Pentair Fleck 4600 MECH User guide

FLECK
4600 MECH
INSTALLER
MANUAL
WATER PURIFICATION

Installer manual Fleck 4600 MECH - Table of Contents
2 / 92 Ref. MKT-IM-027 / C - 12.11.2019
Table of Contents
1 Generalities..................................................................................... 6
1.1 Scope of the documentation ....................................................................... 6
1.2 Release management ................................................................................. 6
1.3 Manufacturer identifier, product ................................................................ 6
1.4 Intended use................................................................................................ 7
1.5 Abbreviations used...................................................................................... 7
1.6 Norms.......................................................................................................... 7
1.6.1 Applicable norms ................................................................................................ 7
1.6.2 Available certificates........................................................................................... 8
1.7 Procedure for technical support................................................................. 8
1.8 Copyright ..................................................................................................... 8
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..................................................................................... 12
2.3 Hazards........................................................................................................ 12
2.3.1 Personnel ............................................................................................................ 12
2.3.2 Material ............................................................................................................... 13
2.4 Hygiene and sanitization ............................................................................. 13
2.4.1 Sanitary issues .................................................................................................... 13
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 ........................................................................................... 17
3.4 Components description and location ........................................................ 18
3.5 System regeneration cycle.......................................................................... 19
3.5.1 Downflow regeneration cycle (5-cycles operation) ............................................ 19
3.5.2 Filter cycle (3-cycles operation) ......................................................................... 21
3.6 Configurations for volumetric and time clock softeners............................ 23
3.6.1 Volumetric ........................................................................................................... 23
3.6.2 Time clock ........................................................................................................... 24
3.7 Options available on the valve..................................................................... 25
4 System sizing................................................................................... 26
4.1 Recommended Injector/DLFC/BLFC-Valve configuration ......................... 26

Installer manual Fleck 4600 MECH - Table of Contents
Ref. MKT-IM-027 / C - 12.11.2019 3 / 92
4.2 Sizing a softener (single unit) ..................................................................... 26
4.2.1 Parameters to be considered ............................................................................. 26
4.2.2 Determining the required volume of resin ......................................................... 27
4.2.3 Resin exchange capacity and capacity of the unit .............................................. 28
4.2.4 Valve configuration.............................................................................................. 29
4.2.5 Cycle time calculation......................................................................................... 30
4.3 Salt amount definition ................................................................................. 30
4.4 Injector flow rates ....................................................................................... 30
4.4.1 1600 injectors ...................................................................................................... 31
4.4.2 1650 injectors ...................................................................................................... 32
5 Installation ...................................................................................... 33
5.1 Warnings...................................................................................................... 33
5.2 Safety notices for installation ..................................................................... 33
5.3 Installation environement ........................................................................... 33
5.3.1 General ................................................................................................................ 33
5.3.2 Water ................................................................................................................... 34
5.3.3 Electrical ............................................................................................................. 34
5.3.4 Mechanical .......................................................................................................... 35
5.4 Integration constraints................................................................................ 35
5.5 Valve connection to piping........................................................................... 36
5.5.1 Top-mounted valve installation .......................................................................... 36
5.6 Block diagram and configuration example................................................. 38
5.7 Regeneration flows ..................................................................................... 39
5.8 Electrical connections................................................................................. 40
5.9 Bypassing .................................................................................................... 41
5.10 Drain line connection .................................................................................. 41
5.11 Overflow line connection............................................................................. 43
5.12 Brine line connection .................................................................................. 44
6 Programming .................................................................................. 45
6.1 Time of day .................................................................................................. 45
6.2 Volumetric ................................................................................................... 46
6.2.1 Calculating the system capacity ......................................................................... 47
6.2.2 Set the system capacity....................................................................................... 47
6.3 Time clock ................................................................................................... 48
6.3.1 Calculating the number of days between two regenerations ............................ 49
6.3.2 Set the number of days between two regenerations.......................................... 49
6.4 Salt volume per regeneration ..................................................................... 50
6.4.1 Salt volume definition ......................................................................................... 50
6.4.2 Set the salt volume per regeneration................................................................. 51
7 Commissioning................................................................................ 52

Installer manual Fleck 4600 MECH - Table of Contents
4 / 92 Ref. MKT-IM-027 / C - 12.11.2019
7.1 Water filling, draining and waterproofness inspection .............................. 52
7.2 Sanitization .................................................................................................. 53
7.2.1 Disinfection of water softeners........................................................................... 53
7.2.2 Sodium or calcium hypochlorite ......................................................................... 53
7.2.3 Electro chlorination............................................................................................. 54
8 Operation......................................................................................... 55
8.1 Display during operation ............................................................................. 55
8.1.1 During service ..................................................................................................... 55
8.1.2 During regeneration............................................................................................ 55
8.2 Recommendations ...................................................................................... 56
8.3 Manual regeneration................................................................................... 56
8.3.1 Manual immediate regeneration ........................................................................ 56
8.3.2 To advance regeneration cycles ......................................................................... 56
8.4 Operation during power failure................................................................... 56
9 Maintenance .................................................................................... 57
9.1 General system inspection.......................................................................... 57
9.1.1 Water quality ....................................................................................................... 57
9.1.2 Mechanical Checks ............................................................................................. 57
9.1.3 Regeneration test................................................................................................ 58
9.2 Recommended maintenance plan .............................................................. 59
9.2.1 Valve used for softening...................................................................................... 59
9.2.2 Valve used for softening...................................................................................... 61
9.3 Recommendations ...................................................................................... 63
9.3.1 Use original spare parts...................................................................................... 63
9.3.2 Use original approved lubricants........................................................................ 63
9.3.3 Maintenance instructions ................................................................................... 63
9.4 Cleaning and maintenance.......................................................................... 63
9.4.1 First steps............................................................................................................ 63
9.4.2 Controller motor replacement............................................................................ 64
9.4.3 Power head disassembly/replacement .............................................................. 65
9.4.4 Piston and/or brine valve and/or seal and spacer kit disassembly/
replacement ........................................................................................................ 66
9.4.5 Micro-switches replacement .............................................................................. 68
9.4.6 Brine cam replacement ...................................................................................... 69
9.4.7 Injector cleaning.................................................................................................. 70
9.4.8 BLFC cleaning ..................................................................................................... 71
9.4.9 Valve on tank assembly....................................................................................... 72
10 Troubleshooting .............................................................................. 73
11 Spare parts and options................................................................... 76
11.1 Valve parts list............................................................................................. 76
11.2 Power head parts list .................................................................................. 78
11.2.1 Volumetric power head parts list........................................................................ 78
11.2.2 Time clock power head specific parts and assembly list................................... 80

Installer manual Fleck 4600 MECH - Table of Contents
Ref. MKT-IM-027 / C - 12.11.2019 5 / 92
11.3 Safety brine valves list ................................................................................ 81
11.4 Safety brine valves parts list....................................................................... 82
11.5 Bypass valve assembly list.......................................................................... 83
11.5.1 1" BSP female stainless steel bypass ................................................................ 83
11.5.2 1" BSP female stainless steel bypass with mixing............................................. 85
11.5.3 Plastic bypass (no yoke)...................................................................................... 86
11.6 Distribution systems parts list.................................................................... 87
11.7 Air checks list .............................................................................................. 87
11.8 Meters parts list .......................................................................................... 88
11.9 CE compliance parts list ............................................................................. 89
12 Disposal........................................................................................... 90

Installer manual Fleck 4600 MECH - Generalities
6 / 92 Ref. MKT-IM-027 / C - 12.11.2019
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, MECH 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 21.03.2018 BRY/KVA First edition.
B 01.06.2018 BRY/FIM Address change, Bleam information and valve on
tank assembly.
C 12.11.2019 BRY Corrections.
1.3 Manufacturer identifier, product
Manufacturer: Pentair International LLC
Avenue de Sevelin 18
1004 Lausanne
Switzerland
Product: Fleck 4600 MECH

Installer manual Fleck 4600 MECH - Generalities
Ref. MKT-IM-027 / C - 12.11.2019 7 / 92
1.4 Intended use
The device is intended for domestic applications use only and it is purpose-built for water
treatment.
1.5 Abbreviations used
Assy Assembly
BLFC Brine Line Flow Controller
BV Brine Valve
CW Cold Water
Distr Distribution
DF Down Flow
DLFC Drain Line Flow Controller
FR Fast Regeneration
HW Hot Water
Imm Immediate
Inj Injector
N/A Not Available
PN Part Number
Regen Regeneration
S&S Seals & Spacers
SBV Safety Brine Valve
STD Standard
Sys System
VB Valve Body
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.

Installer manual Fleck 4600 MECH - Generalities
8 / 92 Ref. MKT-IM-027 / C - 12.11.2019
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.
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
Procedure to follow for any technical support request:
1. Collect the required information for a technical assistance request.
ðProduct identification (see Serial label location [}Page 12] and Recommendations [}
Page 63]);
ðDescription of the device problem.
2. Please refer to the Troubleshooting [}Page 73]. If the problem persists contact your
supplier.
1.8 Copyright
© 2019 Pentair International Sàrl. All rights reserved.

Installer manual Fleck 4600 MECH - Generalities
Ref. MKT-IM-027 / C - 12.11.2019 9 / 92
1.9 Limitation of liability
Pentair Quality System EMEA products benefit, under specific conditions, from a manufacturer
warranty that may be invoked by Pentair’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.

Installer manual Fleck 4600 MECH - Generalities
10 / 92 Ref. MKT-IM-027 / C - 12.11.2019
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.
1. Download the application "Scan & Service" from or in a
smartphone(4).
2. Open the application "Scan & Service".
3. Scan the bleam(3) stuck on the valve(2).
4. Navigate to find information.

Installer manual Fleck 4600 MECH - Safety
Ref. MKT-IM-027 / C - 12.11.2019 11 / 92
2 Safety
2.1 Safety pictograms definition
DANGER
This combination of symbol and keyword indicates an imminently hazardous situation
that will result in serious or fatal injury if not avoided.
WARNING
This combination of symbol and keyword indicates a potentially hazardous situation
that can result in serious or fatal injury if not avoided.
CAUTION
This combination of symbol and keyword indicates a potentially hazardous situation
that can result in minimal or minor injury if not avoided.
Caution - material
This combination of symbol and keyword indicates a potentially hazardous situation
that can result in material damage if not avoided.
Prohibition
Mandatory advice to follow.
Mandatory
Applicable guideline, measure.
Info
Informative comment.

Installer manual Fleck 4600 MECH - Safety
12 / 92 Ref. MKT-IM-027 / C - 12.11.2019
2.2 Serial label location
Model
Part number
Electrical rating
Serial number
Production date
Production order
Mandatory
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.
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
Risk of injury due to improper handling!
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.

Installer manual Fleck 4600 MECH - Safety
Ref. MKT-IM-027 / C - 12.11.2019 13 / 92
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 – 240V);
• 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.
Valid only for Italy
In case of equipment used in accordance with the DM25, apply all the signs and
obligations arising from the DM25.
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 53] ;
• maximum cleanliness is recommended during the assembly and installation;
• for disinfection, use Sodium or Calcium Hypochlorite and perform a manual regeneration.

Installer manual Fleck 4600 MECH - Description
14 / 92 Ref. MKT-IM-027 / C - 12.11.2019
3 Description
3.1 Technical specifications
Design specifications/ratings
Valve body Brass
Rubber components EP or EPDM
Weight (valve with controller) 2.5kg
Recommended operating pressure 1.4 - 8.6bar
Maximum inlet pressure 8.6bar
Hydrostatic test pressure 20bar
Water temperature 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
Flow rates (3.5 bar inlet - valve only)
Continuous service flow (Δp=1bar) 4.5m3/h
Peak service flow (Δp=1.7bar) 5.9m3/h
Cv* 5.2gpm
Kv* 4.5m3/h
Maximum backwash flow
(Δp=1.8bar)
1.6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 Thread 2½" - 8NPSM
Inlet/Outlet ¾" or 1"
Riser tube 26.7mm O.D., 1.05"tube
Drain line ½" O.D.
Brine line (1650) ⅜"
Electrical
Power supply 230VAC, 50/60Hz, 15VA
Transformer output voltage 24VAC, 10VA max.
Motor input voltage 24VAC
Controller input voltage 24VAC
Controller max. power consumption 5W

Installer manual Fleck 4600 MECH - Description
Ref. MKT-IM-027 / C - 12.11.2019 15 / 92
Protection rating IP22
Power supply 100 to 240VAC, 50/60Hz, 0.8A, Class II
Transient overvoltages Within the limits of category II
Pollution Degree 3
Temporary overvoltages must be limited in duration and in frequency.
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.

Installer manual Fleck 4600 MECH - Description
16 / 92 Ref. MKT-IM-027 / C - 12.11.2019
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
Service
Backwash
Flow rate [m³/h]
Pressure drop [bar]

Installer manual Fleck 4600 MECH - Description
Ref. MKT-IM-027 / C - 12.11.2019 17 / 92
3.3 Outline drawing

Installer manual Fleck 4600 MECH - Description
18 / 92 Ref. MKT-IM-027 / C - 12.11.2019
3.4 Components description and location
Green light
Program wheel
24 hours wheel
Red light
Meter
(Not included in case of
time clock)
Drain line
Imlet
Brine cam
Brine valve
Brine line
Injector block
Mixing device
Outlet
Motor
Piston

Installer manual Fleck 4600 MECH - Description
Ref. MKT-IM-027 / C - 12.11.2019 19 / 92
3.5 System regeneration cycle
Info
This valve allows to do filtration and down flow regenerations.
3.5.1 Downflow 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.
Second backwash — cycle C3 (Double backwash units only)
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.
Rapid rinse — cycle C4
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 C5
Water is directed to the brine tank, at a rate controlled by the refill controller [BLFC], to create
brine for the next regeneration. During brine refill, treated water is already available at the valve
outlet.
Info
For illustration purpose only. Always verify inlet and outlet marking on the valve.

Installer manual Fleck 4600 MECH - Description
20 / 92 Ref. MKT-IM-027 / C - 12.11.2019
Outlet Inlet InletOutlet
Drain
SERVICE
NORMAL USE
C1
BACKWASH
Outlet Inlet InletOutlet
Drain
Drain
C2
BRINE DRAW & SLOW RINSE
C3
SECOND BACKWASH
(Double backwash unit only)
From brine
tank
Outlet Inlet InletOutlet
C4
RAPID RINSE
C5
BRINE REFILL
To brine tank
Valve Valve
Valve Valve
Valve Valve
Drain
Untreated water