Softener Unit Model 2900 2" Top Mount Valve
Transcription
Softener Unit Model 2900 2" Top Mount Valve
Model 2900 2" Top Mount Valve Softener Unit Regina, Saskatchewan, Canada Cambridge, Ontario, Canada Read manual thoroughly before proceeding with installation Feb 99 4 5982 _________ Customer_____________ Project f’v’o Unit Serial No.______ Valve Serial No. Regeneration Times Assembly Date______ Assembled By:_______ Model S AS- Steel Tank. Automatic Control Valve Softener Capacity grains I cuft. resin = 30000 grain capacity Valve Size 2750 5 2850 2 2900 3150 203900 3 - Options 0- None, Standard Unit I - Systemax 2000 v/o special options 2 - ET Unit w/o special options X - Non Standard Unit See Below Softener Type FAF - Fiberglass Tank, Automatic Control Valve I - Valve Valve Valve Valve Valve Number of Units S - Single D - Duplex T - Triplex System Type C - Calendar Clock 1- Single Unit. Meter Initiated standard delayed regeneration S - Multiple Unit. Meter Initiated Interlocked Regeneration! Parallel Operation 6- Multiple Unit. Meter Initiated Sequential Regeneration. Parallel Operation 7 Multiple Unit. Meter Initiated Alternating Operation 8- Single Unit. Sensor Initiated Regeneration 9- Multiple Unit. Sensor Initiated Interlocked Regeneration. Parallel Operation Option List Treated Water Regeneration Kit fl Auxilliary Contacts Description! fl fl fl fl fl Systemax 2000 Programmable Controller ET Digital Controller Environmental Enclosure Side Mounted Valve, 3150 &3900 Valves Only 220 VAC!5OHz Power Supply 115 VAC/6OHz standard Other, specify. fl Other,Specify._____________________________ Dec $ Table Of Contents Section 1 Product Summary 1.1 Product Summary Section 2 General Specifications 2.1 Operating Parameters 2.2 Tanks 2.3 Standard Distribution 2.4 Control Valve 2.5 Performance Section 3 Inspection 3.1 General Inspection Section 4 Installation 4.1 Tank Positioning 4.2 Media Installation 4.3 Piping .1 Treated Water Regeneration 4,4 Electrical .1 Standard Mechanical And ET .2 Systemax 4.5 Valve Wiring Diagrams Section 5 Media Specifications 5.1 Media Description 5.2 Media Bed Quantities Section 6 Softener Parts Breakdown 6.0 Major Components 6.1 Control Drive Assembly 6.2 Valve Timer Assembly 6.3 Valve Body Assembly 6.4 Brine Valve Assembly 6.5 Service Valve Operator SVO 6.6 Meter Assembly 6.7 Remote Meter Timers Section 7 Start Up 7.1 Unit Start Up Section S Operation 8.1 Operating Conditions 8.2 Cycle Operation I Service .2 Backwash .3 Brine Draw Position .4 Rinse .5 Brine Tank Refill Section 9 Control 9.1 Calendar Clock 9.2 Meter 9.3 Sensor 9.4 Regeneration Cycle Tinier 9.5 Regeneration Program 9.6 Changing the Regeneration Cycle Times Section 10 Troubleshooting Section 11 Warranty Feb 99 Section LI Product Summary You have just acquired a USF Consumer Products commercial softening system. Your system may be equipped with one of the following control systems. Calendar Clock The calendar clock softener can be a single or multiple unit softener. The single unit comes with standard with delayed regeneration typically 2:00 am and has a hard water bypass piston. The duplex or more units also comes standard with delayed regeneration and has a no hard water bypass pistons. These units are not electrically interlocked so the regeneration time must be staggered so more than one unit does not regenerate at a time. - System 4-The system 4 is a single meter initiated unit. It comes standard with delayed regeneration typically 2:00 am and has a hard water bypass piston. System 5-The system 5 is a duplex meter initiated system with all units in parallel service. Each unit has its own meter and brine tank. Regeneration is immediately at end of service run and an electrical interlock prevents regeneration of a unit while another is in regeneration. No hard water bypass pistons are standard. System 6- The system 6 is a duplex meter initiated system with all units in parallel service. Each unit has its own brine tank but shares a common meter on the outlet header. Regeneration is immediately at end of service run and is series regeneration. No hard water bypass pistons are standard. System 7 The system 7 is a duplex alternating service/stand-by system with one unit on line and the other in regeneration or stand-by. The system comes standard with one brine tank and one meter on the common outlet header. Hard water bypass is prevented with no hard water bypass pistons 2900 or 3900 valve and automatic diaphragm isolation valves on all other types. - System 8-The system 8 is a single sensor initiated unit. It comes standard with delayed regeneration typically 2:00 am and has a hard water bypass piston. System 9-The system 9 is a duplex sensor initiated system with all units in parallel service. Each unit has its own brine tank. Regeneration is immediately at end of service run and an electrical interlock prevents regeneration of a unit while another is in regeneration. No hard water bypass pistons are standard. Options ET Controller A precise electronic available with all of our commercial control valves. A bright 7 digit display shows flow and totalizer information and programming is easy with the simple touchpad design. The enclosure is hinged to allow complete access to all internal pans and has a NEMA 3R rating. - Systemax 2000- New electronic controller monitors and controls up to three water softeners. Featuring a bright 8 digit display, the Systemax can be programmed for each softener individually or as a system, allowing the operator to view flow rates, flow totals and operating status of any softener unit. Electrical connections are simple, prewired interlock cables supplied with the controller. Enclosure rating is NEMA 4X. Feb 99 Section 2. 2900 Valve Softeners General Specifications - 2.1 Operating Parameter 30 Recommended System Operating Range - 100 psig, 20.6 kPa - 68.7 lcPa 2.2 Tanks 14"x65",16"x65"21"x54",21"x69"&24"x72" Size Fiberglass Reinforced Polyethylene Material, Standard 150 psi, 1.03 MPa at 120F, 49C Maximum Working Pressure All tanks are NSF, National Sanitation Foundation, approved. All standard tanks come with a 4" threaded top hole. - 2.3 Distribution PVC & Polypropylene Top Hole Connection, Bottom Hub & Laterals Material, Standard Configuration 2.4 Control Valve Model Size Type Material Connection Working Pressure Range Backwash Flow Control Brine Tank Refill Flow Control Inlet Connection Outlet Connection Drain Connection Recommended Minimum Drain Discharge Piping Size 2900 2" Raw Water Bypass Piston Single Units No Raw Water Bypass Piston Duplex Units Cast Brass Threaded 30- 120 psig, 207 kPa -827 kPa Orifice Flow Control Orifice Flow Control 2"FNPT 2" FNPT I" FNPT The valve is electrically operated by either 115 VAC/6OHz Standard, 220 VAC/50 Hz, or 22OVAC/6OHz - 2.5 Performance Specifications iolel Nuniher FAF9O FAF 120 FAF 150 FAF 180 FAF 210 FAF 240 FAF 270 FAF 300 FAF 330 Resin Ca pat it 15lh/1t3 90,000 120,000 150,000 180,000 210,000 240,000 270,000 300,000 330,000 Resin Ca pacitv 10W/it3 81,000 108.000 135,000 162,000 189,000 216,000 243,000 270,000 297,000 Resin Capacity 1b/ft’ 75,000 100,000 125,000 150,000 175,000 200,000 225,000 250,000 275,000 Service F lowrate continuous 26USgpm 34USgpm 57 USgpm 57 USgpm 57 USgpm 57 USspm 45 USgpm 55 USgpm 60 USgpm Service Flow ‘ate IS psi loss 41 USgpm 49 USgprn 76 USgpm 72 USgpm 67 USgpm 63 USgpm 75 USgpm 73 USgpm 71 USgpni Service Flow rate tZS psi loss 60 USgpm 70 USgpm 03 USgpm 98 USgpm 93 USgpm 89 USgpm 104 USapm 102 USgpm 99 USgpm Fank Size 14"x65" 16"x 65" 21" X54" 21" x 54" 21" x 69" 21" x 69’ 24" x 72’ 24" x 72’ 24" x 72 Feb 9 Section 3. Inspection 3.1 General Check the product summary to determine what options you have received. If you have not received the items that are required for assembly of the softener, please contact your supplier. Inspect the equipment, including internal distribution, for any visible shipping damage. If damaged, noti’ the transportation company and request a damage inspection. Damage to cartons should also be noted. Read manual thoroughly before proceeding with installation. Handle softener unit with care. Damage can result if dropped or set on sharp, uneven projections on the floor. Each softener you have received consists of the following items: * Control valves. includes assembled valve, backwash and brine line flow controls * Fiberglass tank, complete with internal distribution * Softener media and gravel support bed * Brine tank & accessories, ie brine tank, tubing, etc. Note: all standard systems except system 7 have one brine tank per softener. - - - - - - - Other items that may accompany your softener are: * Volumetric meter, meter initiated units only * Systemax 2000 Programmable Controller. comes with interconnecting cables, and operation manual. * Treated water regeneration kit. - Section 4. Installation 4.1 Tank Positioning * Position the tanks as shown on the installation drawing, see Appendix C for drawing Note: ‘The tanks should be located on a level support pad. ic/il, adequate access space on all sides, ‘all sjstenis must be u/thin 3 feet of one another for the interconnect cable to properly attach. * * tt,iits in chip/es and/or triplex Check hub and laterals in the tank for any damage that may have occurred during transport. This is critical because if the distribution is broken, the media will go out into the service lines. Thread the control valve snugly into the tank using silicone grease # 13691 not included on 0-rings, and adjust softener position until the desired orientation is achieved. ivote: Do flat niove tank after this is completed. because once the softener media is installed, ii tel/I be t’ei’ difficult to ‘‘toy occur tf the tank is ovecl ,,‘he,, filled ti/ti, tnedio. move, and danicege 4,2 Media Installation * * * * * Remove the valve from the mineral tank. Temporarily plug the open end of the riser tube to ensure that no resin or gravel falls down into the distribution. Fill mineral tank one quarter full of water to protect distribution during gravel installation. Slowly and carefully add the gravel support bed and the softener media as outlined in Section 5. Media Specifications. leveling each layer as it is placed into the tank. Unplug the riser tube, careflully position the valve over it and turn valve into threads in fiberglass tank, tightening securely into tank. Note: Ensure that the internal Q.ring iii the vah’e fits securely over the riser tube. Silicone grease or othet’foacl grade lubricant. ittay be applied to the 0-ring to ease installation of the riser tube. * * The softener is now charged with softening resin, It is recommended that the softener tank now be completely filled with water SLOWLY to soak the resin for approximately 6 hours before startup. This will allow the media to absorb water as velI as help displace any trapped air. and this will reduce the chance of backvashing resin out during startup. Feb99 4.3 Piping * * * Install the piping conforming to federal, provincial and local codes. Unions andlor flanges are recommended and isolation and by-pass valves should also be installed. Inlet and outlet piping should allow for slight expansion and contraction of the fiberglass tank during operation under system pressure. For proper system operation and startup, and to monitor the softener’s removal capacity and efficiency, sample points and pressure gauges must be installed on each unit immediately before on the inlet piping and after on the outlet piping each softener. See Fig. 4.1 for a typical installation. The drain line should be as short as possible and must be piped to an open drain. Access to the drain and an air gap are necessary for visual inspection and testing of drain water. The floor drain must be sized to carry the maximum listed flow to drain. See section 2 for flowrates It is recommended that the drain pipe size should be at least the same size of pipe or larger as the inlet and outlet piping. See section 2.4 Install the backwash flow control in the drain line piping. The arrow stamped on the side of the control indicates the direction of flow to drain. The backwash flow rate is controlled by a flow control that is factory set, and does not require adjustment on site. This flowrate may be checked by timing and measuring the flow through to the drain. If the treated water exiting the system is flowing into an open reservoir, it is recommended that a loop in the piping be installed in the system outlet to prevent the units from draining down, which can lead to operational problems. The loop must extend above the top of the mineral tanks with a vacuum breaker at the high point of the loop, and then drops into the reservoir. Include an air gap to help prevent siphoning._ The system will have the best service performance if there is some backpressure on the system eg. 30 psi. This could be achieved by partially closing a system outlet valve or putting on flow controllers into the outlet piping not included. Any piping before and after the units must be properly supported, to prevent any stress on the unit by the piping. Fig. 4. I Typical Piping Shown Below. BYPASS VALVE 39LET REMOTE METER SYSTEMS 6 & 7 ONLY _3JTLE7 USED ON SYSTEM 7 thO VALVES ONLY ‘yrruo CO’ilRO. TO OMN WIDTH Fcb99 1 FLOW CONTROL TO DRAIN 1-1/2" BRINE LINE CONNECTION 2’ INLET FLOW CONTROL TO DRAIN OUTLET 1/2" FLOW CONTROL TO ORAIN BRINE LINE.i’ CONNECTION BRINE LINE CONNECTION I" 1-1/2" INLET INLET S FLOW CONTROL TO DRAIN REAR VIEW OF 2900 VALVE REAR VEW OF 2850 VALVE t FLOW CONTROL 10 Oajn BRINt LINE C ONN C C Tb N -BRNE UNC CCNNECTCN REfr yiy Qf Q. WLVE 3" INLET 8ERiOEW OF 3O0 VALVE Fiq. 4.2 ConneCtiOnS On All Softener Valves Mm mum Installation Space Height lnrnm Tank Size 10" Tank 14 Tank 6 Tank 21’" Tank 24’" Tank 30" Tank 36 Tank 42" Tank 4rTank ] I Single - 79 2007 902286 902286 902286 932362 992515 1152921 1132870 1182997 491245 531346 551397 631600 721828 842134 962438 1022591 1142896 Width Irnini Duplex 2 Brine Tanks 942388 1022591 1062692 223099 1403556 1644166 1884775 2005080 2245990 Depth Inniru Duplex I Brine Tank 67 702 751905 792007 922337 042642 1223099 1403556 1523861 1704318 26660 26660 28711 33838 36914 421067 481219 481219 651651 Note: Required installation space is for the top mounted valve and includes the brine tanks at the sides installation size shown for the largest Valve/tank combination. It is recommended that the brine line to the unit is no longer that 5 feet in length. The brine line is included for units up to and including the FAF 570. On units larger than, it is recommended that 3/4" or I" pvc pipe be used not included. Feb99 4.3.1 Optional Treated Water Regeneration Installation The treated water regeneration kit allows a clean, water source to be used as the regeneration water supply which results in a more efficient regeneration. * The treated water regeneration kit consists of two, pneumatically or hydraulically actuated diaphragm valves per unit installed in the piping, as shown on the drawing shown: NORUALLY OPEN OIAPHRAQU VALVE / SO Svo,/._ RAW WATER_..O. INLET-FILTER fI N0RI,w.Ly CLOSED DLAPNRACM VALVE ‘TQ WE] TREATED WATER INLET-FSLIER ii FILTERED WATER OUTLET-FILTER IT Fig. 4.3Treated Water Regeneration Kit Typical Installation The two diaphragm valves are typically controlled by a service valve operator, or SVO, There are two different SVO’s; one used for the 2750, 2850, & 2900 valves, and another used for the 3150 and 3900 valves. Both are shown here. DRAIN LINE FLOW CONTROL a SVO ]NLET OUTLET 3150 SVO LOCATION 2750/2850 SVO LOCATION Fig. 4.4 Service Valve Operator Location 2850 & 3150 shown * An SVO, or service valve operator has three ports, drain, pressure, and control valve, The diagram below illustrates the location of each of these ports on the SVO. To ensure proper operation of the diaphragm valves, the supply pressure must be a continuous water pressure source and the pressure must be equal to the highest pressure the system will see. If this is not possible, air pressure may also be used with the air pressure set to the highest water pressure the system will see. TO O{APHRAOM VALVE SUPPLY PRESSURE ‘SUPPLY PRESSURE DEPRESSED DURING R E QENER A TI ON DEPRESSED DURING REGENERATION DRAIN DRAIN TO DAPHRAcU VALVE 2750/2850 vALVE OPERATOR 3150 VALVE SERVICE VALVE OPERATOR SERvICE VALVE Fig, 4.5 SVO Feb99 4.4 Electrical 4.4.1 3200 and 3200 ET Controlled Units Electrically connect each unit together with the interconnect cable supplied on the units. The lead unit is denoted by having the power cord. External wiring to be done according to federal and provincial regulations, with the power coming from a fused source. LEAD UNIT MIDDLE UNIT IF REQUIRED LAG UNIT IF REQUIRED 0 I. 7 UNITS DNLY Fig. 4.6 Mechanically and ET Controfled Multiple 2750 & 2850 Unit Electrical Connections LEAD UNIT MIDDI..E UNIT IF REQUIRED LAO UNIT IF REQUIRED TE METER SYSTEM 6 & 7 UNITS ONLY Fig. 4.7 Mechanically and ET Controlled Multiple 3150 Unit Electrical Connection Feb99 Electrical Connections For 2900/3900 r r 230 System 6 Immediate Standard System r 2930 System 6 Delayed Optional System r - - System 7 Immediate Standard System F Mech. MPtpr MeaN. Meter MCEH. Valve J L MeaN. F Meter MeaN. - - - - System 7 Immediate Optional LI System MeaN. Lead Valve I F I MeN Lead Valve MecN. Meter Valve L J L. J Fig. 4.8 Meter/Timer Conmnections for 2900/3900 Valves Electrical Connections For 2750/2850/3150 r2lso/asso/31501 r System 6 immediate Standard System 2750/5O/3 ISO - 1 System 6 Delayed OplonaF System F Standard System F F MeaN. MeaN. L MeaN. MeaN. MeaN. MeaN. Meter Valve Meter VaFve J L [ 2750/2650/3150 System 7 Immediate - Lead F F F F F F Meter 2750/2850’3F50 System 7 Immediate Dptioaml El System Lead Valve J Fig. 4.9 Meter/Timer Connections for 2750/2850/3150 Valves ro VENI OR A FM SUPPLY PRESSURE VALVE DIAPHRAGM VALVE SOLENOID Fig. 4.10 Diaphragm/Solenoid Connections for system 7 & 14 on 2750/2850/3 50 Valves Note: Supply pressure can be air or water; Solenoid wires are one green ground and two red AC connections Note: For Sysrema.x, other ETsvstems, and custom applications p/ease refer to complete electrical drawing for wiring details located in their own separate momma! or for custom applications, see addition drawing Feb99 I i i 4.4.2 Systemax 2000 Controlled Units Electrically connect each unit to the Systemax Controller via the interconnect cable supplied on the control panel. All units operated by a System Max Controller are identical, and do not require any particular order. External wiring to be done according to federal and provincial regulations, with the power coming from a fused source. The meter, if required, are electrically connected to the units terminal strip. LEAD UNIT METER MI UNITS ONLY LAG UNIT Ir REOUIREO> METER MI UNITS ONLY <MI METER UNITS ONLY> Fig. 4.10 System Max 2000 Controlled Multiple 2750, 2850 & 2900 Unit Electrical Connections SYSTEM MAX 2000 CONTROLLER LEAD UNIT METER <MI UNITS ONLY> MIDDLE UNIT IF REQUIRED METER <MI UNITS ONLY LAG UNIT IF REOUIREO> METER <MI UNITS ONLY> Fig. 4.11 System Max 2000 Controlled Multiple 3150 & 3900 Unit Electrical Connections Feb99 CQnnection of remote meter to Svstemax controller Ml initiated units only Connect the following terminals: - Red meter wire to terminal #1, on terminal block #2 Black meter wire to terminal #2, on terminal block #2 White meter wire to terminal #8, on terminal block #2 REMOTE METER SWrCH WFRNO METER VALVET82 WHL TE RED BLACK -fi Fig. 4.12 Meter / Systemax Connection 4.5 Valve Wiring Standard Mechanical Units Only, Dual Piston Valves 4,5.1 System 4 System 4 is a single meter initiated unit and the standard is delayed regeneration. Feb99 4,5,2 System 5 System 5 is a duplex softener system, both on line, each with it’s own meter. Regeneration is immediate and the system is interlocked to allow only one unit to regenerate at a time, Feb 99 4,5.3 System 6 System 6 is a duplex softener system, both on line, with one common meter on the system. Regeneration is immediate is series regeneration with one unit to regenerating at a time. LAD tnT :1p5TI OPIVE LO’4tR r ‘ ILY"fl flLO ‘ P cQTVC LEAD VALVE 1: to’r ATfl LAG VALVE Feb 99 45.4 System 7 System 7 is a meter initiated, duplex softener system, one on line with one in regeneration or standby. Regeneration is immediate. LEAn 014ff ORR tAPER L3PEE tAPE LEAD VALVE LAO JAR LPPVE DAtA a LOWER DRIVE LAG VALVE It tWA’ tAt Feb99 Section 5. Media Specifications Each softener size is based upon the volume of softening resin that is in the mineral tank. Each cubic foot of our standard softening resin is FDA approved for potable water and has a generic capacity of 30,000 grains @15 lbs saltlftt. This number is only approximate, and does vary depending upon the influent water quality. For example, an FAF 120 softener has 120,000 grains of generic capacity, i.e.. four cubic feet of softening resin in the mineral tank. Note: Softeners are factory set for 10 lbs salt/ft 5.1 Media Description Media Density Description Ih/Ft PuroliteTM C-IOOE softening resin. 52 Fine Gravel 1/8" x 1/16" graded and washed quartz 100 Medium Gravel 1/4" x 1/8" graded and washed quartz 100 Coarse Gravel 1/2" x 1/4" graded and washed quartz 100 Resin 5.2 Softener Beds: Quantities in cubic feet Atr 10x54 FAF6O 14x50 2 0.15 0 0.15 410002 FAF9O l4x65 3 0.15 0 0.15 410003 FAF 120 16x65 4 0.15 0 0.20 410004 FAF 150 21x54 5 0.15 0.15 020 410005 FAF 180 2lx54 6 0.15 0.15 0.20 410006 FAF2IO 21x69 7 0.15 0.15 020 410007 FAF24O 21x69 8 0.15 015 0.20 410008 FAF 270 24x72 9 0.20 0.20 0.30 410009 FAF 300 24x72 10 0.20 0.20 0.30 410010 FAF 330 24x72 II 0.20 0.20 0.30 410011 FAF 360 30x72 12 0.35 0.35 0,40 410012 FAF 390 30x72 13 0.35 0.35 0.40 410013 FAF 450 30x72 15 0.35 0.35 0.40 410015 FAF 510 30x72 17 0.35 0.35 0.40 410017 FAF 570 36x72 19 0.50 0.50 0.70 410019 FAF 630 36x72 21 0.50 0.50 0.70 410021 FAF 780 42x73 26 1.50 1.50 2.20 410026 FAF 1080 48x78 36 2.00 2.00 2.20 410036 Feb99 Section 6. 2900 Valved Softener Parts Breakdown Note: Unit shown with Environmental Enclosure which is standard on ET and Systemax units. Standard mechanical units equipped with standard enclosure. 6.0.1 6.0.4 50.1 Control Valves: Valves 6.0.3 6.0.5 6.0.6 Fig. 6.1 Softener Unit Part Number Part Number 1700 Brine 1600 Brine System System 290011 2900CC Single 290001 2900CC Duplex 290002 290012 2900 Systemax Single 290003 290013 2900 Single Ml Sys 4 290004 290014 2900 Duplex Ml Sys 5 290005 290015 2900 Duplex Ml Sys 6 290006 290016 2900 Duplex Ml Sys 7 290007 290017 290018 2900 Single Sensor 290008 2900 Duplex Sensor 290009 290019 All above valves require the appropriate valve kit see 6.0.B which includes the backwash flow control, injectors and refill flow control. Backwash flow controller brass bushing may be required 1" x 3/4’ not shown #12702. For system descriptions, see Section 1 Product summary 6.0.2 Remote Meters, not shown, System 6 & 7 Ml initiated units only Meter Size Flow Range Part Gal, Range Number 3-150 USGPM 2" Std. Range 17527 1.250-21,250 3-150 USGPM 2’ Ext. Range Special 6.250-106,250 2" ET wlo Timer 60616 3-150 USGPM N/A 7-300 USGPM 3 Std. Range 17859 3,750-63,750 3" Ext. Range Special 7-300 USGPM 18,750-318,750 60617 7-300 USGPM 3’ ST w/o Timer N/A 6.0.3 Media Sed: See section 5.2.3 for part numbers 0.4 SVO, only. Service Valve Operator: for treated water regeneration #13920. 6.0.5 Tank: See following table in 6.0.8 6.0.6 Distribution: See table in 6.05 6.0.7 Accessories not shown Treated water regen backwash diaphragm valve kit requires SVO - includes one NO. & one NC. Z diaphragm valves #19610 Brine Tank air checks-1600 series FAF 120 & smaller #1 3910 -1700 series FAF 150 & larger #19999 reb 9r Section 6.0.8 2900 Valve FAF 60 FAF90 FAF 120 FAF 150 FAF 180 FAF 210 FAF 240 FAF 270 FAF 300 FAF33O Section 6.1.0 14x50 14x65 16x65 21x54 21x54 21x69 21x69 24x72 24x72 24x72 114506 114656 116656 100416 100416 100423 100423 100424 100424 100424 61000 61000 61000 61001 61001 61001 61001 61001 61001 61001 21x36 21x36 21x36 24x48 24x48 24x48 24x48 24x48 24x48 24x48 410302 410303 410304 410305 410306 410307 410308 410309 410310 410311 2900 Typical Upper Control Drive Assembly P410502 P410503 P410504 P410505 P410506 P410507 P410508 P410509 P410510 P410511 430501 430801 431101 431401 431701 432001 432301 432501 433001 433401 I Section 6.1.0 ITEM NO. 2900 Typical Upper Control Drive Assembly NO.REQ’D. PART NO. I 15156 11828 15226-6 15250 10299 13547 11842 11667 1 2 2 1 1 1 1 15 16 17 18 19 26 28 29 32 33 34 35 36 37 38 39 40 2 1 1 1 5 3 3 1 3 1 2 1 2 1 2 1 1 1 1 2 2 1 1 2 1 2 2 1 2 1 1 14923 10774 10769 14779 10872 10218 10302 10909 10250 10621 10231 12576 10338 13366 11805 12777 11826 14822 15216 15742 15833 15879 17421 13741 15602 10300 12732 19291-020 19367 19010 19009 DESCRIPTION Back Plate Wide Slant Front Back PlateNot Shown Terminal Block Label-Terminal Block Screws-Terminal Block-#6-20x1/2" Strain Relief Power Cord Wire Harness Timer Assembly -Specify_3000,3200,or3210_SERIES Micro Switch Screw-#4-40x1" Motor Bracket Motor 120V., 60Hz. Designer Cover Assembly Not Shown Motor Mount Screw-#8-32x5116" Micro Switch Insulator Connecting Rod Clip Retaining Ring Connecting Rod DriveMountScrew Drive Cam-Separate Time Fill Drive Roll Pin Drive Bearing Micro Switch Screw Brine Valve Cam Motor Bracket-Brine Side Motor Lead Wires-Pigtail Meter Cable Cover Screw Spacer Cable Guide,Assembly Plug,Heyco Plug,Heyco Strain Relief,Harness Screw,Timer Mounting-Not Shown Nut,Terminal Block,Mounting-Not Shown Cover,1 Piece,Black-Not Shown Screw,Cover-Not Shown 9 Pin_Receptacle_Lead_and Middle Valves_Only 9 Pin Cable Middle and Valves Fe 99 Section 6.1.1 2900 Typical Lower Control Drive Assembly 10 Section 6.1.1 2900 Typical Lower Control Drive Assembly ITEM NO. PART NO. 14770 14769 14772 10872 14784 I 14775 1 14759 1 10250 1 11381 1 14813 I 10218 2 10218 2 12 10302 3 10302 2 13 11805 2 14923 2 14 11224 15 1 15926 1 14827 1 15938 I 15936 I 14924 16 17 1 14800 2 15236 18 NOTE: For System 7 Lead Only, Add 1 10218 2 10302 2 11805 1 15713 I 16103 2 11413 1 2 3 4 5 6 7 8 9 10 II NO.REQ’D. 1 1 I 4 I DESCRIPTION Rack Plate Motor Bracket Motor-I1OV.,6OHz. Screw-Motor Mtg. Connecting Rod learing Drive Cam Piston Drive Link Retaining Ring Pin Drive Cam Mtg. Spring Clip Micro Switch-System 4 Micro Switch-System 5,6,7 Insulator-System 4 Insulator-Systems 5,6,7 Screw,Mict-o Switch-system 4 Screw-Micro Switch-systems 5,6,7 Screw-Drive Mounting Wire Harness #4 Wire Harness #5 & #6 Wire harness #7-Lead Valve Wire harness #7 Lag Valve Strain Relief Cover Screw Assy-Cover Micro SwitchNot Shown InsulatorNot Shown Mt.ScrewNot Shown Mtg.PlateNot Shown lnsulatorNot Shown Mtg. ScrewNot Shown, replaces 14923 Eeb?9 1 ‘3 Ut I? -S -S C? -S a UI -a ‘4 0’ I UI Section 6.2 ITEM NO. 1 2 3 4 6 7 8 9 10 11 12 13 14 15 16 18 19 20 21 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 2900 Valve Timer NO. REQ’ D 1 1 1 1 PART NO. 13870-01 13802 13011 19205 19205-01 1 4 2 1 1 1 1 1 1 1 1 1 1 21 1 1 1 1 1 1 1 3 1 1 1 1 13886-01 13296 11999 60405-30 13806 13748 14265 15424 15066 13911 15055 19210 13880-02 15493 13018 13312 13017 13164 15275 13887 13944 14104 13278 13830 13831 14276 14253 2 1 3 1 1 1 Or 2 2 1 1 1 1 1 I 11384 13881 14087 10896 15314 15320 11413 14007 14045 14198 15148 15313 15465 DESCRIPTION Timer Housing Assembly Cycle Actuator Gear Domestic Only Cycle Actuator Gear All Filter Systems 24 Hour Gear AssemblySilver 24 Hour Gear AssemblyTan Delay Valve: Specify_Regeneration_Time_usually_2:00_AM Knob Screw-Timer Knob & Motor Plate Mtg. Button Decal Program Wheel Assembly Program Wheel Retainer Screw-Program Wheel Mtg. Spring Clip Spring-Detent Delay Only Ball-1/4 in. dia. Delay Only Main Drive Gear Delay Only Main Drive Gear Immediate Program Wheel Delay Only Program Wheel Immediate Roll Pin ldlerShaft Spring-Idler Idler Gear Drive Gear Wide Drive Gear Narrow Motor Mounting Plate Motor-IIOV.,6OHz Motor-24V.,6OHz. Screw-Motor Mounting & Ground Wire Drive Pinion-Program Wheel Clutch-Drive Pinion Spring Spring Retainer Not Assigned Screw-Timer Hinge Hinge Bracket Insulator Switch 1/2 Moon Switch Modified Metal Tip Switch White Tip Screw-Switch Mounting Decal-Time of Day Decal-Instructions Delayed Valve Only Decal-Meter Label Indicator Decal-To Manually Start,.. Decal.Instructions Warning Decal-Instructions Ml Valve Caution I 39 1 40 41 2 1 1 1 1 2 2 1 1 1 I ____________ [i_____________ 1 12681 15354-01 14381 14860 13864 13311 13300 14381 13296 1 Timer Motor Harness-Specify Valve, System & Position_Lead,_Lag,_Etc Wire Connector-Not Shown Ground Wire-Not Shown 12 Day Standard CC Skipper Wheel Not Shown 7 Day CC Skipper Wheel Not Shown Skipper Wheel Ring Not Shown Skipper Wheel Spring Not Shown Skipper Wheel Ball Not Shown Skipper Wheel Pointer Not Shown Skipper Wheel Screw Not Shown Timer Assembly CC Valve specify valve Timer Assembly System 4 specify valve Timer Assembly System 5 specify valve Timer Assembly System 6 specify lead or lag valve Timer Assembly System 7 specify valve Section 6.3 2900 Valve Body No hard water by pass piston optional. Feb 9C Section 6.3 2900 Valve Body Assembly CONTROL VALVE PARTS LIST ITEM NO. QUANTITY 1 I 6 5 1 I I 1 1 1 I 1 1 22 23 24 25 26 27 1 1 I 2 1 1 1 2 1 1 1 1 4 2 28 1 29 30 31 32 33 34 35 1 1 1 1 1 1 1 14 15 16 17 18 19 20 36 I____________ PART NO. 14749 10757 107578 10545 11451 16589 14451 14452 10209 10234 10598 10598-01 14805 17776 10914-3 10226-03 10913-3 10225-03 10227 10229 11893 10692 15177 12248 14812 14751 11710 11208 14750 11720 10369 16141 14753 16142 14757 14752 14818 14758 14926 14922 14754-00 14753-10 19276 13577 13575 DESCRIPTION Valve Body End Spacer End Spacer,Hot Water Seal Spacer Spacer,Hot Water Piston Piston Rod Quad Ring-Piston Rod "O"Ring-End Plug End Plug Assembly End Plug Assembly,Hot Water InjectorBodyGasket Injector Body Injector Throat #3,Yellow Injector Throat #3,Hot Water Injector Nozzle #3,Yellow Injector Nozzle #3,Hot Water Injector Screen InjectorCoverGasket InjectorCover Screw-Injectory Body Washer-Flow Control-Specify Size Flow Control Housing 1"NPT Pipe Cap "O"Ring Coupling Coupling "O"Ring-Regeneration Port "O"Ring-Regeneration Port 2" Adapter Valve Seal Spacer Spacer,Hot Water Spacer Spacer,Hot Water Piston Piston-No Hard Water By-Pass Piston Rod Clip Piston Rod Quad Ring-Piston Rod "O"Ring-End Plug End Plug AssemblyWhite End Plug Assembly-No Hard Water By-PassBlack End Plug Assembly-Hot Water "O"Ring-Distributor of Tank I 1 1 2 38 39 40 41 42 43 44 45 46 1 1 1 1 2 1 1 *Injector Throat 14802-03 14802-04 14802-05 14802-06 15210 11224 "O"Ring-Top of "Park" Tank Screw-Valve Mounting Not Assigned Injector Body Injector Throat Injector Nozzle Injector Screen Screw-Injector Body Air Disperser-1600 lnjectornot shown Disperser,Uppernot shown Elbow not shown, used with meter initated Size Color #3C Yellow #4C Green #SC White #6C Red 17777 *14802 *14801 14803 14804 16221 19608-15 15170 *Injector Nozzle 14801-03 14801-04 14801-05 14801-06 Section 6.4.0 1600 Series Brine Valve Assembly 21 20 19 ‘5 ‘7 lb ‘S ‘4 I, ITEM NO. 1 2 3 4 5 6 7 QUANTITY 1 1 2 3 3 1 I 8 9 10 1 1 I PART NO. 10328 12767 10332 10329 10330 15221 60002 60003 12794 Not Supplied 10250 DESCRiPTION 90degree Elbow-1/4 Pipe Thd. to 3/8 Tube Brine Line Screen Insert Sleeve3/8 Tube Fitting Nut3/8 Tube Derlin Sleeve 3/8 Tube Brine Valve Tube #500 Air Check Assembly #500 Air Check Assembly,Hot Water 9Odegree Elbow-3/8 Tube to 3/8 Tube Brine Line Tube3/8 Flexible Tube Retaining Ring Feb FF 11 12 13 14 15 16 17 18 19 20 11749 1 1 1 1 1 1 1 1 1 1 Stem Guide Not Assigned Not Assigned Brine Valve Spring Quad Ring Brine Valve Body Brine Valve Stem Brine Valve Seat "O"Ring BLFC .2SGPM BLFC 50GPM BLFC 1,OGPM Assembly includes #10, 14 to 18 Assembly includes 13805 + II, 19, & 201.0 GPN1 10249 12550 12748 12552 12626 11982 60020-25 60020-50 60020-100 13805 13804 1 1 Section 6.4.1 1700 Series Brine Valve Assembly I? 2 a 15 16 21 18 12 3! nfl Feb ‘F F F F F ,w. Section 6.4.1 1700 Series Brine Valve Assembly ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 NO.REQ D. 20 21 2 2 I 1 1 1 2 1 1 1 1 1 1 1 I 2 2 2 1 1 1 PART NO. 14792 13201 14785 14811 14798 14795 14797 14790 12550 15310 10250 15517 15415 15414 15413 15416 16977 60009 6009-01 16123 16124 19497 DESCRIPTION End Plug "O"Ring-End Plug Washer Flow Controlspecify size Flow Control Retainer Piston Seals Spacer Brine Valve Piston Brine Valve Stem Brine Valve Body Quad Ring-Brine Stem Spring-BrineValve Retaining Ring Stem Guide Insert Nut&Sleeve Elbow BrineTube Reducer Coupling,I/2NPT to 3/8 NPT #900 Air Check Assembly #900 Air Check Assembly,Hot Water Nut Sleeve includes #1 to and 15 to 18 Section 6.5 2900 Valve Service Valve Operator SVO $ 9. 9 12 U 9 *8 7 10 ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 SERVICE VALVE OPERATOR PARTS LIST PART NO. DESCRIPTION NO.REQ’D I 1 11749 Guide,Brine Valve Stem 1 10250 Retaining Ring 1 10249 Spring,Brine Valve 1 12550 Quad Ring 10785 Service Actuator Assembly-.2sgpm 1 1 12552 Brine Valve Stem,1600 1 12626 Seat,Brine Valve 5 10332 Insert ,3/8" 5 10330 Sleeve,3/8 DeIrin 5 10329 Nut,3/8" Brass 1 10328 Elbow,90 114"NPTx3/8"T 2 2 1 12897 16730 13920 Tube connector,MaIel/8"NPT to 318’T Assembly includes #2 to 7 Feb19 Section 6.6 2" Meter Assembly 7A 78 -‘ S 3 12 2 9 ITEM NO. 1 2 3 4 5 6 7A 73 8 9 10 11 12 NO.REQ’D 1 1 1 1 1 1 1 1 4 1 1 1 1 PART NO. 14456 15532 15432 15374 13847 15218 15237 12112 14679 14568 14680 14569 DESCRIPTION Meter Body Impeller Shaft Retainer Impeller Shaft Not Assigned impeller "0" Ring-Meter Cover Meter Cover AssemblyStandard Meter Cover AssemblyExtended Range Screw-Meter Cover "0" Ring-Quick Connect Nipple-Quick Connect Flow Straightener Nut-Quick Connect Feb Section 6.7 Remote Meter Immediate Regeneration Mechanical Timer Assembly Standard 36 2 6 7 16 11 12 13 14 15 6 23 31 32 33 24 34 25 99 Section 6.7 Remote Meter Immediate Regeneration Mechanical Timer Assembly IMMEDIATE REGENERATION TIMER ASSEMBLY ITEM NO. 1 2 5 6 7 3 9 10 11 12 13 14 15 16 17 18 19 20 21 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 39 40 41 42 43 f PART NO. 13870-01 QUANTITY 1 15431 13886-01 13296 60405 13806 13748 14265 15424 15066 15055 13880-04 15493 1 1 4 2 1 1 1 1 1 1 1 1 10 13018 13312 13017 13164 13887 14974 13278 14502 14501 14276 14253 1 1 1 1 1 1 2 1 1 1 1 11384 13881 14087 15314 10896 11413 14007 13902 12681 15354-01 17870 15465 3 1 3 1 1 2 1 1 2 1 1 1 11999 DESCRIPTION Timer Housing Assembly Cycle Actuator Gear Knob Screw-Timer Knob & Motor Plate Mtg. Button Decal Program Wheel Assembly,Specify Gallons Program Wheel Retainer Screw-Program Wheel Mtg. Spring Clip Spring Detent BalI-1/4in. dia. Main Drive Gear Program Wheel 1RPM Roll Pin Not Assigned Idler Shaft Spring Idler Idler Gear DriveeGear Motor Mounting Plate Motor-IIOV.,6OHz.,IRPM Screw-Motor Mounting Drive Pinion-Program Wheel Clutch-Drive Pinion Spring Spring Retainer Not Assigned Screw-Timer Hinge & Ground Wire Hinge Bracket Insulator Switch Switch,1 RPM Screw-Switch Mounting Decal-Time of Day Harness-Not Shown Wire Connector-Not Shown Ground Wire-Not Shown Label,lndicator LabelCaution c-a to NO to to to C-a to U’ to -I a Ca a, a NO Co -s 0 to 01 a, a, a, I P0 to / P i’, Ls Section 6.7.1 Remote Meter Delayed Regeneration Mechanical Timer Assembly DELAYED REGENERATION TIMER ASSEMBLY ITEM NO. 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 23 24 L 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 f L_____________ PART NO. 13870-01 13802 19205 13886-01 13296 11999 60405 13806 13748 14265 15424 15066 13911 19210 15493 QUANTITY 1 1 1 1 4 2 1 1 1 1 1 1 1 1 21 13018 13312 13017 13164 13887 13944 14104 13278 13830 13831 14276 14253 1 1 I 1 1 1 - - 11384 13881 14087 10896 15320 11413 14007 16118 13902 12681 15354-01 17870 15465 2 I 1 1 1 3 1 3 1 1 2 1 1 1 2 1 1 1 DESCRIPTION Timer Housing Assembly Cycle Actuator Gear 24 Hour Gear Assembly Knob Screw-Timer Knob & Motor Plate Mtg. Button Decal Program Wheel Assembly,Specify Gallons Program Wheel Retainer Screw-Program Wheel Mtg. Spring Cup Spring-Detent BalI-lI4in. dia. Main Drive Gear Program Wheel Assembly Roll Pin Not Assigned IdlerShaft Spring-Idler Idler Gear Drive Gear Motor Mounting Plate Motor-IIOV.,6OHz Motor-24V.,SOHz Screw-Motor Mounting Drive Pinion-Program Wheel Clutch-Drive Pinion Spring Spring Retainer Not Assigned Screw-timer Hinge & Ground Wire Hinge Bracket Insulator Switch Switch Screw-Switch Mounting Decal-Time of Day Decal-Instructions Harness-Not Shown Wire Connector-Not Shown Ground Wire-Not Shown Label,Indicator Label Caution Section 7. Recommended Start Up Procedure a. 7.1 Softener Start-Up NOTE: It is important to follow the startup instructions as improper start up may result in unsatisfactory softener operation or possibly damage the softener. * 2. 3. 4. 5. 6. 7. 8. Check all system piping ensuring that it is correct and all connections are complete, see installation drawing fig. 4.1. and ensure the drain line has an air gap. Ensure that all of the manual isolation and by-pass valves are closed prior to start up. Check all electrical connections and ensure that they are correct and complete fig 4.8 or 4.9. With the brine tank empty, add clean water approx. 3,5 US gallons per cubic foot of resin Section 5.2.3 to the brine tank ensuring the water level is at least 2" above the grid plate. Add at least 15 lbs of salt for each cubic foot of resin to the brine tank and allow the brine tank to sit for a couple of hours to make a good brine solution. Plug in the control valve, and manually advance the valve out of the home position. for ET & Systemax, see their respective manuals On all systems except system 7, this is done by the timer on the valve, On system 7 units, the regeneration is initiated by the remote meter which electrically starts the appropriate valve timer .This is done by removing the dust cover, and swinging the cycle timer open, in order to expose the program wheel located inside, mechanical timers only The meter cable may have to be temporarily disconnected. Turn the program wheel out of the home position, until the home switch comes out of the notch in the program wheel. Once the softener is in the backwash position, where the position switch rides up on to the first set of pins, refer to section 8 for position confirmation, unplug the softener. Slowly partially open the inlet isolation valve, and allow the softener to slowly fill with water. When the tank is full, water begins to run out through the drain. If the zen/f is filled too quickly, the media could be bloivn ott!, as well as possible damage the unit. When full, close the inlet valve. Allow the unit to stand for 1-2 hours once the tank is full to saturate the media bed. Plug the unit back into the power supply, and slowly open the inlet isolation valve all of the way, and allow the unit to automatically complete its regeneration cycle. During the backwash cycle, constantly check the drain water for resin to ensure nothing other than fines are being backwashed out. During the brine draw cycle, ensure the unit is drawing brine out of the brine tank. The brine should be drawn out in 15 to 30 minutes depending upon injector size and line pressure. Also check the brine tank refill cycle to ensure the water level returns to above the grid plate and there is no water flowing to the brine tank once the regeneration cycle is complete. Ensure that an adequate supply of salt is available, and that enough salt is situated in the brine tank. For example, if an FAF 120 softener was to be regenerated at 10 lbs/ft3, this equates into 40 lbs of salt required for one regeneration cycle. Thus at least 40 lbs is required in the brine tank for a single regeneration of this softener. If the meter cable was disconnected, ensure it is reconnected. Once the start-up is complete, the valve control system must be configured. To configure a calendar clock, sensor or meter initiated softener, please refer to section 9. To configure either the ET Digital Timer, or the Systemax 2000 Controller, please refer to their service manuals. Upon completion of the steps above, the softener outlet isolation valves are slowly opened, and the bypass valve can then be closed. The softener is now ready for normal service operation.. It is recommended that both the raw water and treated water be tested to confirm the unit is working properly. Feb 99 Section 8. Softener Operation 2900 Valve 8,1 Operating Conditions For correct operation of the softener system, the minimum water pressure required is 30 psig, 206 kPa, in order for valve to operate effectively. Caution: Water Pressure is not to exceed 100 psis. 690 kPa. water temperature is not to exceed 100 F. 38 C, and the unit can not be subjected to freezing conditions without taking special precautions. The manual bypass valve, by others, must always be closed and the manual inlet and outlet isolation valves, by others, open except during maintenance of the equipment. 8.2 Cycle Operation The current position of the control valve can be confimed by opening the control valve cover, and looking at the cycle cam position. Each cycle is completed at specific locations during the cam’s rotation. B AC KPL A T E yE MOTOR r - - - - GEAR BOX MOUNT BRACKETS CAM BRACKET DRIVE LINK TIMER ASSEMBLY REMOVED FOR CLARITY Fig. 8. IA Top Powerhead Schematic Powerhead shown with Standard Backplate. Environmental Powerhead also Available Fig. 8.1 B Lower Powerhead Schematic Left Powerhead Servcie Position Shown Right Powerhead Regeneration / Standby Position Shown Dec’ S Position I Service During service, water is directed into the top of the tank by the control valve and flows downward through the softener media, into the distribution, and out to service. As the water flows through the softener media, the hardness calcium and magnesium dissolved io the water is ionically exchanged with either sodium or potassium present in the softening resin. During service, the drive gear holds the drive link completely horizontal, with the piston withdrawn to its maximum length. CYCLE CAM TIMER REMOVED VALVE FLOW CONTROL INLET OUTLET RESIN TANK BRINE TANK Fig. 8.2 Drive Motor Service Position Program Wheel Location and flow Durine Service As the duration of the service run increases, the softening resin slowly depletes, losing its ion exchange capacity, until the softening resin can no longer remove the hardness calcium and magnesium. It is at this time that regeneration of the softener is required, in order to replenish the bed’s softening capacity. During regeneration the hardness calcium and magnesium that accumulated during the previous service run are replaced on the resin by sodium or potassium. A brine solution rinsed down through the bed is the source of the replenishing sodium or potassium. Oec QS a Position ‘ Backwash The regeneration procedure is performed automatically by the softener after the cycle controller has started. Each regeneration cycle consists of four steps; backwash, brine draw/slow rinse, fast rinse, and refill. During backwash, water is directed upwards through the filter and out to drain. This loosens the softener bed, allowing the brine solution to rinse through the resin more easily during the next cycle. The backwash cycle has been factory preset to take place for 10 minutes. The drive gear holds the drive link completely horizontal, 1800 from the service position, with the piston rod fully inserted into the valve body. CYCLE C FLOW CONTROL N OPTION: NO HARD WATER BY PASS L J INLET INLET OUTLET RESIN TANK BRINE TANK Fig. 8.3 Drive Motor Position. Program Wheel Location and Flow Durina Backwash Oec s Position 3. Brine Draw During the brine draw position, water flows through the injector, drawing in the brine solution. This solution then flows down through the bed, and out the drain. The brine draw cycle ends when the brine tank is empty, and the air check in the brine tank closes, stopping the flow of concentrated brine. Water continues to flow through the injector, and down through the bed, but no brine is drawn in. This is referred to as the slow rinse cycle. When in the brine draw/slow rinse position, the drive link is rotated approximately 40 from the backwash position, until the drive gear stops with the drive link connection at the bottom of the drive gear, with the drive link at approximately 400 angle from the horizontal. CYCLE CAM BACKPLATE BRINE VALVE FLOW CONTROL FLOW CONTROL rt:P INLET OUTLET OUTLET RESIN TANK INLET TANK RESIN TANK BRINE TANK Fig. 8.4 Drive Mowr Program Whee! Locrnioii and flow During Brine DrawIS!ow Rinse Dec15 Position 4, Rinse During rinse, water is directed downwards through the softener and out to drain. This reconsolidates the softener bed and rinses any remaining brine in the softening bed to drain, When in the rinse position, the drive link is rotated another 5 from the settle position, until the drive gear stops with the drive link connection at the bottom of the drive gear with the drive link at a 45 angle from the horizontal. CYCLE CAM BRINE VALVE FLOW CONTROL INLET RESIN TANK BRINE TANK Fig. 85 Drive Motor Position - Program Wheet Location and Ftov During Rinse Oc 18 Brine Tank Refill Eosition 5 Upon the fast rinse cycle ending, the softener advances into what is essentially service, with the exception that a portion of the softened water is diverted backwards through the injector, and into the brine tank. This is known as the brine tank refill cycle. The flow into the brine tank is controlled by a flow control orifice, and is timed in order to measure a calculated volume of water into the brine tank. The brine tank refill position is very similar to the service posItion, but the drive link stops just short of the horizontal, To confirm the refill cycle is occurring, simply watch the tubing running from the softener to the brine tank, and watch the brine tank to ensure that the water level is rising. The water should continue to flow to the brine tank until the microswitch is depressed by the last two pins on the cycle tinier wheel. 0 I, CYCLE CAM BRINE VALVE FLOW CONTROL OUTLET RESIN TANK BRINE TANK Ho. 8.5 Drive Motor Poshion . Prooram WheeL Location and FLow Duri’ig RefiLL Dec C? Section 9. Softener Control The standard softener controller is a mechanical type controller, which automatically initiates the backwash sequence by one of three methods: calendar clock, volumetric meter, or sensor. All systems can be manually initiated by simply moving the manual regeneration knob clockwise. Only a slight turn is required to start the unit into regeneration. Remote meter initiated units should be manually initiated ONLY from the remote meter, which is again started by a slight clockwise movement on the remote meter timer knob. Other control systems are available, such as the ET digital timer, which can replace the standard mechanical controller; and the Systemax 2000 Digital Controller, which looks after the operation of up to three, 3, separate units; including giving visual indication offlowrates, time, and allowing operator control of the method of initiation. For information on configuring either the ET digital tinier or the System Max, please consult their service manuals. For a description of the various systems, see section 1. 9.1 Calendar Clock With calendar clock initiation, a 12-day repeating timer automatically initiates the regeneration sequence after a preset number of days during the 12-day cycle. The regeneration sequence is factory preset to occur at 2:00 AM on the day that the clock initiates regeneration. Once initiated, the cycle timer operates the control valve, advancing the valve into each position, and holding it there for a specific length of time. The interval between regenerations can be adjusted to suit each application, depending on the raw water quality. This time interval is adjustable, with a minimum regeneration sequence interval of one regeneration per day. Bockwosh Knob POnter eb Ine Sst Button Sk;pper ‘s/reel Shows Bocs/wosh 3 Joys Evwry Figure 9.1 Calendar Clock Tinier SettinQ the time ofy: * Press and hold the red button in to disengage the drive gear. * Turn the large gear until the actual time of day is opposite the time of day pointer. * Release the red button to again engage the drive gear. Frequency of regeneration: To set the frequency of regeneration, simply pull out the metal tabs on the skipper wheel on the days that you wish the filter to regenerate, For example, every 3rd tab has been extended in the illustration above, indicating that regeneration of that filter will take place every three, 3, days. 9.2 Volumetric Meter The second method of regeneration initiation is by a volumetric meter, which counts the volume of water as it passes through the filter during service. The meter is attached to a Fleck model 3210 control timer, by a rotating cable. The control timer has an adjustable volume dial on it, where the volume of water to pass through the meter between regenerations can be set. As the water flows through the fiowmeter, the cable rotates, slowly moving the volume dial on the timer towards zero. On Feb all standard single units, once the meter reaches zero, the start signal will be delayed until the preset time. This is why on single units a reserve capacity needs to be calculated into the meter setting. On all standard duplex units, once the meter reaches zero, it immediately signals the cycle timer to begin the regeneration sequence provided that the other unit is not already in regeneration., Once signalled, the cycle timer takes over for the duration of the regeneration cycle, controlling the regeneration sequence, just as in the calendar clock control method. WHITE GOT RED TIME SET OUTTON sERVIcE POSITION INDICATOR AANUAL REGENERATION HOG 24 HOUR GEAR Fig. 9.2A Delayed Meter Timer Fig, 9,2B Immediate Meter Timer Meter Settin2 Procedure System 4 -Take the number of cubic feet of resin in the tank and multiply by 27,000 grains per cubic foot for a 10 lbs salt setting. -Divide this number by the compensated grains of hardness in the water. This gives you the total number of gallons the softener can treat before regeneration is required. REMEMBER that I pan of iron is equal to 4 grains of hardness and 1 part of manganese is equal to Spans of hardness. For commercial units, the combined ppm maximum for iron + 2x manganese is ONE. -Since system 4 is delayed regeneration, a reserve typically one-day must be built into the meter setting. -Typically for a three-day sizing, the reserve is 1/3 of the bed so take the total number of gallons and divide by three. This is what you set the meter for. -For a two day sized unit, take the total number of gallons and divide by two. This is what you set the meter for System 5 or 7 -Take the number of cubic feet of resin in ONE tank and multiply by 27,000 grains per cubic foot. -Divide this number by the compensated grains of hardness in the water. This gives you the total number of gallons the softener can treat before regeneration is required. REMEMBER that 1 pan of iron is equal to 4 grains of hardness and I part of manganese is equal to 8 parts of hardness. For commercial units, the combined ppm maximum for iron – 2x manganese is ONE. -Since system 5 & 7 is immediate regeneration, a reserve is not normally required. System 6 -Take the number of cubic feet of resin in BOTH tanks and multiply by 27,000 grains per cubic foot. -Divide this number by the compensated grains of hardness in the water. This gives you the total number of gallons the softener can treat before regeneration is required. REMEMBER that I pan of iron is equal to Fcb 4 grains of hardness and part of manganese is equal to 8 parts of hardness. For commercial units, the combined ppm maximum for iron + 2x manganese is ONE. -Since system 6 is immediate regeneration, a is not normally required, but due to the fact that typically you get more water through one unit than the other, you may want to adjust the gallonage setting down to compensate for this factor. 9.3 Sensor The final method of initiation is by sensor. A sensor located in the resin bed combined with the circuit on the valve monitors the condition of the bed and when it is depleted, will initiate a regeneration. On single units, the start signal will be delayed until the preset time. On all standard duplex units, once the unit requires regeneration, it immediately signals the cycle tinier to begin the regeneration sequence provided that the other unit is not already in regeneration.. 9.4 Regeneration C’ycle Timer mectianicaD The cycle timer controls the operations of the valve during the regeneration sequence by incoporating a series of switches ,which are opened and closed in a specific order to control the movement of the valve drive motor at certain times. The cycle timer rotating a program wheel accomplishes this. In this program wheel, there are holes spaced so that each hole takes two minutes to pass by. By inserting pins into these holes, and having the switches depressed by these pins as the program wheel rotates, the switches can be depressed in a specific order, The regeneration cycle timer is illustrated below. Note: you can tell if the motor is running by looking at the "viewport" located on the motor. OLJ’TSIDE swiTcH 4IOOLE swiTcH HOME 5WiFH. INSIDE SWtTHWPORT Figure 9.3 Regeneration Cycle Tinier Rear View The various typical standard softener control tinier uses only the home, inside, and middle switches, with the outside switch being used only in specific custom applications. When certain switches in the control valve are closed simultaneously, the timer allows the valve drive motor to rotate, moving the piston to certain positions during the backwash sequence. 9.5 Regeneration Program The regeneration cycle program on your filter has been factory pre-set. Typical cycle times are 10 minutes backwash., varying brine draw and slow rinse times dependent upon the unit, ]0 minutes rinse, and varying brine tank refill times dependent upon the unit. It should be noted however, that these cycle times may be lengthened or shortened to suit local conditions. The pins on the program wheel determine the length of each cycle. Each pin represents two minutes of cycle time. The length of each cycle is either the number of pins for backwash or fast rinse or Feb the number of holes for brine draw/slow rinse and brine tank refill. Please note that, when one set of pins is moved, it may affect the cycle time of other cycles unless other pins are also adjusted accordingly. NOTE: Ensure pins for inside switch, if required, do not extend far enough to cause interference with lower gear. 9.6 changing rite Regeneration Times * To expose cycle program wheel, grasp the timer in upper left-hand corner and pull, releasing snap and swinging timer to the right. * To change the regeneration cycle program, the program wheel must be removed. Grasp the program wheel and squeeze protruding lugs toward centre lift prooram wheel off timer switch arms may require movement to facilitate removal. * Add or remove pins in the backwash or rinse cycles in order to lengthen or shorten the cycle times. See figure 9.5 for factory preset pin settings * Make certain all electrical wires Locate above snap retainer post when closing the timer assembly r03M MItt PER HOLE /1 / CONTROL OF REGENERATION CYcLE SEcThON 2MIN. PER PIN RgFILL SECTION PER HOLE BACKWASH SECTION 2 MItt. PER PIN Fig. 9.5 Typical Preset Pin Settings Section 10 Softener Trouble Shooting Guide PROBLEM POSSIBLE CAUSE REMEDY I. No water flowing to service. A. Inlet and/or outlet isolation valves closed. B. Unit unplugged during last regeneration. A. By-Pass valve either partially open or not sealing, A. Open isolation valves. 2. Untreated water passing out to service, B. Insufficient regeneration frequency and/or times and / or no salt in brine tank. C. Injector / screen plugged. D. Insufficient water flowing into brine tank. E. Service flowrate exceeding maximum allowable rate. F. Broken or leaking distribution. G. Leak or crack in control valve seals. Particles partially jamming control valve. H. Flowrate through meter too low or meter not operating correctly. I. Have raw water bypass piston or no raw water bypass piston assembly failed. . J. Fouled mineral bed, K. Reserve capacity has been exceeded. B. Plug unit in, and return unit to service position. A. Inspect bypass valve position and seal, replace or repair if necessary. B. Increase regeneration frequency and/or backwash time and maintain salt level to above water level. C. Clean injector / screen assembly. D. Check brine tank fill time and clean brine line flow control if plugged. E. Confinti service flowrate does not exceed recommended rate. Reduce if necessary. F. Inspect distribution, replace if necessary. Check 0-ring between distribution riser tube and valve. 0. Inspect seals, for damage and/or interference; replace if necessary, H. Check meter with meter checker. Size meter to suit flowrate, Ensure meter operating correctly. Pull cable out of meter cover and rotate manually. Program wheel must move without binding and clutch must give positive ‘clicks" when program wheel strikes regeneration stop. If not working properly, replace timer. I. Raw water bypass piston assemblies have white end plugs. No raw water bypass assemblies have black end plugs. Inspect piston & seals. Lubricate and/or replace internals if required. J. Clean bed using resin cleaner. Replace bed if necessary. Most common fouling found on water containing iron and! or manganese. K, Check capacirv and salt dosage requirements. Reset 3. Control valve fails to regenerate unit. A. Loss of power to control valve. B. Drive motor and/or timer assembly not receiving power. C. Drive gears and/or motor binding in gearbox. D. Control valve piston jammed in valve body due to foreign material in valve body. E. Broken or shorted microswitch. 4. Control valve continuously cycles unit. 5. Water flows to drain continuously, 6,Media flowing out though service. 7. Loss of mineral through drain line F. Flowrate through meter too low A. Broken or shorted microswitch. A. Inadequate sealing of seals due to foreign material trapped in valve body. B. Damaged and/or broken seals or spacers C. Unit unplugged during last regeneration. A. Broken distributor A. Air in system B. Improper sized drain line flow control 8. Unit used too much salt. A. Improper salt setting B Excessive water in brine tank. 9. Excessive water in brine tank 10. Fails to draw brine properly. A. Plugged drain line flow control B. Plugged injector / screen C. Foreign material in brine valve, D. Foreign material in brine line flow control A. Drain line flow control plugged B. Plugged njector / screen program wheel to provide additional reserve. A. Inspect power supply, ensure that control valve is powered and all connections are correct. Reset time of day if required. B. Check continuity ofwiring for shorts, breaks, etc. C. Check motor and gearbox. ensure that they run smoothly. D. Remove piston, clean piston and seal/spacer assembly with water, and lubricate. Replace seals & spacers if required. B. Check microsw itches for continuity replace damaged switch. F. Size meter to suit flowrate. A. Check microswitches for continuity, replace damaged switch. A. Remove Piston, inspect seals and spacers, flush with water. B. Replace damaged and or broken seals or spacers. C. Plug unit in, and return unir to service position. A. Replace distribution A. Assure that system has proper air eliminator control. Check for dry well conditions. B. Check for proper drain rate. Note: if water temperature is very low, the drain line flow rate may have to be reduced. A. Check salt usage and salt setting. B. See problem #9 A. Clean flow control B. Clean injector / screen assembly. C. Replace brine valve seal and clean valve. D. Clean brine line flow control. A. Clean drain line flow control B. Clean injector / screen assembly. . C. Foreign material in brine valve, D. Foreign material in brine line flow control E. Line pressure too low F. Internal control leak H. Service adapter did not cycle 11. Loss of water pressure. 12. Drain flows continuously. I. Brine tank line too long or brine tank too far away. A. Scale or iron buildup in line to unit B. Inlet to valve plugged with foreign material, C. Iron buildup in unit. A. Valve not programmed correctly. B. Foreign material in control. C. Internal control leak. C. Replace brine valve seal and clean valve. D. Clean brine line flow controL E. Increase line pressure to 30 psi minimum. F. Change seals, spacers and piston assembly. H. Check drive motor and switches. 1. Shorten brine line recommended 5 feet maximum. A. Clean lines to unit. B. Clean and inspect valve for damage. Repair as required. C. Clean control valve and media bed. A. Check tinier program and position of control. If not positioning properly, check for faulty microswitches and / or adjustments. B. Check brine valve and ensure it is operating properly. Remove powerhead and inspect bore. Remove any foreign material and check valve in various regeneration positions. C. Change seals, spacers and piston assembly. Treated Water Regeneration On!y No supply/raw water available during service. A. Inlet diaphragm valve installed incorrectly, No treated water supply available during regeneration. A. Treated Water Supply diaphragm valve installed incorrectly, A. Inspect inlet piping, confimi proper locations for treated water regeneration diaphragm valves. Reinstall in correct locations if required. Check pressure source to the SVO. Ensure it is a continuous pressure supply equal to the max. pressure the filter is subjected to. A. Inspect inlet piping, confirm proper locations for treated water regeneration diaphragm valves. Reinstall in correct locations if required. Ensure it is a continuous pressure supply equal to the max. pressure the filter is subjected to. Treated water regeneration diaphragm valves not operating properly A. Treated Water Supply diaphragm valve installed incorrectly. B. Diaphragm valves sticking A: Inspect tubing connections to diaphragm valves see section 4. Ensure it is a continuous pressure supply equal to the max. pressure the filter is subjected to. B. Inspect diaphragm valves internals and repair or replace as necessary. Feb QQ Section 11 Warranty Commercial Unit Warranty All equipment manufactured by USF Watergroup Inc. is warranted against defects in material or workmanship for the following periods -Fiberglass tanks 5 Years -Brine Tank -3 Years -Control Valve and Electronics 2 Years -Brine Tank Air Check Valve -2 Years -All other components are for a period of one year - - If a part proves defective within the warranty period, it should be returned to the factory, transportation charges prepaid, together with the serial number of the unit and the model number and a replacement part will be supplied free of charge. This warranty is limited to the replacement of defective parts, fob. our factory, and does not cover any labor charges or payment for damages. USF Watergroup INC. assumes no responsibility for consequential damage, labor or expense incurred as a result of a defect or failure to meet the terms of this warranty because of circumstances beyond it’s control. Further, the warranty on any components, not of USF Watergroup INC. manufacture, is limited to the warranty or guarantee given by the manufacturer of the component. Use of the product for any purpose other than its intended use will void all warranties. USF Watergroup INC. 580 Park Street Regina, 5K S4N 5A9 USF Watergroup INC. 265 Industrial Road Cambridge, ON N3H 4R9 Ret