Pentair Fleck 4600 MECH Installer Manual Download

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Installer manual Fleck 4600 MECH - Generalities

Ref. MKT-IM-027 / C - 12.11.2019

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1.4

Intended use

The device is intended for domestic applications use only and it is purpose-built for water
treatment.

1.5

Abbreviations used

Assy

Assembly

BLFC

Brine Line Flow Controller

Brine Valve

Cold Water

Distr

Distribution

Down Flow

DLFC

Drain Line Flow Controller

Fast Regeneration

Hot Water

Imm

Immediate

Inj

Injector

N/A

Not Available

Part Number

Regen

Regeneration

S&S

Seals & Spacers

SBV

Safety Brine Valve

STD

Standard

Sys

System

Valve Body

1.6

Norms

1.6.1

Applicable norms

Comply with the following guidelines:

• 2006/42/EC: Machinery Directive;

• 2014/35/UE: Low Voltage Directive;

• 2014/30/UE: Electromagnetic compatibility;

• 2011/65/UE: Restriction of use of certain hazardous substances in electrical and electronic

equipment (RoHS);

• UNI EN ISO9001.

Summary of Contents for Fleck 4600 MECH

Page 1: ...FLECK 4600 MECH INSTALLER MANUAL WATER PURIFICATION...

Page 2: ...inition 11 2 2 Serial label location 12 2 3 Hazards 12 2 3 1 Personnel 12 2 3 2 Material 13 2 4 Hygiene and sanitization 13 2 4 1 Sanitary issues 13 2 4 2 Hygiene measures 13 3 Description 14 3 1 Tech...

Page 3: ...r 34 5 3 3 Electrical 34 5 3 4 Mechanical 35 5 4 Integration constraints 35 5 5 Valve connection to piping 36 5 5 1 Top mounted valve installation 36 5 6 Block diagram and configuration example 38 5 7...

Page 4: ...3 Regeneration test 58 9 2 Recommended maintenance plan 59 9 2 1 Valve used for softening 59 9 2 2 Valve used for softening 61 9 3 Recommendations 63 9 3 1 Use original spare parts 63 9 3 2 Use origi...

Page 5: ...e valves parts list 82 11 5 Bypass valve assembly list 83 11 5 1 1 BSP female stainless steel bypass 83 11 5 2 1 BSP female stainless steel bypass with mixing 85 11 5 3 Plastic bypass no yoke 86 11 6...

Page 6: ...llowed This manual is a reference and will not include every system installation situation The person installing this equipment should have training in the Fleck series MECH controllers and water soft...

Page 7: ...low DLFC Drain Line Flow Controller FR Fast Regeneration HW Hot Water Imm Immediate Inj Injector N A Not Available PN Part Number Regen Regeneration S S Seals Spacers SBV Safety Brine Valve STD Standa...

Page 8: ...at this list is not an exhaustive list of all our certifications In case of need for more information please contact us 1 7 Procedure for technical support Procedure to follow for any technical suppor...

Page 9: ...assembly of systems or products with this product and vice versa use of a non compatible lubricant grease or chemicals of any type and not listed by the manufacturer as compatible for the product fail...

Page 10: ...nstantaneously access to all updated information related to the product such as valve s and tanks detailed configuration manuals spare parts lists troubleshooting recommendations multi lingual videos...

Page 11: ...ord indicates a potentially hazardous situation that can result in serious or fatal injury if not avoided CAUTION This combination of symbol and keyword indicates a potentially hazardous situation tha...

Page 12: ...any other legal regulations accident prevention and environmental protection measures as well as any recognized technical regulations relating to appropriate and risk free methods of working which ap...

Page 13: ...manual regenerations in order to clean the media bed During such operations do not use the water for human consumption Perform a disinfection of the system in the case of installations for treatment o...

Page 14: ...ient temperature 5 40 C Flow rates 3 5 bar inlet valve only Continuous service flow p 1 bar 4 5 m3 h Peak service flow p 1 7 bar 5 9 m3 h Cv 5 2 gpm Kv 4 5 m3 h Maximum backwash flow p 1 8 bar 1 6 m3...

Page 15: ...ltages Within the limits of category II Pollution Degree 3 Temporary overvoltages must be limited in duration and in frequency Environmental conditions Indoor use only temperature from 5 C to 40 C max...

Page 16: ...alve itself at different flow rates It allows predetermining the maximum flow rate going through the valve depending on the system settings inlet pressure etc It also allows to determine the valve pre...

Page 17: ...Installer manual Fleck 4600 MECH Description Ref MKT IM 027 C 12 11 2019 17 92 3 3 Outline drawing...

Page 18: ...MKT IM 027 C 12 11 2019 3 4 Components description and location Green light Program wheel 24 hours wheel Red light Meter Not included in case of time clock Drain line Imlet Brine cam Brine valve Brine...

Page 19: ...hen directed down through the resin bed and up through the riser tube to the drain The hardness ions on the resin beads are replaced by sodium ions and are sent to the drain The resin is regenerated d...

Page 20: ...Outlet Drain SERVICE NORMAL USE C1 BACKWASH Outlet Inlet Inlet Outlet Drain Drain C2 BRINE DRAW SLOW RINSE C3 SECOND BACKWASH Double backwash unit only From brine tank Outlet Inlet Inlet Outlet C4 RA...

Page 21: ...the media Backwash cycle C1 The flow of water is reversed by the valve and directed down through the riser tube and up through the filter media During the backwash cycle the filter bed is expanded an...

Page 22: ...600 MECH Description 22 92 Ref MKT IM 027 C 12 11 2019 Outlet Inlet Inlet Outlet Drain SERVICE NORMAL USE C1 BACKWASH Outlet Inlet Inlet Outlet Drain C2 RAPID RINSE SERVICE NORMAL USE Untreated water...

Page 23: ...clock softeners To configure the valve as volumetric or time clock softener the 24 hour gear the skipper or program wheel and the meter must be set as shown below 3 6 1 Volumetric Program wheel assy 8...

Page 24: ...Installer manual Fleck 4600 MECH Description 24 92 Ref MKT IM 027 C 12 11 2019 3 6 2 Time clock Skipper wheel assy 7 days PN 14860 Skipper wheel assy 12 days PN 24100 24 hour gear PN 13009 21SP...

Page 25: ...he mixing can be set from 0 to 50 of hard water i e 0 turn 0 of hard water with 100 of treated water and 1 turn 50 of hard water with 50 of treated water 0 turn 1 turn turn 1 turn turn 1 turn turn Fas...

Page 26: ...r specification To ensure that no additional pretreatment prior to softening is required The below sizing method can be applied for both residential and industrial softeners The sizing of a softener m...

Page 27: ...l be sufficient so that even when the peak flow rate is reached the velocity is still between the above values depending on the hardness When sizing a softener always choose the resin volume and tank...

Page 28: ...between 2 regenerations This last capacity takes into account the hardness of the water to be treated and is expressed in m3 or litre the combined capacity which represents the volume of water that c...

Page 29: ...dH Mandatory If a mixing device is set on the valve before meter use TH THINLET THOUTLET Having determined the previous capacity allows the operator to know the service cycle duration 4 2 4 Valve conf...

Page 30: ...al flow rate passing through the injector L h BV bed volume of resin L Info This value does not correspond to the brine draw flow rate but to the total flow rate passing through the injector Refer to...

Page 31: ...MKT IM 027 C 12 11 2019 31 92 4 4 1 1600 injectors INJECTOR 0 Total Rinse Draw Flow rate l min Inlet pressure bar Rinse Draw INJECTOR 1 Total Rinse Draw Flow rate l min Inlet pressure bar INJECTOR 2 T...

Page 32: ...g 32 92 Ref MKT IM 027 C 12 11 2019 4 4 2 1650 injectors INJECTOR 0 Total Rinse Draw Flow rate l min Inlet pressure bar INJECTOR 1 Total Rinse Draw Flow rate l min Inlet pressure bar INJECTOR 2 Total...

Page 33: ...he device please ensure to have disconnected the transformer from the power source to shut off inlet water supply to the valve and to drain water pressure opening a tap down line of the valve 1 Be car...

Page 34: ...me clock hot water version a minimum of 1 4 bar dynamic pressure on injector of water pressure is required for the regeneration valve to operate effectively Mandatory Do not exceed a maximum of 8 6 ba...

Page 35: ...mm in diameter Use 19 mm pipe if the backwash flow rate is greater than 26 5 lpm or the pipe length is greater than 6 m do not support the weight of the system on the valve fittings plumbing or the b...

Page 36: ...all so that the weight of it is not applying any stress on the valve and tank Support to the wall min 200 mm flexible The diagrams above illustrate how the flexible piping connection should be mounted...

Page 37: ...may void the warranty of Pentair products in the same way using lubricant Page 37 on the valve thread is not allowed and will void the warranty for the valve and tank Indeed using lubricant there wil...

Page 38: ...tegrated in the valve Pressure gauge Valve Resin tank Filter cartridge BU28518 XX 21675 Main inlet Pressure regulator Suggested options Check valve to prevent water harm By pass Meter Mixing device Dr...

Page 39: ...sage and regenerates the system as soon as the system capacity is reached delayed control The controller measures water usage and regenerates the system at the specified regeneration time 02h00 after...

Page 40: ...600 MECH Installation 40 92 Ref MKT IM 027 C 12 11 2019 5 8 Electrical connections Green lamp Service Red lamp Regeneration 220 V 50 Hz 220 V 50 Hz N O N C Cam Valve motor Valve motor Microswitch C Wi...

Page 41: ...to bad mounting Do not solder pipes with lead based solder Do not use tools to tighten plastic fittings Over time stress may break the connections Do not use petroleum grease on gaskets when connectin...

Page 42: ...un does not exceed 4 6 m and water pressure at the softener is not less than 2 76 bar Elevation can increase by 61 cm for each additional 0 69 bar of water pressure at the drain connector Where the dr...

Page 43: ...n the side of the tank Insert the overflow fitting into the tank and tighten with plastic thumb nut and gasket as shown below Attach a 12 7 mm I D tubing not supplied to fitting and run to drain Do no...

Page 44: ...hoses may shrink because of the vacuum during brine draw The brine line from the tank connects to the valve Make the connections and hand tighten Be sure that the brine line is secure and free from ai...

Page 45: ...Installer manual Fleck 4600 MECH Programming Ref MKT IM 027 C 12 11 2019 45 92 6 Programming 6 1 Time of day 1 Press the clutch 1 2 Turn the hour wheel 2 to display the correct hour in the window 3...

Page 46: ...l 2 Available capacity Shows the system remaining capacity 3 Program wheel Defines the system capacity in m3 4 Time of day Shows the current time 5 Service position Service Regeneration Backwash Brine...

Page 47: ...water between two regenerations using the following formula Water capacity m3 Exchange capacity m3 tH Reserve capacity m3 Water hardness tH 6 2 2 Set the system capacity 1 Lift the transparent disc 1...

Page 48: ...ock 1 24 hours wheel 2 Program wheel Defines the number of days between two regenerations 3 Time of day Shows the current time 4 Service position Service Regeneration Backwash Brine draw slow rinse Br...

Page 49: ...serve capacity m3 Water hardness tH Number of days between regenerations Water capacity m3 Daily water consumption m3 6 3 2 Set the number of days between two regenerations 1 Push the pins 1 out to se...

Page 50: ...ume definition Set the weight of salt to be used during regeneration using the following table and formula Salt weight g Lresin Exchange capacity tH m3 Lresin Salt weight g tH m3 80 4 20 125 5 25 180...

Page 51: ...eration 1 Calculate the weight of salt needed per regeneration see Salt volume definition Page 50 2 Remove the screws 2 and the cover 1 3 Loosen 5 4 Adjust the segment of the brine cam 4 on the sticke...

Page 52: ...position 8 Fill approximately 25mm of water above the grid plate if used Otherwise fill to the top of the air check in the brine tank Do not add salt to the brine tank at this time 9 Initiate a manua...

Page 53: ...esins synthetic gel zeolite greensand and bentonites 5 25 Sodium hypochlorite If stronger solutions are used such as those sold for commercial laundries adjust the dosage accordingly Dosage Polystyren...

Page 54: ...Fleck 4600 MECH Commissioning 54 92 Ref MKT IM 027 C 12 11 2019 7 2 3 Electro chlorination Valves or systems already equipped with an electrochlorinator device or system will be sanitized during the...

Page 55: ...Ref MKT IM 027 C 12 11 2019 55 92 8 Operation 8 1 Display during operation 8 1 1 During service Valve in service 8 1 2 During regeneration During regeneration the display shows the current cycle step...

Page 56: ...s which may reduce the lifetime of the ion exchange resins Refer to the technical guides for resins in common use providing necessary checks on the system 8 3 Manual regeneration Mandatory The control...

Page 57: ...tion of softener filter and associated ancillaries and check for any leaks ensure valve connection to piping is made with adequate flexibility as per manufacturer instruction 2 Inspection of electrica...

Page 58: ...i e outlet shut off during regeneration and or brine line shut off valve s 4 Test and record Total Hardness of outlet water from softener vessel s 9 1 3 2 Valve used for filtration 1 Initiate manual...

Page 59: ...sary Check clean replace if necessary Replace O rings Check for watertightness clean or replace in case of leakage Check for watertightness clean or replace in case of leakage Check for watertightness...

Page 60: ...Check Check Check Valve to piping watertightness Check Check Check Check Check Wear parts durability strongly affected by raw water quality and regeneration frequency Electronic parts durability stro...

Page 61: ...ace O rings Check for watertightness clean or replace in case of leakage Check for watertightness clean or replace in case of leakage Check for watertightness clean or replace in case of leakage Check...

Page 62: ...to piping watertightness Check Check Check Check Check Wear parts durability strongly affected by raw water quality and regeneration frequency Electronic parts durability strongly affected by power so...

Page 63: ...motors Refer to maintenance sheet 9 3 2 Use original approved lubricants Dow Corning 7 Release Agent 9 3 3 Maintenance instructions Disinfect and clean the system at least once a year or if the treat...

Page 64: ...27 C 12 11 2019 9 4 2 Controller motor replacement 1 Using a flat screwdriver unscrew 4 and remove the cover 3 2 Disconnect the motor 1 3 Using a Philips screwdriver unscrew 2 and remove the motor 1 4...

Page 65: ...ect the meter cable 1 if available 2 Using a flat screwdriver unscrew 5 and remove the cover 4 3 Using a flat screwdriver unscrew 3 and remove the washer 2 4 Using a flat screwdriver or an 8 mm wrench...

Page 66: ...er 1 remove a spacer 8 6 Repeat the two previous steps for all the seals and spacers 7 Lubricate each new seals 7 8 Put back a seal 7 using the stuffer 2 9 Put back a spacer 8 using the stuffer 2 10 R...

Page 67: ...Installer manual Fleck 4600 MECH Maintenance Ref MKT IM 027 C 12 11 2019 67 92 Item Part number Description Packaging quantity 1 13061 Puller 1 2 12763 Stuffer 1...

Page 68: ...T IM 027 C 12 11 2019 9 4 5 Micro switches replacement 1 Using a flat screwdriver unscrew 2 and remove the cover 1 2 Using a Phillips screwdriver unscrew 5 and extract the protection plate 4 and the m...

Page 69: ...12 11 2019 69 92 9 4 6 Brine cam replacement 1 Remove the power head see Power head disassembly replacement Page 65 2 Using a flat screwdriver unscrew 1 3 Remove the washer 2 and the brine cam 3 4 Cha...

Page 70: ...move the injector nozzle 3 6 Using a flat screwdriver remove the injector throat 1 7 Clean or change the injector throat 1 the injector nozzle 3 the filter 2 and the seal 4 8 Lubricate all seals with...

Page 71: ...he BLFC 3 from the grid 4 4 Clean with a terry cloth or change the BLFC 3 and the seal 2 5 Clean the grid 4 6 Lubricate the seal 2 with approved lubricant only Caution material Risk of damage due to w...

Page 72: ...cross threaded 3 Rotate the valve 1 clockwise and freely without using force until it comes to a stop Info This stop position is considered point zero 4 Rotate the valve 1 clockwise from point zero t...

Page 73: ...lean or replace injector and or filter Insufficient water flowing into brine tank Check brine tank filling time and clean flow regulator Hot water tank hardness Repeated flushing of the hot water tank...

Page 74: ...he brine tank Plugged drain line flow control Clean drain line flow control Plugged injector system Clean injector and screen change if necessary Faulty brine valve Change brine valve Bad programming...

Page 75: ...correctly Power head not operating properly Change power head Controller cycles continuously Power head not operating properly Change power head Faulty microswitch or wiring loom Change microswitch or...

Page 76: ...CH Spare parts and options 76 92 Ref MKT IM 027 C 12 11 2019 11 Spare parts and options 11 1 Valve parts list Item Part number Description Packaging quantity 1 BU28518 01 VB assy 4600 filter 1 BU28518...

Page 77: ...2473SP Screw hex washer 10 24 x 5 8 18 8SS 50 3 11737SP Screw TH M5x12 50 4 BU13546 Top plate 1 5 18928 US Piston assy 4600 5600 filter 1 24116 US Piston assy 4600 5600 1 24117 US Piston assy 4600 560...

Page 78: ...00 DF 1 24121 0 25 Brine cam assy 4600 5600 DF 1 24121 0 50 Brine cam assy 4600 5600 DF 1 24121 1 Brine cam assy 4600 5600 DF 1 25736 0 12 Brine cam assy 4600 5600 DF FR 1 25736 0 25 Brine cam assy 46...

Page 79: ...gear 10 15 13312SP Spring idler 50 16 13018SP Idler pinion 50 17 13170SP Main drive gear shaft 10 18 13300SP Ball dia 50 19 14457SP Spring detent 50 20 18158SP Screw 50 21 14087SP Insulator 50 22 102...

Page 80: ...quantity 1 13011 ARM cycle actuator 1 2 13296SP Screw 50 3 13014 Pointer regen 1 4 24100 Skipper wheel assy 12 days 1 14860 Skipper wheel assy 7 days 1 5 BU26968 Front label TC picto with lights 10 2...

Page 81: ...e 10 Not shown BU28233 Brine cam salt label 3 14 kg black 10 Not shown BU28234 Brine cam salt label 6 28 kg red 10 Not shown 13300SP Ball dia 50 Not shown 13311SP Spring detent 50 Not shown 13864SP Sk...

Page 82: ...625SP Brine Valve 1650 plastic nut assy 10 5 19649 Flow disperser 1 6 PWG19652 01 Poppet assy SBV with o ring 1 7 18312SP Retainer drain 10 8 PWG19803 Safety brine valve arm assy 1 9 19645 Body safety...

Page 83: ...Installer manual Fleck 4600 MECH Spare parts and options Ref MKT IM 027 C 12 11 2019 83 92 11 5 Bypass valve assembly list 11 5 1 1 BSP female stainless steel bypass...

Page 84: ...10 3 24419 10SP Bypass handle red 10 4 15727 Screw Hex washer head 10 24 x 0 5 8 5 13604 01 Label bypass standard 1 6 BU11978 Cover bypass Top 1 7 BU11972 Plug bypass 1 8 14105SP Seal bypass 560CD 5...

Page 85: ...xing Item Part number Description Packaging quantity 1 24734 10 Bypass 1 BSP female brass with mixing 1 2 BU28642 Screw TC slotted M6x30 10 3 24419 10SP Bypass handle red 10 4 11737SP Screw TH M5x12 8...

Page 86: ...tom 1 11 5 3 Plastic bypass no yoke Item Part number Description Packaging quantity 1 BU26054 Bypass plastic 1 2 13314SP Screw slot ind hex 8 18 x 0 60 50 3 13255SP Clip mounting 12 4 13305 01SP O rin...

Page 87: ...tributor assy 1 high flow HW 1m10 24 21675 Distributor assy 1 high flow HW 1m88 12 2 BU28509 Distributor assy 1 UF high capacity HW 1 m 10 24 25639 Distributor assy 1 high capacity HW 1m88 24 3 BU2850...

Page 88: ...are parts and options 88 92 Ref MKT IM 027 C 12 11 2019 Item Brine system Part number Description Packaging quantity 1600 18168 Air checks 500A 915mm 36 48 26773 Air checks 500A 1m25 48 23473 Air chec...

Page 89: ...meter except 2 3 10 5 24102 Meter body assy ring 1 6 25871 Meter assy extended plastic 90 1 7 BR15659 Meter cover assy plastic extended 90 1 8 26156 10 Eco bypass assy 40 m red handle HW 1 9 15218 Co...

Page 90: ...country of installation The components included in the system must be separated and recycled in a waste recycling center that conforms with the legislation in force in the country of installation Thi...

Page 91: ...Installer manual Fleck 4600 MECH Notes Ref MKT IM 027 C 12 11 2019 91 92...

Page 92: ...www pentairaquaeurope com...

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