Master Water Conditioning MP-MCA-30T User manual

MP-MCATop Mount Water Softeners
with MCA100 Control Valve
July 2014 Version
Installation and Operation Manual

Table of Contents
Page
No.
Topic Description
1
Performance Data Sheet
MP-MCA-30T
2
Performance Data Sheet
MP-MCA-45T
3
Performance Data Sheet
MP-MCA-60T
4
Model # and Packaging
Packaging Information
Component Packaging Description
Packaging Description
5
Certification
NSF/ANSI 44 Information
Softening System
System Positioning
6
MP-MCA Control Valve
Attaching Valve to Tank
MP-MCA Control Valve
Attaching Valve, cont’d
7
Service & Drain Piping
Drain Piping
8
Service & Drain Piping, cont’d
Drain Piping
9
System Schematic
Piping Layout
10
Electrical Supply
Electrical Requirements
Brine Tank / Brine Tubing
Brine tank w/shut off
11
Filling Softener with Water
Details for Filling Softener Tank with Water
12
MP-MCA-Control Valve Timer
Setting the timer
13
Final Check
Final Installation Check
Disinfection
Conditioner Disinfection
14
Manual Regeneration
Instructions for Manual Regeneration
Power loss/ Error codes
“What if” Instructions
15
Bypass
Bypass Operation
16
Troubleshooting
Problem/ Cause / Solution
17
Troubleshooting
Problem/ Cause / Solution
18
Troubleshooting
Problem/ Cause / Solution
19
Error Code Troubleshooting
Problem/ Cause / Solution
20
Error Code Troubleshooting, cont’d
Problem/ Cause / Solution, cont’d
21
Valve Parts List
Part Numbers List
22
Valve Parts List
Part Numbers List
23
Valve Parts List
Part Numbers List
24
Valve Parts List
Part Numbers List
25
Valve Parts List
Part Numbers List
26
Valve Parts List
Part Numbers List
27
Valve Parts List
Part Numbers List
28
Warranty
Warranty

1
Model Number MP-MCA-30T
Rated Service Flow (gpm) 17.8
Pressure Drop at Rated Service Flow
Rate (psi)
15
Rated Softening Capacity (KGrains) 18.8 @ 4.5 lbs salt
20.0 @ 6.0 lbs salt
28.9 @ 15.0 lbs salt
Efficiency at the 1.0 lb. Salt setting
(Grains/lbs salt)
4186
Min.-Max. Working Pressure (psi) 20 to 100
Min.-Max. Operating Temperature
(°F)
35 to 100
Max. Flow Rate (gpm) to Drain
During Regeneration Cycle
1.7
Amount of High Capacity Resin
(cu ft)
1.0
These softeners conform to NSF/ANSI 44 for the specific performance claims as verified and substantiated by
test data. These models are efficiency rated. The efficiency rating is valid only at the stated salt dose and
maximum service flow rate. They have a demand initiated regeneration (D.I.R.) feature that complies with
specific performance specifications intended to minimize the amount of regenerant brine and water used in their
operation. These softeners have a rated softener efficiency of not less than 3350 grains of total hardness
exchange per pound of salt (based on sodium chloride) and shall not deliver more salt than their listed ratings.
The rated salt efficiency is measured by laboratory tests described in NSF/ANSI Standard 44. These tests
represent the maximum possible efficiency that the systems can achieve. Operational efficiency is the actual
efficiency after the system has been installed. It is typically less than the efficiency due to individual application
factors including water hardness, water usage, and other contaminants that reduce the softener’s capacity. These
systems are not intended for use with water that is microbiologically unsafe or of unknown quality without
adequate disenfection before or after the system. Refer to Installation/operation manual and warranty for further
details on installation, parts and service, maintenance and further restrictions or limitations to the use of the
product.
Master Water Conditioning
224 Shoemaker Rd.
Pottstown, PA 19464
610.323.8358
610.323.5526
www.masterwater.com
Performance Data Sheet

2
Model Number MP-MCA-45T
Rated Service Flow (gpm) 15.4
Pressure Drop at Rated Service Flow
Rate (psi)
15
Rated Softening Capacity (KGrains) 28.3 @ 6.75 lbs salt
30.0 @ 9.0 lbs salt
43.4 @ 22.5 lbs salt
Efficiency at the 1.0 lb. Salt setting
(Grains/lbs salt)
4186
Min.-Max. Working Pressure (psi) 20 to 100
Min.-Max. Operating Temperature
(°F)
35 to 100
Max. Flow Rate (gpm) to Drain
During Regeneration Cycle
1.7
Amount of High Capacity Resin
(cu ft)
1.5
These softeners conform to NSF/ANSI 44 for the specific performance claims as verified and substantiated by
test data. These models are efficiency rated. The efficiency rating is valid only at the stated salt dose and
maximum service flow rate. They have a demand initiated regeneration (D.I.R.) feature that complies with
specific performance specifications intended to minimize the amount of regenerant brine and water used in their
operation. These softeners have a rated softener efficiency of not less than 3350 grains of total hardness
exchange per pound of salt (based on sodium chloride) and shall not deliver more salt than their listed ratings.
The rated salt efficiency is measured by laboratory tests described in NSF/ANSI Standard 44. These tests
represent the maximum possible efficiency that the systems can achieve. Operational efficiency is the actual
efficiency after the system has been installed. It is typically less than the efficiency due to individual application
factors including water hardness, water usage, and other contaminants that reduce the softener’s capacity. These
systems are not intended for use with water that is microbiologically unsafe or of unknown quality without
adequate disenfection before or after the system. Refer to Installation/operation manual and warranty for further
details on installation, parts and service, maintenance and further restrictions or limitations to the use of the
product.
Master Water Conditioning
224 Shoemaker Rd.
Pottstown, PA 19464
610.323.8358
610.323.5526
www.masterwater.com
Performance Data Sheet

3
Model Number MP-MCA-60T
Rated Service Flow (gpm) 18.3
Pressure Drop at Rated Service Flow
Rate (psi)
15
Rated Softening Capacity (KGrains) 37.7 @ 9.0 lbs salt
40.0 @ 12.0 lbs salt
57.9 @ 30.0 lbs salt
Efficiency at the 1.0 lb. Salt setting
(Grains/lbs salt)
4186
Min.-Max. Working Pressure (psi) 20 to 100
Min.-Max. Operating Temperature
(°F)
35 to 100
Max. Flow Rate (gpm) to Drain
During Regeneration Cycle
2.7
Amount of High Capacity Resin
(cu ft)
2.0
These softeners conform to NSF/ANSI 44 for the specific performance claims as verified and substantiated by
test data. These models are efficiency rated. The efficiency rating is valid only at the stated salt dose and
maximum service flow rate. They have a demand initiated regeneration (D.I.R.) feature that complies with
specific performance specifications intended to minimize the amount of regenerant brine and water used in their
operation. These softeners have a rated softener efficiency of not less than 3350 grains of total hardness
exchange per pound of salt (based on sodium chloride) and shall not deliver more salt than their listed ratings.
The rated salt efficiency is measured by laboratory tests described in NSF/ANSI Standard 44. These tests
represent the maximum possible efficiency that the systems can achieve. Operational efficiency is the actual
efficiency after the system has been installed. It is typically less than the efficiency due to individual application
factors including water hardness, water usage, and other contaminants that reduce the softener’s capacity. These
systems are not intended for use with water that is microbiologically unsafe or of unknown quality without
adequate disenfection before or after the system. Refer to Installation/operation manual and warranty for further
details on installation, parts and service, maintenance and further restrictions or limitations to the use of the
product.
Master Water Conditioning
224 Shoemaker Rd.
Pottstown, PA 19464
610.323.8358
610.323.5526
www.masterwater.com
Performance Data Sheet

4
Installation and Operating Instructions for
MP-MCA CONTROL
Top Mount Water Softener
Model #:
_______ MP-MCA-30T CS * 1.0 CF Crawl Space Water Softener
_______ MP-MCA-30T 1.0 CF Water Softener
_______ MP-MCA-45T 1.5 CF Water Softener
_______ MP-MCA-60T 2.0 CF Water Softener
*Not Tested or certified to NSF/ANSI Standard 44
Shipping Carton Description / unit:
# of
cartons Contents Description
1 Mineral tank Distributor pipe installed
1 Brine tank 464 shutoff valve assembly. *NOTE:
MP-MCA valve is shipped in brine tank.
1 MP-MCA control
valve
MP-MCA timer and backwash flow
control and bypass with 1” copper or
pvc connection
C-800 Pre-loaded @ factory
NOTE: THIS SOFTENER IS NOT INTENDED TO BE USED FOR TREATING WATER THAT
IS MICROBIOLOGICALLY UNSAFE OR OF UNKNOWN QUALITY WITHOUT
ADEQUATE DISINFECTION WHETHER BEFORE OR AFTER THE SYSTEM.

5
NOTE: The model MP-MCA-30T has been tested and certified by the Water Quality
Association according to NSF/ANSI 44 for the specific performance claims as verified
and substantiated by test data as follows:
Rated Efficiency: 4186 Grains per pound of salt
4.5 lbs salt: 18.8 Kg Capacity
6 lbs salt: 20.0 Kg Capacity
15 lbs salt: 28.9 Kg Capacity
Rated Service Flow: 17.8 GPM @ 15 psi pressure drop
Resin: 1.0 Cubic Ft. Cation Exchange resin
NOTE: The model MP-MCA-45T has been tested and certified by the Water Quality
Association according to NSF/ANSI 44 for the specific performance claims as verified
and substantiated by test data as follows:
Rated Efficiency: 4186 Grains per pound of salt
6.75 lbs salt: 28.3 Kg Capacity
9 lbs salt: 30.0 Kg Capacity
22.5 lbs salt: 43.4 Kg Capacity
Rated Service Flow: 15.4 GPM @ 15 psi pressure drop
Resin: 1.5 Cubic Ft. Cation Exchange resin
NOTE: The model MP-MCA-60T has been tested and certified by the Water Quality
Association according to NSF/ANSI 44 for the specific performance claims as verified
and substantiated by test data as follows:
Rated Efficiency: 4186 Grains per pound of salt
9 lbs salt: 37.7 Kg Capacity
12 lbs salt: 40.0 Kg Capacity
30 lbs salt: 57.9 Kg Capacity
Rated Service Flow: 18.3 GPM @ 15 psi pressure drop
Resin: 2.0 Cubic Ft. Cation Exchange resin
Water Softener Positioning:
1. Place water softener in desired position, far enough from walls and
other obstructions to allow for servicing the unit.
2. Place the water softener within reasonable access to a grounded
115V/60 HZ circuit and a legal drain line connection.

6
MP-MCA Control Valve:
1. When facing the front of the MP-MCA timer, the inlet connection is
located on the right and the outlet connection is on the left. The
control valve's inlet and outlet connections are either 1” copper or
PVC equipped with split ring and nut.
Front View Top View
2. Turn the control valve upside down and ensure that the control
valve distributor o’ring is in place. Use silicone lubricant on the
o'ring.
**DO NOT USE PETROLEUM!**
**USE ONLY SILICONE **
3. Place the control valve onto the distributor pipe and into the tank
opening.
4. Thread the control valve hand tight . Do not overtighten.
4. Locate the bypass valve assembly that is packaged with the
control valve. The bypass valve has two red handles that
indicate flow direction, two threaded connections for the tail
piece kit and two o’ring seal connections with nuts for the control
valve. Align the insert connection ends with o’ring seals and
nuts to the inlet and outlet connections of the control valve.
Hand tighten the nuts. DO NOT OVERTIGHTEN THE NUT!
Control Valve

7
5. Locate the tail piece kit that is packaged with the control valve.
The standard tail piece kit is 1” copper with optional 1”/ 3/4” PVC or
¾” copper kits available as a special order. Each tail piece,
o’ring, split ring and nut is presassembled at the factory. Align a
tail piece assembly to the bypass valve threaded inlet and insert
until the nut can be tightened. Hand tighten the nut because
excessive tightening will damage the assembly. REPEAT THE
PROCEDURE FOR THE OUTLET CONNECTION.
Service and Drain Piping:
1. Pipe water softener into the service lines .The inlet and outlet
connections of the control valve are 1” copper or PVC and are
located on the back of the valve body. As you face the timer the inlet
is on the right and the outlet is on the left. Always follow local
plumbing codes when installing our water treatment equipment.
2. If sweat fittings are used, be sure soldering is done in such a manner
as not to allow heat to reach the control valve or bypass. (If
Schedule 80 PVC is used make sure to follow the proper primer and
solvent instructions.)
3. The drain line connection is 5/8” OD or ¾” npt and is located on the
top left of the valve as you face the timer. It is recommended you
install a ¾” union on the drain line for servicing if not using 5/8 OD.
The drain line must be of adequate size to allow for full regeneration
flow.
Control Valve Bypass Valve Tail piece assembly

8
•The control valve drain connection is 3/4" npt.
•Never decrease the drain piping size to below the
drain connection size.
•Maximum drain line length is 30 feet with proper
sloping the entire length.
•Maximum drain line height is 6 feet above the control
valve.
•The drain line must be piped to an open air gap (See
Figure above)
•Always follow local plumbing codes.
UNDER NO CIRCUMSTANCES SHOULD THERE BE A DIRECT
CONNECTION WITH SANITARY SEWAGE FACILITIES.
NOTE: The drain flow rate during regeneration (backwash)
will be:
MP-MCA-30T 1.7 GPM
MP-MCA-45T 1.7 GPM
MP-MCA-60T 2.7 GPM
*NOT TESTED OR CERTIFIED TO NSF/ANSI STANDARD 44
DRAIN LINE
CONNECTION

9
MASTER
Water Conditioning Corp.
Water Conditioning Corp.Water Conditioning Corp.
Water Conditioning Corp.
Well Tank
NOTE: All Master Water Conditioners must be
installed after the well tank or water meter if its
public water supply.
Master Water
Conditioner
Brine tank
Air Gap Drain
Overflow
fitting to
floor drain
gravity
Untreated
TYPICAL PIPING LAYOUT FOR
MP-MCA SERIES SOFTENER
Treated
Temperature : MAX: 120 F, MIN: 34F
Pressure: MAX: 100 PSI, MIN: 20 PSI
Electrical: 115V 60 HZ

10
Electrical Requirements:
Always follow all local electrical codes when installing our water
treatment equipment.
1. Provide an 115v/60Hz properly grounded dedicated electrical
Outlet. (It’s very important that the polarity be correct)
Avoid using outlets that are switch controlled.
2. Maximum amperage required is 5 amps.
3. Make sure the electrical service provides power 24 hours per day.
We recommend installing a surge protector to protect unit from
power surges, which are not covered by warranty.
Brine Tank:
1. The brine tank should be located directly beside the water softener
mineral tank.
2. Connect the 3/8" poly tubing to the 3/8” black elbow quick-connect
fitting located on the top left side of the MCA control valve.
See Figure Below.
The brine tank is equipped with a shutoff valve, the float height
was preset at the factory.
3/8” BRINE LINE
CONNECTION

11
Filling Water Softener with Water:
1. Connect the MP-MCA control valve transformer into the electrical
outlet provided.
2. Press and hold the REGEN button until the drive motor starts. When
the drive motor stops, the display will read “BACKWASH” position.
3. Open the inlet ball valve a ¼ turn of its full open position to allow
water to enter the water softener mineral tank slowly. The water is
going to enter the tank from the bottom of the distributor pipe and
leave the tank from the top. This will slowly purge all the air from the
tank.
IF WATER ENTERS THE TANK TOO FAST, ALL THE CATION
RESIN WILL BE FLUSHED TO DRAIN DURING START UP.
4. When only water is running to the drain, open the inlet and outlet ball
valves fully.
5. Press the REGEN again until the drive motor starts. When the drive
motor stops, the display will read “BRINE” position.
6. Press the REGEN button until the drive motor starts. When the drive
motor stops, the display will read “RINSE” position. The fast rinse
position will rinse the softener tank.
7. The control valve will automatically advance to the brine refill position
where the brine tank will fill with the proper amount of water. The
display will read “REFILL”.
NOTE: THE TIMER WILL AUTOMATICALLY ADVANCE TO THE
SERVICE POSITION AND THE DISPLAY WILL READ THE CAPACITY
REMAINING, IN GALLONS.

12
MP-MCA Control Valve Timer Settings:
Note: The control valve is set at the factory. You only need to set the
time of day , hardness and regeneration time if required, which is preset
at 2 am.
Time of Day Setting
1) Press the CLOCK button. The screen will show the Time of Day
in blinking numbers.
2) To change the Time of Day, use the UP and DOWN arrows to set
the Hour.
3) To change the Minutes, press the CLOCK button, and use the UP
and DOWN arrows to set the Minutes
4) Press the CLOCK button.
Hardness Setting (the factory default is 10)
1) Press the NEXT and UP arrow, hold for 3 seconds. The screen
will show the Hardness as grains per gallon in blinking numbers.
2) To change the number, use the UP or DOWN arrows.
3) Press the NEXT button.
If water was tested by Master Water Conditioning, follow
recommendations on water analysis, for hardness setting
Regeneration Day Override Setting (the factory default is OFF)
1) The screen will show the Regeneration Day Override in blinking
numbers.
2) To change the number, use the UP or DOWN arrows.
3) Press the NEXT button.
Time of Regeneration Setting (the factory default is 2 AM)
1) The screen will show the Time of Regeneration in blinking
numbers.
2) If Regeneration time change is desired, use the UP or DOWN
arrows to set the hour.
3) Press the NEXT button, and use the UP or DOWN arrows to set
the minutes.
4) Press the NEXT button.
NOTE: SALT SETTING AND CAPACITY ARE PRESET AT THE
FACTORY.

13
Final Check:
1. Fill the brine tank with Solar Salt and the Res-Up Feeders with Res-
Up (one quart is provided).
2. Make sure the drain line connection meets all plumbing codes and
that the drain line size can handle the backwash flow rate of the
softener.
3. Make sure the Inlet and Outlet on bypass valve are open.
4. Make sure the control valve timer is plugged into an electrical outlet
with power 24 hours per day.
5. Check all piping for leaks.

14
Manual Regeneration:
Note: For softeners, if brine tank does not contain salt, fill with salt
and wait at least 2 hours before regeneration.
To initiate manual regeneration immediately, press and hold the
“REGEN” button for three seconds. The system will begin to regenerate
immediately. The request cannot be cancelled.
To initiate a manual regeneration at the preset delayed regeneration
time, when the regeneration time option is set to “NORMAL” or
“NORMAL + on 0”, press and release “REGEN”. The words “REGEN
TODAY” will flash on the display to indicate that the system will
regenerate at the preset delayed regeneration time. If you pressed
“REGEN” in error, pressing the button again will cancel the request.
Note: If the regeneration time option is set to “on 0” there is no set
delayed regeneration time so “REGEN TODAY” will not activate if
“REGEN” button is pressed.
Power Loss
If the power goes out for less than two hours, the system will
automatically reset itself. If an extended power outage occurs, the time
of day will flash on and off which indicates the time of day should be
reset. The system will remember the rest.
Error Message
If the word “ERROR” and a number are alternately flashing on the
display, contact a service technician for help. This means the valve is
unable to function properly. ( See page 21 )

15

16
Troubleshooting
Symptom: Water conditioner fails to regenerate.
Possible Cause Solution
Power supply to MP-MCA125
control has been interrupted.
Determine reason for power
interruption and correct. Reset time of
day.
Water pressure lost Restore water pressure.
Control valve has incorrect
program values.
Reset values.
Meter clogged Remove meter and clean.
Defective control. Replace control assembly.
No Solar Salt in brine tank Add Solar Salt, wait 4 hours and
regenerate.
Insufficient Solar Salt Check brine float height and clean
assembly if necessary. Check flow
rate capabilities of safety float and air
check assembly.
Manual bypass valve is open. Close manual bypass valve.
Leak at riser pipe seal Insure that riser pipe is properly sealed
at o’ring seal. Inspect pipe for cracks.
Plugged injector or injector screen Inspect and clean injector and/or
injector screen.
Symptom: No Brine Draw
Possible Cause Solution
Plugged injector or injector screen Inspect and clean injector and/or
injector screen.
Insufficient water pressure Increase water pressure above 25
psig (172kPa) minimum.
Obstructed drain line Remove obstruction.

17
Symptom: Insufficient Brine draw
Possible Cause Solution
Partially clogged injector or injector
screen
Inspect and clean injector and/or
injector screen assembly.
Restricted flow rate in brine line Check flow rate capabilities of the
safety float/aircheck assembly.
Insufficient water pressure Increase water pressure above 25
psig (172kPa) minimum.
Excessive back pressure on
injector due to elevated drain line
Reduce drain line elevation to height
of valve.
Damaged piston assembly Inspect and if damaged replace the
piston assembly.
Control valve has incorrect program
values.
Reset values.
Partially restricted drain line Remove restriction.
Symptom: Insufficient Refill to Brine Tank
Possible Cause Solution
Control valve has incorrect program
values.
Reset values.
Restricted flow rate in brine line Check flow rate capabilities of the
safety float/aircheck assembly.
Problem: Leak to Drain
Possible Cause Solution
No flow control installed in drain
line.
Install drain line flow control.
Insufficient water pressure. Increase water pressure above 25
psig (172kPa) minimum.

18
Symptom: Excessive Water in Brine Tank
Possible Cause Solution
Plugged drain line flow control Clean flow control.
Control valve has incorrect program
values.
Reset values.
Plugged injector and/or injector
screen
Inspect and clean injector and/or
screen.
Symptom: Loss of Media to Drain
Possible Cause Solution
No flow control installed in drain
line
Install drain line flow control.
Symptom: Loss of Water Pressure
Possible Cause Solution
Fouled softener media bed due to
iron accumulation or chlorine.
Replace media bed.
Slots in riser pipe or laterals are
filled with softener media fines.
Inspect and clean distributor pipe slots
as needed.
Symptom: Brine in Water to Service After Regeneration
Possible Cause Solution
Injector is too small for system size. Install correct injector.
Plugged injector and/or injector
screen
Inspect and clean injector and/or
injector screen.
Brine draw time excessively long
due to low water pressure
Increase water pressure above 25
psig (172 kPa) minimum.
Restricted drain line Remove drain line restriction.
Insufficient rinse volume Increase slow rinse time, fast rinse
time, or both.
Damaged piston assembly or
spacer kit
Inspect and if damaged replace the
piston assembly.
Control valve has incorrect program
values.
Reset values.