wires from the main DC electrical panel to the Feed Pump location.
Splice with butt connectors or a terminal block. Seal connectors. A switch located near the feed
pump will facilitate maintenance. Voltage drop will impair performance of the system. Wire
length is the sum of the Positive and Negative wires.
Wire Size Guide for Ventura Tropical 20012V
Protect with 15 Amp Fuse or Circuit Breaker
# 10 Gauge (6mm) to 15 feet (4.5M)
# 8 Gauge (10 mm) to 25 feet (7.5M)
#6 Gauge (16mm) to 35 feet (10.6M)
Wire Size Guide for the Ventura Tropical 20024V
Protect with 7 Amp Fuse or Circuit Breaker
#12 Gauge(4mm) to 10 feet (3M)
#10 Gauge (6mm) to 25 feet (7.6M)
#8 Gauge (10mm) to 35 feet (10.6M)
Main DC Electrical Panel
DC negative buss bar
To Battery
Feed Pump wiring, Red is Positive
Black is Ground.
Cooling Fan Connects in parallel with the Feed
pump. Same color code.

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If you do not have adequate space to install the feed pump inlet module it is possible to re-
move and relocate the feed pump. Before you install the module, disconnect the hose that
connects the feed pump to the module plumbing. Remove the cooling fan and the heat sink
from the pump. Both are friction fits with no fasteners. Remove the 4 machine screws hold-
ing the pump to the module.
Feed Pump Relocation
Cooling fan
Heat sink
With the pump on a flat surface. Remove the three
screws that hold the pump head on. See Fig1
Re-orient the pump head 120 degrees. See Fig2
Reinstall the screws and tighten firmly. See Fig3
Now the feed pump may be installed where you wish.
Do not install the pump with the head above the mo-
tor in case of leaks.
Fig 1
Fig 2 Fig 3
Machine Screws

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Avoid running the Ventura system if the vessel is in contaminated water, such as in a polluted
harbor or canal. The system should be fully run tested before leaving on your cruise. If the lo-
cation or weather prevents proper testing refer to the section “Dry Testing.” Do not operate
the watermaker if the sea temperature is below 50°F (10°C).
Warning! Damage may occur if the purge sequence is bypassed and the membrane is
pressurized with storage chemical in it, or if the sea temperature is too low.
?? Thru-hull inlet valve is open and the brine discharge valve is open.
?? All of your hose connections are tight.
?? The “WARNING” tag and spacer from under the pressure relief valve has been
removed.
?? The pressure relief valve is open 1/2 turn.
?? The sampling valve is set to the sample position.
1. First check that:
2. Turn on the feed water pump. Check that it is primed by inspecting the brine discharge.
About 1.5 gpm (6 lpm) of water should be going overboard with a pulsation every few sec-
onds.
3. Run the system without pressure for 20 minutes to purge the storage chemicals. The system
should have an open flow pressure on the gauge of about 20 PSI (1.2 bar).
4. Close the pressure relief valve. The pressure should rise to 60-80 PSI (4.2-5.7 bar). After
several minutes, water should begin to flow out of the sampling tube. If the vessel is located
in brackish or fresh water the pressure will be lower.
5. Allow the system to run for 5-10 minutes and then test the product with your hand held sa-
linity tester. When the product is below 750 PPM it is considered potable and may be diverted
to the tank.
Ventura Deluxe New System Start-Up and Testing
Open 1/2 Turn to Purge Chemicals!Remove Tag and Washer!

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Ventura Deluxe Dry Testing With Artificial Ocean
If it is not possible to test run the system with the boat in the water, testing may be accomplished with
an artificial ocean. Purchase enough aquarium salt to make 5 gallons (20 liters) of salt water.
Make sure that the domestic water system is powered up and that there is at least 30 gallons (120 Li-
ters) of water in the tank. Confirm that the charcoal filter is installed in the fresh water flush module
and that the domestic water line had been installed and all valves are open.
1. Open Pressure Relief Valve on the Clark Pump. Remove the green tag and spacer!
2. Close the yellow service valve on the inlet module. This will be the center location.
3. Open the grey fresh water flush valve.
4. Start the feed pump and let it run 20 minutes to purge the storage chemical overboard.
5. Stop the feed pump
6. Hook up your inlet and brine discharge service hoses per the photo and route them into the 5 gal-
lon (20 Liter) container. Turn your product sample valve to the sample position. Route the prod-
uct output into the bucket.
7. Restart the feed pump and fill the bucket with fresh water from the brine discharge. Stop the
pump and close the fresh water flush valve.
8. Rotate the yellow service valve to the service position.
9. Mix the salt to the proper proportion or use an aquarium hydrometer to adjust the salinity level.
10. Start the feed pump, allow to prime and then close the pressure relief valve. The system should
build pressure and after several minutes start making water.
11. Run the system under pressure and check for proper operation and leaks.
After testing the system stop the feed pump and replace the brine discharge hose. Restart and drain
the bucket. You can now store the system by using the above procedure for adding fresh water to the
bucket and using the storage procedure. If the system is to continue to be commissioned performing,
a fresh water flush will hold the system for 4-5 days.
Valves in flush position Valves in service position
Inlet service hose connected. Connecting the Brine Discharge service hose.

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Ventura Deluxe Operation
Normal operation
The Ventura Tropical 200 is designed to be operated only in areas where the sea tempera-
ture will not drop below 50°F (10°C). Damage may result if operated using colder feed water.
If the system has been pickled or stored or contains cleaning compounds, use the “New
System Startup” procedure.
1. Check to see that the inlet seacock is open.
2. Turn the product valve to the “Sample” position.
3. Start the feed pump and check for flow by inspecting the brine discharge or checking for
pressure on your analog gauge. If there is no flow open the pressure relief valve on the
Clark Pump and bleed the air out of the feed pump.
4. Check the product water with your hand held salinity tester. When it is below 750 ppm, you
may divert it into your tank.
5. Run the system until you have filled your tank or have made enough to meet your require-
ments for several days.
6. Turn on the fresh water flush valve and close the service valve.
7. Flush for 2 1/2minutes or until the pressure drops on the gauge indicating that the membrane
is flooded with fresh water. Stop the feed pump.
8. Return the service valve and the flush valve to their run positions.
You may now leave the system unattended for up to five days without further attention
We recommend operating the system for longer periods and effecting a fresh water flush rather
than running the machine every day and not flushing the system. Remember that you need to
run the system almost a half an hour to make the flushing water. You may notice that the sys-
tem output is higher while charging your batteries as the machine is voltage sensitive.
Inlet Module with valves in the
normal “Run” Position. Inlet Module with valves in the
“flush” Position.
Closed
Open Closed
Open

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Long Term Storage Procedures
Watermakers are best run continuously. When not in use, biological growth in the mem-
brane is the leading cause of membrane fouling. A warm environment will cause more
growth than a cold environment. The fresh water flush system will greatly reduce biologi-
cal growth but may not stop it completely in certain conditions. If an optional “Zeta Guard”
or Z-Brane water treatment system is installed in the system, then three to five day flushing
intervals will maintain the system as long as fresh water is provided and the charcoal filter
maintained.
System Storage or “Pickling”
If the system is to be left unused for more than five days, perform the following storage pro-
cedure. The procedure introduces a chemical compound into the system that prevents bio-
logical growth. This procedure requires de-chlorinated water which can be made with the
charcoal filter. Charcoal filters last a maximum of 6 months once wetted.
Spectra SC-1 a special storage compound used by the US Navy. It is formulated to be
compatible with the modern engineering plastics and composites in the Spectra pumps.
Do not use any substitute except propylene glycol. If you wish to use glycol for storage,
follow the winterizing instructions. SC-1 Storage Compound has to be mixed at a ratio
of 1 container to 3 gallons (12L) of fresh water to have the proper solution for short
term storage (under two months use 1/2of a container)
Caution! Avoid contact with skin, eyes, or lungs with the storage chemical.

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Ventura Deluxe Storage Procedure
1. Perform a fresh water flush as described in the normal operation section. Shut down the
feed pump but leave the valves in the flush position.
2. Remove the quick disconnect fitting from the brine discharge outlet of the Clark Pump and
replace with a quick disconnect service hose from your service kit. Lead the hose to a 5 gal-
lon bucket or container.
3. Start and run the feed pump until you have one gallon of fresh water in the bucket.
4. Mix 1 container of SC-1 storage compound with the water in the bucket.
5. Connect the service hose, using the garden hose barb fitting from your service kit, to the
service port of the fresh water flush module. Lead the hose into the bucket. Turn the service
valve on the fresh water flush module 180°, so the intake is now coming from the bucket.
6. Make sure the pressure relief valve on the
Clark Pump is OPEN (unpressurized)
by turning 1/2turn counterclockwise
7. Turn on the feed pump. Circulate the storage
chemical in the system for approximately 10
minutes. Turn off the feed pump when fin-
ished.
Clean Up
Remove the quick disconnect from the Clark Pump brine discharge, and replace the original
hose that leads to the thru-hull. You may at this point, if you choose to, pump the bucket dry
by using the feed pump switch. Stop when the bucket is empty.
Turn the service valve 180° back to its original position, and remove the service hose.
Close the seacock and drain and clean the strainer and any filters in the system. Reassemble
dry.

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Pickling and Winterizing with Antifreeze
The watermaker can be stored for periods up to one year in any climate using this procedure.
1. Close the yellow service valve, open the Grey flush valve, and run the feed pump 4 minutes
to effect a complete fresh water flush. Shut the pump and flush valve off.
2. Connect the inlet service hose and put it in the service container or bucket.
3. Turn the service valve to the service position.
4. Pour 2 gallon (8L) of propylene glycol in the bucket.
5. Make sure that the pressure relief valve is OPEN (un-pressurized).
6. Turn on the feed pump until antifreeze begins to show at the brine overboard fitting, then
stop the pump. Add more antifreeze if necessary.
7. Connect the brine discharge service hose and place it in the bucket.
8. Circulate the antifreeze for about five minutes.
9. Stop the pump. Reconnect the brine discharge hose. Restart the pump until the bucket is
empty.
10. Close the seawater intake and the service valve. Drain the strainer and the hose leading to
the inlet module. Disconnect the product tubing and blow any residual water out of the tub-
ing with compressed air. Empty the charcoal filter housing and flush water lines.
Valves in flush position Open the pressure relief valve
Valves in service position
Connecting brine discharge hose

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Maintenance
The Seawater Strainer
The sea water strainer’s stainless steel element should be inspected, removed, and cleaned as
needed. Be careful to ensure that the thru-hull is closed before disassembly and the gasket is in
place before reassembly. When the system is put into storage, remove, rinse, and reassemble
dry to impede corrosion. Check frequently during operation.
The Prefilter
?? Service the prefilter on a regular basis. The pressure will rise on the remote gauge when the
filter becomes dirty. Extremely dirty filters will harm system performance and may cause
the feed pump to cycle on the high pressure switch. Do not leave dirty filters in the machine
during long idle periods, as biological contamination could result.
?? To service the filters, shut off the service valve, open the housing, and discard the old filter.
Clean out the housing bowl, reassemble the housing with a new 5 micron filter element.
Leave dry until next startup.
?? Use only Spectra approved filters or you may void your warranty. The filters may be
cleaned several times with a soft brush and water in a bucket. Occasionally, lightly lube the
filter housing O-ring with silicone grease.
?? Replace the charcoal filter element at least every 6 months! This filter protects the mem-
brane by removing chlorine from the fresh flush water. Use only a Spectra replacement!
Oil Water Separator (Optional)
To install oil water separator capability install the additional filter housing with its oil removal
filter upstream of the 5 micron filter. Service at the same time as the 5 micron filter.
General
Periodically inspect the entire system for leakage and chafe on the tubing and hoses. Repair
any leaks you find as soon as practical. Some crystal formation around the Clark Pump blocks
is normal. Wipe down any salt encrusted areas with a damp cloth.
The Charcoal Fresh Water Flush Filter
The Feed Pump and Clark Pump
The feed water pump and the Clark Pump require no routine maintenance except inspection for
leaks. Tighten any hose clamps or fittings the show signs of leakage. The high pressure fittings
threaded into the Clark Pump have O-ring seals with a straight thread. These should never leak
and should never be over tightened. If one of the tube nuts starts to leak, it can be un-threaded,
sealed with a bit of silicone grease or silicone sea, and tightened with two wrenches very
tightly.