Pentair 48ES NXT, 51ES NXT Stager Controller Service Manual

48ES and 51ES NXT Stager Controller

Service Manual

TABLE OF CONTENTS

NXT STAGER DIMENSIONS .................................................2

SYSTEM SPECIFICATIONS 48ES AND 51ES SERIES ........2

SYSTEM DEFINITIONS .........................................................3

SYSTEM OPERATION IN SERVICE

(SYSTEM 14-DEMAND) .........................................................4

TIMER DISPLAY FEATURES.................................................5

NETWORK/COMMUNICATION

CABLES & CONNECTIONS ..................................................5

TIMER OPERATION ..............................................................6

MASTER PROGRAMMING MODE FLOW CHART ...............7

USER PROGRAMMING MODE FLOW CHART ....................9

DIAGNOSTIC PROGRAMMING MODE FLOW CHART ........9

PLUMBING DIAGRAMS .........................................................11

SOLENOID USE.....................................................................14

STAGER CONTROLLER, 48ES, NEMA 4 24V/50-60Hz

ASSEMBLY ............................................................................15

STAGER CONTROLLER, 51ES, NEMA 4 24V/50-60Hz

ASSEMBLY ............................................................................16

WIRING DIAGRAM 48/51ES STAGER CONTROLLER ........17

TROUBLESHOOTING ...........................................................18

SERVICE ASSEMBLIES ........................................................19

IMPORTANT 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 the 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.

• Warranty of this product extends to manufacturing defects. Misapplication of this product may result in failure to properly condition water, or damage to product.

• A prefilter 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]

8.91 [226.3]

Optional

Solenoid

10.50 [266.6]

5.25 [133.4]

1.41 [35.8]

(6X) 1/8" NPT PORT 60 APART

*

ø

0.733 [18.62 mm]

4 places

* ø

0.88

[22.4 mm]

1/8" NPT Drain

2.45 [62.2]

2.06 [52.3]

2.75 [69.9] 2.75 [69.9]

4.00 [101.6]

48ES STAGER

3.50 [88.9]

2.72 [69]

2.00 [50.8]

1/8" NPT Filtered Inlet

6.42 [163.1]

1.25 [31.7]

6.00 [152.4]

(4X) R.16 [4]

(4X) .19 [4.8]

11.13 [282.7]

.32 [8.1]

1/8" NPT Drain

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

3

) for every 1-255 pulses

Example: 35 gallons/100 pulses

(=3.5 gallons/10 pulses, = 0.35 gallons/1 pulse)

• Meter must operate at 5 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.

1.75 [44.4]

1/8" NPT Filtered Inlet

(8X) 1/8" NPT - 45 APART

*

ø

0.733 [18.62 mm]

4 places

1/8" NPT Drain

*

ø

0.88

[22.4 mm]

51ES STAGER

*

NOTE: Drill as required. These holes

will only be drilled at factory if

required.

Figure 1

2 • NXT Stager Controller AU11

SYSTEM DEFINITIONS

System

Number

4

System

Description

Single Unit

# of

Tanks/

Controls

1

5 Interlocked

Type

Time Clock: No Meter

Immediate: One Meter

Delayed: One Meter

Remote Signal Start: No Meter

2, 3, or 4 Immediate: All Meters


6

7

9

14

Service Outlet Valve

Controlled by...

Operation Discussion

Stager

(no solenoid required)

Single tank configuration. During

Regeneration no water available to service unless optional bypass valve #2A installed.

Series

Regeneration

Twin

Alternating

Multiple Tank

Alternating

Demand

Recall

2, 3, or 4

2

2, 3, or 4

2, 3, or 4


Delayed: One Meter




Immediate: All Meters


Immediate: All Meters

Stager


Stager


Solenoid

(plug stager port 2)

Solenoid


Solenoid


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 begin

Regeneration. No more than one unit will be in Regeneration at a time.

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.

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.

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, the regenerated unit will enter

Standby. Standby on each tank is controlled by a solenoid connected to the service outlet valve of that tank.

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 at all times (the "primary tank").

5. The third tank returns to Standby as demand decreases past the second trip point.

1 2 3 4

1 2 3 4

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.

Flow Split Between

Two Meters

Standby

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.

1

Full Capacity

4th in Standby

(Primary Valve) order.

2

3/4 Capacity

3rd in Standby

3

1/2 Capacity

2nd in Standby

7. The primary tank regenerates. The next tank with the least remaining volume becomes 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

System Operation in Regeneration:

4

1/4 Capacity

1st in Standby

1 2 3 4

First Trip Point

(Primary Valve)

In Service

Standby

Total Flow Split

Between Two Meters

3. The flow rate demand decreased below the first trip point.

The tank returns to Standby.

1 2 3 4

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.

1 2 3 4

Full Capacity

4th in Standby

3/4 Capacity

3rd in Standby

1/2 Capacity

First Trip Point

Programmed Rate

1/4 Capacity

New Primary Tank

If two tanks are In Service and both reach

Volume Remaining = 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 = 0 will shift into In Service to maintain a steady flow. Operating for extended periods in this mode may degrade the water quality.

1 2 3

Flow Split Between

Three Meters

4

Standby


TIMER DISPLAY FEATURES

Valve State

(SBY, SRV, INI, LCK)

Valve

Address

System

Number

Flow

Indicator

Time of Day

Display Screen

Time of Day alternates with Error Screen

Example: Valve #, Volume

Remaining, Errors

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 & 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

Status LED

Down Button

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 & Connections” section of this manual.

LED Status Lights

Blue LED - Illuminates 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 - Illuminates when the unit is in Regeneration mode. A blinking green light indicates the timer is in Standby, and not in Regeneration.

Red LED- Illuminates 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

& CONNECTIONS

Use a CAT5 Network/Communication cable.

Connect the network/communication 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

Lock Regen

Communication Ports

Figure 2 Current NXT Circuit Board


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.

Example: 12 minutes remaining in Cycle 1

Press the Extra Cycle button during 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.

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. This 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.

WARNING:

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 volume 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

CAUTION

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 the time of day display to 12:01 PM or 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 Cycle 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.

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:

30 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.


TRIP POINT 2: gpm

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.


TRIP DELAY 2:

30 SECONDS



TRIP POINT 3: gpm

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.


TRIP DELAY 3:

30 SECONDS




REGENERATION DAY

OVERRIDE:OFF

REGENERATION DAY

OVERRIDE:01 DAYS

Example:

Off

(Default for Meter)

On

(Default for Time Clock)

Example:

1 Day

Options: Off (Default for Meter) or On (Default for Time Clock)

Range: 1 to 99 Days

REGENERATION

TIME: 02:00AM

Example:

2:00 A.M.

(Default)

Options: A.M. (U.S. Format)

HR (Metric Format)

NOTE: Regeneration time will not appear unless Regeneration Day Override is on.

CYCLE 1 00:10:00

Example: Backwash

00:10:00

(Default 48-00 Stager & 51-09 Stager)

(Hours:Minutes:Seconds)

CYCLE 2 01:00:00

Example: Brine

01:00:00



Options: 01:00:00 for Conditioner for the 48-00 Stager & 51-09 Stager (Default)

00:00:00 for Filter for the 48-00 Stager

CYCLE 3 00:10:00

Example: Fast Rinse

00:10:00



CYCLE 4 OFF

CYCLE 4 00:12:00

Example:

Off

(Default 48-00 Stager)

Example: Refill

00:12:00



CYCLE 5 OFF

Example:

Off


NOTE: This screen will only display when cycle 4 is not OFF.

AUXILIARY RELAY:

DISABLED

Options: Enabled

Disabled

(Default)

Example:

Auxiliary Relay is Disabled

AUX RELAY OUTPUT

START 1 00:00:00

Example:

Auxiliary Relay Output Start 1 at

0 hours, 0 minutes, & 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 & 7.

AUX RELAY OUTPUT

END 1 00:00:00

Range: 00:00:00 to 18:00:00

Example:

Auxiliary Relay Output End 1 at


CHEMICAL PUMP:

DISABLED

Example:

Chemical Pump is Disabled


Disabled

(Default)

NOTE: This screen will only display on the lead unit for System Types 6 & 7.

For all other System Types, it will display for all units.

CPO AUX RELAY

VOLUME: 000 9

Example:

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

SELECT LANGUAGE:

ENGLISH

Options: English

Espanol

Portugues

Deutsch

Francais

Example:

English

SYSTEM TYPE: 4

SINGLE UNIT

Example:

System Type 4, Single Unit

Options: System 4 (single unit)

System 5 (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

VALVE ADDRESS:

#2

Example:

Valve Address #2 (Second Control Valve)

(Default)

Options: Valve Address #1 (First 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.

SYSTEM SIZE:

2 VALVES

Example:

2 Valves in the System

(Default)

Options: 2 Valves in the System (Default)



Range: 2 to 4 Valves in the System


REGEN TYPE:

TIME CLK DELAYED

Example:

Time Clock Delayed

(Default)

Options: Time Clock Delayed (System 4 Only) (Default)

Meter Immediate (All System Types)

Meter Delayed Fixed Reserve (Systems 4 & 6 Only)

VALVE TYPE:

STAGER-NOTCH CAM

Example:

Stager - Notch Cam

(Default)

Options: 2750

2850

2900

3150

3900

Stager - Notch Cam

(Default)

REMOTE SIGNAL

START:OFF

Example:

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-GALLONS

Example:

U.S. Gallons

(Default)

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.

UNIT CAPACITY:

0300000 GRAINS

Example:

0300000 Grains

(Default)

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

3

Capacity in Metric Format

NOTE: Use the Shift button to move to the left.

CAPACITY SAFETY

FACTOR: 00%

Example:

00%

(Default)

Range: 0 to 50%


FEED WATER

HARDNESS: 15 GPG

Example:

15 GPG (U.S. Format)

(Default)

Range: 1 to 199 Grains/Gallon (U.S. Format)

2 to 199 miligrams CaCO s

/L (Metric Format)




TRIP POINT 1:

000 gpm

CPO AUX RELAY

TIME: 00:00:00

Range: 00:00:00 to 02:00:00

Example:

Each time chemical pump relay is on, run for

30 seconds (00:00:30)

FLOW METER:

1.0 PADDLE

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 & 7. All other system types it will display for all units.

MAXIMUM FLOW

RATE: 0000 gpm

Example:

Maximum Flow Rate of 0 gpm

Range: 20 - 2000 gpm (U.S. Format)

20 - 2000 Lpm (Metric Format)

NOTE: Only displayed if “Generic” is chosen for the flow meter.

ADD 01 GALLONS

EVERY 001 PULSES

Example:

Add 1 Gallon for Each Pulse in U.S. Format

Options: Gallons (U.S. Format)

Liters (Metric Format)

Range: 1 - 99 Gallons (U.S. Format)

0.1 - 09.9 L (Metric Format)

Pulses: 1 - 99


PROGRAMMING UNIT

PLEASE WAIT...

Example:

Master Programming Mode is Exiting

1 to 997 gpm

1 to 3997 Lpm



TRIP DELAY 1:

30 SECONDS



TRIP POINT 2: gpm


2 to 998 gpm

1 to 3997 Lpm



TRIP DELAY 2:

30 SECONDS



TRIP POINT 3: gpm

3 to 999 gpm

1 to 3997 Lpm




TRIP DELAY 3:

30 SECONDS




REGENERATION DAY

OVERRIDE:OFF

REGENERATION DAY

OVERRIDE:01 DAYS

Example:

Off


On


Example:

1 Day



REGENERATION

TIME: 02:00AM

Example:

2:00 A.M.

(Default)


HR (Metric Format)


CYCLE 1 00:10:00


00:10:00



CYCLE 2 01:00:00

Example: Brine

01:00:00





CYCLE 3 00:10:00


00:10:00



CYCLE 4 OFF

CYCLE 4 00:12:00

Example:

Off


Example: Refill

00:12:00



CYCLE 5 OFF

Example:

Off



AUXILIARY RELAY:

DISABLED


Disabled

(Default)

Example:


AUX RELAY OUTPUT

START 1 00:00:00

Example:



Range: 00:00:00 to 18:00:00



Types 6 & 7.

AUX RELAY OUTPUT

END 1 00:00:00

Range: 00:00:00 to 18:00:00

Example:



CHEMICAL PUMP:

DISABLED

Example:



Disabled

(Default)



CPO AUX RELAY

VOLUME: 000 9

Example:





SELECT LANGUAGE:

ENGLISH


Espanol

Portugues

Deutsch

Francais

Example:

English

SYSTEM TYPE: 4

SINGLE UNIT

Example:








VALVE ADDRESS:

#2

Example:


(Default)



(Default)




SYSTEM SIZE:

2 VALVES

Example:


(Default)






REGEN TYPE:

TIME CLK DELAYED

Example:

Time Clock Delayed

(Default)




VALVE TYPE:

STAGER-NOTCH CAM

Example:

Stager - Notch Cam

(Default)

Options: 2750

2850

2900

3150

3900

Stager - Notch Cam

(Default)

REMOTE SIGNAL

START:OFF

Example:

Off

(Default)




DISPLAY FORMAT:

US-GALLONS

Example:

U.S. Gallons

(Default)





24-hour time.

UNIT CAPACITY:

0300000 GRAINS

Example:

0300000 Grains

(Default)





3



CAPACITY SAFETY

FACTOR: 00%

Example:

00%

(Default)

Range: 0 to 50%


FEED WATER

HARDNESS: 15 GPG

Example:


(Default)



/L (Metric Format)




TRIP POINT 1:

000 gpm

CPO AUX RELAY

TIME: 00:00:00

Range: 00:00:00 to 02:00:00

Example:


30 seconds (00:00:30)

FLOW METER:

1.0 PADDLE

Example:



1.0 Turbine

1.5 Paddle

1.5 Turbine

2.0 Paddle

3.0 Paddle

Generic


MAXIMUM FLOW

RATE: 0000 gpm

Example:





ADD 01 GALLONS

EVERY 001 PULSES

Example:






Pulses: 1 - 99


PROGRAMMING UNIT

PLEASE WAIT...

Example:


1 to 997 gpm

1 to 3997 Lpm



TRIP DELAY 1:

30 SECONDS

MASTER PROGRAMMING MODE FLOW

CHART continued


TRIP POINT 2: gpm

2 to 998 gpm

1 to 3997 Lpm



TRIP DELAY 2:

30 SECONDS



TRIP POINT 3: gpm

3 to 999 gpm

1 to 3997 Lpm




TRIP DELAY 3:

30 SECONDS




REGENERATION DAY

OVERRIDE:OFF

REGENERATION DAY

OVERRIDE:01 DAYS

Example:

Off


On


Example:

1 Day



REGENERATION

TIME: 02:00AM

Example:

2:00 A.M.

(Default)


HR (Metric Format)


CYCLE 1 00:10:00


00:10:00



CYCLE 2 01:00:00

Example: Brine

01:00:00





CYCLE 3 00:10:00


00:10:00



CYCLE 4 OFF

Example:

Off


CYCLE 4 00:12:00

Example: Refill

00:12:00




CYCLE 5 OFF

Example:

Off



AUXILIARY RELAY:

DISABLED


Disabled

(Default)

Example:


AUX RELAY OUTPUT

START 1 00:00:00

Example:



Range: 00:00:00 to 18:00:00



Types 6 & 7.

AUX RELAY OUTPUT

END 1 00:00:00

Range: 00:00:00 to 18:00:00

Example:



CHEMICAL PUMP:

DISABLED

Example:



Disabled

(Default)



CPO AUX RELAY

VOLUME: 000 9

Example:





SELECT LANGUAGE:

ENGLISH


Espanol

Portugues

Deutsch

Francais

Example:

English

SYSTEM TYPE: 4

SINGLE UNIT

Example:








VALVE ADDRESS:

#2

Example:


(Default)



(Default)




SYSTEM SIZE:

2 VALVES

Example:


(Default)






REGEN TYPE:

TIME CLK DELAYED

Example:

Time Clock Delayed

(Default)




VALVE TYPE:

STAGER-NOTCH CAM

Example:

Stager - Notch Cam

(Default)

Options: 2750

2850

2900

3150

3900

Stager - Notch Cam

(Default)

REMOTE SIGNAL

START:OFF

Example:

Off

(Default)




DISPLAY FORMAT:

US-GALLONS

Example:

U.S. Gallons

(Default)





24-hour time.

UNIT CAPACITY:

0300000 GRAINS

Example:

0300000 Grains

(Default)





3



CAPACITY SAFETY

FACTOR: 00%

Example:

00%

(Default)

Range: 0 to 50%


FEED WATER

HARDNESS: 15 GPG

Example:


(Default)



/L (Metric Format)




TRIP POINT 1:

000 gpm

CPO AUX RELAY

TIME: 00:00:00

Range: 00:00:00 to 02:00:00

Example:


30 seconds (00:00:30)

FLOW METER:

1.0 PADDLE

Example:



1.0 Turbine

1.5 Paddle

1.5 Turbine

2.0 Paddle

3.0 Paddle

Generic


MAXIMUM FLOW

RATE: 0000 gpm

Example:





ADD 01 GALLONS

EVERY 001 PULSES

Example:






Pulses: 1 - 99


PROGRAMMING UNIT

PLEASE WAIT...

Example:


1 to 997 gpm

1 to 3997 Lpm



TRIP DELAY 1:

30 SECONDS



TRIP POINT 2: gpm

2 to 998 gpm

1 to 3997 Lpm



TRIP DELAY 2:

30 SECONDS



TRIP POINT 3: gpm

3 to 999 gpm

1 to 3997 Lpm




TRIP DELAY 3:

30 SECONDS




REGENERATION DAY

OVERRIDE:OFF

REGENERATION DAY

OVERRIDE:01 DAYS

Example:

Off


On


Example:

1 Day



REGENERATION

TIME: 02:00AM

Example:

2:00 A.M.

(Default)


HR (Metric Format)


CYCLE 1 00:10:00


00:10:00



CYCLE 2 01:00:00

Example: Brine

01:00:00





CYCLE 3 00:10:00


00:10:00



CYCLE 4 OFF

CYCLE 4 00:12:00

Example:

Off


Example: Refill

00:12:00



CYCLE 5 OFF

Example:

Off



AUXILIARY RELAY:

DISABLED


Disabled

(Default)

Example:


AUX RELAY OUTPUT

START 1 00:00:00

Example:



Range: 00:00:00 to 18:00:00



Types 6 & 7.

AUX RELAY OUTPUT

END 1 00:00:00

Range: 00:00:00 to 18:00:00

Example:



CHEMICAL PUMP:

DISABLED

Example:



Disabled

(Default)



CPO AUX RELAY

VOLUME: 000 9

Example:





SELECT LANGUAGE:

ENGLISH


Espanol

Portugues

Deutsch

Francais

Example:

English

SYSTEM TYPE: 4

SINGLE UNIT

Example:








VALVE ADDRESS:

#2

Example:


(Default)



(Default)




SYSTEM SIZE:

2 VALVES

Example:


(Default)






REGEN TYPE:

TIME CLK DELAYED

Example:

Time Clock Delayed

(Default)




VALVE TYPE:

STAGER-NOTCH CAM

Example:

Stager - Notch Cam

(Default)

Options: 2750

2850

2900

3150

3900

Stager - Notch Cam

(Default)

REMOTE SIGNAL

START:OFF

Example:

Off

(Default)




DISPLAY FORMAT:

US-GALLONS

Example:

U.S. Gallons

(Default)





24-hour time.

UNIT CAPACITY:

0300000 GRAINS

Example:

0300000 Grains

(Default)





3



CAPACITY SAFETY

FACTOR: 00%

Example:

00%

(Default)

Range: 0 to 50%


FEED WATER

HARDNESS: 15 GPG

Example:


(Default)



/L (Metric Format)




TRIP POINT 1:

000 gpm

CPO AUX RELAY

TIME: 00:00:00

Range: 00:00:00 to 02:00:00

Example:


30 seconds (00:00:30)

FLOW METER:

1.0 PADDLE

Example:



1.0 Turbine

1.5 Paddle

1.5 Turbine

2.0 Paddle

3.0 Paddle

Generic


MAXIMUM FLOW

RATE: 0000 gpm

Example:





ADD 01 GALLONS

EVERY 001 PULSES

Example:






Pulses: 1 - 99


PROGRAMMING UNIT

PLEASE WAIT...

Example:


USER PROGRAMMING MODE FLOW

CHART

Entering User Programming Mode

Hold the Up and Down buttons for 5 seconds.

DIAGNOSTIC PROGRAMMING MODE

FLOW CHART

Entering Diagnostic Programming Mode

1. Push and release the "D" button.

2. Press the Extra Cycle button once per display until all displays are viewed and Normal Display is resumed.

3. Push and release the"D" button at anytime during diagnostic mode and the timer will exit the mode.

4. Depending on the current controller programming, certain displays may not be able to be viewed or set.

FEED WATER

HARDNESS: gpg

Options:

U.S. Format

Metric Format

[gpg]

[mgL]

REGENERATION DAY

OVERRIDE: OFF

Options:

U.S. Format

Metric Format

[OFF] = default

[OFF] = default

REGENERATION DAY

OVERRIDE:99 DAYS

REGENERATION

TIME: 02:00AM

Options:

U.S. Format

Metric Format

[02:00AM] = default

[02:00] = default

CURRENT FLOW

RATE: 0 gpm

Explaination:

Flow rate at this time.

PEAK FLOW RATE:

0 gpm

Explaination:

Peak flow since last regeneration.

TOTALIZER:

130 g

Explaination:

Gallons at the outlet since installation.

LAST TWO REGENS:

0 HOURS

Explaination:

Hours between the last regeneration and the one before it.

LAST REGEN

0 HOURS

Explaination:

Hours since last regeneration.

VOLUME REMAIN:

1000 g

Explaination:

Volume remaining; can be adjusted.

VALVE ADDRESS

#2

Explaination:

Controller unit number.

VERSION:

X.XX

Explaination:

Installed software level of the controller in use.



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 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)

Optional Hard

Water Bypass Valve

Drain Line Flow

Control not shown

B

A

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.


PLUMBING DIAGRAMS continued

4 Position Filter (48-00 Stager) 5 Position Softener w/Timed Brine Refill

(51-09 Stager)

Customer

Supplied Valve

Optional Hard

Water Bypass Valve

Optional Hard

Water Bypass Valve

4 POSITION FILTER

Drain Line Flow

Control not shown

Installer to plug (with

PN1071903)for filter operation

Plugs installed at factory

Drain Line Flow

Control not shown

B

A

B

A

C




Note C: Program Cycle 2 time to 00:00:00 for filter operation.





PLUMBING DIAGRAMS continued

Multiple Tank 4 Position Softener (48-00 Stager)

EJECTOR

RAW WATER

5A

BRINE

INLET

2A

1A

4A

3A

6A

5B

2B

1B

4B

3B

To Additional Tanks

As Required

6B

UNIT A

NOTE: All valves normally open, pressure to close.

NOTE: Valve 2 for each tank is controlled by solenoid for system 7, 9, 14

DRAIN

Multiple Tank 5 Position Softener (51-09 Stager)

Customer Supplied

Check Valve

Ejector

To Brine Tank

3A

Customer Supplied

Check Valve

To Brine Tank

Ejector

SERVICE

UNIT B

5A

INLET

7A

To Brine Refill

2A

1A

4A

To Brine Refill

6A

5B

7B

2B

1B

4B

DRAIN LINE FLOW

CONTROL NOT SHOWN

3B

To Additional Tanks

As Required

6B

UNIT A

DRAIN

NOTE: All valves normally open, pressure to close.

NOTE: Valve 2 for each tank is controlled by solenoid for system 7, 9, 14

SERVICE

UNIT B

DRAIN LINE FLOW

CONTROL NOT SHOWN


SOLENOID USE

Solenoids only required for Systems 7, 9 and 14

Series 48-00/51-09 Stager

Installer to

Plug Port 2

Solenoid

Valve

Drain

3

Inlet Pressure

1 2

2

3

2

3

1

Flow

1

Flow

Solenoid De-energized Solenoid 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.


STAGER CONTROLLER, 48ES, NEMA 4

24V/50-60Hz ASSEMBLY

41

39

38

47

1

2

3

7

4

23

16

3

3

27

51

49

17

5

22

21

18

19

11

6

9

15

8

14

12

20

10

12

13

BOTTOM DETAIL VIEW

SCALE 1:2

Item No. QTY Part No. Description

1 .................. 1 ......... 43001 ................... Motor, 24V, 50/60Hz, 5/8 RPM

2 .................. 1 ......... 1070436 ............... Plate, Motor MTG, Stagers

3 .................. 6 ......... 1075746 ............... Screw, 6-32 x 1/4", Phil

4 .................. 4 ......... 1072371 ............... Screw, 6-32 x .375, RD.HD, SS

5 .................. 1 ......... 1075737 ............... Gasket, Stager MTG, 48

6 .................. 1 ......... 1071667 ............... O-ring, 2-010, Nitrile

7 .................. 1 ......... 1075454* .............. Thumb Wheel, Molded

8 .................. 1 ......... 1074074 ............... Washer, 302, SS

9 .................. 1 ......... 1070448 ............... Shaft, Stem Assy, 48 Series

10 ................ 1 ......... 1074784 ............... Backplate, 48-00, Brass

11 ................ 1 ......... 1074793 ............... Bonnet, 48, Brass

12 ................ 1 ......... 1074825 ............... Inlet Strainer, Assy

13 ................ 3 ......... 1075759 ............... Screw, Pan Head, 6-32 x .88"

14 ................ 1 ......... 1076234 ............... Spring, Wave, 17-7 SS, 48 STGR

15 ................ 1 ......... 1074845 ............... Stemplate, 48, -00

16 ................ 1 ......... 1076245* .............. Cam, Cycle, Machined

17 ................ 1 ......... 1070437 ............... Plate, Bottom MTG, Stager

18 ................ 2 ......... 1075499 ............... Switch, Micro

19 ................ 1 ......... 1075455 ............... Switch Spacer, Insulator

20 ................ 1 ......... 1084171 ............... Gasket, Backplate, 48 Nitrile

21 ................ 2 ......... 1073593 ............... Washer, Lock, Internal, #4, SS

22 ................ 2 ......... 1075757 ............... Machine Screw, 4-40 x 1.00, SS if 2 switches

2 ......... 1072389 ............... Screw, 4-40 x 1-3/8" if 3 switches

23 ................ 1 ......... 1075453* .............. Cam, Auxiliary, Blank

24 ................ 2 ......... 3014200 ............... Screw, Slotted HX HD, 10-32


26 ................ 1 ......... 14202-01 .............. Screw, Hex Washer #8-32 x 5/16

27 ................ 1 ......... 43077-00 .............. Label, Dial, STGR, 2 3/8 x 7/8

28 ................ 2 ......... 17967-01 .............. Nut, Liquid Tight, HeyCo 3169

29 ................ 2 ......... 17967-02 .............. Fitting, Liquid Tight, Black

30 ................ 1 ......... 1075538 ............... Terminal Block, 10

31 ................ 2 ......... 1072369 ............... Screw, Pan HD, 4-40 x 5/8, SS

32 ................ 1 ......... 1076219 ............... Label, Ground, .75 Dia.

31

24

30 33

34

48

25

28

29

AUX 1 (RED)

35

26

50

32

47

44

43

CYCLE (WHITE)

36

45

46

KIT BR61764

SCALE 1:4

40

42

37

61803 Rev D


33 ................ 1 ......... 1073732 ............... Label, Terminal Strip, 1-10

34 ................ 1 ......... 43094-01 .............. Enclosure, 48ES, NEMA 4

35 ................ 1 ......... 43093 ................... Panel, A10P, 8" x 6" Modified

36 ................ 1 ......... 43046* .................. Keypad Label Assy, XT, NEMA 4

37 ................ 1 ......... 1070649 ............... Solenoid, N1, 24/60

38 ................ 4 ......... 42827-04 .............. Stand-off, Plastic, .625"

39 ................ 1 ......... 42753U* ............... Circuit Board, XT, ML

40 ................ 4 ......... 43092 ................... Screw, FLT HD, #6-20, TYP-B

41 ................ 1 ......... 40941 ................... Harness, Upper Drive

42 ................ 1 ......... 43090 ................... Washer, Sealing, Conduit, 1/2"

43 ................ 1 ......... 43140 ................... Fitting, NPT 1/2, Conduit

44 ................ 1 ......... 43141 ................... Washer, Lock, 7/8, INT Tooth

45 ................ 1 ......... 61764 ................... Cable Assy, COM, CAT 5E, NEMA 4

46 ................. 1 ..........19121-09 ...............Meter Cable Assy, NT, 99.5"

47 ................. 4 ..........1081780 ................Mount, Cable Tie, 4-Way

48 ................. 1 ..........1072379 ................Screw, 10-32 x 5/8", RND HD, SS

49 ................. 1 ..........1071660 ................Nut, Hex, 10-32, KEPS

50 ................. 1 ..........43177 ....................Washer, Lock, #8, INT, 18-8 SS

51 ................. 1 ..........1071648 ................Nut

Not Shown

1 ......... 61500-48/51LNE .. Line Drawing

9 ......... 1073701 ............... Tie, Cable, HeyCo VNT#4-18

2 ......... 1073702 ............... Wire Tie

3 ......... 1073955 ............... Terminal, Ring, #10, 16-14 GA

1 ......... 1073875 ............... Wire, Black, 18 AWG

1 ......... 1073880 ............... Wire, White, 18 AWG

1 ......... 1073874 ............... Wire, Green, 14 AWG

1 ......... 43163 ................... Literature, 3214 NXT Stager,S/M

1 ......... 43012 ................... Wiring Diagram, 48/51ES

1 ......... 61784 ................... Service Kit, 48/51, Timer

1 ......... 61783 ................... Service Kit, 48/51, Solenoid

1 ......... 1071903 ............... 1/8" NPT Pipe Plug Brass

*Only sold as Service Assembly


STAGER CONTROLLER, 51ES, NEMA 4

24V/50-60Hz ASSEMBLY

30

AUX 1 (Red)

20 23

39

36

21

29

27

3

5

13

8

4

1

2

50

6

3

17

12

11

9

10

38

52

14

35

15

37

18

19

24

51

16

22

36

32

33

34

CYCLE (White)

25

ISO FRONT VIEW

SCALE 1:4

28

31

26

KIT BR61764

SCALE 1:4

43

40

41

44

46

47

48

45

42

7

42

BOTTOM DETAIL VIEW

SCALE 1:2

49


1 .................. 1 ......... 43001 ................... Motor, 24V, 50/60Hz, 5/8 RPM

2 .................. 1 ......... 1070436 ............... Plate, Motor MTG, Stagers

3 .................. 6 ......... 1075746 ............... Screw, 6-32 x 1/4", Phil

4 .................. 2 ......... 1072371 ............... Screw, 6-32 x .375, RD.HD, SS

5 .................. 1 ......... 1075454* .............. Thumb Wheel, Molded

6 .................. 1 ......... 1075674 ............... Gasket, Stager MTG, 51, 96

7 .................. 1 ......... 1074825 ............... Inlet Strainer, Assy

8 .................. 1 ......... 1076243* .............. Cam, Cycle, Machined

9 .................. 2 ......... 1075499 ............... Switch, Micro

10 ................ 1 ......... 1075455 ............... Switch Spacer, Insulator


12 ................ 2 ......... 1075757 ............... Machine Screw, 4-40 x 1.00, SS

13 ................ 1 ......... 1075453* .............. Cam, Auxiliary, Blank

14 ................ 2 ......... 3014200 ............... Screw, Slotted HX HD, 10-32


16 ................ 1 ......... 14202-01 .............. Screw, Hex Washer #8-32 x 5/16

17 ................ 1 ......... 43078-09 .............. Label, Dial, STGR, 2 3/8 x 7/8

18 ................ 2 ......... 17967-01 .............. Nut, Liquid Tight, HeyCo 3169

19 ................ 2 ......... 17967-02 .............. Fitting, Liquid Tight, Black

20 ................ 1 ......... 1075538 ............... Terminal Block, 10

21 ................ 2 ......... 1072369 ............... Screw, Pan HD, 4-40 x 5/8, SS if 2 switches

2 ......... 1072389 ............... Screw, 4-40 x 1-3/8" if 3 switches

22 ................ 1 ......... 1076219 ............... Label, Ground, .75 Dia.

23 ................ 1 ......... 1073732 ............... Label, Terminal Strip, 1-10

24 ................ 1 ......... 43093 ................... Panel, A10P, 8" x 6" Modified

25 ................ 1 ......... 43046* .................. Keypad Label Assy, ST, NEMA 4

26 ................ 1 ......... 1070649 ............... Solenoid, N1, 24/60

27 ................ 1 ......... 42753U* ............... Circuit Board, XT, ML

28 ................ 4 ......... 43092 ................... Screw, FLT HD, #6-20, TYP-B

29 ................ 4 ......... 42827-04 .............. Stand-off, Plastic, .625"

30 ................ 1 ......... 40941 ................... Harness, Upper Drive

31 ................ 1 ......... 43090 ................... Washer, Sealing, Conduit, 1/2"

32 ................ 1 ......... 43141 ................... Washer, Lock, 7/8, INT Tooth

61804 Rev D


33 ................ 1 ......... 43140 ................... Fitting, NPT 1/2, Conduit

34 ................ 1 ......... 61764 ................... Cable Assy, COM, CAT 5E, NEMA 4

35 ................ 1 ..........19121-09 ...............Meter Cable ASSY, NT, 99.5"

36 ................ 4 ..........1081780 ................Mount, Cable Tie, 4-Way

37 ................ 1 ..........1072379 ................Screw, 10-32 x 5/8", RND HD, SS

38 ................ 1 ..........1071660 ................Nut, Hex, 10-32, KEPS

39 ................ 1 ......... 43094-02 .............. Enclosure, 51ES, NEMA 4

40 ................ 1 ......... 1075241 ............... Washer, 302, SS

41 ................ 1 ......... 1070438 ............... Shaft, Stem Assy, 51 Series

42 ................ 2 ......... 1071903 ............... Male Pipe Plugs

43 ................ 1 ......... 1074883 ............... Bonnet, 51, Brass

44 ................ 1 ......... 1075647* .............. Stemplate, 96, Alpha

45 ................ 1 ......... 1075242 ............... Spring, Compression

46 ................. 1 ..........1084172 ................Gasket, Backplate, 51 & 96 STGRS

47 ................. 1 ..........1074866* ...............Backplate, D.V. Nest

48 ................. 1 ..........1071716 ................O-ring, EP, ORE-011

49 ................. 4 ..........1075760 ................Screw, Machine, #6-32 x 1 1/8

50 ................. 1 ..........1077824 ................MTG Plate, BTM, STGR, 51ES

51 ................. 1 ..........43177 ....................Washer, Lock, #8, INT, 18-8 SS

52 ................. 1 ..........1071648 ................Nut

Not Shown

1 ......... 61500-48/51LNE .. Line Drawing

9 ......... 1073701 ............... Tie, Cable, HeyCo VNT#4-18

2 ......... 1073702 ............... Wire Tie

3 ......... 1073955 ............... Terminal, Ring, #10, 16-14 GA

1 ......... 1073875 ............... Wire, Black, 18 AWG

1 ......... 1073880 ............... Wire, White, 18 AWG

1 ......... 1073874 ............... Wire, Green, 14 AWG

1 ......... 43163 ................... Literature, 3214 NXT Stager,S/M

1 ......... 43012 ................... Wiring Diagram, 48/51ES

1 ......... 61784 ................... Service Kit, 48/51, Timer

1 ......... 61783 ................... Service Kit, 48/51, Solenoid

*Only sold as Service Assembly


WIRING DIAGRAM 48/51ES STAGER

CONTROLLER

RT TA

UT

TE MO

CK

D

RE

LO

GN

LOWPER DRIVE

N

ITE

CK

WH

BLA

CK

EE

BLA

GR

W

BLK

CK

GE

LE

AN

RP

LLO

WT/

BLA

YE

OR

PU

OW ELL N/Y EE GR

CK BLA

OW ELL N/Y EE GR

LE RP PU

CK BLA

N.C

N.O

C

1 SW

GE AN OR

N.C

N.O

CK BLA C

2 SW

N.O

N.C

C

3 SW

E

E

BLU

BLU

OW ELL N/Y EE GR

W

EL

N

EE

R

G

GR

EE

N/

YE

LL

OW


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.

• Any unit in Regeneration when the error occurs completes Regeneration and goes to In Service.

• No units 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

Flashing time

Detected Error = No Message #1




Detected Error = E2 Reset Unit

Test Mode

Black Squares on screen

INI on screen for more than 2 minutes

CHG on screen for more than 2 minutes

Power outage.

Cause For Error Correction

Program time by holding UP on Unit #1.

Program each unit with unique valve address number in Master Programming.

Confirm Master Programming for each unit.

No power to Control #1.

Power Control #1.

Communication Cable to Valve Address #1 bad or missing.

Connect or replace Communication Cable.


Power Control #2.




Power Control #3.




Power Control #4.



This message appears after a software reset.

Reprogram control using Master

Programming section.

Circuit Board was not programmed at factory.

Bad Circuit Board.

Replace Circuit Board.

Replace Circuit Board.

Circuit board not getting feedback from cycle switch.

Inspect Motor - should be rotating.

Connect wire harness to cycle switch.

Check Cycle Micro Switch.

Control programmed incorrectly as 2900 or 3900 valve type. Reprogram unit as Stager Valve type.


SERVICE ASSEMBLIES

48-00 ES Stager Assembly

61808-01 ....................Stager Assy, 48-00, NXT 24VAC, HMG

No 2nd 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 Assy, 48-00, Inverted, NXT

24VAC, HMG No 2nd Aux Switch


24VAC, SA, 2nd Aux Notched in Service


24VAC, SC, 2nd Aux Notched In

Backwash

1074817......................Kit, Internal Parts, 48-00 Stager

61817-01 ....................Cam Assy, 48-00 NXT, HMG, no 2nd

Aux Cam

61817-02 ....................Cam Assy, 48-00 NXT, SA, 2nd Aux

Notched in 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 ....................Stager Assy, 51-09, NXT 24VAC, SH,

2nd Aux Notched in Refill


24VAC, HMG, No 2nd Aux Switch


24VAC, SA, 2nd Aux Notched in Service


24VAC, SD, 2nd Aux Notched in

Backwash


24VAC, SH, 2nd Aux Notched in Refill

1074888......................Kit, Internal Parts, 51-09 Stager

61818-01 ....................Cam Assy, 51-09 NXT, 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

60613..........................Meter Assy, 1", Elec., Brass Body, PDL

60614..........................Meter Assy, 1-1/2", Elec., Brass Body,

PDL



60625..........................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

61560-13 ....................Meter Assy, 1-1/2", Elec., Plastic,

Turbine

Service Parts Common To Both 48ES & 51 ES Stager Control

61783..........................Kit, 48/51 ES NEMA4, Solenoid

61784..........................Kit 48/51 ES, 3214 NXT, CKT Board &

Keypad

61764..........................Cable Assy, Communication, CAT 5,

5 Meters Long

42469..........................Transformer, 120V/24V, 40VA

41049..........................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......................Wire Harness, 2nd Aux Switch

43001..........................Motor


© 2011 Pentair Residential Filtration, LLC 43037 Rev D AU11

Pentair 48ES NXT, 51ES NXT Stager Controller Service Manual

Assistant Bot

48ES and 51ES NXT Stager Controller

Service Manual

TABLE OF CONTENTS

IMPORTANT PLEASE READ:

NXT STAGER DIMENSIONS

SYSTEM SPECIFICATIONS 48ES AND

51ES SERIES

Generic Meter Guidelines

Electrical Rating

Humidity

Temperature

Pressure

*

SYSTEM DEFINITIONS

SYSTEM OPERATION IN SERVICE

(SYSTEM 14-DEMAND)

System Operation in Regeneration:

TIMER DISPLAY FEATURES

Valve State

LED Status Lights

Flow Indicator

NETWORK/COMMUNICATION CABLES

& CONNECTIONS

TIMER OPERATION

Set Time of Day

Manually Initiating a Regeneration

Timer Operation During Regeneration

Press the Extra Cycle button during a

Regeneration Cycle to immediately advance the valve to the next cycle and resume normal timing.

Flow Meter Equipped Timer

Timer Operation During Programming

Timer Operation During A Power Failure

Remote Lockout

Regeneration Day Override Feature

WARNING:

Auxiliary Relay Output

Chemical Pump Output

MASTER PROGRAMMING MODE FLOW

CHART

CAUTION

Entering Master Programming Mode

Exiting Master Programming Mode

Resets

MASTER PROGRAMMING MODE FLOW

CHART continued

USER PROGRAMMING MODE FLOW

CHART

Entering User Programming Mode

DIAGNOSTIC PROGRAMMING MODE

FLOW CHART

Entering Diagnostic Programming Mode

Stager Operation

Stager Installation

Inverted Type Stagers

PLUMBING DIAGRAMS

4 Position Softener (48-00 Stager)

PLUMBING DIAGRAMS continued

4 Position Filter (48-00 Stager) 5 Position Softener w/Timed Brine Refill

(51-09 Stager)

PLUMBING DIAGRAMS continued

Multiple Tank 4 Position Softener (48-00 Stager)

Multiple Tank 5 Position Softener (51-09 Stager)

SOLENOID USE

Solenoids only required for Systems 7, 9 and 14

Energized To Close

Inverted Stagers Only - Energize to Open

STAGER CONTROLLER, 48ES, NEMA 4

24V/50-60Hz ASSEMBLY

STAGER CONTROLLER, 51ES, NEMA 4

24V/50-60Hz ASSEMBLY

WIRING DIAGRAM 48/51ES STAGER

CONTROLLER

TROUBLESHOOTING

Detected Errors

SERVICE ASSEMBLIES

Key Features

Frequently Answers and Questions

What are the maximum operating temperature limits for the Stager Controller?