Table of Contents
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48ES and 51ES NXT Stager Controller
Service Manual
TABLE OF CONTENTS
NXT STAGER DIMENSIONS .................................................2
SYSTEM DEFINITIONS .........................................................3
(SYSTEM 14-DEMAND) .........................................................4
TIMER DISPLAY FEATURES.................................................5
CONNECTIONS .....................................................................5
TIMER OPERATION ..............................................................6
MASTER PROGRAMMING MODE FLOW CHART ...............7
USER PROGRAMMING MODE FLOW CHART ....................9
DIAGNOSTIC PROGRAMMING MODE FLOW CHART ........9
PLUMBING DIAGRAMS .........................................................12
SOLENOID USE.....................................................................13
24V/50-60Hz ASSEMBLY .......................................................14
24V/50-60Hz ASSEMBLY .......................................................15
WIRING DIAGRAM 48/51ES STAGER CONTROLLER ........16
TROUBLESHOOTING ...........................................................17
SERVICE ASSEMBLIES ........................................................18
IMPORTANT PLEASE READ:
• The information, specifications and illustrations in this
manual are based on the latest information available
at the time of printing. The manufacturer reserves the
right to make changes at any time without notice.
• This manual is intended as a guide for service of the
controller only. System installation requires information
from a number of suppliers not known at the time of
control manufacture. This product should be installed
by a plumbing professional.
• This product must be installed in compliance with all
state and municipal plumbing and electrical codes.
Permits may be required at the time of installation.
• If daytime operating pressure exceeds 80 psi,
nighttime pressures may exceed pressure limits. A
pressure reducing valve must be installed if pressure
exceeds 125 psi.
• Do not install the unit where temperatures may drop
below 32°F (0°C) or above 110°F (43°C).
• Do not place the unit in direct sunlight. Black units will
absorb radiant heat increasing internal temperatures.
• Do not strike the controller or any of the components.
• Warranty of this product extends to manufacturing
defects. Misapplication of this product may result
in failure to properly condition water, or damage to
product.
• A prefilter should be used on installations in which free
solids are present.
• Correct and constant voltage must be supplied to the
controller to maintain proper function.
43037 Rev B
FE11
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Table of Contents
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Page 1: Table Of Contents
48ES and 51ES NXT Stager Controller Service Manual TABLE OF CONTENTS IMPORTANT PLEASE READ: NXT STAGER DIMENSIONS ..........2 • The information, specifications and illustrations in this manual are based on the latest information available SYSTEM SPECIFICATIONS 48ES AND 51ES SERIES ..2 at the time of printing. The manufacturer reserves the right to make changes at any time without notice. SYSTEM DEFINITIONS ............3 • This manual is intended as a guide for service of the SYSTEM OPERATION IN SERVICE controller only. System installation requires information (SYSTEM 14-DEMAND) ............4 from a number of suppliers not known at the time of control manufacture. This product should be installed... -
Page 2: Nxt Stager Dimensions
NXT STAGER DIMENSIONS SYSTEM SPECIFICATIONS 48ES AND 51ES SERIES 11.13 [282.7] 8.91 [226.3] Generic Meter Guidelines Optional Solenoid • Open collector output 10.50 [266.6] • Pulse rate generated must not exceed 100 pulses per second (100 Hz), or 6,000 pulses per minute • Support for meter outputs in the range of 1-255 gallons 5.25 [133.4] (25.5 m ) for every 1-255 pulses Example: 35 gallons/100 pulses 1.41 [35.8] (=3.5 gallons/10 pulses, = 0.35 gallons/1 pulse) • Meter must operate at 5 VDC Electrical Rating (6X) 1/8"... -
Page 3: System Definitions
SYSTEM DEFINITIONS System System # of Connect meter and/or remote Type Operation Discussion Number Description Tanks/ regeneration input to... Controls Single Unit Time Clock: No Meter Stager Single tank configuration. During (no solenoid required) Regeneration no water available to service Immediate: One Meter unless optional bypass valve #2A installed. Delayed: One Meter Remote Signal Start: No Meter Interlocked 2, 3, or 4 Immediate: All Meters Stager All tanks in parallel supplying treated water. (no solenoid required) Each unit in the system will have its own Remote Signal Start: No Meter flow meter/sensor input. The control will delay the start of Regeneration if another... -
Page 4: System Operation In Service (System 14-Demand)
SYSTEM OPERATION IN SERVICE (SYSTEM 14-DEMAND) 5. The third tank returns to Standby as demand decreases The system operates as part of a multi-tank regeneration past the second trip point. system. This example applies to either a 2, 3 or 4 tank system. Each tank in the system will have an active flow meter input, even in Standby. The number of tanks In Service depends on the flow rate. Examples of a Four-Unit System: 1. One Tank is In Service at all times (the "primary tank"). Flow Split Between Standby Two Meters 6. Tanks return to Standby due to decreased total flow rate and trip points programmed. The tank with the most remaining volume will be the first to go into Standby. In Service (Primary Tank) Standby 2. The total flow rate to the primary tank increased past the first trip point programmed rate. The flow stayed past the trip point delayed time. The next tank (least volume remaining) changes from Standby to In Service. This then splits the total flow between two meters. -
Page 5: Timer Display Features
TIMER DISPLAY FEATURES NETWORK/COMMUNICATION CABLES & CONNECTIONS Valve State Display Screen (SBY, SRV, INI, LCK) Time of Day alternates with Error Screen Use a CAT5 Network/Communication cable. Valve Example: Valve #, Volume Address Connect the network/communication cable to either port before Remaining, Errors Flow System Time programming. Indicator Number of Day Volume Remaining The maximum cable length between timers is 100 feet. -
Page 6: Timer Operation
TIMER OPERATION Remote Lockout Set Time of Day The timer does not allow the unit/system to go into Hold the Up or Down button to change time. While in time Regeneration until the regeneration lockout input signal to the change mode press Shift to adjust next digit over. On multiple unit is cleared. This requires a contact closure to activate the tank systems change time on #1 control only. All other controls lockout. The recommended gauge wire is 20 with a maximum in system will mirror the time on control #1. length of 500 feet. Manually Initiating a Regeneration Regeneration Day Override Feature 1. When timer is In Service or Stand By, press the Extra Cycle If the Day Override option is turned on and the actual number button on the main screen for five (5) seconds to force a of days since last regeneration exceeds the set regeneration manual regeneration if another unit is not in Regeneration. day override value, the Regeneration cycle starts. If other units 2. The timer reaches Regeneration cycle Step #1. are in regeneration, it is added to a regeneration queue. This 3. Press the Extra Cycle button once to advance valve to the occurs regardless of the remaining volume available. next Regeneration cycle. This unit is not designed to drive/power WARNING: external devices. -
Page 7: Master Programming Mode Flow Chart
Example: SYSTEM SIZE: 2 Valves in the System (Default) 2 VALVES MASTER PROGRAMMING MODE FLOW Options: 2 Valves in the System (Default) 3 Valves in the System 4 Valves in the System CHART Range: 2 to 4 Valves in the System NOTE: This screen will not display for System Type 4. - Page 8 TRIP DELAY 1: Example: CYCLE 4 OFF 30 SECONDS Off (Default 48-00 Stager) Example: Refill MASTER PROGRAMMING MODE FLOW CYCLE 4 00:12:00 00:12:00 (Default 51-09 Stager) NOTE: Display will only appear on the master timer and it must be (Hours:Minutes:Seconds) CHART continued programmed as valve position #1.
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Page 9: User Programming Mode Flow Chart
USER PROGRAMMING MODE FLOW DIAGNOSTIC PROGRAMMING MODE CHART FLOW CHART Entering User Programming Mode Entering Diagnostic Programming Mode Hold the Up and Down buttons for 5 seconds. 1. Push and release the "D" button. 2. Press the Extra Cycle button once per display until all displays are viewed and Normal Display is resumed. 3. Push and release the"D" button at anytime during diagnostic mode and the timer will exit the mode. 4. Depending on the current controller programming, certain displays may not be able to be viewed or set. FEED WATER HARDNESS: Options: U.S. Format [gpg] Metric Format [mgL] CURRENT FLOW RATE: 0 gpm... - Page 10 10 • NXT Stager Controller FE11...
- Page 11 Stager Operation Stagers are motor driven, rotary multi-port valves used to control a set of valves in a predefined sequence. They function by internally connecting inlet pressure to a defined set of control ports and allowing other control ports be vented through a drain. Control ports are used to open and close valves in a preset sequence. As the stager advances to various positions, different valves are open and closed in a system. The control port pressure and vent sequence is preset at the factory and cannot be field altered. Stager Installation 1. Connect a constant pressure water or air source to the 1/8" NPT stager inlet. Control fluid pressure must be equal to or greater than system pressure. To ensure long trouble free operation, a 100 micron filter in the control pressure line is recommended. 2. Stager drain port should be left open or discharged to unrestricted or open drain. DO NOT plug or restrict drain port. 3. Connect the 1/8" NPT control ports to appropriate valves. Refer to tubing schematic provided in the Plumbing Diagrams section of this manual. Tubing inside diameter should be 1/8" or larger. NXT Stager Controller FE11 • 11...
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Page 12: Plumbing Diagrams
PLUMBING DIAGRAMS 4 Position Softener (48-00 Stager) 4 Position Filter (48-00 Stager) Optional Hard Optional Hard Water Bypass Valve Water Bypass Valve 4 POSITION FILTER Installer to plug for filter operation Note: Program Cycle 2 time to 00:00:00 for filter operation. Note: All valves normally open except optional valve 2A. -
Page 13: Solenoid Use
PLUMBING DIAGRAMS continued SOLENOID USE 5 Position Softener w/Timed Brine Refill Solenoids only required for Systems 7, 9 and 14 (51-09 Stager) Series 48-00/51-09 Stager Installer to Drain Plug Port 2 Solenoid Valve Inlet Pressure Optional Hard Water Bypass Valve Flow Flow Solenoid Energized... -
Page 14: Stager Controller, 48Es, Nema 4
STAGER CONTROLLER, 48ES, NEMA 4 24V/50-60Hz ASSEMBLY 30 33 AUX 1 (RED) HOFFMAN PARTS BAG SCALE 1:4 CYCLE (WHITE) ISO FRONT VIEW SCALE 1:4 KIT BR61764 SCALE 1:4 TO METER NOT CONNECTED 61803 Rev D BOTTOM DETAIL VIEW SCALE 1:2 Item No. -
Page 15: Stager Controller, 51Es, Nema 4
STAGER CONTROLLER, 51ES, NEMA 4 24V/50-60Hz ASSEMBLY AUX 1 (Red) 20 23 HOFFMAN PARTS BAG CYCLE (White) SCALE 1:4 ISO FRONT VIEW SCALE 1:4 KIT BR61764 SCALE 1:4 61804 Rev D BOTTOM DETAIL VIEW SCALE 1:2 Item No. Part No. Description Item No. -
Page 16: Wiring Diagram 48/51Es Stager Controller
WIRING DIAGRAM 48/51ES STAGER CONTROLLER 16 • NXT Stager Controller FE11... -
Page 17: Troubleshooting
TROUBLESHOOTING Detected Errors If a communication error is detected, an Error Screen will alternate with the main (time of day) screen every few seconds. • All units In Service remain in the In Service position. • All units in Standby go to In Service. • Any unit in Regeneration when the error occurs completes Regeneration and goes to In Service. • No units are allowed to start a Regeneration Cycle while the error condition exists, unless they are manually forced into Regeneration. • When an error is corrected and the error no longer displays (it may take several seconds for all of the units in a system to stop displaying the error message), the system returns to normal operation. NOTE: During the error condition the control continues to monitor the flow meter and update the volume remaining. Once the error condition is corrected all units return to the operating status they were in prior to the error. -
Page 18: Service Assemblies
SERVICE ASSEMBLIES Service Parts Common To Both 48ES & 51 ES Stager Control 48-00 ES Stager Assembly 61783......Kit, 48/51 ES NEMA4, Solenoid 61808-01 ....Stager Assy, 48-00, NXT 24VAC, HMG 61784......Kit 48/51 ES, 3214 NXT, CKT Board & No 2nd Aux Switch Keypad 61808-02 ....Stager Assy, 48-00, NXT 24VAC, SA, 61764......Cable Assy, Communication, CAT 5, 2nd Aux Notched in Service 5 Meters Long 61808-03 ....Stager Assy, 48-00, NXT 24VAC, SC, 42469......Transformer, 120V/24V, 40VA 2nd Aux Notched In Backwash... - Page 19 NXT Stager Controller FE11 • 19...
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