MARLO MGT 1200, Installation, Operation And Maintenance Manual

Page 1: ...2 SERIES MODEL NO SERIAL NO DATE INSTALLED DEALER COMPLETE FOR FUTURE REFERENCE COMMERCIAL WATER CONDITIONER INSTALLATION OPERATION AND MAINTENANCE MANUAL Standard Image Equipment appearance may differ Twin system shown with skid mount option 8 634 ...

Page 2: ... loading procedure Improper loading of media will damage components inside media tank PRIOR TO Media Loading AFTER Media Loading SIDE VIEW Lateral Hub Distributor Tube Media Tank Softener Filter Media Gravel Media TOP VIEW Media Tank Lateral Hub 5 272 IMPORTANT PLEASE READ Warranty of this product extends to manufacturing defects The information specifications and illustrations in this manual are ...

Page 3: ...nstallation 11 OPERATION Timer Display Features 12 System Operation 13 Timer Operation 13 Start Up Procedures 15 User Mode Programming Flow Chart 16 Batch Size Calculation 17 Diagnostic Mode Flow Chart 18 Master Programming Flow Chart 19 Master Programming Guide 21 Flow Diagrams 22 Wiring Diagram 24 MAINTENANCE Powerhead Assembly 25 NXT2 Timer Assembly 27 Control Valve Assembly 28 Brine Injector A...

Page 4: ...going warranty is exclusive and in lieu of all other expressed implied warranty except of title including but not limited to implied warranty of merchantability and fitness for particular purpose Manufacturer will not be subject to and disclaims the following 1 Any other obligations or liabilities arising out of breach of contract or out of warranty 2 Any obligations whatsoever arising from tort c...

Page 5: ...MGT 240M 1200M NXT2 3 TWIN ALTERNATING SYSTEM INFORMATION 2 5 232 ...

Page 6: ... REMARKS 1 12 13 13 AJJG ADDED VACUUM RELIEF VALVES DATE RESIN TANK BRINE TANK RESIN TANK AUTOMATIC BACKWASH FLOW CONTROLLER BY PASS VALVE NORMALLY CLOSED 3 RAW WATER INLET 30 100 PSIG 3 SOFT WATER OUTLET INLET ISOLATION VALVE OUTLET ISOLATION VALVE OVER FLOW TO DRAIN NOTES 1 OVERALL HEIGHT IS FOR REFFERENCE ONLY ACTUAL HEIGHT MAY VARY BASED ON TANK PROVIDED ALLOW 36 FOR RESIN LOADING WATER INLET ...

Page 7: ... BRINE Inches 240 3 24x72 24x50 89 24 95 300 3 24x72 24x50 89 24 95 450 3 30x72 30x50 115 30 93 600 3 36x72 39x60 129 39 94 750 3 42x72 39x60 140 42 113 900 3 42x72 42x60 143 42 113 1050 3 48x72 42x60 155 48 113 1200 3 48x72 42x60 155 48 113 Leave a minimum 24 inch clearance to the height of the unit for loading media Dimensions are for general arrangement use only ...

Page 8: ...GRN RED WHT BLU BLU YEL MAX SALT DOSAGE MAX LBS 120 150 225 300 375 450 600 REFILL TIME MAX MIN 20 25 15 20 13 15 20 MIN SALT DOSAGE MIN LBS 48 60 90 120 150 180 240 REFILL TIME MIN MIN 8 10 6 8 5 6 8 REGENERATION WASTE VOLUME GAL 520 544 860 1020 1210 1315 2100 NOTES 1 FLOW RATES Continuous pressure loss does not exceed 15 psig Peak pressure loss does not exceed 25 psig Backwash Flush maximum flo...

Page 9: ...ng and erecting so that no items are damaged 5 The distributor assembly has been shipped inside the fiberglass mineral tank Check to make sure that there is no damage to the riser pipe baskets laterals or hub if applicable NOTE A prefilter should be used on installations in which free solids are present LOCATE SOFTENER 1 Select a location that is accessible and near a floor drain that has adequate...

Page 10: ... opening in the tank Caution The softener resin is very slippery Take care when stepping on any pilled resin Remove spilled resin from standing immediately 6 When loading is complete remove plastic cap cork or rag that was used to plug the distributor riser pipe Be careful not to let any foreign debris fall into the pipe The result could be damage to system 7 Repeat instruction steps 1 6 for each ...

Page 11: ...refer to the diagram on the next page to connect the tubing After connecting the tubing on both ends verify that the brine line tubing is not kinked or restricted Run flexible tubing not provided from the brine tanks over flow fitting to an appropriate nonelevated open drain Using a bucket or hose fill brine tank with water to about 2 above salt platform Do not add salt at this time Note In the pr...

Page 12: ...IPPLE 3 4 X 2 1 2 PVC SCH 80 TOE 1883 025 3 4 A2053001 PIPE 3 4 PVC SCH 80 2 3 000 in 5 A2031201 REDUCER 1 X 3 4 BRASS BELL 2 6 A2479005 TEE 3 4 PVC SCH 80 SXSXS 1 7 A2484005 UNION 3 4 PVC SCH 80 SOCKET 3 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 A A B B C C D D DATE FRAC DRN APP D _ DEC _ DRAWING NO SCALE FILE ID SHEET REV OF BRINE LINE ASSY TWN 3 4 10GPM 1800 FABRICATION DRAWING 1 1 REVISIONS NO BY REMARK...

Page 13: ...the back of the control and into the controller Connect the meter cable to the circuit board in the lower right as shown System 7 Twin Alternating CAT 5 CABLE UNIT 1 UNIT 2 NETWORK COMMUNICATION CABLES CONNECTIONS Use either a CAT3 or CAT5 Network Communication cable 1 Connect the network communication cable first before programming 2 The maximum cable length between timers is 100 feet 3 Connect e...

Page 14: ...ing away from the control valve See installation diagram or valve manual for the location Install a drain line from backwash control assembly to an appropriate drain using a minimum of elbows Install a union near the backwash control to facilitate cleaning Do not install a valve on the drain line NOTE If distance of drain line is over a 10 ft vertical or 25 ft horizontal run increase drain line on...

Page 15: ...Time of Day Master Indicator Status LEDs Display Screen Alternates between Date Flow Rate and Volume Remaining If a regeneration is queued displays time until regeneration Left Button Press Navigate to previous menu option Press and Hold Enter Diagnostic menu Blue LED On Unit in Service Blinking Regeneration Queued Green LED On Unit in Regeneration Blinking Unit in Standby Red LED On Error present...

Page 16: ...ntil the Regeneration Lockout Input signal to the unit is cleared This requires a contact closure to activate the unit The recommended gauge wire is 16 AWG with a maximum wire length run of 50 feet REGENERATION DAY OVERRIDE FEATURE If the Day Override option is turned on and the valve reaches the set Regeneration Day Override value the Regeneration Cycle starts if no other unit is in Regeneration ...

Page 17: ...ation Cycle Step 5 if active 7 Press the Extra Cycle button once more to advance the valve back to In Service NOTE A manually initiated or queued regeneration can be cleared by pressing and holding the Back button A system queued regeneration can only be cleared by stepping through a manual regeneration If regeneration occurs for any reason prior to the delayed regeneration time the manual regener...

Page 18: ...8 Slowly open the manual inlet supply valve of the unit that is in backwash Do not open the valve fully Water will enter from the bottom of the mineral tank as air is expelled from the top to the drain Full flow of water could cause loss of mineral Continue to fill slowly until all air is expelled and only water flows to the drain 9 When only water flows to the drain open the inlet valve fully and...

Page 19: ... Set Regeneration Time Press the Up and Down buttons to change the time value Holding a button down will speed through the setting Press the Extra Cycle button to proceed to the next step 4 Set Feed Water Hardness Press the Up and Down buttons to change the value of the numbers Press the Extra Cycle button to to proceed to the next number Range is 0 999 gpg After the third number is entered pressi...

Page 20: ... be 20 grains per gallon Using our equation take 300 000 20 15 000 gallons 10 Safety factor reserve capacity 1 500 gallons 15 000 gallons 1 500 gallons 13 500 gallons batch size For immediate regeneration type meter control the meter setting would be at 15 000 gallons Commonly this value is adjusted to 90 percent of the actual value in this example 13 500 gallons to assure not over running the sof...

Page 21: ...me since last regeneration LAST REGEN 4 H Example Installed software version SOFTWARE VERSION 13026 Example Total number of regenerations since installation NO OF REGENS 32 Example Duration between regenerations REGEN INTERVAL 3 D 21 H Example Last time programming settings were changed LAST SETTINGS CHANGE 14 H 0 M Example Record of error events chronologically ERROR LOG ERROR LOG EMPTY SUN DAILY...

Page 22: ...g will be displayed When regeneration has been completed the display will return to the main screen 9 If any values are changed make sure Push Settings is set to ON so the values are pushed to the other unit s Example On View settings without the ability to alter settings Off User has ability to alter settings OFF ON SETTINGS REVIEW Example English Francais Duetsch Italiano Espanol Nederlandse Por...

Page 23: ...ER TYPE OFF ON CONTINUOUS FLOW DETECT Example Off Alarm Based Cycle Based Time Based Volume Based Standby OFF ALARM BASED STANDBY AUXILIARY 1 Example Off Alarm Based Cycle Based Time Based Volume Based Standby OFF ALARM BASED STANDBY AUXILIARY 2 OFF ON SAVE AS NON FACTORY Example Off Delayed Enter Code Time Based OFF DELAYED TIME BASED LOCK SETTINGS ON OFF PUSH SETTINGS END PIPE SIZE inches GENERI...

Page 24: ...TION Off Off Delayed Immediate DAY OVERRIDE TIME DRIVEN 7 Off 99 Days REGEN TIME 02 00AM Any Time LOCK WINDOW 1 Off Off On LOCK WINDOW 2 Off Off On BACKWASH 10 M 0 240 Mins DRAW see data table 0 240 Mins RAPID RINSE 10 M 0 240 Mins REFILL see data table 0 240 Mins PAUSE 0 M 0 240 Mins METER TYPE Refer to K Factor Setting on Previous Page Generic Paddle 0 75 1 00 1 50 2 00 3 00 Turbine 0 75 1 00 1 ...

Page 25: ...ributor tube thru the bottom distributor and up thru the mineral around the piston and out the drain If optional no hard water by pass piston is used water flow to service outlet is prevented by an extension on the service outlet until the end of the rapid rinse cycle or brine tank refill cycle depending on options chosen Hard water enters at valve inlet flows thru injector nozzle and throat to dr...

Page 26: ...tion valve directly down thru the mineral into the bottom distributor up the distributor tube around the piston and out the drain Hard water enters at valve inlet flows thru nozzle and thru throat to brine valve to refill the brine tank Inlet flow also continues down thru mineral to the bottom distributor Conditioned water flows up thru the distributor tube around the piston and out the outlet Not...

Page 27: ...NCE 24 NXT2 WIRING DIAGRAM VDM VDM VDM IMPORTANT DO NOT USE P18 TO POWER NON PENTAIR DEVICES USE AUX1 AUX2 INSTEAD FLOW METER FM WIRING GROUND POWER SIGNAL FLECK BLACK RED GREEN SIGNET SHIELD BLACK RED CLACK BLACK RED WHITE AUTOTROL CLEAR RED BLACK ...

Page 28: ...WERHEAD ASSEMBLY 5 1 4 3 2 6 7 5 9 27 26 11 46 7 8 12 6 47 40 42 4 11 45 15 25 35 16 43 23 44 18 17 20 21 22 31 23 27 26 11 10 8 13 12 11 19 15 25 17 16 24 34 9 14 28 29 32 28 38 30 50 24 28 49 32 52 37 48 23 31 22 21 20 18 33 52 39 39 51 41 31 14 36 58 53 55 54 56 57 ...

Page 29: ...ee Service Assemblies on Page 41 Power Supplies See Service Assemblies on Page 41 Power Supplies See Service Assemblies on Page 41 36 1 19121 Meter Cable Assembly 19121 08 Meter Cable Assembly 35 inch long with connector 19121 09 Meter Cable Assembly 100 inch long with connector 19121 10 Meter Cable Assembly 304 inch long with connector 37 1 14202 01 Screw Hex Wsh 8 32 X 5 16 38 1 17421 Plug 1 20 ...

Page 30: ...ATING MAINTENANCE 27 NXT2 TIMER ASSEMBLY 2510 2750 2850 2900 3150 3900 VALVES Item No QTY Part No Description 1 1 62115 Timer Assy NXT2 Service Assemblies 2 1 62120 Control Panel Assy NXT2 Programmed 3 1 40941 Wire Harness Upper Drive ...

Page 31: ...M NXT2 3 TWIN ALTERNATING MAINTENANCE 28 3900 CONTROL VALVE BODY 1 2 3 4 5 6 7 8 9 11 13 14 15 16 17 18 21 22 23 24 25 27 28 29 30 31 32 33 36 35 34 10 6 12 20 26 24 29 24 16 17 19 2 3 2 2 4 2 3 37 38 39 40 41 42 43 ...

Page 32: ...3 1 16800 O ring 238 24 2 16345 O ring 362 25 1 16255 Tank Adapter 6 inch 8 26 2 16257 Flange Segment 27 12 11238 Screw Hex Head 28 1 16088 Pipe Plug 2 inch NPT 35 1 16258 Flow Disperser 37 60106 00 Piston Assy 3900 3150 STD 60106 10 Piston Assy 3150 Upflow 38 60131 Seal Spacer Kit 3900 Upper 3150 60131 10 Seal Spacer Kit Silicone Chemical Resistent 3900 Upper 3150 39 60107 00 Piston Assy 3900 HWB...

Page 33: ...MGT 240M 1200M NXT2 3 TWIN ALTERNATING MAINTENANCE 30 50 49 48 47 45 44 42 50 49 48 46 45 44 43 15 16 40 30 41 39 31 29 32 33 34 35 36 37 38 20 27 22 23 24 25 26 28 21 19 18 1800 BRINE SYSTEM ...

Page 34: ...crew Hex Wsh 10 24 x 5 8 7 1 16341 02 Plug Injector 1800 8 1 19054 O ring 021 560CD 9 1 16497 01 Stem Assy 1800 Brine Valve 10 1 18713 Brine Valve Body 1800 11 1 11772 Spring 3150 Brine Valve 12 1 11774 Ring Retaining 13 1 16498 01 Stem Guide Assy Brine 14 1 16387 Plug Pipe 1 2 inch NPT Item No QTY Part No Description 15 2 18702 Fitting Tube 1 2 NPT 5 8 16 1 18703 Tube Brine 5 8 OD Annealed 18703 ...

Page 35: ...ric 45 gpm 60812 50 DLFC 2 inch BSP Metric 50 gpm 60812 55 DLFC 2 inch BSP Metric 55 gpm 60812 70 DLFC 2 inch BSP Metric Item No QTY Part No Description Item No QTY Part No Description 70 gpm 60812 75 DLFC 2 inch BSP Metric 75 gpm 60812 80 DLFC 2 inch BSP Metric 80 gpm 60812 90 DLFC 2 inch BSP Metric 90 gpm 60812 95 DLFC 2 inch BSP Metric 95 gpm 60812 100 DLFC 2 inch BSP Metric 100 gpm 22 2 27913 ...

Page 36: ...60710 25 BLFC 1 inch F x 1 inch M NPT 25 gpm 44 16530 Housing BLFC 1 M x 1 F 45 19292 O ring 020 46 19279 Retainer Flow Control Flow 9 0 25 gpm 47 19053 Retainer Flow Control Flow 2 0 7 0 gpm 48 12085 Washer Flow 1 2 gpm 12087 Washer Flow 2 0 gpm 12088 Washer Flow 2 4 gpm 12089 Washer Flow 3 0 gpm 12090 Washer Flow 3 5 gpm 12091 Washer Flow 4 0 gpm 12092 Washer Flow 5 0 gpm 12408 Washer Fow 7 0 gp...

Page 37: ...ndard Range 61935 11 Meter Assy 3 Inch Inline Stainless Steel NPT Extended Range 61935 20 Meter Assy 3 Inch Inline Stainless Steel BSP Standard Range 61935 21 Meter Assy 3 Inch Inline Stainless Steel BSP Extended Range 3 1 19791 Meter Cable Assembly 19791 02 Meter Cable Assembly 28 inch long with connector 19791 04 Meter Cable Assembly 100 inch long with connector 19791 05 Meter Cable Assembly 304...

Page 38: ...ETER SETTINGS TEE GALVANIZED TEE PVC SADDLE IRON 1 213 352 1 1 4 128 177 1 1 2 94 118 2 59 67 54 2 1 2 43 38 3 27 23 K FACTOR TABLE SIGNET 2536 Pulses per Gallon ITEM NUMBER PART NUMBER DESCRIPTION 1 A2296001 Flow Sensor 2 A2456004 Rotor Paddle 3 A2294012 Tee Install 1 Galv A2294002 Tee Install 1 1 4 Galv A2294003 Tee Install 1 1 2 Galv A2294004 Tee Install 2 Galv 4 A2295001 Saddle 2 1 2 Iron A229...

Page 39: ...WS1 5 METER HOUSING NPT V3401 04 7 WS2 METER HOUSING NPT V3754 01 7 WS3 METER HOUSING NPT V3844 01 Not Shown A2503006 WS1 5 FLOW STRAIGHTENER V3437 Not Shown WS2 FLOW STRAIGHTENER V3488 Not Shown WS3 FLOW STRAIGHTENER V3602 K FACTOR TABLE pulses per gallon METER SIZE K FACTOR 1 1 2 37 2 20 3 8 NOTES 1 When installing the meter make sure the arrow on the meter body is going in the same direction as...

Page 40: ...019 Brine Valve 474 for MGT 300 B1180020 4 1 2 Overflow Elbow w Nut A2250003 5 5 x 46 Drilled Brine Well B1015008 6 5 Red Cap plug A2072001 7 1 1 2 SDR or SCH40 DWV Pipe A2275007 8 1 2 Poly Insert A2476001 9 1 2 x 3 8 Black Poly Tubing A2165002 10 Complete Brine Tank Assembly for MGT 240M 20 Shelf Height B1295019 Complete Brine Tank Assembly for MGT 270M 23 Shelf Height B1295020 Complete Brine Tan...

Page 41: ...ll B1015005 3 Brine Valve Assembly 16 1 4 x 24 B1042007 4 5 Red Cap plug A2072001 5 1 2 Overflow Elbow w Nut A2250003 6 30 Plastic Top Bottom Grid Plate A2284010 7 1 1 2 SDR or SCH40 DWV Pipe A2275007 8 1 2 Poly Insert A2476001 9 1 2 x 3 8 Black Poly Tubing A2165002 10 Complete Brine Tank Assembly for MGT 450M B1141009 4 5 1 6 3 7 8 9 2 10 BRINE SYSTEM MGT 450M ...

Page 42: ...10 1 4 X 30 B1042006 3 Grid Support Set 39 Dia 22 B1043009 4 Salt Shelf 38 1 8 Dia B1041003 5 Salt Screen 39 Dia B1040003 6 Brine Well 5 X 48 Slotted B1015005 7 Cap Brine Well Red 5 Inch A2072001 8 Brine Tank Overflow Assembly B1233003 9 Insert 1 2 Poly P8TS6 A2476001 10 Tubing 1 2x3 8 Black Poly H1041 A2165002 11 MGT 600M Brine Tank Assembly B1141005 7 1 6 8 2 4 5 3 9 10 11 ...

Page 43: ...T 750 B1040003 SALT SCREEN 42 DIA MGT 900 MGT 1200 B1041004 4 SALT SHELF 39 DIA MGT 750 B1041003 SALT SHELF 42 DIA MGT 900 MGT 1200 B1041003 5 GRID SUPPORT SET 39 HT MGT 750 B1043009 GRID SUPPORT SET 24 HT MGT 900 B1043030 GRID SUPPORT SET 29 HT MGT 1050 B1043011 GRID SUPPORT SET 33 HT MGT 1200 B1043013 6 BRINE WELL 5x46 DRILLED B1015008 7 CAPPLUG RED 5 INCH A2072001 8 ELBOW OVERFLOW 1 2 W NUT 2PC...

Page 44: ...t 60132 SERVICE EQUIPMENT A2475003 Seal Spacer stuffer tool upper 11098 A2474003 Spacer puller tool upper 12682 A2423002 Silicone 2 4 oz Tube BRINE LINE FLOW CONTROLS A2355006 1 Brine Line Fitting 2 gpm 60710 2 0 A2355011 1 Brine Line Fitting 5 gpm 60710 5 0 A2355017 1 Brine Line Fitting 10 gpm 60710 10 METER ASSEMBLIES A2360085 Fleck 3 Stainless Steel Meter Assy 61935 10 A2360072 Clack 3 Stainles...

Page 45: ...e For Error Correction Error Valve Count Mismatch Number of NXT2 detected does not match selected system type in Master Programming Push correct valve settings in Master Settings Motor Stall No Changes Detected in the Optical Sensor for 6 Seconds The motor is on but no encoder pulses are detected within a given duration while homing Check the P11 connection and trigger a manual regeneration Motor ...

Page 46: ...ke Sure Distributor Tube Is Not Cracked Check O Ring And Tube Pilot G Replace Seals and Spacers And Or Piston H Check Drive Motor And Switch 3 Unit Used Too Much Salt A Improper Salt Setting B Excessive Water in Brine Tank A Check Salt Usage and Salt Set ting B See Problem No 7 4 Loss Of Water Pressure A Iron Buildup In Line To Water Con ditioner B Iron Buildup in Water Conditioner C Inlet of Cont...

Page 47: ...rol Is Plugged B Injector Is Plugged C Injector Screen Plugged D Line Pressure Is Too Low E Internal Control Leak F Service Adapter Did Not Cycle A Clean Drain Line Flow Control B Clean Injector C Clean Screen D Increase Line Pressure To 20 P S I E Change Seals Spacers and Piston Assembly F Check Drive Motor And Switches 9 Control Cycles Continuously A Misadjusted Broken or Shorted Switch A Determ...

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