Marlo Incorporated MR Series Installation, Operation And Maintenance Manual Download

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MR 150–1050M

PLC CONTROLLER

COMMERCIAL WATER CONDITIONERS

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

MODEL NO:

SERIAL NO:

DATE INSTALLED:

DEALER:

COMPLETE FOR FUTURE REFERENCE:

Marlo Incorporated

2227 South Street
P.O. Box 044170
Racine, WI 53404-7003
www.Marlo-Inc.com

8-217 R5

Summary of Contents for MR Series

Page 1: ...AL WATER CONDITIONERS INSTALLATION OPERATION AND MAINTENANCE MANUAL MODEL NO SERIAL NO DATE INSTALLED DEALER COMPLETE FOR FUTURE REFERENCE Marlo Incorporated 2227 South Street P O Box 044170 Racine WI 53404 7003 www Marlo Inc com 8 217 R5 ...

Page 2: ...r 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 installe...

Page 3: ...________________________ _________________________________________________________ ____________________________________________________________ MAINTENANCE Electrical Controls Drawings_________________________________________________________ Replacement Valve Table __________________________________________________________ Diaphragm Valve Repair Kits _______________________________________________...

Page 4: ...rer 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 the manufacturer or any undertakings acts or omissions relating ...

Page 5: ...00 grains of hardness removed per pound of salt Freeboard is the distance between the surface of the resin and the top side shell of the tank On continuous flow rates pressure loss does not exceed 15 psig On peak flow rates pressure loss does not exceed 25 psig Minimum operating pressure is 30 psi Maximum operating pressure is 100 psi Standard units are designed to soften unheated water in the ran...

Page 6: ... Minutes 60 60 60 60 60 60 60 60 Pins 3 3 3 3 3 3 3 3 Fast Flush Minutes 6 6 6 6 6 6 6 6 Pins 2 2 2 2 2 2 2 2 TIMER PINWHEEL SETTINGS Return to Service Minutes 4 4 4 4 4 4 4 4 Size Dia x Ht Inches 20x54 24x54 30x54 30x60 36x60 36x72 42x60 42x72 Gravel Subfill Pounds 100 200 300 300 400 400 600 600 Resin Cubic Feet 5 7 10 15 20 25 30 35 SOFTENER TANK Freeboard Inches 23 24 26 20 23 26 19 25 Tank Si...

Page 7: ...MR 150M 1050M PLC CONTROLLER SYSTEM INFORMATION 4 Page 4 MR 150M 1050M PLC INSTALLATION ...

Page 8: ... 2 MR 300 1 MR 300 2 MR 300 2 MR 300 3 76 60 108 156 38 42 43 44 1 1 2 2 3 MR 450 1 MR 450 2 MR 450 2 MR 450 3 82 66 114 162 38 42 43 44 1 1 2 2 3 MR 600 1 MR 600 2 MR 600 2 MR 600 3 89 81 135 189 44 48 49 50 1 1 1 2 2 3 MR 750 2 MR 750 2 MR 750 3 101 81 135 189 48 49 50 1 1 2 2 3 MR 900 2 MR 900 2 MR 900 3 94 90 150 218 54 55 56 1 2 2 2 3 MR 1050 2 MR 1050 2 MR 1500 3 106 98 158 218 54 55 56 1 2 ...

Page 9: ...n unheated water in the range is 35 100 F Special valve assemblies are available to handle heated water supplies exceeding 100 F Consult factory if applicable Catalog softeners are shipped fully assembled with face piping and controllers Care must be taken not to damage valves or controllers during uncrating and installation During unpacking the brine tank miscellaneous parts are shipped inside th...

Page 10: ...ncrease of backpressure will cause problems when drawing brine 1 Install piping as shown on the layout drawing located on page 31 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 ...

Page 11: ...MR 150M 1050M PLC CONTROLLER INSTALLATION 8 TUBING DIAGRAM VALVE NEST MULTITANK ASCO SOLENOID ...

Page 12: ... pressure is run through the solenoid to the service outlet diaphragm valve The solenoid installed at the factory is a universal type It is plumbed in an energize to close configuration When a tank enters Regeneration or Standby the solenoid is energized Pressure from solenoid port 1 passes to port 2 The diaphragm valve 2 will close When a tank enters In Service the solenoid is de energized The in...

Page 13: ...ification Table on page 3 for settings Place brine valve into brine well Brine valve assembly will not sit on bottom of brine tank 4 Connect the brine valve to the brine injector 5 Open the injector feed water valve and allow the brine tank to fill with water To speed this process the tank can be filled with hose to about 2 below the platform The tank will continue to fill until the float rises an...

Page 14: ...4 The equipment provided has a plastic lower distributor system Care should be exercised in the loading of the gravel in order to insure that the distributors are not damaged 5 Slowly and gently pour the gravel marked for the mineral tank into the unit 6 Drain the tank down until the gravel and water levels are the same 7 Carefully level the gravel before loading the resin RESIN LOADING 1 Reopen t...

Page 15: ...te stager enclosure cover on Unit 1 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 4 Manually advance the operator interface to the Presets Screen Verify the cycle time and K factor are correct for your unit size Change if required 5 Manually advance the oper...

Page 16: ...hile the Unit 1 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 12 Advance Unit 1 to the Fast Rinse position The Unit 1 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 wil...

Page 17: ...nd unit that was 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 pushbutton on the OIT A regeneration lockout is built into the logic so that only one unit can be in regeneration at a time Note Follow all applicable codes and re...

Page 18: ... TIMES BATCH K FACTOR PRESETS 1 SCREEN 3 MANUAL START REGENERATION ADVANCE SCREEN 4 REGEN START CHOICE AND ELAPSED TIME OVERRIDE SCREEN 5 FLOW DELAY PRESETS FLOW RATE SETPOINTS SCREEN 6 TOTALIZERS SCREEN 7 SYSTEM RESET CONFIGURATION SCREEN 8 SCREEN CHANGES SCREEN 9 ALARM HISTORY ALL SCREENS ARE NOT SECURED ...

Page 19: ...ll be put into service Mode each unit s mode is displayed here The modes indicate which cycle the unit is in These can be any one of the following SERVICE STANDBY BACKWASH BRINE SLOW RINSE 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 Regener...

Page 20: ... set in the field after knowing the hardness 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 To change a value press the corresponding yellow box This will bring up a numeric keypad Use the keypad to enter the desired number Press enter when done Initial set points were as follows Backwash...

Page 21: ...ation 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 There is a 3 second delay on these buttons to verify operator intent Once a button is activated the operator will be locked out from activating the button again for 10 seconds in order to allow the valve time to rotate to its next position Thi...

Page 22: ...to regenerate the softener system Use the keys below this box to move the arrow and press enter to select the method of regeneration Elapsed Time Override enter the number of hours that must elapse before the service unit will go into regen This entry will only be valid if elapsed time or both is selected Elapsed Time Override Time Remaining the number of hours remaining before the service unit wi...

Page 23: ...add second unit set point Flow rate to add second unit online this set point is the value in which the second unit will be brought online When the flow rate exceeds this flow rate value for the preset delay the second unit will be brought on line If the total flow rate decreases below set point for a delayed amount of time the second unit will be taken offline To change a value press the correspon...

Page 24: ...w the number of gallons have passed for any unit while it was in service To reset any units totalizer press the corresponding button at the bottom of the screen There is a 3 second delay on the totalizer reset buttons to verify operator intent Screen change button when this button is pressed it will bring up the screen changes screen ...

Page 25: ...or a minimum of 5 continuous seconds will reset the system This will take any unit that is currently in regeneration out of regeneration to service or standby Unit A will be set as primary B as secondary and C as third Config access this allows the operator to go to the OIT configuration menu This has already been preset and access to this should not be necessary Screen change button when this but...

Page 26: ...MR 150M 1050M PLC CONTROLLER OPERATION 23 CONTROLS CONTINUED OPERATOR INTERFACE SCREENS SCREEN 8 SCREEN CHANGES This screen can be used to change to a different screen ...

Page 27: ...ISTORY BANNER An alarm banner will occur if any of the stagers in the LCP s fail to rotate home Flow is detected on the unit in standby If elapsed time is selected and the regen start choice is batch Press the clear button to clear the alarm The alarm history screen will keep track of alarms as they occur ...

Page 28: ...he 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 pos...

Page 29: ...r was measured to be 20 grains Using our equation take 300 000 20 15 000 gallons 10 reserve capacity 1500 gallons 15 000 gallons 1500 gallons 13 500 gallons batch size For immediate regeneration type meter control the meter setting would be at 15 000 gallons Commonly this value is adjusted to 90 percent of the actual value in this example 13 500 gallons to assure not over running the softener For ...

Page 30: ...es 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 2 Brine Rinse 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 it...

Page 31: ...MR 150M 1050M PLC CONTROLLER OPERATION 28 PAGE 28 FLOW DIAGRAM Page 28 MR 150M 1050M PLC OPERATION ...

Page 32: ...he resulting level may be 2 to 10 inches above the platform depending on the amount of salt for regeneration During regeneration the brine injector creates suction which opens the brine valve and draws into the softener tank When the brine level falls below the brine valve the valve seats and prevents air from entering the system RECOMMENDED TYPES OF SALT Only purified salt should be used in the b...

Page 33: ...ne tank refill time to the minimum setting according to the specification table Refer to the Setting the regeneration cycle timer page Monitor the water daily for hardness It may also be necessary to adjust the regeneration frequency since the capacity of the unit has changed 1 Remove brine valve assembly from brine well 2 Remove air check from assembly 3 Shorten the riser tube by removing the top...

Page 34: ... 210 2 1 2 110 160 30 110 60 220 300 1 1 2 70 100 15 70 30 140 300 2 90 130 25 90 50 180 300 2 1 2 120 190 35 140 70 280 300 3 140 230 50 160 100 320 450 1 1 2 70 90 15 60 30 120 450 2 110 120 25 80 50 160 450 2 1 2 140 170 35 120 70 240 450 3 175 190 50 140 100 280 600 1 1 2 90 100 20 70 40 140 600 2 110 130 25 110 50 220 600 2 1 2 140 190 35 140 70 280 600 3 175 250 50 175 100 350 750 2 90 120 2...

Page 35: ...TOR Table Program values for XX PIPE SIZE Inches TEE Galvanized TEE PVC SADDLE Iron SADDLE PVC WELDOLET Carbon Steel 1 213 352 1 1 4 128 177 1 1 2 94 118 2 59 67 54 67 2 1 2 43 38 43 38 3 27 23 27 24 4 15 13 15 14 6 7 8 8 Page 32 MR 150M 1050M PLC OPERATION ...

Page 36: ...MR 150M 1050M PLC CONTROLLER MAINTENANCE 33 ...

Page 37: ...MR 150M 1050M PLC CONTROLLER MAINTENANCE 34 ...

Page 38: ...MR 150M 1050M PLC CONTROLLER MAINTENANCE 35 ...

Page 39: ...MR 150M 1050M PLC CONTROLLER MAINTENANCE 36 ...

Page 40: ...MR 150M 1050M PLC CONTROLLER MAINTENANCE 37 ...

Page 41: ...MR 150M 1050M PLC CONTROLLER MAINTENANCE 38 ...

Page 42: ...MR 150M 1050M PLC CONTROLLER MAINTENANCE 39 ...

Page 43: ...10108B B2010208B A2009001B A2010001B B2010201B A2007001B A2007001B 1 5 B2010104B B2010204B A2009002B A2010002B B2010202B A2007002B A2007002B 2 B2010105B B2010205B A2009002B A2010002B B2010202B A2007002B A2007002B 2 5 B2010107B B2010207B A2009002B A2010002B B2010202B A2007002B A2007002B 3 B2010108B B2010208B A2009002B A2010002B B2010202B A2007002B A2007002B 2 B2010105B B2010205B A2009002B A2010002B...

Page 44: ...2089028 A2089071 A2089078 A2089085 A2089092 A2089098 A2137001 A2137008 1 424 A2089029 A2089072 A2089079 A2089086 A2089093 A2089099 A2137002 A2137009 1 424 A2089029 A2089072 A2089079 A2089086 A2089093 A2089099 A2137002 A2137009 2 425 A2089030 A2089073 A2089080 A2089087 A2089094 N A A2137003 A2137010 2 426 A2089031 A2089074 A2089081 A2089088 A2089095 N A A2137004 A2137011 3 427 A2089032 A2089075 A20...

Page 45: ...02 TEE INSTALL 1 1 4 GALV A2294003 TEE INSTALL 1 1 2 GALV A2294004 TEE INSTALL 2 GALV A2295001 SADDLE 2 1 2 IRON A2295002 SADDLE 3 IRON 3 4 PVDF Insert Iron Strap on Saddle with PVDF Insert Galvanized Iron Threaded Tee with NPT Threads 1 213 1 1 4 128 1 1 2 94 2 59 54 2 1 2 38 3 23 Pulses per Gallon K Factor Table Pipe Size Inches Saddle Iron Tee Galvanized Page 42 MR 150M 1050M PLC MAINTENANCE ...

Page 46: ...ID PLATE PLASTIC 30DIA 5BW 4 A2275007 PIPE 1 1 2 SDR OR SCH40 DWV B1042001 BRINE VALVE ASSEMBLY MR 150 B1042002 BRINE VALVE ASSEMBLY MR 210 B1042003 BRINE VALVE ASSEMBLY MR 300 450 6 B1015008 BRINE WELL 5x46 DRILLED 7 A2072001 CAP PLUG RED 5 INCH 8 A21200002 ELBOW OVERFLOW 1 2 W NUT 9 A2476001 INSERT 1 2 POLY 10 A2165002 TUBING 1 2x3 8 BLACK POLY 1 3 5 Models Part Number Shelf Height MR 150 B10390...

Page 47: ... 8 DIA MR 600 750 B1041004 SALT SHELF 41 1 4 DIA MR 900 B1041005 SALT SHELF 49 DIA MR 1050 B1040003 SALT SCREEN 39 DIA MR 600 750 B1040004 SALT SCREEN 42 DIA MR 900 B1040005 SALT SCREEN 50 DIA MR 1050 B1042002 BRINE VALVE ASSY 22 GRID MR 600 750 1050 B1042003 BRINE VALVE ASSY 29 GRID MR 900 6 B1015008 BRINE WELL 5x46 DRILLED 7 A2250003 ELBOW OVERFLOW 1 2 W NUT 8 A2072001 CAP PLUG RED 5 9 A2476001 ...

Page 48: ...stager valve Replace 10 Controller out of sequence due to A Turning position dial manually when time switch is not in OFF position or turning the cycle adjustment knob too quickly for stager to index With time switch mechanism in normally OFF position Red arrowhead pointing straight down manually turn Position Dial clockwise to No 4 Service position B Temporary low voltage condition of poor electr...

Page 49: ...t when servicing 7 Check water pressure Water pressure must be a least 30 psi during regeneration Failure to draw brine 8 Turn position dial clockwise to position 2 Break union in suction line to injector and feel for suction 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 Pl...

Page 50: ...drain flow during backwash 19 Turn position dial to position 1 and then position 3 Compare flow at drain 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 procedures 14 and 15 20 Open vent in top of softener tank and check for air in tank 1 ...

Page 51: ...MR 150M 1050M PLC CONTROLLER 48 NOTES ...

Page 52: ...2227 South Street P O Box 044170 Racine WI 53404 7003 www Marlo Inc com 8 217 R5 ...

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