Valve Nest Stager Installation and Operation Manual

Valve Nest Stager Installation and Operation Manual

STAGER OPERATION The 8-Position Stager is used to operate the diaphragm valves nest on all softener models. The stager connects to the controller by way of a twist lock connector on the end of the cable. Each stager has it s own transformer for operation. The controller receives it s power from the stager controlling unit #1. The stager is designed such that it supplies air pressure to the top side of each diaphragm valve to hold it closed. During regeneration the pressure is relieved from the top of the valve which is open during a particular cycle. ( See regeneration cycles). The stager is provided with hardware to mount it to the piping of the unit. The controller is also capable of being mounted to the piping of the unit. Connect the twist lock harness to the controller prior to plugging in the transformer. The stager opens and closes the diaphragm valves during the six steps of operation. A small window is provided to observe the current regeneration cycle of the unit. This indicator window is located on the right side of the stager. (Shown on the wiring diagram). The regeneration cycles are listed in sequence at the right. The corresponding Step is provided for each regeneration cycle. The stand-by step is only used with duplex alternating systems, and is skipped if not programmed as duplex alternating. Step No. 0 Service 1 Backwash 2 Brine Draw 3 Fast Rinse 4 Brine Refill 5 Stand-by Cycle

The stager has two switches mounted inside. Each switch is activated by its own cam. The bottom switch is the Positioning Switch. It tells the controller the cycle of regeneration the stager is in. The top switch is the Auxiliary Switch, which is activated during regeneration, and deactivated during service. The Auxiliary Switch can be used to obtain a signal to turn off and on a Reverse Osmosis system, a regeneration pump, or to activate indicator lights for service and regeneration. The wiring diagram is shown below. Wiring Diagram: NO NC Step Indicated in Window

TUBING CONNECTIONS The hydraulic tubing is connected to the diaphragm valves as shown below. It is recommended to use air to operated the diaphragm valves. Water can be used but is not recommended. Impurities in the water can plug the small orifices in the stager. The air pressure must be 10 psi greater than the water pressure to unsure proper operation of the diaphragm valves. Tubing Diagram: Note: Tubing diagram shown for Single and Parallel operation, for Alternating and Variable plug Port #2 and connect Valve V2 to Port #4.

REGENERATION FLOW DIAGRAMS Service Cycle: Hard water flows through Valve V1, into the top of the tank. It then flows down through the resin where the hardness is ion exchanged for sodium. The soft water flows through the gravel underbedding, into the lower distributors and out to service through Valve V2. When the resin becomes exhausted, regeneration is required. Backwash Cycle: Backwash is the first cycle of regeneration. Valves V1 and V2 close while Valves V3 and V4 open. Water flows down through Valve V3 into the outlet distributors into the gravel underbedding and up through the resin. This reverse flow expands the resin, loosening the bed and turbidity collected during service is pushed to the top of the tank. The water flows out through the upper baffle, down through Valve V4 to drain.

REGENERATION FLOW DIAGRAMS Brine Draw Cycle: Valves V1 and V2 remain closed. Valves V3 and V4 close while Valve V5 opens. Water is directed through the eductor creating a vacuum on Valve V6, which causes it to open and supply brine from the salt tank. The water in the eductor mixes with the brine, diluting it to the proper strength. The brine enters the top of the tank and flows down through the resin. The sodium rich brine causes the hardness collected during Service to be regenerated off the resin. This hardness flows down through the gravel underbedding into the distributors, out through Valve V5 to drain. Slow Rinse Cycle The unit continues in brine draw until the air-check in the brine tank stops the flow of brine. When the ball checks, water continues to flow through the eductor. This low rate of water flow is called slow rinse. Slow rinse displaces the brine from the resin and rinses it down the drain. REGENERATION FLOW

DIAGRAMS Fast Rinse Cycle: Valve V1 opens pressurizing the tank, and closing Valve V6. Water enters the top of the tank as in service and flows down through the resin compacting the bed and rinsing out the last of the excess brine, into the distributors and out to drain through Valve V5. Refill Cycle: The softener returns to Service or Stand-by after Fast Rinse. Valve V1 is open, and Valve V6 is powered open by the stager. Water flows down the brine line, through the air-check and into the brine tank. The brine tank fills for a specified time. The water dissolves the salt making more brine for the next regeneration.