MARLO MATD 9500 XT User manual

MATD 9500 XT
1-
2
” Systems
AUTOMATIC WATER
DEALKALIZER
INSTALLATION, OPERATION, AND
MAINTENANCE MANUAL

TABLE OF CONTENTS
Commercial and Industrial Product Warranty and Water Conditioner Guarantee . ...................... 1
General Arrangement Drawings and Dimensional Data ............................................................ 2
Specifi cation Table ..................................................................................................................... 3
Control Dimensions.................................................................................................................... 4
Dealkalizer General Information .................................................................................................5
Locate Dealkalizer ....... ...............................................................................................................9
Load Dealkalizer Tank ................................................................................................................9
Mounting Control Valve Assembly ............................................................................................10
Mounting Water Meter Assembly ...............................................................................................10
Piping Installation ......................................................................................................................11
Start-up Procedure ....................................................................................................................12
Dealkalizer General Operation .................................................................................................13
Recommended Types of Salt ....................................................................................................14
Calculation of Capacity ..............................................................................................................14
Flow Diagrams ..........................................................................................................................16
Setting Specification Sheet ........................................................................................................19
XT Timer Operation ................................................................................................................... 20
Master Programming Instructions ............................................................................................. 24
User Programming Instructions ................................................................................................ 34
Diagnostic Mode ....................................................................................................................... 35
9500 Power Head Parts Lists ................................................................................................... 37
XT Timer 9500 Valve Wiring Diagram ...................................................................................... 39
Meter Flow Rate & Pressure Drop ............................................................................................40
Injector Flow Rate & Pressure Drop ......................................................................................... 41
Parts Lists & Assemblies ...........................................................................................................42
Troubleshooting .........................................................................................................................51
Appendix:
8Series 150 Chemical Feed Pump Manual
MATD 9500
XT MANUAL

Page 1
PRODUCT WARRANTY
Marlo, Inc. 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. The
fiberglass mineral tank(s) alone have a warranty for a period of five (5) year from the date of
shipment. 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 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 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 warranty 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 negligence 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.
Labor charges, change backs or handling charges are excluded from Marlo Inc.’s warranty
provisions.
WATER CONDITIONER GUARANTEE
Under normal operating conditions:
1. The loss of resin through attrition during the first three (3) years shall not exceed 3% per year.
2. The resin shall not be washed out of the system during backwash.
3. 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.
• 2227 South Street • P.O. Box 044170
• Racine, Wisconsin 53404-7003
• Phone: [phone] • Fax: [phone]
www.marlo-inc.com

Page 3
SPECIFICATION TABLE
MODEL MATD-60-1-1/2
SPECIFICATIONS
Design Temperature 35-100ºF
Design Pressure 30-100 psig
Power Requirements 120 VAC 60 Hz
Resin Capacity 60,000 grains @ 5 lbs. Salt Dosage and 0.3 lbs Caustic
SYSTEM FLOW RATES
Continuous Service 14.0 gpm
Backwash Rate 6.0 gpm
Brine Draw Rate 0.6gpm
Brine Rinse Rate 1.75 gpm
Fast Rinse Rate 6.0 gpm
Caustic Injection Rate 1.6 gph
MINERAL TANK
Mineral Tank Size 21inch diameter / 62inch side shell
Gravel Quantity 80 lbs. / tank
Resin Quantity 6ft3
CONNECTIONS
Inlet / Outlet 1.5" inch inlet / outlet
Drain Size 1 inches
Brine Connection 1/2 inch
BRINE MEASURING TANK
Brine Measuring Tank Size 18 inch diameter / 40inch height
Refill Water Volume Requirement 12 gallons of water required @ 5 lbs. Salt dosage
Brine Volume Requirement 15gallons of brine required @ 5 lbs. Salt dosage
Brine Draw Dimension 13 inches Refill Height
Salt Requirements 5 lbs. salt (Dry Total) dosage per cubic foot of resin
CAUSTIC PUMP
Pump Model Chemtech X068 Series 150 (X068-XA-AAAAXXX)
Pump Setup 3.33 lbs. caustic (Dry) Dosage per Cuft of Resin
Caustic Volume Requirement 0.31 Gallons @ 50% Sodium Hydroxide
Caustic Injection Rate 0.94 gph
Duration 20 min
Caustic Volume Requirement 50% Sodium Hydroxide (RAYON GRADE)

MODEL MATD 50 60 80 100
Valve Size Inches 1-1/2 1-1/2 1-1/2 1-1/2
Capacity
(Kilograins) 50 60 80 100
FLOWRATE (GPM)
Service Continuous 12.5 15 20 25
Peak 25 30 40 50
Backwash &
Fast Flush 5 6 8 12
Brine Draw
& Rinse 1.5 1.5 3.2 3.2
Brine Tank
Rell 2222
TIMER SETTINGS
Backwash Minutes 10 10 10 10
Brine Draw
& Rinse Minutes 60 60 60 60
Fast
Flush Minutes 10 10 10 10
Brine Tank
Rell Minutes 4 5 7 8
SOFTENER
TANK
Size Dia x Height
Inches 18 x 65 21 x 62 24 x 72 30 x 72
Gravel
Subll Pounds 40 80 120 225
Resin Cubic Feet 5 6 8 10
Freeboard Inches 24 23 30 22
BRINE SYSTEM
Tank Size Dia x Height
Inches 18 x 40 18 x 40 24 x 40 24 x 40
Injector Code 3C 4C 5C 5C
Color YEL GRN WHT WHT
Maximum Salt
Storage Pounds 325 325 550 550
Salt Dosage u25 30 40 50
Caustic Dosage
v0.23 0.28 0.37 0.55
Rell Time Minutes 4 5 7 8
Caustic Pump
Setting w1 1.2 1.5 2.2
Regeneration
per Salt Rell 13 10 13 11
Regeneration
Waste Volume Gallons 200 250 490 520
NOTE u: Salt is pellet salt which is 99% Sodium Hydroxide
NOTE v: Caustic dosage is 50% Sodium Hydroxide Rayon Grade or better
NOTE w: Set Caustic Pump
Page 17
WATER CONDITIONER FLOW DIAGRAMS
MATD9500
XT MANUAL
SPECIFICATIONS

9500 Control Dimensions
Page 4
MATD 9500
XT MANUAL

Page 5
INSTALLATION INSTRUCTIONS
WATER DEALKALIZER
GENERAL INFORMATION
1. Minimum operating pressure is 25 psi.
If pressures less then 25 psi are encountered, a pump must be installed.
Note: The control valve will not operate correctly if feeding into an atmospheric tank. A
pressure control devise must be added to the outlet to maintain the minimum pressure.
2. Maximum operating pressure is 120 psi.
If pressures greater then 120 psi are encountered, a pressure regulator must be installed.
3. Power requirements are shown on inside cover of the control valve.
4. Standard units are designed to condition unheated water not to exceed 100°F.
Special valve assemblies are available to handle heated water supplies exceeding 100°F.
Consult factory if applicable.
5. Each dealkalizer tank is shipped with distributor manifold and control valve preassembled.
Take care when uncrating and erecting so that no items are damaged.
6. The distributor assembly has been shipped inside the fiberglass mineral tank.
Check to make sure that there is no damage to the riser pipe, baskets, laterals, or hub.
8. Freeboard is the distance between the surface of the resin and the top of the tank.
9. Regeneration waste volume is the total gallons of water that is discharged per regeneration.
10.The water meter has a flow range of 1.5to 75 gpm with accuracy ±5%.
11.On continuous flow rates pressure loss does not exceed 15 psig.
On peak flow rates pressure does not exceed 25 psig.

Page 6
DEALKALIZATION
Alkalinity is a measure of a waters ability to neutralize an acid. There are three
components to alkalinity including, bicarbonate (HCO3), carbonate (CO3) and hydroxide (OH).
The existence of these ions is pH dependent. HCO3will be the predominant constituent of
alkalinity at a pH of 4.3 to 8.3. The CO3ion will begin to form at a pH greater than 8.3. At a pH
of approximately 1O the OH ion will start to exist.
The relationship between the components of alkalinity and pH allows for the accuracy of
the water analysis to be verified. If water has a pH of 9.0 and only the bicarbonate alkalinity was
reported on the analysis, the analytical results are deficient. Carbonate alkalinity should have
also been reported on the analysis. In order to eliminate the potential for error in the water
analysis a total alkalinity test can be performed. Total alkalinity is run by testing for P and M
alkalinity. P alkalinity or phenolphthalein endpoint is a measure of the amount of acid required
to neutralize the alkalinity down to a pH of approximately 8.3. M alkalinity or methyl orange
endpoint is a measure of the amount of acid required to neutralize the alkalinity down to pH of
approximately 4.3. The actual concentrations of HCO3, CO3, and OH are derived from
calculations using the P and M alkalinity; see Standard Methods Edition 17 Method 2320 B.
The most common question asked is why when caustic (NaOH) is added to acidic water
and the pH is elevated to 8 that no OH alkalinity exists? The answer goes back to pH. No OH
alkalinity can exist at this pH. The OH will react with CO2to form bicarbonate, at this pH.
If water’s alkalinity concentration becomes too high, it can have a bitter taste. Anion ion
exchange resin can be used to remove alkalinity, thereby reducing the pH and bitter taste
associated with high concentrations of alkalinity. If the alkalinity concentration in the influent
water is high, the replacement of alkalinity with chloride may result in a salty taste. The salty
taste may be noticed at levels of 600 to 800 ppm TDS. An R/O system should be used to
eliminate the salty taste.
Alkalinity is also a problem with boiler feed water. The bicarbonate and/or carbonate ions
can be broken down to form OH and CO2when water is converted to steam in the boiler. The
OH ion remains in the water while the steam contains CO2. When this steam condenses the
CO, forms carbonic acid (H2CO3), which will attack most metals, it will shorten the life of the
condensate return system. For this reason dealkalization of water used in boilers may be
required, depending on the conditions of operation. Consult your local water doctor.
A type II anion resin is generally used to dealkalize water. There are two types of
regeneration. The first utilizes only salt, the second uses a combination of salt and caustic
(NaOH). If salt is used, the hardness in the influent water should be less than 10 grains / gallon
to prevent the precipitation of CaCO3. In most cases, where dealkalization is necessary, the
hardness will have to be removed, since scaling may occur. If salt and caustic are used, the
water that is fed into the dealkalizer, as well as the water used to regenerate it, should be soft.
The biggest difference between the two regeneration processes is that the salt and caustic will
achieve higher capacities than salt alone.

Page 7
DEALKALIZATION continued
When sizing a dealkalizer, the water analysis must as a minimum include the following
parameters; total alkalinity, chloride (Cl), sulfate (SO4), total hardness and TDS. The Cl and SO
must then be converted to their CaCO3equivalents. Remember, the total alkalinity is already
expressed as CaCO3. The next step is to calculate the percentage of alkalinity as a function of
the total anions. From the capacity curve using the percent alkalinity the operating capacity
(kgr/cu.ft.) can be obtained. When using only salt, a dosage of 5 lbs/cu.ft. is used to regenerate
the resin. Higher concentrations can be utilized; however, capacity will not be significantly
increased. When caustic is utilized, 0.25 lbs of 100% NaOH are used in conjunction with 5 lbs
of salt. The amount of caustic employed in the regeneration can be adjusted, so that the
effluent OH concentration will be at a desired level. In boiler treatment some OH alkalinity is
desirable to assure the corrosion potential is reduced to a minimum. Leakage will be
approximately 10% of the influent alkalinity. This is applicable to either type of regeneration.
When caustic is used in conjunction with salt as the regenerant, leakage must be calculated.
The 10% leakage is carbonate alkalinity. Hydroxide alkalinity will exchange off the resin bed
and exist in the effluent along with the carbonate alkalinity resulting in a high pH effluent.
Caustic soda is normally used when the dealkalizer is supplying water for boiler make-up.
Caustic soda should not be used as a regenerant when dealkalizing potable water.

Page 8

Page 9
LOCATE DEALKALIZER
1. Select a location that is accessible and near a floor drain that has adequate carrying capacity
to handle the backwash flow. See specification table for the flow rate.
2. Erect the mineral tanks on a concrete or other firm foundation and level.
3. Position the brine tank according to the illustration and supplementary brine tank information.
Keep the brine tank as close as possible to the mineral tanks.
Note: The distance between the mineral tanks and brine tanks will affect the brine injector
performance, as the distance increases the injector performance decreases. This may
cause an inadequate regeneration.
4. A grounded electric receptacle is required for the control valves.
LOAD DEALKALIZER TANK
1. On tank sizes 12 inches and smaller the media has been pre-loaded at the factory. Skip this
section and go to “Mount Control Valve Assembly”.
2. Fill tank approximately 1/3 full of water using a hose, bucket, etc. Plug the PVC distributor
manifold pipe using a plastic cap, cork, rag, etc. No gravel or resin should go into this
distributor manifold pipe.
3. Verify the distributor manifold is center in the tank with the distributor resting on the bottom of
the tank. Verify the riser pipe is still plugged.
Note: Reference the specification table in the front of this manual for the correct quantities of
gravel and resin. These quantities are for each tank. Make sure you have the required
amounts on site before you begin.
4. With care not to damage any lateral, pour in the gravel provided for each tank through the
top opening in the tank and level out evenly. This will cover the distributor assembly.
Note: Wetting the gravel in the bags before loading will eliminate the normal amount of dust.
5. When gravel is loaded and leveling is completed, proceed as follows:
6. With the distributor riser pipe still plugged, add the proper amount of resin supplied for each
tank through the top opening in the tank.
Caution:The softener resin is very slippery. Take care when stepping on any spilled resin.
Remove spilled resin from standing surface immediately.
7. When loading is complete, remove plastic cap, cork, or rag that was used to plug the
distributor riser pipe. Be careful not to let any foreign debris fall into the pipe. The result
could be damage to system.
8. Repeat instruction steps 1-7 for each softener.

Page 10
MOUNTING CONTROL VALVE ASSEMBLY
1. On the right side tank, verify that the distributor riser pipe is not plugged.
2. Lubricate the distributor o’ring on the bottom of the control valve with silicone.
3. Screw the control valve into top opening of tank making sure the distributor riser pipe slides
easily through the distributor o’ring. Care must be taken not to “nick” this o’ring as hard
water leakage could result.
4. Tighten down the control valve to ensure positive o’ring seal at top of tank.
5. On the left side tank, verify that the distributor riser pipe is not plugged on the second
softener tank.
6. Lubricate the distributor o’ring on the bottom of the second tank adapter assembly with
silicone.
7. Screw the second tank adapter assembly into top opening of tank making sure the distributor
riser pipe slides easily through the distributor o’ring. Care must be taken not to “nick” this
o’ring as hard water leakage could result.
8. Attach the second tank adapter assembly to the control valve.
9. A grounded electric receptacle is required for the control valve.
MOUNTING WATER METER ASSEMBLY
1. Locate the water meter. The water meter has a flow arrow stamped on it. The flow arrow on
the meter should be pointing away from the control valve. Attach the meter to the control
valve's water outlet.
2. The digital water meter is connected to the control valve with a transducer wire cable. Attach
the one end of the cable with a small rectangular box on it into the dome of the meter.
Secure the transducer with attached screw clamp on the top of the meter dome. Wire the
other end of this cable to the control valve's terminal strip. Reference the electrical wiring
diagram located in the back of this manual.

Page 11
INSTALLATION OF CONNECTION PIPING
Note:
•Use thread sealing tape on all threaded piping connections.
•Install the piping conforming to federal, provincial, and local codes.
•Unions or flanges are recommended at the control valve's inlet and outlet connections
•To enhance the monitoring of the system's performance sample valves and pressure gauges
can be installed at the inlet and outlet piping of the softening unit.
•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.
Caution: All piping must be properly supported. The tank and valve assemblies are not meant
to support the connecting piping.
1. Install piping as shown on installation diagram. It is recommended that unions be installed
before the inlet and outlet valves to facilitate service of unit. Be sure piping is free of thread
chips and other foreign matter. The connecting piping should be the same size or larger
then the service inlet and outlet of the control valve.
3. Verify that the flow arrow stamped on the flow controller is pointing away from the control
valve. See installation diagram or valve manual for the location. Install a drain line from
backwash control assembly to an appropriate drain using a minimum of elbows. Install a
union near the backwash control to facilitate cleaning.
Note: Do not install a valve on the drain line.
3. Connect the brine line tubing to the control valve and to the brine tank. Verify that the brine
line tubing is not kinked or restricted
4. Run flexible tubing from the brine tank's over flow fitting to an appropriate, non-elevated,
open drain.

Page 12
CAUSTIC PUMP INSTALLATION
Refer to the pump installation, operation, and maintenance manual located in the back of this
manual.
START-UP
1. Again, make sure all plumbing is complete and tight including drain line and brine line. Make
all electrical connections per wiring diagrams provided.
2. Using a bucket or hose, fill brine tank with water to 2” above salt platform. Do not add salt at
this time.
3. Make sure inlet and outlet isolation valves are closed then connect electrical power to the
controll valve by plugging in the valve. Once the Valve is powered it will drive to the service
position.
4. During cold weather it is recommended that the installer warn the timer up to room
temperature before operating.
5. Program the XT controller by following Option Setting Level #1 Programming
Chart of the 3200 XT Timer Service Manual found in the manual.
Note: Start up only one (1) tank at a time.

Page 13
WATER DEALKALIZER GENERAL OPERATION
Backwash: The cycle duration is factory set at 10 minutes for clean feed water
applications. Increase time duration to 15 minutes when turbidity is present
in the feed water.
Brine/Rinse: The cycle duration is factory is set at 60 minutes to assure the required
amount of brine is introduced and rinsed from the resin. Increase time
duration when the injector feed pressure is below 40 psi.
Flush: The cycle duration is factory set at 10 minutes to rinse chlorides from the
resin prior to the softener is placed online. Increase time duration to 15
minutes if traces of chlorides are present in the service outlet water.
Brine Tank Refill: The cycle duration is factory set at the maximum valve to achieve maximum
softener capacity..
Cycle End: The cycle duration is factory set at 4 minutes. Its purpose is to identify the
end of regeneration and advance the softener control valve to the standby
cycle.
Note: Brine Draw / Slow Rinse step is actually two events. The brine is suctioned from the
brine tank until the level falls to the bottom of the brine valve. An air check in the valve
will close once the brine is to low. This is the end for the Brine Draw step and should last
about twenty (20) minutes. The rest of the time in Step 2 is Slow Rinse. The caustic
injection is simultaneous to the Brine Draw step.

Page 14
RECOMMENDED TYPES OF SALT
Only purified salt should be used in the brining system. Palletized salt (“Button”, “Nugget”, and
“Pellet”) or block salt (free binders) is recommended. Do not use granulated salt, as it will fall
through the platform screen.
Rock salt is not normally recommended. Most rock salt contains sludge-forming insoluble that
collect on the platform and prevents proper salt-water contact.
Only salt containing 0.5% or less of insolubles will provide continued satisfactory operation. If,
salt with more insolubles is used, the brine maker will require periodic cleaning.
DEALKALIZATION EXAMPLE CALCULATION
The Water Analysis
Total Alkalinity as CaCO3 200 ppm
Chloride as Cl 100 ppm x1.41 141 ppm
Sulfate as SO, 5 ppm x 0 52 ppm as CaCO3
TDS as CaCO3 400 ppm
pH 7.8
Total Hardness as CaCO3 350 ppm
SALT REGENERATION
1. The water should be softened prior to dealkalization.
2. The percentage of alkalinity as a function of total anions.
T.A. T.A. Cl SO,
{ 200 / ( 200 + 141 + 52 ) ] x 100 = 51%
T.A. = Total Alkalinity
Cl = Chloride
SO4 = Sulfate
3. Convert ppm as CaCO3 to grains / gallon.
200 / 17.1 = 11.7 grains / gallon
17.1 is a constant that converts ppm to grains / gallon
4. From the capacity chart Figure 1 for Ionac ASB-2 using 50% alkalinity and 400 TDS the
capacity is approximately 5 kgr / cu.ft.
This should be downgraded by 10%. 5 kgr x .9 = 4.5 kgr / cu.ft. 5.
5 .To calculate the throughput capacity
(4.5 kgr x 1000) / 11.7 grains / gallon = 385 gallons / cu.ft.
6. Leakage will be approximately 10% of the influent alkalinity or 20 ppm as CaCO3salt and
caustic regeneration.

Page 15
SALT and CAUSTIC REGENERATION
Steps 1 - 3 are the same in this calculation.
4. From the capacity chart Figure 2 for Ionac ASB-2 using 50% alkalinity and 400 TDS the
capacity is approximately 8 kgr / cu.ft.
This should be downgraded by 10% 8 kg-r x .9 = 7.2 kgr / cu.ft. 5.
5. To calculate the throughput capacity
(7.2 kgr x 1000) / 11.7 = 615 gallons / cu.ft.
6. Leakage will be approximately 10 % of the influent alkalinity, 20 ppm CO, or HCO3as CaCO3.
The calculation to determine total carbonate alkalinity leakage when caustic soda is used as
part of the regenerant is as follows:
2 x P alkalinity = Carbonate present
MO alkalinity - (2 x P alkalinity) = Bicarbonate present
Carbonate alk. + Bicarbonate alk.= Total Carbonate Alkalinity Leakage
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 time delay type meters the amount of gallons is determined as in our example except an
additional amount of gallons must be deducted from the actual gallons to allow soft water to be
available until the softener regenerates at he selected delay time of day or night. This
compensation is necessary since the meter will indicate regeneration-required time prior to the
set delay time.

Page 16
WATER CONDITIONER FLOW DIAGRAMS
MATD 9500
XT MANUAL

Page 17
WATER CONDITIONER FLOW DIAGRAMS
MATD 9500
XT MANUAL