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MR 150M–1050M - PLC CONTROLLER

INSTALLATION

PAGE

SOFTENER INSTALLATION INSTRUCTIONS

GENERAL INFORMATION

Before beginning installation, thoroughly review the following instructions to familiarize yourself with

the general placement and identification of all components.

These instructions are written for a single unit installation, but they also generally apply to twin and

triple units. Refer to specific equipment layout drawing, water meter installation instruction, and

interconnecting electrical wiring diagram for your system.

Minimum operating pressure is 30 psi.

If pressure less then 30 psi is encountered, a pump must be installed.

Maximum operating pressure is 100 psi.

If pressure greater then 100 psi is encountered, a pressure regulator must be installed.

Power requirements are shown on electrical wiring diagram.

Standard units are designed to soften unheated water in the range is 35-100



Special valve assemblies are available to handle heated water supplies exceeding 100

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 the brine tank. These parts

include hardness test kit, injectors, extra manuals and other parts that may apply to your particular

system. Care should be taken when unpacking the brine tank.

SOFTENER LOCATION

1. Select a position near a floor drain that has adequate carrying capacity to handle the water

softener backwash rate. See the Specification Table for the backwash rate of your system.

2. Refer to your specific equipment layout drawing located on page 31 for tank locations. The

approximate dimensions required for your particular system is shown on page 4. Make sure the

softeners are placed on a level concrete surface.

Page 6

MR 150M–1050M PLC

INSTALLATION

Содержание MR Series

Страница 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 ...

Страница 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...

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

Страница 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 ...

Страница 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...

Страница 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...

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

Страница 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 ...

Страница 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...

Страница 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 ...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

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

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

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

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

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

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

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

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

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

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

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