Gulfstream 400 Spectra Form – Fill Out and Use This PDF

GULFSTREAM 400

OPERATION AND INSTALLATION

MANUAL

Spectra Watermakers

A Division of Edinger Marine Service, Inc.

page 1

Introduction

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 service 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

Start-Up Performance Readings

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

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Shipping List

Standard System

(1)Operation and Installation Manual

(1)Clark Pump

(1)Membrane and Housing Assembly

(1)Main Pump Module including: Pumps, heat sinks, and cooling fans Sea water strainer Accumulator tank

Monitor and control panel Automatic salinity control system Automatic fresh water backflush system 20 and 5 micron pre-filter assemble

(1)Remote Control Panel and Wiring Harness

(1)Installation Kit Including:

Clark Pump mounting hardware Membrane housing assembly mounts (10’) high pressure tube

50’ of 5/8” hose

25’ of 1/4” product tubing Hose and tube fittings Hose clamps

One container of SC-1 storage chemical

Options

Clark Pump Mounting Bracket

Basic Cruise Kit

Includes three 20-micron filters, three 5-micron filters, and two SC-1 storage

chemical containers

Offshore Kit

Includes Clark pump seals, tools, two SC-2 cleaning chemical containers, and overhaul instructions

Spare Feed Pump

Hand held salinity monitor

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Shopping List

In addition to the installation kit.

Refer to manual for wire size and type of fasteners

Fasteners/Hardware for mounting components to desired surfaces. Marine grade duplex wire, connectors and wire ties with mounts. One 2 gallon plastic mixing container.

One 25 amp fuse or circuit breaker switch

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 Spectra Gulfstream a full featured, semi-modular version of the Spectra 380c. It is ideal for larger sailing and motor yachts. Powered by DC current, a generator set is not mandatory.

Using the patented Clark Pump and paying careful attention to system efficiency, the Spectra Gulfstream, in the efficiency mode, operates on a fresh water to power ratio that surpasses everything in the marine industry. The system makes an average of 9 gallons per hour on 9 amps @ 12.5v DC, less than 13 watt hours per gallon! That means that making one gallon of fresh water is like running only a small DC cabin light for one hour! In high production mode, the Spectra Gulfstream produces up to 17 gallons per hour using less than 20 amps.

The semi-modular design allows for easy installation. All of the pumps, pre-filters, automatic systems, gauges, controls, and service valves are mounted in and on a lightweight non-corrosive enclosure. The Clark Pump and the membrane are easily mounted in any convenient location. The system’s feed pumps are self priming so they can be up to 4 feet above the water line!

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 400 gallon per day unit running in 61 degree F water will only make 280 gallons per day. The Spectra Gulfstream will still be producing up to 400 gallons per day on a fraction of the power.

The automatic salinity control system, automatic fresh water flush system, and a full function remote control panel are included standard

Pressures are self-regulating, eliminating the need for adjustments, even when operating in brackish waters. The feed pressure is limited to 125 psi.

Self priming multi-diaphragm feed pumps are all that drive the system. No additional boost pump is needed, or even helpful. The Spectra Gulfstream'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 20-micron and 5-micron dual pre-filter assembly is provided standard for maximum system life and reduced filter maintenance.

The system’s noise level is exceptionally low and unobtrusive, especially compared to other systems of similar capacity. The feed pumps have a smooth, steady sound and almost no vibration.

An installation kit is included.

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Spectra Gulfstream Performance Specifications:

Efficiency Mode (one feed pump)

Sea water temperature @ 50 degrees F (10 degrees C):

Sea water temperature @ 77 degrees F (25 degrees C):

Sea water temperature @ 90 degrees F (32 degrees C):

High Production Mode (two feed pumps)

Sea water temperature @ 50 degrees F (10 degrees C):

Sea water temperature @ 77 degrees F (25 degrees C):

Sea water temperature @ 90 degrees F (32 degrees C):

Sea water salinity @ 35,000 parts per million TDS

Salt rejection: 99.0% ~99.4% Typical purity test: < 400 mhos, 200 ppm, 99.4% pure Performance Tolerance +/- 10%

Maximum Operating Temperature 113 degrees F (45 degrees C)

Dry weight: 80.5 lbs.

Component Description

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Note: The main module components are pre-plumbed and wired at the factory. All installation plumbing connections are made to the outside. Main power wiring connections are made inside. The remote-control panel connects to a pig-tail outside. To gain access, remove the two 1/4” screws in the top panel, it will now hinge open. If further access is needed, the face panel is removable. By removing the eight mounting screws, valve handles, and disconnecting the tubes, the panel can be pulled clear enough for access without disconnecting the wiring .

*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 control circuits to allow single pump or duplex pump operation modes. The single pump mode is used when energy efficiency is desired. The system can be run directly off charged batteries with out having a charging source running at the same time. Feed pressures average about 70 psi and the power draw averages 8.5 amps per hour. In duplex pump mode, feed pressure averages about 95 psi, drawing less than 20 amps per hour . It is very important that the cooling fans be operational when both pumps are running. Each pump is drawing almost 10 amps which may generate too much heat for the cooling fins to dissipate adequately in a high temperature environment. The high pressure cut out switches are are factory set at 125 psi.

*20 and 5 Micron Dual Pre-filter Assembly

The pre-filters do the essential job of cleaning the sea water before it gets to the Clark Pump and R.O. membrane. Replaceable pleated fiber filters are 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 only 20 or 30 micron filtered water. The 20 micron filter plumbed in front of the 5 micron reduces filter maintenance.

*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. Its 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.

*Feed Pressure Gauge

The feed pressure gauge is an indicator of system operational status. Higher than normal pressures indicates the need for pre-filter service.

Component Description, cont.

*Product Water Flow Meter

The product water flow meter indicates the flow in gallons per hour. The reading is taken at the middle of the indicator ball.

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*Power Control Module

The Spectra power control module is a plastic enclosure that is mounted inside on the lid of the main enclosure. The power feed wires connect to the face. It has all of the power relays, fuses, and electronics for the feed pumps, the salinity control system, and 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, salinity and backflush solenoid valves, salinity probe, and the remote paned are all wired to the control module.

*Service Valve Manifold

The service valves are in the feed, brine discharge, and product lines to provide easy access for proper maintenance. The service hoses attach to the panel face and are lead to a cleaning container. IMPORTANT: The intake and discharge service valves will close off all the ports if the lever is moved to the “Off” position. The product service 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. The salinity control solenoid, the backflush solenoid, and the feed water check valve are incorporated in the manifold.

*Salinity Control System

The salinity control is integrated with the power control module and controls a product water diversion valve mounted in the service valve manifold. There are “reject” and “good”

salinity indicator lights on the main and remote control panels. 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.

*Automatic Fresh Water Backflush Systems

Warning: The ship’s domestic water system must be pressurized before flushing

An automatic fresh water backflush system allows the operator to start a timed backflush cycle from the control panels. The automatic system incorporates a charcoal filter to remove chlorine, an electric solenoid valve, a check valve mounted in the service manifold, and a power relay to run one feed pump. 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. Replace the charcoal filter every 6 months.

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.

Component Description, cont.

* Remote Pressure Relief Valve

The pressure relief valve on the panel face duplicates the function of the pressure relief valve on the Clark Pump. It is plumbed to a SS fitting on the top of the Clark Pump with high pressure 1/4” tubing. The high pressure 1/4” tubing is different than the product 1/4” tubing

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and should not be interchanged. Opening the valve 1/2 turn will allow the system to be run without developing pressure. This is necessary for priming and membrane cleaning.

Remote Control Panel

The Spectra remote control panel is integrated with the Spectra power control module, salinity control system, and the automatic back flush system. The panel has switches for both 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 by a waterproof connector on a pig-tail.

Sea Water Strainer

The strainer filters the salt water to the feed pump. 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.

Installation Kit

The installation kit includes 50 feet of 5/8” reinforced non-toxic feed and discharge hoses, 10 feet of 1/2” high pressure tubing, 25 feet of 1/4” plastic product water tubing, standard mounting brackets, and all of the required fittings and hose clamps for most installations.

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.

Basic Cruise Kit (optional)

The kit includes three 20-micron and three 5-micron filters and the SC-1 storage and scale cleaning compound (pickling) for 2 storage procedures.

Offshore Kit (optional)

The kit includes all seals and o-rings, composite valve sleeves, field tools and rebuild instructions for the Clark Pump and the SC-2 alkaline membrane cleaning chemical compound.

Operating Procedures

New System Start-Up

Caution: Avoid running the system if the vessel is in contaminated water, such as in a harbor or canal. Membrane damage and pre-filter clogging may result. Move the vessel to cleaner water. If the boat cannot be moved, test the system by running the fresh water flush cycle 5 times with

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the pressure relief valve open and again 5 times with the pressure relief valve closed with the product water diverted. This will flush the storage solution from the membrane. The system can now be run using a clean source of sea water in the cleaning container. Unchlorinated fresh water mixed with sea salt can also be used. Use the intake and brine discharge service hoses to recirculate the salt water from the container.

1.Check battery voltage. A nominal 12.8v DC to 14.4v DC should be indicated.

2.Confirm that the intake thru-hull is open and the strainer is clear.

3.Have the intake and brine discharge service valves in the normal run position and the product service valve in the “Service” position. Direct the product service tube to a container or into the bilge. The pressure relief valve on the Clark Pump should be closed.

4.Open the pressure relief valve on the panel face 1/2 turn and start one feed pump from the main or 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. 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 15-20 psi should be indicated between shifts with one pump running and about 35-40 psi with two pumps running. The pumps must be primed separately!

5.Check the feed pump high pressure cut out switch set point. Do one pump at a time. With the system primed and running unpressurized, block the brine flow by moving the brine discharge service valve lever to the “Off” position. 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 125 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. Now is a good time to check for leaks in the feed and brine connections as they are now pressurized to maximum.

6.Run the system unpressurized for 30 minutes after start-up to purge the pickling solution in a new membrane.

7.Close the pressure relief valve to pressurize the system and watch for the feed pressure to rise. If the pressure does not rise, check that the pressure relief valve on the Clark Pump is closed. 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

Operating Procedures, cont.

times in the efficiency mode and under 100 psi in high production mode. The feed pumps should never be allowed to cycle their high pressure cut out switches 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, check the high pressure cut out set point and/or check the accumulator pre-charge. If the feed water is around 55 degrees or colder and/or is extra salty, the high production mode feed pressure might go high enough to cycle one pump on and

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off even when all else is normal. In those conditions only run one feed pump.

8.After one hour, the product service valve can now be switched the “Run” position to direct the flow to the water tank. The “Good” salinity indicators on the panels should light. Break open the product line to the tank to see if the water is flowing to confirm proper operation of the diversion valve.

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, compare them to the specification page and enter 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), start the system in the desired mode and close the pressure relief valve, if it is open. The automatic salinity control will reject any brackish product water with the diversion valve and the red “Reject” indicator will light. When the salinity probe detects potable water, product is directed to the tank and the “Green” indicator will light.

2.If air is in the system and one or both feed pumps have lost their prime, open the pressure relief valve and run one pump at a time to purge the system. The feed pumps cannot prime if their output is under any pressure. Remember to purge the 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, page 8 ). 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.

Warning!

On start up, if the feed pressure keeps rising until the feed pumps shut off and the Clark Pump is not shifting, depressurize the system and press the reset button on the side of the reversing valve on the Clark Pump, all the way in, to unstall the system. To avoid a stall condition, always turn off the system right after the Clark Pump “shifts”. Also check that the service valves are in the normal run position.

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. Attach the product service line lead to a container or into the bilge. Switch the product service valve to the “Service” position to manually reject any product water. Close the pressure relief valve to pressurize the system. Run for another 30 minutes then switch the product service valve back to the “Run” position.

Operating Procedures, cont.

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 running the system:

Open the pre-filters and inspect their condition. If the filters are black and smell bad, that’s one indication that the system is fouled. Install new or cleaned pre-filters. Attach the brine discharge service hose and place it into a container and move the brine discharge service valve to the “Service” position. Open the pressure relief valve and start the system. Watch the

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brine that first comes out. If the water is discolored and smells bad, perform an SC-2 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. Ideal performance is achieved by running the system until the tanks are full, turning off the system, then starting the flush cycle.

In moderate climates, if the membrane is mounted in a cool place, it is not necessary to flush the system every time if the unit is used once every one to two days. Flush the system if it’s not going to be operated for more than two days and up to one week. Flush the system after every use in hot conditions. Pickle the system if longer periods of non-operation are expected.

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.

The system’s automatic salinity control manually diverts any brackish product water into the brine discharge and the “Reject” light will illuminate. When potable water is detected, the “Good” light will illuminate and the product will be directed to the tank.

Use the high production mode (both feed pumps running) when the batteries are under

charge.

Use the efficiency mode (one feed pump running) when the batteries are not being charged.

If too much air is introduced into the system when the system is running and pressurized, the feed pumps will cavitate and water flow will stop or only one will cavitate and the production will be fall to the efficiency mode level. This will not damage the system. Open the pressure relief valve and reprime the 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 affected very little.

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2. When the back flush cycle stops and one gallon of fresh water is in the container, mix one container of the SC-1 into the cleaning container. Re-check that the pressure relief valve is open. Turn the intake and brine discharge valves to the “Service” position, reprime both pumps, then run the system with both feed pumps on for 10 minutes. Light discoloring of the solution is acceptable.

Do not let skin, eyes, or lungs have any contact with the storage and cleaning chemical.

If the solution becomes excessively discolored, mineral scale and live biological growth may be present and membrane cleaning is recommended. Refer to the membrane cleaning section for further instructions.

3.After 10 minutes, turn the brine discharge valve to the “Run” position. When the container is empty, shut off the system.

4.Close the intake thru-hull and turn the intake service valve back to the “Run” position. If the system shares an intake thru-hull, move the intake service valve lever to the “Off” position. This will close off all ports and isolate the watermaker.

5.Remove and clean the sea water strainer screen and pre-filters. Reassemble dry.

6.When returning the system to service after pickling, check that the intake thru-hull open and service valves are in the “Run” position. Run unpressurized for at least 30 minutes to purge the system. Manually discard the product water for another 30 minutes after pressurizing.

7. To winterize, Open the pressure relief valve and flush 5 gallons of potable water system antifreeze through the system instead of using the normal SC-1 storage procedures.

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

The Micron Pre-filters

Service the pre-filters when the feed pressure is about 5 psi over normal for the conditions. The easiest way to service the filters is to first shut off the thru-hull, open the housings, discard the old filters, remove the O-rings to avoid loosing them, and clean the housings. Reinstall the O-rings and reassemble the pre-filters with new 20 and 5-micron filter elements. The 5-micron filter goes down stream from the 20-micron. 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 Charcoal Backflush Filter

Replace the charcoal filter element every 6 months.

The Membrane

The membrane needs to be cleaned only when it has lost up to 10% of its capacity due to fouling or the product quality degrades. The leading cause of fouling is from biological growth that occurs when the system is left unused for long periods without flushing or pickling. Fouling from mineral scaling can happen under certain sea water conditions, and from rust. Poor tasting water or the “Reject” light on continuously and/or 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 (SC-2) is used to remove biological by-products, 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, 120º, is highly recommended 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 unchlorinated fresh water before the system is run under pressure. A simple test can be performed to see if biological growth has occurred: Before running the system, remove the pre-filters and examine their condition. If the housings are full of discolored smelly water, the system was not properly stored. Install clean pre-filters if they were bad. Next check the membrane. Attach the brine discharge service hose and lead to a container. Open the pressure relief valve 1/2 turn and turn the brine discharge service valve to the “Service” position. 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 unchlorinated water before running the system pressurized. If the brine is fairly clean, the system can be run normally and checked for performance. Clean the membrane only if its performance is reduced.

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 Gulfstream system. This water has to be figured in the mixture. The cleaning solution needs to be heated to 120º F. A 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 get over 135º F!

1.Attach the service hoses to the face of the unit and direct them to heated container. Make sure the domestic water pressure system is on then start the automatic backflush system. When the flush cycle stops, move the brine discharge to the “Service” position and restart the flush cycle. Allow one gallon of flush water to flow into the container, then move the brine discharge valve back to “Run”. Do not use tap water or chlorinated water! Distilled or charcoal filtered water is acceptable if using the flush water is not an option.

3.Open the bypass valve one half turn, this is important! Mix 1 Spectra chemical container into the 1 gallon in the container Do not let skin, eyes, or lungs have any contact with the storage and cleaning chemical.

3.Place the intake, brine discharge, and product service valves in the “Service” position. Start heating the water.

4.Re-prime both feed pumps and run the system unpressurized for one hour while maintaining the solution at 120º F, then turn off for one hour to let the membrane soak. Run the system

again Membrane cleaning, cont.

for 1 hour while heating the solution, then turn off for one hour. Do not let the water get above 135º F!

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5.Turn the brine discharge service valve to the “Run” position, then run the system until the container is empty.

6.Place the intake service valve to the “Run” position. Run the system unpressurized for at least 30 minutes to purge the cleaning solution.

7.After purging, close the pressure relief valve to pressurize the system. Manually divert the product water with the product service valve into the cleaning container. After 30 minutes, check the feed 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 30 minutes after cleaning.

8.If the membrane performance is still poor and no other problem can be found, contact Spectra Watermakers for further assistance.

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the system. To insure this does not happen, leave the very first thread uncoated.

General Plumbing

Follow the Clark Pump and Plumbing Diagrams on pages 27, 29, and 30 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 degree 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 125 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 125 psi minimum working pressure.

Feed and Discharge Hoses

Route the 5/8" hose smoothly from the intake thru-hull to the strainer, main module, Clark pump, back to the main module, and then to the discharge thru-hull. 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 Tubes

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 degree 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 32. 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 hose 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.

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.

General Plumbing, cont.

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Refer to the Dimension & Plumbing Diagrams on pages 28 & 29

Main Pump and Control Module

The main pump module is designed to mount on a horizontal surface that can be up to 4’ above the waterline. Locate in an area that allows easy access to the face panel and the service hoses can reach a container placed in a spot where water spillage is acceptable. Allow for a minimum of 2” of clearance on the sides and 13” over the top, and at least 1” of clearance at the back. Extra space over the top is preferred for easier internal access through the hinged top. Use the unit itself as a template for drilling the mounting bolt holes. Use quarter inch bolts or lag screws with washers. If lag bolts are used they must thread into at least 1” of solid material. Drill pilot holes for lags bolts.

Clark Pump

Refer to the the Clark Pump Mounting Diagram on page 31 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. Mounting on a vertical surface can be expedited by using the optional "L" mount 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. The Clark Pump can be mounted in any position if it is hard mounted without using the brackets. More noise may be transferred to the vessel.

Allow room in the front and back for access to the high pressure tubes and hose connections. If the space behind the unit is restricted, attach the high pressure tubes to the Clark Pump before final mounting. The 90 degree 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 34, 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 degrees F.

Component Placement, cont.

Membrane and Housing Assembly

Mount the membrane and housing assembly as close to the Clark Pump and in as cool a

page 25

place as possible. Use 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. 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 and re-label.

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

Remote Control Panel

The remote control panel can be mounted anywhere that’s dry and convenient. Use the cut-out template on page 34. 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 remote panel cable through the cutout, to the main pump module, and connect to the pigtail plug coming from the power control module inside the main module. The remote panel harness can be disconnected from the terminal strip on the remote panel if necessary. The terminals are labeled for the wire colors. If access to the back of the panel is limited, leave enough cable to be able to take the panel off for servicing. Fold the extra cable back through the cut-out and secure the panel with # 4 screws.

page 26

End block A

page 27

Gulfstream 400 Plumbing Diagram

Clark Pump Mounting

page 31

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.

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 1-2/3 turns (10 flats) after a good finger tight. Use the index mark on the nut as a guide. The threads should be completely covered by the nut.

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.

Figure 1.

Cut tube square

Insert tube 0.9" until it stops

page 32

Step 2:

Step 3: Gently fit the tube into the body and loosely thread on the nut.

Step 4: Push the tube into the body until it bottoms out then hand tighten the nut.

DO NOT OVER TIGHTEN!

1/4" Tube Fitting Assembly

page 33

page 34

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

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