Manual EZ Charge Water Softener 1268KB Jul
Contents
1. remedies provided herein are the customer s sole and exclusive remedies In no event shall PROCHEM be liable for any direct indirect special incidental or consequential damages whether based on contract tort or any other legal theory You PROCHEM Wvater Softener is designed to give you years of reliable service However if a problem should arise after the warranty period follow the troubleshooting procedures in the Operation and Service Manual If you are still unable to determine the cause and solution to the problem contact your nearest PROCHEM Service Center for details fo the service available Components provided by PROCHEM but supplied by other manufacturers will only be warranted to the extent that they shall be warrented to PROCHEM2. resin The brine tank contains a solution of regular table salt sodium chloride processed and available in pellet form specifically for use in water softening systems In order to hold the mineral ions in this special resin has to five something in exchange sodium from the salt This resin however can only hold so much diluted limestone because it has a limited amount of sodium to give in exchange When the resin runs out of sodium hard water will flow through the resin in the water softener and into the truckmount unit The resin has become saturated with limestone particles calcium and magnesium ions To cleanse the resin of the diluted limestone particles replenish it with sodium a process called Regeneration is used Regenerating the EZ Charge Water Softener is very easy to do Simply run a fresh water salt solution from the brine tank through the special resin in the resin tank This is done automatically once the brine tank is properly connected Now the resin will hold the sodium and release the limestone minerals back to nature Sodium rich water free of calcium and magnesium ions is what is called soft water The water softener is now ready for another run Soft water does not adversely affect the solution system in truckmounted units In contrast it virtual eliminates calcium and magnesium mineral deposit build up in the system filters and chemical and check valves Soft water also helps do a better cle
3. the unit and only need to be replace if damaged due to freezing Given regular maintenance inspected as needed and regenerated as required the EZ Charge Water Softener will last you for many years TROUBLESHOOTING SPECIFIC PROBLEMS PROBLEM CAUSE SOLUTION Water softener needs regenerating Regenerate water softener a tube extends tom Check tube and oring seal replace if Softener delivers hard water bottom of manifold down into softener Ae ded resin tank i Water softener resin damaged by Replace resin Always protect unit from freezing freezing Loss of resin through water Cracked or broken distributor tube or Replace tube or screen outlet screen Add filter to inlet on water softener Loss of water pressure Iron or particulate build up in softener paper cartridge type 50 micron max Recharge water softener Iron in softened water Fouled resin bed frequently Refill brine tank see Preparing Brine Insufficient salt in brine tank Tank in this manual Allow the slat to completely dissolve Salt bridging in brine tank Too much Refill brine tank see Preparing Brine Clean aa disassembly 545521 558555 may be required Replace if needed Period between regeneration too long Insufficient regeneration schedule Check and regenerate system more frequently Loss of resin through drain Air in water softener system Purged Insure unit is properly purged of air see h
4. BLK 27 100225 GSKT FOAM WTR SOFT 48 941385 TAG WARNING START UP WTR 11 800275 ELL ST 3 8 BR OA 56 501999 TRAY SOFT WTR SOFT 30B 56 502273 TRAY SOFT WTR SQUARE _ 212 6 8 9 980144 11 04 03 TANK amp TRAY FILTER ASSEMBLY 10 N lt 9 2 e 9 5 3 980144 11 04 03 REF PARTNO DESCRIPTION DISCONNECT 3 8M X 3 8FP FTTG BRB 3 8P X 5 8H BR CLMP HOS 10 9 16MIN HOSE WTR 5 8 30 1 2 FTTG BRB 1 2P X 5 8H BR 6 11 800041 ELL STREET 1 2 BR STRNR IN LINE 1 2FP BS 8 09 805382 HOSE WTR 5 8X 97 9 11 800275 ELL ST 3 8 BR FILTER ASSEMBLY 13 806008 DSC 3 8F X 3 8FP 980144 11 04 03 5 4 BRINE TANK ASSEMBLY PART OF ITEM 3 980144 11 04 03 5 5 REF PARTNO DESCRIPTION FUNNEL BIG BLU ELL 1 4P X 3 8 POLY BR CONN 1 4P BLKHD LNG BR ELL BRB 1 4P X 1 4H BR 03 000065 CLAMP HOSE 4 SST 09 805537 SHOE BRD 1 4X 30IN 6 48 941326 DEC CDNSD REGEN OPER 8 13 806008 DSC 3 8F X 3 8FP 9 11 800118 BUSH 3 8 X 1 8 BR NIPPLE 1 8 CLOSE INJ W 1JET JUG 5 GAL 13 806009 DISCONNECT 3 8M X 3 8FP 15 808117 VLV AIR CHK W STEM 4560 980144 11 04 03 BRINE TANK ASSEMBLY NOTES 5 7 980144 11 04 03 LIMITED WARRANTY PROCHEM warrants your Water Softener to be free of defects in material and workmanship This warranty shall extend to the designated parts for the specific time period listed from the dat
5. EZ CHARGE Water Softener Operating Instructions ENG MODELS PROCHEM JON DON Read instructions before operating the machine 980144 A 11 04 03 Welcome and congratulations on your purchase of the EZ Charge Water Softener This instruction manual has been designed as a guide for operating and serving you unit NOTE Read this manual completely before installing or operating this unit Proper operating and service are essential to the efficient functioning of the unit When maintained correctly this unit will have a long trouble free life The service methods describe in this manual are explained in such a manner that servicing may be performed accurately and safely Proper service varies with the choice of procedure the skill of the mechanic and the tools or parts available Before attempting any repair make certain that you are thoroughly familiar with this equipment and equipped with the proper tools Any questions pertaining to operating or servicing this unit should be directed to you nearest dealer Make certain that you read all instructions entirely before proceeding with the operation of the unit THIS UNIT MUST BE INSTALLED IN ACCORDANCE WITH THE INSTALLATION INSTRUCTIONS DESCRIBED IN THIS MANUAL This operation and service manual is written specifically for EZ Charge Water Softener which is manufactured by Professional Chemicals Corporation 325 South Price Road Chandler Arizona 85224 Information in thi
6. ING PLATE INSTALLATION WATER FLATWASHER SOFTENER CAP SCREW FLATWASHER a LOCKWASHER 4 1 980144 11 04 03 INSTALLATION 13 4 35 MOUNTING FOR WATER SOFTENERS WITH 56 501999 13 4 035 MOUNTING FOR WATER SOFTENERS WITH 56 502273 980144 11 04 03 4 2 OPERATION THEORY OF WATER SOFTENING What is hard water Hard water is water containing dissolved limestone usually consisting chiefly of calcium and magnesium minerals which are sedimentary by nature Ground water slowly dissolves limestone and carries it in solution downstream Why does hard water cause problems When heat is applied to hard water such as in your truckmount unit the minerals come out of the solution and slowly deposit inside fittings check valves strainers pressure hoses etc Basically it is producing rock inside the solution water system of the truckmount much the same way as nature does by using heat and pressure Given time the mineral deposits will be as hard as concrete In addition calcium and magnesium minerals interfere with the cleaning performance of some detergents How does a water softener work The EZ Charge Water Softener is a cation exchange type system This specifically made water softener consists of two 2 tanks a resin tank and a brine tank The resin tank contains a special ion exchange
7. NG THIS EQUIPMENT These symbols mean WARNING or CAUTION Failure to follow warnings cautions could result in fatality personal injury to yourself and or others or A CAUTION property damage Follow these instructions carefully READ the operator s manual before installing or operating this unit Failure to adhere to instructions can result in severe injury or could be fatal DO NOT damage the vehicle in any manner during installation Before drilling any mounting holes in the vehicle floor make certain that when drilling you will not do any damage to the fuel tank fuel lines or vital component which might affect the operation or safety of the vehicle DO NOT allow water softener to freeze Freezing may damage the resin tank valves hoses fittings or other components of the water softener In addition freezing will destroy the ion exchange resin in the water softener tank The resin must be replace if frozen It is not possible to use antifreeze to freeze protect the unit The water softener must always be protected from freezing by either storing the vehicle in above freezing temperatures or by removing the water softener from the vehicle and storing it in a warm area NEVER attempt to freeze protect your water softener with antifreeze PURGE all air from the water softener system before operation A newly installed water softener or a softener which has been disconnected for a period may have air in the tank
8. aning job with less chemicals and helps keep carpet fibers soft 4 3 980144 11 04 03 Always check hoses for A CAUTION cuts and abrasions where leaks may occur and kinks in the lines that may cause water flow restrictions Check that the connections are properly made and disconnects are connected fully to prevent restrictions FIRST RUN OPERATION NOTE Before connecting your water hose to the supply faucet flush out the faucet until the water is free of any debris Flush out any debris which may be in your water inlet hose Before running your softener for the first time you need to purge air from the system 1 Disconnect the soft water supply hose from the truckmount unit and install the adapter provided onto the end Be sure that adapter is connected or there will be no flow through the system during purging Place the end of the hose in a proper disposal drain NEVER dispose of the WARNING waste solution in storm drains water ways or on ground areas Always dispose of waste in accordance with Local State or Federal law 2 Connect your water supply hose to the INLET disconnect on the manifold on the resin tank and turn on the water supply During this first time you must turn the water supply on SLOWLY to purge any air that may be present inside the resin tank Failure to do so may result in a loss of softening resin If a loss of resin does occur the softener will not function properly and may requ
9. ation below locate the water softener nest to the truck mount console where the chemical draw lines are located This will allow you to use the bracket as a chemical jug holder when the brine tank is not needed during normal operation Be sure NOT to position the softener too close that when routing hoses they don t become kinked or damaged due to rubbing against abrasive edges 2 Place the bracket in place you ve located and mark the mounting holes You can also use the dimensional data below to mark out the mounting holes Using a drill with a 3 8 drill bit drill 4 mounting holes Using the hardware provided bolt the bracket into place see mounting detail After securely bolting the bracket into position place the softener cylindrical tank into the bracket and tighten the clamp around the tank using the wingnuts provided Bolt the water filter bracket to the back of the tank bracket and place the water filter hose assembly into the filter bracket Make sure to route the long hose from the filter towards the truckmount water inlet disconnect Connect the short hose from the filter to the OUTLET disconnect of the water softener Connect the long hose from the filter to the water inlet disconnect on the truckmount unit NOTE The softener has the words IN and OUT clearly marked on the tank manifold The water filter has a arrow mark on tip indicating water flow Your softener is now ready to use MOUNT
10. ctions refer to manual for full directions and frequency of regeneration cycles WARNING Refer to Manual Before Operating Soft Water Read All Instructions and Precautions Before Using 2 Connect outlet hose to softener tank inlet 3 Place full brine tank with brine flow reversal for backwash injector in softener bracket 6 Connect adapter to soft water hose end 5 Connect water supply hose to brine injector Route soft water hose to sanitary disposal site 7 After 15 minutes turn water supply off Disconnect soft water hose from truck mount Run water supply for 15 minutes Disconnect water supply hose from brine injector 8 Disconnect brine injector and remove empty brine tank 9 After 3 minutes turn water supply off from softener bracket refill brine tank at this time Disconnect water supply hose from softener tank outlet 10 Gonneet outlet hose to water softener tank outlet Connect soft water hose to truck mount Connect water supply hose to water softener tank outlet Remove adapter from soft water hose end Continue Normal Operation Run water supply for 3 minutes Disconnect outlet hose from water softener tank inlet 980144 11 04 03 4 6 MAINTENANCE The EZ Charge Water Softener requires very little maintenance Other than keeping the soft water supply filter assembly clean and general up keep of hoses and disconnects the EZ Charge Water Softener should last for many years The resin should last as long as
11. e of delivery to the user If PROCHEM receives notice of such defects during the warranty period PROCHEM will either at it s option repair or replace products which prove to be defective Any local or distant transportaion related service labor and diagnostic calls are not included Fiberglass Tank fee ee es area atria ene ee 1 year Softener injector system fittings hoses o rings connectors and other maintenance items are not under warranty The ion exchange resin is NOT covered under the warranty This warranty shall not apply to defects resulting from improper installation or operation inadequate maintenance by the customer unauthorized modification misuse a unit which is improperly repaired or exposure to freezing temperature conditions To obtain warranty service products must be returned to a service facility designated by PROCHEM Customer shall prepay shipping charges for products returned to PROCHEM for warranty service and PROCHEM shall pay for return of the products to customer PROCHEM makes no other warranty either expressed or implied with respect to this product PROCHEM disclaims the implied warranties of merchantabilty and fitness for a particular pupose Any implied warranty of merchantability or fitness is limited to the specific duration of this limited warranty This warranty gives you specific legal right and you may also have other rights which may vary from state to state or province to province The
12. er softener bracket also as a chemical jug holder You will need to remove the chemical jug for the next part of the operation REGENERATING THE WATER SOFTENER IMPORTANT During CAUTION regeneration the water flow must be reversed for a proper regeneration Failure to follow these instructions will adversely affect the water softener decrease the output efficiency as well as shorten the life of the softener resin Use the copy of the decal on the following page as you read through these instructions 1 This is the normal operating connection for the water softener The outlet hose short hose from filter connected to the outlet disconnect on the manifold and the supply hose long hose from filter connected to the water inlet disconnect on the truckmount unit 2 Disconnect the outlet hose from the outlet disconnect on the manifold 3 Connect the outlet hose into the inlet disconnect on the manifold 4 Place the brine tank with the salt solution into the water softener bracket Face the decal on the brine tank out to use as a guide for regenerating process 5 Connect the brine injector assembly on the brine tank into the OUTLET disconnect on the manifold 6 Connect a water supply hose into the disconnect on the brine injector assembly Disconnect the soft water supply hose from the truckmount unit 7 Connect the adapter supplied to the disconnect on the water softener supply hose Be sure the adapter
13. ire maintenance 3 Purge the system until the water being discharged is clean and free of debris Shut off the water supply remove the adapter from the soft water supply hose and reconnect hose to water inlet on truckmount unit OPERATION Your EZ Charge Water Softener is now ready for its first run operation NOTE This procedure should also be done ifthe system has not been used for a period of time or if resin has been added or replace in the resin tank CHECKING WATER HARDNESS Periodically the water hardness of the output water of you water softener should be checked Supplied is a roll of water hardness test strips Dip a strip of the water hardness test paper into the output water from the softener and compare the color of the test strip to the color chart on the box of output water reaches a maximum of 5 grains of hardness 980144 11 04 03 4 4 REGENERATION PREPARING THE BRINE TANK The EZ Charge Water Softener utilizes a solution of regular table salt Sodium Chloride in pellet form to recharge the unit This salt can be purchase at grocery stores in the swimming pool supplies area Use the COARSE type because it dissolves much faster than the large size pellets Put 3 gallons of HOT tap water into the brine tank square blue tank with injector attached which is supplied Then add 10 pounds of the salt into the brine tank and allow the salt to dissolve for about two 2 hours NOTE If you are using the wat
14. is connected or there will no flow through the system during regeneration Place the end of the hose in a proper disposal drain and turn on the water supply This will back flush the waste solution out of the water softener NEVER dispose of the WARNING waste water solution in storm drains water ways or on ground areas Always dispose of waste in accordance with Local State or Federal law 8 After about 15 minutes turn the water supply off Disconnect the water supply hose from the brine injector assembly 9 Disconnect the brine injector assembly from the OUTLET on the manifold and remove the brine tank from the mounting bracket Flush out the brine tank and store until next use Connect the water supply hose to the OUTLET on the manifold and turn on the water supply for about 3 minutes to finish flushing the system 10 About 3 minutes turn the water supply off Disconnect the water supply hose Remove the adapter from the water softener supply hose Disconnect the outlet hose from the INLET on the manifold 11 Connect he outlet hose into the OUTLET disconnect on the manifold Connect the water softener supply hose into the water inlet disconnect on the truckmount unit The system is now ready for normal operation 4 5 980144 11 04 03 REGENERATION EZ CHARGE CONDENSED REGENERATION INSTRUCTIONS NOTE Follow these instructions in proper sequence for normal regeneration cycle These are condensed instru
15. on PART NO column lists the part number for the part DESCRIPTION column is a brief description of the part NOTES column for information not noted by the other columns NOTE If a service or option kit is installed on your machine be sure to keep the KIT INSTRUCTIONS which came with the kit It contains replacement parts numbers needed for ordering future parts NOTE The 98 on the lower left corner of the front cover is the part number for this manual 980144 11 04 03 3 RECEIVING YOUR UNIT ACCEPTANCE OF SHIPMENT Every part of you EZ Charge Water Softener was carefully checked tested and inspected before it left our manufacturing plant Upon receiving the unit make the following acceptance checks 1 The unit should not show any outward signs of damage If damage notify the common carrier immediately 2 Check you equipment and packing list The standard EZ Charge Water Softener should arrive equipped with the following items unless otherwise specified EQUIPMENT LIST Cation resin softener tank prefilled Mounting base and bracket Brine tank and brine injector system Water hose with filter assembly and bracket Operation and service manual Installation bolting kit 5 gallon chemical jug with lid 1 roll of hard water test strips Funnel used for filling brine tank with salt Soft water supply hose adapter 1 1 980144 11 04 03 IMPORTANT SAFETY INSTRUCTIONS READ ALL INSTRUCTIONS BEFORE USI
16. or lines This air must be purged slowly from the system before operation or a lose of resin will occur 980144 11 04 03 2 1 SPECIFICATIONS The EZ Charge Water Softener is specifically designed to use in conjunction with the truck mount extractors This compact light and yet efficient water softener has the capacity to regenerate over 1 000 gallons of softened water per softening run figure is bases on a water hardness of 10 grains SOFTENER CAPACITY There are many factors which determine how long the water softener can operate between regeneration s Water hardness Water consumption of your truck mount Volume of water flow On wand versus two wand operation Cleaning procedures Truck mount scheduling are some of the major factors Remember the harder the water in your area the more frequent recharging of the system the chart below gives the amount of softened water supplied based on the water hardness that enters the system Water Hardness Soft Water Capacity Water Flow in G P M Grains Gallons Gallons Per Minute Model 18 Model 30 2 00 gals 3 000 gals 5 G P M minimum 1 200 gals 2 000 gals 5 G P M minimum If the output water from the system reaches 5 grains of hardness filtered drinking water the system should be recharged WATER SUPPLY TEMPERATURE The EZ Charge Water Softener is recommended for use with inlet water temperatures of up to 125 F 52 C Temperature above 125 F 52 C may damage the
17. ose to fast First Run Operation in this manual Use higher pressure water supply Water supply pressure 16 low Water supply must have a minimum pressure of 20 psi Softener fails to draw brine Air leak in brine line Check brine system for leaks repair or replace defective components ee Clean injector assembly disassembly Nor asceiibly iS plugged may be required Replace if needed 4 7 980144 11 04 03 980144 07 11 03 NOTES TANK amp TRAY e E 4 EN N 4 AS 177 75 6700 29 x A gt 28 980144 07 11 03 5 1 REF PARTNO DESCRIPTION 13 806008 DCS 3 8F X 3 8FP 11 800368 NIP 3 8 X CL SST 11 800038 BUSH 3 4 X 3 8 ALUM 12 800390 ADPT TNK 50 0271 14 806559 DIST TOP 41 2514 54 501691 TB PVC 13 16 27 14 806558 COLLECTOR LWR 41 2410 49 876138 TNK WTR SOFT 30 BLU 01 000277 NUT WING 3 8 16 51 503350 STRAP WTR SOFT CLAMP 56 501997 CLAMP TNK WTR SOFT 87171 WASHER 3 8 FLAT 87163 WASHER 3 8 SPLIT LOCK 70368 SCR 3 8 16 X 1 3 4 HHCS PLT 56 501998 PNL SOFT MTG WTR SOFT CIR GRAY 70507 SCR 3 8 16 X 3 4 HHCS GR5 PLTD 8 941326 DEC CDNSD REGEN OPER 0 501773 HLDR FLTR WTR SOFT 2 000066 FLATWASHER 1 4 87162 WASHER 1 4 SPLIT LOCK PLTD 70558 SCR 1 4 20 X 5 8 HHCS PLTD 57031 NUT 5 16 18 HEX 2 000143 WASHER FLAT PLTD 0 500511 PLATE INSTALL MT 70258 SCR 5 16 18 X 1 5 HHCS BR5PLT 27 100179 TRIM FLX 1 16 X 29 64
18. ry Of Water 4 3 First 4 4 Checking Water 5 4 4 REGENERATION Preparing The Brine Tank 4 5 Regenerating The Water Softener 4 5 MAINTENANCE JrouUbjeshoobng 44 4 7 2 980144 11 04 03 This manual contains the following sections HOW TO USE THIS MANUAL SAFETY OPERATIONS MAINTENANCE PARTS LIST The HOW TO USE THIS MANUAL section will tell you how to find important information for ordering correct repair parts Parts may be ordered from authorized dealers The SAFETY section contains important information regarding hazard or unsafe practices of the machine Levels of hazards is identified that could result in product or personal injury or severe injury resulting in death The OPERATIONS section is to familiarize the operator with the operation and function of the machine The MAINTENANCE section contains preventive maintenance to keep the machine and its components in good working condition They are listed in this general order Regular maintenance Troubleshooting HOW TO USE THIS MANUAL The PARTS LIST section contains assembled parts illustrations and corresponding parts list The parts lists include a number of columns of information REF column refers to the reference number on the parts illustrati
19. s document is subject to change without notice and does not represent a commitment on the part of Professional Chemicals Corporation All rights reserved Copyright 1995 by Professional Chemical Corporation No part of this work may be reproduced or used in any form or by means graphic electronic photocopying taping or electronic retrieval systems without the express written permission of Professional Chemicals Corporation Published by Professional Chemicals Corporation 980144 11 04 03 1 TABLE 5 ii rn 1 PARTS LIST Table Of Contents 2 amp 00999 998 5 1 HOW USE THIS MANUAL Filter Assembly 5 3 Brine Tank Assembly 5 5 How Use This Manual 1 1 Warranty asse aa n ae eae n Ea eeoa 5 8 RECEIVING YOUR UNIT Acceptance Of 7 7 Equipment List 1 1 SAFETY Safety INStrUCtIONS 2 2 2 7 SPECIFICATIONS Softener Capacity 3 1 Water Supply Temperature 3 1 Water Hardness 3 2 INSTALLATION Positioning The Unit In Vehicle 4 1 Dimensional Data 4 2 OPERATION Theo
20. unit permanently and void warranty 3 1 980144 11 04 03 SPECIFICATIONS Hard water deposits will adversely affect the plumbing and heat exchange systems of your truck mount extractor unit The map below will give you an idea where areas of high water hardness may occur Though any water supply obtained from a well is almost always hard water and a water softener will be needed to help protect you truckmount equipment Figure 1 HARD WATER MAP 980144 11 04 03 Using a water softener will reduce maintenance and decrease down time caused by hard water scaling It will also allow cleaning chemicals to be more effective in lower concentrations NOTE Most warranties will not cover equipment malfunction or component failure caused by hard water scaling C LESS THAN 3 5 ES 35707 more THAN 7 INSTALLATION DO NOT damage the WARNING vehicle in any manner during installation Before drilling any mounting holes in vehicle floor make certain that when drilling you will not do any damage to fuel tank fuel lines or any vital components which might affect the operation or safety of the vehicle POSITIONING THE UNIT IN VEHICLE Because vehicles vary in size and openings individuals have their own preference as to where they want their softener installed The following is a suggested location that gives you ease of operation and utilizes all aspects of the EZ Charge Water Softener 1 Using the illustr
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