Marlo Incorporated MR Series User manual

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

MR 150M–1050M - PLC CONTROLLER
Please Circle and/or Fill in the Appropriate Data for Future Reference:
Softener Model: MR _____________
System Size: Single/Twin/Triple/Quad
Meter Size: ________________
Configuration: Timeclock/Twin Alt/Parallel/Progressive
Unit Capacity: ________________ Grains
Feed Water Hardness: ________________ Grains
Treated Water: ________________ Gallons/Liters
BW/Regen Time ________________ AM/PM or OFF
Additional 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.
Page 1
MR 150M–1050M PLC

MR 150M–1050M - PLC CONTROLLER
TABLE OF CONTENTS
Water Treatment Product Warranty and Softener Guarantee 1
Specification 2
3
General Arrangement Drawing 4
INSTALLATION
Piping Installation ________________________________________________________________
10
11
OPERATION
Start Up Instructions________________________________________________________________
14
12
_________________________________________________ __
________________________________________________________
________________________________________________________
_________________________________________________________
____________________________________________________________
MAINTENANCE
Electrical Controls Drawings_________________________________________________________
Replacement Valve Table __________________________________________________________
Diaphragm Valve Repair Kits _________________________________________________________
Signet Flow Sensor ________________________________________________________________
Brine Assemblies __________________________________________________________________
Troubleshooting Guides _____________________________________________________________
26
27
28
29
30
31
32
33
40
41
42
43
45

MR 150M–1050M - PLC CONTROLLER
SYSTEM INFORMATION
1
Page 1
PRODUCT WARRANTY
Manufacturer's warrants all 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 manufacturer's satisfaction to be
defective, those products will be replaced, or the price refunded at manufacturer’s option.
Manufacturer'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 manufacturer'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.
Manufacturer 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 thereto.
3. All consequential, incidental, and contingent damages.
Labor charges, change backs or handling charges are excluded from manufacturer's warranty
provisions.
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 (18) months after shipment, whichever comes first, shall be replaced FOB factory.
Page 1
MR 150M–1050M PLC

MR 150M–1050M - PLC CONTROLLER
SYSTEM INFORMATION
2
Page 2
SPECIFICATION NOTES
Maximum salting is 15 pounds of salt per cubic foot of resin. This setting gives the longest time
between regenerations. It has an efficiency of 2,000 grains of hardness removed per pound of
salt. The Brine tank and Regeneration timer are setup for maximum salting at the factory.
Minimum salting is 6 pounds of salt per cubic foot of resin. It has an efficiency of 3,300 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 range is 35-100F.
Power requirements are 120 Volt, 60 Hertz, Single Phase, 2 amps
Salt specifications are pelletized or solar salt, 99% pure, containing less than 1% insolubles.
The Pinwheel Setting time intervals are adjustable.
Page 2
MR 150M–1050M PLC

MR 150M–1050M - PLC CONTROLLER
SYSTEM INFORMATION
3
Page 3
SPECIFICATION TABLE
MODEL MR 150 210 300 450 600 750 900 1050
Valve Size inches
1
1 ¼ 1 ½
2
1 ¼ 1 ½
2
2 ½ 1 ½
2
2 ½
3
1 ½
2
2 ½
3
1 ½
2
2 ½
3 2
2 ½
3 2
2 ½
3 2
2 ½
3
Max 150 210 300 450 600 750 900 1050
Capacity
(Kgrains) Min 100 140 200 300 400 500 600 700
Cont’s.
32 42 45 57 41 64 80
115
68 92
140 165
63 82
120
140
72
110
140 175
90
140 160
105 150 188
95
135
173
Service
Peak
55 78 69 97 57 86
110 160
92
125 190
230
90
115 170 190
94
125 190 250 116 190 230
133 218 279
124 210 259
Backwash
& Flush 10 15 20 20 30 30 45 45
FLOW RATE (GPM)
Brine Draw
& Rinse 2.5 3.5 5 5 7 7 10 10
Pins 5 5 5 5 5 5 5 5
Backwash
Minutes 10 10 10 10 10 10 10 10
Pins 30 30 30 30 30 30 30 30
Brine Draw
& Rinse 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 23½ 24 26½ 20 23 26½ 19½ 25
Tank Size Dia x Ht
Inches 24X50 24x50 24x60 30x60 39x60 39x60 42x60 50x60
Code 2.0-050 3.5-075 5.0-075 5.0-075 7.0-100 7.0-100 10.0-100 10.0-100
Injector
Color Red White Blue Blue Red Red White White
Max Salt
Storage Pounds 700 600 600 1000 1900 1700 1900 2300
Max. 75 105 150 225 300 375 450 525
Salt
Dosage Min. 30 42 60 90 120 150 180 210
Max. 9 5 4 4 6 4 4 4
Regens per
Salt Refill Min. 23 14 10 11 15 11 10 10
Max. 12 19 26 26 19 26 26 19
BRINE SYSTEM
Brine Valve
Float Height Min. 3 8 9 9 8 9 9 8
Page 3
MR 150M–1050M PLC

MR 150M–1050M - PLC CONTROLLER
SYSTEM INFORMATION
4
Page 4
MR 150M–1050M PLC
INSTALLATION

MR 150M–1050M - PLC CONTROLLER
INSTALLATION
5
Page 4
INSTALLATION DIMENSIONS AND SPECIFICATIONS
Length
MODEL
Approx.
Height
(inches) L1
Single
L2
Twin
L3
Triple
Width
(Inches)
Brine
Pipe Size
(inches)
Drain
Pipe Size
(inches)
Pipe
Size
(inches)
MR-150-1
MR-150-1
MR-150-1
MR-150-2
72 50 88 126
29
30
30
34
1
1
1
1
2
MR-210-1
MR-210-1
MR-210-2
MR-210-2
73 54 96 138
32
32
36
37
1
1
1
2
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
2
2
*When less than 4 hours is expected between regeneration’s of a twin or triple softener, a brine tank for each
softener is required.
Page 5
MR 150M–1050M PLC
INSTALLATION
3

MR 150M–1050M - PLC CONTROLLER
INSTALLATION
6
PAGE 7
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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 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

MR 150M–1050M - PLC CONTROLLER
INSTALLATION
7
PAGE 8
PIPING INSTALLATION
Note:
•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
can 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 increase
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.
Note: 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).
2. 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.
3. After the piping has been completed, make sure to close all isolation valves.
Page 7
MR 150M–1050M PLC
INSTALLATION