Marlo_EP-100029-A MHC 3000 Triple PLC IOM

Transcription

INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
MHC 1200M–5400M
TRIPLE AB 1200
PLC CONTROLLER
COMMERCIAL WATER CONDITIONERS
COMPLETE FOR FUTURE REFERENCE:
MODEL NO:
SERIAL NO:
DATE INSTALLED:
DEALER:
Marlo Incorporated
2227 South Street
P.O. Box 044170
Racine, WI 53404-7003
Ph. (262) 681-1300
Fax (262) 681-1318
[email protected]
www.Marlo-Inc.com
EP-100029-A
MHC 1200M-1500M TRIPLE AB 1200 PLC CONTROLLER
NOTES
IMPORTANT PLEASE READ:
• Warranty of this product extends to manufacturing defects.
• The information, specifications and illustrations in this manual are based on the latest information available at the time of printing.
The manufacturer reserves the right to make changes at any time without notice.
• This product should be installed by a plumbing professional on potable water systems only.
• This product must be installed in compliance with all local and state and municipal plumbing and electrical codes. Permits may be required at
the time of installation.
• If operating pressure exceeds 100 psi a pressure reducing valve must be installed. If operating pressure drops below 30 psi a booster
pump must be installed.
• Do not install the unit where temperatures may drop below 32°F or rise above 100°F.
• A prefilter should be used on installations in which free solids are present.
• A constant voltage of 120V/60Hz (unless otherwise specified) must be supplied to the controller to maintain proper function.
• Union or flange fittings are recommended at the control valve’s inlet, outlet, and drain connections
• If distance of drain line is over a 10 ft. vertical or 25 ft. horizontal run, increase drain line one pipe size over that provided on the control valve.
• Do not make a direct connection to the drain. Provide an air gap of at least four times the diameter of the pipe to conform to sanitation codes
and to permit observation of the flow.
PLEASE CIRCLE AND/OR FILL IN THE APPROPRIATE DATA FOR FUTURE REFERENCE:
Softener Model: MHC _____________
System Size: Twin/Triple/Quad
Meter Size: ________________
Configuration: Twin Alt/Parallel/Progressive
Unit Capacity: ________________ Grains
Feed Water Hardness: ________________ Grains
Treated Water: ________________ Gallons/Liters
BW/Regen Time ________________ AM/PM or OFF
Additional Notes: _______________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
Phone: (262) 681-1300 • Web: www.Marlo-Inc.com • E-mail: [email protected]
2
TABLE OF CONTENTS
SYSTEM INFORMATION
Product Warranty............................................................................................................................................................1
General Arrangement Drawings ....................................................................................................................................2
Specification Table ........................................................................................................................................................3
Wiring Diagram...............................................................................................................................................................5
Tubing Diagram............................................................................................................................................................12
INSTALLATION
Piping Installation.........................................................................................................................................................13
Loading Softener .........................................................................................................................................................13
Resin & Gravel Loading ..............................................................................................................................................14
Brine Tank Installation .................................................................................................................................................14
OPERATION
Start-Up Instructions . ..................................................................................................................................................15
Batch Calculation.........................................................................................................................................................16
General Softener Operation.........................................................................................................................................17
Flow Diagrams.............................................................................................................................................................18
Piping & Instrumentation Diagram................................................................................................................................19
OPERATOR INTERFACE
Allen Bradley 1200 PLC...............................................................................................................................................20
Change Screen ...........................................................................................................................................................21
Main Screen ................................................................................................................................................................22
Flow Totals ..................................................................................................................................................................23
Presets 1......................................................................................................................................................................24
Manual Start/Advance Regeneration...........................................................................................................................25
Batch/K-Factor.............................................................................................................................................................26
Flow Delay Presets......................................................................................................................................................27
Flow Rate Setpoints.....................................................................................................................................................27
Recommended Setpoints.............................................................................................................................................28
Alarm History................................................................................................................................................................29
MAINTENANCE
Aquamatic Valve Repair Kits........................................................................................................................................30
2536 Flow Sensor........................................................................................................................................................31
Troubleshooting............................................................................................................................................................32
SYSTEM INFORMATION
COMMERCIAL AND INDUSTRIAL PRODUCT WARRANTY
Marlo, Inc. warrants all commercial and industrial water treatment products manufactured and/or distributed by it to be
free from defects in materials and workmanship for a period of one (1) year from the date of shipment. If within that
period any products shall be proven to Marlo, Inc.’s satisfaction to be defective, those products will be replaced or the
price refunded at Marlo Inc.’s option.
Marlo Inc.’s obligations or nonperformance, defective, or any damage caused by its products or their use, and buyer’s
exclusive remedy therefore, shall be limited to product replacement or refund and shall be conditioned upon Marlo
Inc.’s receiving written notice together with a demand for such replacement or refund:
The foregoing warranty is exclusive and in lieu of all other expressed implied warranty (except of title) including but
not limited to implied warranty of merchantability and fitness for particular purpose.
Marlo Inc. will not be subject to and disclaims the following:
1.Any other obligations or liabilities arising out of breach of contract or out of warranty.
2.Any obligations whatsoever arising from tort claims (including negligence and strict liability or arising under other theories of law with respect to products sold or services rendered by Marlo Inc. or any undertakings, acts, or
omissions relating thereto.
3.All consequential, incidental, and contingent damages.
Labor charges, charge backs or handling charges are excluded from Marlo Inc.’s warranty provisions.
COMMERCIAL AND INDUSTRIAL WATER SOFTENER GUARANTEE
Under normal operating conditions:
1.The softener effluent shall be zero soft as determined by a soap test.
2.The loss of softening resin through attrition during the first three (3) years shall not exceed 3% per year.
3.The softening resin shall not be washed out of the system during backwash.
4.The color and turbidity of the softener effluent shall not be greater than the incoming water.
Any mechanical equipment proving defective in workmanship or material within one year after installation or
eighteen (18) months after shipment, whichever comes first, shall be replaced FOB factory.
1
A
B
C
D
8
ALL PRESSURE VESS EL INTERNAL DISTRIBUTORS TO BE SCH 80 WITH ABS SLOTTED NO ZZLES .
ALL AUTOMATIC FLOW VALVES TO BE “Y” PATTERN DIAPHRAGM OPERATED GLOBES VALVES HYDRAULICALY
OPE RATED. VALVES TO BE MANUFACTURED OF CAST IRON WITH BRASS O R S TAINLE SS STE EL TRIM.
VALVES TO BE AQUA-MATIC SERIES 430.
ALL MANUAL ISOLATING VALVES 4” AND LARGER TO BE KEYSTONE SERIES 222 LUG STYLE BUTTERFLY
VALVES WITH STAINLES S STE EL DISC AND LEVE R LOCK HANDLE. ALL MANUAL ISOLATING VALVES 3”
AND SMALLER TO BE BRO NZE BODY GATES VALVE S WITH NON-RISING STE MS AND FPT CONNE CTIONS.
ALL EXTERNAL PIPING TO BE S CH 40 GALVANIZED STEEL WITH THREADE D OR PLAIN ENDS. ALL EXTERNAL
FITTINGS 6” AND LARGER TO BE SCH 40 BUTT WELDED. ALL EXTERNAL FITTINGS 3” AND SMALLER TO BE
150 LB GALVANIZ ED THRE ADED MALLEABLE IRON.
ALL HYDRAULIC VALVE CONTROL TUBING TO BE ¼” OD POLYETHYLENE BLACK TUBING. ALL TUBING TO BE
NEATLY BUNDLE D TO PIPING MANIFOLDS
ALL ELECTRICAL CONTROL ENCLOSURE S TO BE NE MA 4X FIBERGLASS . THE WATER SOFTENER CONTROLLE R
TO BE AN ALLEN BRADLEY MICROLOGIX 1200 WITH PANELVIEW 300 OPERATOR INTERFACE. ALL AUTOMATIC
VALVES WILL BE CONTROLLED BY A 4 POSITION MOTOR DRIVEN PILOT S TAGE R. ALL OUTLET VALVES WILL
BE OPERATE D WITH A 3- WAY ELECTRIC SOLE NOID VALVE. THE CONTROLLER WILL BE PRE-PROGRAMMED FOR
A TRIPLE UNIT PROGESSIVE FLOW.
5.
6.
7.
8.
9.
70,000 LBS
17. OPERATING WEIGHTS :
8
7
VIEW A-A
NAVAL STATION GREAT LAKES
BLDG 11 CENTRAL STEAM PLANT
WATER SYSTEM
MARLO JOB NO. EP-100029
H-O-H PURCHASE ORDER 041190-00
JOSEPH J. HENDERSON PURCHASE ORDER 1245-00-11-001-01
DIMENSIONS CERTIFIED
FOR CONSTRUCTION
18. THE COMPLE TE WATER SOFTE NER SKID WILL HAVE A FULL HYDRO-TEST AT 100 PSIG FOR 2 HOURS TO INSURE
THE SKID TO BE LEAK FREE BEFORE SHIPPING. IF MINOR LEAKS OCCUR AFTER START-UP MARLO WOULD NOT
CONSIDER THOS E TO BE COVE RED UNDER THE NORMAL EQUIPMENT WARRANTY.
11,500 LBS
23,400 LBS
34,900 LBS
16. SHIPPING WEIGHTS:
EQUIPMENT ONLY:
MEDIA ONLY:
TOTAL:
15. SOFTE NING MEDIA AND SUPPORT GRAVEL PER TANK
SOFTENING MEDIA:
100 CU. FT. STRONG ACID CATION
LOWER SUPPORT:
25 CU. FT.1/8” X 1/16” GRAVEL
14. FLOW RATES PER TANK:
SE RVICE:
500 GPM AT A 15 PSIG PRESS URE DROP
BACKWASH:
140 GPM
BRINE DRAW:
60 GPM
SLOW RINSE:
40 GPM
FAST RINS E:
140 GPM
13. ALL EXTERIOR HIGH VOLTAGE (115V OR HIGHER) WIRING TO BE CONTAINE D IN EMT STEEL CONDUIT WITH
LIQUID TIGHT FITTINGS. CONDUIT RUNS 6’ OR SHORTER MAY BE CONTAINED IN LIQUID TIGHT FLEXIBLE
CONDUIT SUITABLE FOR OUTDOOR USE . ALL EXTERIOR LOW VOLTAGE CONDUIT (24V OR LOWER) WILL BE 3
WIRE CABLE NEATLY BUNDLE D WITH THE MANIFOLD PIP ING.
12. THE WATER SOFTENER TO BE PROVIDED WITH AN ALL PVC BRINE INJECTOR TO CO NTRO L
ALL SATURATE D BRINE AND SLOW RINSE FLOW RATES. A BRINE ME ASURING TANK IS TO BE PROVIDED.
11. EACH WATER SOFTE NER TO HAVE A SIGNET MODEL 2536 FLOW SENSOR INS TALLE D ON THE SOFT WATER
OUTLET PIPING.
10. EACH WATER SOFTE NER TO HAVE INLET AND OUTLET PRES SURE GAUGE S AND SAMPLE VALVES .
ALL PRESSURE VESS ELS AND STRUCTURAL STEE L SKID TO BE S ANDBLASTED TO A COMMERCIAL BLAS T
AND COATED WITH 4-6 MILS OF TNEMEC SERIES 161 MARLO SAFETY BLUE EPOXY.
4.
ALL PRESSURE VESS ELS TO BE SANDBLASTED INTE RNALLY TO WHITE METAL AND COATE D WITH 8-10
MILS OF TNEMEC SERIES 20 E POXY.
3.
2.
7
ALL PRESSURE VESS ELS CONSTRUCTED PER THE LATEST ASME CODE FOR UNFIRED PRESSURE VE SSELS,
SO S TAMPED AND CERTIFIED. WORKING PRESSURE DES IGN IS 100 PS IG WITH A TE ST PRES SURE OF
130 PSIG.
CONSTRUCTION NOTES:
1.
ITEM
A
B
C
D
A
OUTLET PRESSURE GAUGE &
SAMPLE COCK
35 5/8"
FROM
BRINE
INLET
FLOW
SENSOR
A
DESCRIPTION
HARD WATER INLET
SOFT TREATED WATER OUTLET
DRAIN
GRAVITY FEED BRINE INLET
6
CONTROL VALVE
FLOWMETER
CHECK VALVE
INJECTOR
4" OUTLET
ISOLATION
VALVE
4" INLET
ISOLATION
VALVE
INLET PRESSURE GAUGE &
SAMPLE COCK
6
231"
226 3/8"
SIZE
6"
6"
3"
1-1/2"
3" AUTOMATIC
BACWKASH FLOW
CONTROLLER
(140 GPM)
CONNECTION
150# FLANGED
150# FLANGED
150# FLANGED
150# FLANGED
MINERAL TANK
72" DIA. x 72" SIDESHELL
CONTROLLER
115 VAC
CONNECTION TABLE
LOCATION
MAX. FLOW
MHC-3000-4
500 GPM
MHC-3000-4
500 GPM
MHC-3000-4
140 GPM
MHC-3000-4
5
Y-STRAINER
MINERAL TANK
78"
5
78"
37 1/2"
MATERIAL
CS GALV
CS GALV
CS GALV
SCH 80 PVC
4
NO.
1
DATE
4/23/10
REMOTE STAGER
MINERAL TANK
4
A
141 5/8"
SOFT WATER
OUTLET
A
101"
3
BY
REMARKS
AJJG RE MO VED BRINE TANK; ROTATE D MANYWAY
REVISIONS
8 7/8"
3" FLANGED
DRAIN
C
B
93 1/2"
126 1/2"
B
85 1/4"
3
INCORPORATED
2
NAVAL STATION BLDG #11 CENTRAL STEAM PLANT
GREAT LAKES, IL
RAW WATER INLET
30-100 PSIG
2
147 1/8"
DATE
3/4/2010
DEC.
MARK
DRN.
APP'D.
FRAC.
SHEET
1
1
EP10-0029-03-01
DRAWING NO.
SCALE
FILE ID.
OF
1
1
REV.
MHC-3000-4 TRIPLE PROGRESSIVE WATER SOFTENER
GENERAL ARRANGEMENT
6" BY-PASS VALVE
(NORMALLY CLOSED)
1
A
B
C
D
SYSTEM INFORMATION
2
SYSTEM SIZE
FLOWRATE (GPM)
TIMER SETTINGS
SOFTENER TANK
EQUIPMENT
INJECTOR
SALT
DOSAGE
1200
50
66x46
900
40
56x62
GRAVEL (LBS)
RESIN (FT3)
TANK SIZE
600
240
SALT DOSAGE- MIN
(LBS)
12 gpm
FLOW RATE
SALT DOSAGE- MAX
(LBS)
1 ½”
SIZE
2600
54x72
48x72
SIZE (IN)
MAX SALT
STORAGE (LBS)
6
6
FAST FLUSH
(MIN)
300
750
15 gpm
1 ½”
3300
60
10
15
60
80
308
BRINE DRAW &
RINSE (MIN)
191
3
225
10
143
165
BACKWASH &
FAST FLUSH (MIN)
410
102
2-1/2
12
300
310
2
BRINE DRAW &
RINSE (GPM)
186
215
4
60
140
PEAK
(GPM)
160
3
1000
1500
1500
BACKWASH &
FAST FLUSH (GPM)
100
CONTINUOUS
(GPM)
2-1/2
800
MIN CAPACITY
(KILOGRAINS)
2
1200
MAX CAPACITY
(KILOGRAINS)
VALVE SIZE (IN)
1200
MODEL
600
405
4
145
104
2
1 ½”
4000
60x66
65
1500
60x72
6
60
10
20
100
325
235
3
390
975
20 gpm
193
168
2-1/2
1300
1950
1950
650
445
4
199
175
2
1 ½”
5800
66x72
80
2400
66x72
6
60
10
24
120
690
480
3
480
1200
30 gpm
340
245
2-1/2
1600
2400
2400
940
650
4
355
255
3
600
1500
40 gpm
2"
7300
82x60
100
2600
72x72
6
60
10
40
140
720
500
4
2000
3000
3000
1050
700
6
SYSTEM INFORMATION
SPECIFICATION CHART
3
BRINE SYSTEMS
SYSTEM SIZE
FLOWRATE (GPM)
TIMER SETTINGS
SOFTENER TANK
EQUIPMENT
INJECTOR
SALT
DOSAGE
6
78x72
3300
120
82x60
6000
2"
45 gpm
60
6
72x72
2600
100
82x60
7300
2"
40 gpm
1500
600
FAST FLUSH
(MIN)
SIZE (IN)
GRAVEL (LBS)
RESIN (FT3)
TANK SIZE
MAX SALT
STORAGE (LBS)
SIZE
RINSE RATE
SALT DOSAGE- MAX
(LBS)
SALT DOSAGE- MIN
(LBS)
720
1800
60
10
45
BRINE DRAW &
RINSE (MIN)
165
1100
10
730
750
BACKWASH &
FAST FLUSH (MIN)
360
520
6
40
1050
260
4
BRINE DRAW &
RINSE (GPM)
720
700
3
140
355
PEAK
(GPM)
500
6
2400
3600
3600
BACKWASH &
FAST FLUSH (GPM)
255
CONTINUOUS
(GPM)
4
2000
MIN CAPACITY
(KILOGRAINS)
3
3000
MAX CAPACITY
(KILOGRAINS)
VALVE SIZE (IN)
3000
MODEL
1430
950
8
365
265
3
6
60
10
55
190
1130
3900
840
2100
55 gpm
2"
7500
90x60
140
6
780
84x72
760
540
4
2800
4200
4200
1450
1000
8
753
600
4
960
2400
60 gpm
2"
6500
90x60
160
4600
90x72
6
60
10
60
220
1005
800
6
3200
4800
4800
1670
1060
8
820
675
4
1080
2700
70 gpm
2"
7700
90x60
180
5600
96x72
6
60
10
70
250
1250
880
6
3600
5400
5400
1700
1150
8
SYSTEM INFORMATION
SPECIFICATION CHART - cont’d
4
BRINE SYSTEMS
Vendor No
A16148CHSCFG
A16P14
2711-M3A19L1
1761-CBL-HM02
200221 BEV/ADH
41034
2868648
3048386(3004906
FNM-5(FLM-5)
1762-L24BWA
G1X2WH6
C1WH6F
1492-F2
1492-N18
1492-N23
1171007
72522
3444-01-W3165
MTW18GY
MTW18OE
MTW18BEX2500
MTW18WE
MTW18RD
MTW18GN
MTW18BK
1
2
4
5
6
8
9
10
11
12
13
14
15
16
17
20
21
22
23
23
23
23
23
23
23
A2147029
A2148010
A2586005
A2325013
A2150200
A2242018
A2331075
A2399019
A2392008
A2331001
A2547010
A2103098
A2307004
A2318002
A2307007
A2199009
A2457007
A2394007
A2173046
A2173015
A2173014
A2173005
A2173004
A2173003
A2173002
Seqn Item Number
ENCLOSURE 16X14X8 FRP SCREW CVR
SUBPANEL 16 X 14
PANELVIEW 300 MICRO 24VDC DH-485
CABLE ASSY 6.5FT 8P-8P(1761CBLHM02
NAMEPLATE 7/8X3.25 BLANK W/TAPE WHT
TRANSFORMER 5AMP 120/24 100VA(41034
POWER SUPPLY 1.75A STEP 24VDC UL
FUSEHOLDER W/DISC LEVER 10.3 38MM
FUSE 250V 5AMP
CONTROL MICRO 1200 PLC 120V BWA
DUCT WIRE 1X2 WHITE(WAS E1X2WH6)
COVER WIRE DUCT 1 WHITE
BLOCK TERMINAL
BARRIER TERMINAL END (1492N18)
ANCHOR END TERMINAL BLOCK
WASHER #8 FLAT SS
SCREW 8-32X3/8 MACH PH HD SS
GRIP CORD .064-.210 (3444-01)
WIRE MTW 18 STRANDED GRAY
WIRE MTW 18 STRANDED ORANGE(FT)
WIRE MTW 18 STRANDED BLUE(2500' RL)
WIRE MTW 18 STRANDED WHITE
WIRE MTW 18 STRANDED RED
WIRE MTW 18 STRANDED GREEN
WIRE MTW 18 STRANDED BLACK
Qty Description
1
1
1
1
1
1
1
1
1
1
4
4
47
2
4
8
8
3
20
20
10
10
20
1
1
MR 150M–1050M AB 1200 PLC CONTROLLER
SYSTEM INFORMATION
TRIPLE CONTROLLER DIAGRAM
5
Vendor No
A16148CHSCFG
A16P14
2711-M3A19L1
1761-CBL-HM02
200221 BEV/ADH
41034
2868648
3048386(3004906
FNM-5(FLM-5)
1762-L24BWA
G1X2WH6
C1WH6F
1492-F2
1492-N18
1492-N23
1171007
72522
3444-01-W3165
MTW18GY
MTW18OE
MTW18BEX2500
MTW18WE
MTW18RD
MTW18GN
MTW18BK
1
2
4
5
6
8
9
10
11
12
13
14
15
16
17
20
21
22
23
23
23
23
23
23
23
A2147029
A2148010
A2586005
A2325013
A2150200
A2242018
A2331075
A2399019
A2392008
A2331001
A2547010
A2103098
A2307004
A2318002
A2307007
A2199009
A2457007
A2394007
A2173046
A2173015
A2173014
A2173005
A2173004
A2173003
A2173002
Seqn Part No
ENCLOSURE 16X14X8 FRP SCREW CVR
SUBPANEL 16 X 14
PANELVIEW 300 MICRO 24VDC DH-485
CABLE ASSY 6.5FT 8P-8P(1761CBLHM02
NAMEPLATE 7/8X3.25 BLANK W/TAPE WHT
TRANSFORMER 5AMP 120/24 100VA(41034
POWER SUPPLY 1.75A STEP 24VDC UL
FUSEHOLDER W/DISC LEVER 10.3 38MM
FUSE 250V 5AMP
CONTROL MICRO 1200 PLC 120V BWA
DUCT WIRE 1X2 WHITE(WAS E1X2WH6)
COVER WIRE DUCT 1 WHITE
BLOCK TERMINAL
BARRIER TERMINAL END (1492N18)
ANCHOR END TERMINAL BLOCK
WASHER #8 FLAT SS
SCREW 8-32X3/8 MACH PH HD SS
GRIP CORD .064-.210 (3444-01)
WIRE MTW 18 STRANDED GRAY
WIRE MTW 18 STRANDED ORANGE(FT)
WIRE MTW 18 STRANDED BLUE(2500' RL)
WIRE MTW 18 STRANDED WHITE
WIRE MTW 18 STRANDED RED
WIRE MTW 18 STRANDED BLACK
Qty Description
1
1
1
1
1
1
1
1
1
1
4
4
45
2
4
8
8
2
20
20
10
10
20
1
1
SYSTEM INFORMATION
SUB PANEL DIAGRAM
6
SYSTEM INFORMATION
TRIPLE WIRING DIAGRAM
7
SYSTEM INFORMATION
TRIPLE WIRING DIAGRAM
8
Item Number
A2147021
A2150201
A2435043
A2155094
A2130007
A2445043
A2148003
A2221002
A2130013
A2394002
A2453007
A2150202
A2307015
A2307016
A2173017
A2173003
A2173016
A2173018
A2173015
Seqn
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
15
15
15
15
Vendor No
MTW18OE
MTW18PE
MTW18BN
MTW18GN
1015/18B16-U
260-331
260-337
A2150202
5262
CG1250
W172PL-4-2
8320G1 24/60/1
A10P8
260-361
W169PL-4-2
V3926-01
7000-4000
200221
A1086CHSCFG
Qty
3
2
2
1
3
7
1
1
1
1
2
1
1
2
11
1
2
1
1
Description
WIRE MTW 18 STRANDED ORANGE
WIRE MTW 18 STRANDED PURPLE
WIRE MTW 18 STRANDED BROWN
WIRE MTW 18 STRANDED LIGHT BLUE
TERMINAL BLOCK MODULAR GREY
TERMINAL BLOCK MODULAR GREEN
NAMEPLATE .50X.75 BLANK NO TAPE WHT
RING SEALING 1/2
GRIP CORD 1/2 .125-.187 (CG1250)
TEE BRANCH 1/4TX1/8MPT
VALVE SOLENOID ASCO 24/60/1 8320G1
SUBPANEL 10 X 8
PLATE END W/FIXING FLANGE
ELBOW MALE 1/4TX1/8MPT
STAGER 4 POS NOTCH 2 SWTCH 24VAC
KIT SURGE SUPRESSOR FOR 7000 CONTRO
NAMEPLATE 7/8X3.25 BLANK NOTAPE WHT
ENCLOSURE 10X8X6 NEMA 4X
SYSTEM INFORMATION
STAGER ASSEMBLY UNIT 1
9
Item Number
A2147021
A2150201
A2435043
A2155094
A2130007
A2445043
A2148003
A2221002
A2130013
A2394002
A2453007
A2150202
A2307015
A2307016
A2173017
A2173003
A2173016
A2173018
A2173015
Seqn
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
15
15
15
15
MTW18PE
MTW18OE
MTW18GN
MTW18BN
260-337
1015/18B16-U
A2150202
260-331
CG1250
5262
8320G1 24/60/1
W172PL-4-2
260-361
A10P8
V3926-01
W169PL-4-2
200221
7000-4000
A1086CHSCFG
Vendor No
Qty
2
3
1
2
1
3
1
7
1
1
1
2
2
1
1
11
1
2
1
Description
GRIP CORD 1/2 .125-.187 (CG1250)
RING SEALING 1/2
SUBPANEL 10 X 8
SYSTEM INFORMATION
10
Item Number
A2147021
A2150201
A2435043
A2155094
A2130007
A2445043
A2148003
A2221002
A2130013
A2394002
A2453007
A2150202
A2307015
A2307016
A2173017
A2173003
A2173016
A2173018
A2173015
Seqn
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
15
15
15
15
Vendor No
MTW18BN
MTW18PE
MTW18OE
260-331
260-337
1015/18B16-U
MTW18GN
W172PL-4-2
CG1250
5262
A2150202
V3926-01
W169PL-4-2
260-361
A10P8
8320G1 24/60/1
A1086CHSCFG
200221
7000-4000
Qty
2
2
3
7
1
3
1
2
1
1
1
1
11
2
1
1
1
1
2
Description
GRIP CORD 1/2 .125-.187 (CG1250)
RING SEALING 1/2
SUBPANEL 10 X 8
SYSTEM INFORMATION
11
SYSTEM INFORMATION
SOLENOID
VALVE
STAGER
MULTIPLE TANK
SYSTEMS
TUBING DIAGRAM - MULTITANK
12
INSTALLATION
INSTALLATION INSTRUCTIONS
PIPING INSTALLATION:
1. Install piping as shown on the layout drawing. Include unions and shut-off valves on the inlet and outlet of each softener. Also, include a shut-off valve for each injector provided with the system. It is recommended that a union be installed in each softener drain-line to facilitate cleaning the backwash flow control.
2. Do not reduce drain-line pipe size. Do not install a shut off valve in the drain-line. Provide an air gap in the drain line in accordance with local codes (minimum four (4) pipe diameters).
3. If your system has a water meter thoroughly read the meter instructions manual located in the back of this manual before installing any water meters or flow sensors,. Water meters typically must be installed in a particular manner (i.e. horizontal, plane or with recommend pipe lengths) to function properly.
4. After the piping has been completed, make sure to close all isolation valves.
NOTES:
• Install the piping conforming to federal, provincial, and local codes.
• Union or flanges are recommended at the control valve’s inlet, outlet, and drain connections
• To enhance the monitoring of the system’s performance sample valves and pressure gauges are be installed at the
inlet and outlet piping to each control valve.
• If distance of drain line is over a 10 ft. vertical or 25 ft. horizontal run, increase drain line one pipe size over that
provided on the control valve.
• Do not make a direct connection to the drain. Provide an air gap of at least four times the diameter of the pipe to
conform to sanitation codes and to permit observation of the flow.
• It is not recommended that an overhead or a long horizontal drain run be used. The increased backpressure will
cause problems when drawing brine.
SOFTENER LOADING
Do not begin loading until you have confirmed all of the required media is on site.
Locate your unit on the Specification Table for the correct amount of gravel and resin per tank and separate
quantities.
Before loading, visually check the lower distributor for shipping damage. All radial arms and baskets strainers are in
place and pointing downward. Tighten any loose laterals. Do not load tank if there is damage is evident. Call the factory if any damage is observed.
Slowly open the inlet valve and fill the tank half way or as full as possible with water. There might be a flow of water to
drain.
Care should be exercised in the loading of the gravel in order to insure that the distributors are not damaged. The
equipment provided has a PVC lower distributor system.
13
INSTALLATION
INSTALLATION INSTRUCTIONS
GRAVEL LOADING
1. Slowly and gently pour the gravel marked for the mineral tank into the unit.
2. Drain the tank down until the gravel and water levels are the same.
3. Carefully level the gravel before loading the resin.
RESIN LOADING
1. Reopen the inlet valve and fill the tank to1/3 to 1/2 full of water.
2. Pour the quantity of resin marked for the tank in through the top opening.
3. Reopen the inlet valve and fill the tank with water to the top access opening.
4. Close and secure the top access opening.
5. Open inlet valve and continue to fill the tank with water until it is fully
pressurized.
BRINE TANK INSTALLATION
1. The brine tank should be installed on a smooth level surface. If none is available, the tank should be placed on a
smooth piece of exterior plywood and leveled by placing shims underneath the plywood.
2. Load the two layers of gravel 3/4 x 1/2 and 1/4 x 1/8 and level. Make sure the brine draw pipe located in the tank
is as vertical as possible.
3. Load the brine tank with the recommended amount of salt. Do not fill the tank past half way with salt.
4. Check the Specification Table for the float setting for your particular system. (Units are shipped with the float set
for maximim salting). If the setting is incorrect, adjust the stop collars to the proper setting,
5. Connect the brine valve to the brine injector. Make sure the pipe size matches the size of the transfer valve (i.e. 1”
valve use 1” pipe).
6. Open the manual injector feed water valve and allow the brine tank to fill with water. To speed this process the
tank can be filled with a garden hose to about 2” below the float. The tank will continue to fill until the float rises
and shuts off the flow.
7. Adjust the counter weight to insure that the brine valve arm rides up and down.
8. Place cover back on the brine tank (if supplied).
Note:
In the process of making brine for the first regeneration, the solution volume will increase (one gallon of water will be
1.2 gallons of brine). The final level of the liquid will be several inches above the float.
14
OPERATION
START-UP INSTRUCTIONS
Before proceeding to start-up:
• Make sure the unit is properly installed with all piping complete
• All of the required media has been properly loaded in the tank
• Read the controls section located in this manual
• Do not fill Brine Tank with salt
With all piping and installation completed, and with the mineral in the tank, proceed as follows:
1. Open the manual by-pass valve. The manual inlet and outlet valves are to remain closed.
2. Connect the power to the PLC controller. The controller display window will light up.
3. Verify the following and change if required.
The FLOW RATE SETPOINTS are correct for your system
The K FACTOR is correct for your unit size
The BATCH volume is correct for your application
UNIT STAGER
4. Open the cover of the enclosure and manually rotate the stager to the #1 (BACKWASH) position. The stager motor will rotate back to the #4 (SERVICE) position. This is done to confirm the controller’s homing signal is operational.
5. Press and hold the F1 UNIT A START/ ADV REGEN button on the operator control screen. This will advance Unit
1 to the backwash step. The Unit 1 stager should rotate to the step 1 (BACKWASH) position.
6. Slowly open the softener’s manual inlet supply valve. Do not open fully. Full flow of water could cause loss of media. Continue to fill slowly until all air is expelled and only water flows to the drain. Water will enter from the bottom
of the resin tank as air is expelled from the top drain. If the system is supplied with an air vent make sure that the
valve is open during this process.
7. When only water flows to the drain and out the air vent (if applicable), open the manual inlet valve all of the way.
Backwash until the water looks clean when caught in a container.
8. Advance Unit to the brine/slow rinse step by pressing and holding the ADVANCE button. The stager should rotate
to the STEP 2 (BRINE/SLOW RINSE) position. There will be a slow flow to the drain.
9. While the unit is in the Brine/Slow Rinse position, check the level in the brine tank. The level should be dropping
at a slow rate (approximately 2” per minute).
15
OPERATION
START-UP INSTRUCTIONS - (cont’d)
10. Advance Unit to the Fast Rinse position. The stager should rotate to the STEP 3 (FAST RINSE) position. There
will be a high flow of water to the drain. Allow the water to flow to the drain until clear. During this time, the brine
tank will fill with water until the float closes the brine tank valve. Check that all brine fittings are tight and that the
water level in the brine tank is according to the unit specifications.
11. Advance Unit to the service position. The stager should rotate to STEP 4 (SERVICE) position. There will be no
flow of water to the drain.
12. Repeat steps 5 through 11 for the other tanks.
13. Fill the brine tank with the proper amount and type of salt recommended for use with the system.
See RECOMMENDED TYPES OF SALT.
14. Close the manual by-pass valve and open all outlet valves fully. The system is now in service.
BATCH CALCULATION
Batch size is the term used for the amount of water being softened by the water softener between regenerations. This
is a simple calculation provided two pieces of information are known:
Capacity of the water softener in grains (gr.) per gallon - (i.e. MHC-1200 has 1,200,000 grains capacity per tank).
Hardness of the raw water being treated by the water softener.
BATCH SIZE EQUATION:
Batch Size =
Capacity of Softener (grains)
Hardness of Water (grains per gallon)
SAMPLE CALCULATION
Assume:
Unit is a model MHC-1200 softener
The hardness of the water was measured to be 20 grains per gallon
Using our equation take 1,200,000 ÷ 20 = 60,000 gallons.
For immediate regeneration type meter control the meter setting would be at 60,000 gallons. Commonly this value is
adjusted to 90 percent of the actual value (in this example 54,000 gallons) to assure not over-running the softener.
10% Safety factor - reserve capacity = 6,000 gallons.
60,000 gallons – 6,000 gallons = 54,000 gallons (batch size)
The softener in this example can treat 54,000 gallons of water before requiring a regeneration.
16
OPERATION
GENERAL SOFTENER OPERATION
Hard water passes through the valve manifold into the top of the softener tank. It flows downward through the mineral
bed and out through the bottom of the tank to service. As the water passes through the mineral bed, the hardness
present is removed through the process of ion exchange and at the same time sediment present is removed by
filtration action of the mineral. Once the mineral has extracted all the hardness it can, it must be regenerated and have
its capacity restored by the following procedure:
SERVICE
1. Service – Hard water enters the softener, is treated and exits the system.
REGENERATION
2. Backwash: The flow through the mineral bed is reversed and allowed to flow to drain. The up-flow action washes any sediment or foreign material collected in the unit out to drain. At the same time the mineral itself is restratified, thereby eliminating any possibility of channeling (approximately 10 minutes).
3. Brine Draw: The flow through the unit is returned to down-flow to drain at a slow controlled rate and during the first
stage of this step the brine is injected to react with the mineral and restore its softening capacity (approximately
20 minutes).
4. Slow Rinse: The flow through the unit is a slow flow of water to rinse all of the exchanged hardness and salt from the unit (approximately 40 minutes).
5. Fast Flush: The downward flow to drain in this step is increased to a high rate which will repack the mineral bed and remove the last traces of salt and hardness from the regenerated equipment just before its return to service (approximately 6 minutes)
HOW THE STAGER FUNCTIONS
The regeneration of the equipment provided is carried out through the redirection of flow through the valve manifold.
This manifold consists of individual diaphragm valves, which are controlled by the hydraulic stager mounted at the
bottom of the stager controller. The stager applies or relieves water pressure to close or open valves as required.
When water pressure is applied to the top of a diaphragm valve, it forces a diaphragm in causing it to close the seat
assembly. When pressure is relieved from the top of the valve, by venting it to drain through the stager, the water
pressure under the diaphragm forces it out thereby opening the seat assembly.
Note: If stager somehow gets out of sequence either:
• Rotate thumb wheel in direction of arrow.
• Be patient, unit will return to service position and be in sequence within 2 hours.
17
OPERATION
FLOW DIAGRAM - WATER SOFTENERS
18
OPERATION
PIPING & INSTRUMENTATION DIAGRAM - WATER SOFTENERS
19
MR 150M–1050M TRIPLE AB 1200 PLC CONTROLLER
OPERATOR INTERFACE SCREENS
FEATURES OF THE AB 1200 CONTROLLER
ELECTRICAL CONTROLS OPERATION
General-the main control panel (MCP) contains the programmable logic controller (PLC) and the operator interface
(OIT). The system is controlled by the PLC. Operator intervention and control along with some program set point access is through the OIT. The PLC controls the system so that one or more units will be online (in service) based on
flow demand. If flow is low then only one unit will be online. If flow increases past the set point for bringing the second
unit online then the second unit will come online. When the flow increases above the set point for bringing the third
unit online then the third unit will come online. As flow decreases, the additional units that were brought online will be
taken offline to standby status. A unit will be automatically regenerated when its gallon batch throughput set point has
been reached. A unit can also be manually forced into regeneration by using a push-button on the OIT. A regeneration
lockout is built into the logic so that only one unit can be in a regeneration at a time.
Note: Follow all applicable codes and regulations when wiring in this system.
Caution: Verify all power is disconnected before servicing the equipment.
Power- Wire 120V/60hz/1phase power 15 amp max. surge protected to terminals L, N and G in the MCP.
SCREEN 1 – MAIN SCREEN
SCREEN 2 – FLOW TOTALS
SCREEN 3 – PRESETS 1 - CYCLE PRESETS SCREEN
SCREEN 4 – MANUAL START/ADV REGEN
SCREEN 5 – FLOW DELAY PRESETS
SCREEN 6 – FLOW RATE SETPOINTS
SCREEN 7 – ALARM HISTORY
SCREEN SAVER – after 20 minutes of no activity on the screen, the screen will go blank. This is the screen saver.
Press any key on the OIT and the screens will come back on.
STAGERS – Each stager is located in its own enclosure on the individual units themselves. They operate the diaphragm vales on the unit. The stager has multiple ports on it to pressurize and vent diaphragm valves in order to
open and close them. Pressure to a valve opens the valve. A vent to a valve allows the valve to open.
The stager has 4 numbers on its indexing wheel inside of the enclosure. Each position represents a different regeneration cycle.
4 – SERVICE/STANDBY
1 – BACKWASH
2 – BRINE/SLOW RINSE
3 – FAST RINSE
If for some reason power is disrupted the stager can be manually rotated to the different positions in order to manually
regenerate the unit.
STAGER HOMING – if for some reason the stager gets out of sync with the PLC, the PLC will drive the stager back
to its service #4 position. This can occur if someone manually rotates the stager out of service while there is power to
the unit. This is designed to correct the situation if someone happens to tamper with the stagers.
SOLENOIDS- the solenoids are mounted on the side of each stager enclosure and are used to override the service
outlet valve. It closes the service outlet valve, keeping the unit in standby until the flow demand calls for that unit to
be on line.
20
CHANGE SCREEN SELECTOR
SCREEN SELECTOR
This screen allows the user to scroll through the list of screens and choose which one they want. There are shortcuts
that will allow the user to navigate to frequently used screens using a function key. Use the up/down arrow keys to
scroll through the list. Press enter when the cursor is on the desired screen.
F2 MAIN SCREEN – Use this button to go to the main screen without having to use the list.
21
SCREEN 1 - MAIN SCREEN
SCREEN 1-MAIN STATUS SCREEN
The main screen displays the following:
Unit- each unit is identified as A, B, and C in a left to right sequence as you face the units from the front. Each unit’s
status is displayed next to the unit identifier. The status indicates whether the unit is first or second in line to come
online based on flow rate. The primary unit is the first to be in service. As the flow increases the secondary (2) unit will
be put into service.
Mode - Each unit’s mode is displayed here. The modes indicate which cycle the unit is in.
The mode can be any one of the following:
SERV = Service
STDBY = Standby
BW = Backwash
BRN/SR = Brine slow rinse
FR = Fast Rinse
FLOW - each units flow rate is shown here in gallons per minute (gpm)
BATCH - each units gallons remaining in the batch is displayed here.
This display counts the gallons down from the preset to zero.
REGENERATION CYCLE TIME - in the lower part of the screen the regeneration cycle time remaining will be displayed if a unit is in regeneration.
F1 FLOW TOTALS – Use function button to go to the flow totals screen
F4 CHNG SCREEN – When this button is pressed it will bring up the screen changes screen.
22
SCREEN 2 - FLOW TOTALS
SCREEN 2 – SERVICE FLOW TOTALS
This screen can be used to view the amount of water that the system has treated since it was installed or the last
reset.
A – Total volume of the treated water passed through Unit A.
B – Total volume of the treated water passed through Unit B
C – Total volume of the treated water passed through Unit C
F1 RESET A – Resets the totalized value for Unit A
F2 RESET B – Resets the totalized value for Unit B
F3 RESET C – Resets the totalized value for Unit B
F4 CHNG SCREEN – Use function button to go to the screen select list screen.
23
SCREEN 3 - PRESETS 1
SCREEN 3 – PRESETS 1
This screen can be used to change the following set points:
• Backwash time in minutes
• Brine Injection/Slow Rinse time in minutes
• Fast rinse time in minutes
The initial optimal setpoints were entered at the factory and should not need to be changed. These set points are
displayed on this screen.
Initial set points were as follows:
• Backwash cycle time in minutes = 12
• Brine Inj/Slow Rinse in minutes = 60
• Fast rinse time in minutes = 10
K-factor- This is the pulses per gallon that the flow sensor sends to the PLC. It varies according to the type and size
of the pipe and the flow sensor fitting.
If a change is necessary then use the left and right arrow keys to force the cursor to scroll to the desired setpoint.
Press the enter key (long arrow key) to allow access to changing that value. Use the numeric keypad to enter in the
new value. There is a minimum and maximum value that can be entered. This value is displayed on the screen when
changing the value. When the new value is entered then press the enter key.
Batch- This is the amount of gallons that can pass through a unit before it needs to be regenerated.
This needs to be set in the field after hardness has been tested.
To change a value, press the one of the side arrow keys. This will cause the curser to move. When the curser is on
the desired field, press the enter button. This will bring up a numerical entry field. Use the up/down arrows to enter the
desired number. Use the side arrow keys to go to the desired digits field. When the new value is entered then press
the enter key.
F2 MAIN SCREEN– Use this button to go to the main screen without having to use the list.
F4 SCREEN CHNGS – Use function button to go to the screen select list screen.
24
SCREEN 4 - MANUAL START/ADVANCE REGEN
SCREEN 4 - MANUAL START/ADVANCE REGEN
This is the main screen used for manual operator control. It is primarily used to initiate a manual regeneration and
manually advance the unit to the next regeneration steps. Once a manual regeneration has begun, the regeneration
cycle time is preset and the unit will automatically advance itself through the regeneration steps if the start/advance
regeneration function button is not used.
Along the top row are three function push buttons:
F1 UNIT A START/ ADV REGEN
F2 UNIT B START/ ADV REGEN
F3 UNIT C START/ ADV REGEN
These allow the operator to manually start a regeneration on any of the units. Once in regeneration this button also
allows the operator to manually advance the unit to its next regeneration cycle. Only one unit can be sent into regeneration at a time.
Once the button is pressed, it must be held for 4 seconds to prevent an operator from accidentally placing a
unit into regeneration.
Once a button is activated the operator will be locked out from activating the button again for 20 seconds in order to
allow the stager time to rotate to its next position. This lockout is indicated by the text “pb/lo” (push-button lockout)
flashing in the lower left corner of the screen.
If another unit is currently in regeneration, the program will not allow another unit to be manually sent into regeneration via its button. There is no memory of this button being depressed if another unit is already in regeneration.
F4 SCREEN CHNG – Use function button to go to the screen select list screen.
25
SCREEN 5 - BATCH/K FACTOR
SCREEN 5 - BATCH/K FACTOR
This screen is used to enter in the K factor and batch set points.
K factor- This is the pulses per gallon that the flow sensor sends to the PLC. It varies according to the type and size
of the pipe and the flow sensor fitting.
Batch- This is the amount of gallons that can pass through a unit before it needs to be regenerated.
This needs to be set in the field after hardness after hardness has been tested.
the desired field than press the enter button. This will bring up a numerical entry field. Use the up/down arrows to
enter the desired number. Use the side arrow keys to go to the desired digits field. Press enter when done.
BATCH CALCULATION
Batch size is the term used for the amount of water being softened by the water softener between regenerations. This
is a simple calculation provided two pieces of information are known:
Capacity of the water softener in grains (gr.) per gallon - (i.e. MHC-1200 has 1,200,000 grains capacity per tank).
Hardness of the raw water being treated by the water softener.
BATCH SIZE EQUATION:
SAMPLE CALCULATION
Batch Size =
Capacity of Softener (grains)
Hardness of Water (grains per gallon)
Assume:
Unit is a model MHC-1200 softener
The hardness of the water was measured to be 20 grains per gallon
Using our equation take 1,200,000 ÷ 20 = 60,000 gallons.
For immediate regeneration type meter control the meter setting would be at 60,000 gallons. Commonly this value is
adjusted to 90 percent of the actual value (in this example 54,000 gallons) to assure not over-running the softener.
10% Safety factor - reserve capacity = 6,000 gallons.
60,000 gallons – 6,000 gallons = 54,000 gallons (batch size)
The softener in this example can treat 54,000 gallons of water before requiring a regeneration.
26
SCREEN 6 - FLOW DELAY PRESETS
SCREEN 6 - FLOW DELAY PRESETS
This screen can be used to change the following set points:
Timed delay (seconds) before the second and third units will be added due to flow exceeding the flow rate setpoints.
Timed delay (seconds) before the second and third units will be taken off line due to flow falling below the flow rate
setpoints. The initial optimal set points were entered in at the factory and should not need to be changed. These set
points are displayed on this screen.
This screen can be used to change to a different screen.
F4 SCREEN CHGS – Use function button to go to the screen select list screen.
SCREEN 7 - FLOW RATE SETPOINTS
SCREEN 7 - FLOW RATE PRESETS
This screen can be used to change the flow rate setpoint where the secondary unit will come online:
The initial optimal set points were entered in at the factory. These set points are displayed on this screen.
This screen can be used to change to a different screen.
F4 CHNG SCREEN – Use function button to go to the screen select list screen.
27
RECOMMENDED SETPOINTS
MODEL
1200
1500
PIPE SIZE
in
SETPOINT 1
(Twin Systems)
gpm
SETPOINT 2
(Triple Systems)
gpm
2
100
200
2½
160
320
3
215
430
4
310
620
2
102
204
2½
165
330
3
225
450
4
405
810
104
1950
2400
3000
3600
4200
4800
5400
2
104
208
2½
168
340
3
235
470
4
445
890
2½
175
350
3
245
490
4
480
960
6
650
1300
3
255
510
4
500
1000
6
700
1400
3
260
520
4
520
1040
6
750
1500
8
950
1900
3
265
530
4
540
1080
6
780
1560
8
1000
2000
4
600
1200
6
800
1600
8
1060
2120
4
675
1350
6
880
1760
8
1150
2300
28
SCREEN 8 - ALARM HISTORY
SCREEN 8 - ALARM HISTORY
This screen displays all alarms that have occurred.
F2 CLEAR LIST – Use this button to go to the main screen without having to use the list.
29
MAINTENANCE
AQUAMATIC REPAIR KITS
Spring Assist Closed
Cast Iron Body
Spring Assist Open
RA - Diaphragm & Seal Kits - Includes Buna N Seals and Diaphragm (Items 3(2),5,6,8(2),9,14&7)
RF - Metal Parts Kit (Normally Open) - (Items 4,7,10,11(2), 17)
RG - Metal Parts Kit (Normally Closed) - (Items 4,7,10,11(2), 23)
SC - Repair Kit (Spring Assist Closed) - (Items 24,27,28)
SO - Repair Kit (Spring Assist Open) - (Items 8,31,32)
GT - Tool - To Install & Remove O-Ring Retainer (Not Shown)
Pipe
Size
Valve
Series
3/4"
REPAIR KITS
SHAFTS (ITEM 16)
RA
Type
RF
Type
RG
Type
SC
Type
SO
Type
GT
Tool
Normally
Open
Normally
Closed
421
A2089028
A2089071
A2089078
A2089085
A2089092
A2089098
A2137001
A2137008
1"
421
A2089028
A2089071
A2089078
A2089085
A2089092
A2089098
A2137001
A2137008
1-1/4"
424
A2089029
A2089072
A2089079
A2089086
A2089093
A2089098
A2137002
A2137009
1-1/2"
424
A2089029
A2089072
A2089079
A2089086
A2089093
A2089099
A2137002
A2137009
2"
425
A2089030
A2089073
A2089080
A2089087
A2089094
N/A
A2137003
A2137010
2-1/2"
426
A2089031
A2089074
A2089081
A2089088
A2089095
N/A
A2137004
A2137011
3"
427
A2089032
A2089075
A2089082
A2089089
A2089096
N/A
A2137005
A2137012
3 FLGD
427
A2089032
A2089075
A2089082
A2089089
A2089096
N/A
A2137005
A2137012
4 FLGD
428
A2089033
A2089076
A2089083
A2089090
A2089097
N/A
A2137006
A2137013
6 FLGD
429
A2089034
A2089077
A2089084
A2089091
N/A
N/A
A2137007
A2137014
30
MAINTENANCE
2536 FLOW SENSOR AND FITTINGS
2
1
Item
Description
Part Number
1
Complete2536FlowSensor
A2296001
2
ReplacementPaddle/Rotor
A2456004
3
Pin
A2098027
4
ReplacementPaddleRotor&Pin
B1175025
Description
Part Number
4
3
2536 GF SIGNET FLOW SENSOR FITTINGS
1
Item
1
2
2
A2295014
A2295001
3”IronStrap-onSaddle
A2295002
A2295003
A2295005
1”GalvanizedIronThreadedTeeNPT
A2294012
1-1/4”GalvanizedIronThreadedTeeNPT
A2294002
1-1/2”GalvanizedIronThreadedTeeNPT
A2294003
2”GalvanizedIronThreadedTeeNPT
A2294004
2”PVCSaddle
A2295026
2-1/2”PVCSaddle
A2295009
3”PVCSaddle
A2295010
4”PVCSaddle
A2295011
3
3
4
2-1/2”IronStrap-onSaddle
6”PVCSaddle
A2295012
4
2-1/2”Weldolet
A2579002
1”CopperTeeSweat
A2569004
5
1-1/2”CopperTeeSweat
A2569009
2”CopperTeeSweat
A2294009
5
31
MAINTENANCE
PROBLEM/SYMPTOM
PROCEDURE
POSSIBLE CAUSE
1. Slight leak to drain.
A. Disconnect tubing at backwash control
A. Flow indicates leaky seal in stager valve.
B. If stager is not leaking, use soap test kit
and check hardness of water at drain.
B. If water tests soft, Valve #6 is leaking:
If water tests hard, Valve #3.
See Problem 5
A. Check position dial.
A. If not in position #4, rotate stager clockwise
to this position.
B. If position dial is in #4, check for water
leakage from Valve#3 or Valve #6 vent
holes.
B. Leakage indicates:
1. Ruptured diaphragm
2. Loose diaphragm nut
C. If vent hole is not leaking, use soap test kit
and check hardness of water at drain.
C. If water tests soft, Valve #6 is open:
If water tests hard, Valve #3.
See Problem 5
A. Check that manual brine valve is open
wide.
A. Valve must be open at all times, except
when servicing.
B. Check water pressure.
B. Water pressure must be a least 30 psi during regeneration.
C. Turn position dial clockwise to position #2.
Break union in suction line to injector and
feel for suction.
C. If there is suction, automatic brine valve
may be clogged.
No suction indicates:
1. Drain pipe to small or discharging at
level too high above floor.
2. Plugged pilot strainer.
3. Plugged injection nozzle.
4. Valves #1, #4, or #2 not closing fully.
See Problem#5
5. Plugged backwash controller.
6. Dirty mineral bed.
4. Slight leak from vent hole.
A. Turn position dial clockwise to a position,
which relieves pressure on valve.
A. If leaking stops, there is possibly a loose
diaphragm nut, a small Tear in diaphragm,
or the washer under diaphragm is missing.
If leaking does not stop, shaft guide O-ring
is damaged, shaft guide is not seated
against gasket, or shaft is damaged.
5. Diaphragm valve does not close or seat
completly.
A. Check that vent hole is not plugged.
A. If vent hole is plugged, air in space between
diaphragm and shaft guide will compress
and prevent valve from closing.
B. Check for water leak at vent hole.
B. See Problem 4
C. Loosen tubing nut at diaphragm cap.
C. If there is no flow, pilot strainer may be
plugged.
D. Turn off water pressure and disassemble
diaphragm valve.
D. Seat washer may be dirty, worn or loose.
A. Check that vent hole is not plugged.
A. If vent hole is plugged, a partial vacuum
will be created in the space between the
diaphragm and shaft guide, preventing
valve from opening.
B. Loosen tubing nut at diaphragm cap.
B. Check for flow
1. If there is flow, stager valve is leaking.
2. If there is no flow, tubing fitting may be
plugged.
A. Close inlet and outlet valves and inspect
by-pass valve.
A. Examine valve
1. Seat washer may be loose or worn.
2. Seat may be rough.
3. Shaft orifice plugged.
4. Diaphragm ruptured.
B. Check that Valve#4 is seating.
B. See Problem 5.
2. High flow to drain during service.
3. Failure to draw brine.
6. Diaphragm valve does not open.
7. Hard water leakage into service lines.
Seat may be eroded.
32
MAINTENANCE
PROBLEM/SYMPTOM
PROCEDURE
POSSIBLE CAUSE
8. Restricted or no drain flow during
backwash.
A. Either Valve#1 or Valve#2 is not opening
fully. To determine which one: Turn position dial to position #1 and then to position
#3. Compare flow at drain.
A. Flow should be the same for both positions.
1. If no difference is noted, valve #4 is not
opening properly.
2. If backwash flow is higher, valve #1 is
not opening properly.
See problem #7.
B. Turn position dial to position #1 and then
position #3. Compare flow at drain.
B. Flow should be the same. If flow for
position also is low.
1. Inlet water pressure may be low.
2. Backwash flow control may be plugged.
If position #3 flow rate is higher, either
valve #4 or valve #3 is not opening.
See problem #7.
9. Loss of softening resin (evidence of
resin in drain lines).
10. Loss of softening resin (evidence of
resin and/or gravel in service lines..
A. Open vent in top of softener tank and check A. If air is present
for air in tank.
1. Vent completely and recheck prior to
next regeneration.
2. If recheck discloses a recurring build-up
of air, check brine system(s) for possible
leaks in suction line or brine valve not
seating properly.
3. If brine system is functioning properly
source of air may be in the water supply
to unit. Use of an automatic air relief
valve is indicated in this situation (consult factory for recommendation).
B. Check automatic backwash control valve
for rate of flow in excess of listed flow
(gpm).
B. Check for excessive inlet water supply
pressures– reduce to rated pressure.
A. Check for damage to softener under-drain
system.
A. Investigation of damage to under-drain
generally requires unloading of softener
tank. Consult factory for recommended
procedures before proceeding.
33
NOTES
34
NOTES
35
NOTES
36
2227 South Street • P.O. Box 044170 • Racine, WI 53404-7003
Ph. (262) 681-1300 • Fax (262) 681-1318 • [email protected] • www.Marlo-Inc.com
EP-100029-A

Marlo_EP-100029-A MHC 3000 Triple PLC IOM

Transcription

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