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MARLO MR Series Installation, Operation And Maintenance Manual

Twin softener with 400c hmi plc controller
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PLC CONTROLLER
COMPLETE FOR FUTURE REFERENCE:
MODEL NO:
SERIAL NO:
DATE INSTALLED:
DEALER:
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
MR 150–1050M
TWIN SOFTENER
WITH 400C HMI
COMMERCIAL
WATER CONDITIONERS
Marlo Incorporated
2227 South Street
P.O. Box 044170
Racine, WI 53404-7003
www.Marlo-Inc.com
8-612 R3

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Summary of Contents for MARLO MR Series

  • Page 1 AND MAINTENANCE MANUAL MR 150–1050M TWIN SOFTENER WITH 400C HMI PLC CONTROLLER COMMERCIAL WATER CONDITIONERS COMPLETE FOR FUTURE REFERENCE: MODEL NO: Marlo Incorporated SERIAL NO: 2227 South Street P.O. Box 044170 DATE INSTALLED: Racine, WI 53404-7003 DEALER: www.Marlo-Inc.com 8-612 R3...
  • Page 2 MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER MR 150M–1050M PLC SYSTEM INFORMATION IMPORTANT PLEASE READ: � Warranty of this product extends to manufacturing defects. � 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.
  • Page 3 MR 150M–1050M PLC MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER TABLE OF CONTENTS Water Treatment Product Warranty and Softener Guarantee Specification General Arrangement Drawing INSTALLATION Piping Installation ________________________________________________________________ OPERATION Start Up Instructions_______________________________________________________________ _________________________________________________ __26 ________________________________________________________ ________________________________________________________ 30 _________________________________________________________ 31 ____________________________________________________________ MAINTENANCE Electrical Controls Drawings_________________________________________________________ 33...
  • Page 4 Any damage, discrepancies and/or freight claims must be made immedi- orders must include Marlo Incorporated part numbers and pricing. ately and directly, in writing within ten (10) days to Marlo Incorporated. Marlo Purchase orders must also state if partial shipments are allowed. If you do Incorporated will help as much as possible in settling claims.
  • Page 5 MR 150M–1050M PLC MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER SYSTEM INFORMATION SPECIFICATION NOTES Maximum salting is 15 pounds of salt per cubic foot of resin. This setting gives the longest time between regenerations. It has an efficiency of 2,000 grains of hardness removed per pound of salt.
  • Page 6 MR 150M–1050M PLC MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER SYSTEM INFORMATION SPECIFICATION TABLE MODEL 1050 Valve Size inches 1050 Capacity (Kgrains) Cont’s. Service Peak Backwash & Flush Brine Draw & Rinse Pins Backwash Minutes Pins Brine Draw & Rinse Minutes Pins Fast Flush...
  • Page 7 MR 150M–1050M PLC MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER SYSTEM INFORMATION INSTALLATION Page 4...
  • Page 8 MR 150M–1050M PLC INSTALLATION MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER INSTALLATION INSTALLATION DIMENSIONS AND SPECIFICATIONS Approx. Length Brine Drain Pipe Width MODEL Height Pipe Size Pipe Size Size (Inches) (inches) (inches) (inches) (inches) Single Twin Triple MR-150-1 MR-150-1 1...
  • Page 9 MR 150M–1050M PLC MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER INSTALLATION INSTALLATION SOFTENER INSTALLATION INSTRUCTIONS GENERAL INFORMATION Before beginning installation, thoroughly review the following instructions to familiarize yourself with the general placement and identification of all components. These instructions are written for a single unit installation, but they also generally apply to twin and triple units.
  • Page 10 MR 150M–1050M PLC MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER INSTALLATION INSTALLATION PIPING INSTALLATION Note: • Install the piping conforming to federal, provincial, and local codes. • Union or flanges are recommended at the control valve's inlet, outlet, and drain connections •...
  • Page 11 MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER INSTALLATION TUBING DIAGRAM - VALVE NEST - MULTITANK - ASCO SOLENOID...
  • Page 12 MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER INSTALLATION TUBING DIAGRAM - VALVE NEST - MULTITANK - PARKER SOLENOID...
  • Page 13 MR 150M–1050M PLC MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER INSTALLATION INSTALLATION BRINE TANK INSTALLATION TO INJECTOR EXTENSION TO INJECTOR OVERFLOW (PIPE TO DRAIN) FLOAT BRINE WELL DRY SALT STORAGE FLOAT BRINE VALVE FLOAT HEIGHT SALT SHELF LIQUID BRINE BRINE VALVE 1.
  • Page 14 MR 150M–1050M PLC INSTALLATION MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER INSTALLATION SOFTENER TANK LOADING GRAVEL LOADING UPPER DISTRIBUTOR 1. See the Specification Table on page 3 for the correct amount of gravel and resin. Do not begin loading until you have confirmed all of the required media is on site.
  • Page 15 MR 150M–1050M PLC MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER OPERATION OPERATION START-UP INSTRUCTIONS PLC PROGESSIVE CONTROLLER Note: Read the controls description section located in this manual before proceeding. With all piping and installation complete, and the mineral in the tank, proceed as follow: 1.
  • Page 16 MR 150M–1050M PLC MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER OPERATION OPERATION 7. Advance Unit 1 to the backwash step. The unit 1 stager should rotate to the step 1 (backwash) position. 8. Slowly open the manual inlet supply valve. Do not open fully. Full flow of water could cause loss of media.
  • Page 17 MR 150M–1050M PLC MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER OPERATION OPERATION 15.Fill the brine tank with the proper amount and type of salt recommended for use with the system. See RECOMMENDED TYPES OF SALT. 16.Close the manual by-pass valve and open all outlet valves fully. The system is now in service.
  • Page 18 MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER OPERATION TWIN ALTERNATING SOFTENER ELECTRICAL CONTROLS OPERATION General-the main control panel (MCP) contains the programmable logic Controller (PLC) and the operator interface (OIT). The system is controlled by the PLC. Operator intervention and control along with some program setpoint access is through the oit. The plc controls the system so that one unit will be online (in service) while the other unit is in standby or regeneration.
  • Page 19 MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER OPERATION OPERATOR INTERFACE SCREENS-LOCATED ON THE FRONT OF THE MCP IS THE OPERATOR INTERFACE (OIT). IT ALLOWS OPERATOR MONITORING AND ACCESS TO THE PROGRAM. Summary Screen 1- MAIN SCREEN FOR STATUS INDICATION Screen 2- REGENERATION START/ADVANCE Screen 3- PRESETS 1 (CYCLE TIMES), BATCH &...
  • Page 20 MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER OPERATION OPERATOR INTERFACE SCREENS SCREEN 1-MAIN SCREEN The main screen displays the following: MODE-each units mode is displayed near the upper part of the screen. The modes indicate which cycle the unit is in these can be any one of the following: SERVICE STANDBY BACKWASH...
  • Page 21 MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER OPERATION CONTROLS CONTINUED: OPERATOR INTERFACE SCREENS SCREEN 2 REGENERATION START/ADVANCE-OPERATOR CONTROL 1 This is the main screen used for manual operator regeneration start and advance. It is mainly used to manually start and advance a unit through it regeneration steps.
  • Page 22 MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER OPERATION CONTROLS CONTINUED: OPERATOR INTERFACE SCREENS SCREEN 3 PRESETS 1 SCREEN This screen can be used to change the following setpoints: BACKWASH CYCLE TIME IN MINUTES BRINE SLOW RINSE TIME IN MINUTES FAST RINSE TIME IN MINUTES BATCH IN GALLONS KFACTOR...
  • Page 23 MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER OPERATION CONTROLS CONTINUED: OPERATOR INTERFACE SCREENS SCREEN 4 OPERATOR CONTROL 2 This screen allows the system to be reset or allows access to the configuration of the OIT. SYSTEM RESET-this button when depressed for a minimum of 5 continuous seconds will reset the system.
  • Page 24 MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER OPERATION CONTROLS CONTINUED: OPERATOR INTERFACE SCREENS SCREEN 5 SYSTEM TOTALIZER This screen is used to view the number of gallons have passed for both units while they were in service. To reset the totalizer press the button at the bottom of the screen. -There is a 3 second delay on the totalizer reset button to verify operator intent.
  • Page 25 MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER OPERATION CONTROLS CONTINUED: OPERATOR INTERFACE SCREENS SCREEN 6 SCREEN CHANGES This screen can be used to change to a different screen. On some Screens there are shortcuts to often used screens using a function key. This screen allows the user to scroll through the list of screens and choose which one they want.
  • Page 26 MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER OPERATION CONTROLS CONTINUED: OPERATOR INTERFACE SCREENS ALARMS: TRIGGERS/BANNERS Alarms – this system will alarm under two conditions 1) If unit a stager does not return home for any reason. 2) If unit b stager does not return home for any reason.
  • Page 27 MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER OPERATION CONTROLS CONTINUED: OPERATOR INTERFACE SCREENS Screen Saver- after 10 minutes of no activity on the screen, the screen will go blank. This is the screen saver. Press any key on the OIT and the screens will come back on. Plc memory- The memory of the plc is protected by flash memory and does not require battery backup when power is removed.
  • Page 28 MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER OPERATION Controls continued Miscellaneous Plc memory- The memory of the plc is protected by flash memory and does not require battery backup when power is removed. Power loss- If power is lost and then it comes back on again the controller will remember where it was and continue on where it last was.
  • Page 29 MR 150M–1050M PLC MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER OPERATION OPERATION HOW TO CALCULATE SOFTENERS CAPACITY “Batch size” is the term used for the amount of water passing through and being softened by the water softener between regenerations. This is a simple calculation provided two pieces of information are known: •...
  • Page 30 MR 150M–1050M PLC MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER OPERATION OPERATION WATER SOFTENER GENERAL OPERATION Hard water passes through the valve manifold into the top of the softener tank. It flows downward through the mineral bed and out through the bottom of the tank to service. As the water passes through the mineral bed, the hardness present is removed through the process of ion exchange and at the same time sediment present is removed by filtration action of the mineral.
  • Page 31 MR 150M–1050M PLC MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER OPERATION OPERATION FLOW DIAGRAM Page 28 PAGE...
  • Page 32 MR 150M–1050M PLC MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER OPERATION OPERATION BRINE MAKER OPERATION The brine-maker is an automatic brining system, which is easily adjusted to provide maximum TO INJECTOR operating efficiency of your water softener. It is a OVERFLOW combination salt storage and brine-measuring tank (PIPE TO DRAIN)
  • Page 33 MR 150M–1050M PLC MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER OPERATION OPERATION MINIMUM SALTING ADJUSTMENT Minimum salting is the most efficient use of salt. But it does minimize the capacity of the unit, which will decrease the time between regenerations. Only make this adjust after the unit has completed a brine tank refill step and the water level was checked to be above the salt platform.
  • Page 34 MR 150M–1050M PLC MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER OPERATION OPERATION Flow Rate Trip Point Table Program Values for A, B, C & D MODEL Alternating Operation Parallel Operation (gpm) (gpm) Second Unit Trip Second Unit Trip *Third Unit Trip Flow Range Flow Range Flow Range...
  • Page 35 MR 150M–1050M PLC MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER OPERATION OPERATION K FACTOR Table Program values for XX PIPE SIZE SADDLE SADDLE WELDOLET (Inches) Galvanized Iron Carbon Steel 1 1/4 1 1/2 2 1/2 Page 32 PAGE...
  • Page 36 MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER MAINTENANCE...
  • Page 37 MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER MAINTENANCE...
  • Page 38 MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER MAINTENANCE...
  • Page 39 MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER MAINTENANCE...
  • Page 40 MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER MAINTENANCE...
  • Page 41 MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER MAINTENANCE...
  • Page 42 MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER MAINTENANCE Replacement Valve Table Location# Function Position Service Inlet NORMALLY OPEN Service Outlet NORMALLY OPEN Bypass Valve - NORMALLY CLOSED Single Systems Only Backwash Outlet NORMALLY OPEN Backwash Inlet NORMALLY OPEN NORMALLY OPEN Brine Inlet SPRING ASSIST OPEN NORMALLY OPEN...
  • Page 43 MR 150M–1050M PLC MAINTENANCE MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER MAINTENANCE AQUAMATIC REPAIR KITS RA - Diaphragm & Seal Kits - Includes Buna N Seals and Diaphragm (Items 3(2),5,6,8(2),9,14&16) RF - Metal Parts Kit (Normally Open) - (Items 4,7,10,11(2), 17) RG - Metal Parts Kit (Normally Closed) - (Items 4,7,10,11(2), 23) SC - Repair Kit (Spring Assist Closed) - (Items 24,27,28) SO - Repair Kit (Spring Assist Open) - (Items 8,31,32)
  • Page 44 MR 150M–1050M PLC MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER MAINTENANCE MAINTENANCE 2536 Standard Mount Sensor Galvanized Iron Threaded Tee with NPT Threads PVDF Insert Iron Strap-on Saddle with PVDF Insert K- Factor Table (Pulses per Gallon) Pipe Size Saddle Inches Galvanized...
  • Page 45 MR 150M–1050M PLC MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER MAINTENANCE MAINTENANCE BRINE SYSTEM FOR MGT 150-450 Models Part Number Shelf Height MR 150 B1039001 15" MR 210 B1039002 22" MR 300 B1039003 29" MR 450 B1039009 29" Item Number Part Number Item Description B1002007...
  • Page 46 MR 150M–1050M PLC MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER MAINTENANCE MAINTENANCE BRINE SYSTEM FOR MGT 600-1050 Models Part Number Shelf Height MR 600 B1039005 22" MR 750 B1039005 22" MR 900 B1039007 29" MR 1050 B1039008 22" Item Number Part Number Item Description B1002010 BRINE TANK W/HOLES 39x60 - (MR 600-750)
  • Page 47 MR 150M–1050M PLC MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER MAINTENANCE MAINTENANCE SERVICE CHART STAGER CONTROLLER SYMPTOM PROBABLE CAUSE HOW TO CORRECT 1. No electrical power. Check circuit. Start a regeneration with Manual Regeneration Lever. 2. Frequency levers on Time Dial not Refer to “How to Set set properly.
  • Page 48 MR 150M–1050M PLC MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER MAINTENANCE MAINTENANCE SERVICE CHART WATER SOFTENERS IMPORTANT: Many softener complaints result from oversights (poor electric connections, out of salt, regenerating at wrong hour etc.) rather than from a mechanical failure. Troubleshooting guide for the MX controller is located in the back of this manual page 33.
  • Page 49 MR 150M–1050M PLC MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER MAINTENANCE MAINTENANCE SERVICE CHART WATER SOFTENERS continued PROBLEM OR CHECK PROCEDURE CAUSE SYMPTOM If vent hole is plugged, a partial vacuum will be created in the space between the 14.
  • Page 50 MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER MAINTENANCE NOTES...
  • Page 51 MR 150M–1050M TWIN - 400C HMI PLC CONTROLLER NOTES...
  • Page 52 2227 South Street • P.O. Box 044170 • Racine, WI 53404-7003 • www.Marlo-Inc.com 8-612 R3...

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