The World's Most Efficient Watermaker	MODEL 200c & MODEL 380c OPERATION AND INSTALLATION MANUAL REVISED 3/2/99

Thank you for choosing a Spectra Watermaker!  It is our wish for you to be completely satisfied with our product.  We have inspected and tested all of the components before shipping, and feel we have produced one of the finest products available.

Your long term satisfaction with this system will depend greatly on how the Spectra system is installed.  The unique performance is obtained not only by our new pressurization process, but by careful attention to reducing flow restriction, mechanical friction and electrical resistance.  All of this is affected by the final installation, and that is ultimately up to you.  By reading, understanding and following this manual, even if you are not doing the installation yourself, we are confident you will be happy with your new Spectra system.

With years of experience installing and repairing many different kinds of watermakers, we have seen nearly everything that should or should not be done.  This manual includes the summation of that knowledge, tailored for the Spectra Watermakers.

It is very important that you follow the instructions in this manual.  They are designed to help you "customize" the installation to your boat, while maintaining performance.  If any questions arise, please call us for help immediately.  This is a unique product so be careful of "experts," as they most likely will not have gone through the same learning curve as we have during the development of the Spectra systems.

If someone else is installing the watermaker for you, review all aspects of the system with them before the drilling and cutting begins. This will help avoid making mistakes.  If you have any doubts, please call us.  We will be happy to help tailor the system to your particular needs.  As with any sophisticated device, there may be "bugs" or minor problems.  Please call us for consultation or advice before attempting to repair a new system.

"Use it or lose it" really does apply to watermakers, but we prefer "use it or pickle it".  All watermakers will suffer damage if they are run and left without storage treatment or "pickling". We have found that if the pickling and cleaning processes are made easy there is a higher probability of it happening.  This is why we have included the "Y" valves in the Installation Kit.  Even though the system can work without them, they are very helpful in the servicing of your system.

In conclusion, having an adequate and reliable watermaker can improve the quality of life on board more than almost any other piece of equipment.  It is our sincere desire that you will be able to take full advantage of your new Spectra Watermaker, confirming that you have indeed made the best choice!  And don’t forget to tell all your friends!

Thank you from all of us at Spectra Watermakers. 

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System and Start Up Log

System Information

Model Number	________________
Serial Number	________________
Date Purchased	________________
Purchased From	____________________________
	____________________________
	____________________________
Installation Date	________________

Start up performance readings

Measure after 3 and 24 hours of pressurized run time in similar conditions.
 

	3 hours	24 hours
Feed Water Temperature	__________	__________
Battery Voltage	__________	__________
Amperage Draw (amps)	__________	__________
Feed Pressure (psi)	__________	__________
Product Water Flow (gph)	__________	__________

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Shipping List
 

(1)	Operation and Installation Manual
(1)	Clark Pump and mounting hardware
(1)	Feed Pump and heat sink (model 200c)
(2)	Pumps, heat sinks, cooling fan kits, and fittings (Spectra 380c)
(1)	Accumulator Tank
(1)	Membrane and Housing Assembly with mounts
(10’)	High Pressure Tube
(1)	Sea Water Strainer
(1)	Pre-filter and Bracket
(1)	Monitor Panel
(1)	Hand-held Salinity Monitor
(1)	Installation Kit  (optional)
(1)	Mounting Bracket  (optional)
(1)	Automatic Salinity Control  (optional) Includes power control module, remote  panel, salinity sensor, and reject valve
(1)	Manual Fresh Water Flush System  (optional) Includes charcoal filter, Y valve, and fittings
(1)	Automatic Fresh Water Backflush System  (optional) Includes a timer in the power control module, a switch in the remote control panel, a charcoal filter, solenoid valve, check valve, and fittings
(1)	20 micron Pre-filter Kit  (optional) Includes filter housing and bracket, 6 filter elements, and fittings
(1)	Basic Cruise Kit  (optional) Includes six 5-micron filters and 2 SC-1 storage chemical containers
(1)	Offshore Kit  (optional) Includes Clark pump seals, pump shaft, tools, 2 SC-2 cleaning chemical containers, and overhaul instructions
(1)	Spare Feed Pump  (optional)
(1)	Cooling Fan  (optional)

Shopping List

In addition to the optional installation kit.
Refer to manual for size and type of fasteners

Fasteners/Hardware for mounting components to desired surfaces
Marine grade duplex wire, connectors and wire ties with mounts
2 five gallon containers
One 15 amp fuse or circuit breaker switch for the Spectra 200c or
Two 15 amp fuses or circuit breakers for the Spectra 380c
One 25 amp fuse or circuit breaker for a remote control system

Tools Required

Wrench set to 7/8"
Adjustable wrench
3/8" drill, drill index and a hole saw set
Jig saw or coping saw
Screwdrivers
5/16" nut driver for hose clamps
Wire cutter
Wire stripper
Electrical crimping tool for insulated connectors 

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Features

The new Spectra Watermaker systems are designed to meet the needs of a wide range of cruising yachts.  The Spectra 200c is ideal for the small yacht with limited power, but will easily handle the water needs of medium size yachts.  The Spectra 380c is ideal for the larger sail and motor yachts.

Using the patented Clark Pump and paying careful attention to system efficiency, the Spectra 200c operates on a fresh water-to-power ratio that surpasses everything in the marine industry.  The system makes an average of 8.3 gallons per hour on 8 amps @ 12.5 vdc, less than 13 watt hours per gallon!  That means that making one gallon of fresh water is like running only a small cabin light for one hour!

The Spectra 380c with two fan cooled feed pumps produces 16 gallons per hour using less than 20 amps.  It also offers the option of running only one pump, and performing just like the Spectra 200c.

The system’s modular components allow for easy custom installations.  Component layout can be optimized for efficiency, ease of operation and maintenance.  The system’s feed pump is self priming and can be mounted up to 4 feet above the water line!  The rest of the system can go even higher.

The production of fresh water is stable through the system’s normal operating sea water temperature and salinity range.  Only the working pressures change with the water conditions.  A typical leading brand "200 gallon per day" unit running in 61° F water will only make 144 gallons per day.  The Spectra 200c will still be producing 200 gallons per day or more on a fraction of the power.

Total water flow through the system has been minimized in order to extend the life of the pre-filter and for energy efficiency, but is within membrane manufacture’s operating limits.

Pressures are self-regulating, eliminating the need for adjustments, even when operating in brackish waters.  The feed pressure is limited to 100 psi maximum for the Model 200c and 120 psi for the Model 380c.

A self priming multi-diaphragm feed pump is all that drives the system.  No additional boost pump is needed, or even helpful.  The Spectra 380c’s duplex pump system allows the choice of using one pump for maximum efficiency or both pumps for maximum production.  Each pump includes a small low watt cooling fan.

A 5 micron pre-filter is provided standard for maximum system life, no extra boost pump is needed to use this filter.

The system’s noise level is exceptionally low and unobtrusive, especially compared to other systems of similar capacity.  The feed pump has a smooth, steady sound and almost no vibration, and can be placed almost anywhere on board.

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The Clark Pump

This is the heart of the system.  The Clark Pump uses two opposing cylinders and pistons that share a single rod through a center block.  A reversing valve, controlled by a pilot valve that is actuated by the pistons, allows the cylinders to alternate between driving and pressurizing.  Pressurization is achieved by the rod being driven into the other cylinder.  As the rod enters the cylinder, it pushes the piston which circulates the water out through the membrane and back to the reversing valve.  The valve directs the water back into the same cylinder behind the piston, creating a closed loop.  The rod displaces water as it enters the cylinder, raising the pressure enough for reverse osmosis to occur in the membrane, thus fresh water equal to the volume of the rod is produced on every stroke.  The driving cylinder has feed pressure pushing on the top of the piston which has ten times the surface area than in the end of the rod.  The water under the piston (brine) is discharged overboard.  This gives the piston a 10-to-1 advantage over the rod, allowing it to drive the rod into the pressurizing cylinder.  When the piston bottoms out on the center block, it actuates the pilot valve and the process is instantly reversed.  High efficiency is achieved because there is no "back stroke," allowing one cylinder to always be under pressure.

The speed of this process is determined by the water flow from the feed pump.  The pump has a nearly constant flow rate at a given voltage so the production of fresh water is nearly constant, only the pressures change with changes in sea water temperature and salinity. (see "Membrane" section)

A pressure relief valve is incorporated in the Clark Pump to depressurize the system for priming and service. (refer to the Clark Pump diagram)

The Spectra 200c Feed Pump

The feed pump is the sole driving force in the system.  It is a self priming, continuos duty, multi-diaphragm water pump similar to the pumps used for domestic pressure water systems.  The pump has a flow rate of 1.8 gpm.  Feed pressure averages 65 psi, drawing 8 amps @ 12.5 vdc.  The high pressure cut out switch is factory set at 100 psi.

The Spectra 380c Dual Feed Pump System

The system is simply two identical self priming, multi-diaphragm, fan cooled, feed pumps with that are plumbed in parallel.  They are individually wired to separate circuits to allow single or duplex operation.  In duplex pump mode, the feed flow rate is 2.6 gpm.  Feed pressure averages 95 psi, drawing less than 20 amps per hour @ 12.5 vdc.  In single pump mode, the performance is the same as the Spectra 200c.  It is very important that the cooling fans be operational when both pumps are running.  Each pump is drawing almost 10 amps which will generate too much heat for the cooling fins to dissipate adequately.  The high pressure cut out switches are are factory set at 120 psi.

The Reverse Osmosis Membrane

The membrane is what does the real work.  A semi-permeable membrane and a capillary layer are attached and wrapped around a center catch tube, then encased in fiberglass.  The ends of the windings are open, allowing the salt water to freely pass from end to end.  This "membrane" is enclosed in a high pressure housing that directs the pressurized salt water to flow through the membrane and lets the product (fresh) water escape from the center catch tube.  Threaded ports are provided for hose connections in the end caps of the pressure housing. In the Spectra 200c, approximately 85 gph of high pressure salt water flows across the membrane as 8.5 gph of fresh water is forced through the membrane and lead by a capillary layer to the catch tube.  The excess salt water flowing out of the membrane is approximately 1/10th saltier and is called “brine.”  No salts are collected in the membrane.

Membrane function is affected by sea water temperature and salinity.  The warmer or less salty the water, the easier it is for the fresh water to pass through the membrane.  This means that since the water production of the Spectra systems are nearly constant, warmer water lowers the operating pressures.  The membrane is carefully sized to handle typical sea water temperatures and salinity, keeping the pressures within limits.

The R.O. membrane theoretically will not let microbes or viruses through with the product water.  This cannot be guaranteed, however, because of the possibility of microscopic flaws in the membrane or the brine seals in the pressure housing that could let these contaminates pass through.  This is the reason that it is recommended that water made in a possibly contaminated environment should not be directed into the tank.  An optional ultra violet sterilizer is available for additional protection.

The Sea Water Strainer

The strainer filters the salt water to the feed pump for it’s protection.  It has a cleanable, fine mesh, stainless steel element.  The filter mesh is sized to stop debris that could jam in the pump’s check valves. A coarse strainer should not be substituted.

The 5 Micron Pre-filter

The pre-filter does the essential job of cleaning the sea water before it gets to the Clark Pump and R.O. membrane.  A replaceable 5 micron pleated fiber filter is used.  Filter maintenance is crucial to the efficiency and life of the system.  Five micron filtered sea water is important.  A reverse osmosis system running on 5 micron filtered water will last much longer than one running on 20 or 30 micron filtered water.

Accumulator Tank

The accumulator tank is an air chamber divided by a rubber diaphragm.  The top chamber is pressurized with air to 10 psi below the expected feed pressure. For example, if the feed pressure is 70 psi, the tank should be pressurized to 60 psi when the system is off.  When running, feed water will enter the lower chamber until the pressures equalize.  It’s function resembles a cushion to smooth out the feed pressure spikes when the Clark Pump “shifts.”  This will extend the life of the feed pump and quiet the shifts between strokes.

The Standard Monitor Panel

The monitor panel gives information on the system’s status.  It shows feed pressure and it’s related high pressure and product water flow.  The feed pressure gauge must be level in the panel so the high pressure readings will correspond properly to the feed pressure.  The air bubble in the pressure gauge is normal.

The Service Y Valves

(Note: The common port is opposite the handle shaft)

The valves are installed on the feed, brine discharge and product lines to provide easy access for proper maintenance.  The alternate hoses should be able to lead to the five gallon cleaning containers.  IMPORTANT:  The intake and discharge Y valves will close off all the ports if the lever is moved to the middle position, i.e. half way between the normal and alternate positions.  The smaller product Y valve cannot close the ports when the lever is moved half way.  This precludes the possibility of blocking the product flow and causing an over pressure condition that could burst the tube.

Remote Control Panel (optional)

The Spectra remote control panel is integrated with the Spectra power control module, salinity control system, and the optional automatic back flush system. The panel has switches for one or two feed pumps, a switch to start a backflush cycle, and lights that indicate when a feed pump is on, the backflush cycle in in progress, product water is being rejected, and when good product water and going to the tanks.  The remote panel is wired to the power control module.

Power Control Module (optional)

The Spectra power control module is a plastic enclosure that has all of the power relays and electronics for the feed pumps and the salinity control system.  It also can incorporate the timer for the automatic backflush system.  The module is connected to the ships power from a single breaker that is rated for all the system loads.  The feed pumps or pumps, salinity and backflush solenoid valves, salinity probe and the remote paned are all wired to the control module.

Salinity Control System (optional)

The salinity control is integrated with the remote control system.  The system includes the Spectra power control module, a salinity probe that is mounted in a plastic pipe tee, an electric three way  valve, fittings, and the Spectra remote control panel.  The probe and diversion valve are plumbed into the product line,  The salinity control continuously samples the purity of the product water.  If the probe detects non-potable product the diversion valve rejects the product overboard.

Manual Fresh Water Backflush Kit (optional)

An easy way to flush the salt water out of the system for longer intervals between run times.  The manual system uses a Y valve to switch from the sea water inlet to charcoal filtered fresh water from the ship’s pressure water system, or direct from the tank.  The kit includes a charcoal filter and housing, 3-way Y valve, and fittings for a typical installation.

Automatic Fresh Water Backflush Systems (optional)

An automatic fresh water backflush system allows the operator to start a timed backflush cycle from the remote control panel.  The automatic system incorporates an electric solenoid valve, controlled by an adjustable timer, a power relay to run one feed pump, and a check valve.  When the timer is initialized the valve opens to let pressurized charcoal filtered fresh water into the feed system and one feed pump starts.  The check valve prevents the fresh water from going out the intake thru-hull.  The system will run until the salt water is flushed then automatically shuts down.  The timer is adjusted at installation.

Purging the system with nonchlorinated fresh water is advisable when the system is not going to be used for three day to one week.

The pressure relief valve does not have to be opened during purging because the Spectra’s unique high pressure system will not generate membrane damaging excessive product flow when brackish or fresh water is introduced into a pressurized system.  The length of time to purge the system depends on the installation.  Longer hose runs and extra pre-filters will lengthen the purge time.  The feed pump is run during the purge.  The flush time is determined by recording the time it takes for the feed pressure to drop and then stabilize as the salt water leaves the membrane, and then adding at least 1 more minute.

Installation Kit (optional)

The installation kit includes 50 feet of 5/8”reinforced non-toxic feed and discharge hoses, 25 feet of 1/4” plastic product water tubing, special 3-way Y valves for service procedures, and all of the required tube fittings, hose fittings and hose clamps.

Mounting Bracket (optional)

The mounting bracket is a powder-coated aluminum “L” bracket for easy bulkhead mounting of the Clark Pump.  Two brackets can be used for overhead mounting.

Second 20-micron Pre-filter Kit (optional)

Add a second 20-micron pre-filter assembly before the 5-micron pre-filter for longer intervals between filter service.  Recommended for systems that will run for long periods of time and may be operated in turbid sea water conditions.  Six 20-micron filters and plumbing fittings are included.

Basic Cruise Kit (optional)

The kit includes six 5-micron filters and the SC-1 storage and scale cleaning compound (pickling) for 2  storage procedures.

Offshore Kit (optional)

The kit includes all the seals, a piston rod, tools, and rebuild instructions for the Clark Pump and the SC-2 alkaline membrane cleaning chemical compound.

Cooling Fan Kit (optional)

The kit includes a low watt DC muffin fan mounted on a plastic shroud that slips over the cooling fins of the feed pump and instructions.

Spares, Accessories and Supplies

Spare feed pump

Cooling clip for feed pump

Hand-held salinity monitor

SC-1 membrane cleaning and storage compound

SC-2 alkaline membrane cleaning compound

5-micron filters

20-micron filters

Charcoal filters

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Operating Procedures

New System Start-Up

Caution:  If the vessel is in contaminated water, such as in a harbor, do not direct the product to the main tank.  Do not run the system if the sea water is extremely turbid, as the pre-filter will clog.  Move the vessel to cleaner water.

1. Check battery voltage.  A nominal 12.8 vdc to 14.4 vdc should be indicated.
    
2. Check that the accumulator tank is pre-charged to 60 psi
    
3. Confirm that the intake thru-hull is open and the strainer is clear.
    
4. Have the intake and brine discharge Y valves in the normal position and the product Y valve in the alternate position.  Direct the product alternate tube to a container or into the bilge.
    
5. Open the pressure relief valve 1/2 turn and start the system.  On standard systems the pump is started using the breaker on the panel.  For systems with the power control module the pumps are starts from the remote control panel.  Listen for the feed pump to prime itself and the Clark Pump start to “shift.”  Check the brine discharge for water flow.  The Spectra 380c’s two feed pumps must be purged separately.  Start one pump and run until there is good water flow.  Shut down the first pump and start the second pump.  After the second pump is primed, the first pump can be restarted.  Check the feed pressure, about 20 psi should be indicated with one pump running (for both the 200c & 380c systems), and about 40 psi with two pumps running (the 380c system).
    
6. Check the feed pump high pressure cut out switch set point.  For the Spectra 380c do one pump at a time.  With the system primed and running unpressurized, block the brine flow by moving the brine discharge Y valve lever to the center position, half way between the normal and alternate positions.  This will stop the water flow and cause the feed pump to shut off.  Check the feed pressure gauge, it should be holding steady at about 115 to 120 psi.  The pressure can be adjusted by tightening (higher pressure) or loosening (lower pressure) the Allen head set screw on the pump switch using a 5/64” Allen wrench.  Repeat for the second pump on the Spectra 380c.  Now is a good time to check for leaks in the feed and brine connections as they are now pressurized to maximum.
    
7. Run the system unpressurized for 30 minutes after start-up to purge the pickling solution in a new membrane.  Close the pressure relief valve to pressurize the system. Re-check the whole system for leaks, especially the high pressure hose connections.  If any are found, turn off the system and repair them before continuing.  Run the system under pressure for at least one hour while rejecting the product water.  Compare the voltage, feed pressure, water temperature and amp draw to the specification table.  The feed pressure should not spike more than 5 to 10 lbs. over normal when the Clark Pump shifts and should stay under 85 psi at all times for the Spectra 200c and under 100 psi for the Spectra 380c.  The feed pump(s) should never be allowed to cycle their high pressure cut out switch on and off during the shift.
      The pump sound should remain almost steady.  If the pressure spikes are high and/or the pump stops momentarily during the shift, re-check the accumulator pre-charge and/or check the high pressure cut out set point.  If the feed water is around 55 deg. or colder and/or is extra salty, the 380c's feed pressure might go high enough to cycle one pump on and off even when all else is normal.  In those conditions only run one feed pump.
    
8. After one hour, use the hand held salinity meter to check the product water.  The salinity meter reads in parts per million (ppm) of total dissolved solids (TDS).  Readings should be below 500 ppm.  Typical readings are 200 ppm - 300 ppm.  If the water is good, the Y valve can now be switched the normal position to direct the flow to the water tank.  If an optional automatic salinity control is installed, watch the “reject” and “good” product water indicator lights on the remote panel after product water Y is turned to normal.   The green light should be on and the diversion valve directing the product water to the tank.  Break open the product line to the tank to see if the water is flowing.  If not recheck solenoid valve plumbing and electrical connections.
    
9. At three hours of pressurized run time and again at 24 hours, re-check for leaks and take note of the system feed pressure, product flow and amp draw, entering them into the start up log.

Normal Start-Up

1. For normal start-up (meaning the unit has been run within the last 3 days, or has been flushed with fresh water only), reject the product water by switching the product Y valve to the alternate position and start the system.  It is not necessary to open the pressure relief valve.  The first two pints of product water may be brackish.  Wait a few minutes then test the water.  If it is OK, switch the Y valve to the normal position.  If the system has the automatic salinity control system there is no need to switch the Y valve.  Any brackish product water will automatically be diverted to the brine discharge.  When the salinity probe detects potable water, the diversion valve sends it to the tank.  Periodically check the product water with the hand-held salinity probe to test the the automatic system.
    
2. If air is in the system and the feed pump has lost it’s prime, open the pressure relief valve to allow the air to purge from the system. The feed pump cannot prime if it’s output is under pressure.   Remember to purge the Spectra 380c’s pumps separately
    
3. After starting and pressurizing the unit, check for leaks and wait for it to stabilize, then check for proper readings (see Specifications pages).  Air in the system will cause erratic shifts and readings until it is purged out of the system.  This may take up to 10 minutes.

Pickled System Start-Up

If the system has biocide in it (also known as “pickling” or storage solution),  open the pressure relief valve 1/2 turn and run the system unpressurized for 30 minutes to purge the biocide.  Direct the product line to a bucket or into the bilge by switching the product Y valve to the alternate position.  Close the pressure relief valve to pressurize the  system.  Manually reject the product water.  Do not rely on the salinity control system at this point.  Run for another 30 minutes, then test the water by using the hand held salinity probe even if the automatic salinity control system is installed.  If the water is OK, switch the Y valve back to the normal position.

Unknown Condition Start-Up
(CAUTION: Do not start the system yet!)

If the system has been left unpickled for an extended length of time or the history is unknown, perform this simple test:

Before starting the system, open the pre-filter(s) and inspect its condition.  If the filter is black and smells bad it’s an indicator that the system is fouled.  Install a new or cleaned pre-filter then open the pressure relief valve and direct the brine discharge into a bucket.  Start the system and watch the brine that first comes out.  If the water is discolored and smells bad, perform an alkaline cleaning on the system before pressurizing ( see cleaning instructions).  Pressurizing a system with a fouled membrane will compact the biological growth into the membrane and make it harder to clean.  If the water is only slightly discolored and smells OK, perform a Pickled System Start Up.  Compare the system readings to the performance specifications to see if the system is performing properly.

Before starting the system, open the pressure relief valve and direct the brine discharge into a bucket.  Start the system and watch the brine that first comes out.  If the water is discolored and smells bad, perform an alkaline cleaning on the system before pressurizing (see cleaning instructions).  Pressurizing a system with a fouled membrane will compact the biological growth into the membrane and make it harder to clean.  If the water is only slightly discolored and smells OK, perform a Pickled System Start Up.  Compare the system readings to the performance specifications to see if the system is performing properly.

Normal Operation

Spectra Watermakers are designed to run continuously with only pre-filter maintenance performed as necessary.  Daily usage will vary with individual needs, but the Spectra’s high capacity will allow for shorter run times.  Running the unit during charging cycles will produce more water because of the higher voltage (see Performance Specifications).  System readings should be periodically checked and compared to the start-up log readings and performance specifications.  Look for asymmetrical readings and listen for any change in the sound of the system that may indicate potential problems.

If the system has the automatic salinity control, manually diverting the product water at start up is unnecessary, but periodically test the water manually to see if the automatic system is working properly.

If too much air is introduced into the system when the system is running and pressurized, the feed pump will cavitate and water flow will stop.  This will not damage the system.  Open the pressure relief valve to allow the feed pump to re-prime.  Remember to re-prime the Spectra 380c’s feed pumps separately.

All reverse osmosis watermakers are affected by water temperature and salinity.  The Spectra operating pressures will rise with colder temperatures and/or higher salinity, and fall with warmer temperatures and/or lower salinity, but the product flow is effected very little. 

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Shutdown Procedures

Biological growth in the membrane when it’s not in use, is the leading cause of membrane fouling.  A warm environment will cause faster growth than a cold environment.  The following procedures assume a warm environment, such as in the tropics.  In colder conditions, the day count could be safely doubled.

It is recommended to store at least 5 gallons of system product water in clean containers to have as a back up source of nonchlorinated fresh water to flush, pickle, or clean the system if making the water is not practical at the time.

Short Term Shutdown, less than three days

Check system for normal operation.  If OK, turn off power and close thru-hull.

Extended Shutdown,  four days - one week

Start the unit and make 5 gallons of water allowing it to flow into a container using the product Y valve.  Do not use tap water or chlorinated water!  Distilled or charcoal filtered water is acceptable if making it’s own water is not an option.  Open the pressure relief valve one half turn.  Draw the fresh water through the system using the intake Y valve.  Service the pre-filter(s) and strainer leave them empty and dry if possible.

If a manual fresh water flush system is installed, switch the flush Y valve to the alternate position while the system is running and pressurized.  Watch for the feed pressure to fall and stabilize, wait 1 minute more and then shut down the system.  Return the flush Y valve to the normal position.  Service the pre-filter(s) and strainer.

If an automatic flush system is installed, stop the system, make sure that the ships pressure water system is on, and then start the flush cycle.  When the system turns itself off, service the pre-filter(s) and strainer if necessary.

Storage Shutdown or "Pickling"

The Spectra SC-1 Storage and Cleaning chemical is specially formulated to be able to clean mineral scale and be used as a system preservative.  Sodium bisulfite or metabisulfite should not be used as a preservative in the Spectra systems.  Sodium bisulfite will attack materials used in the Spectra systems.

The SC-1 Storage and Scale Cleaning Compound has to be mixed at 1 Spectra container  to 3 gallons of  fresh water to have the proper solution.  An average of two gallons of water is in the Spectra system.  This water has to be figured in the mixture.

1. Perform the applicable start-up procedure and make 5 gallons of water allowing it to flow into a clean container using the product Y valve.  Do not use tap water or chlorinated water!  Distilled or charcoal filtered water is acceptable if making it’s own water is not an option.
    
2. Open the pressure relief valve one half turn to depressurize the system.  Flush the first 4 gallons through the system using the intake Y valve. Leave 1 gallon in the container.
       Now mix 1 container of SC-1 into the 1 gallon that is left.  Do not let skin, eyes, or lungs have any contact with the storage and cleaning chemical.
       If a fresh water flush system is installed, perform a normal flush, then, using the discharge Y valve, divert 1 gallon of fresh water into the cleaning container.  Shut down the system and mix in 1 container of storage and scale cleaning compound.
    
3. Direct the brine discharge into the container using the discharged Y valve.  Run the system, recirculating the solution for 5 minutes to completely mix the chemicals and saturate the membrane.  Light discoloration of the solution is acceptable.  After 5 minutes return the discharge Y valve to the normal position and empty the container.
   If the solution becomes excessively discolored, mineral scale and live biological growth may be  present.  Refer to the membrane cleaning section for further instructions.
    
4. Close the intake thru-hull and switch the intake Y valve back to the normal position.  If the system shares an intake thru-hull, move the intake Y valve lever midway between normal and alternate positions.  This will close off both ports and isolate the watermaker.
    
5. Remove and clean the sea water strainer screen and pre-filter.  Reassemble dry.
    
6. When returning the system to service after pickling, check the intake thru-hull and Y valves, then run unpressurized for at least 30 minutes to purge the system.  Discard the product water for another 20 minutes after pressurizing.
    
7. To winterize, Flush the system with 5 gallons of potable water system antifreeze instead of  using the normal SC-1 storage procedures.

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Maintenance

The Sea Water 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 seal and element are in place on reassemble.  When the system is put into storage, remove, rinse and reassemble dry to impede corrosion.  Check frequently during operation.

The Micron Pre-filter   (Replace with 5 micron filters only)

The pleated fiber 5-micron pre-filter will need the most attention.  The easiest way to service the filter is to first shut off the thru-hull, open the housing, discard the old filter, remove the o-ring and clean the housing.  Reinstall the o-ring and reassemble the pre-filter with a new 5-micron filter element.  Leave dry until the next start-up.

Used pleated elements can be carefully cleaned if they are not too compacted.  Do not use full pressure from a garden hose or scrub with a hard brush on the pleats.   Gently spray the outside with water and then plug one end with your hand, filling from the other end to flush from the inside.  Be careful to not distort the pleats.  Another way is to tow them behind the boat until clean, 4 knots maximum.  Slip a line through the filter and tie a stopper knot.  Elements that show any signs of deterioration should be replaced.  Check for leaks on the first run after a filter service.

The Membrane

The membrane needs to be cleaned only when it has lost up to 10% of  its capacity due to fouling.  The leading cause of fouling is from biological growth that occurs when the system is left unused for long periods, such as a week or longer, without pickling.  Fouling from mineral scaling can happen under certain sea water conditions, and from rust.  Higher than normal pressures and amp draw for the sea water temperature and salinity conditions are the main indicators of membrane fouling.  Other conditions can cause high pressure (such as in very cold water).   Low product flow is usually due to low voltage or a clogged pre-filter.  Look for all other causes before cleaning the membrane.

There are two types of cleaners: acid and alkaline.  The acid cleaner (SC-1) will remove mineral scaling and kill live microbes and is also used for storage.  The alkaline cleaner is used to remove biological byproducts, oil and dirt particles that get past the pre-filters.  If membrane performance is reduced and has not been pickled recently, cleaning with both chemicals is recommended. The acid cleaner should be used first.  The acid cleaner is also used as the storage solution so scale is automatically reduced when the system is “pickled”.  If  biological growth is suspected the alkaline cleaner can be used on the next start up after the unit has been "pickled".

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.  Call Spectra Watermakers before removing a membrane. 

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Membrane Cleaning Procedures

For normal cleaning the SC-1 Storage and Cleaning Compound is used first then the SC-2 Alkaline Cleaning Compound.  If the unit has been "pickled" recently with the SC-1 solution then some cleaning has already occurred, so use the SC-2 first.  If the membrane does not respond to the SC-2 use the SC-1, following  the normal cleaning procedures.  Using hot water, 120 deg., is mandatory as it greatly enhances the ability of the cleaners to do there jobs.

If the history of the system is unknown or has been left “unpickled” for an extended length of time and biological growth is present, it is recommended that the system is cleaned with the SC-2, using an alternate source of unclorinated fresh water before the system is pressurized.  A simple test can be performed to see if biological growth has occurred:  Before running the system, remove the pre-filter and examine its condition.  If the housing is full of discolored smelly water, the system was not properly stored.  Next check the membrane. Open the pressure relief valve 1/2 turn and divert the brine discharge into a container using the Y valve.  Install a clean pre-filter if it was bad then run the system for one minute.  Examine the brine water, if it’s discolored and smells bad, perform a SC-2 cleaning with an alternate source of nonchlorinated water before running the system pressurized.  If the brine is fairly clean, the system can be run and checked for performance.  Clean the membrane only if the performance is reduced by 10%.

Cleaning Procedures

Note: procedures are the same for the SC-1 and SC-2 cleaners

The SC-1 and SC-2 Cleaning Compounds have to be mixed at 1 Spectra container to 3 gallons of  fresh water to have the proper solution.  Do not mix yet!  An average of two gallons of water is in the Spectra system.  This water has to be figured in the mixture.  The cleaning solution needs to be heated to 120 deg. F.  A large stainless steel pot and a hot plate instead of the cleaning bucket is one way.  An accurate thermometer is necessary.  Do not let the solution over heat!

1. Perform the applicable start-up procedure and make 5 gallons of water allowing it to flow into a clean container using the product Y valve.  Do not use tap water or chlorinated water!  Distilled or charcoal filtered water is acceptable if making it’s own water is not an option.
    
2. Open the bypass valve one half turn to depressurize the system.  Flush the first 4 gallons through the system using the intake Y valve.  Leave 1 gallon in the container.  Now mix 1 Spectra container into the 1 gallon that is left.  Do not let skin, eyes, or lungs have any contact with the storage and cleaning chemical.
   If a fresh water flush system is installed, perform a normal flush, then divert the brine discharge into the container using the discharge Y valve to get 1 gallon of filtered fresh water needed.  Mix in 1 Spectra container of cleaner.
    
3. Divert the brine discharge into the cleaning container along with the intake hose and the product tube using the Y valves to create a closed loop.  Three lines will now be in the cleaning solution container.
    
4. Run the system unpressurized for one hour while maintaining the solution at 120 deg.F, then turn off for one hour to let the membrane soak.  Run the system again for 1 hour while heating the solution, then turn off for one hour.
    
5. Re-direct the brine discharge overboard using the Y valve, then run the system until the container is empty.
    
6. Move the intake Y valve to the normal position.  Run the system unpressurized for at least 30 minutes to purge the cleaning solution.
    
7. After purging, tighten the bypass valve to pressurize the system.  Manually divert the product water.  When the system has stabilized, check the pressure, product flow and quality to determine if the membrane is functioning normally.  If the cleaning solution became very discolored during the cleaning process, it is recommended to repeat the process.  If the alkaline cleaning did not affect the membrane enough, repeat the cleaning process using the acid cleaner.  Always manually reject the product water for 20 minutes after cleaning.
    
8. If the membrane performance is still poor and no other problem can be found, contact Spectra Watermakers for further assistance.

Membrane Element Replacement

Do not remove the membrane from the housing unless absolutely necessary.  Troubleshoot for all other causes of poor performance and try the recommend procedures first.

Disassembly:

Disconnect the high pressure tubes, cut the housing mount bands, and move the membrane housing to a work area that can handle water spillage.  Clean off any deposits on the ends with a stiff brush and fresh water.  Note which end goes where so they can be reinstalled the same way later.

Cut the SS safety wires from the small socket head screws that hold the retainer brackets.  Loosen the retainer screws the until threads are just visible above the retainer segment.  Each screw is an integral part of a retainer bracket, do not separate.  If the screws are frozen apply penetrating oil around the screw heads, allow to penetrate, then retry.  Using a rubber mallet, plus a piece of wood or hard plastic as a cushion, tap on the end plug until it moves in slightly and away from the retainer brackets.  Remove the retainers.  They can be removed with the factory plumbing fittings in place.  Remove the end plugs by pulling on the product port connections.  A sharp, forceful tug plus some side to side rocking may be required to break the seal between the plug and the vessel bore.

Find and remove the large O-rings.  Remove the small O-rings from the end plug product tube bore with the dull pick.  Inspect the end plugs for damage or corrosion, replace if necessary.

Push the membrane element out of the housing by first pushing on the outlet end.  If it resists, try pushing on the other end.  If the membrane is going to be kept for any reason, seal it in plastic before it dries out.  Do not open the new membrane packaging until ready to install.

Assembly:

Install the inlet end plug first. Use new O-rings.  Lubricate the O-rings with glycerin or with a thin layer of a pure silicone lubricant and insert the end plug, then using both thumbs apply equal pressure on the plug until moves in and clear of the retainer bracket groove in the collar.  Lube the retainer screw threads before installing the retainers.

Check that the new element has a brine seal on one end only.  Lubricate the element brine seal and wet the inside of the housing.  Insert the brine seal end of the element into the outlet end of the housing.  A gentle push with a slight rocking motion should compress the brine seal lip so it slips inside.  Push the element into the housing, the brine seal will give some resistance, until it completely engages the inlet end plug.  The element product  catch tube engaging and passing through the small O-ring can be felt.  The element brine seal should now be next to the inlet plug.

Install the outlet end plug the same way as the first.  It will go in harder because of the product tube O-ring engaging the element.

Safety wire the screws and remount and plumb the housing.  A new membrane has a pickling solution in it and should be thoroughly flushed before use.  Follow the new system start up procedures.

Open the pressure relief valve 1/2 turn and start the system.  Look for leaks at the end plugs.  If a large leak is present, the large O-ring around the end plug is not seated properly and the end plug will have to be removed and redone.  After flushing, close the relief valve and check system for proper operation. 

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Installation Basics

The Spectra Watermakers are designed for energy efficiency.  All aspects of the system have been optimized for this goal, therefore any changes in the basic layout or components will most likely reduce this efficiency.  The overall length of the feed, discharge and high pressure hoses have little effect on performance and can even help smooth out the Clark Pump shift pulses but that every hose bend or 90° fitting absorbs power.  Since a minimum amount of power is used to run the system, there is little allowance for waste.  Avoid adding 90° fittings.  Use gentle hose bends where possible.  Careful consideration of the direction of water flow through the pre-filters and boost pump in relation to how they mount will minimize hose lengths and turns.  The system diagram shows the components mounted port side on the aft face of a bulkhead.  If the layout was mirrored to the starboard side, the hose runs would be much more convoluted.   A good installation will be a proper compromise between minimum hose and wire runs, accessibility, environment and esthetics.

Thruhulls

It is recommended that a designated 3/4” intake thru-hull and seacock be installed for the system as far below the water line as possible .  Sharing a thru-hull with another system is acceptable, but can introduce unforeseen problems such as intermittent flow restriction, air bubbles and contaminates.  If the system is sharing an intake thru-hull, the intake Y valve can be used to shut off water to the system.

Do not install the intake close to or down stream of a head discharge.  Install as far below the water line and as close to center line as possible to avoid contamination and air induction.

We recommend that a reputable boatyard install any underwater thru-hulls.

The discharge thru-hull should be mounted above the waterline, in or just above the boot stripe to minimize water lift.  Having the discharge feed into a cockpit or sink drain will work, but can make an unpleasant gurgle sound.

Double clamp all hose connections below the water line if possible.

Fittings

Pipe fittings that are to thread into plastic should be coated with at least 3 wraps of Teflon tape.  To avoid cracking the plastic, tighten until only 1/2 of the threads are buried.  This may not seem tight, but they will not, and should not, bottom out like a metal to metal connection.

Metal to metal pipe connections should have 1-1/2 to 2 Teflon wraps only.

Be very careful to avoid getting any tape over the end of the fitting that might get into the system.  To insure this does not happen, leave the very first thread uncoated. 

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General Plumbing

Follow the Plumbing Diagram below for hose and tube connections.  All feed and discharge hoses are made of 5/8" reinforced nylon.  The high pressure tubing is 1/2” OD connected with 1/2” tube to pipe 316 SS compression fittings.  The 90° high pressure SS tube fittings mounted in the high pressure in and out on the Clark Pump can be rotated up to 1/2 turn for better tube runs.  Straight SS tube fittings can also be used.  The product water lines are 1/4" black plastic tubing with connectors.  Feed water operating pressure up to 100 psi requires vigorous hose clamp tightening.  It is recommended to lubricate the clamp screw and use a nut driver for the final tightening.  Double clamp all connections that are below the water line on the suction line to the feed pump.  Re-tighten all hose clamps and check for leaks after the first few hours of running.

If you use feed hose or product tubing that is not supplied by Spectra Watermakers, it is mandatory to use products with a minimum burst pressure of 250 psi.  If other types of pre-filter housings are used, they need to rated at 120 psi minimum working pressure.

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Feed and Discharge Hoses

Route the 5/8" hose smoothly between the components.  Use straight hose fittings and gentle turns in the hose where possible.  Minimum hose bend radius is 6”.  Tightly secure hoses with tie wraps to avoid chafe.

High Pressure Hoses

Be sure to follow the Clark Pump and Plumbing Diagrams for proper connection between the Clark pump and the membrane housing.  Membrane water flow direction is marked on the housing.  Rotate the 90 deg. high pressure tube fittings on the Clark Pump for ideal tube runs.  The high pressure tubes are usually made in place.  Loosely route the tubes between the Clark pump and the membrane and cut long.  Minimum tube bend radius is 6”.  Follow the tube connection instructions on page 39.  Connect the tubes to one of the components, secure the tube runs, and then trim and connect to the other component.  A 90° bend in a hose is better than a 90° 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.

If other than the Spectra supplied tube and fittings are used, they need to be at least 1/2" ID if hose, 1/2” OD if tube, with non-ferrous 1/2” high pressure fitting,s and have a working pressure of at least 2000 psi.

When connecting the tubes to the components, be sure to hold fitting body during the final tightening.

Product Water Tubing

The product water lines are 1/4" plastic tubing.  Minimum tube bend radius is 3".  Connection can be made to either end of the membrane housing.  Refer to the tube fitting assembly diagram below.   IMPORTANT: The product water flow should not be restricted in any way.  If the line gets blocked, the pressure will build until the line fails. Restricting the flow will reduce efficiency and may cause damage to the membrane.  Connect to the water tank at or near the top.  The ideal spots are to tee into the tank vent line or the fill hose.  Do not tap into the bottom of the tank or a tank feed manifold.  Air can be pulled through the membrane and affect the domestic water system.

1/4" Tube Fitting Assembly Diagram

Y Valves

Carefully study the function of Y valves before committing to a plumbing plan.  It is easy to design a clean looking layout only to find out that it doesn’t work.  The stem of the tee shape is the common port so the valve will always introduce a 90° turn in the line.  Try to mount the valves so that normal working positions of the handles are the same, such as all vertical or all to the right.  The alternate port 5/8” hoses can be attached to the Y valves using hose barbs or brass garden hose couplings for easy removal and storage.  The product alternate tube can be easily removed by unscrewing the plastic gland nut.

Fittings

Pipe fittings that are to thread into plastic should be coated with at least 3 wraps of Teflon tape.  To avoid cracking the plastic, tighten until only 1/2 of the threads are buried.  This may not seem tight, but they will not, and should not, bottom out like a metal to metal connection.

Metal to metal pipe connections should have 1-1/2 to 2 Teflon wraps only.  Be very careful to avoid getting any tape over the end of the fitting that might get into the system.  To insure this does not happen, leave the very first thread uncoated. 

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Component Placement
Refer to the Plumbing Diagrams above

Intake Y Valve   (Note: Intake (common) port is opposite the handle shaft)

Install the 1/2” intake Y valve between the thru-hull and the intake strainer.  Use the “U” clamps provided.  It is ideal to have the intake, discharge and product Y valves accessible from a single position.  The hose attached to the alternate port should reach a container that is positioned in a stable area that can handle water spillage.  Moving the lever to the center position half way between the normal and alternate positions will close all the ports.

Sea Water Strainer

Mount the sea water strainer between the intake Y valve and feed pump in a protected, accessible and visible spot that is not above water sensitive equipment.  Secure it with the black plastic mount and tie provided.  Allow a minimum of 1-1/2" space below for the strainer bowl removal.  Note the direction of flow on the housing and mount to minimize hose lengths and bends.

Feed Pump  (Note: Cooling fins can snap or slide off the motor for mounting access)

Mount the feed pump in a vertical position, pump head down, in a dry area and as far below the water line as practical to provide positive feed pressure.  Do not mount over water sensitive equipment.  The pump is self priming and can be mounted up to 4 feet above the water line, but keep it as low as possible.  Note the direction of flow through the pump and mount to minimize hose lengths and bends.  Use the feed pump mounting hole template taped into place, see page 44, to mark and drill for the fasteners.  Avoid mounting the pump on large unsupported panels to help reduce noise.  For quieter operation, do not mount the pump with the rubber feet, instead hang the pump by the hoses and secure the motor with large wire ties with a piece of foam underneath  Do not mount the pump horizontally, priming problems can occur.  If the pump has to be mounted in a hot area, installing the optional cooling fan is recommended.  To install the optional fan, slip the split plastic shroud over the cooling fins, with the split on the mount side, till the fan touches the end of the motor.  Make sure the pump wiring is clear.  Leave a minimum of 1”clearance above the cooling fan.

Dual Feed Pump System  (Spectra 380c)

Mount the two fan cooled pumps in the same manner as specified in the last paragraph.  Mounting the pumps close to each other allows for easier plumbing but is not necessary.  The pumps are plumbed in parallel using the 5/8” tees supplied.  Orient the tees so that if the feed  to a pump is straight through the top if a tee, that the discharge goes into the stem of the tee and turning a right angle.  The other pump will be opposite.  This helps balance the flow through the pumps.  Follow the Plumbing Diagram above for proper tee connections.

Pre-filter

Refer to pre-filter plumbing on the diagram below.  Use the bracket as a template for the mounting fasteners.  The bracket can be mounted with the angle down by first mounting the bracket, then attaching the filter it to with the screws provided.  Mount the pre-filter in an accessible location that can be reached with both hands, as the bowl can get tight.  Wrenches designed for filter removal are available.  Salt water will be spilled during servicing, so do not mount the pre-filter above any sensitive equipment.  Note the flow direction and mount to minimize hose lengths and bends, allowing room for the hose fittings and gentle hose bends.  Allow 1-1/2” of space below the filter for housing removal.  Mounting an optional feed pressure gauge before the filter can aid in determining pre-filter condition.

Pre-filter Plumbing Diagram

Clark Pump

Refer to the The Clark Pump Mounting Diagram below to install the mounting brackets and shock mounts.  Bolt the mounting brackets to the base of the center block with the short 5/16” SS bolts and washers, sandwiching the plastic washers in between the center block and the brackets.   The brackets will over hang from the front and back of the center block.  Moisten the rubber shock mounts and slip them into the bracket holes then install the plastic inserts.

The Clark Pump can be mounted on any horizontal surface that will support it’s weight and is not subjected to excessive vibration.  Height above or below the water line is unrestricted.  Allow for easy access to the pressure relief valve for system servicing.  Mounting on a vertical surface can be expedited by using the optional "L" bracket.  For hanging from overhead, use two of the "L" brackets.  Avoid mounting in the middle of a large unsupported flat surface that could amplify the sound of the pump shift.

Allow room in the front and back for access to the high pressure tube and hose connections.  The 90° fittings supplied are acceptable for the feed and high pressure tube connections to the unit and can be rotated for easy tube runs.  Straight fittings can also be used.  The brine discharge hose connection to the reversing valve body should be straight if possible, and can be connected to either end of the reversing valve.  Plug the unused port.

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.

Use the Clark Pump mounting hole template, see page 44, to mark and drill for the fasteners.  1/4" bolts and Nylock nuts are preferred, but lag bolts are acceptable if they penetrate at least 1" into solid material.  Drill pilot holes for lags bolts.

Caution: Tighten the fasteners until there is light pressure on the plastic inserts.  The plastic inserts will collapse if over tightened.  The 1/4” fender washer must be on top to prevent the mounting brackets from slipping out of the rubber mounts under adverse conditions.

Do not mount the Clark Pump in an area that is subject to sustained temperatures over 120 deg. F.

Clark Pump Mounting Diagram


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Membrane and Housing Assembly

Mount the membrane and housing assembly as close to the Clark Pump as possible, using the black plastic brackets and heavy duty black tie wraps provided.  The plastic tie wraps allow the membrane housing to expand and contract with pressure changes without damage.  Mount the membrane preferably at or below the level of the valve body on the Clark Pump to help purge air.  It is OK to mount the membrane above the Clark Pump, but keep it as close as possible.  The membrane housing is marked for water flow direction and can be mounted at an angle or vertical, but the brine outlet end should be up to help purge air.  If the flow direction mark on the housing is lost the high pressure brine outlet is on the end where the product tube fitting was factory mounted.  The high pressure inlet end only has a plug in the center product port.  Re-mark the housing.  If the plumbing was changed or if you are uncertain, refer to the membrane housing assembly instructions to remove the membrane cartridge and check for the brine lip-seal on one end of the membrane.  The high pressure inlet and membrane brine seal go on the same end.

Route the high pressure tubing to and from the membrane housing as smoothly as possible.  Avoid clamping the tubes tightly to any surfaces for sound dampening.  "Hanging" the tubes away from a surface with wire ties so that they are neither tight nor completely loose is best.

The product water tube can be connected to either end of the membrane.  Plug the unused product port.

Do not mount the membrane in an area that is subject to sustained temperatures over 120 deg. F.

Brine Discharge Y Valve

Mount the brine discharge Y valve between the Clark Pump and discharge thru-hull, within reach of the other Y valves if possible.  Use the “U” clamps provided.  The alternate hose should easily reach the cleaning container.  Moving the lever to the center position half way between the normal and alternate positions will close all the ports.

Spectra Monitor Panel

Mount the panel vertically in an easily visible area that can be reached by the feed pressure and product water tubing.  Use the Spectra Panel cut-out template, page 45, taped into position to mark and drill for the fasteners and cut-out.  Since keeping tabs on the system is vital for longevity, mount the panel where you will see it often.  Make sure there is room behind the panel for the tube connections.  If the mounting area is finished wood, tape the outside perimeter of the cutout and use a reverse tooth saw blade to prevent splintering.

Refer to the Plumbing Diagram above and the Panel Diagram below.  The product water tube from the membrane is connected to the bottom of the flow meter.  The top port is connected to the product Y valve, and finally to a tee in the tank vent.  The feed pressure gauge is connected to the extra  port in the accumulator tank.  Use the 1/4” black tubing and fittings.  If access to the back of the panel is limited leave enough extra tubing to allow the connections to be made before the panel is secured.  Route the tubes so they won't kink when the panel is pushed into place.  Fasten with # 4 screws.

Monitor Panel Plumbing
Use 1/4" black tubing and straight or 90 deg. tube fittings

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Product Water Y Valve

The 1/4” product water Y valve can be placed anywhere between the Spectra Panel and the tank.  The ideal location is within reach of the other Y valves.  Use the “U” clamps provided.  The alternate line should be long enough to reach the cleaning container for servicing.  Moving the product Y valve lever to the center cannot close the ports.

Accumulator Tank

Refer to the Plumbing Diagram above.  The accumulator tank mounts between the feed pump and the Clark Pump, as close to the Clark Pump as possible.   Connect one port to a tee installed in the feed line using the 5/8” feed hose.  The 1/4” feed pressure gauge line is connected to the other port.

Manual Fresh Water Backflush System (optional)

The optional Manual Fresh Water Flush system uses a charcoal filter that is in the same housing as the micron pre-filter and the same 1/2” Y valve as the intake and brine Y valves.  They mount the same way.  The backflush Y valve can be placed anywhere between the intake thru-hull and the feed pump but is usually mounted between the intake Y valve and the Strainer.  See the Manual Fresh Water Flush Diagram on page 42.  The fresh water is normally drawn from the tank in the same manner as the domestic water pressure pump.  Water from the pressure side of the domestic system can be used but there is a higher chance of leaks.

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Power Control Module (optional)

(For automatic salinity control with remote panel and automatic backflush options)

The power control module ideally should be mounted between the ships power panel and the feed pump(s).  Mount in a dry area preferably on a vertical surface with the wires down.  It can also be mounted horizontally.  Refer to the wiring diagram on page 50 for proper breaker and wire sizing.  Run all the wires through the hole in the bottom side leaving enough extra to make the connections to the electrical boards and can gently fold the wires into the box as the lid is installed.

Remote Control Panel (optional)

The remote control panel is designed to fit just above or below the monitor panel but can be mounted anywhere that’s dry and convenient.  Use the cut-out template on page 45.  The dotted lines show where the sides of the panel will be.  If the mounting area is finished wood, tape the outside perimeter of the cutout and use a reverse tooth saw blade to prevent splintering.  Run the multi-conductor cable between the power control module and the panel cut-out leaving extra at ether end.  Connect the wires to the terminal strips on the power control module and the panel, matching colors.  If access to the back of the panel is limited, leave enough cable to be able to make the connections before the panel is secured.  Fold the extra cable back through the cut-out and secure the panel with # 4 screws.

Automatic Salinity Control Probe and Diversion Valve

Follow the Salinity Control Plumbing diagram page 36.  The probe assembly and the diversion valve are usually mounted together as illustrated.  They can be mounted separately but the probe must be up stream of the diversion valve.  The probe assembly must be mounted with the probe on the bottom so any trapped air will not affect the system.  Mount the probe and valve between the product Y valve and the water tank.  Plumb the reject port on the diversion valve to a tee in the brine discharge line between the brine discharge Y valve and the brine thru-hull.  The tee can be hard plumbed to the Y valve or the thru-hull if desired.  Do not mount the tee up stream of the brine discharge Y valve or damage to the membrane may result.  Orientation of the diversion valve is not critical and the ports are labeled.  Follow the General Plumbing section in the Spectra manual for proper pipe connections.

Follow the 380c with Salinity Control and Backflush Options Wiring Diagram on page 50 for proper wire connections.  For 200c models, pump 2 and the fans are omitted.

Automatic Fresh Water Backflush System

Follow the automatic backflush plumbing diagram below (page 43).  The check valve must be mounted vertical with flow upwards to prevent the possibility of it sticking open and the solenoid valve must be plumbed down stream of the charcoal filter to prevent salt water contamination of the filter element. The components can be mounted separately if desired. Follow the 380c with salinity control and backflush options wiring diagram on page 50 for proper wiring.  The flush time is factory set.  After installation check if the timing is correct.  Run the system normally then shut down.  Make sure the ships pressure water system is on then activate the backflush system and watch the feed pressure at the monitor panel.  The feed pressure will drop and stabilize.  The system should continue run for 30 to 90 seconds after the feed pressure stabilizes then turn itself off.  To adjust, open the power control module and adjust the backflush pot that is wired to the timer.  Turn clockwise to increase flush duration, counter-clockwise to decrease.

Spectra High Pressure Tube Fitting Assembly

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.
Figure 1. 
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.
Figure 2. 
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.
Figure 3. 
The tube connectors can be disconnected and re-tighten several times.  To reconnect, insert the tube and ferrule into the body then hand tighten the nut.  Hold the body and tighten the nut with a wrench a little past where resistance is encountered.  When correct, the nut should be tightened a little past where it was before disassembly.  Always check for leaks. 

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Electrical

See the wiring diagrams on the following pages.

A robust electrical connection is crucial to the proper operation of the system.  Examine your electrical system carefully to determine the proper place from which to draw power.  If power will be drawn from a breaker(s) (15 amp) on the main distribution panel, make sure the panel has at least #8 gauge wire for panel positive feed and ground.  Check all connections for tightness, including the ground buss.  Refer to the wiring diagrams below (pages 49 and 50).

If the panel is inadequate or too far away, a direct connection to a battery is possible.  An in-line fuse (15 amp-slow blow) next to the battery and a switch (15 amp minimum rating) will be necessary for each pump on standard 200c and 380c models.  If the system has the power control module-remote control panel option, a 25 amp fuse is required.  For 24 VDC systems use 7 amp breakers for the feed pump wiring and a 15 amp breaker for the power control module.

For standard 12 VDC systems with individual pump wiring use a 15 amp breaker and #12 gauge wire for all lengths up to 10 feet, #10 gauge up to 18 feet, and #8 gauge up to 28 feet.  A terminal strip mounted next to the feed pump can help connect the large wire to the #14 gauge wire from the pump.  For 24 VDC systems use a 7 amp breaker and step up one wire gauge number.

For systems with a power control module, use a 25 amp breaker and #10 gauge to 10 feet, #8 gauge to 18 feet, and #6 gauge to 28 feet from the power source to the module and follow the individual pump wiring directions in the last paragraph for the feed pump wiring from the power control module.  For 24 VDC systems use a 15 amp breaker and step up one wire gauge number.

Use marine grade insulated double-crimp connectors that match the wire gauge.  Size ring terminals to the size of the fasteners.  Crimp the connectors with a crimper designed for insulated connectors using both hands as hard as you can for the main crimp, and a little easier for the insulation crimp.  Pull on the connector to test the strength of the crimp, you should not be able to pull it off.  If butt connectors are used to connect #10 gauge wire to #14 wire, strip twice the amount of insulation from the small wire, then fold the bare wire back on itself before inserting into the connector.  Heat shrink all connections where possible.  Remember to slip the heat shrink onto the wires before crimping.

If the optional cooling fan is used, or in the Spectra 380c, insert the fan wires in the connectors along with the pump wires, positive with positive, negative with negative.

Follow the pattern of the original factory wiring when adding a new circuit.  When adding a new wire to an existing wire bundle, remove all the old tie wraps where possible, run the new wire, then tie at even intervals.  This will result in a clean and "original" look.

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Troubleshooting Guide

SYMPTOM	CAUSE	REMEDY
System does not run.	*Tripped breaker or blown fuse.	*Check wiring to motor
	*Pump power relay faulty. (relay optional)	*Replace relay.
	*Motor burned out.	*Replace motor.
	*System over pressurized.	*Check for fouled membrane.
Feed pump runs but no fresh water flow.	*Thruhull closed.	*Check system, then open thruhull.
	*Pressure relief valve open.	*Close relief valve.
	*Pump air-locked.	*Open relief valve to purge air, then close.
Lower water production, high amp draw, low feed pressure.	*Pre-filter clogged.	*Service pre-filter.
Low water production, normal to low amp draw, normal to low feed pressure.	*Relief valve partially open.	*Tighten hand tight only.
	*Leak in high pressure hoses or fittings.	*Tighten or replace fitting and/or hose.
	*Internal leakage in the Clark Pump.	*See Clark Pump Repair Manual.
	*Debris in feed pump check valves.	*Disassemble pump head and clean.
Water production normal, feed pressure high, high amp draw.	*Cold sea water temperature.	*Normal operation.
	*Membrane starting to foul.	*Clean membrane.
Water production normal, feed pressure low, amp draw low.	*Warm sea water temperature.	*Normal operation.
Water production high, poor water quality.	*Seal failure inside membrane housing.	*Disassemble and check for bad seals and/or corrosion.
	*Membrane failure.	*Replace membrane.
Asymmetrical pressure and flow readings between shifts.	*Reversing valve seal leaking.  *Shaft seal leaking.  *Pin seal leaking.  *Check valve leaking.  *Scored cylinder wall.  *Piston seal leaking.	*See Clark Pump Repair Manual.

Note: Variances in cylinder wall break-in can cause small asymmetrical readings for periods of time and are normal.

For instructions on repairing the Clark Pump, please contact Spectra Watermakers.

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LIMITED WARRANTY

Spectra Watermakers warrants to the original purchaser that all components, except for the Clark Pump, are free from any defects in material and/or workmanship for a period of one year from the date of purchase.

Spectra Watermakers warrants to the original purchaser that the Clark Pump is free from any defects in material and/or workmanship for a period of three years from the date of purchase.

If any such defect is discovered and reported within the warranty period, Spectra Watermakers will repair or replace the affected component free of charge, subject to verification of the defect or malfunction upon inspection at Spectra Watermakers.  The customer is responsible for all costs incurred for removal, shipping to and from our facility, and reinstallation.

This warranty does not apply to malfunctions or physical damage resulting from abuse, neglect, accident, alteration, modification, submersion, shipping damage, hoses and fittings not supplied by Spectra Watermakers, improper membrane maintenance, or improper installation. Consumables such as pre-filter elements are not covered.

Spectra Watermakers, under no circumstances, shall be liable for any consequential damages arising out of, or in any way connected with, the failure of the product to perform as set forth herein.  This limited warranty is in lieu of any and all other expressed or implied warranties.

Spectra Watermakers reserves the right to make changes or improvements on its products without incurring the obligation to retrofit such changes or improvements on previously manufactured units.

If a possible warranty problem is detected, please contact one of our service representatives before any disassembly for assistance, and to receive a Return Authorization number if a component is to be returned for a warranty repair.

Proof of purchase, return address, and a Return Authorization number are required for all warranty repairs.  Ship to address below. 

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Letzte Änderung / Last change: Freitag, 10. Dezember 1999