Softener Unit Model 2900 2" Top Mount Valve

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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