Pentair FLECK 3150 NXT User guide

FLECK 3150
NXT/NXT2
INSTALLER
MANUAL
WATER PURIFICATION

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Table of Contents
1 Generalities..................................................................................... 7
1.1 Scope of the documentation ....................................................................... 7
1.2 Release management ................................................................................. 7
1.3 Manufacturer identifier, product ................................................................ 7
1.4 Intended use................................................................................................ 7
1.5 Abbreviations used...................................................................................... 7
1.6 Norms.......................................................................................................... 8
1.6.1 Applicable norms ................................................................................................ 8
1.6.2 Available certificates........................................................................................... 9
1.7 Procedure for technical support................................................................. 9
1.8 Copyright ..................................................................................................... 9
1.9 Limitation of liability.................................................................................... 9
1.10 Scan & Service application.......................................................................... 10
2 Safety .............................................................................................. 11
2.1 Safety pictograms definition ....................................................................... 11
2.2 Serial label location..................................................................................... 11
2.3 Hazards........................................................................................................ 11
2.3.1 Personnel ............................................................................................................ 12
2.3.2 Material ............................................................................................................... 12
2.4 Hygiene and sanitization ............................................................................. 12
2.4.1 Sanitary issues .................................................................................................... 12
2.4.2 Hygiene measures............................................................................................... 13
3 Description ...................................................................................... 14
3.1 Technical specifications .............................................................................. 14
3.2 Performance flow rate characteristics....................................................... 16
3.3 Outline drawing ........................................................................................... 16
3.4 Components description and location ........................................................ 17
3.4.1 With NXT controller and AC motor ..................................................................... 17
3.4.2 With NXT controller and DC motor ..................................................................... 18
3.4.3 With NXT2 controller and DC motor ................................................................... 19
3.5 System regeneration cycle.......................................................................... 20
3.5.1 DF regeneration cycle (5-cycles operation)........................................................ 20
3.5.2 UF regeneration cycle (5-cycles operation)........................................................ 22
3.5.3 Filter cycle (3-cycles operation) ......................................................................... 24
3.6 Injector block position for DF and UF configurations................................. 26
4 System sizing................................................................................... 27
4.1 Recommendations ...................................................................................... 27

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4.1.1 Injector/DLFC/BLFC-Valve configuration........................................................... 27
4.2 Sizing a softener (single unit) ..................................................................... 27
4.2.1 Parameters to be considered ............................................................................. 27
4.2.2 Determining the required volume of resin ......................................................... 28
4.2.3 Resin exchange capacity and capacity of the unit .............................................. 29
4.2.4 Valve configuration.............................................................................................. 31
4.2.5 Cycle time calculation......................................................................................... 31
4.3 Salt amount definition ................................................................................. 34
4.4 1800 Injector flow rates............................................................................... 34
5 Installation ...................................................................................... 37
5.1 Warnings...................................................................................................... 37
5.2 Safety notices for installation ..................................................................... 37
5.3 Installation environement ........................................................................... 38
5.3.1 General ................................................................................................................ 38
5.3.2 Water ................................................................................................................... 38
5.3.3 Electrical ............................................................................................................. 38
5.3.4 Mechanical .......................................................................................................... 39
5.4 Integration constraints................................................................................ 39
5.5 Valve connection to piping........................................................................... 40
5.5.1 Top-mounted valve installation .......................................................................... 40
5.5.2 Side-mounted valve installation ......................................................................... 42
5.6 Block diagram and configuration example................................................. 43
5.7 System types ............................................................................................... 44
5.7.1 Single valve (System #4) ..................................................................................... 45
5.7.2 Multiple valves, parallel interlock system (System #5) ..................................... 45
5.7.3 Multiple valves, parallel series regeneration system (System #6).................... 46
5.7.4 Duplex alternating immediate system (System #7) ........................................... 46
5.7.5 Duplex alternating delayed system (System #8) (NXT2 only) ............................ 47
5.7.6 Multiple valves, parallel system with standby unit (System#9)........................ 47
5.7.7 Multiple valves, system on-demand (System #14)............................................. 48
5.8 Electrical connections................................................................................. 52
5.8.1 NXT controller connections ................................................................................ 53
5.8.2 NXT2 controller connections .............................................................................. 54
5.8.3 NXT controller connections for multiple valves ................................................. 55
5.8.4 NXT2 controller connections for multiple valves ............................................... 56
5.9 Bypassing .................................................................................................... 57
5.10 Drain line connection .................................................................................. 57
5.11 Overflow line connection............................................................................. 58
5.12 Brine line connection .................................................................................. 59
6 Programming .................................................................................. 60
6.1 NXT controller ............................................................................................. 60
6.1.1 Display ................................................................................................................. 60

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6.1.2 Commands .......................................................................................................... 61
6.1.3 Setting the time of the day .................................................................................. 61
6.1.4 Basic programming............................................................................................. 61
6.1.5 Master programming mode................................................................................ 64
6.1.6 Diagnostic............................................................................................................ 78
6.1.7 Resetting the controller...................................................................................... 80
6.2 NXT2 Controller........................................................................................... 81
6.2.1 Display ................................................................................................................. 81
6.2.2 Commands .......................................................................................................... 83
6.2.3 Time of day menu ................................................................................................ 84
6.2.4 Basic programming............................................................................................. 85
6.2.5 Master programming mode................................................................................ 87
6.2.6 Diagnostic............................................................................................................ 115
6.2.7 Resetting the controller...................................................................................... 121
7 Commissioning................................................................................ 123
7.1 Water filling, draining and waterproofness inspection .............................. 123
7.1.1 Activating a single valve system (System #4)..................................................... 123
7.1.2 Activating a multiple valves system (Systems #5, #6, #7, #8, #9 and #14) ...... 124
7.2 Sanitization .................................................................................................. 124
7.2.1 Disinfection of water softeners........................................................................... 124
7.2.2 Sodium or calcium hypochlorite ......................................................................... 125
7.2.3 Electro chlorination............................................................................................. 125
8 Operation......................................................................................... 126
8.1 Display ......................................................................................................... 126
8.1.1 NXT controller ..................................................................................................... 126
8.1.2 NXT2 controller ................................................................................................... 126
8.1.3 LED status ........................................................................................................... 128
8.2 Recommendations ...................................................................................... 128
8.3 Manual regeneration................................................................................... 128
8.3.1 Manual delayed regeneration ............................................................................. 128
8.3.2 Immediate regeneration ..................................................................................... 129
8.3.3 To advance regeneration cycles ......................................................................... 129
8.3.4 To stop a regeneration (NXT2 only) .................................................................... 129
8.4 Operation during a power failure................................................................ 129
9 Maintenance .................................................................................... 130
9.1 General system inspection.......................................................................... 130
9.1.1 Water quality ....................................................................................................... 130
9.1.2 Mechanical Checks ............................................................................................. 130
9.1.3 Regeneration test................................................................................................ 131
9.2 Recommended maintenance plan .............................................................. 132
9.2.1 Valve used for softening...................................................................................... 132
9.2.2 Valve used for filtration....................................................................................... 134
9.3 Recommendations ...................................................................................... 135
9.3.1 Use original spare parts...................................................................................... 135

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9.3.2 Use original approved lubricants........................................................................ 135
9.3.3 Maintenance instructions ................................................................................... 135
9.4 Cleaning and maintenance.......................................................................... 135
9.4.1 First steps............................................................................................................ 135
9.4.2 Power head motor replacement......................................................................... 136
9.4.3 NXT to NXT2 controller upgrade......................................................................... 140
9.4.4 NXT2 controller replacement ............................................................................. 142
9.4.5 Power head, piston and/or seal and spacer kit disassembly/replacement ...... 143
9.4.6 Micro-switches replacement .............................................................................. 145
9.4.7 Cams replacement.............................................................................................. 146
9.4.8 Injector throat and washer cleaning................................................................... 147
9.4.9 BLFC cleaning ..................................................................................................... 149
9.4.10 DLFC cleaning ..................................................................................................... 150
9.4.11 Valve on tank assembly....................................................................................... 151
10 Troubleshooting .............................................................................. 152
10.1 Error detection ............................................................................................ 152
10.2 Programming error..................................................................................... 154
10.3 Examples of error displayed ....................................................................... 155
10.3.1 NXT controller ..................................................................................................... 155
10.3.2 NXT2 controller ................................................................................................... 156
11 Spare parts and options................................................................... 157
11.1 Valve parts list............................................................................................. 157
11.2 Power head 3150 parts list.......................................................................... 159
11.3 1800 injector parts list................................................................................. 161
11.4 BLFC parts list............................................................................................. 162
11.5 DLFC parts list............................................................................................. 164
11.6 Safety brine valves list ................................................................................ 165
11.7 Distribution systems parts list.................................................................... 165
11.7.1 Thread 4", tank 21" to 36", TM, slots 0.2mm ..................................................... 166
11.7.2 Flanged 6", tank 21" to 36", TM, slots 0.2mm ................................................... 167
11.7.3 Flanged 6", tank 42", TM, slots 0.2mm.............................................................. 168
11.7.4 Threaded 4", tank 21" to 36", SM, top distribution, elbow 63mm, external
glue connection ...................................................................................................
169
11.7.5 Threaded 4", tank 21" to 36", SM, bottom distribution, elbow 63mm, external
glue connection ...................................................................................................
170
11.7.6 Threaded 4", tank 21" to 36", SM, top distribution, straight 63mm, external
glue connection ...................................................................................................
171
11.7.7 Threaded 4", tank 21" to 36", SM, bottom distribution, straight 63mm,
external glue connection.....................................................................................
172
11.7.8 Flanged 6", tank 21" to 36", SM, top distribution, external flange 65mm
connection ...........................................................................................................
173
11.7.9 Flanged 6", tank 21" to 36", SM, bottom distribution, external flange 65mm
connection ...........................................................................................................
174

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11.7.10 Hot water, flanged 6", tank 42" to 63", SM, top and bottom distribution,
external flange 80mm connection, slots 0.2mm ..............................................
175
11.7.11 Hot water, flanged 6", tank 21" to 36", SM, top and bottom distribution,
external flange 65mm connection, slots 0.2mm ..............................................
176
11.8 Air checks list .............................................................................................. 176
11.9 Meters parts list .......................................................................................... 177
11.9.1 Brass meters parts list ....................................................................................... 177
11.9.2 Stainless steel meters parts list......................................................................... 178
11.10 Kit meter & Meter cables list...................................................................... 178
11.10.1 Mecanical cable meter........................................................................................ 178
11.10.2 Brass kit meter & Meter cables list.................................................................... 178
11.10.3 Stainless steel kit meter & Meter cables list ..................................................... 179
11.11 Kits............................................................................................................... 179
11.12 Other components list................................................................................. 180
12 Disposal........................................................................................... 181

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1 Generalities
1.1 Scope of the documentation
The documentation provides the necessary information for appropriate use of the
product. It informs the user to ensure efficient execution of the installation, operation
or maintenance procedures.
The content of this document is based on the information available at the time of
publication. The original version of the document was written in English.
For safety and environmental protection reasons, the safety instructions given in this
documentation must be strictly followed.
This manual is a reference and will not include every system installation situation. The
person installing this equipment should have:
• training in the Fleck series, NXT/NXT2 controllers and water softener installation;
• knowledge of water conditioning and how to determine proper controller settings;
• basic plumbing skills.
This document is available in other languages on https://www.pentairaquaeurope.com/
product-finder/product-type/control-valves.
1.2 Release management
Revision Date Authors Description
A 09.12.2016 BRY/PBO First edition.
B 28.05.2018 BRY/FIM Address change, Bleam information and
valve on tank assembly.
C 18.10.2019 BRY/FLA NXT2 controller.
1.3 Manufacturer identifier, product
Manufacturer: Pentair International LLC
Avenue de Sevelin 18
1004 Lausanne
Switzerland
Product: Fleck 3150 NXT/NXT2
1.4 Intended use
The device is intended for industry environment use only and it is purpose-built for
water treatment.
1.5 Abbreviations used
Assy Assembly
BLFC Brine Line Flow Control
BV Brine Valve

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DF Down Flow
DLFC Drain Line Flow Control
HW Hot Water
Inj Injector
NBP No By Pass
PH Power Head
QC Quick Connect
Regen Regeneration
S&S Seals & Spacers
SBV Safety Brine Valve
SM Side Mounted
TC Time Clock
TM Top Mounted
UF Up Flow
1.6 Norms
1.6.1 Applicable norms
Comply with the following guidelines:
• 2006/42/EC: Machinery Directive;
• 2014/35/UE: Low Voltage Directive;
• 2014/30/UE: Electromagnetic compatibility;
• 2011/65/UE: Restriction of use of certain hazardous substances in electrical and
electronic equipment (RoHS);
• UNI EN ISO9001.
Meets the following technical standards:
• EN 55014-1;
• EN 55014-2;
• EN 61000-6-1;
• EN 61000-6-2;
• EN 61000-6-3;
• EN 61000-6-4;
• EN 61010-1;
• EN 61000-3-2;
• EN 61000-3-3.

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1.6.2 Available certificates
• CE;
• DM174;
• ACS.
Please find beside the certifications for some of
our product families. Please note that this list is
not an exhaustive list of all our certifications. In
case of need for more information please contact
us.
1.7 Procedure for technical support
üProcedure to follow for any technical support request:
a) Collect the required information for a technical assistance request.
ðProduct identification (see Serial label location [}Page 11] and
Recommendations [}Page 135]);
ðDescription of the device problem.
b) Please refer to the Troubleshooting [}Page 152]. If the problem persists contact
your supplier.
1.8 Copyright
© 2019 Pentair International Sàrl. All rights reserved.
1.9 Limitation of liability
Pentair Quality System EMEA products benefit, under specific conditions, from a
manufacturer warranty that may be invoked byPentair’s direct customers. Users
should contact the vendor of this product for applicable conditions and in case of a
potential warranty claim.
Any warranty provided by Pentair regarding the product will become invalid in case of:
• improper installation, improper programming, improper use, improper operation
and/or maintenance leading to any kind of product damages;
• improper or unauthorized intervention on the controller or components;
• incorrect, improper or wrong connection/assembly of systems or products with
this product and vice versa;
• use of a non-compatible lubricant, grease or chemicals of any type and not listed
by the manufacturer as compatible for the product;
• failure due to wrong configuration and/or sizing.
Pentair accepts no liability for equipment installed by the user upstream or
downstream of Pentair products, as well as for process/production processes which
are installed and connected around or even related to the installation. Disturbances,
failures, direct or indirect damages that are caused by such equipment or processes
are also excluded from the warranty. Pentair shall not accept any liability for any loss
or damage to profits, revenues, use, production, or contracts, or for any indirect,
special or consequential loss or damage whatsoever. Please refer to the Pentair List
Price for more information about terms and conditions applicable to this product.

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1.10 Scan & Service application
Scan & Service mobile application is the ideal support for the maintenance person in
his daily business. A simple scan of an identification (ID) label (1) present on the valve
with a smartphone gives an instantaneously access to all updated information related
to the product, such as:
• valve’s and tanks detailed configuration;
• manuals;
• spare parts lists;
• troubleshooting recommendations;
• multi-lingual videos, detailing how to best service a part;
• informations about new products, latest technologies, novelties about the Blue
Network program, etc.
a) Download the application "Scan & Service" from or in a
smartphone (4).
b) Open the application "Scan & Service".
c) Scan the bleam (3) stuck on the valve (2).
d) Navigate to find information.

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2 Safety
2.1 Safety pictograms definition
CAUTION
Warns of a risk of minor injury or
major material damage to the device
or environment.
WARNING
Warns against serious personal
injury and damage to health.
DANGER
Warns against serious personal
injury or death.
Mandatory
Standard or measure to apply.
Info
Comment.
Prohibition
Restriction to be observed.
2.2 Serial label location
Model
Part number
Electrical rating
Serial number
Production date
Production order
Info
Ensure that the serial label and the safety labels on the device are completely legible
and clean. If necessary, replace them with new labels in the same positions.
2.3 Hazards
All the safety and protection instructions contained in this document must be observed
in order to avoid temporary or permanent injury, damage to property or environmental
pollution.
At the same time, any other legal regulations, accident prevention and environmental
protection measures, as well as any recognized technical regulations relating to
appropriate and risk-free methods of working which apply in the country and place of
use of the device must be adhered to.

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Any non-observation of the safety and protection rules, as well as any existing legal and
technical regulations, will result in a risk of temporary or permanent injury, damage to
property or environmental pollution.
2.3.1 Personnel
CAUTION
Only qualified and professional personnel, based on their training, experience and
instruction as well as their knowledge of the regulations, safety rules and operations
performed, are authorized to carry out necessary work.
2.3.2 Material
The following points must be observed to ensure proper operation of the system and
the safety of user:
• be careful of high voltages present on the transformer (100 - 240V);
• do not put your fingers in the system (risk of injuries with moving parts and shock
due to electric voltage).
2.4 Hygiene and sanitization
2.4.1 Sanitary issues
Preliminary checks and storage
• Check the integrity of the packaging. Check that there is no damage and no signs
of contact with liquid to make sure that no external contamination occurred;
• the packaging has a protective function and must be removed just before
installation. For transportation and storage, appropriate measures should be
adopted to prevent the contamination of materials or the objects themselves.
Assembly
• Assemble only with components which are in accordance with drinking water
standards;
• after installation and before use, perform one or more manual regenerations in
order to clean the media bed. During such operations, do not use the water for
human consumption. Perform a disinfection of the system in the case of
installations for treatment of drinking water for human use.
Info
This operation must be repeated in the case of ordinary and extraordinary
maintenance. It should also be repeated whenever the system remains idle for a
significant time.
Info
Valid only for Italy: In case of equipment used in accordance with the DM25, apply all
the signs and obligations arising from the DM25.

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2.4.2 Hygiene measures
Disinfection
• The materials used for the construction of our products meet the standards for
use with potable water; the manufacturing processes are also geared to
preserving these criteria. However, the process of production, distribution,
assembly and installation, may create conditions of bacterial proliferation, which
may lead to odor problems and water contamination;
• it is therefore strongly recommended to sanitize the products. See Sanitization [}
Page 124] ;
• maximum cleanliness is recommended during the assembly and installation;
• for disinfection, use Sodium or Calcium Hypochlorite and perform a manual
regeneration.

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3 Description
3.1 Technical specifications
Design specifications/ratings
Valve body Brass
Rubber components EP or EPDM
Weight (valve with controller) 22.8 kg (max)
Recommended operating pressure 1.8 - 8.6 bar
Maximum inlet pressure 8.6 bar
Hydrostatic test pressure 20 bar
Water temperature std 1 - 43°C
Water temperature for HW volumetric 1 - 65°C
Water temperature for HW time clock 1 - 82°C
Ambient temperature 5 - 40°C
Regeneration flow DF or UF
Bypass of raw water during regeneration:
Standard Yes
NBP version No
Flow rates (3.5 bar inlet - 16°C - valve only)
Continuous service flow (Δp=1bar) Top Mount 22.0 m3/h; Side Mount 23.0 m3/
h
Peak service flow (Δp=1.8bar) Top Mount 28.0 m3/h; Side Mount 29.0 m3/
h
Cv* 24.8
Kv* 21.5
Maximum backwash flow (Δp=1.8bar) Top Mount 24.0 m3/h; Side Mount 25.0 m3/
h
*Cv: Flow rate in gpm across the valve at a pressure drop of 1 psi at 60°F.
*Kv: Flow rate in m3/h across the valve at a pressure drop of 1 bar at 16°C.
Valve connections
Tank adapter thread 4" – 8 UN thread
Side mount adapter 2" BSP female
Inlet/Outlet 2" BSP female
Distributor pilot 63 mm [DN50]
Drain line 2" BSP
Brine line (1800) 1" NPT male

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Electrical
Controller operating voltage 24 VAC for NXT / 24 VDC for NXT2
Input supply frequency 50 or 60 Hz (controller configuration
dependent)
Transformer voltage 24 VAC for NXT / 24 VDC for NXT2
Motor input voltage until March 2019 24 VAC
Motor input voltage April 2019 onwards 24 VDC with AC-DC inverter
Controller power consumption 60 W
Controller protection rating IP 22
Valve protection rating IP 44
Power supply 230 VAC, 50/60 Hz,60 VA, Class II
Transient overvoltages within the limits of category II
Pollution Degree 3
Temporary overvoltages must be limited in duration and in frequency.
Model without transformer
CAUTION
A switch or circuit-breaker must be included in the installation, it must be suitably
located and easily reached, it must be marked as the disconnecting device for the
equipment.
CAUTION
The power must be achieved by a transformer in which the primary windings are
separated from the secondary windings by REINFORCED INSULATION, DOUBLE
INSULATION, or a screen connected to the PROTECTIVE CONDUCTOR TERMINAL.
CAUTION
It is required the installation of a fuse as overcurrent protection, it has to be positioned
between the system and the secondary of the transformer in the installation with the
following characteristics: V≥30VDC or VAC, Imax=5.0A(ES.5x205.0A)
Environmental conditions
• Indoor use only;
• temperature from 5°C to 40°C;
• maximum relative humidity 80% for temperatures up to 31°C decreasing linearly
to 50% relative humidity at 40°C;
• mains supply voltage fluctuations up to ±10% of the nominal voltage.

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3.2 Performance flow rate characteristics
The graph shows the pressure drop created by the valve itself at different flow rates. It
allows predetermining the maximum flow rate going through the valve depending on
the system settings (inlet pressure etc). It also allows to determine the valve pressure
drop at a given flow rate, and therefore to evaluate the system pressure drop vs flow
rate.
FLOW RATE VS PRESSURE DROP
(single valve)
Service
Backwash
Flow rate [m³/h]
Pressure drop [bar]
3.3 Outline drawing

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3.4 Components description and location
3.4.1 With NXT controller and AC motor
Meter
Outlet
Diagnostic button
Status LED
Micro-switches
Brine valve
AC motor
NXT controller
Piston
Camshaft
Drain line
Brine line
Injector
Inlet
Display
Regeneration button
Shift button
Setting button
Power head

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3.4.2 With NXT controller and DC motor
Info
As of April 2019, NXT valves are supplied with 24VDC motor. This motor is equipped
with an AC-DC converter allowing it to be powered with 24VAC or 24VDC. Therefore,
when used with NXT boards which require 24VAC power supply and therefore send
24VAC to the motor, the inverter will convert it into 24VDC.
Meter
Outlet
Diagnostic button
Status LED
Micro-switches
Brine valve
DC motor
NXT controller
Piston
Camshaft
Power head
Brine line
Injector
Inlet
Display
Regeneration button
Shift button
Setting button
AC to DC converter
Drain line

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3.4.3 With NXT2 controller and DC motor
Meter
Outlet
Up button
Status LED
Micro-switches
Brine valve
DC motor
NXT2 controller
Piston
Camshaft
Power head
Brine line
Injector
Inlet
Display
Regen button
Left button
Down button
AC to DC converter
Drain line

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3.5 System regeneration cycle
Info
This valve allows to do filtration, down flow and up flow regenerations.
3.5.1 DF regeneration cycle (5-cycles operation)
Service — normal use
Untreated water is directed down through the resin bed and up through the riser tube.
The hardness ions attach themselves to the resin and are removed from the raw water
being exchanged on the resin beads by sodium ions. The water is conditioned as it
passes through the resin bed.
Backwash — cycle C1
The flow of water is reversed by the valve and directed down the riser tube and up
through the resin bed. During the backwash cycle, the bed is expanded and debris is
flushed to the drain, while the media bed is remixed.
Brine draw & slow rinse — cycles C2
The valve directs water through the brine injector and brine is drawn from the brine
tank. The brine is then directed down through the resin bed and up through the riser
tube to the drain. The hardness ions on the resin beads are replaced by sodium ions
and are sent to the drain. The resin is regenerated during the brine cycle. When the air
check valve closes brine drawing finishes, and then the slow rinse phase starts.
Rapid rinse — cycle C3
The valve directs water down through the resin bed and up through the riser tube to the
drain. Any residual brine is rinsed from the resin bed, while the media bed is re-
compacted.
Brine tank refill — cycle C4
Water is directed to the brine tank, at a rate controlled by the refill controller, to create
brine for the next regeneration. During brine refill, treated water is already available at
the valve outlet.
Pause & Delay — cycle C5
The valve is in stand-by until the end of the cycle. In multiplex, if the brine tank is
shared, allows to leave a brine preparation time.
Info
The cycle Pause & Delay is optional with NXT controller. The factory value is set to
0minute.
Info
For illustration purpose only. Always verify inlet and outlet marking on the valve.