Watts Autotrol Magnum User Manual

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Magnum Cv and Magnum IT Valves

Installation and Service Manual

Section

1.0 Installation Profile Summary - - - - - - - - - - - - - - - - - - - - - - - - - - - 1

2.0 Introduction to the Magnum Cv and Magnum IT Series - - - - - - - - - - - - - - - 2

2.1 Assembling the Control to the Valve - - - - - - - - - - - - - - - - - - - - 3

2.2 General Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - 7

2.3 Dimensional Specifications - - - - - - - - - - - - - - - - - - - - - - - - 8

3.0 General Installation Information - - - - - - - - - - - - - - - - - - - - - - - - - 10

3.1 Typical Installation Drawings - - - - - - - - - - - - - - - - - - - - - - - 12

4.0 Flow Diagrams - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13

5.0 Control Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19

5.1 Manual Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19

5.2 Mechanical Control - - - - - - - - - - - - - - - - - - - - - - - - - - - 24

5.2.1 Common Settings - - - - - - - - - - - - - - - - - - - - - - - 24

5.2.2 Regenerating Iron Filter - - - - - - - - - - - - - - - - - - - - - 25

5.2.3 Backwashing Filter - - - - - - - - - - - - - - - - - - - - - - - 25

5.2.4 Salt Use Table - - - - - - - - - - - - - - - - - - - - - - - - - 26

5.2.5 Potassium Permanganate Use Table- - - - - - - - - - - - - - - 27

5.3 Impulse Controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28

5.4 Electronic Controls- - - - - - - - - - - - - - - - - - - - - - - - - - - - 29

5.4.1 Connecting the 962 Control- - - - - - - - - - - - - - - - - - - 31

5.4.2 Connecting the 962M and the 962S Control - - - - - - - - - - - 32

5.4.3 Connecting the 962 Twin and Triple Parallel Control- - - - - - - - 33

6.0 Programming Tables for Electronic Controls - - - - - - - - - - - - - - - - - - - 34

6.1 Table I - Level I Values - - - - - - - - - - - - - - - - - - - - - - - - - - 34

6.2 Table IIA - Level II Program Values 962 Single Twin or Triple Parallel Tank Softener or Dealkalizer - - - - - - - - - - - - - - - - - - - - - - - 35

6.3 Table IIB - Level II Program Values 962F

Single Tank Filter Mode Parameters - - - - - - - - - - - - - - - - - - - 36

6.4 Table IIC - Level II Program Values 962 Twin Tank Alternating

Softener - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 37

6.5 Table IID - Level II Program Values - Electronic Timeclock

Filter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 38

6.6 Table IIE - Level II Program Values - Electronic Timeclock

Softener - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 39

6.7 Explanation of Parameter Values for the 962 Single and Parallel

Tank Controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40

6.8 New Features in the 962 Family Controls - - - - - - - - - - - - - - - - - 42

6.9 Table III Historical Data - - - - - - - - - - - - - - - - - - - - - - - - - 43

6.10 Table IV Error Messages - - - - - - - - - - - - - - - - - - - - - - - - 44

7.0 Multi-Tank Systems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 45

7.1 Twin Alternating - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 45

7.1.1 Control Set-up - - - - - - - - - - - - - - - - - - - - - - - - - 46

7.1.2 Additional Checks - - - - - - - - - - - - - - - - - - - - - - - 47

7.2 Twin and Triple Parallel - - - - - - - - - - - - - - - - - - - - - - - - - 48

7.2.1 Control Set-up - - - - - - - - - - - - - - - - - - - - - - - - - 50

8.0 Start-Up Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 51

9.0 Service Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 52

9.1 Magnum Valve Cartridge Removal Procedure - - - - - - - - - - - - - - - 54

10.0 Performance Data - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55

10.1 Injector Data- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55

10.2 Refill Control Chart (P6 Values) - - - - - - - - - - - - - - - - - - - - - 57

10.3 Injector Chart (P7 Values) - - - - - - - - - - - - - - - - - - - - - - - - 58

10.4 Drain Line Flow Control Chart- - - - - - - - - - - - - - - - - - - - - - 59

10.5 Autotrol Drain Line Flow Controls (5 gpm - 40 gpm)- - - - - - - - - - - - 60

11.0 Wiring Diagrams - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61

11.1 962 Series Remote Start - - - - - - - - - - - - - - - - - - - - - - - - 61

11.2 952 Impulse - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 62

11.3 952 QC Impulse - - - - - - - - - - - - - - - - - - - - - - - - - - - - 62

11.4 962 Twin and Triple Parallel - - - - - - - - - - - - - - - - - - - - - - - 63

11.5 962 Twin Alternating - - - - - - - - - - - - - - - - - - - - - - - - - - 64

12.0 Assembly Drawings and Parts Lists - - - - - - - - - - - - - - - - - - - - - - 65

12.1 942Man and 942FMan Manual Controls - - - - - - - - - - - - - - - - - 65

12.2 942 and 942F Timeclock Controls - - - - - - - - - - - - - - - - - - - - 66

12.3 952,952F, and 952QC Impulse Controls - - - - - - - - - - - - - - - - - 67

12.4 962, 962F, 962TC, 962FTC, 962M, and 962S Electronic Controls - - - - - 69

12.5 Injector Assemblies - - - - - - - - - - - - - - - - - - - - - - - - - - 72

12.6 Refill Control Assemblies - - - - - - - - - - - - - - - - - - - - - - - - 73

12.7 2-inch Turbine Assembly - - - - - - - - - - - - - - - - - - - - - - - - 74

12.8 Installation Adapters - - - - - - - - - - - - - - - - - - - - - - - - - - 75

12.9 Valve Cartridges - - - - - - - - - - - - - - - - - - - - - - - - - - - - 77

12.10 Cam and Pilot Valve Assemblies - - - - - - - - - - - - - - - - - - - - 78

12.11 Kits and Assemblies - - - - - - - - - - - - - - - - - - - - - - - - - - 80

12.12 962 Optional Switch Kits Available - - - - - - - - - - - - - - - - - - - 81

1.0 Installation Profile Summary

Installation Date: ______________________________

Installation Location: ___________________________

Installer(s): ____________________________________

Phone Number:________________________________

Valve Number:_________________________________

Application Type: (Softener) (Filter) (Dealkalizer)

Water Source:

(Public Well) (Private Well)

(Surface Supply)

(Other)

Water Test Results:

Hardness:_______________ Iron:_______________

Other: ________________________________________

Misc:

Capacity: _______ Flow Rates:______ min. ____ max.

Tank Size: Diameter ________ Height: __________

Resin or Media Volume:_________________________

Resin or Media Type: ___________________________

Brine Tank Volume:_____________________________

Salt Setting per Regeneration: ___________________

Control Valve Configuration:

Valve Type:____________________________________

Impulse

(480) (Other) ___________________________________

Salt Setting:____________________________________

Electronic Demand Settings

P1 Time of Day _________________

P2 Time of Day Regen _________________

P3 Hardness of Water _________________

P4 Salt Amount _________________

P5 Capacity of Unit _________________

P6 Refill Control Value _________________

P7 Brine Draw Value _________________

P9 Backwash Time _________________

P10 Slow Rinse Time _________________

P11 Fast Rinse Time _________________

P12 Units of Measure _________________

P13 Clock Mode _________________

P14 Calendar Override _________________

P15 Reserve Type _________________

P16 Fixed Reserve Cap.

or Initial Ave. Value _________________

P17 Operation Type _________________

P18 Salt Change Lock Out _________________

P19 Flow Sensor Size _________________

(Hard Water Bypass) (No Hard Water Bypass)

Refill Control:______________________________ gpm

Injector Control: ___________________________ gpm

Backwash Control: _________________________ gpm

Manual Control:

(Softener) (Filter)

Mechanical Timeclock:

(7 day) (12 day)

Salt Setting: __________________________________

Regeneration Frequency:

SM T W T F S

123456789101112

______________________________________________

P20 K-Factor or Pulse

Equivalent _________________

P21 Remote Regeneration

Switch Delay _________________

P22 Factory Use Only _________________

Twin Parallel Triple Parallel

Regeneration Type (P15): ___________

3 = Fixed Reserve with Immediate Regeneration

Fixed Reserve (P16):____________% (0% only)

Twin Alternating

Regeneration Type (P15): ___________

0 = Immediate Regen 1 = Delayed Regen

Fixed Reserve (P16): _____________ %

2.0 Introduction to the Magnum Cv and Magnum IT Series

The Magnum Cv

and Magnum ITTM Series valves offer a high degree of installation simplicity and flexibility. Figure 2.1 provides an overview of the major components and connections of the 2-inch (5.08-cm) Magnum IT valve.

Magnum IT Series Valve

The Magnum valve is available in either a 1-1/2-inch (3.81-cm) (Magnum Cv

) or a 2-inch (5.08-cm) (Magnum IT™) configuration. Throughout this manual, the 2-inch (5.08-cm) Magnum Cv is shown in illustrations where the model type is irrelevant to what is being demonstrated.

Figure 2.1

Internal Turbine Assembly

2.1 Assembling the Control to the Magnum Valve

The control and the Magnum valve work together as an integral system to ensure synchronization. Follow the steps outlined below to install the control on the Magnum valve.

Remove Cam Cover

Remove the cam cover by pressing in on the cover release tabs (Figure 2.2). Note the cover locking tab and the slot in the top plate. When you reassemble the cover, the locking tab is placed in the slot first and the cover lowered into position.

Locking Tab and Slot

Slide Camshaft

Slide the camshaft toward the back of the valve by pressing on the release tab and pulling on the back end of the camshaft (Figure 2.4). The front end of the camshaft will be flush with the mounting plate.

Release Tabs

Figure 2.4

Mount Control

Mount the control onto the valve by sliding the mounting tabs over the mounting plate. Note that all models of Magnum controls mount to the valve in the same manner (Figure 2.5).

Cover Release Tabs

Figure 2.2

Align Camshaft

The camshaft is keyed and should only be engaged or disengaged when in the position illustrated (Figure 2.3). If the camshaft is not in the proper position, rotate the cam assembly counterclockwise until the camshaft arrow aligns with pillow block arrow.

Camshaft Arrow

Figure 2.3

Pillow Block Arrow

Mounting Tabs

Mounting Plate

Figure 2.5

Engage Assembly

Engage the control by pressing on the release tab and pushing the camshaft into the control (Figure 2.6). Do not force the camshaft. If the camshaft does not slide freely into the control, check the alignment of the camshaft to ensure it is in the proper position (Figure 2.3). The control indicator must be in the REGENERATION COMPLETE position for the 942, 942Man, 952, and 962 when engaging the camshaft into the control. The control indicator must be in the BACKWASH COMPLETE position for the 942F, 942FMan 952F, and 962F when engaging the camshaft

into the control. The control indicator must be in the midpoint of the SERVICE position for the 962M and 962S when engaging the camshaft into the control.

Release Tab and Camshaft

Figure 2.6

Important:

When 942, 942Man, 952, or 962 controls are installed, control dials must be in the REGENERATION COMPLETE position.

When 942F, 942FMan, or 952F controls are installed, control dials must be in the BACKWASH COMPLETE position.

When 962M or 962S controls are installed, control dials must be in the SERVICE position.

Figure 2.7

No Hardwater Bypass Feature

The Magnum control valve may be configured for “Hard Water Bypass” or “No Hard Water Bypass”. With Hard Water Bypass, unsoftened or unfiltered water is allowed to bypass the Magnum control valve during regeneration or backwash. With No Hard Water Bypass, a valve cartridge ensures that no unsoftened or unfiltered water bypasses the valve during regeneration or backwash.

It is easy to observe which option is installed in the valve. Note that the Hard Water Bypass End Cap has much longer standoffs than the No Hard Water Bypass cartridge. The No Hard Water Bypass assembly will look identical to the other three valve cartridges on the valve and will have a label identifying the cartridge assembly (Figure 2.8).

No Hard Water Bypass No Unfiltered Water Bypass

Normal Standoffs

To disassemble the control from the valve, reverse the assembling procedure.

Inlet, Outlet and Drain Connections

The inlet, outlet, and drain connections are designed to accept an GE Osmonics supplied CPVC or brass adapter (Figure 2.7). The adapters provide a convenient union for the three connection ports on the valve. In addition, they incorporate a positive O-ring face seal for ease of installation and leak free operation. DO NOT OVERTIGHTEN THE ADAPTERS. As a general guideline, hand tightening the nut onto the valve will be adequate. If additional tightening is required, never exceed a quarter turn beyond the hand tight position.

The outlet of the 2-inch Magnum IT has an integrated turbine. The turbine measures the flow of water through the outlet. This information is used by the control to determine the best time to recycle.

Extended Standoffs

With Hard Water Bypass End Cap

Figure 2.8

Hydraulic Output Signal

An optional hydraulic output signal is available on the valve. An optional cam lobe on pilot valve #6 is used on the camshaft assembly to initiate the hydraulic output signal during regeneration or backwash (Figure 2.9). The hydraulic line pressure signal will be available through the 1/4-inch connection on the back of the valve marked “AUX”. (Remove the tube cap installed for shipping.)

Optional cam lobes available are:

P/N 1000554 Provides a hydraulic signal from the

beginning of BACKWASH through the

of REFILL.

start

P/N 1000553 Provides a hydraulic signal from the

beginning of BACKWASH through the

of REFILL.

end

P/N 1001622 Used on Twin Alternating Systems

Only. Provides a hydraulic signal from the beginning of BACKWASH through and during

STANDBY.

P/N 1041064 Breakaway cam. Can be programmed

to send a hydraulic signal at any time during the REGENERATION or BACKWASH cycle. Note: The camshaft must be turning for the signal to change states, i.e. switch from OFF to ON, or from ON to OFF.

Auxiliary Hydraulic Output Port “AUX”

Pilot Drain Port

Figure 2.10

Magnum Tank Adapter

The tank adapter on the control valve is designed to be compatible with a 4 inch-8UN (8 threads per inch) tank opening. In addition, the adapter is designed to accept a full 1-1/2-inch (3.81-cm) riser pipe with outside diameter of 1.90 to 1.91 inches (48.26 to 48.51 mm) (Figure 2.11). The riser pipe is sealed by an O-ring on the inside of the tank adapter, Figure 2.11. It is recommended that the riser pipe extend beyond the top of the tank by 1/4 inch ± 3/8 inch (6 mm ± 9 mm).

For hydraulic output signal install one of following cam lobes:

1000553 1000554 1001622 1041064

Optional Cam

Lobe Position #6

“Hydraulic Output

Signal”

O-ring

Tank O-ring

Top of Tank

.375" (9.52 mm)

0.8125"

(20.64 mm)

Riser O-ring

O-ring

Figure 2.11

Optional Switch Assembly

On single, twin parallel, and triple parallel tank configurations, a single optional feedback switch kit is available to provide an electrical signal during the entire regeneration or backwash cycle (Figure 2.12). The switch may be wired in the “Normally Open” or “Normally Closed” position and is rated for 0.1 amp at 125 volts AC. An optional 5.0 amp switch at 1/10 HP 125/250 volts AC is available upon request.

Figure 2.9

Common

Normally Open

Normally Closed

Figure 2.12

On ALL Magnum tank configurations, optional multiswitch kits are available to provide additional electrical or switch closure signals during the regeneration or backwash cycles. Coupled with the optional breakaway cams, signals can be sent to external system equipment at virtually any time while the control/camshaft motor is running. Consult the instruction sheet covering the multi-switch option for additional application and programming information. The instruction sheet is sent with the switch kit.

2.2 Magnum General Specifications

Operating and Environmental

Operating Pressure ............................................................................................... 25 to 125 psig (172 to 862 kPa)

100 psig (688kPa) maximum in Canada

Operating Water Temperature Range................................................................................. 34 to 100

Ambient Temperature Range.............................................................................................. 34 to 120

F (1 to 36oC)

F (1 to 50oC)

Cap Bolt Torque ...................................................................................................35-40 inch lbs. (3.95 to 4.51 N

Connections

Inlet and Outlet................................................................................................................... 1-1/2 inch-Magnum Cv

2-inch-Magnum IT

Tank ....................................................................................................................................................... 4-inch-8UN

Brine ....................................................................................................................................................3/4-inch NPT

Pilot Drain and Auxiliary Hydraulic Out .................................................................................... 1/4-inch tube fitting

Riser Pipe Fitting .....................................................................................................................1-1/2-inch (3.81-cm)

Drain ........................................................................................................................................ 1-1/2-inch (3.81-cm)

Physical

Dimensions..................................................................................................... Refer to drawings on pages 8 and 9

Approximate Weight (Valve and Control).................................................................................... 23.3 lbs. (10.6 kg.)

Electrical*

Voltage - 962 Series Control .......................................................................... 12 VAC wall mount transformer only

)

Voltage - 942 Series Control ..................................................................120 VAC, 12 VAC wall mount transformer

Voltage - 952 Series Control ........................................................................................................ 24 VAC, 120 VAC

Power Draw........................................................................................................................................4.5 volt-amps

*See section on Electronic Controls for alternative electrical configurations.

2.3 Magnum Cv Dimensional Specifications

1 1/2-inch Inlet, Outlet and Drain

15.539 (39.47 cm)

1.113 (2.82 cm)

3.993 (10.14 cm)

9.000 (22.86 cm)

13.481 (34.24 cm)

11.471 (29.13 cm)

8.680 (22.04 cm)

4.018 (10.20 cm)

2.817 (7.15 cm)

7.000 (17.78 cm)

14.000 (35.56 cm)

19.500 (49.53 cm)

6.493 (16.5 cm)

7.500 (19.05 cm)

22.796 (57.90 cm)

Magnum IT Dimensional Specifications 2-Inch Inlet and Outlet, 1 1/2-Inch Drain

8.710

3.998

13.481

9.000

2.817

7.000 6.500

9.750

4.429

16.250

4.500 4.500

4.429

13.993

11.376

27.224

15.539

1.113

3.0 General Installation Information

Please review the following items thoroughly to ensure an efficient and safe installation of the water treatment system. Page 12 shows typical installation line drawings for the Magnum valves.

Operating Conditions -

A minimum dynamic operating water pressure of 25 psig (172 kPa) is required for the Magnum control valve to operate properly.

125 psig (862 kPa). In Canada, water pressure is not to exceed 100 psig (688 kPa). Water temperature is not to exceed 100 freezing conditions.

Space Requirements - Allow adequate space for the water treatment system and associated piping. The General Specifications section (pages 7-9) provides the overall dimensions of the control valve as well as the dimensional reference information for each of the connection ports. A minimum of 4 1/2 inches (11.5 cm) front and rear clearance is required for cartridge assembly and removal.

Plumbing - Always follow good plumbing practices and conform to local codes. Check existing pipes for lime and/or iron buildup. Replace piping if heavy buildup exists and initiate the proper treatment to prevent additional occurrences. Locate the equipment close to a drain that is capable of handling the maximum drain flow rate during backwash.

Flexible Connectors - Some tanks expand and contract over the acceptable range of operating water pressures of the Magnum control valve. The use of flexible connectors is recommended on polywound or fiberglass tank installations of 24-inch (60.96-cm) diameter and larger. Follow the tank manufacturer’s instructions for more information.

Inlet and Outlet Piping - Inlet and outlet plumbing should be adequately supported to avoid excessive loads on the valve. Install a manual bypass system to provide for occasions when the water conditioner must be bypassed for servicing.

Drain LIne Piping - To prevent mineral loss during backwash, and to ensure proper operation of the Magnum Cv Series control valve, A DRAIN LINE FLOW CONTROL must be plumbed into the drain line prior to placing the valve in the service mode. Flow controls from 5 to 40 gpm (18.92 to 151.4 Lpm) are available from GE Osmonics and can be easily installed in the drain line (Figure 3.1). Flow controls greater than 40 gpm (151.4 Lpm) must be plumbed externally. Selection of the proper drain line flow control will depend on the tank size and media used for the installation. See Table 10.3.

F (36oC). Do not subject the valve to

Water pressure is not to exceed

The following general drain line piping guidelines should be observed:

• 1 inch (2.54 cm) or larger piping

• Should not exceed 20 feet (6.1 m)

• Should not be elevated higher than the control

valve

• No shut-off valves should be installed in drain line

• Minimal number of elbows and fittings should be

installed in drain line

• Piping must be self-supporting

• Install air gap to provide a siphon break

• Flow control should be installed as close to the

Magnum Cv Series control valve as possible if an external flow control is used.

Drain Line Flow Control Disk

Figure 3.1

Brining System - The Magnum control valve utilizes timed water refill to add water to the salt tank. A refill tube with check ball is required in the brine tank that will not restrict the refill or brine draw flow rate capabilities of the valve. Although not required, a separate brine valve (safety float) system is recommended for use with Magnum installations. Select a “High-Flow” brine valve that will not restrict the refill or brine draw flow rate capabilities of the valve. The “Performance Data and Charts” section (Section 10.0) of this manual contains flow rate information for various size injectors and refill controllers.

Pilot Drain - During regeneration, a small amount of water (200 ml or 1 cup) is discharged from the 1/4-inch (6.3-mm) tube fitting on the back of the valve marked DRAIN (Figure 3.2). To prevent this water from being discharged to the floor, plumb this connection to a nonpressurized drain or to the brine tank. Do not plug or

apply back pressure to the pilot drain at any time.

Crimping the pilot drain line or installing the line to go up, which causes backpressure, will prevent the diaphragm cartridges from shifting properly through the cycles of regeneration or backwash.

Auxiliary Hydraulic

Output Port - Plugged

Pilot Drain Port

Figure 3.2

Electrical

1. Electrical requirements for the installation will depend on the configuration of the control.

2. The standard North American Series 962 electronic control is supplied with a 12 volt wall mount transformer. Optional wall mount transformers are available in the following configurations: Japanese plug @ 100 volts/50 or 60 Hz, Australian/Argentine plug @ 240 volts/50 Hz, British plug @ 240 volts/50 Hz, European/Italian plug @ 230 volts/50 Hz. Optional transformers must be ordered separately for all international 12 VAC configurations.

3. The standard North American Series 952 impulse controls use 120 VAC or 24 VAC/50 or 60 Hz power.

Lubricants

It is very important that 100% silicone lubricant is the only lubricant used for installing the Magnum control valve. Any other lubricant may cause material degradation and potential failure of the valve components.

NOTE: Some silicone based lubricants contain petroleum-based ingredients. If there is a question about the lubrication that you are using contact the manufacturer of that lubricant.

3.1 Typical Installation Drawings

Inlet Valve

Drain Line Flow Control (Required)

Drain

962 Control

1.5” Riser Tube

Hub & Lateral

Magnum Cv

Manual Bypass Valve

Outlet Valve

Turbine (standard with 962 Control)

Note: Support Inlet and Outlet Piping Adequately.

Brine Line

Brine Tank

Magnum IT

Figure 3.3 Magnum Cv and Magnum IT, Single Tank Softener Units with 962 Electronic Control

4.0 Flow Diagrams

The Magnum control valve utilizes a series of pilot valves to properly position the diaphragm valve cartridges (Figure 4.1). The pilot valves are activated by the camshaft (Figure 4.2). The flow diagrams that follow represent the Service Cycle for a 5-cycle softener, 3-cycle filter, and 5-cycle twin alternating softener

Figure 4.1 Pilot Valve Principle of Operation

configuration. Both the Hardwater Bypass and No Hardwater Bypass service flow diagrams are presented.

Figure 4.2 Cam Assembly

Brine

Service Cycle

Tank

Refill

Control

Pilot

B1B2

Valves

Injector

Screen

Pressure

Regulator

Pilot

Screen

654321B2B1

OPEN OPEN OPENCLSD CLSDCLSDCLSD

CLSD

OPEN OPEN CLSDCLSDOPEN CLSD CLSD

CLSD

OPEN OPEN

OPENOPENOPEN CLSD CLSD

CLSD

CLSDCLSD

OPEN OPEN OPEN OPENCLSD

CLSD

OPEN OPENCLSD OPEN OPENOPEN

CLSD CLSD

Injector

5 Cycle - Co-current - Hard Water Bypass - Softener

Untreated

Water

Treated

Water

Backwash

Water

Regenerant

Service

Backwash

Brine/Slow Rinse

Drain

Fast Rinse

Refill/Service

Outlet

agnum

Bypass

Hard Water

Pilot Drain

Tank Bottom

Aux. Pilot

Output

Inlet

Resin Tank

Tank Top

Brine

Service Cycle

Tank

Refill

Control

Pilot

B1B2

Valves

Injector

Screen

Pressure

Regulator

Pilot

Screen

654321B2B1

OPEN OPEN OPENCLSD CLSDCLSDCLSD

CLSD

OPEN OPEN CLSDCLSDOPEN CLSD CLSD

CLSD

OPEN OPEN

OPENOPENOPEN CLSD CLSD

CLSD

CLSDCLSD

OPEN OPEN OPEN OPENCLSD

CLSD

OPEN OPENCLSD OPEN OPENOPEN

CLSD

Injector

Untreated

Water

5 Cycle - Co-current - No Hard Water Bypass - Softener

Treated

Water

Backwash

Water

Regenerant

Service

Backwash

Brine/Slow Rinse

Drain

Fast Rinse

Refill/Service

Outlet

agnum

No Hard

Water Bypass

Pilot Drain

Tank Bottom

Aux. Pilot

Output

Inlet

Resin Tank

Tank Top

leService Cycle

Service Cyc

Pilot

B1B2

Valves

Pressure

Regulator

Pilot

Screen

654321B2B1

OPEN OPEN OPENCLSD CLSDCLSDCLSD

CLSD

OPEN OPEN CLSDCLSDOPEN CLSD CLSD

CLSD

CLSDCLSDOPEN OPEN OPEN OPENCLSD

CLSD

3 Cycle - Unfiltered Water Bypass - Filter

Plugged Injector

Untreated

Water

Treated

Water

Backwash

Water

Regenerant

Service

Drain

Backwash

Fast Rinse

Outlet

agnum

Unfiltered

Water Bypass

Pilot Drain

Tank Bottom

Aux. Pilot

Output

Inlet

Media Tank

Tank Top

leService Cycle

Service Cyc

Pilot

B1B2

Valves

Pressure

Regulator

Pilot

Screen

654321B2B1

OPEN OPEN OPENCLSD CLSDCLSDCLSD

CLSD

OPEN OPEN CLSDCLSDOPEN CLSD CLSD

CLSD

CLSDCLSDOPEN OPEN OPEN OPENCLSD

CLSD

Plugged Injector

3 Cycle - No Unfiltered Water Bypass - Filter

Untreated

Water

Treated

Water

Backwash

Water

Regenerant

Service

Drain

Backwash

Fast Rinse

Outlet

agnum

No Unfiltered

Water Bypass

Tank Bottom

Pilot Drain

Aux. Pilot

Output

Inlet

Media Tank

Tank Top

leService Cycle

Service Cyc

Brine

Tank

Refill

Control

Pilot

B1B2

Valves

Injector

Screen

Pressure

Regulator

Pilot

Screen

654321B2B1

OPEN OPEN OPENCLSD CLSDCLSDCLSD

CLSD

OPEN OPEN OPENCLSD CLSDCLSDOPEN

CLSD

OPEN OPEN CLSDCLSDOPEN CLSD CLSD

CLSD

OPEN OPEN

OPENOPENOPEN CLSD CLSD

CLSD

CLSDCLSD

OPEN OPEN OPEN OPENCLSD

CLSD

OPEN OPEN

OPEN

CLSD OPEN OPENOPEN

CLSD

CLSDCLSD

OPEN

CLSD OPEN OPENOPEN

CLSD

5 Cycle - Co-current - Twin Alternating Softener

Injector

Untreated

Water

Treated

Water

Backwash

Water

Regenerant

Service

Backwash

First Standby

Refill

Fast Rinse

Second Standby

Brine/Slow Rinse

Drain

Outlet

agnum

No Hard

Water Bypass

Pilot Drain

Tank Bottom

Aux. Pilot

Output

Inlet

Resin Tank

Tank Top

5.0 Control Settings

5.1 Manual

Series 942Man Controls

The 942Man represents the maximum in versatility and ease of operation for the manual control valve system. Upgrade to an automatic system is easily accomplished by switching the manual control to a clock or demand control.

DO NOT TURN THE INDICATOR KNOB CLOCKWISE AT A N Y T IM E .

Regeneration Instructions

1. Move indicator knob COUNTERCLOCKWISE from the Regeneration Complete position to the center of the Backwash (Figure 5.1) position. DO NOT turn the knob clockwise.

Figure 5.2

4. When the slow rinse is complete, move the indicator knob COUNTERCLOCKWISE to the center of the Fast Rinse position (Figure 5.3). The indicator knob should remain in the Fast Rinse position for the appropriate amount of time. specific fast rinse times are determined by water quality, clarity of drain water, water pressure, and flow. Fast rinse serves to eliminate excess salt and repack the resin bed for the service run. Typically fast rinse should continue for 5 - 15 minutes*.

Important: If excessive fast rinse time is required to return the service effluent to quality, there could be an underlying cause, such as low pressure, fouled resin bed, fouled injector, etc.

Figure 5.1

2. The indicator knob should remain in the Backwash position for the appropriate amount of time. Specific backwash times are determined by the inlet water quality (i.e.: the amount of iron, manganese, turbidity), the amount of time between regenerations, water pressure, and flow. The typical backwash time is 10-15 minutes*. The unit should be in backwash until water at the drain is clear.

3. When the backwash is complete, move the indicator knob COUNTERCLOCKWISE to the center of the Brine/Slow Rinse position (Figure 5.2). See the “Suggested Brine Draw/Slow Rinse Table” to determine the correct draw/rinse time. Please note that the tables are given at three salting levels and four pressures. The indicator knob should remain in the Brine/Slow Rinse position for the time* indicated in the table.

*Note: The times given are only general guidelines. Adjustment of the times may be necessary for specific applications and conditions.

Figure 5.3

5. When the fast rinse is complete, move the indicator knob COUNTERCLOCKWISE to the Refill position (Figure 5.4). Determine the correct refill time* from Table 5.1 below. The indicator knob should remain in the Refill position for the time indicated in the table.

Figure 5.4

Table 5.1 Suggested Refill Times

Refill Flow Rate

Tank

Diameter

Resin

cu.ft.

Refill PN

gpm (lpm)

@ 60 psig

(414 kPa)

14 in (35.5 cm) 3 1040679 0.7 (2.6 lpm) 9 minutes 15 minutes 22 minutes 16 in (40.6 cm) 4 1040680 0.8 (3 lpm) 10 minutes 17 minutes 25 minutes 18 in (45.7 cm) 5 1040681 1.0 (3.8 lpm) 10 minutes 17 minutes 25 minutes 21 in (53.5 cm) 7 1040682 1.4 (5.31 lpm) 10 minutes 17 minutes 25 minutes 24 in (60.9 cm) 10 1040683 2.0 (7.6 lpm) 10 minutes 17 minutes 25 minutes 30 in (76.2 cm) 15 1040684 3.0 (11.4 lpm) 10 minutes 17 minutes 25 minutes 36 in (91.4 cm) 20 1040685 5.0 (18.9 lpm) 8 minutes 14 minutes 20 minutes

6. When the refill is complete move the indicator knob COUNTERCLOCKWISE to the Regeneration Complete position (Figure 5.5). The unit will now provide softened water.

Minimum Salting

(6 lbs/ft

)

(96.1 kg/m

Regenerating Iron Filters - Model 942Man

Refer to Regenerating Iron Filters Model 942 in Section

5.2 for information on this type of system application. All common control settings, control regenerant

Medium Salting

)

( 160.18 kg/m

(10 lbs/ft

Salting (15 lb/ft

)

(240.27 kg/m

settings, and regenerant usage which apply to the 942Man control are the same as those used on the 942 control.

When using the 942Man control however, the time of each cycle cannot be predicted exactly. Note the following regeneration cycle parameters:

• Backwash the filter until the drain water flows clear,

typically 5 - 15 minutes.

• Regenerant draw continues until the check ball

closes to end draw.

• Slow Rinse should continue until there is NO pink

color to the drain water flow. This is typically four times that of the regenerant draw time.

• Fast Rinse time continues until there is no pink

Figure 5.5

*Note: The times given are only general guidelines. Adjustment of the times may be necessary for specific applications and conditions.

color to the drain water flow, typically 5 - 15 minutes.

• Refill time is determined by the size of the refill flow

control and the amount of regenerant required for a particular size system. Refer to Regenerant Use Table in Section 5.2.

Maximum

)

Table 5.2 Suggested Brine Draw/Slow Rinse Times Based on 25 psi and 2.5 Bed Volumes of

Slow Rinse

Tank Size in. (cm) 14 (35.5) 16 (40.6) 18 (45.7) 21 (53.3) 24 (60.9) 30 (76.2) 36 (91.4) Resin Vol. cu. ft. (cu m) 3 (0.085) 4 (0.113) 5 (0.142) 7 (0.200) 10 (0.283) 15 (0.425) 20 (0.566)

Brine/ Rinse Time 78 min 72 min 85 min 73 min 79 min 89 min 77 min

Total Lb. Salt [Min.] (kg) 18 (6.72) 24 (8.96) 30 (11.2) 42 (15.68) 60 (22.39) 90 33.59)

Capacity (kgr) 60 80 100 140 200 300 400 Brine/Rinse Time 87 min 83 min 98 min 87 min 89 min 100 min 86 min

Total Lb. Salt [Mid] (kg) 30 (11.2) 40 (14.93) 50 (18.66) 70 (21.13)

Capacity (kgr) 75 100 125 175 250 375 500 Brine/Rinse Time 99 min 98 min 113 min 103 min 102 min 114 min 98 min

Total Lb. Salt [Max] 45 (16.8) 60 (22.39) 75 (27.99) 105 (39.19

Capacity (kgr) 90 120 150 210 300 450 600 Injector Number 1000441 1000442 1000443 1000444 1000445 1000446 1000447

100

(37.32)

150

(55.99)

150

(55.99)

225

(83.98)

120

(44.79)

200

(74.65)

300

(111.97)

Table 5.3 Suggested Brine Draw/Slow Rinse Times Based on 50 psi and 2.5 Bed Volumes of

Slow Rinse

Tank Size in. (cm) 14 (35.5) 16 (40.6) 18 (45.7) 21 (53.3) 24 (60.9) 30 (76.2) 36 (91.4) Resin Vol. cu. ft. (cu m) 3 (0.085) 4 (0.113) 5 (0.142) 7 (0.200) 10 (0.283) 15 (0.425) 20 (0.566)

Brine/ Rinse Time 65 min 58 min 70 min 65 min 66 min 76 min 68 min

Total Lb. Salt [Min.] (kg) 18 (6.72) 24 (8.96) 30 (11.2) 42 (15.68) 60 (22.39) 90 33.59)

Capacity (kgr) 60 80 100 140 200 300 400 Brine/Rinse Time 74 min 70 min 83 min 77 min 77 min 87 min 77 min

Total Lb. Salt [Mid] (kg) 30 (11.2) 40 (14.93) 50 (18.66) 70 (21.13)

Capacity (kgr) 75 100 125 175 250 375 500 Brine/Rinse Time 99 min 85 min 98 min 94 min 90 min 101 min 89 min

Total Lb. Salt [Max] 45 (16.8) 60 (22.39) 75 (27.99) 105 (39.19

Capacity (kgr) 90 120 150 210 300 450 600 Injector Number 1000441 1000442 1000443 1000444 1000445 1000446 1000447

100

(37.32)

150

(55.99)

150

(55.99)

225

(83.98)

120

(44.79)

200

(74.65)

300

(111.97)

Table 5.4 Suggested Brine Draw/Slow Rinse Times Based on 75 psi and 2.5 Bed Volumes of

Slow Rinse

Tank Size in. (cm) 14 (35.5) 16 (40.6) 18 (45.7) 21 (53.3) 24 (60.9) 30 (76.2) 36 (91.4) Resin Vol. cu. ft. (cu m) 3 (0.085) 4 (0.113) 5 (0.142) 7 (0.200) 10 (0.283) 15 (0.425) 20 (0.566)

Brine/ Rinse Time 55 min 52 min 61 min 57 min 58 min 66 min 55 min

Total Lb. Salt [Min.] (kg) 18 (6.72) 24 (8.96) 30 (11.2) 42 (15.68) 60 (22.39) 90 33.59)

Capacity (kgr) 60 80 100 140 200 300 400 Brine/Rinse Time 64 min 64 min 73 min 70 min 69 min 76 min 64 min

Total Lb. Salt [Mid] (kg) 30 (11.2) 40 (14.93) 50 (18.66) 70 (21.13)

Capacity (kgr) 75 100 125 175 250 375 500 Brine/Rinse Time 75 min 79 min 88 min 85 min 82 min 90 min 75 min

Total Lb. Salt [Max] 45 (16.8) 60 (22.39) 75 (27.99) 105 (39.19

Capacity (kgr) 90 120 150 210 300 450 600 Injector Number 1000441 1000442 1000443 1000444 1000445 1000446 1000447

100

(37.32)

150

(55.99)

150

(55.99)

225

(83.98)

120

(44.79)

200

(74.65)

300

(111.97)

Table 5.5 Suggested Brine Draw/Slow Rinse Times Based on 100 psi and 2.5 Bed Volumes of

Slow Rinse

Tank Size in. (cm) 14 (35.5) 16 (40.6) 18 (45.7) 21 (53.3) 24 (60.9) 30 (76.2) 36 (91.4) Resin Vol. cu. ft. (cu m) 3 (0.085) 4 (0.113) 5 (0.142) 7 (0.200) 10 (0.283) 15 (0.425) 20 (0.566)

Brine/ Rinse Time 50 min 48 min 56 min 53 min 54 min 59 min 50 min

Total Lb. Salt [Min.] (kg) 18 (6.72) 24 (8.96) 30 (11.2) 42 (15.68) 60 (22.39) 90 33.59)

Capacity (kgr) 60 80 100 140 200 300 400 Brine/Rinse Time 59 min 60 min 68 min 65 min 64 min 69 min 59 min

Total Lb. Salt [Mid] (kg) 30 (11.2) 40 (14.93) 50 (18.66) 70 (21.13)

Capacity (kgr) 75 100 125 175 250 375 500 Brine/Rinse Time 70 min 75 min 83 min 81 min 77 min 82 min 70 min

Total Lb. Salt [Max] 45 (16.8) 60 (22.39) 75 (27.99) 105 (39.19

Capacity (kgr) 90 120 150 210 300 450 600 Injector Number 1000441 1000442 1000443 1000444 1000445 1000446 1000447

100

(37.32)

150

(55.99)

150

(55.99)

225

(83.98)

120

(44.79)

200

(74.65)

300

(111.97)

Minimum salting: 6 lb. salt = 20 kgr/cu. ft.

Medium salting: 10 lb. salt = 25 kgr/cu. ft.

Maximum salting: 15 lb. salt = 30 kgr/cu. ft.

942FMan - Manual Filter Control for the Magnum Valve

The 942FMan represents the maximum in versatility and ease of operation for the manual control valve system. Upgrade to an automatic system is easily accomplished by switching the manual control to a clock or demand control.

DO NOT TURN THE INDICATOR KNOB CLOCKWISE AT A N Y T IM E .

Backwash Instructions:

1. Move the indicator knob COUNTERCLOCKWISE from the Backwash Complete position to the center of the Backwash (Figure 5.6) position. DO NOT turn the knob clockwise. The knob should remain in the Backwash position for 5 to 20 minutes*, or until the water runs clear at the drain.

3. After the fast rinse is complete, return the filter to service by rotating the indicator knob COUNTERCLOCKWISE to the Backwash Complete position (Figure 5.8).

Figure 5.8

Figure 5.6

2. When the backwash is finished, move the indicator knob COUNTERCLOCKWISE to the center of the Fast Rinse position (Figure 5.7). The knob should remain in the Fast Rinse position for 5 to 20 minutes*, or until the water runs clear at the drain.

*Note: the times given are only general guidelines. Adjustment of the times may be necessary for specific applications and conditions.

Figure 5.7

5.2 Mechanical

regeneration. Reset day pins when completed.

Series 942 Mechanical Controls

The Series 942 mechanical controls provide mechanical timeclock function for water softening and filter applications; 942 model for softening applications, (Figure 5.9) 942F model for filtering applications. Identification of the specific model is provided on the front of the control. The controls are very similar in appearance, function, and settings. However, they require different gear drives and camshafts to function properly. The softener and filter camshafts are identified in the Assembly Drawings and Parts List, Section 12.10, of this manual.

Setting the Days of Regeneration

Setting the days that the conditioner will regenerate is accomplished in two simple steps:

1. Pull all of the day pins outward.

2. Push in the day pin(s) for the day(s) on which a regeneration or backwash is desired.

NOTE: The NEXT DAY pin is noted on the control face. Pushing this pin will insure a regeneration the next day at approximately 2:00 a.m. since the Calendar Cap progresses in a clockwise direction, pushing the day pin immediately following the NEXT DAY pin counterclockwise will insure a regeneration occurs the following day at approximately 2:00 a.m. This progression is noted on the control face as “FUTURE DAYS”.

Manual Regeneration

Excessive water usage or other service related issues may create the need to manually regenerate the conditioner. This function is performed by rotating the Indicator Knob COUNTERCLOCKWISE to the “START” position. Once in this position, the conditioner will begin a regeneration or backwash within a few minutes. The normal schedule, established with the pushed in day pins, will not be disrupted by a manual regeneration or backwash.

Indicator Knob

Day Pin

Calendar Cap

Figure 5.9

Clock Dial

5.2.1 Common Settings

Setting the Time of Day, the Days of Regeneration or Backwash and performing manual regenerations or backwashing are the same for 942 and 942F controls.

Setting the Time of Day

Rotate the Clock Dial clockwise until the pointer indicates the correct time of day. With the time of day set, the conditioner will regenerate at approximately 2:00 a.m. If it is desired to have the unit regenerate at an earlier or later time, simply offset the current time of day accordingly. For example, to have the unit regenerate at 4:00 a.m., set the Clock Dial 2 hours earlier than the actual current time of day.

Note: Do not rotate the Calendar Cap by hand. The Clock Dial indexes the Calendar Cap daily. To manually index the Calendar Cap, rotate the Clock Dial clockwise one complete turn for every day to be indexed. Day pins should be in the outward position during Clock Dial rotation to prevent an undesired

24 Hour Clock

All Magnum 942 and 942F controls utilize a 24 hour clock dial. This is typically referred to as “Military Time”. The hours of the day between 12:00 a.m. (midnight) and 12:00 p.m. (noon) are designated on the clock dial by the numbers 1 through 12, with 1 being 1:00 a.m. The hours of the day between 12:00 p.m. (noon) and 12:00 a.m. (midnight) are designated on the clock dial by the numbers 13 through 24, with 13 being 1:00 p.m. Be sure to set the correct time of day accordingly.

Adjusting the Salt Setting - Model 942

The Salt Dial (Figure 5.10) controls the total amount of salt used per regeneration. With the Indicator Knob in the REGENERATION COMPLETE position, rotate the Salt Dial counterclockwise at least one full turn to cancel out the current setting. A light clicking sound will be replaced by a heavier clicking sound when the previous setting is cancelled. Once the heavier clicking is heard, the new setting may be set by rotating the Salt Dial counterclockwise to the desired setting.

Salt Dial

Indicator Knob

Figure 5.10 Regeneration Complete

It is important to note that the numbers on the Salt Dial represent “MINUTES” of water refill time. To determine the total pounds of salt that will be used for a regeneration, it is necessary to know the refill control that is used in the conditioner. The refill control determines the flow rate of water into the salt tank during the refill cycle. Refer to the Salt Use Table 5.8 to determine the total pounds of salt used per regeneration for the various size tanks.

NOTE: Only two sizes of refill flow controls are recommended when the Magnum Cv Series control valve is used in a manganese greensand filter system. The Magnum control valve must be ordered with the proper size refill flow control or changed in the field. The incorrect refill flow control could underfill or overfill the regenerant tank resulting in a system malfunction.

5.2.3 Backwashing Filter - Model 942F

Adjusting the Backwash Setting

The Backwash Dial (Figure 5.11) controls the backwash time. With the Indicator Knob in the BACKWASH COMPLETE position, rotate the Backwash Dial counterclockwise at least one full turn to cancel out the current setting. A light clicking sound will be replaced by a heavier clicking sound when the previous setting is cancelled. Once the heavier clicking is heard, the new setting may be set by rotating the Backwash Dial to the desired setting. The numbers on the Backwash Dial represent “MINUTES” of backwash time.

Table 5.6 Cycle Times for 942 Control

Cycle Time (Minutes)

Backwash 17

Brine/Slow Rinse 95

Purge 9

Refill 2 to 24

5.2.2 Regenerating Iron Filters - Model 942

Filter medias used in the water treatment industry generally require only a periodic backwashing with water to maintain their filtering efficiencies. These type of filters would use the 942F control described in the next section. Manganese greensand media, typically used for iron removal, requires regular regeneration with an oxidizing chemical, potassium permanganate (KMNO with salt. This application requires the use of the Model 942 control.

Common Settings

Setting the Time of Day, Days of Regeneration, and the initiation of a Manual Regeneration are as previously described in this section.

) similar to the regeneration of a water softener

Backwash Dial

Figure 5.11 Backwash Complete

Table 5.7 Cycle Times for 942F Control

Cycle Time (Minutes)

Backwash 8 - 30

Purge 9

Adjusting The Regenerant Setting - Model 942

Refer back to the previous heading in this section Adjusting the Salt Setting - Model 942. Setting the number of “MINUTES” of refill time determines the amount of regenerant chemical used per regeneration. Refer to the Regenerant Use Table 5.9 for the proper setting based on tank size and the number of cubic feet of media used.

5.2.4 Salt Use Table

Table 5.8 Model 942, 952, 952QC - Salt Used per Regeneration

Tank Size/Dia.

inches (cm)

Resin Volume

cu. ft. (cu. m.)

Refill Flow

Rate

GPM (LPM)

14 (35.5) 16 (40.6) 18 (45.7) 21 (53.3) 24 ( 60.9) 30 (76.2) 36 (91.4)

3 (0.85) 4 (0.113) 5 (0.142) 7 (0.200)

(0.283)

0.7 (2.65) 0.8 (3.03) 1.0 (3.78) 1.4 (5.30) 2.0 (7.57)

(0.425)

3.0

(11.36)

Salt Dial

Setting

Approximate Pounds of Salt per Regeneration

(Minutes)

8 18----------120 10 21 24 30 42 60 90 150 12 25 29 36 50 72 108 180 14 29 34 42 59 84 126 210 16 34 38 48 67 96 144 240 18 38 43 54 76 108 162 270 20 42 48 60 84 120 180 300 22 45 53 66 92 132 198 --

(0.566)

5.0

(18.93)

24 -- 60 75 105 150 225 --

Notes:

1. Flow rates for refill controls are based on 60 psig (414 kPa) inlet pressure.

2. Take into account the type of brine system used when determining the actual amount of salt delivered during regeneration. (i.e. dry salt/grid plate or wet salt)

3. Salt Use Table reflects minimum salting of 6 lbs./cu.ft. (96.11 kg/m (240.27 kg/m

) through maximum salting of 15 lbs./cu.ft.

4. To use potassium chloride (KCl) increase salt dosage by approximately 25%.

5. Chloride/Anion dealkalizers regenerate with 5 lbs./cu.ft. (80.09 kg/m

) salt (NaCl) which yields approx. 7500 gr/ cu. ft. Injecting sodium hydroxide (NaOH) i.e. caustic soda, at a rate of 1/10 that of the salt dosage, during the brine draw cycle, increases capacity to approx. 10000 gr./cu. ft. Exact capacity, based on tank size, must be calculated using water analysis and resin manufacturer’s capacity curves.

5.2.5 Regenerant Use Table - Potassium Permanganate (KMnO4)

Table 5.9 Model 942, 952, 952QC - Regenerant Used Per Regeneration

Tank Size/Dia.

inches (cm)

Media Volume

cu. ft. (cu. m.)

Refill Flow

Rate

GPM (LPM)

Salt Dial Settings

(minutes)

KMnO4

oz. (grams)

Refill Water

gal. (liters)

Notes:

1. Chemical dosage recommendations typify requirements for single batch regenerations.

2. When combining batch regeneration with continual feed of either chlorine or potassium permanganate, reduce recommended chemical dosages above by 50%.

3. Table above reflects a 4 oz./cu. ft. of media, regenerant dosage, dissolved in 1 gallon of water/cu. ft. of media. Dosage rates will vary with various media manufacturers’ recommendations. Check manufacturers’ specifications for dosage recommendations.

14 (35.5) 16 (40.6) 18 (45.7) 21 (53.3) 24 ( 60.9) 30 (76.2) 36 (91.4)

3 (0.085) 4 (0.113) 5 (0.142) 7 (0.200)

0.8 (3.03) 0.8 (3.03) 0.8 (3.03) 1.0 (3.78) 1.0 (3.78) 1.0 (3.78) 1.0 (3.78)

4 6 7 7 10 15 20

12(340) 16 (454) 20 (567) 28 (794) 40 (1134) 60 (1701) 80 (2268)

3 (11.36) 4 (15.14) 5 (18.93) 7 (26.50)

(0.283)

(37.85)

(0.425)

(56.78)

(0.566)

(75.71)

5.3 Impulse

Series 952 Impulse Controls

The Series 952 impulse controls initiate a regeneration, or backwash, upon receiving an external line powered switch closer signal for a minimum of three minutes. The three models available are:

Control Description

952 5 Cycle Softener

952F 3 Cycle Filter

952QC 5 Cycle Softener with Quick-Connect Cables

Once the external signal is received, the control automatically steps the valve through the appropriate cycles. Cycle positions are identified by the Indicator Knob.

Once the control has reached the REGENERATION COMPLETE position, the 952 control will be ready for the next external line powered switch closure signal. If a switch closure signal is received during a regeneration or backwash, it will be ignored.

Regenerating Iron Filters - Model 952

Refer to the heading Regenerating Iron Filters - Model 942 in Section 5.2 for information on this type of system application. All common control settings, control regenerant settings, and regenerant usage which apply to the 942 control are the same as those used on the 952 control. This iron filter information applies to potassium permanganate regenerated manganese greensand filter systems only.

Adjusting the Backwash Setting - Model 952F

The Backwash Dial (Figure 5.13) controls the backwash time. With the Indicator Knob in the BACKWASH

COMPLETE position, rotate the Backwash Dial counterclockwise at least one full turn to cancel out

the current setting. A light clicking sound will be replaced by a heavier clicking sound when the previous setting is cancelled. Once the heavier clicking is heard, the new setting may be set by rotating the Backwash Dial to the desired setting. The numbers on the Backwash Dial represent “MINUTES” of backwash time.

Adjusting the Salt Setting - Model 952 and 952QC

The Salt Dial (Figure 5.12) controls the total amount of salt used per regeneration. With the Indicator Knob in the REGENERATION COMPLETE position, rotate the Salt Dial COUNTERCLOCKWISE at least one full turn to cancel out the current setting. A light clicking sound will be replaced by a heavier clicking sound when the previous setting is cancelled. Once the heavier clicking is heard, the new setting may be set by rotating the Salt Dial counterclockwise to the desired setting.

Salt Dial

Indicator Knob

Figure 5.12 Regeneration Complete.

It is important to note that the numbers on the Salt Dial represent “MINUTES” of water refill time. To determine the total pounds of salt that will be used for a regeneration, it is necessary to know the refill control that is used in the conditioner. The refill control determines the flow rate of water into the salt tank during the refill cycle. Reference the Salt-Use Table on page 26 to determine the total pounds of salt used per regeneration for various size tanks.

Backwash Dial

Figure 5.13 Backwash Complete.

Table 5.11 Cycle Times for 952F Control

Cycle Time (Minutes)

Backwash 8 - 30

Purge 9

Wiring the 952 Series Controls

The 952 and 952F controls come with 21-foot (6.4-m) of wire for connection to the external signaling device. Refer to wiring illustration in the Wiring Diagram Section of this manual for further installation information. The 952QC is pre-wired with a standard 7-foot (2.13-m) cable assembly designed to plug directly into an Autotrol 480QC. Optional 14-foot (4.27-m) and 21-foot (6.4-m) cable assemblies are available. An optional feed back switch assembly, mounted on the Magnum control valve, is required, when operating in the 952QC configuration.

Table 5.10 Cycle Times for 952 Control

Cycle Time (Minutes)

Backwash 17

Brine/Slow Rinse 95

Purge 9

Refill 2 - 24

5.4 Electronic

Series 962 Electronic Demand Controls

The Series 962 Electronic Controls provide sophisticated, demand-based water conditioning by combining a microprocessor with a flow meter to electronically monitor the amount of water used. This fully programmable series of controls provide the ability to fine tune the conditioner’s operation to meet the application requirements. There are four basic 962 Demand models available:

Control Description

962 Single or Multi Tank Softener

962F Single or Multi Tank Filter 962M Main Control for Twin Alternating 962S Secondary Control for Twin Alternating

Series 962 Electronic Time Clock Controls

The 962 Time Clock Controls allow regeneration/ backwash initiation several different ways. Choose the day of the week to regenerate/backwash or set it to regenerate/backwash on an interval basis. External initiation is also available. This fully programmable series of controls provide the ability to fine tune the conditioners application to meet the operations requirements. There are two basic 962 Time Clock models available:

Control Description

962TC Softener or Multitank Softener

962FTC Filter or Multitank Filter

This section of the manual defines the basic operating and programming features for each of these models.

Special Features of the Series 962 Controls

• Memory Retention - During a power outage,

critical operating information is stored in memory. This information includes all programming data and the number of days since the last regeneration. When power is restored, the information is returned to the microprocessor and operation resumes as if an outage never occurred. The time of day will be late by the length of the power outage and must be reset. No other reprogramming is necessary. An optional rechargeable battery backup will allow the control to keep track of time and water usage for up to eight hours during a power outage. The

control will not initiate a regeneration or backwash while on battery backup.

• Programmable Cycles - The control is flexible in

defining the appropriate cycles of operation.

• Double Regeneration - For single tank

applications (Model 962 and 962F) the control automatically calls for a second regeneration or

backwash the following day if the current operating cycle exceeds the defined capacity by 150% or more.

• Capacity and Salt Setting Lockout - The control

can be programmed to lock the values for Salt Amount and Capacity so they cannot be altered after installation.

Reserve Type Control

Specific time of day regeneration 962 and 962M

Immediate regeneration 962 and 962M

Fixed reserve 962

Variable reserve 962

• U.S. or Metric Units of Measure - To meet your

display and programming requirements, the 962 control uses grains per gallon of hardness, pounds of salt and kilograins of capacity for U.S. units, or, parts per million of hardness, kilograms of salt and kilograms of capacity for metric units. The 962 control displays capacity as gallons or cubic meters.

• Calendar Override - If the volume of water used

has not caused a regeneration, the 962 control can be set to regenerate every one to thirty days.

• Manual Regeneration - A separate REGEN button

is provided for manual regenerations. A double manual regeneration feature is included that allows back-to-back regenerations.

• Operating Histories (Demand Controls Only) -

Important operating data is stored in memory and is retrievable upon demand. The historical data includes peak flow rate as well as average daily water usage for each day of the week.

• Remote Regeneration - A set of terminals is

provided as a standard feature on the 962 control that allows for a regeneration to be initiated from a remote location. This feature can be used to facilitate manual regeneration requirements or assist in further automating the control system.

• Selectable Automatic Regenerations/

Backwashes - There are two automatic regeneration/backwash methods - immediate and delayed. Immediate regeneration is used to start automatic regenerations/backwashes when the softening capacity is exceeded. Delayed regeneration is used to start automatic regenerations/backwashes at a predetermined time of day. A regeneration/backwash will start at the programmed regeneration time when the remaining capacity falls below the reserve capacity, which may be fixed or variable.

• Selectable Reserve Options (Demand Controls

Only) - To meet the conditioned water requirements of the application, the 962 control allows selection of one of two reserve types:

– Fixed Reserve - The reserve is fixed at a

progammable percentage (30% factory preset) of the total softening capacity.

– Variable Reserve - The controller monitors the

daily water usage and at the programmed time of regeneration, calculates the average water used for each day of the week. The reserve capacity is set to 120% of the average water usage for the next day.

• Delayed Regeneration on Twin-alternating

Systems - The twin-alternating system does not use a reserve capacity. The service tank switches when the softening capacity is exhausted. Regeneration of the exhausted tank will occur at the specified time of day when using the delayed regeneration feature.

• Immediate Regeneration on Twin and Triple

Parallel Systems - The twin and triple parallel systems use a reserve capacity of “0” along with immediate regeneration. Regeneration of an exhausted tank in the system will occur immediately after reaching its maximum capacity, IF, there are no other tanks within the system already regenerating.

Normal Display Modes

In the normal operating mode the Series 962 control will alternate between Capacity Remaining (gallons or

) and Flow Rate (gallons per minute or m/hr). In the

m event of power loss, the display will alternate between Time of Day and Capacity Remaining once power has been restored. The normal operating display mode of the twin alternating system scrolls through three displays. They are: Capacity Remaining of tank 1 in gallons, Capacity Remaining of tank 2 in gallons, and Flow Rate. If a power outage has occurred, the flow rate display will change to Time of Day. In both cases the control will remain in Power Loss display mode until the Time of Day is reset or until any button is pressed. (Electronic Time Clock displays Time of Day only).

Programming the Series 962 Controls

This section contains common aspects of programming the 962, 962F, and 962M controls and retrieving historical operating data. The 962S control is a secondary unit that always works in conjunction with the 962M main control for twin alternating tank applications. The operating values for the 962S are the same as the operating values in the 962M control. An adhesive installation label is provided with each 962, 962F, and 962M control. It is recommended that this be filled out with programming parameters on start-up and placed on the inside of the cam cover.

Factory Default Values - The control is shipped from the factory with a default value for Salt Amount of 10 lb. (4 kg for metric units). Capacity, Hardness, Refill and

Brine Draw values are set to 0 and must be changed to appropriate values before the control will operate. “Err 4” will be displayed until a valid number is entered for each of these items. Program

variable P12 is preset at the factory to define the U.S. units of measure for North American application or metric units of measure for application outside North America.

Program Levels - The Series 962 controls have been designed to facilitate different levels of programming requirements. Level I includes program variables that are frequently referenced by users, operators, installers, and service personnel, and is accessible without the requirement of codes. Level II includes variables that are most typically used at the time of installation and initial setup and is accessible with special access codes. Level III locations are used primarily for accessing operating history information. Level III parameters also require access codes. Programming levels are further defined in Section 6 (page 34).

Levels Access Code

I None required

III

Press and hold the ↑ ↓ for approximately 3 seconds

Press and hold the ← ↑ arrow buttons for approximately 3 seconds

Table I on page 34 lists the Level I program values for the 962, 962F, 962TC, 962FTC and 962M controls.

Tables IIA through IIE, on pages 35-41, list the Level II program values for all 962 series controls.

Program Values and Locations - The P values that are programmed into the Series 962 controls are listed in the Level I and Level II tables.

Locating a Program Value - To locate and display a P value in Level I press the UP [↑ ] or DOWN [↓] arrow button until the desired value is displayed.

To locate and display a P value in Level II, simultaneously press the UP [↑ ] and

DOWN [↓] arrow

buttons for 3 seconds to gain access. Press the UP [↑ ]

DOWN [↓] arrow buttons until the desired location is

or displayed. Press LEFT [←] to display a value in P locations.

To locate and display an L value in Level III, simultaneously press the LEFT [←] and

UP [↑ ] arrow

buttons for 3 seconds to gain access and the press the UP [↑ ] or

DOWN [↓] arrows buttons until the desired

location is displayed. Press LEFT [←] to display value in the L location.

Changing a Program Value - Once the P value you want to change is displayed, press the LEFT [←] arrow button to display the current entry for that value. To change or modify the value, press the SET button. The character on the right hand side of the display will begin to flash. Use the UP [↑ ] or select the desired entry. Once the desired entry is obtained, press the LEFT [←] button to move to the next character and change as needed. Once you have completed the appropriate changes, press the SET button. When you press the SET button the new entry is stored and the control automatically scrolls to the next P value. If a beep sounds, the new entry was not accepted. Tables I and II list the range available for a specific program value.

Exit Mode - To exit the Level II programming mode, simultaneously press and hold the UP [↑ ] and [↓] arrow buttons for 3 seconds, or wait 30 seconds without pressing a button, and the display will return to alternate between Capacity Remaining and Flow Rate.

Level I Program Values (Table I)

Level I Program Values are identified by the legend on the faceplate of the control. Each Level I P value has a green LED that is illuminated when displayed. Following are the Level I P values:

DOWN [↓] arrow buttons to

DOWN

• Time of Day P1

• Time of Regen P2

• Hardness P3

• Salt Amount P4

• Capacity P5

Time of Day - How to Change AM and PM

Press the SET button. The display will show the Time of Day with the minutes digit blinking. To change this number press the UP [↑ ] arrow button to increase the number or the DOWN [↓] arrow button to decrease the number. To skip the number without changing, press the LEFT [←] arrow button. The first digit will stop flashing and the next digit will start flashing. You can only change the flashing number. When the far left digit is reached, pressing the LEFT [←] arrow button returns the flashing to the far right digit. Continue changing numbers until the desired Time of Day is displayed. Press the SET button to enter the value.

Use the same procedure to modify any of the other Level I or Level II P values.

The PM indicator is set when changing the left most digit in the time display. The left most digit will be a zero "O" or a "1”. When the PM indicator light is illuminated the time will be PM.

Level II Program Values (Tables IIA, IIB, IIC, IID, IIE and III)

The Level II Parameters are defined as P6 through P22. The available range for the Refill Controller (P6), and the Brine Draw Value (P7), may be found in the section entitled Performance Data and Charts Section of this manual (pages 55 and 55).

Table IV on page 43 lists the Level III historical data.

Manual Regeneration or Backwash

To initiate a manual regeneration or backwash, simply press and hold the REGEN button for 3 seconds. If an immediate second regeneration or backwash is desired, wait for at least one minute after the first regeneration or backwash begins and then press and hold the REGEN button for 3 seconds. A second regeneration or backwash will be performed immediately following the first. The display will freeze and only show the Regeneration Time Remaining as an indication that the second regeneration or backwash will be initiated.

When the first regeneration or backwash is complete, the second regeneration or backwash will begin and the display will alternate between Flow Rate and Regeneration Time Remaining.

Note: Series 962M and 962S Twin Alternating Systems have a two minute time period, after the manual regeneration button is pressed, where the standby unit drives to service. If an immediate second regeneration is required of the OTHER unit in the system, wait for at least three minutes after pressing the manual regeneration button the first time, then press and hold the REGEN button for three seconds.

Battery Backup

If the battery backup is provided with the Series 962 control, make sure that it is properly connected. Reference pages 32 and 33. Water usage and time of day will be maintained. The control has a trickle charge circuit that will recharge a rechargable but not a standard battery in the event it is depleted by a power outage.

5.4.1 Connecting the 962 Control

When the 962 control is used for single tank applications, two standard connections are required for operation: the power transformer and the flow sensor. Figure 5.14 outlines these standard features as well as how to connect the battery backup parallel connector and the optional remote regeneration feature.

Battery Backup

Wall Transformer

Flow Sensor

Parallel Connector

AC Power Jack

Figure 5.14

5.4.2 Connecting the 962M and the 962S Control

The 962M and 962S controls are used for twin alternating tank applications. Five standard connections are required for operation: the power transformer, the flow sensor, feedback switches and the connection between the 962M and 962S controls. Figure 5.15 outlines these standard features as well as the battery backup and the optional remote regeneration feature.

Battery Backup

Feedback Switch

Wall Transformer

Optional Remote Regeneration Feature

Important: The normally-closed position of the feedback switch is protected with a rubber boot. DO NOT REMOVE. The normally-closed position is not available to provide an auxiliary electrical signal.

Flow Sensor

Feedback Switch

962M

Figure 5.15

962 M + S Connection

962S

Optional Remote

Regeneration Feature

5.4.3 Connecting the 962 Twin and Triple Parallel Control

The 962 control can be used for twin and triple tank applications, operating in a parallel mode. Six standard connections are required for twin parallel operations; the power transformer and flow sensor for each control and the twin interconnecting cable between the

controls. Nine standard connections are required for triple parallel operation: the power transformer and flow sensor for each control and the triple interconnecting cable between the controls. Figure 5.16 outlines these standard features, as well as the battery backup and the optional remote regeneration feature.

PARALLEL SYSTEM CONNECTION PROCEDURE

Connect turbine flow meters

Connect interlock cables

Attach optional batteries

Plug transformers into outlets on common circuit

Twin Cable

Optional Remote Regeneration Feature

Figure 5.16

Triple Cable

PARALLEL INTERCONNECT CABLES PN 1034312 - Twin System Cable - 10 feet

PN 1035587 - Triplex System Cable - 10 feet each PN 1035593 - Extension Cable - 2 feet

6.0 Programming Tables

6.1 Table I - Level 1 Values

Level I Program Values for 962, 962F, 962TC, 962FTC, and 962M Controls

Description of

Program Values

P3 Hardness of water

P4 Salt amount

Day of Week

Time of day

Time of day to start

regeneration

Range of Values

1:00 - 12:59 AM/PM 00:00 - 23:59

3-250 30-2500

5-1250 2-500

Min.

Incre-

Setting

ment

1 None hour:minute

1 None

5 2

Factory

Value

0 0

Units of

Measure

hour:minute

grains/gallon

(ppm)

pounds

(kilograms)

Notes

Range depends on value selected for P13. For day of week Sun = 1, Mon = 2, Tues = 3, Wed = 4, Thurs = 5, Fri = 6, Sat = 7.

Range depends on value selected for P13 For 962M, used only if P15 = 1

Unit of measure depends on value selected for P12

Unit of measure and factory value depends on value selected for P12

P5 Capacity of unit

1-2600

0.1-260.0

0.1

Level II, III values on following pages.

Unit of measure 0 0

kilograins

(kilograms)

depends on

value selected

for P12

6.2 Table IIA

Level II Program Values - 962 Single Twin or Triple Parallel Tank Softener or Dealkalizer (P17=0)

Parameter

P1 Day of Week and

P2 Time of day to start

P3 Hardness of water 3-250

P4 Salt amount 5 – 1250

P5 Capacity of unit 1-2600

P6 Refill controller 2 - 99 1 0 Selected from chart in Performance Data

P7 Brine draw rate 2 - 99 1 0 Selected from chart in Performance Data

P9 Backwash time 4 - 30 1 14 Minutes May be adjusted for application P10 Rinse time 7 - 125 1 40 Minutes May be adjusted for application P11 Purge time 2 - 19 1 4 Minutes May be adjusted for application P12 Units of measure 0 - 1 1 0 0 = US, 1 = Metric P13 Clock mode 0 - 1 1 0 0 = 12 hour clock, 1 = 24 hour clock P14 Calendar override 0 - 30 1 0 Days 0 = no calendar override P15 Reserve Type 0 - 3 1 0 0=Variable Reserve, 1=Fixed Reserve

P16 Initial average

P17 Operation type 0 - 2 1 0 0 = Single or Parallel

Description of

Program Values

Time of day

regeneration

usage or fixed

reserve

Range of Values

(1-7) 1:00 - 12:59

AM or PM

Metric (1-7)

0:00 - 23:59 1:00 - 12:59

AM or PM

00:00 - 23:59

30-2500

2 - 500

0.1-260.0

0 - 70 1 30 Percent of Total

Min.

Increment

(1 day)

1 minute

1 None Hour

5 2

0.1

Factory

Value

None Hour

0 0

4 0

Units of Measure Notes

Range depends on value selected for P13. For day of week SUN=1, MON=2,

Minute

Grains per gallon

ppm

Pounds

Kilograms Kilograins

Kilograms

capacity

TUE=3, WED=4, THU=5, FRI=6, SAT=7. This is the left most digit on the display.

Range depends on value selected for P13 Use only if P15 = 0 or 1

Unit of measure depends on value selected for P12

Unit of measure and factory value depends on value selected for P12

Unit of measure depends on value selected for P12

Sections, page 57

Sections, page 58

2=Variable Reserve with immediate regeneration , 3=Fixed Reserve with immediate regeneration

P18 Salt/Capacity

Change Lock Out

P19 Flow Sensor select 0 0 = Magnum IT NHWB, 1 = 1.0" Autotrol

P20 K-factor or Pulse

equivalent

P21 Remote

Regeneration Switch Delay

P22 Factory Use Only

– DO NOT

CHANGE

0 - 1 1 0 0 = none, 1 = Salt /Capacity Change

Locked Out

turbine, 2 = 2.0” Autotrol turbine, 3 = User defined K-factor, 4 = User defined pulse equivalent, 5 = Magnum IT HWB

0.01 - 255.00 .01 0.01 Number used for Meter K-factor or Pulse equivalent

1 - 254 1 60 S econds Time remote switch must be active to

start a regeneration.

Do not change

Note: This programming sheet is for use with controls manufactured after 09 Aug 2000.

6.3 Table IIB

Parameter

Description of

Parameter

Level II Program Values - 962F Single Tank Filter (P17=4)

Range of Values

Min.

Increment Factory Value Units of Measure Notes

P1 Day of Week and

Time of day

P2 Time of day to start

regeneration

P3 Factory 10

P4 Salt amount 0.5 – 125.0

P5 0 U.S. - Divide the volumetric capacity

P6 Refill controller 2 - 200 1 200 P7 Brine draw rate 2 - 200 1 200 P9 Backwash time 7 - 60 1 14 Minutes May be adjusted for application.

P10 Does not apply 7 - 125 1 8 Minutes

P11 Purge time 9 - 60 1 9 Minutes P12 Units of measure 0 - 1 1 0 0 = US, 1 = Metric P13 Clock mode 0 - 1 1 0 0 = 12 hour clock, 1 = 24 hour clock P14 Calendar override 0 - 30 1 0 Days 0 = no calendar override P15 Reserve Type 0 - 3 1 0 0 = variable reserve 1 = fixed reserve,

P16 Initial average

usage or fixed

reserve P17 Operation type 0 - 7 4 0 4 = filter P18 Salt/Capacity

Change Lock Out

P19 Flow Sensor select 1 - 4 1 0 0 = Magnum IT NHWB

P20 K-factor or Pulse

equivalent

P21 Remote

Regeneration

Switch Delay

P22 Factory Use Only 0 - 9 1 99 Do not change.

1:00 - 12:59

AM or PM

0:00 - 23:59

1:00 - 12:59 AM or PM

00:00 - 23:59

0.2 - 50.0

0 - 70 1 30 Percent of T otal

0 - 1 1 0 0 = none 1 = Salt /Capacity Change

0.01 -255.00 0.01 0.01 Number used for Meter K-factor or

1 - 254 1 60 Seconds Time remote switch must be active to

1 None Day

Hour:Minute

1 2:00 AM Hour:Minute Range depends on value selected for

Grains per gallon

0.5

0.2

100

0.5

0.2

ppm

Pounds

Kilograms

gpm x 100 gpm x 100

capacity

Range depends on value selected for P13. For day of week SUN=1, MON=2, TUE=3, WED=4, THU=5, FRI=6, SAT=7. This is the lef t most digit on the display.

P13. Use only if P15 =1 Unit of measure depends on value

selected for P12 Unit of measure and factory value

depend on value selected for P12

(gallons) of the filter by 100 and enter this number into P5.

Metric - Divide the volumetric capacity (cubic meters) by 10 and enter this number into P5.

Do not change. Do not change.

Do not change May be adjusted for application.

2 = variable reserve with immediate regen, 3 = fixed reserve with immediate regen.

Description depends on value entered for P15.

Locked Out

1 = 1.0" Autotrol Turbine 2 = 2.0” Autotrol Turbine 3 = User defined K-factor 4 = User defined pulse equivalent

5 = Magnum IT HWB

Pulse equivalent

start a regeneration.

6.4 Table IIC

Level II Program Values - 962 Twin Tank Alternating Softener (P17=2)

Parameter

P1 Day of Week and

P2 Time of day to start

P3 Hardness of water 3-250

P4 Salt amount 5 – 1250

P5 Capacity of unit 1-2600

P6 Refill controller 2 - 99 1 0 Selected from chart in

P7 Brine draw rate 2 - 99 1 0 Selected from chart in

P9 Backwash time 4 - 30 1 14 Minutes P10 Rinse time 7 - 125 1 40 Minutes P11 Purge time 2 - 19 1 4 Minutes P12 Units of measure 0 - 1 1 0 0 = US, 1 = Metric P13 Clock mode 0 - 1 1 0 0 = 12 hour clock, 1 = 24 hour clock P14 Calendar override 0 - 30 1 0 Days 0 = no calendar override P15 Regeneration

P16 Capacity that must

P17 Operation type 0 - 2 1 2 2 = Twin Alternating P18 Salt/Capacity

P19 Flow Sensor select 0 0 = Magnum IT NHWB, 1 = 1.0" Autotrol

P20 K-factor or Pulse

P21 Remote

P22 Factory Use Only

Description of

Program Values

Time of day

regeneration

delay

be left on 2nd tank

to permit delayed

regeneration of 1st

tank

Change Lock Out

equivalent

Regeneration

Switch Delay

– DO NOT

CHANGE

Range of Values

(1-7) 1:00 - 12:59

AM or PM

Metric

(1-7) 0:00 - 23:59

1:00 - 12:59 AM or PM

00:00 - 23:59

30-2500

2 - 500

0.1-260.0

0 - 1 1 0 0 = Immediate regeneration

0 - 70 1 30 Percent of Total

0 - 1 1 0 0 = none 1 = Salt /Capacity Change

0.01 -255.00 .01 0.01 Number used for Meter K-factor or Pulse

1 - 254 1 60 Seconds Time remote switch must be active to

Min.

Increment

(1 day)

1 minute

1 None Hour

5 2

0.1

Factory

Value

None Hour

0 0

4 0 Kilograins

Units of Measure Notes

Range depends on value selected for P13. For day of week SUN=1, MON=2,

Minute

Grains per gallon

ppm

Pounds

Kilograms

capacity

TUE=3, WED=4, THU=5, FRI=6, SAT=7.

THIS IS THE LEFT MOST DIGIT ON THE DISPLAY.

Range depends on value selected for P13. Use only if P15 =1

Unit of measure depends on value selected for P12

Unit of measure and factory value depend on value selected for P12

Total capacity for each tank. Unit of measure depends on value selected for P12

Performance Data Sections, page 57

Performance Data Sections, page 58

1 = Regeneration delayed until time programmed in P2 is reached

Used only if P15 is set to 1

Locked Out

Turbine, 2 = 2.0” Autotrol Turbine, 3 = User defined K-factor, 4 = User defined pulse equivalent, 5 = Magnum IT HWB

equivalent

start a regeneration.

Do not change

6.5 Table IID

Level II Program Values - Electronic Timeclock Filter (P17=7)

Parameter Description Range of Values

P1 Day of Week

and Time of day

P2 Time of day to

start regenera-

tion

P3 Factory 10 P4 Does not apply 0.5

P5 Factory 10

P6 Refill controller 2 - 200 1 200 Do not change P7 Brine draw rate 2 - 200 1 200 Do not change

P9 Backwash time 7 - 60 1 14 Minutes May be adjusted for application P10 Does not apply 7 - 125 1 8 Minutes May be adjusted for application P11 Fast Rinse 9 - 60 1 9 Minutes May be adjusted for application P12 Units of

measure P13 Clock mode 0 - 1 1 0 0 = 12 hour clock, 1 = 24 hour clock P14 Interval

Regeneration

P15 Does not apply

for Timeclock

operation

P16 Does not apply

for Timeclock

operation P17 Operation type 7 7 = Filter TimeClock P18 Salt Change

Lock Out

P19 Does not apply

for Timeclock

operation P20 Does not apply

for Timeclock

operation P21 Remote

Regeneration

Switch Delay

P22 Factory Use

Only – DO NOT

CHANGE

(1-7) 1:00 - 12:59

AM or PM

Metric

(1-7) 0:00 - 23:59

1:00 - 12:59

AM or PM

00:00 - 23:59

0 - 1 1 0 0 = US, 1 = Metric

0 - 30 1 0 Days

0 - 1 1 0 0 = none 1 = Salt /Capacity Change

1 - 254 1 60 Seconds Time remote switch must be active to

Min.

Increment

(1 day)

1 minute

Factory Value

Current Day and

Time

As required Hour

0.2

Units of

Measure

Hour

Minute

between

regeneration

Notes

Range depends on value selected for P13

For day of week SUN=1, MON=2, TUE=3, WED=4, THU=5, FRI=6, SAT=7. THIS IS THE LEFT MOST

DIGIT ON THE DISPLAY

Range depends on value selected for P13 Use only if P15 = 0 or 1

U.S.- Divide the volumetric capacity (gallons) of the filter by 100 and enter this number into P5 Metric - Divide the volumetric capacity (cubic meters) by 10 and enter this number into P5

0 = No Interval chosen - *May be adjusted for application

Locked Out

start regeneration.

Do not change

6.6 Table IIE

Level II Program Values - Electronic Timeclock Softener (P17=1)

Parameter Description Range of Values

P1 Day of Week and

Time of day

P2 Time of day to start

regeneration

P3 Hardness 10 P4 Salt Amount 5 – 1250

P5 Does not apply for

TimeClock operation

P6 Refill controller 2 - 200 1 0 Selected from chart in

P7 Brine draw rate 2 - 200 1 0 Selected from chart in

P9 Backwash time 4 - 60 1 14* Minutes *May be adjusted for application

P10 Rinse time 7 - 125 1 40* Minutes *May be adjusted for application

P11 Fast Rinse 2 - 60 1 4* Minutes *May be adjusted for application P12 Units of measure 0 - 1 1 0 0 = US, 1 = Metric P13 Clock mode 0 - 1 1 0 0 = 12 hour clock, 1 = 24 hour

P14 Interval

Regeneration

P15 Does not apply for

Timeclock operation

P16 Does not apply for

Timeclock operation

P17 Operation type 1 1 = Magnum Cv Softener

P18 Salt Change Lock

Out

P19 Does not apply for

TimeClock operation

P20 Does not apply for

TimeClock operation

P21 Remote

Regeneration

Switch Delay

P22 Factory Use Only –

DO NOT CHANGE

(1-7) 1:00 - 12:59

AM or PM

Metric

(1-7) 0:00 - 23:59

1:00 - 12:59

AM or PM

00:00 - 23:59

2 - 500

0 - 30 1 0 Days

0 - 1 1 0 0 = None 1 = Salt /Capacity

1 - 254 1 60 Seconds Time remote switch must be

Min.

Increment

(1 day)

1 minute

5 2

Factory Value

Current Day and Time Hour

As required Hour

As required Unit of Measure depends on

Units of

Measure

Minute

between

regeneration

Notes

Range depends on value selected for P13

For day of week SUN=1, MON=2, TUE=3, WED=4, THU=5, FRI=6, SAT=7. THIS IS THE LEFT

MOST DIGIT ON THE DISPLAY

Range depends on value selected for P13 Use only if P15 = 0 or 1

selection in P12

Performance Data Sections,

page 57

Performance Data Sections,

page 58

clock 0 = No Interval chosen - *May be

adjusted for application

TimeClock

Change Locked Out

active to start regeneration.

Do not change

6.7 Explanation of Parameter Values for the 962 Single and Parallel Tank Controls

This section contains a detailed explanation of the programming parameters in the 962 electronic control.

Number

P1* Time of Day and Day

Description of

Program Values

of Week

Explanation

The day of the week is displayed with the time of day in the far left digit. It is programmed at P1, the same as the time of day. The day of week will automatically increment at midnight. This will allow correlation to the daily usage history stored in L7 through L13 to days of the week. Customer should use day 1 = Sunday through day 7 = Saturday. Then L7 will hold the usage history for Sunday through L13 holding the usage history for Saturday. The daily averages stored in the L-values will still be updated at the time of regeneration, not midnight. This is required to keep an accurate record for reserve capacity needed at the time of regeneration. Customers should understand that the L-value displayed for the average water usage for Sunday “day one” will be the average water usage for Sunday at 2:00 a.m. to Monday at 2:00 a.m. assuming the time of regeneration is set for 2:00 a.m. Customers can reduce this two hour shift by setting the time of regeneration to 12:01 a.m.

P2* Time of

Regeneration

If P15 is set at 0 (smart reserve), the unit will check at the P2 time to see if the smart reserve capacity has been reached. If it has, the unit WILL regenerate at the specified P2 time. If the capacity display reaches

zero gallons (m

) at any time during the day, the unit will NOT regenerate until the specified P2 time is

reached. If P15 is set at 1 (fixed reserve), the unit will check at the P2 time to see if the fixed reserve capacity (P16)

has been reached. If it has, the unit WILL regenerate at the specified P2 time. If the capacity display reaches zero gallons (m

) at any time during the day, the unit will NOT regenerate until the specified P2

time is reached. If P15 is set at 2 (smart reserve with immediate regen), the unit will check at the P2 time to see if the

smart capacity has been reached. If it has, the unit will regenerate at the specified P2 time. If the capacity display reaches zero gallons (m

) at any time during the day, the unit WILL regenerate immediately . It will ALSO continue checking at the specified P2 time to see if the fixed reserve capacity has been reached, initiating a regeneration at the P2 time if it has. If the fixed reserve is set to zero, the unit will ONLY regenerate when the capacity display reaches zero.

If P15 is set to 3 the unit will operate almost exactly the same as if it were set to 1. The only difference when set to 3 is that if the capacity were to reach zero at any time the unit will initiate an immediate regeneration. If calendar override is used P14), the unit will regenerate every 1 to 30 days at the specified P2 time.

Fixed Reserve: Fixed percentage of capacity defined by user (gallons) (m Smart Reserve: 120% of the daily average (gallons) (m

) calculated from historical values stored in

NOVRAM.

P3** Hardness of water

If the 962 controller is programmed at P12 to use U.S. units, enter hardness in grains per gallon (gpg). If the 962 controller is programmed at P12 to use metric units, enter hardness in parts per million (ppm).

P4** Salt Amount Enter your TOTAL salt amount per regeneration. For example, salting at 10 lb (4.5 kg) per cubic foot on a

) x (3 ft3) = 30 lb. salt. [(4.5 kg/ft3) x (3 ft3) = 13.6 kg salt].

unit with a resin capacity

P5 Capacity of Unit

unit with 3 cubic feet of resin, enter 30 (10 lb/ft Enter the capacity of the unit here, in kilograins (kilograms). For example, a 3 ft

of 25,000 grains (1620 grams) per ft

, enter 75 here. (25,000 grains/ft3) x (3 ft3 = 75,000 grains = 75

kilograins.

[(1620 grams/ft

) x (3 ft3) = 4860 grams = 4.86 kilograms]. Note: 15 lb/cu ft salting yields 30,000 grains/cu ft resin 10 lb/cu ft salting yields 25,000 grains, cu ft resin 6 lb/cu ft salting yields 20,000 grains/cu ft resin Reduced salting yields a reduced capacity 1 kilograin (1000 grains) = 0.0648 kilograms (64.8 grams)

P6 Refill controller This value is the refill flow rate times 10, rounded to the next whole number. For example, on a 16-inch

tank, the refill control has a flow rate of 0.8 gpm. Calculate: 0.8 gpm x 10 = 8. Enter 8.

P7 Brine draw rate This is the injector draw rate times 10, rounded to the next whole number. For example, on a 16-inch tank,

the injector has a draw rate of 0.8 gpm. Enter 8 (0.8 gpm x 10 = 8).

P8 Not used P8 is reserved for furture use. P9 Backwash time Self explanatory. Generally, 5 to 15 minutes or until water runs clear or specific water conservation needs

are met.

Number

Description of

Program Values

Explanation

P10 Slow rinse Time, in minutes, to achieve adequate slow rinse volume for resin type used. Resin manufacturers recom-

mend one to two and one half bed volumes of slow rinse water. The required amount of time is calculated using the injector performance curves provided in Section 10.0 of this manual.

For example, assuming 4 cubic feet of resin and two bed volumes of slow rinse water for a 16 x 65, 50 psi inlet pressure, program 43 minutes in Parameter P10. (4 cubic feet) x (7.5 gallons/cubic foot) = 60 gallons of slow rinse water. A “16” injector is recommended for a 16-inch tank. From the “16” injector performance chart the nominal slow rinse rate is 1.75 gpm. 60 gallons divided by 1.75 gallons per minute equals 34.2 minutes. Round up to 35 minutes and enter in P10.

P11 Fast rinse Time, in minutes, to achieve adequate fast rinse volume for resin type used. For example, for standard

softening resin (lonac C-249), fast rinse at 30 gallons (0.11 m resin will require 90 gallons (0.34 m

(30 gal/ft

x 3 ft3) = 90 gallons. (0.11 m3/ft3 x 3 ft3 = 0.34 m3). The fast rinse flow rate is controlled by the

) of water to obtain the resin manufacturer’s recommended fast rinse.

drain line flow control. For this example, assume a 5 gpm (1.14 m minutes in P10. (90 minutes/5 gpm) = 18 minutes (0.34 m

) per cubic foot of resin. A unit with 3 ft3 of

/hr) drain line flow control. Enter 18

/1/14 m3/hr = 0.3 hr/ x 60 min = 18 minutes). P12 Units of measure Self explanatory. Enter 0 for U.S., enter 1 for metric. P13 Clock mode Self explanatory. Enter 0 for 12-hour clock, enter 1 for 24-hour clock. P14 Calendar override P15 Reserve type

0 = No calendar override. 1 - 30 = Maximum number of days between regeneration/backwash. See P2. Not used in Alternating mode.

Immediate or delay regeneration

P16*** Fixed Reserve

capacity

If P15 is set at 1 or 3, enter the fixed reserve capacity (in gallons) (m explained in numbers P2 and P15 above. Not used in Alternating mode.

) that the unit will look for. This is

P17 Operation type Self explanatory. 0 = Single or Parallel Softener; 4 = Single or Parallel Filter. P18 Salt/capacity lockout

Allows for the lock out of P4 and P5 so that NO unauthorized changes to the programmed values can be made.

P19 Flow Sensor Select

This parameter is used to select the flow sensor that is to be used with the system. The factory-preset value is 0. The range is 0 - 5. 0 = Magnum IT NHWB, 1 = Autotrol 1-inch turbine, 2 = Autotrol 2-inch turbine, 3 = user programmable Kfactor, 4 = user programmable pulse equivalent, 5 = Magnum IT HWB. The respective meter manufacturer should supply the K-factors or pulse equivalents for individual meters.

P20 K-factor or pulse

equivalent

The range is 000.01 to 255.00 in 0.01 steps. How this number is used is defined by the values stored in P12 (units of measure) and P19 (flow sensor select). P12 is used to define gallons or liters (0 = gallons, 1 = liters). P19 is used to define K-factor which is defined as pulses per gallon or pulses per liter. Signet and Sea-Flow are two flow sensor manufacturers that publish a K-factor. The control can now use any flow sensor as long as the programmed K-factor is correct. The pulse equivalent is defined as gallons or liters per pulse. The control will register 5 gallons of flow for every pulse if P12 = 0, P19 = 4 and P20 = 5.00. Badger Meter is one manufacturer that uses a pulse equivalent. The control will not show flow rate if P19 = 4 (pulse equivalent). This is because pulses are accumulated over 10 seconds and flow rate is displayed in gallons per minute. The control will alternate between time of day and capacity remaining or regeneration time remaining during normal operation.

P21 Remote

regeneration/ backwash switch delay

This parameter is used to program the length of signal time required to initiate a regeneration/backwash using a differential pressure switch or remote start button/contact. This range is 1 to 254 seconds in 1second steps. The default is 60 seconds. A counter starts when there is a closed dry contact (no voltage) to this imput. A regeneration/backwash will start when the contacts remain closed for the programmed time. The counter will reset to zero when the contacts open for at least 0.02 seconds. The remote regeneration input cannot be used to perform a double manual regeneration. The remote regeneration input is ignored during a regeneration/backwash.

P22 Factory use only

DO NOT CHANGE

*The 962 controller functions in either a 12-hour or 24-hour clock mode. Programming P13 (clock mode) before P1 or P2 will eliminate any confusion when setting these parameters.

**The 962 controller functions in either U.S. or metric units. Programming P12 (units of measure) before P3 or P4 will eliminate any confusion when setting these parameters.

***The calculated gallon amount loaded into the daily registers (L7 through L13) at START-UP, uses this percentage of capacity. Example: 90,000 grains in P5 ÷ 10 grains in P3, 90,000/10 = 9,000 gallon capacity, 9,000 x .3 (30% in P16) = 2700 gallons, which is loaded into L7 through L13, the daily average) = 3240 gallon. This daily average will change as actual water usage information is gathered

6.8 New Features in The 962 Family Controls

P1 Day of Week Programming

The day of the week is now displayed with the time of day in the far left digit. It is programmed at P1 the same as the time of day. The shift key will move the flashing digit to the far left digit skipping the blank digit between time of day and day of week. The day of week will automatically increment at midnight. This change will allow correlation of the daily usage history stored in L7 through L13 to days of the week. Use day 1 = Sunday through day 7 = Saturday. Then L7 will hold the usage history for Sunday through L13 holding the usage history for Saturday. The daily averages stored in the Lvalues will still be updated at the time of regeneration not midnight. This is required to keep an accurate record for reserve capacity needed at the time of regeneration. The L-value displayed for the average water usage for Sunday “day one” will be the average water usage for Sunday at 2:00AM to Monday at 2:00AM. Assuming the time of regeneration is set for 2:00AM. To more closely match the averages to the days set the time of regeneration to 12:01AM.

P19 Flow Sensor Select

P19 will not show 1.0, 1.5, 2.0, 3.0 for flow sensor sizes as before. P19 will now show “0” for Magnum IT NHWB, “1” for Autotrol 1 inch turbine, “2” for Autotrol 2 inch turbine, “3” for user programmable K-factor, and “4” for user programmable pulse equivalent, “5” for Magnum IT HWB. The K-factors or Pulse equivalents for individual meters should be supplied by the respective meter manufacturer. The control is no

longer preprogrammed for the Data Industrial 1.5 inch and 3.0 inch flow sensors. The default value is

“0” for use with the Magnum IT NHWB.

P20 K-factor or Pulse Equivalent

P20 is now used for user defined K-factor or pulse equivalent. The range is 000.01 to 255.00 in 0.01 steps. How this number is used is defined by the values stored in P12 (units of measure) and P19 (flow sensor select). P12 is used to define gallons or liters (0 = gallons, 1 = liters). P19 is used to define K-factor or pulse equivalent (3 = K-factor, 4 = pulse equivalent). K-factor is defined as pulses per gallon or pulses per liter. Signet and Sea-Flow are two flow sensor manufacturers that publish a K-factor. The control can now use any flow sensor as long as the programmed K-factor is correct. The pulse equivalent is defined as gallons or liters per pulse. The control will register 5 gallons of flow for every pulse if P12 = 0, P19 = 4 and P20 = 5.00. Badger Meter is one manufacturer that uses a pulse equivalent. The control will not show flow rate if P19 = 4 (pulse equivalent). This is because pulses are accumulated over 10 seconds and flow rate is displayed in gallons

per minute. The control will always alternate between time of day and capacity remaining or regeneration time remaining.

P21 Remote Regeneration Delay

P21 is used to program the delay time for the remote regeneration start. The range is 1 to 254 seconds in 1 second steps. The default is 60 seconds. This function was added because customers are connecting differential pressure switches to this input. A counter starts when the conductors of this input are connected with a dry contact closure. A regeneration will start when the conductors remain connected for the programmed time. The counter will reset to zero when the connection is broken for at least 0.02 seconds. The remote regeneration input cannot be used to perform a double manual regeneration. The remote regeneration input will be ignored when the control is doing a regeneration.

P22 Factory Programming Use Only!

P22 is used by the factory for preset programming of the 962 control. 99 is entered into this location by the software. Any number entered into P22 will cause all previous programming to be lost. If P22 is accidentally entered via the set button and a digit is flashing the control should be left to exit program mode on its own. This will occur after 30 seconds. P22

should not be changed except at the factory!

Regeneration Cycle Advance

A function was added to advance the control to the next stop position during a regeneration. Pressing and holding the left arrow key for three seconds will cause the control to advance to the next stop position of the regeneration. The regeneration time remaining will decrease by the amount of stop time that was skipped. This function will not work when the motor is on. The control will beep if the left arrow key is held for 2.5 seconds and the motor output is on. During regeneration the control would not stop in the correct position if time was skipped during a motor-on time.

Regeneration Cancel

To cancel a regeneration in progress press and hold the LEFT (←) arrow and set button for three seconds. An “Err 3” will appear on the control, the motor will start, and the control will advance to home. The cam may be manually advanced to just prior to Regeneration Complete. The control must be at least two minutes into the regeneration before it can be cancelled.

Battery Backup Option

All 962 family controls are now battery backup capable. There is a door in the backplate that allows access to the battery harness. A 9 volt rechargeable battery is available from GE Osmonics P/N 1075768. The battery

is a VARTA, TYPE V7/8H (AccuPlus Nickle Hydride Nimh 9v 150 mAH, No. 5522). A standard nonrechargeable battery is an option for backup but needs to be replaced periodically.

Level IV Day of Week Regeneration

It is now possible to program individual days that the system will regenerate regardless of water usage. When programmed, this feature will override the demand regeneration and will reset capacity remaining upon completion of the regeneration. This feature insures that a regeneration will occur on programmed days. All other times the system will operate as a demand system. Level IV must be accessed to program Day of Regeneration. Simultaneously press the LEFT and DOWN arrow buttons for 3 seconds to gain access and then press the UP or DOWN arrow buttons until the desired Day location (1-7) is displayed. Press the LEFT arrow button to display value in the location, 0 = no Regeneration - 1 = Regeneration. To program a regeneration for a specific day, go to that day and change the 0 to 1. A regeneration will occur at

6.9 Table III - Historical Data

the time that is programmed into P2. A regeneration will occur every week on the day(s) that is (are) programmed with a 1.

Level III Memory Locations

To assist in troubleshooting the Water Conditioning System, the contents of the controller memory can be examined to determine the status of the control and the history of water usage. To view the controller’s memory locations “L1” to “L15” described in Table III, the location viewing mode must be selected. This mode can be selected by simultaneously pressing the LEFT (←) and the UP (↑ ) buttons. The control will then show “L1” on the display. Locations can be stepped through in the same method as described for Level II programming. However, the [SET] button is inactive except for L4. If [SET] is pressed when L4 is displayed, Peak Flow is reset to zero. If [SET] is pressed when any other location is displayed, the control will beep.

Level III Historical Data

Location Range Description

L1 1 - 7 Day L2 0 - 255 Days since last regeneration

L3 L4 0-200 (0-50.0) Peak Flow in gallons per minute (m

L5 0-655360(0-6553.6) Water used today in gallons (m L6 0-655360(0-6553.6) Water used since last regeneration in gallons (m3) L7 0-655360(0-6553.6) Average water usage for Day 1 in gallons (m L8 0-655360(0-6553.6) Average water usage for Day 2 in gallons (m

L9 0-655360(0-6553.6) Average water usage for Day 3 in gallons (m L10 0-655360(0-6553.6) Average water usage for Day 4 in gallons (m L11 0-655360(0-6553.6) Average water usage for Day 5 in gallons (m L12 0-655360(0-6553.6) Average water usage for Day 6 in gallons (m L13 0-655360(0-6553.6) Average water usage for Day 7 in gallons (m

L14 0-999990(0-99999.9)

L15 0-167(0-16)

1:00-12:59 AM/PM 0:00-23:59

Time of day that peak flow occurred

/hr) since location reset

) since time of regeneration

Total water used since controller installed in gallons or (m digits)

Total water used since controller installed in gallons x 10 significant digits)

)

)(least significant

or (m3)(most

6.10 Table IV

Model 962 Error Messages

Indication Description Cause Solution

Err1 Electronics failure

Improper finish of regeneration. Improper finish of a regeneration (control indicates that it is in either

Err2

Err3

standby, service, or regeneration complete and it should not Regeneration failure (no start)

Improper start of regeneration. Regeneration was not completed within calculated time. Improper start of a regeneration (control cycle position pointer indicates that it is in regeneration and it should be in either standby, service, or regeneration complete.)

be)

a. Control settings need

reprogramming

a. Valve camshaft has been

manually rotated during a

regeneration b. Faulty motor or gears c. Faulty motor drive d. Faulty switch

a. Valve camshaft has been

manually rotated out of

“regeneration complete”

position b. Faulty motor or gears c. Faulty motor drive d. Faulty switch

a. Press any key to load default

values. Refer to Programming the Series 962 Control

a. Press any key to silence the

alarm. (Note: alarm automatically clears at “TIME

OF REGEN”) b. Replace control c. Replace control d. Replace control

a. The control will turn the motor

on and drive the camshaft to the

proper location b. Replace control c. Replace control d. Replace control

Err4 Improper control settings

a. One or more settings out of

the allowable range

a. Hardness:

Adjust range: 3 to 250

(30-2500)

Capacity:

Adjust range: .1-260.0

(.1-260.0)

Refill Control:

Adjust range: 2-99

Brine Draw Value:

Adjust range: 2-99

7.0 Multi-Tank

7.1 Twin Alternating Systems

The Magnum IT valve is available in a preconfigured twin-alternating package which assure the flow of

softened water at all times. One tank provides service water while the other is in regeneration or standby.

Figure 7.1 Magnum IT Twin Alternating System with 962M and 962S (Main and Secondary) Controls

7.1.1 Twin Alternating Control Set-Up

Task

1. Open manual bypass valve

2. Close manual inlet and outlet valves

3. Mount 962M main and 962S secondary controls [962M and 962S controls must be in the midpoint of the SERVICE position before inserting camshaft]

4. Connect 12VAC power supply to 962M control

5. Program the 962M main control. (See Table IIC for programming parameters.) [LED will show ERR4 message indicating controls require programming]

6. Exit programming mode. Depress up and down buttons for 3 seconds or wait 30 seconds

7. Disconnect 12VAC power supply from 962M control

962M Main Control Position

962S Secondary Control

Tank 1

SERVICE SERVICE

Position

Tank 2

8. Manually rotate camshafts to REFILL REFILL REFILL

9. Connect external cam switches REFILL REFILL

10. Connect 962M main and 962S

REFILL REFILL

secondary controls with factory-installed 4-pin connector.

11. Reconnect 12VAC power supply and

REFILL REFILL

optional battery backup to the 962M

Important: When connecting the optional battery backup, the black wire Connecting the red wire first could result in serious

Condamage to the circuit board.

12. Observe controls for proper operation.

should be connected first!

STANDBY REFILL

[Tank 1 control will rotate to the STANDBY position followed by Tank 2]

13. Observe controls for proper operation.

STANDBY SERVICE

[962M will remain in STANDBY. 962S will rotate to SERVICE]

14. System is now ready for operation STANDBY SERVICE

7.1.2 Additional Checks:

Task

1. Initiate Manual Regeneration (Press and hold REGEN button for 3 seconds). LED display will alternate between Tank 2 FLOW and Tank 2 REGEN TIME REMAINING for 2 minutes. After two minutes, Tank 1 will rotate to SERVICE position and Tank 2 will begin BACKWASH cycle. LED will display Tank 1 FLOW and Tank 2 REGEN TIME REMAINING.

2. Observe for proper operation. After 2 minutes, manually rotate the 962S secondary control (Tank 2) through the entire regeneration cycle. To continue operational checks, go to the next step.

3. Manually rotate 962S control (Tank

2) cam shaft to STANDBY. LED display will show ERR2 indicating the regeneration on Tank 2 ended too soon.

962M Main Control Position

Tank 1

STANDBY

SERVICE

962S Secondary Control

Position

Tank 2

SERVICE

BACKWASH BRINE / SLOW RINSE FAST RINSE REFILL

STANDBY

4. Clear ERR2 by pressing LEFT button [← ]. LED display will alternate between Tank 1 FLOW and CAPACITY.

5. Test the optional battery power by momentarily disconnecting the AC power jack. Reconnect power jack. When power jack is reconnected, LED display should continue to alternate between Tank 1 FLOW and CAPACITY. If the control is not getting power, the LED display will alternate between CAPACITY and

TIME OF DAY.

MANUAL REGENERATION

The 962M main control allows the operator to select the tank to be regenerated by pressing the left arrow [← ] button. When the desired tank is shown in the LED display (far left character), a regeneration of the displayed tank can be initiated by depressing the REGEN button for 3 seconds. If the tank that is currently in SERVICE is selected, the opposite tank will rotate from STANDBY to SERVICE while the selected tank is regenerating. Depressing the REGEN button for 3 seconds while the selected tank is regenerating will initiate a regeneration on the opposite tank once the selected tank has completed its regeneration cycle.

SERVICE

STANDBY

7.2 Twin or Triple Systems

The Magnum Electronic Controls may be configured as a twin parallel or triple parallel system which assures, through an electrical interlock built into the 962 controls, that only one unit will regenerate at a time. Compared to a single system, the parallel system also provides twice the available service flow rate when both units are on line in a twin system and three times the available service flow rate when all three units are

on line in a triple system. When the capacity of one of the units in a parallel system has been exhausted, the 962 control takes the unit “off-line”, regenerates the unit, then returns the unit to “on-line” status while preventing the other units in the system from regeneration through an internal electrical lockout.

Figure 7.2 Magnum IT Twin Parallel Configuration

Optional Second Brine Tank

Figure 7.3 Magnum IT Triple Parallel Configuration

7.2.1 Parallel Control Set-Up

Initial Setup

• It is advantageous to perform all control

programming prior to start up of the entire water treatment system.

• Open the system manual bypass valve and close

all inlet and outlet valves.

• Mount all 962 controls on the valves. All controls

must indicate that they are in the REGENERATION COMPLETE position before inserting the camshaft.

• Connect the 12VAC power supply to each control.

• Connect the interconnect cable provided with the

system to the factory installed 4 pin connector on each control. Also connect the optional battery back-up if provided.

• Program each 962 control in the system. See Table

IIA and Special Programming below for programming parameters. On initial power-up, the LED display will show an ERR4 message which indicates that one or more of the programming parameters are not set or is out of the allowable range. Enter and exit the programming mode by depressing the UP [ ↑ ] and DOWN [ ↓ ] buttons for 3 seconds. The programming mode can also be exited by not

pressing a button for 30 seconds.

• Set all other parameters, 1 through 20, except

those identified above, as you would a standard 962 single control.

Additional Conditions

• Each 962 control requires its own 12-volt

transformer. They should all be plugged into the same power circuit. Power loss to only one transformer within the system may cause the system to malfunction.

• Each control valve should be equipped with a no

hard-water bypass cartridge.

• The flow through each control valve should be

balanced.

• The programming for all controls should be the

same.

• Three brine tanks are recommended on triple

parallel systems. This will provide adequate salt brine for all regenerations and eliminates concern for lack of brine strength when utilizing a single brine tank, should back to back regenerations take place.

Special Programming

• Set P5-Capacity - below actual capacity - a reserve

sufficient to provide two hours of service flow is recommended. This provides soft water when regeneration is delayed because another unit is already in regeneration.

• Set P15-Reserve Type - “3” - fixed reserve with

immediate regeneration. This causes the control to do an immediate regeneration when the gallons remaining reaches zero.

• Set P16-Fixed Reserve - “0” - zero reserve. This

prevents the control from initiating a regeneration at the programmed time, P2.

8.0 Start-Up Procedure

The following steps provide general guidelines for the start-up of a water conditioning system with a Magnum control valve. Start up only one unit at a time. It is advantageous to perform all 962, 962F, or 962M programming prior to start-up.

1. Disconnect the electric power to the Magnum control. Fill the brine tank with 6 inches of water but

add salt to the brine tank at this time.

do not

2. The manual inlet and outlet valves should remain closed with the manual bypass valve open.

3. Remove the cam cover to reveal camshaft. Verify that the correct cam is inserted all the way into the control. Access to the camshaft is required to manually index the control valve to the desired cycles of operation.

4. Advance the control to the Backwash position by turning the camshaft COUNTERCLOCKWISE. (Pilot flappers #2, #3, and #5 are OPEN.) THE PROPER SIZE DRAIN LINE FLOW CONTROL FOR THE SYSTEM BEING STARTED UP MUST BE INSTALLED IN THE DRAIN LINE AS CLOSE TO THE CONTROL VALVE AS POSSIBLE.

5. Slowly open the manual inlet valve. Water will begin to flow to drain. Water pressure must build to approximately 20 pounds per square inch (psi) (137 kPa) in the control valve and tank for the pilot/diaphragm valve system to operate properly. Continue to open the manual inlet valve slowly. (Note: large capacity systems will flow an extremely large amount of water to drain while pressure builds within the system). A definite change in the flow to drain and sound, as the diaphragm cartridges shift into position, will indicate that adequate pressure has been built up in the system. When the control valve does shift into the backwash position, the air in the tank will be pushed out through the drain line. Monitor the drain line closely during this time. If backwash flow during start-up is too high, resin or mineral could be pushed out of the tank through the drain line. The manual inlet valve can be closed slightly to prevent resin loss, however, a minimum pressure must be maintained within the system for continued pilot/diaphragm valve operation.

Note: There are times when the system has a difficult time building enough pressure for proper pilot/diaphragm valve operation, such as low pressure applications and larger pipe sizes. If water flows to drain in all cycles and does not shut off in service, typically, either the inlet valve is not open far enough or the drain line flow control has not been installed in the drain line.

6. After all the air has been purged from the tank, allow the backwash water to flow to drain until clear.

7. Advance the control camshaft to the Brine/ Rinse position by rotating the camshaft COUNTERCLOCKWISE. (Pilot flappers #B1, #B2, #1, #3, and #5 are OPEN on softeners only--this cycle is skipped on 3-cycle filters.) The water flow to drain should reduce significantly and brine draw should be observed. Reference the Performance Data and Charts section.

8. Advance the control to the Fast Rinse position by turning the camshaft COUNTERCLOCKWISE. (Pilot flappers #1, #3, #4, and #5 are OPEN.) The water flow to drain should increase significantly, to approximately the same as the backwash flow.

9. Advance the control valve to the Refill position by rotating the camshaft COUNTERCLOCKWISE. (Pilot Flappers #B1, #B2, #1, #2, and #4 are OPEN. Pilot Flapper #3 on Twin Alternating systems is also OPEN. This cycle is skipped on 3-cycle filters). A flow of water should be filling the brine tank. The brine tank can be filled to the proper level if the water height is known. There should be NO flow to drain. Reference the Performance Data and Charts section.

10. Advance the control valve to a position just before the Regeneration Complete position (softener) or the Backwash Complete position (filter). Connect electrical power to the controller. Allow the control to drive the camshaft to the home position. Note: See the special section 7.1.1 for Twin Alternating control set-up.

11. Open the manual outlet valve completely and close the manual bypass valve. Perform any 942 or 942F control programming if necessary. Check the effluent for soft or iron-free water. Add salt to the brine tank.

water

9.0 Service Instructions

Symptom Pos si bl e Ca us e Solution

1. Water conditioner fails to regenerate. No soft water.

2. No Brine Draw. a. Plugged injector or injector screen.

3. Insufficient brine draw. a. Partially clogged injector or injector

4. Insufficient Refill to Brine Tank.

5. Excessive Water in Brine Tank.

a. Power supply to Magnum control

has been interrupted. b. Water pressure lost. c. For 942 series control, day pins are

not pushed in. d. For 962 series control, improper or

no initial programming. e. For 952 series control, no start of

regeneration signal received or

length of signal is insufficient. f. Defective control. g. No salt in brine tank. h. Manual bypass valve is open. i. For 962 series control, turbine meter

is clogged or restricted. j. Leak at riser pipe seal. k. Insufficient brine. l. Plugged injector or injector screen.

b. Insufficient water pressure. c. Obstructed drain line.

screen. b. Restricted flow rate in brine line. c. Insufficient water pressure. d. Excessive back pressure on injector

due to elevated drain line. e. Partially restricted drain line.

a. Restricted flow rate in brine line. b. P6 (Refill) value incorrectly set. c. P7 (Brine Draw) value incorrectly

set. a. Plugged drain lin e flow control. b. Plugged injector and/or injector

screen. c. Incorrect refill control.

a. Determine reason for power interruption

and correct.Reset time of day. b. Restore water pressure. c. Push day pins in for desired

regeneration days. d. Check programming val ues in 962

control and correct as needed. e. Test source signal to ensure positive

closure and length of signal. A minimum

signal length of 3 minutes is required. f. Replace control assembly. g. Add salt and regenerate. h. Close manual bypass valve. i. Inspect turbine meter assembly, clean

or replace. j. Insure that riser pipe is properly sealed

at tank adapter o-ring. Inspect pipe for

cracks. k. Check refill control and clean if

necessary. Check control settings.

Check flow rate capabilities of safety

float and air check assembly. l. Inspect and clean injector and/or injector

screen. a. Inspect and clean injector and/or injector

screen. b. Increase water pressure above 25 psig

(172 kPa) minimum. c. Remove obstruction. a. Inspect and clean injector and/or injector

screen assembly. b. Check flow rate capabilities of the safety

float/aircheck assembly. c. Increase water pressure above 25 psig

(172kPa) minimum. d. Reduce drain line elevation to height of

valve. e. Remove restriction. a. Check flow rate capabilities of the safety

float/aircheck assembly. b. Reprogram P6. c. Reprogram P7. a. Clean flow control. b. Inspect and clean injector and/or

screen. c. Install correct control.

Symptom Pos si bl e Ca us e Solution

6. Leak to Drain. a. No flow control installed in drain line. b. Insufficient water pressure. c. Plugged injector and/or injector

screen.

d. Back pressure on pilot drain port.

7. Loss of Media to Drain. a. No flow control installed in drain line. a. Install drain line flow control.

8. Loss of Water Pressure. a. Fouled resin bed due to iron

accumulation.

b. Slots in riser pipe or laterals are filled

with resin fines.

9. Salt in Water to Service

After Regeneration.

10. Err1, Err2, Err3, Err4. a. See Table IV. a. See Solution in Table IV.

11. Both tanks of Twin Alternating system in Standby.

12. Display shows flow on tank in Standby.

a. Injector is too small for system size. b. Brine draw time excessively long

due to low water pressure. c. Restricted drain line. d. Insufficient rinse volume. e. Plugged injector and/or injector

screen.

a. Defective cam switch. b. Miswired cam switch.

a. Cams were turned manually. a. Follow procedure in Section 7.1.1 to

a. Install drain line flow control. b. Increase water pressure above 25 psig

(172 kPa) minimum.

c. Inspect and clean injector and/or injector

screen.

d. Plumb pilot drain line to atmospheric

position (i.e. brine tank).

a. Clean Magnum control valve and

mineral bed with cleaner.

b. Inspect and clean distributor pipe slots

as needed. a. Install correct injector. b. Increase water pressure above 25 psig

(172 kPa) minimum. c. Remove drain line restriction. d. Increase slow rinse time, fast rinse time,

or both. e. Inspect and clean injector and/or injector

screen.

a. Replace cam switch. b. Replace wiring.

synchronize controls.

Magnum Cv Leak to Pilot Drain Troubleshooting

One possible cause is obstruction in valve disc area preventing disc from sealing. Another possibility is a tear in the diaphragm. This chart will help locate possible problem area.

Not Leaking During Suspect Cartridge

Service Cycle #3 NHWB

Backwash #1 Drain

Brine/Slow Rinse #2 Rinse

Fast Rinse #4 Inlet

9.1 Magnum Valve Cartridge Removal Procedure

Removal of cartridges should be done only after reviewing all other possible causes of the problem(s) being addressed. There may be some difficulty removing cartridges in valves that have been in service for a period of time. Scale or iron build up around the O-ring seals may cause breakage in the cage assembly of the cartridge. If this occurs the cartridge must be replaced.

To remove the number 1 or number 2 cartridges the control must be removed first (see Assembly instruction in the Magnum instruction manual, page 3).

What follows is a step-by-step procedure for cartridge removal:

1. Remove the four bolts securing the cartridge.

2. There are two parts or sections in the “cap” of the cartridge assembly. The first part is the cover for the diaphragm. The second part is attached to the main cartridge assembly. This part is in contact with the body of the Magnum valve. When referring to inserting screwdrivers for cartridge removal it is the area between the Magnum valve body and the

second part of the cartridge that is being referred to. See Figure 9.1.

3. A small flat blade screwdriver should be inserted as indicated in drawing. Pry a small opening between the Magnum valve body and the second part of the cartridge. This will allow the insertion of two larger flat blade screwdrivers that will be used to remove the cartridge.

4. Insert the two larger flat blade screwdrivers at the 10 o’clock and 2 o’clock positions on the cartridge. These should be inserted approximately 1/2 inch into the opening created by the small blade screwdriver. Use the two screwdrivers to slowly move the cartridge out of the valve body.

5. The cartridge should be removed for inspection. Look for damaged O-ring or debris on sealing surface ring of poppet.

There are two nipples at the 5:30 and 6:30 locations on the inside of the cartridge cap which transfer water to and from the diaphragm. There are two O-rings associated with the nipples. The O-rings must be in place when the cartridge is re-installed into the valve body.

Remove bolts (4)

Correct Insertion Point

Incorrect Insertion Point

Figure 9.1

10.0 Performance Data and Charts

10.1 Magnum Injector Data

* Brine draw and Rinse rates on empty tank

10.2 Magnum Flow Controls

Refill Control Identification

.495

Cavity Number

X X X

X X

Flow Rate (gpm)

Table 10.1 Magnum Refill Control Chart (P/N Indicates 3-Pack)

Tank

Part Number

1040679 14 (35.6) 0.7 (2.65) 7

Diameter

In. (cm)

Flow Rate

GPM (LPM)

Program P6 Value

1040680 16 (40.6) 0.8 (3.03) 8 1040681 18 (45.7) 1.0 (3.79) 10 1040682 21 (53.3) 1.4 (5.30) 14 1040683 24 (61.0) 2.0 (7.57) 20 1040684 30 (76.2) 3.0 (11.36) 30 1040685 36 (91.4) 5.0 (18.93) 50

Note: All flow rates are based on an inlet pressure of 60 psig (413 kPa). Actual rates will vary with pressure, temperatures and other system variables.

10.3 Magnum Injector Controls

Injector Identification

Table 10.2 Magnum Injector Chart

Tan k S i z e

Part Number

1000441 1040670 14 (35.6) 0.5 (1.89) 5 1000442 1040671 16 (40.6) 0.5 (1.89) 5 1000443 1040672 18 (45.7) 0.6 (2.27) 6 1000444 1040673 21 (53.3) 0.9 (3.41) 9 1000445 1040674 24 (61.0) 1.4 (5.30) 14 1000446 1040675 30 (76.2) 2.0 (7.57) 20 1000447 1040676 36 (91.4) 3.3 (12.5) 33 1000448 1040677 Blank 0.0 Filter Application Only

Note: All flow rates are based on an inlet pressure of 60 psig (413 kPa). Actual rates will vary with pressure, temperatures and other system variables.

Part Number

with O-rings

Tank

Diameter

In. (cm)

Draw Rate

GPM (LPM)

Program P7 Value

10.4 Drain Line Flow Control

Table 10.3 Recommended Backwash Flow Rates for Various Media

Tank Diameter

Media

14 in

(35.6 cm)

Tank

16 in

(40.6 cm)

Tank

18 in

(45.7 cm)

Tank

Cubic Feet of Media/Drain Line Flow Control in GPM

*Softening Resin (4.5 gpm/ft (1.1 Lph/cm

)

3/5 4/6 5/8 7/12 10/15 15/25 20/30

*Fine Mesh Softening Resin (3.4 gpm/ft (.83 Lph/cm

)

3/4 4/5 5/6 7/8 10/10 15/17 20/15

Multi Layer

(15 gpm/ft

)

(3.66 Lph/cm

)

3/15 4/20 5/25 6/30 7/50 10/70 15/105

Birm, Greensand, Carbon (10 gpm/ft

)

(2.44 Lph/cm

)

3/10 4/15 5/17 7/20 10/30 15/50 20/70

*60 oF (15 oC) water temperature, 50% bed expansion

21 in

(53.3 cm)

Tank

24 in

(61.0 cm)

Tank

30 in

(76.2 cm)

Tank

36 in

(91.4 cm)

Tank

10.5 Autotrol Drain Line Flow Control

Table 10.4 Autotrol Drain Line Flow Controls (5 gpm - 40 gpm)

Part Number

1040720 5 1.135 Blue Black Black Black 1040721 6 1.362 Red Black Black Black 1040722 7 1.589 Brown Black Black Black 1040723 8 1.816 Green Black Black Black 1040724 9 2.043 White Black Black Black 1040725 10 2.27 Blue Blue Black Black 1040726 11 2.497 Red Blue Black Black 1040727 12 2.724 Red Red Black Black 1040728 13 2.951 Brown Red Black Black 1040729 14 3.178 Brown Brown Black Black 1040740 15 3.405 Blue Blue Blue Black 1040741 16 3.632 Green Green Black Black 1040742 17 3.859 White Green Black Black 1040743 18 4.086 White White Black Black 1040744 19 4.313 White Orange Black Black 1040745 20 4.54 Blue Blue Blue Blue 1040746 21 4.767 Brown Brown Brown Black 1040747 22 4.994 Green Green Red Black 1040748 23 5.221 Green Green Brown Black 1040749 24 5.448 Red Red Red Red 1040730 25 5.675 Green Green White Black 1040731 26 5.902 White White Green Black 1040732 27 6.129 White White White Black 1040733 28 6.356 Brown Brown Brown Brown 1040734 29 6.583 Brown Brown Brown Green 1040735 30 6.81 Orange Orange Orange Black 1040736 31 7.037 Green Green Green Brown 1040737 32 7.264 Green Green Green Green 1040738 33 7.491 Green Green Green White 1040739 34 7.718 Green Green Green Orange 1040750 35 7.945 White Green Green Green 1040751 36 8.172 White White White White 1040752 37 8.399 White White White Orange 1040753 38 8.626 Orange Orange Orange Green 1040754 39 8.853 Orange Orange Orange White 1040755 40 9.08 Orange Orange Orange Orange

Flow Control Disk

gpm

Insert 1 Insert 2 Insert 3 Insert 4

Note: Drain Line Flow Controls above 40 gpm require external control installed in drain line.

11.0 Wiring Diagrams

11.1 Model 962 Series Electronic Control Remote Regeneration Initiation

Magnum 962

CONTROL SOURCE POWER .2mA @ 12 VAC

SOURCE POWER ..... 2mA@

(FROM 962, 962M

(FROM 962, 962M) 12VDC

TRANSFORMER)

INITIATE BY PUSH BUTTON

PUSH BUTTON SWITCH

SWITCH OR ALTERNATE

OR ALTERNATE SWITCH

SWITCH OPERATION - DRY

OPERATION

CONTACT CLOSURE

MINIMUM SIGNAL LENGTH

... 3 SECONDS

0.3 SECONDS

MAXIMUM SIGNAL LENGTH 254 SECONDS

NOTE: The 962 Series Electronic Control is not recommended for pressure differential initiation or sequential regeneration of multiple tank systems. Please consult GE Osmonics for these applications.

11.2 Model 952 Twin Series Impulse Control

952 Switch

CNONC

Black

Red

Start

11.3 Model 952QC Impulse Control

Motor

White

LEGEND YELLOW ISOLATION RED START REGENERATION BLACK HOT WHITE NEUTRAL GRN/YEL GROUND FEEDBACK CABLE

RED AND BLACK

FEEDBACK SIGNAL WIRES / CONNECTORS

QC CABLE

CNO NC

BLACK

RED

BLACK

RED

BLACK WHITE RED

RED

WHITE

BLACK

YELLOW

MOTOR

MOTOR LEADS

WHITE

GROUND NOT USED IN THIS APPLICATION

GREEN / YELLOW

YELLOW / WHITE ISOLATION SIGNAL

11.4 Triple Parallel Wiring

Model 962 Twin or Triple Parallel Wiring Schematic

11.5 Model 962 Twin Alternating System Main/Secondary Wiring Schematic

12.0 Assembly Drawings and Parts List

Magnum Controls

12.1 Manual Controls

Figure 12.1 Magnum 942MAN

Table 12.1 942 Manual Control Configurations

Part Number Description

1034398 Manual Control/942Man Softener/English 1034399 Manual Control/942FMan Filter/English

Figure 12.2 Magnum 942F MAN

12.2 Mechanical Timeclock Controls

Magnum 942

Figure 12.3 Magnum 942 (Softener)

Magnum 942F

Table 12.2 Mechanical Timeclock 12V/50 Hz Configurations

Part Number Description

1046850 Timeclock Control/942 Softener/7 Day/24 Hour/12 VAC/50 Hz

Figure 12.4 Magnum 942F (Filter)

1046851 Timeclock Control/942 Softener/12 Day/24 Hour/12 VAC/50 Hz 1046852 Timeclock Control/942F Filter/7 Day/24 Hour/12 VAC/50 Hz 1046853 Timeclock Control/942F Filter/12 Day/24 Hour/12 VAC/50 Hz

Table 12.3 942 Mechanical Timeclock 12V/60 Hz Configurations

Part Number Description

1046868 Timeclock Control/942 Softener/7 Day/24 Hour/12 VAC/60 Hz 1046869 Timeclock Control/942 Softener/12 Day/24 Hour/12 VAC/60 Hz 1046870 Timeclock Control/942F Filter/7 Day/24 Hour/12 VAC/60 Hz 1046871 Timeclock Control/942F Filter/12 Day/24 Hour/12 VAC/60 Hz

Table 12.4 942 Mechanical Timeclock 120V/60 Hz Configurations

Part Number Description

1046317 Timeclock Control/942 Softener/7 Day/24 Hour/120 VAC/60 Hz 1046318 Timeclock Co nt ro l/9 42 Soft en er /1 2 Da y/2 4 Ho ur /1 20 VAC/6 0 Hz 1046319 Timeclock Control/942F Filter/7 Day/24 Hour/120 VAC/60 Hz 1046320 Timeclock Control/942F Filter/12 Day/24 Hour/120 VAC/60 Hz

12.3 Impulse Controls

Magnum 952

Figure 12.5 Magnum 952

Magnum 952F

Figure 12.6 Magnum 952F

Magnum 952QC

Figure 12.7 Magnum 952QC

Table 12.5 952 Impulse Control 50 Hz Configurations

Part Number Description

1046854 Impulse Control/952 Softener/24 VAC/50 Hz 1046855 Impulse Con tr ol/ 95 2F Filt er /2 4 VAC/5 0 Hz 1046856 Impulse Control/952QC Softener/24 VAC/50 Hz - 7 foot (2.1 m) Cable 1046857 Impulse Control/952QC Softener/24 VAC/50 Hz - 14 foot (4.2 m) Cable 1046858 Impulse Control/952QC Softener/24 VAC/50 Hz - 21 foot (6.3 m) Cable

Table 12.6 Impulse Control 60 Hz Configurations

Part Number Description

1046321 Impulse Control/952 Softener/120 VAC/60 Hz 1046323 Impulse Control/952F Filter/120 VAC/60 Hz 1046322 Impulse Control/952 Softener/24 VAC/60 Hz 1046324 Impulse Con tr ol/ 95 2F Filt er /2 4 VAC/6 0 Hz 1046325 Impulse Control/952QC Softener/24 VAC/60 Hz - 7 foot (2.1 m) Cable 1046336 Impulse Control/952QC Softener/24 VAC/60 Hz - 14 foot (4.2 m) Cable 1046337 Impulse Control/952QC Softener/24 VAC/60 Hz - 21 foot (6.3 m) Cable

12.4 Electronic Controls

Magnum 962

Magn um Cv 962F

Magnum 962F

Figure 12.8 Magnum 962

Magnum 962M

Figure 12.10 Magnum 962M

Magnum 962S

BACKWASH

FLOW PM

COMPLETE

SET

Figure 12.9 Magnum 962F

TIME OF DAY TIME OF BACKWASH SET VALUE T O 10 SET VALUE T O 5

CAPACITY BACKWASH TIME

REMAINING

BACKWASH

Figure 12.11 Magnum 962S

Magnum 962TC

Magnum 962FTC

Magn um Cv 962FTC

BACKWASH

Figure 12.12 Magnum 962TC

COMPLETE

FLOW PM

Figure 12.13 Magnum 962FT C

Table 12.7 962 Electronic Control 12V/50 Hz Configurations

Part Number Description

1046860 Electronic Control/962 Softener/Battery Backup/12 VAC/50 Hz* 1046862 Electronic Control/962M Main/Battery Backup/12 VAC/50 Hz* 1046863 Electronic Control/962S Secondary/12 VAC/50 Hz 1046873 Electronic Control/962F Filter/Battery Backup/12 VAC/50 Hz*

SET

TIME OF DAY TIME OF BACKWASH SET VALUE T O 10

SET VALUE T O 5

CAPACITY BACKW ASH TIME

REMAINING

BACKWASH

* Battery Not Included.

Table 12.8 962 Electronic Control 12 V/ 60 Hz Configurations

Part Number Description

1046327 Electronic Control/962 Softener/Battery Backup/12 VAC/60 Hz* 1046329 Electronic Control/962M Main/Battery Backup/12 VAC/60 Hz* 1046330 Electronic Control/962S Secondary/12 VAC/60 Hz 1046867 Electronic Control/962F Filter/Battery Backup/12 VAC/60 Hz*

1053846

1053847 Electronic Time Clock Control/962FTC Filter/Battery Backup/12 VAC/60 Hz

* Battery Not Included.

Electronic Time Clock Control/962TC Softener/Battery Backup/12 VAC/60 Hz

Table 12.9 Transformers

Part Number Description

1000810 12 V Wall Mount Transformer/100 VAC/50/60 Hz/150 mA/Japanese Plug 1000811 12 V Wall Mount Transformer/120 VAC/60 Hz/150 mA/North American Plug 1000812 12 V Wall Mount Transformer/240 VAC/50 Hz/150 mA/Australian/Arentine Plug 1000813 12 V Wall Mount Transformer/240 VAC/50 Hz/150 mA/British Plug 1000814 12 V Wall Mount Transformer/230 VAC/50 Hz/150 mA/European/Italian Plug

Table 12.10 Miscellaneous Parts

Part Number Description

1075768 Battery Rechargable

12.5 Magnum Flow Controls

Injector Assembly

Item Part Number Description

1 1040670 Injector for 14-inch (35.6 cm) Tank - 0.5 GPM (1.9 LPM) (includes O-rings) 1 1040671 Injector for 16-inch (40.6 cm) Tank - 0.5 GPM (1.9 LPM) (includes O-rings) 1 1040672 Injector for 18-inch (45.7 cm) Tank - 0.6 GPM (2.27 LPM) (includes O-rings) 1 1040673 Injector for 21-inch (53.3 cm) Tank - 0.9 GPM (3.41 LPM) (includes O-rings) 1 1040674 Injector for 24-inch (61.0 cm) Tank - 1.4 GPM (5.3 LPM) (includes O-rings) 1 1040675 Injector for 30-inch (76.2 cm) Tank - 2.0 GPM (7.57 LPM) (includes O-rings) 1 1040676 Injector for 36-inch (91.4 cm) Tank - 3.3 GPM (12.5 LPM) (includes O-rings) 1 1040669 Injector, Blank (includes O-rings) 2 1040677 Injector Assembly (Less Injector) 3 1040678 Injector Screen (3 pack) 4 1040688 Plug for Injector, Refill and Pressure Regulator Ports (including O-rings)

12.6 Magnum Flow Controls

Refill Control Assembly

Item Part Number Description

4 1040679 Refill Flow Control for 14-inch (35.6 cm) Tank - 0.7 GPM (2.6 LPM) (3 pack) 4 1040680 Refill Flow Control for 16-inch (40.6 cm) Tank - 0.8 GPM (3.0 LPM) (3 pack) 4 1040681 Refill Flow Control for 18-inch (45.7 cm) Tank - 1.0 GPM (3.8 LPM) (3 pack) 4 1040682 Refill Flow Control for 21-inch (53.3 cm) Tank - 1.4 GPM (5.3 LPM) (3 pack)

4 1040683 Refill Flow Control for 24-inch (61.0 cm) Tank - 2.0 GPM (7.6 LPM) (3 pack) 4 1040684 Refill Flow Control for 30-inch (76.2 cm) Tank - 3.0 GPM (11.4 LPM) (3 pack) 4 1040685 Refill Flow Control for 36-inch (91.4 cm) Tank - 5.0 GPM (19.0 LPM) (3 pack) 5 1040686 Refill Flow Control Cage (3 pack) 3 1040687 Refill Assembly (Less Refill Flow Control) 1 1040688 Plug for Injector, Refill and Pressure Regulator Ports (includes O-ring)

12.7 Magnum IT Flow Sensor

Turbine Assembly

Item Part Number Description

1 1000074 Insert, Corner 2-inch 2 1232965 As sem b ly, T urbin e 2- inc h Elbo w 3 1000318 Assembly, Plug

12.8 Installation Adapters

Adapters- Magnum

Item Part Number Description

Not Shown 1001657 Magnum Cv 1.5-inch Adapter Kit - Brass NPT for inlet, outlet, drain Not Shown 1001658 Magnum Cv 1.5-inch Adapter Kit - Brass BSP for inlet, outlet, drain

1 1001655 Magnum Cv 1.5-inch Adapter Kit - CPVC for inlet, outlet, drain Not Shown 1040544 1.5-inch NPT Brass Adapter with Glass Filled Noryl Nut (24 Pack) Not Shown 1040555 1.5-inch BSP Brass Adapter with Glass Filled Noryl Nut (24 Pack)

1 1050556 1.5-inch CPVC Adapter with Glass Filled Noryl Nut (24 Pack)

2 1000356 Glass Filled Noryl Nut for 1.5-inch Adapter Not Shown 1000360 1.5-inch Brass NPT Adapter Not Shown 1000361 1.5-inch Brass BSP Adapter

3 1000356 1.5-inch CPVC Adapter Not Shown 1001995 1-1/2-inch Brass NPT Adapter with Drilled and Tapped 1/4-inch NPT Port Not Shown 1001996 1-1/2-inch Brass BSP Adapter with Drilled and Tapped 1/4-inch BSP Port

Adapters-Magnum IT

Item Part Number Description

Not Shown 1040782 Magnum IT Adapter Kit - Brass NPT for inlet, outlet, drain Not Shown 1040783 Magnum IT Adapter Kit - Brass BSP for inlet, outlet, drain Not Shown 1040784 Magnum IT Adapter Kit - CPVC for inlet, outlet, drain Not Shown 1040786 2-inch NPT Brass Adapter with Zinc Diecast Nut (24 Pack) Not Shown 1040787 2-inch BSP Brass Adapter with Zinc Diecast Nut (24 Pack) Not Shown 1040788 2-inch CPVC Adapter with Zinc Diecast Nut (24 Pack) Not Shown 1030664 2-inch Cast Zinc Diecast Nut Not Shown 1030663 2-inch Brass NPT Adapter Not Shown 1033863 2-inch Brass NPT Adapter with Drilled and Tapped 1/4-inch NPT Port

Item Part Number Description

Not Shown 1030665 2-inch Brass BSP Adapter Not Shown 1033864 2-inch Brass BSP Adapter with Drilled and Tapped 1/4-inch BSP Port Not Shown 1030666 2-inch CPVC Adapter Not Shown 1030667 63-mm Metric PVC Adapter Not Shown 1002906 1.5-inch to 2-inch Brass Bell Reducer Coupling Not Shown 1010160 1.5-inch Adapter O-Ring Not Shown 1010165 2.0-inch Adapter O-Ring

12.9 Magnum Valve Cartridges

1 - Drain Valve Cartridge

3 - No Hard Water Bypass Valve Cartridge

2 - Rinse Valve Cartridge

4 - Hard Water Bypass Cap

Item Part Number Description

1 1000366 Drain Valve Cartridge

2 1000365 Rinse Valve Cartridge

3 1000366 No Hardwater Bypass Valve Cartridge

4 1000336 Hardwater Bypass Cap

5 1000317 Inlet Valve Cartridge

6 1010157 O-Ring

7 1010158 O-Ring

8 1010159 O-Ring

5 - Inlet Valve Cartridge

9 1010116 O-Ring (qty. 2 per Cartridge)

Note: Items 1 and 3 are identical valve cartridges.

12.10 Cam and Pilot Valve Assembly

Black

Item Part Number Description

1 1000535 Camshaft Assembly - 5 Cycle Softener

2 1000538 Camshaft Assembly - 3 Cycle Filter

3* 1001751 Camshaft Assembly - Twin Alternating

4 1000341 Camshaft

5 1000461 Brine Cam - Co-current 5 Cycle Softener (Maroon)

6 1000462 Universal Cam Switcher (Black)

7 1000464 Pilot Cam - Co-current 5 Cycle Softener #1 (Maroon)

8 1000465 Pilot Cam - Co-current 5 Cycle Softener #2 (Blue)

9 1000466 Pilot Cam - Co-current 5 Cycle Softener #3 (Green)

Item Part Number Description

10 1000467 Pilot Cam - Co-current 5 Cycle Softener #4 (Yellow) 11 1000468 Pilot Cam - Co-current 5 Cycle Softener #5 (Orange) 12 1000469 Pilot Cam - Co-current 5 Cycle Softener #6 (Red) 13 1000460 Spacer Cam - 3 Cycle Filter (Grey) 14 1000462 Universal Cam Switcher (Black) 15 1000470 Pilot Cam - 3 Cycle Filter #1 (Grey) 16 1000471 Pilot Cam - 3 Cycle Filter #2 (Blue) 17 1000472 Pilot Cam - 3 Cycle Filter #3 (Green) 18 1000473 Pilot Cam - 3 Cycle Filter #4 (Yellow) 19 1000474 Pilot Cam - 3 Cycle Filter #5 (Orange) 20 1000469 Pilot Cam - 3 Cycle Filter #6 (Red) 21 1000499 Brine Cam - Twin Alternating (Tan) 22 1001750 Universal Cam Switcher (Tan) 23 1001620 Pilot Cam - Twin Alternating #1 (Tan) 24 1001621 Pilot Cam - Twin Alternating #2 (Blue) 25 1001622 Pilot Cam - Twin Alternating #3 (Green) 26 1001623 Pilot Cam - Twin Alternating #4 (Yellow) 27 1001624 Pilot Cam - Twin Alternating #5 (Orange) 28 1000469 Pilot Cam - Twin Alternating #6 (Red) 29 1000589 Pillow Block Cap

Not Shown 1006095 Pillow Block Cap Screw (4) (not shown)

31 1000339 Top Plate Not Shown 1006093 Top Plate Screw - Short (5) (not shown) Not Shown 1006095 Top Plate Screw - Long (9) (not shown)

34 1000391 Brine Flapper Valve

35 1000328 Pilot Flapper Valve Not Shown 1000553 Cam for Auxiliary output, shuts off at end of refill Not Shown 1000554 Cam for Auxiliary output, shuts off at beginning of refill Not Shown 1001580 Flapper Return Spring Not Shown 1000343 Cam Cover

* For use with 962M and 962S controls only.

12.11 Kits and Assemblies

Switch Kit

Pilot Filter Screen Assembly

Part Number Description

1041049 Switch Kit Assembly 0.1 amp rating (also used on 962M and 962S Controls)

1041063 Switch Kit Assembly - 5 amp rating

1000226 Pilot Screen Assembly (includes Pilot Screen, Pilot Screen Cap and O-ring)

1040691

1040692 Pilot Flapper Kit (pilot, brine and springs)

1040668 External Pilot Feed Adapter (separate source pilot water)

Valve O-ring Kit (tank adapter O-ring, (3) O-rings for 1-1/2-inch inlet, outlet, drain and distributor O-ring)

External Pilot Feed Adapter

Pilot System Check Valve

1000878 Outdoor Cover (962 control)

1009115 Top Stacking Distributor

1005953 Top Plate Screws (15 req’d)

1006093 Top Plate Screws (5 req’d)

1034312 Twin Parallel Interface Cable (10 feet) (3 m)

1035587 Triple Parallel Interface Cable (10 feet) (3 m)

1035593 Parallel Interconnect Extension Cable (Used to connect two 10-foot cables)

1010162 Tank Adapter O-ring

1010160 Riser Tube O-ring

1009817 Piilot System Check Valve

12.12 962 Optional Switch Kits

Part Number Description Items Included

(2) SPDT Switches with gold cross contacts hardware to mount 3 switches

1041037

1041038

1041039

1041048

Switch Kit for Twin Alt 962 Controls .1 amp

Switch Kit for Twin Alt 962 Controls 5 amp

Switch Kit for Single Tank 962 Controls .1 amp

Switch Kit for Single Tank 962 Controls 5 amp

(6) crimp on connectors (2) breakaway switch cams (1) short twin/alt switch cam (1) instruction sheet

(2) SPDT Switches with standard contacts hardware to mount 3 switches (6) crimp on connectors (2) breakaway switch cams (1) short twin/alt switch cam (1) instruction sheet

(3) SPDT Switches with gold cross contacts hardware to mount 3 switches (9) crimp on connectors (1) switch bracket (3) breakaway switch cams (1) instruction sheet (1) bracket screw

(3) SPDT Switches with standard contacts hardware to mount 3 switches (9) crimp on connectors (1) switch bracket (3) breakaway switch cams (1) instruction sheet (1) bracket screw

(1) SPDT Switch with gold cross contacts hardware to mount 1 switch

1041049

1041063

1041064 Pilot Flapper Breakaway Kit

1041065 10-foot Switch Cable Assembly (1 ) 10-foot cable with fast-on switch connector housing 1041066 20-foot Switch Cable Assembly (1 ) 20-foot cable with fast-on switch connector housing

1041211 Breakaway Cam .1 amp

Switch Kit for Single Tank Controls .1 amp

Switch Kit for Single Tank Controls 5 amp

1041212 Breakaway Cam 5 amp

(3) crimp on connectors (1) switch bracket (1) instruction sheet (1) bracket screw

(1) SPDT Switch with standard contacts hardware to mount 1 switch (3) crimp on connectors (1) switch bracket (1) instruction sheet (1) bracket screw

(1) Breakaway pilot cam (1) Spacer (1) instruction sheet

(3) Breakaway cam (1) Bracket

P/N 1018092 Rev. G

Watts Autotrol Magnum User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

Section

1.0 Installation Profile Summary

2.0 Introduction to the Magnum Cv and Magnum IT Series

2.1 Assembling the Control to the Magnum Valve

2.2 Magnum General Specifications

2.3 Magnum Cv Dimensional Specifications

3.0 General Installation Information

3.1 Typical Installation Drawings

4.0 Flow Diagrams

5.0 Control Settings

5.1 Manual

5.2 Mechanical

5.2.1 Common Settings

5.2.3 Backwashing Filter - Model 942F

5.2.2 Regenerating Iron Filters - Model 942

5.2.4 Salt Use Table

5.2.5 Regenerant Use Table - Potassium Permanganate (KMnO4)

5.3 Impulse

5.4 Electronic

5.4.1 Connecting the 962 Control

5.4.2 Connecting the 962M and the 962S Control

6.0 Programming Tables

6.1 Table I - Level 1 Values

6.2 Table IIA

6.3 Table IIB

Level II Program Values - 962F Single Tank Filter (P17=4)

6.4 Table IIC

Level II Program Values - 962 Twin Tank Alternating Softener (P17=2)

6.5 Table IID

6.6 Table IIE

6.7 Explanation of Parameter Values for the 962 Single and Parallel Tank Controls

6.8 New Features in The 962 Family Controls

6.9 Table III - Historical Data

6.10 Table IV

7.0 Multi-Tank

7.1 Twin Alternating Systems

7.1.1 Twin Alternating Control Set-Up

7.1.2 Additional Checks:

7.2 Twin or Triple Systems

7.2.1 Parallel Control Set-Up

Special Programming

8.0 Start-Up Procedure

9.0 Service Instructions

9.1 Magnum Valve Cartridge Removal Procedure

10.0 Performance Data and Charts

10.1 Magnum Injector Data

10.2 Magnum Flow Controls

10.3 Magnum Injector Controls

10.4 Drain Line Flow Control

11.0 Wiring Diagrams

11.1 Model 962 Series Electronic Control Remote Regeneration Initiation

11.2 Model 952 Twin Series Impulse Control

11.3 Model 952QC Impulse Control

11.4 Triple Parallel Wiring

Model 962 Twin or Triple Parallel Wiring Schematic

11.5 Model 962 Twin Alternating System Main/Secondary Wiring Schematic

12.0 Assembly Drawings and Parts List

Magnum Controls

12.1 Manual Controls

12.2 Mechanical Timeclock Controls

12.3 Impulse Controls

12.4 Electronic Controls

12.5 Magnum Flow Controls

12.6 Magnum Flow Controls

12.7 Magnum IT Flow Sensor

12.8 Installation Adapters

12.9 Magnum Valve Cartridges