48ES and 51ES NXT Stager Controller
Contents
1. 1 TH Lit Wyo xnv WVO WVH9O d wvo xnv VNOILdO LLYM 09 05 AvZ oni loota 97 Ti o o la 5 5 Mauos m 5 5 5 E m a o z E E 2 5 E 0r a gt x i E Q m 6 m 3 1 9 31IHM 31IHM xovis bovis ama aaa lt L yovia N Mov1a ol lo SLIHM a S w AseSe milles LEE 5 5 BIR 5 o gt 2 0 m x SAA mim m 5 B UU bbb ba 5 el ol 18 2 H Cu yovia m H a H 12 zova 2 s E MOTI3A N3349 V O L ZHO9 OS OVAvZ LNdLNO 9d ABGNVLS NOLLVS3N3O3H G3ZI9HAN3 VA GIONSIOS IVNOLLdO Jo EE ESSN HHH INA zwo m m OL dN 3GIS LNANI Q3 18VN3 NOILdO 11 NOILVHAN3934 S31VILINI LOVINOO 43 079 30A OL ACIS LNANI NOLLVH3N3933 SIN3A3Hd LOVINOO Q3S0O10 3ALLSIS3H VE OGA0 SALLSIS3H VE OVATZ TION TEVIS IION 1n03501 HOLIMS LYVLS TYNOIS 310W33 1YNOILdO o o MOOTH3INI TVNOLLdO uve CO N HOLIMS un LOH Q3HOLIMS 1nd1nO O N 5 ONINNG NO2. Stager Assy 51 09 NXT 24VAC SH 2nd Aux Notched in Refill 61809 10 Stager Assy 51 09 Inverted NXT 24VAC HMG No 2nd Aux Switch 61809 20 Stager Assy 51 09 Inverted NXT 24VAC SA 2nd Aux Notched in Service 61809 30 Stager Assy 51 09 Inverted NXT 24VAC SD 2nd Aux Notched in Backwash 61809 40 Stager Assy 51 09 Inverted NXT 24VAC SH 2nd Aux Notched in Refill 1074888 Kit Internal Parts 51 09 Stager 61818 01 Assy 51 09 HMG No 2nd Aux Switch 61818 02 Cam Assy 51 09 NXT SA 2nd Aux Notched in Service 61818 03 Cam Assy 51 09 NXT SD 2nd Aux Notched in Backwash 61818 04 Cam Assy 51 09 NXT SH 2nd Aux Notched in Refill Meter Assembly In Line 60619 Eb Meter Assy 1 Elec Brass Body PDL 60614 nim Meter Assy 1 1 2 Elec Brass Body PDL 60616 Meter Assy 2 Elec Brass PDL 600617 sites Meter Assy 3 Elec Brass Body PDL 60625 iiti Meter Assy 2 Elec Plastic PDL 61560 01 Meter Assy 1 Elec Plastic Turbine 61560 07 Meter Assy 1 Elec Brass THDS Turbine 61560 09 Meter Assy 1 1 2 Elec Brass THDS Turbine 61560713 tris Meter Assy 1 1 2 Elec Plastic Turbin
3. 3 4 2 D E BRINE 5 6 2A F 5 RINSE 1 6 1 6 2A Note A All valves normally open except optional valve 2A Note B Inverted Stager types will have these ports pressurized Inverted Stager to be used with all valves normally closed except optional valve 2A Note C Program Cycle 2 time to 00 00 00 for filter operation 12 NXT Stager Controller AU11 5 Position Softener w Timed Brine Refill 51 09 Stager rd y X 5S ii 3 1 Customer f H To Supplied Valve BRINE TANK 1 et NLET 2 1 Optional Hard pg Water Bypass Valve BRINE REFILL m Cn 7 KA E 1 1 V3 KA 1 T I I 1 I 2 4 6 1 I 1 n oo SERVICE fa 1 5 POSITION SOFTENER W TIMED BRINE REFILL Plugs installed at factory SM SERIES 51 09 STAGER STAGER PORTS 2 3 4 6 9
4. 1 5 7 8 1 2 S 5 6 7 R8 gt 4 NOTCH POS FUNCTION PORTS VALVES VENTED SERVICE BACKWASH BRINE SLOW RINSE FAST RINSE 1 7 BRINE REFILL 1 2 8 1 2 7 Note A All valves normally open except optional valve 2A Note B Inverted Stager types will have these ports pressurized Inverted Stager to be used with all valves normally closed except optional valve 2A Drain Line Flow Control not shown PLUMBING DIAGRAMS continued Multiple Tank 4 Position Softener 48 00 Stager EJECTOR RAWWATER amp lt To Additional Tanks As Required SERVICE UNITB DRAIN LINE FLOW CONTROL NOT SHOWN NOTE All valves normally open pressure to close NOTE Valve 2 for each tank is controlled by solenoid for system 7 9 14 Multiple Tank 5 Position Softener 51 09 Stager Customer Supplied Customer Supplied Check Valve Check Valve Ejector r3 I iti To Additional Tanks S INLET I As Required UNIT A DRAIN UNIT B DRAIN LINE FLOW CONTROL NOT SHOWN NOTE All valves normally open pressure to close NOTE Valve 2 for each tank is controlled by solenoid for system 7 9 14 NXT Stager Controller AU11 13 SOLENOID USE Solenoids only required for Systems 7 9 and 14 Series 48 00 51 09 Stager STAGER PORTS 1 2 O
5. 91 1 00 00 20 10 00 00 00 00 20 10 00 00 51917 6666 1000 666 pelgesiq peigeug 0 O pels 18101 O1 10 00 00 pelqesiq peiqeuz 00 00 70 00 00 00 HO 00 00 70 00 00 00 HO 00 00 70 00 00 00 HO 00 00 70 00 00 00 HO 00 00 70 00 00 00 69 62 00 00 urd 6 Ure 001 Po HO SpuooeS 66 02 SPUODES 66 02 wd 666 Z 666 z 1utog du Spuooes 66 OE Spuooes 66 0 spuooes 66 02 66 0 ud 766 0 wd6766 0 6661 n3 swypeo sn x 00 68 10 10 00 00 HO EURE 1114 1114 Mond moyumog Ix x x x x jeDvis 006 OGLE 0062 098Z 092Z x MEME ejeipeuuuu H90 9 XE I x EE G n ze e elele v s uosineq jouedsz usifpu3 Buneuiayy 19 bui d vL 6 2 sesind S1917 10 SUOJ EE PPY OUOU8E J8JeN MOI Aejay OdO auinjoA Odd 21 pus indjno Aejay ueis indjno Aejay Aeii
6. 1 2 3 4 5 6 bad 2 A NOTCH POS FUNCTION 4 SERVICE 1 2 1 2 BACKWASH E 2 BRINE 5 6 F 3 RINSE 1 6 5 6 2A 1 6 2A Note A All valves normally open except optional valve 2A Note B Inverted Stager types will have these ports pressurized Inverted Stager to be used with all valves normally closed except optional valve 2A NXT Stager Controller AU11 11 PLUMBING DIAGRAMS continued 4 Position Filter 48 00 Stager bu N INLET ei PA KA 2 Optional 4 6 Water Bypass Valve 22 2 2 ET SERVICE a 4 POSITION FILTER val j Drain Line Flow Control not shown Installer to plug with PN1071903 for filter operation STAGER PORTS SERIES 48 00 PA 6 5 e E Ze 4 4 s E 7 1 3 6 DA PORTS VALVES NOTCH POS FUNCTION VENTED OPEN A SERVICE
7. CHG on screen for more than 2 minutes Control programmed incorrectly as 2900 or 3900 valve type Reprogram unit as Stager Valve type 18 NXT Stager Controller AU11 SERVICE ASSEMBLIES 48 00 ES Stager Assembly 61808 01 Stager 48 00 24VAC HMG No 2 Aux Switch 61808 02 Stager Assy 48 00 NXT 24VAC SA 2nd Aux Notched in Service 61808 03 Stager Assy 48 00 NXT 24VAC SC 2nd Aux Notched In Backwash 61808 10 Stager 48 00 Inverted 24VAC HMG No 2nd Aux Switch 61808 20 Stager Assy 48 00 Inverted NXT 24VAC SA 2nd Aux Notched in Service 61808 30 Stager Assy 48 00 Inverted NXT 24VAC SC 2nd Aux Notched In Backwash 1074817 Kit Internal Parts 48 00 Stager 61817 01 Assy 48 00 HMG 2nd Aux 61817 02 48 00 SA 2nd Aux Notched Service 61817 03 Cam Assy 48 00 NXT SC 2nd Aux Notched in Backwash 51 09 ES Stager Assembly 61809 01 Stager Assy 51 09 NXT 24VAC HMG No 2nd Aux Switch 61809 02 Stager Assy 51 09 NXT 24VAC SA 2nd Aux Notched in Service 61809 03 Stager Assy 51 09 NXT 24VAC SD 2nd Aux Notched in Backwash 61809 04
8. 5251334 i t 7 141 958 V c L 6 1 8 NPT PORT 60 APART Js UTR amp x g0733 1862mm 4 places amp E L 0088 22 4 mm CD x j QN t 3 50 88 9 amp 2 72 69 2 00 50 x i 275 69 9 2 75 169 9 4 il 4l L 4 00 101 6 1 8 NPT Filtered Inlet 2 06 52 3 48ES STAGER I 642 163 1 ie 125 31 7 6 00 152 4 4X R 16 H 4X 19 4 8 T omg TES ej e 41 13 282 7 ET Ol m A 0 n H 0 Lx F 3281 7 X AN 1 8 NPT Drain G G 1 8 NPT Filtered Inlet on 1 TE 1761844 8X 1 8 NPT 45 APART 9 0 733 1862 mm 4 places CD p t gt TA 7 e oo 0 88 22 4 mm 1 8 NPT Drain 51ES STAGER NOTE Drill as required These holes will only be drilled at factory if required Figure 1 2 NXT Stager Controller AU11 SYSTEM SPECIFICATIONS 48ES AND 51ES SERIES Generic Meter Guidelines Open collector output Pulse rate generated must not exceed 100 pulses per second 100 Hz or 6 000 pulses per minute Support for meter outputs in the range of 1 255 gallons 25 5 m for every 1 255 pulses Example 35 gallons 100 pulses 73 5 gallons 10 pulses 0 35 gallons 1 pulse Meter must operate at 5
9. Example 12 minutes remaining in Cycle 1 l Press the Extra Cycle button during a A Regeneration Cycle to immediately advance the valve to the next cycle and resume normal timing Flow Meter Equipped Timer During normal operation the Time of Day screen alternates with the Error screen if errors are present As treated water is used the Volume Remaining display counts down from the calculated system capacity to zero When zero is reached a Regeneration cycle begins if no other units are in regeneration Timer Operation During Programming The timer enters the Program Mode in Standby or Service Mode as long as it is not in regeneration While in the Program Mode the timer continues to operate normally monitoring water usage Timer programming is stored in memory permanently Timer Operation During A Power Failure During a power failure all timer displays and programming are stored for use upon power re application The timer retains all values without loss The timer is fully inoperative and any calls for regeneration are delayed The timer upon power re application resumes normal operation from the point that it was interrupted NOTE A flashing Time of Day display indicates a power outage Hold the Up or Down button to reset time 6 NXT Stager Controller AU11 Remote Lockout The timer does not allow the unit system to go into Regeneration until the regeneration lockout input signal to the unit is cleared Thi
10. Odd NOLLVH3N3933H NIXNA NO AWNd HOLOW TWNOILdO AU11 17 NXT Stager Controller TROUBLESHOOTING Detected Errors If a communication error is detected an Error Screen will alternate with the main time of day screen every few seconds All units In Service remain in the In Service position All units in Standby go to In Service Anyunit in Regeneration when the error occurs completes Regeneration and goes to In Service Nounits are allowed to start a Regeneration Cycle while the error condition exists unless they are manually forced into Regeneration When an error is corrected and the error no longer displays it may take several seconds for all of the units in a system to stop displaying the error message the System returns to normal operation NOTE During the error condition the control continues to monitor the flow meter and update the volume remaining Once the error condition is corrected all units return to the operating status they were in prior to the error Regeneration queue is rebuilt according to the normal system operation Or if more than one unit has been queued for regeneration then the queue is rebuilt according to which one communicates first Message Displayed Cause For Error Correction Flashing time Power outage Program time by holding UP on Unit 1 Two or more units programmed with the same valve Detected Error Matching Address address number Progr
11. 22 inu Teens 43000 Washer Sealing Conduit 1 2 Fitting NPT 1 2 Conduit Washer Lock 7 8 INT Tooth Cable Assy COM CAT 5E NEMA 4 Meter Cable Assy NT 99 5 Mount Cable Tie 4 Way Screw 10 32 x 5 8 RND HD SS Nut Hex 10 32 KEPS 12525 iiu Washer Lock 8 INT 18 8 SS ry TEE 1071648 Nut Not Shown Tasse 61500 48 51LNE Line Drawing 9 TOTS TOV POORER Tie Cable HeyCo VNT 4 18 2 10793702 Wire Tie guis 1073955 55 Terminal Ring 10 16 14 GA 1073875 Wire Black 18 AWG LEES 1073880 Wire White 18 AWG 1073874 Wire Green 14 AWG Literature 3214 Stager S M dons 43012 en Wiring Diagram 48 51ES Service Kit 48 51 Timer Service Kit 48 51 Solenoid 1 8 NPT Pipe Plug Brass Only sold as Service Assembly NXT Stager Controller _ AU11 15 STAGER CONTROLLER 51ES NEMA 4 24V 50 60Hz ASSEMBLY Description Motor 24V 50 60Hz 5 8 RPM Plate Motor MTG Stagers Screw 6 32 x 1 4 Phil Screw 6 32 x 375 RD HD SS Thumb Wheel Molded Gasket Stager MTG 51 96 Inlet Strainer Assy Cam Cycle Machined Switch Micro Switch Spacer Insulator Washer Lock Internal 4 SS Machine Screw 4 40 x 1 00 SS Cam Auxiliary Blank Screw Slotted HX HD 10 32 Washer Lock Internal 10 SS Screw Hex Washer 48 32 x 5 16 Label Dial STGR 2 3 8 x 7 8 Nut
12. Liquid Tight HeyCo 3169 Fitting Liquid Tight Black Terminal Block 10 Screw Pan HD 4 40 x 5 8 SS if 2 switches Screw 4 40 x 1 3 8 if 3 switches Label Ground 75 Dia Label Terminal Strip 1 10 Panel A10P 8 x 6 Modified Keypad Label Assy ST NEMA 4 Solenoid N1 24 60 Circuit Board XT ML Screw FLT HD 26 20 TYP B Stand off Plastic 625 Harness Upper Drive Washer Sealing Conduit 1 2 Washer Lock 7 8 INT Tooth 16 NXT Stager Controller AU11 AUX 1 Red e 0 HOFFMAN PARTS BAG SCAETA KIT BR61764 61804 Rev D Item No QTY PartNo Description o 12 4 43140 Fitting NPT 1 2 Conduit siluis 1 2 61764 Cable Assy COM 5 4 SO decer 19121 09 Meter Cable ASSY NT 99 5 1081780 Mount Cable Tie 4 Way ai suus decore 1072379 Screw 10 32 x 5 8 RND HD SS BO ds LR 10710660 Nut Hex 10 32 KEPS 43094 02 Enclosure 51ES NEMA 4 1079241 Washer 302 SS 1070438 Shaft Stem Assy 51 Series 1071903 Male Pipe Plugs 1074883 Bonnet 51 Brass 1075647 Stemplate 96 Alpha 1075242 Spring Compression 1084172 Gasket Backplate 51 amp 96 STGRS 1074866 Backplate D V Nest 1071716 O ring EP ORE 011 107
13. VDC Electrical Rating 24 VAC Transformers 115 VAC 20 input 24 VAC output w 40 VA maintain input voltage in this range 230 VAC 20 input 24 VAC output w 108 VA maintain input voltage in this range Max Rated Power 15W Humidity 95 RH non condensing Temperature Maximum control fluid temperature 140 F 60 C Operate where ambient temperatures are above 32 F and below 110 F Pressure Maximum control fluid pressure 125 psi 8 5 bar Control fluid can be either water or air and must be equal to or greater than system pressure SYSTEM DEFINITIONS System Number System Description of Tanks Controls Type Service Outlet Valve Controlled by Operation Discussion 4 Single Unit 1 Time Clock No Meter Immediate One Meter Delayed One Meter Remote Signal Start No Meter Stager no solenoid required Single tank configuration During Regeneration no water available to service unless optional bypass valve 2A installed 5 Interlocked 2 3 0r4 Immediate All Meters Remote Signal Start No Meter Stager no solenoid required All tanks in parallel supplying treated water Each unit in the system will have its own flow meter sensor input The control will delay the start of Regeneration if another unit is already in Regeneration Once that unit has completed a Regeneration cycle and has returned to Service the unit with longest regeneration queue time will
14. at 0 hours 0 minutes amp 0 seconds AUX RELAY OUTPUT EHD 88 88 88 Range 00 00 00 to 18 00 00 CHEHICRL PUMP DISRBLED Example Chemical Pump is Disabled Options Enabled Disabled Default NOTE This screen will only display on the lead unit for System Types 6 amp 7 For all other System Types it will display for all units CPO AUX RELAY Example UDLLMHE 3 Energize Chemical Pump relay every 50 gals 50 Energize Chemical Pump relay every 200 L 200 Range 1 to 999 gallons in U S Format 1 to 9999 L in Metric Format CPO AUX RELAY TIHE aa Example Each time chemical pump relay is on run for 30 seconds 00 00 30 Range 00 00 00 to 02 00 00 FLOW METER 1 4 PADOLE Example 1 0 Paddle Flow Meter Options 1 0 Paddle 1 0 Turbine 1 5 Paddle 1 5 Turbine 2 0 Paddle 3 0 Paddle Generic NOTE Default flow meter type is based on the valve type This screen will only display on the lead unit for System Types 6 amp 7 All other system types it will display for all units HASI MUM FLOU Example Maximum Flow Rate of 0 gpm RAT BEGG Range 20 2000 gpm U S Format 20 2000 Lpm Metric Format NOTE Only displayed if Generic is chosen for the flow meter AOD 21 GALLONS EVERY 881 PULSES Example Add 1 Gallon for Each Pulse in U S Format Options Gallons U S Format Liters Metric
15. at all times the primary tank In Service Primary Tank Standby 2 The total flow rate to the primary tank increased past the first trip point programmed rate The flow stayed past the trip point delayed time The next tank least volume remaining changes from Standby to In Service This then splits the total flow between two meters First Trip Point In Service Primary Valve Total Flow Split Between Two Meters 3 The flow rate demand decreased below the first trip point The tank returns to Standby Standby Flow Rate Demand Below First Trip Point Primary Valve Standby 4 Total flow rate demand increased past a second trip point programmed rate The second and third tank least volume remaining changes from Standby to In Service The total flow is split between the three meters Standby Flow Split Between Three Meters 4 NXT Stager Controller AU11 5 The third tank returns to Standby as demand decreases past the second trip point Flow Split Between Two Meters 6 Tanks return to Standby due to decreased total flow rate and trip points programmed The tank with the most remaining volume will be the first to go into Standby Standby Full Capacity 3 4 Capacity 1 2 Capacity Ath in Standby 3rd in Standby 2nd in Standby Primary Valve 1 4 Capacity 1st in Standby 7 The primary tank regenerates The next tank with the least remaining volume become
16. should be left open or discharged to unrestricted or open drain DO NOT plug or restrict drain port 3 Connect the 1 8 NPT control ports to appropriate valves Refer to tubing schematic provided in the Plumbing Diagrams section of this manual Tubing inside diameter should be 1 8 or larger Inverted Type Stagers Stagers that are ordered inverted would be used on systems with all normally closed valves Inverted Stagers send pressure signals to open valves and vent signals to close valves PLUMBING DIAGRAMS 4 Position Softener 48 00 Stager Pd S H N 3 BRINE m D d BRE UE HG D BRINE 5 65 BE E Th INLET TT za KA gi P4 2 Optional Hard 4 6 Water Bypass Valve 22 SERVICE min LI 7 Drain Line Flow Control not shown 4 POSITION SOFTENER SERIES 48 00 STAGER STAGER PORTS 1 2 3 4 5 6
17. 32 x 1 4 Phil Screw 6 32 x 375 RD HD SS Gasket Stager MTG 48 O ring 2 010 Nitrile Thumb Wheel Molded Washer 302 SS Shaft Stem Assy 48 Series Backplate 48 00 Brass Bonnet 48 Brass Inlet Strainer Assy Screw Pan Head 6 32 x 88 Spring Wave 17 7 SS 48 STGR Stemplate 48 00 Cam Cycle Machined Plate Bottom MTG Stager Switch Micro Switch Spacer Insulator Gasket Backplate 48 Nitrile Washer Lock Internal 4 SS Machine Screw 4 40 x 1 00 SS if 2 Switches Screw 4 40 x 1 3 8 if 3 switches Cam Auxiliary Blank Screw Slotted HX HD 10 32 Washer Lock Internal 10 SS Screw Hex Washer 8 32 x 5 16 Label Dial STGR 2 3 8 x 7 8 Nut Liquid Tight HeyCo 3169 Fitting Liquid Tight Black Terminal Block 10 Screw Pan HD 4 40 x 5 8 SS Label Ground 75 Dia el KIT BR61764 SCALE TA METER NOT CONNECTED 61803 Rev D Item No QTY PartNo Description CRE 1 1073732 Label Terminal Strip 1 10 43094 01 Enclosure 48ES NEMA 4 ic Lo de 43093 eee eee Panel A10P 8 x 6 Modified ulcus 43046 Keypad Label Assy XT NEMA 4 f usas ds 1070649 Solenoid N1 24 60 luus C NES 42827 04 Stand off Plastic 625 iu Tes 42T753U Circuit Board XT ML Aire dis 43092 Screw FLT HD 6 20 TYP B De LES 40941 sue Harness Upper Drive
18. 48ES and 51ES NXT Stager Controller Service Manual TABLE OF CONTENTS STAGER 2 SYSTEM SPECIFICATIONS 48ES AND 51ES SERIES 2 SYSTEM DEFINITIONS n tiec 3 SYSTEM OPERATION IN SERVICE SYSTEM 14 DEMAND eese 4 TIMER DISPLAY FEATURES 5 NETWORK COMMUNICATION CABLES amp CONNECTIONS neret 5 TIMER OPERATION sisi tenant eret 6 MASTER PROGRAMMING MODE FLOW CHART 7 USER PROGRAMMING MODE FLOW CHART 9 DIAGNOSTIC PROGRAMMING MODE FLOW CHART 9 PLUMBING 5 seems 11 SOLENOID USE eite EA teneri dont AAAS 14 STAGER CONTROLLER 48ES NEMA 4 24V 50 60Hz ASSEMBLY traen 15 STAGER CONTROLLER 51ES 4 24 50 60 2 ASSEMBLY tertie accu basate EASRA 16 WIRING DIAGRAM 48 51ES STAGER CONTROLLER 17 TROUBLESHOOTING oia eter ha etre 18 SERVICE ASSEMBDLIES 5 ener 19 PORTANT PLEASE READ The information specifications and illustrations in this manual are based on the latest information available at the time of printing The manufacturer reserves the right to make changes at any time without notice This manual is intended as a guide for service of the controller only System installation requires information from a number of suppliers not known at th
19. 5760 Screw Machine 6 32 x 1 1 8 MTG Plate BTM STGR 51ES Washer Lock 8 INT 18 8 SS Not Shown T 61500 48 51LNE Line Drawing 1073701 Tie Cable HeyCo VNT 4 18 1073702 Wire Tie 1073955 Terminal Ring 10 16 14 GA secus 1073875 Wire Black 18 AWG Ts 1073880 Wire White 18 AWG aus 10738745 Wire Green 14 AWG 43169 cess Literature 3214 NXT Stager S M 43012 es Wiring Diagram 48 51ES lis 61784 e Service Kit 48 51 Timer 61783 seit Service Kit 48 51 Solenoid Only sold as Service Assembly WIRING DIAGRAM 48 51ES STAGER CONTROLLER 3 ed CIOEY SNOILVOl lddv NOLLVH3N393MW LHVLS WONIS 3 L0W3H HO 512019 3IALL GSYINDAY LON YSLAW TVNOLLdO 31949 NMOHS SI SYNSOTONS YWAIN Z HSOIAN3S NI NMOHS SSHOLIMS 7 si ONISNOH HOLIMS IVO 9NIWOH SALON ONILNNOW 15 LS 8 19000 15
20. BGIfd5PHM UDLUME Down Button Status LED Adjusts Values Down Figure 1 Valve State INI Initializing INI will display on the screen for 30 to 45 seconds when initializing after a power failure reset or programming RGQ Regeneration Queued RGQ indicates that the reserve has been entered in a delayed system and regeneration has been queued When in the main screen press the Extra Cycle button to toggle service SRV with RGQ Service SRV SRV will display when the unit is In Service LCK Lock Lock will be displayed when contact closure is applied across the interlock terminals on the circuit board See the Network Communication Cables amp Connections section of this manual LED Status Lights Blue LED llluminates while the unit is In Service and no errors exist The unit will always be In Service unless a regeneration trigger has occurred green LED light will be displayed A blinking blue light indicates the timer is In Service and queued for regeneration Green LED llluminates when the unit is in Regeneration mode A blinking green light indicates the timer is in Standby and not in Regeneration Red LED llluminates when there is an error Flow Indicator A rotating line appearing as a rotating star shape will display on the screen when flow is going through the meter NETWORK COMMUNICATION CABLES amp CONNECTIONS Use a CAT5 Network Communication cable Connect the network communicati
21. Format 1 99 Gallons U S Format 0 1 09 9 L Metric Format Pulses 1 99 NOTE Only displayed if Generic is chosen for the flow meter Range Example Master Programming Mode is Exiting PROGRAMMING UNIT PLEASE WAIT USER PROGRAMMING MODE FLOW CHART Entering User Programming Mode Hold the Up and Down buttons for 5 seconds gt 0 FEED HATER HARDHESS Options U S Format Metric Format W c REGENERATION DAY OVERRIDE OFF Options U S Format Metric Format days desired REGEHERATION DAY OVERRI DE 99 DAYS REGENERATION TIME 82 BEAN Options U S Format Metric Format User Mode is Exited 2 lt Enter User Mode by holding the Up and Down buttons for five 5 seconds 9 9 OFF default OFF default Use the Set Up and Set Down buttons to change from OFF to Use the Set Up and Set Down buttons to change to days desired 02 00AM default 02 00 default DIAGNOSTIC PROGRAMMING MODE FLOW CHART Entering Diagnostic Programming Mode 1 2 Push and release the D button Press the Extra Cycle button once per display until all displays are viewed and Normal Display is resumed Push and release the D button at anytime during diagnostic mode and the timer will exit the mode Depending on the current controller programming certain displays may not be able to be viewe
22. Installer to Plug Port 2 Solenoid Valve ISX 1 1 Flow Flow Solenoid Energized Solenoid De energized Energized To Close The NXT Stager control can operate an optional 24 VAC solenoid to control when a tank is off line This solenoid is electrically connected to the lower drive connection on the circuit board and control pressure is run through the solenoid to the service outlet diaphragm valve The solenoid installed at the factory is a universal type It is plumbed in an energize to close configuration when service outlet valve is normally open When a tank enters Regeneration or Standby the solenoid is energized Pressure from solenoid port 1 passes to port 2 The diaphragm valve 2 will close When a tank enters In Service the solenoid is de energized The inlet pressure to solenoid port 2 is stopped The diaphragm valve is vented through solenoid port 2 to port 3 drain The valve 2 opens Inverted Stagers Only Energize to Open If the service outlet vavle is normally closed connect constant pressure source to solenoid port 3 Connect solenoid port 2 to service outlet valve Solenoid port 1 is drain 14 NXT Stager Controller AU11 STAGER CONTROLLER 48ES NEMA 4 24V 50 60Hz ASSEMBLY BOTTOM DETAIL VIEW oS SONET2 Item QTY Part No Description Motor 24V 50 60Hz 5 8 RPM Plate Motor MTG Stagers Screw 6
23. NOTE Display will only appear on the master timer and it must be programmed as valve position 1 System size must be 3 or 4 to appear Use the Shift button to move one space to the left NOTE This screen will only display for System 14 TRIP 3 sPm Examples Brings 4th Valve In Service after 350 gpm Brings 4th Valve In Service after 1 32 m m 3 to 999 gpm 1 to 3997 Lpm NOTE Display will only appear on the master timer and it must be programmed as valve position 1 System size must be 4 to appear Use the Shift button to move one space to the left NOTE This screen will only display for System 14 30 Default 350 1 32 Range TRIP DELAY 3 Example Trip point delay until valve goes to Service Range 30 to 99 seconds NOTE Display will only appear on the master timer and it must be programmed as valve position 1 System size must be 4 to appear Use the Shift button to move one space to the left NOTE This screen will only display for System 14 30 Default REGEHERRTIUOH DAY Example DUERRIDE OFF Off Default for Meter On Default for Time Clock REGENERATION DAY Example DUERRIDE 21 DAYS 1 Day Options Off Default for Meter or On Default for Time Clock Range 1 to 99 Days REGENERATI OW TIME 82 Options A M U S Format HR Metric Format Example 2 00 A M Default NOTE Regenerat
24. OIHT 1 888 Examples Default will need to be changed before next step 000 Default Brings 2nd valve In Service after 125 gpm 125 Brings 2nd valve In Service after 47 m m 0 47 Range 1 to 997 gpm 1 to 3997 Lpm NOTE Display will only appear on the master timer and it must be programmed as valve position 1 Use the Shift button to change each decimal position NOTE This screen will only display for System 14 TRIP DELAY 1 38 SECONDS Example Trip point time delay until valve goes into service 30 Default Range 30 to 99 seconds NOTE Display will only appear on the master timer and it must be programmed as valve position 1 Use the Shift button to move one space to the left NOTE This screen will only display for System 14 NXT Stager Controller AU11 7 MASTER PROGRAMMING MODE FLOW CHART continued t amp t RN RA t Een I Re TRIP POINT 2 SP i Examples Brings 3rd valve In Service after 250 gpm Brings 3rd valve In Service after 95 m m 2 to 998 gpm 1 to 3997 Lpm NOTE Display will only appear on the master timer and it must be programmed as valve position 1 System size must be 3 or 4 to appear Use the Shift button to move one space to the left NOTE This screen will only display for System 14 250 0 95 Range TRIP DELAY 2 38 SECONDS Trip point time delay until valve goes into Service 30 to 99 seconds
25. am each unit with unique valve address number in Master Programming Master program parameters do not match between two or Detected Error Program Mismatch more controls Confirm Master Programming for each unit No power to Control 1 Power Control 1 Detected Error No Message 1 Communication Cable to Valve Address 1 bad or missing Connect or replace Communication Cable No power to Control 2 Power Control 2 Detected Error No Message 2 Communication Cable to Valve Address 2 bad or missing Connect or replace Communication Cable No power to Control 3 Power Control 3 Detected Error No Message 3 Communication Cable to Valve Address 3 bad or missing Connect or replace Communication Cable No power to Control 4 Power Control 4 Detected Error No Message 4 Communication Cable to Valve Address 4 bad or missing Connect or replace Communication Cable Detected Error E2 Reset Unit This message appears after a software reset Reprogram control using Master Programming section Test Mode Circuit Board was not programmed at factory Replace Circuit Board Black Squares on screen Bad Circuit Board Replace Circuit Board INI on screen for more than 2 Circuit board not getting feedback from cycle switch minutes Inspect Motor should be rotating Connect wire harness to cycle switch Check Cycle Micro Switch
26. begin Regeneration No more than one unit will be in Regeneration at a time 6 Series Regeneration 2 3 or4 Immediate One Meter Delayed One Meter Remote Signal Start No Meter Stager no solenoid required All tanks in parallel supplying treated water Only 1 control will monitor flow meter sensor input When a regeneration is required for the system it will regenerate valve address 1 first immediately followed by 2 then 3 then 4 if installed No more than one unit will be in Regeneration at a time 7 Twin Alternating Immediate One Meter Remote Signal Start No Meter Solenoid plug stager port 2 One tank online supplying treated water one tank in Standby Only 1 control will monitor its flow meter sensor input Regeneration of a unit will begin after the other control has left Standby and returned to Service When the Regeneration cycle is complete the regenerated unit will enter Standby Standby on each tank is controlled by a solenoid connected to the service outlet valve of that tank 9 Multiple Tank Alternating 2 3 4 Immediate All Meters Remote Signal Start No Meter Solenoid plug stager port 2 One two or three tanks online supplying treated water one tank in Standby Meter sensor input is required on each tank Regeneration of a unit will begin after the other control has left Standby and returned to Service When the Regeneration cycle is complete th
27. cle button while powering up the unit This resets all of the parameters in the unit Check and verify the choices selected in Master Programming Mode SELECT LANGUAGES Example ENGLI SH English Options English Espanol Portugues Deutsch Francais ev SYSTEM TYPE 4 SINGLE UNIT Options System 4 System 5 Example System Type 4 Single Unit single unit 2 4 units Parallel Interlock System 6 2 4 units Parallel Series Regeneration System 7 2 units Alternating System 9 2 4 units Alternating System 14 2 4 units Demand Recall Cr Example Valve Address 2 Second Control Valve Default UALUE ADDRESS Options Valve Address 1 First Control Valve Valve Address 2 Second Control Valve Default Valve Address 3 Third Control Valve Valve Address 4 Fourth Control Valve NOTE This screen will not display for System Type 4 u cr SYSTEM SIZE 2 VALVES Example 2 Valves in the System Default Options 2 Valves in the System Default 3 Valves in the System 4 Valves in the System Range 2 to 4 Valves in the System NOTE This screen will not display for System Type 4 u Re a ep ui Ke a u 2 A BS u HEEL Y REGEH Example CLE DELAYED Time Clock Delayed Default Options Time Clock Delayed System 4 Only Default Meter Immediate All System Types Mete
28. d or set CURREHT FLOW RATE B Explaination Flow rate at this time Fr PERH FLOH RATE B Explaination Peak flow since last regeneration x LA TOTALI ZER 138 Explaination Gallons at the outlet since installation EE Re imm LAST THO REGEHS B HOURS Explaination Hours between the last regeneration and the one before it t LAST REGEN Fr HOURS Explaination Hours since last regeneration imm LUE REHAI 1888 Explaination Volume remaining can be adjusted Fr URLUE RDDRESS 2 Explaination Controller unit number ay F VERSION Explaination Installed software level of the controller in use re of Diagnostic Mode NXT Stager Controller AU11 9 IM ue uesouo si 1849 MOJ4 2 eq ejeg 2 jou si eoruieu aq jou ue pejqeus si n pasn s Aeq JI II 990 990 51911 992 00 500120 980 Wd11 000 Oc 000c 0 e pped eipped z eutqin
29. e Service Parts Common To Both 48ES amp 51 ES Stager Control 61783 E E Kit 48 51 ES Solenoid 61784 Kit 48 51 ES 3214 Board amp 61764 Cable Assy Communication CAT 5 5 Meters Long 42409 cil Transformer 120V 24V 40VA 41049 ies Transformer 220 24V EUR 108VA 41050 Transformer 220 24V AUST 108VA 19121 09 Meter Cable 99 5 Paddle Wheel 19121 10 Meter Cable 303 5 Paddle Wheel 19791 04 Meter Cable 100 Turbine 19791 05 Meter Cable 304 Turbine 1075499 Switch Micro 40941 Wire Harness Upper Drive 1075502 aset Wire Harness 2nd Aux Switch 43001 Motor NXT Stager Controller _ AU11 19 2011 Pentair Residential Filtration LLC 43037 Rev D AU11
30. e regenerated unit will enter Standby Standby on each tank is controlled by a solenoid connected to the service outlet valve of that tank 14 Demand Recall 2 3 or4 Immediate All Meters Solenoid plug stager port 2 Meter input is required on each tank Unit 1 will begin In Service with 2 3 and 4 if installed will begin in Standby At least one unit is In Service at all times When flow rate to the Primary Service Unit increases to a user specified rate the next unit in sequence will move from Standby to Service As the flow rate falls below the user specified rate subsequent tanks will return to Standby When the Primary Service Unit regenerates the next unit in sequence will become the new Primary Service Unit As each units capacity is reached the controller will initiate a Regeneration of that unit Depending on the number of units in the system and flow rate demand the regenerated unit will then be placed either into Standby or Service Only one unit will be in Regeneration at a time NXT Stager Controller AU11 3 SYSTEM OPERATION IN SERVICE SYSTEM 14 DEMAND The system operates as part of a multi tank regeneration system This example applies to either a 2 3 or 4 tank system Each tank in the system will have an active flow meter input even in Standby The number of tanks In Service depends on the flow rate Examples of a Four Unit System 1 One Tank is In Service
31. e time of control manufacture This product should be installed by a plumbing professional This product must be installed in compliance with all state and municipal plumbing and electrical codes Permits may be required at the time of installation If daytime operating pressure exceeds 80 psi nighttime pressures may exceed pressure limits A pressure reducing valve must be installed if pressure exceeds 125 psi Do not install the unit where temperatures may drop below 32 F 0 C or above 110 F 43 C Do not place the unit in direct sunlight Black units will absorb radiant heat increasing internal temperatures Do not strike the controller or any of the components e Warranty of this product extends to manufacturing defects Misapplication of this product may result in failure to properly condition water or damage to product Aprefilter should be used on installations in which free solids are present Correct and constant voltage must be supplied to the controller to maintain proper function 43037 Rev D AU11 NXT STAGER DIMENSIONS 11 13 282 7 891 226 3 A 8 Optional Solenoid N 40 50 266 6 X eg
32. ion time will not appear unless Regeneration Day Override is on CYCLE 1 88 18 88 CYCLE 2 88 88 Example Backwash 00 10 00 Default 48 00 Stager amp 51 09 Stager Hours Minutes Seconds Example Brine 01 00 00 Default 48 00 Stager amp 51 09 Stager Hours Minutes Seconds Options 01 00 00 for Conditioner for the 48 00 Stager amp 51 09 Stager Default 00 00 00 for Filter for the 48 00 Stager CYCLE 3 88 18 88 CYCLE 4 OFF CYCLE 4 88 12 88 8 NXT Stager Controller Example Fast Rinse 00 10 00 Default 48 00 Stager amp 51 09 Stager Hours Minutes Seconds Example Off Default 48 00 Stager Example Refill 00 12 00 Default 51 09 Stager Hours Minutes Seconds AU11 N u 2 RA u u To LT e e nid u t t Lr NN NUN 5 CYCLE 5 OFF Example Off Default 51 09 Stager NOTE This screen will only display when cycle 4 is not OFF AUXILIARY RELAY OI SABLED Example Auxiliary Relay is Disabled Options Enabled Disabled Default AUX RELAY OUTPUT START 1 88 GG aa Example Auxiliary Relay Output Start 1 at 0 hours 0 minutes amp 0 seconds Range 00 00 00 to 18 00 00 NOTE Only displayed if Auxiliary Relay is enabled in previous screen Auxiliary Relay will only display if Chemical Pump is OFF for System Types 6 amp 7 Example Auxiliary Relay Output End 1
33. on cable to either port before programming The maximum cable length between timers is 100 feet Connect units together from one communication port to the next communication port The order is not important Ground Communication Ports o las ruo CisH C20 pl Eg 951 Bl De U mL MIRE LA GL c17 74 4 4 CINE ER Figure 2 Current Circuit Board NXT Stager Controller AU11 5 TIMER OPERATION Set Time of Day Hold the Up or Down button to change time While in time change mode press Shift to adjust next digit over On multiple tank systems change time on 1 control only All other controls in system will mirror the time on control 1 Manually Initiating a Regeneration 1 When timer is In Service or Stand By press the Extra Cycle button on the main screen for five 5 seconds to force a manual regeneration if another unit is not in Regeneration 2 The timer reaches Regeneration cycle Step 1 3 Press the Extra Cycle button once to advance valve to the next Regeneration cycle Timer Operation During Regeneration In the Regeneration cycle step display the timer shows the current Regeneration cycle number the valve is in or has reached and the time remaining in that step Once all regeneration steps are complete the timer returns to In Service and resumes normal operation Hours Minutes Seconds CYCLE 1 OO 12 00
34. r Delayed Fixed Reserve Systems 4 amp 6 Only VALUE TYPE Example STAGER HOTCH Stager Notch Cam Default Options 2750 2850 2900 3150 3900 Stager Notch Cam Default REMOTE SIGHAL Example START OFF Off Default Options 00 06 00 Hours Munutes Seconds Range 1 second to 99 minutes 1 hour 39 minutes NOTE This display will not be viewed in System 14 DISPLAY FORMAT US GALLOWS Options U S Gallons Default EU Metric Liters Metric NOTE In U S Gallons mode the display will be in 12 hour time NOTE In European Units Liters Metric mode the display will be in 24 hour time Example U S Gallons Default Example 0300000 Grains Default UHIT CAPACITY 8369068 GRAINS Options Grains in U S Format Default Grams in Metric Format Range 1 to 9 900 000 Grain Capacity in U S Format 1 0 to 190 000 grams CaCO Capacity in Metric Format NOTE Use the Shift button to move to the left CAPACITY SAFETY Example FACTOR aux 00 Default Range 0 to 50 NOTE Use the Shift button to move to the left FEED HATER Example HARDNESS 15 GPG 15 GPG U S Format Default Range 1 to 199 Grains Gallon U S Format 2 to 199 miligrams CaCO L Metric Format NOTE Use the Shift button to move to the left NOTE This screen will only display on the lead unit for System Types 6 amp 7 For all other System Types it will display for all units TRIP P
35. s requires a contact closure to activate the lockout The recommended gauge wire is 20 with a maximum length of 500 feet Regeneration Day Override Feature If the Day Override option is turned on and the actual number of days since last regeneration exceeds the set regeneration day override value the Regeneration cycle starts If other units are in regeneration it is added to a regeneration queue This occurs regardless of the remaining volume available This unit is not designed to drive power external devices Transformer must be grounded Ground wire must be terminated to the back plate where grounding label is located Auxiliary Relay Output The Auxiliary Relay Output on the circuit board can be programmed to be closed during a window of time within the regeneration sequence The Aux Relay Output Start time sets the turn on time referenced to the start of regeneration The Aux Relay Output End time sets the turn off time referenced to the start of regeneration The Auxiliary Relay Output shares the same relay as the Chemical Pump Output See wiring diagram for connection information Chemical Pump Output When the Chemical Pump Output feature is enabled the control will calculate volume of water used and close the relay when the set CPO Aux Relay Volume is reached Once activated the relay will stay closed for the amount of time set in CPO Aux Relay Time The Chemical Pump Output only functions while in service and the CPO vol
36. s the new primary tank The tank with the next least volume remaining will be the first trip point programmed rate Tanks continue operating in this order System Operation in Regeneration Full Capacity 3 4 Capacity 4th in Standby 3rd in Standby 1 2 Capacity First Trip Point Programmed Rate If two tanks are In Service and both reach Volume Remaining 7 0 the other two tanks will shift from Standby to In Service The lead tank with Volume Remaining 0 will start Regeneration The second tank with Volume Remaining 0 will enter Standby If flow increases past the trip point a third tank needs to enter In Service The tank in Standby with Volume Remaining O will shift into In Service to maintain a steady flow Operating for extended periods in this mode may degrade the water quality 1 4 Capacity New Primary Tank TIMER DISPLAY FEATURES Valve State Display Screen SBY SRV INI LCK Time of Day alternates Valve with Error Screen Address Example Valve Volume System Flow Time Remaining Errors Number Indicator of Day Volume Remaining Diagnostic Button View Flow Rate Peak Flow Rate Totalizer Hours Between Last Two Regenerations Hours Since Last Regeneration Adjustable Volume Remaining Valve Position Send amp Receive Errors Software Version Extra Cycle Button Cycle Valve in Regeneration Cycle Programming Steps Shift Button Adjusts Values to the Left Up Button Adjusts Values Up mii SRELE
37. ume is reset to zero each regeneration The Chemical Pump Output shares the same relay as the Auxiliary Relay Output See wiring diagram for connection information MASTER PROGRAMMING MODE FLOW CHART Before entering Master Programming please contact your local professional water dealer When the Master Programming Mode is entered parameters can be set to make the timer s function as needed NOTE Depending on current option settings some displays cannot be viewed or set Entering Master Programming Mode 1 Press and hold the Shift and Up buttons for 5 seconds OR 2 Set time of day display to 12 01 PM 12 01HR Press and hold Up or Down buttons to set the time Then press the Up and Down buttons at the same time for 5 seconds Exiting Master Programming Mode 1 Press the Extra Cycle button once per display until all are viewed Master Programming Mode is exited and the normal display screen appears 2 To exit the Master Programming Mode without saving changes press the Diagnostic button NOTE If no keypad activity is made for 5 minutes while in the Master Programming Mode or if there is a power failure no changes will be saved and the unit will go back to the main display screen Resets Soft Reset Press and hold the Up and Down buttons for 25 seconds until 12 00PM or 12 00HR appears This resets all parameters except for the flow meter totalizer volume Master Reset Hold the Extra Cy
38. xny TINO 9 o o o o o o o o 9 gt SS 5 OUI eq Aejaq du e du c SSOUPIEH pee Ajayes Aioede9 Ayoedeg yewo ejdsiq euis 4 ed eA eA adh 921 uieis sS oDenDue 129 9 ALA p ej q paN paN Y Y ed uiejs S sobuey pue oeDenBue7 NINN LXN AU11 NXT Stager Controller 10 Stager Operation Stagers are motor driven rotary multi port valves used to control a set of valves in a predefined sequence They function by internally connecting inlet pressure to a defined set of control ports and allowing other control ports be vented through a drain Control ports are used to open and close valves in a preset sequence As the stager advances to various positions different valves are open and closed in a system The control port pressure and vent sequence is preset at the factory and cannot be field altered Stager Installation 1 Connect a constant pressure water or air source to the 1 8 NPT stager inlet Control fluid pressure must be equal to or greater than system pressure To ensure long trouble free operation a 100 micron filter in the control pressure line is recommended 2 Stager drain port
Download Pdf Manuals
Related Search