Page 1
MP-MCA Top Mount Water Softeners
Installation and Operation Manual
with MCA100 Control Valve
July 2014 Version
Page 2
Table of Contents
Page
No.
1
Performance Data Sheet
MP-MCA-30T
2
Performance Data Sheet
MP-MCA-45T
3
Performance Data Sheet
MP-MCA-60T
4
Model # and Packaging
Packaging Information
Component Packaging Description
Packaging Description
5
Certification
NSF/ANSI 44 Information
Softening System
System Positioning
6
MP-MCA Control Valve
Attaching Valve to Tank
MP-MCA Control Valve
Attaching Valve, cont’d
7
Service & Drain Piping
Drain Piping
8
Service & Drain Piping, cont’d
Drain Piping
9
System Schematic
Piping Layout
10
Electrical Supply
Electrical Requirements
Brine Tank / Brine Tubing
Brine tank w/shut off
11
Filling Softener with Water
Details for Filling Softener Tank with Water
12
MP-MCA-Control Valve Timer
Setting the timer
13
Final Check
Final Install ati on Chec k
Disinfection
Conditioner Disinfection
14
Manual Regeneration
Instructions for Manual Regeneration
Power loss/ Error codes
“What if” Instructions
15
Bypass
Bypass Operation
16
Troubleshooting
Problem/ Cause / Solution
17
Troubleshooting
Problem/ Cause / Solution
18
Troubleshooting
Problem/ Cause / Solution
19
Error Code Troublesho oti ng
Problem/ Cause / Solution
20
Error Code Troublesho oti ng , cont’d
Problem/ Cause / Solution, cont’d
21
Valve Parts List
Part Numbers List
22
Valve Parts List
Part Numbers List
23
Valve Parts List
Part Numbers List
24
Valve Parts List
Part Numbers List
25
Valve Parts List
Part Numbers List
26
Valve Parts List
Part Numbers List
27
Valve Parts List
Part Numbers List
28
Warranty
Warranty
Topic Description
Page 3
Performance Data Sheet
Model Number MP-MCA-30T
Rated Service Flow (gpm) 17.8
Pressure Drop at Rated Service Flow
Rate (psi)
15
Rated Softening Capacity (KGrains) 18.8 @ 4.5 lbs salt
20.0 @ 6.0 lbs salt
28.9 @ 15.0 lbs salt
Efficiency at the 1.0 lb. Salt setting
4186
(Grains/lbs salt)
Min.-Max. Working Pressure (psi) 20 to 100
Min.-Max. Operating Temperature
(°F)
Max. Flow Rate (gpm) to Drain
During Regeneration Cycle
Amount of High Capacity Resin
(cu ft)
These softeners conform to NSF/ANSI 44 for the specific performance claims as verified and substantiated by
test data. These models are efficiency rated. The efficiency rating is valid only at the stated salt dose and
maximum service flow rate. They have a demand initiated regeneration (D.I.R.) feature that complies with
specific performance specifications intended to minimize the amount of regenerant brine and water used in their
operation. These softeners have a rated softener efficiency of not less than 3350 grains of total hardness
exchange per pound of salt (based on sodium chloride) and shall not deliver more salt than their listed ratings.
The rated salt efficiency is measured by laboratory tests described in NSF/ANSI Standard 44. These tests
represent the maximum possible efficiency that the systems can achieve. Operational efficiency is the actual
efficiency after the system has been installed. It is typically less than the efficiency due to individual application
factors including water hardness, water usage, and other contaminants that reduce the softener’s capacity. These
systems are not intended for use with water that is microbiologically unsafe or of unknown quality without
adequate disenfection before or after the system. Refer to Installation/operation manual and warranty for further
details on installation, parts and service, maintenance and further restrictions or limitations to the use of the
product.
Master Water Conditioning
224 Shoemaker Rd.
Pottstown, PA 19464
610.323.8358
610.323.5526
www.masterwater.com
35 to 100
1.7
1.0
1
Page 4
Performance Data Sheet
Model Number MP-MCA-45T
Rated Service Flow (gpm) 15.4
Pressure Drop at Rated Service Flow
Rate (psi)
15
Rated Softening Capacity (KGrains) 28.3 @ 6.75 lbs salt
30.0 @ 9.0 lbs salt
43.4 @ 22.5 lbs salt
Efficiency at the 1.0 lb. Salt setting
4186
(Grains/lbs salt)
Min.-Max. Working Pressure (psi) 20 to 100
Min.-Max. Operating Temperature
(°F)
Max. Flow Rate (gpm) to Drain
During Regeneration Cycle
Amount of High Capacity Resin
(cu ft)
These softeners conform to NSF/ANSI 44 for the specific performance claims as verified and substantiated by
test data. These models are efficiency rated. The efficiency rating is valid only at the stated salt dose and
maximum service flow rate. They have a demand initiated regeneration (D.I.R.) feature that complies with
specific performance specifications intended to minimize the amount of regenerant brine and water used in their
operation. These softeners have a rated softener efficiency of not less than 3350 grains of total hardness
exchange per pound of salt (based on sodium chloride) and shall not deliver more salt than their listed ratings.
The rated salt efficiency is measured by laboratory tests described in NSF/ANSI Standard 44. These tests
represent the maximum possible efficiency that the systems can achieve. Operational efficiency is the actual
efficiency after the system has been installed. It is typically less than the efficiency due to individual application
factors including water hardness, water usage, and other contaminants that reduce the softener’s capacity. These
systems are not intended for use with water that is microbiologically unsafe or of unknown quality without
adequate disenfection before or after the system. Refer to Installation/operation manual and warranty for further
details on installation, parts and service, maintenance and further restrictions or limitations to the use of the
product.
Master Water Conditioning
224 Shoemaker Rd.
Pottstown, PA 19464
610.323.8358
610.323.5526
www.masterwater.com
35 to 100
1.7
1.5
2
Page 5
Performance Data Sheet
Model Number MP-MCA-60T
Rated Service Flow (gpm) 18.3
Pressure Drop at Rated Service Flow
Rate (psi)
15
Rated Softening Capacity (KGrains) 37.7 @ 9.0 lbs salt
40.0 @ 12.0 lbs salt
57.9 @ 30.0 lbs salt
Efficiency at the 1.0 lb. Salt setting
4186
(Grains/lbs salt)
Min.-Max. Working Pressure (psi) 20 to 100
Min.-Max. Operating Temperature
(°F)
Max. Flow Rate (gpm) to Drain
During Regeneration Cycle
Amount of High Capacity Resin
(cu ft)
These softeners conform to NSF/ANSI 44 for the specific performance claims as verified and substantiated by
test data. These models are efficiency rated. The efficiency rating is valid only at the stated salt dose and
maximum service flow rate. They have a demand initiated regeneration (D.I.R.) feature that complies with
specific performance specifications intended to minimize the amount of regenerant brine and water used in their
operation. These softeners have a rated softener efficiency of not less than 3350 grains of total hardness
exchange per pound of salt (based on sodium chloride) and shall not deliver more salt than their listed ratings.
The rated salt efficiency is measured by laboratory tests described in NSF/ANSI Standard 44. These tests
represent the maximum possible efficiency that the systems can achieve. Operational efficiency is the actual
efficiency after the system has been installed. It is typically less than the efficiency due to individual application
factors including water hardness, water usage, and other contaminants that reduce the softener’s capacity. These
systems are not intended for use with water that is microbiologically unsafe or of unknown quality without
adequate disenfection before or after the system. Refer to Installation/operation manual and warranty for further
details on installation, parts and service, maintenance and further restrictions or limitations to the use of the
product.
Master Water Conditioning
224 Shoemaker Rd.
Pottstown, PA 19464
610.323.8358
610.323.5526
www.masterwater.com
35 to 100
2.7
2.0
3
Page 6
Installation and Operating Instructions for
MP-MCA CONTROL
Top Mount Water Softener
Model #:
_______ MP-MCA-30T CS * 1.0 CF Crawl Space Water Softener
_______ MP-MCA-30T 1.0 CF Water Softener
_______ MP-MCA-45T 1.5 CF Water Softener
_______ MP-MCA-60T 2.0 CF Water Softener
*Not Tested or certified to NSF/ANSI Standard 44
Shipping Carton Description / unit:
# of
Contents Description
cartons
1 Mineral tank Distributor pipe installed
1 Brine tank
464 shutoff valve assembly. *NOTE:
MP-MCA valve is shipped in brine tank.
1 MP-MCA control
valve
MP-MCA timer and backwash flow
control and bypass with 1” copper or
pvc connection
C-800 Pre-loaded @ factory
NOTE: THIS SOFTENER IS NOT INTENDED TO BE USED FOR TREATING WATER THAT
IS MICROBIOLOGICALLY UNSAFE OR OF UNKNOWN QUALITY WITHOUT
ADEQUATE DISINFECTION WHETHER BEFORE OR AFTER THE SYSTEM.
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NOTE: The model MP-MCA-30T has been tested and certified by the Water Quality
Association according to NSF/ANSI 44 for the specific performance claims as verified
and substantiated by test data as follows:
Rated Efficiency: 4186 Grains per pound of salt
4.5 lbs salt: 18.8 Kg Capacity
6 lbs salt: 20.0 Kg Capacity
15 lbs salt: 28.9 Kg Capacity
Rated Service Flow: 17.8 GPM @ 15 psi pressure drop
Resin: 1.0 Cubic Ft. Cation Exchange resin
NOTE: The model MP-MCA-45T has been tested and certified by the Water Quality
Association according to NSF/ANSI 44 for the specific performance claims as verified
and substantiated by test data as follows:
Rated Efficiency: 4186 Grains per pound of salt
6.75 lbs salt: 28.3 Kg Capacity
9 lbs salt: 30.0 Kg Capacity
22.5 lbs salt: 43.4 Kg Capacity
Rated Service Flow: 15.4 GPM @ 15 psi pressure drop
Resin: 1.5 Cubic Ft. Cation Exchange resin
NOTE: The model MP-MCA-60T has been tested and certified by the Water Quality
Association according to NSF/ANSI 44 for the specific performance claims as verified
and substantiated by test data as follows:
Rated Efficiency: 4186 Grains per pound of salt
9 lbs salt: 37.7 Kg Capacity
12 lbs salt: 40.0 Kg Capacity
30 lbs salt: 57.9 Kg Capacity
Rated Service Flow: 18.3 GPM @ 15 psi pressure drop
Resin: 2.0 Cubic Ft. Cation Exchange resin
Water Softener Positioning:
1. Place water softener in desired position, far enough from walls and
other obstructions to allow for servicing the unit.
2. Place the water softener within reasonable access to a grounded
115V/60 HZ circuit and a legal drain line connection.
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MP-MCA Control Valve:
1. When facing the front of the MP-MCA timer, the inlet connection is
located on the right and the outlet connection is on the left. The
control valve's inlet and outlet connections are either 1” copper or
PVC equipped with split ring and nut.
Control Valve
Front View Top View
2. Turn the control valve upside down and ensure that the control
valve distributor o’ring is in place. Use silicone lubricant on the
o'ring.
**DO NOT USE PETROLEUM!**
**USE ONLY SILICONE **
3. Place the control valve onto the distributor pipe and into the tank
opening.
4. Thread the control valve hand tight . Do not overtighten.
4. Locate the bypass valve assembly that is packaged with the
control valve. The bypass valve has two red handles that
indicate flow direction, two threaded connections for the tail
piece kit and two o’ring seal connections with nuts for the control
valve. Align the insert connection ends with o’ring seals and
nuts to the inlet and outlet connections of the control valve.
Hand tighten the nuts. DO NOT OVERTIGHTEN THE NUT!
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Bypass Valve
Control Valve
Tail piece assembly
5. Locate the tail piece kit that is packaged with the control valve.
The standard tail piece kit is 1” copper with optional 1”/ 3/4” PVC or
¾” copper kits available as a special order. Each tail piece,
o’ring, split ring and nut is presassembled at the factory. Align a
tail piece assembly to the bypass valve threaded inlet and insert
until the nut can be tightened. Hand tighten the nut because
excessive tightening will damage the assembly. REPEAT THE
PROCEDURE FOR THE OUTLET CONNECTION.
Service and Drain Piping:
1. Pipe water softener into the service lines .The inlet and outlet
connections of the control valve are 1” copper or PVC and are
located on the back of the valve body. As you face the timer the inlet
is on the right and the outlet is on the left. Always follow local
plumbing codes when installing our water treatment equipment.
2. If sweat fittings are used, be sure soldering is done in such a manner
as not to allow heat to reach the control valve or bypass. (If
Schedule 80 PVC is used make sure to follow the proper primer and
solvent instructions.)
3. The drain line connection is 5/8” OD or ¾” npt and is located on the
top left of the valve as you face the timer. It is recommended you
install a ¾” union on the drain line for servicing if not using 5/8 OD.
The drain line must be of adequate size to allow for full regeneration
flow.
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DRAIN LINE
CONNECTION
• The control valve drain connection is 3/4" npt.
• Never decrease the drain piping size to below the
drain connection size.
• Maximum drain line length is 30 feet with proper
sloping the entire length.
• Maximum drain line height is 6 feet above the control
valve.
• The drain line must be piped to an open air gap (See
Figure above)
• Always follow local plumbing codes.
UNDER NO CIRCUMSTANCES SHOULD THERE BE A DIRECT
CONNECTION WITH SANITARY SEWAGE FACILITIES.
NOTE: The drain flow rate during regeneration (backwash)
will be:
MP-MCA-30T 1.7 GPM
MP-MCA-45T 1.7 GPM
MP-MCA-60T 2.7 GPM
*NOT TESTED OR CERTIFIED TO NSF/ANSI STANDARD 44
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Page 11
Treated
Air Gap Drain
MASTER
Water Conditioning Corp.
Water Conditioning Corp.
Water Conditioning Corp.Water Conditioning Corp.
TYPICAL PIPING LAYOUT FOR
MP-MCA SERIES SOFTENER
Untreated
Master Water
Conditioner
Overflow
fitting to
floor drain
gravity
Brine tank
NOTE: All Master Water Conditioners must be
installed after the well tank or water meter if its
Temperature : MAX: 120 F, MIN: 34F
Pressure: MAX: 100 PSI, MIN: 20 PSI
Electrical: 115V/ 60 HZ
9
public water supply.
Well Tank
Page 12
Electrical Requirements:
Always follow all local electrical codes when installing our water
treatment equipment.
1. Provide an 115v/60Hz properly grounded dedicated electrical
Outlet. (It’s very important that the polarity be correct)
Avoid using outlets that are switch controlled.
2. Maximum amperage required is 5 amps.
3. Make sure the electrical service provides power 24 hours per day.
We recommend installing a surge protector to protect unit from
power surges, which are not covered by warranty.
Brine Tank:
1. The brine tank should be located directly beside the water softener
mineral tank.
2. Connect the 3/8" poly tubing to the 3/8” black elbow quick-connect
fitting located on the top left side of the MCA control valve.
See Figure Below.
3/8” BRINE LINE
CONNECTION
The brine tank is equipped with a shutoff valve, the float height
was preset at the factory.
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Filling Water Softener with Water:
1. Connect the MP-MCA control valve transformer into the electrical
outlet provided.
2. Press and hold the REGEN button until the drive motor starts. When
the drive motor stops, the display will read “BACKWASH” position.
3. Open the inlet ball valve a ¼ turn of its full open position to allow
water to enter the water softener mineral tank slowly. The water is
going to enter the tank from the bottom of the distributor pipe and
leave the tank from the top. This will slowly purge all the air from the
tank.
IF WATER ENTERS THE TANK TOO FAST, ALL THE CATION
RESIN WILL BE FLUSHED TO DRAIN DURING START UP.
4. When only water is running to the drain, open the inlet and outlet ball
valves fully.
5. Press the REGEN again until the drive motor starts. When the drive
motor stops, the display will read “BRINE” position.
6. Press the REGEN button until the drive motor starts. When the drive
motor stops, the display will read “RINSE” position. The fast rinse
position will rinse the softener tank.
7. The control valve will automatically advance to the brine refill position
where the brine tank will fill with the proper amount of water. The
display will read “REFILL”.
NOTE: THE TIMER WILL AUTOMATICALLY ADVANCE TO THE
SERVICE POSITION AND THE DISPLAY WILL READ THE CAPACITY
REMAINING, IN GALLONS.
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Page 14
MP-MCA Control Valve Timer Settings:
Note: The control valve is set at the factory. You only need to set the
time of day , hardness and regeneration time if required, which is preset
at 2 am.
Time of Day Setting
1) Press the CLOCK button. The screen will show the Time of Day
in blinking numbers.
2) To change the Time of Day, use the UP and DOWN arrows to set
the Hour.
3) To change the Minutes, press the CLOCK button, and use the UP
and DOWN arrows to set the Minutes
4) Press the CLOCK button.
Hardness Setting (the factory default is 10)
1) Press the NEXT and UP arrow, hold for 3 seconds. The screen
will show the Hardness as grains per gallon in blinking numbers.
2) To change the number, use the UP or DOWN arrows.
3) Press the NEXT button.
If water was tested by Master Water Conditioning, follow
recommendations on water analysis, for hardness setting
Regeneration Day Override Setting (the factory default is OFF)
1) The screen will show the Regeneration Day Override in blinking
numbers.
2) To change the number, use the UP or DOWN arrows.
3) Press the NEXT button.
Time of Regeneration Setting (the factory default is 2 AM)
1) The screen will show the Time of Regeneration in blinking
numbers.
2) If Regeneration time change is desired, use the UP or DOWN
arrows to set the hour.
3) Press the NEXT button, and use the UP or DOWN arrows to set
the minutes.
4) Press the NEXT button.
NOTE: SALT SETTING AND CAPACITY ARE PRESET AT THE
FACTORY.
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Final Check:
1. Fill the brine tank with Solar Salt and the Res-Up Feeders with ResUp (one quart is provided).
2. Make sure the drain line connection meets all plumbing codes and
that the drain line size can handle the backwash flow rate of the
softener.
3. Make sure the Inlet and Outlet on bypass valve are open.
4. Make sure the control valve timer is plugged into an electrical outlet
with power 24 hours per day.
5. Check all piping for leaks.
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Page 16
Manual Regeneration:
Note: For softeners, if brine tank does not contain salt, fill with salt
and wait at least 2 hours before regeneration.
To initiate manual regeneration immediately, press and hold the
“REGEN” button for three seconds. The system will begin to regenerate
immediately. The request cannot be cancelled.
To initiate a manual regeneration at the preset delayed regeneration
time, when the regeneration time option is set to “NORMAL” or
“NORMAL + on 0”, press and release “REGEN”. The words “REGEN
TODAY” will flash on the display to indicate that the system will
regenerate at the preset delayed regeneration time. If you pressed
“REGEN” in error, pressing the button again will cancel the request.
Note: If the regeneration time option is set to “on 0” there is no set
delayed regeneration time so “REGEN TODAY” will not activate if
“REGEN” button is pressed.
Power Loss
If the power goes out for less than two hours, the system will
automatically reset itself. If an extended power outage occurs, the time
of day will flash on and off which indicates the time of day should be
reset. The system will remember the rest.
Error Message
If the word “ERROR” and a number are alternately flashing on the
display, contact a service technician for help. This means the valve is
unable to function properly. ( See page 21 )
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15
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Troubleshooting
Symptom: Water conditioner fails to regenerate.
Possible Cause Solution
Power supply to MP-MCA125
control has been interrupted.
Water pressure lost Restore water pressure.
Control valve has incorrect
program values.
Meter clogged Remove meter and clean.
Defective control. Replace control assembly.
No Solar Salt in brine tank Add Solar Salt, wait 4 hours and
Insufficient Solar Salt Check brine float height and clean
Manual bypass valve is open. Close manual bypass valve.
Leak at riser pipe seal Insure that riser pipe is properly sealed
Plugged injector or injector screen Inspect and clean injector and/or
Symptom: No Brine Draw
Determine reason for power
interruption and correct. Reset time of
day.
Reset values.
regenerate.
assembly if necessary. Check flow
rate capabilities of safety float and air
check assembly.
at o’ring seal. Inspect pipe for cracks.
injector screen.
Possible Cause Solution
Plugged injector or injector screen Inspect and clean injector and/or
Insufficient water pressure Increase water pressure above 25
Obstructed drain line Remove obstruction.
16
injector screen.
psig (172kPa) minimum.
Page 19
Symptom: Insufficient Brine draw
Possible Cause Solution
Partially clogged injector or injector
screen
Inspect and clean injector and/or
injector screen assembly.
Restricted flow rate in brine line Check flow rate capabilities of the
safety float/aircheck assembly.
Insufficient water pressure Increase water pressure above 25
psig (172kPa) minimum.
Excessive back pressure on
injector due to elevated drain line
Reduce drain line elevation to height
of valve.
Damaged piston assembly Inspect and if damaged replace the
piston assembly.
Control valve has incorrect program
Reset values.
values.
Partially restricted drain line Remove restriction.
Symptom: Insufficient Refill to Brine Tank
Possible Cause Solution
Control valve has incorrect program
Reset values.
values.
Restricted flow rate in brine line Check flow rate capabilities of the
safety float/aircheck assembly.
Problem: Leak to Drain
Possible Cause Solution
No flow control installed in drain
Install drain line flow control.
line.
Insufficient water pressure. Increase water pressure above 25
psig (172kPa) minimum.
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Page 20
Symptom: Excessive Water in Brine Tank
Possible Cause Solution
Plugged drain line flow control Clean flow control.
Control valve has incorrect program
Reset values.
values.
Plugged injector and/or injector
screen
Inspect and clean injector and/or
screen.
Symptom: Loss of Media to Drain
Possible Cause Solution
No flow control installed in drain
Install drain line flow control.
line
Symptom: Loss of Water Pressure
Possible Cause Solution
Fouled softener media bed due to
Replace media bed.
iron accumulation or chlorine.
Slots in riser pipe or laterals are
filled with softener media fines.
Inspect and clean distributor pipe slots
as needed.
Symptom: Brine in Water to Service After Regeneration
Possible Cause Solution
Injector is too small for system size. Install correct injector.
Plugged injector and/or injector
screen
Brine draw time excessively long
due to low water pressure
Inspect and clean injector and/or
injector screen.
Increase water pressure above 25
psig (172 kPa) minimum.
Restricted drain line Remove drain line restriction.
Insufficient rinse volume Increase slow rinse time, fast rinse
time, or both.
Damaged piston assembly or
spacer kit
Control valve has incorrect program
Inspect and if damaged replace the
piston assembly.
Reset values.
values.
18
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ERROR CODES
19
Page 22
20
Page 23
21
Page 24
22
Page 25
23
Page 26
24
Page 27
25
Page 28
26
Page 29
27
Page 30
MASTER
Water Conditioning Corp.
12 YEAR LIMITED WARRANTY
As of Oct. 1, 1995
This Residential Water Conditioner is warranted for a period of one year from date of
purchase by first user against defects in materials and workmanship. In addition, the complete
control valve is warranted for five years. The control valve body (excluding internals and electrical
parts) is warranted for six years. The mineral tank, plastic brine tank or cabinet tank (excluding
mineral) is warranted against rust, corrosion or bursting for a period of twelve years from date of
manufacture. Except, as specifically set forth in this paragraph, Master Water Conditioning
Corporation makes no other warranties, express or implied.
This warranty shall be void if the conditioner is moved from the place of original installation,
or if damage is caused by misuse, misapplication, accident, freezing, flood, fire or if not installed in
accordance with instructions furnished by Master Water Conditioning Corporation.
This warranty shall be void in the event of damages from external sources or where the
conditioner has been operated at pressure in excess of 100 pounds per square inch or at a temperature
greater than 100 degrees F. or less than 32 degrees F. Incidental costs or consequential damages are
not covered by this warranty.
All defective parts shall be returned prepaid to Master Water Conditioning Corporation for
inspection. Master shall not be liable for labor charges other than Master factory repairs.
This warranty gives you specific legal rights, and you may have other rights which vary from
state to state. Some states do not allow limitations on duration of implied warranties or exclusion of
incidental or consequential damages, so the above limitations may not apply to you.
All claims must be submitted in writing to Master Water Conditioning Corporation at 224
Shoemaker Road, Pottstown, Pennsylvania 19464 within thirty (30) days from the discovery of the
defect. Master Water Conditioning Corporation thereafter will correct defective parts and
workmanship or rusting, corrosion or bursting within sixty (60) days.
224 Shoemaker Rd. Pottstown, Pa. 19464
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