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MARLO MR Series User manual

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MR 150–1050M
TWIN SOFTENER
WITH 400C HMI
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
8-612 R3
MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER
SYSTEM INFORMATION
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 TWIN - 400C HMI PLC CONTROLLER
Page 1
MR 150M–1050M PLC
TABLE OF CONTENTS
Water Treatment Product Warranty and Softener Guarantee 1
Specification 2
3
General Arrangement Drawing 4
INSTALLATION
Piping Installation ________________________________________________________________
10
9
11
OPERATION
Start Up Instructions_______________________________________________________________
13
12
_________________________________________________ __26
7
________________________________________________________ 8
9
________________________________________________________ 30
_________________________________________________________ 31
____________________________________________________________ 32
MAINTENANCE
Electrical Controls Drawings_________________________________________________________ 33
Replacement Valve Table __________________________________________________________ 39
Diaphragm Valve Repair Kits _________________________________________________________40
Signet Flow Sensor ________________________________________________________________41
Brine Assemblies __________________________________________________________________42
Troubleshooting Guides _____________________________________________________________44
MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER
Ordering:
Orders may be phoned, faxed, or emailed to Marlo Incorporated Purchase
orders must include Marlo Incorporated part numbers and pricing.
Purchase orders must also state if partial shipments are allowed. If you do
not have the correct part numbers, pricing, or case quantities, please con-
tact our customer service department.
Order Confirmations:
All purchase orders will be confirmed by phone, fax, or email. Any discrep-
ancies in part numbers, pricing, descriptions, or case quantities will be
listed in the order confirmation. It is the customer’s responsibility to review
the order confirmations and advise if any changes are to be made. If we
do not hear from the customer regarding the confirmation within 24 hours,
we will assume everything is correct and will invoice and ship accordingly.
Quotes & Prices:
Quotations are valid for a period of up to 45 days or for the term stated
on the quote, whichever term is shortest. We make every effort to notify
customers with price change information. However, prices are subject to
change or correction without notice. Shipping weights, dimensions and
anticipated ship dates are all approximate and subject to change.
Minimum Orders:
Minimum order accepted is $25.00, not including freight or taxes.
Taxes:
Taxes are not included. Quoted prices are exclusive of all taxes.
Purchaser shall be responsible for payment of all applicable state/local
taxes. Orders shipped within Wisconsin are subject to applicable state tax
rates unless a completed resellers card or exempt certificate is on file.
Freight:
All shipments are F.O.B. Marlo Incorporated Racine, Wisconsin, unless
otherwise specified.
Shipment:
The shipment method should be specified by the customer on the pur-
chase order; otherwise, Marlo Incorporated will choose the best method of
shipment.
Packaging:
Pricing includes packaging that is satisfactory for air, truck, or container-
ized shipment at no additional cost, unless otherwise stated. Ocean export
crating will require an additional charge.
Terms - Domestic Customers:
Terms of payment on open accounts are net 30 days from the date of
invoice, unless otherwise stated and mutually agreed upon by both par-
ties. This agreement is subject to credit approval. Terms will only be
issued to companies which reside in the United States of America. Orders
will not be shipped if any account is past due and/or until payment by
check has cleared.
Orders in excess of $60,000 will require partial payments prior to ship-
ment. A specific progress payment schedule will be stated in the quotation.
Partial payments may also be required for orders involving special engi-
neering or custom ordered items regardless of order amount.
Interest will be charged on past due accounts. Interest charges will be
calculated on the unpaid balance at 1.5% per month. All questions regard-
ing invoices and terms must be addressed with our accounting department
before invoices become due.
Unless specifically included as a separate item, prices quoted do not
include any city, county, state or federal taxes, or transportation of
merchandise.
Terms - International Customers:
All payments due are in U.S. dollars and must be made in advance by
check (must clear before shipment), money orders, wire transfer, or credit
card. Credit cards that are accepted are Visa, MasterCard, and American
Express. Irrevocable Letters of Credit are accepted with a minimum order
of $25,000.00 U.S. dollars, per order. Unless specifically included as a
separate item, prices quoted do not include any city, county, state or fed-
eral taxes, or transportation of merchandise. A deposit may be required for
special or custom ordered items.
Freight Claims:
Any damage, discrepancies and/or freight claims must be made immedi-
ately and directly, in writing within ten (10) days to Marlo Incorporated. Marlo
Incorporated will help as much as possible in settling claims. However, Marlo
Incorporated will not be held responsible for breakage or shortage after prod-
ucts are accepted by common carrier. All shipments must be inspected for
damages and counted for shortages at the time of delivery.
Order Changes:
Additions to an order may be made at no charge prior to the processing of
an order. Processing of an order typically begins within one hour of receipt
of a purchase order and is typically accomplished within one working day.
Orders cancelled after the order has been processed and sent to shipping
or engineering, will be subject to a minimum 10% cancellation fee, assum-
ing manufacturing has not commenced, and no detailed engineering or
special parts have been ordered. Additional fees may be charged depend-
ing on the level of completion of detailed engineering, manufacturing,
and/or if any special parts have been ordered.
Returns & Restocking:
A Return Goods Authorization (RGA) number must be obtained from Marlo
Incorporated before any product returns can be accepted and/or replace-
ments shipped. All returns for warranty consideration are to be shipped
prepaid and must be returned within ten (10) business days from the
RGA issuance. Returns determined to be in warranty will be replaced or
repaired and will be returned to Buyer prepaid. Products returned, other
than valid warranty claims, may be subject to a restocking charge of up to
25%. Orders shipped incorrectly by Marlo Incorporated are not subject to
restocking charges and correct items will be shipped to Buyer prepaid.
Excusable Delays:
Marlo Incorporated shall not be in default for failure to deliver or delay
in delivery arising out of causes beyond its control and without its negli-
gence, including but not limited to Acts of God or the public enemy; acts
of the Government in either its sovereign or contractual capacity; fires;
floods; epidemics; quarantine restrictions; strikes; shortages of materials
or supplies; labor disputes; freight embargoes; delays in transit; consign-
ments lost or damaged by freight agent(s); and unusually severe weather.
Warranty:
Marlo Incorporated warrants its products to be free from defects in design,
material, or workmanship for a period of 18 months from shipment date
or 12 months from installation, whichever occurs first, when said products
are installed and operated in accordance with the written instructions pro-
vided. The fiberglass reinforced polyester (FRP) resin/media tanks used
in certain products alone have an extended warranty period of five (5)
years from the shipment date. 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 obliga-
tions 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 war-
ranty 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 negli-
gence 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 including labor
charges, back charges or handling charges are excluded from Marlo Inc.’s
warranty provisions.
Policy:
These terms and conditions may be superseded by specific provisions
provided by Marlo Incorporated. However, should any of these terms and
conditions be contrary to or inconsistent with any terms and conditions
contained in any purchase order form or other document between Marlo
Incorporated and the buyer, which is prepared by the buyer and whenever
executed, the provisions hereof shall be controlling and shall supersede
the conflicting terms and conditions which are contained in such other
document. No changes shall be made to our terms and conditions unless
prior written authorization by Marlo Incorporated
5-264
TERMS & CONDITIONS
MR 150M–1050M TWIN - 400C HMI 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 TWIN - 400C HMI 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 TWIN - 400C HMI PLC CONTROLLER
SYSTEM INFORMATION
4
Page 4
MR 150M–1050M PLC
INSTALLATION
MR 150M–1050M TWIN - 400C HMI 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
MR 150M–1050M TWIN - 400C HMI 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 TWIN - 400C HMI 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