Operation and Maintenance Manual for
Contents
1. items not shown in photos OS A KFZSD 1 1 5 Manual 01 04 Rev 1 SYSTEM INSTALLATION The brine tank assembly included with all softeners consists of see Figure 2 2 21 1 1 12 13 14 15 16 17 18 19 20 1 Brine tank with cover 1 Well with cap 1 Salt Grid 1 Overflow fitting 1 Air check safety valve for 18 brine tanks 1 3 8 tube elbow fittings for 9 16 systems 1 0 5 bushing elbow fittings for 18 24 systems 2 lengths tubing with tee for duplex 9 12 systems 1 length 18 tubing with tee for 14 24 systems 1 Air check assembly for 24 brine tanks 1 Grommet for brine line hole in tank Figure 2 2 Brine Tank Components items not shown in photos KFZSD 1 1 5 Manual 01 04 Rev 1 SYSTEM INSTALLATION The following alternating kit components are also included for the duplex system 22 1 25 RJ45 phone cable 23 1 25 3 wire meter cable 24 1 cable fitting with lock nut 25 1 remote meter with bracket and tester ee Figure 2 3 Alternating Kit Components The following valve and solenoid kit components are included with the duplex system 4 end connectors for actuated valves 26 27 2 normally open NO valves w mounted and tubed 24VAC solenoid valve 28 1 Ya Union Tee2. KFZSD 1 1 5 Manual 01 04 Rev 1 SYSTEM INSTALLATION CAUTION 6 Reinstall the injector gasket cover and bolts Note the required Backwash Rapid Rinse flow DLFC in Table 1 1 Out of the bag of in line flow control DLFC washers choose the one with this flow stamped on it flows are in hundredths of a GPM i e 500 5 GPM Install this DLFC flow washer onto the inlet side of the supplied DLFC housing as shown in Figure 2 7 Make sure the numbers on the washer are facing out Install the DLFC housing onto the control valve s drain connection Make sure that the arrow on the housing is pointing away from the valve Install with numbers on this side Da Figure 2 7 DLFC Washer Installation Use a silicone base grease to lubricate the two 2 O rings at the base of each control valve Units with 1 valves only Install the supplied upper disperser to the bottom of each valve by pushing the large end of the disperser into the groove on the bottom of the valve until the disperser locks in place 16 diameter tank systems with 1 valves Thread the supplied tank to valve bushing into each vessel s top opening Carefully thread each control valve into the opening in the top of the tank or bushing if applicable Make sure that the riser tube distributor assembly goes into the center opening in the base of the control valve Hand tighten only do not use a wrench or any device to apply additional tor
3. P6 C Solenoid Valve Piping The supplied Asco 24VAC Universal Solenoid valve is pre mounted and tubed to the diaphragm valve The valve utilizes line pressure to open and close the valve No further assembly is required after it is wired to the 3200NT PCB D Duplex Triplex and Quadplex Network Configuration Wiring The standard systems are duplex alternating systems They can be expanded in the future to be triplex or quadplex operating The 3200NT Timer has the capability to be wired and programmed to operate as a duplex triplex or quadplex system via a 6 place 4 conductor RJ5 telephone cable Refer to the 3200NT Timer Service manual Network Timer System Configuration Wiring Diagrams for the RJ5 cable termination schematics E Duplex Triplex and Quadplex Network Programming 1 Refer to the 3200NT Timer Service Manual Master Programming Mode Flow Chart yellow supplement sheets for programming instructions for the 3200NT In addition refer to the Equipment Specification table in Section 1 4 of this manual for the programming parameters specific to your softener The system utilizes the System 7 programming system type 4 Cycle Steps are utilized during operation of the 3200NT controlled duplex softeners The exact values are located in section 1 4 of this manual a Cycle Step 1 Backwash b Cycle Step 2 Brine In Slow Rinse C Cycle Step 3 Fast Rinse USES 88 KFZSD 1 1 5 Manual 01 04
4. 1600 injector and 3200NT Timer 05 900005988NT 1 5 2850 Valve head with 1700 injector and 3200NT Timer 21 132102728 Flowmeter 1 Brass 21 132102729 Flowmeter 1 5 Brass 18 903001513 Injector Conversion Kit 1600 injector 18 903001516 Injector Conversion Kit 1700 injector 05 03993 16 1 Diaphragm Valve w mounted and tubed 24VAC solenoid 05 02561 16 1 Union SOC Adapters for Diaphragm Valve qty 2 05 03993 18 1 5 Diaphragm Valve w mounted and tubed 24VAC solenoid 05 30476 18 1 5 Union SOC Adapters for Diaphragm Valve qty 2 B10011249 O ring 2750 Valve Distributor Base Fleck PN 11710 refer to page 8 part of o ring kit item 19 in 2750 Control Valve Manual B10011248 O ring 2750 Valve Base Fleck PN 11208 refer to page 8 item 20 in part of o ring kit 2750 Control Valve Manual B10011247 O ring Top of Tank for 2750 Valves Fleck PN 10381 refer to page 8 part of o ring kit item 22 in 2750 Control Valve Manual B10008143 O ring Top of Tank for 2850 Valves Fleck PN 16455 refer to page 6 part of o ring kit item 15 in 2850 Control Valve Manual B10008642 O ring 2850 Valve Fleck PN 13577 refer to page 6 item 16 in 2850 part of o ring kit Control Valve Manual 7 3 QA INSPECTION REPORT The QA Component Inspection Report will follow the manual 7 4 COMPONENT MANUFACTURER LITERATURE The vendor literature for your Duplex Softener will
5. 29 1 20 Y tubing Figure 2 4 Normally Open Diaphragm Valve w mounted 24VAC Solenoid 1 shown of 2 items not shown in photos KFZSD 1 1 5 Manual 01 04 Rev 1 SYSTEM INSTALLATION 2 2 PRECAUTIONS BEFORE INSTALLATION NOTE Be sure to comply with all local state and federal codes A WATER PRESSURE The regeneration valve needs 30 psi minimum pressure to operate effectively Softeners with 16 x 65 vessels require a minimum of 40 psi B WATER TEMPERATURE Feed temperature should be 45 100 F INLET TURBIDITY Maximum inlet turbidity is 5 NTU CAUTION Water pressure is not to exceed 110 PSI water temperature is not to exceed 100 F and the unit cannot be subjected to freezing temperatures D ELECTRICAL FACILITIES An uninterrupted 110V alternating current AC electrical supply is required Make sure the supply is always on and cannot be turned off with another switch E EXISTING PLUMBING Existing plumbing should be free from lime and iron buildup If piping is clogged with iron a separate iron filter unit should be installed ahead of the water softener F LOCATION The softener should be located close to an open drain G MANUAL VALVES Always install manual inlet outlet and bypass valves on the system NOTE If feedwater or utilities do not meet the above requirements or there is some doubt contact your local representative or Technical Support Department at the number provide
6. 9 OPERATING INSTRUCTIONS RegeneratO SCUD msiri erer i ni ee 3 1 System OPIO Sr o ao 3 1 Troubleshooting sc aida 3 1 SHUTDOWN AND STORAGE Shutdown and Storage Procedure icococicrosininercec reci 4 1 SAMPLING AND TESTING General Sampling and Testing Guidelines cccccccccccncnnnnnnnnnnnnnnnn 5 1 Sampling and Testi acia eens 5 1 Resin Sampling Procedure viii att 5 2 SECTION 6 0 6 1 7 0 7 1 7 2 7 3 7 4 TABLE OF CONTENTS DESCRIPTION PAGE MAINTENANCE General Maintenance Guidelines ooocccccccconnnnnoncccnnnnccnnnnnnnnncnnnnnnnnnns 6 1 APPENDIX Glossary of TEMS i iaoeia eaan o e 7 1 Replacement Spare Parts List ccccceeeecceeeeeeeeeeeeeeeeeeeeneeeeeeeees 7 3 QA Inspection Report ii a 7 3 Component Manufacturer Literature cccceeeeeeeeeeeeeeeeeeeeeeeseeeeeeeees 7 3 KFZSD 1 1 5 Manual 01 04 Rev 1 INTRODUCTION 1 0 INTRODUCTION Congratulations on your selection of this water purification system This system is designed and manufactured to the highest standard of quality and fully inspected prior to shipment In order to get maximum performance we ask you to read all of the following instructions before installing and operating this system Any warranty offered will be void unless directions are followed exactly This manual is divided into sections for easy reference Review this manual thoroughly and then return to section 2 0 System Installation for step by s
7. Rev 1 SYSTEM INSTALLATION d Cycle Step 4 Brine Fill 4 Refer to the 3200NT Timer Service Manual Troubleshooting section for information on any communication or programming problems NOTE For Duplex or Triplex and Quadplex applications the Lag unit must be programmed prior to the Lead unit programming Feed water hardness values are programmed in the Lead valve as the water meter is connected to this valve US z2 20 KFZSD 1 1 5 Manual 01 04 Rev 1 OPERATING INSTRUCTIONS 3 1 3 2 3 0 OPERATING INSTRUCTIONS REGENERATION SETUP Before placing your softener into Service use these steps to make sure the regeneration cycle and step times function properly NOTE When initiating a regeneration or stepping through to the next cycle step it is very important to wait until all cams and pistons have stopped moving before stepping to the next cycle step Moving too quickly between steps can cause the timer to get stuck in a particular cycle A Refer to the 3200NT Timer Service Manual Timer Operation Initiate a regeneration manually and cycle through all steps B Briefly open the Product Valve and make sure the meter is functioning Confirm that the Volume Remaining display is changing and that the Flow Indicator light is flashing C Fill the brine tank with salt to about 6 from the top Use rock salt or pellets that contain less than 0 6 calcium and magnesium less than 1 5 sul
8. follow this manual Manufacturer Manufacturer Model Number Component 1 Control Valve 2750 1 5 Control Valve 2850 Network Controller 3200NT For Product and Service Information USFilter 10 Technology Drive Lowell MA 01851 Telephone 978 934 9349 FAX 978 441 6025 For Technical Support Telephone 800 875 7873 Extension 5000 Email Lowell_ TechSupport USFilter com
9. valves should be operated through their full range at least every 6 months to assure they function properly and are free of debris E PRESSURE REGULATORS Any pressure regulators used in conjunction with this system should be inspected occasionally to assure they are set properly F LEAK CHECKING Operators should be alert for leaking pipes valves and components Detecting and repairing a leak while it is still small may prevent lengthy downtime later KFZSD 1 1 5 Manual 01 04 Rev 1 APPENDIX 7 0 APPENDIX 7 1 GLOSSARY OF TERMS The terms commonly used in softening and filtration are defined below BACKWASH BED EXPANSION BED BRINE CAPACITY CONCENTRATION CONTAMINANT CYCLE EFFLUENT EXHAUSTION FINES FLOW RATE FREEBOARD GRAINS GALLON GRAIN The counter current flow of water through a resin bed i e in at the bottom of the vessel out at the top to clean and reclassify the bed after exhaustion The effect produced during backwashing the resin particles become separated and rise in the column The expansion of the bed due to the increase in space between resin particles may be controlled by regulating backwash flow The resin contained in a vessel Water saturated with salt The ability of the resin to remove hardness measured in kilograins per cubic foot The amount of substance in weight moles or equivalents contained in a unit volume Any foreign componen
10. USES Operation and Maintenance Manual for KFZSD KF Series Duplex Alternating Softener Systems With 1 and 1 5 Valves Catalog Serial USFilter 10 Technology Drive Lowell Massachusetts 01851 Tel 800 875 7873 Fax 978 441 6025 Email 68 KFZSD 030 01 04 Rev 1 Lowell_TechSupport USFilter com CAUTIONS AND WARNINGS Prior to operating or servicing this device this manual must be read and understood If something is not clear call for assistance before proceeding Keep this and other associated manuals for future reference and for new operators or qualified service personnel All electrical work should be performed by a qualified electrician in accordance with the latest edition of the National Electrical Code as well as local codes and regulations To avoid electrical shock hazard do not remove covers or panels when power is supplied to the device Do not operate the device when covers or panels are removed A faulty pump motor or wiring can be a serious shock hazard if it or surrounding water is accessible to human contact To avoid this danger DO NOT remove any grounding wire from the system DISCLAIMER STATEMENT This operation and maintenance manual is intended to be used with the component manufacturer literature provided in the Appendix These manuals should provide complete and accurate information to meet your operating and or service requirements based on the information available at
11. are available 1 2 KFZSD 1 1 5 Manual 01 04 Rev 1 INTRODUCTION 1 4 SYSTEM SPECIFICATIONS Table 1 1 Duplex Softener System Specifications Backwash j i Cycle Times 15 ft Rapid i dosage Rinse Color BLFC minutes Flow DLFC gpm Stand BW Brine Slow i Pra acre i i se ak Y 18 x40 350 ss ae os 10 fae 32 710 24 18x40 350 3 5 2B 0 5 10 32 32 10 24 18x40 350 50 3 05 10 26 46 10 32 24x50 700 ERE GES 3 Y 0 5 10 34 58 10 44 24x50 700 70 90 120 3 0 5 10 34 58 10 44 24x50 700 3C Y 4C G 5C W A e 60 6 39 aa Fri 16 x 65 120 23 MUGEN 12 _ 46 _ a Ree o 210 21 52 120 5 300 30 68 150 At higher salt dosages the softener will treat more water between regenerations create less overall waste and produce lower hardness effluent At lower salt dosages the softener will use less overall salt For dosages below 9 ft consult Technical Support at the number on this manual s front cover For other salt dosages use the formula Kgr capacity 30 16 8 x ft resin where salt dosage in lbs f The Brine In and Slow Rinse times are set on each valve timer as a single cycle time which is the two cycle times added together For other salt dosages adjust the Brine In and Brine Tank Fill times using this formula Cycle time Time shown x Salt Dosage 15 For an inlet pres
12. d on the cover of this manual for recommendations NOTE Teflon tape is the only sealant to be used on any threaded fittings 2 3 INSTALLATION OF MEDIA A Place the softener tanks on a firm foundation as close to the floor drain as possible and level the vessels B A riser tube distributor assembly has been shipped in each softener vessel see Figure 2 5 Inspect the slotted basket bottom distributor to be sure it is not damaged Also make sure that the top of the riser pipe is flush with the top of the tank flange when the basket is in the middle of the tank and flat on the bottom Cover the top of the riser pipe with tape or a plastic cap to prevent gravel and resin from getting inside the riser pipe Usa gt KFZSD 1 1 5 Manual 01 04 Rev 1 SYSTEM INSTALLATION Risertube distributor assembly Cation Resin 1 8 x 1 16 4 Gravel if applicable Figure 2 5 Softener vessel riser tube and media C Fill the tank about full with water Center the riser tube distributor assembly in the top opening of the softener tank Pour the proper quantity of 1 8 x 1 16 4 gravel see section 1 4 into the softener make or buy a large funnel to prevent the gravel from spilling 9 and 12 vessels do not use a gravel underbed D Level the gravel as best as possible making sure that all of the strainer slots are covered E Using the same funnel pour the quantity of cation resin see section 1 4 i
13. date these practices and procedures on an ongoing basis in an effort to improve our systems and to insure that they continue to reflect state of the art technology and reliability Quality assurance is the cornerstone of our quality program It begins with the selection and qualification of components and materials Before suppliers are selected their products must meet or exceed rigid standards set by our Quality Assurance Department From that point our incoming material inspection insures only reliable components will be used to manufacture systems Numerous checks are performed as the system passes through the manufacturing process Included with the system is a copy of the QA Data Report that includes the check that all components are included KFZSD 1 1 5 Manual 01 04 Rev 1 INTRODUCTION 13 SYSTEM PART NUMBERS Sample Part Number KFZSD 009 F P Z V A X KFZSD KF Series Duplex Softener Softener Tank Size 009 9 x 40 012 12 x 52 014 14 x 65 016 16 x 65 018 18 x 65 021 21 x 62 024 24 x 72 Vessel Material F Standard Non Code Fiberglass Control Rating P NEMA 3R Skid Z Stand alone unit non skid Control Type V 3200NT w Volume Initiation Pipe Size A 1 B 1 5 Resin Options Options X Standard Volume Note Not all model number combinations
14. erved to avoid personal injury or fatalities CAUTION Cautions indicate a situation that may cause damage or destruction of equipment or may pose a long term health hazard NOTE Notes are used to add information state exceptions and point out areas that may be of greater interest or importance EQUIPMENT SUPPORT USFilter continually strives to provide safe efficient trouble free equipment using the optimum technology for your application If problems should develop USFilter s worldwide network of technical support will be available to provide assistance For service sales parts or additional manual copies call your area representative or USFilter Technical Support Department at the number provided on the cover of this manual SECTION 1 0 2 0 3 0 4 0 5 0 1 1 1 2 1 3 1 4 2 1 2 2 2 3 2 4 2 5 3 1 3 2 3 3 4 1 5 1 5 2 5 3 TABLE OF CONTENTS DESCRIPTION PAGE INTRODUCTION SYSTEM FUNCUON a a as casio 1 1 Quality Assurance Quality ContrOl oooooccccnnnncccconnnocccnnnnancccnnnnnrccnnnnnanccno 1 1 System Part NUMbD GIS coi iS aan 1 2 System Specifications oooocccnnnnnnnocccnnnncnnnccnonancnnnnnnonononnnnnncnnnnnnnnnns 1 3 SYSTEM INSTALLATION Equipment InclUded iii a 2 1 Precautions Before Installation ccccccccceceeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 2 4 Installation of Medisinen ra a 2 4 Valve and Piping Installation omic 2 6 3200NT Controller WI cdas nl veias 2
15. esium which are dissolved minerals that have only limited solubility in water and therefore frequently precipitate as scale on piping water heaters etc Your softener contains a material known as resin which removes these hardness minerals from the water The amount of hardness in the feed water will determine the number of gallons a water softener can treat between regenerations If the feed water hardness changes the length of the service runs must be changed to avoid overrunning the unit or wasting water and salt on excessive regenerations The amount of hardness in the product water is typically used as an endpoint for service runs When the amount of hardness in the product rises to a setpoint the resin is exhausted and must be regenerated with a salt solution brine The proper quantity of brine must be present in the storage tank prior to a regeneration Refer to the Specifications Sheet in Section 1 for the required quantity Your softener system includes a hardness testing kit Use this kit and the included instructions to periodically check the hardness of the softener feed and product streams KFZSD 1 1 5 Manual 01 04 Rev 1 SAMPLING AND TESTING 5 3 RESIN SAMPLING PROCEDURE The material inside your softener called resin should give you years of soft water provided your softener is operated within the guidelines given in this manual Over the years the resin will gradually lose its capacity to remove hardnes
16. fate salts less than 2 0 water soluble impurities and no grease fat or oil D Salt replacement is not an automatic step Operators must check the brine tank periodically to establish a salt refill schedule Refer to Table 1 1 for the maximum salt allowable in the brine tank SYSTEM OPERATIONS Refer to the Model 2750 1 or 2850 1 5 Control Valve Service Manual for descriptions of the valve operations during all cycle steps These descriptions are located near the beginning of the 2750 or 2850 Control Valve Service Manual pages 4 and 5 Refer to the 3200NT Timer Service Manual System Operations System 7 for explanation of the 3200NT Controller typical operation TROUBLESHOOTING For communication or programming errors refer to the 3200NT Timer Service Manual Troubleshooting section For general service and performance issues refer to the Model 2750 or 2850 Control Valve Service Instructions section KFZSD 1 1 5 Manual 01 04 Rev 1 SHUTDOWN AND STORAGE 4 0 SHUTDOWN AND STORAGE If the system must be shut down and stored perform the following steps 4 1 SHUTDOWN AND STORAGE PROCEDURE A Regenerate the unit B When the system returns to Service close all valves in the inlet and outlet piping C Disconnect the power to the controller D Once each week open the inlet valve and put the unit into Rapid Rinse for 10 minutes power must be restored to do this Once complete repeat steps B a
17. ions of similar charge from the absorbent Any particle of less than colloidal size possessing either positive or negative electric charge A unit of weight one thousand grains There are seven kilograins per pound The material resin carbon quartz that is used in a fluid treatment vessel A natural inorganic substance having a definite chemical composition and structure Untreated water from wells or from surface sources The process by which a system is conditioned to ready it for another service cycle Typically a synthetic plastic bead with attached ions that will exchange trade places with with other ions in a process feed stream Used in ion exchange applications The final step in a unit regeneration in which water is flushed through the unit until the effluent quality is proper The precipitate that forms on surfaces in contact with water The removal of hardness calcium and magnesium from water The ratio of the mass of a body to the mass of an equal volume of water at 4 C or other specified temperature Total Dissolved Solids in parts per million ppm The amount of solution passed through an exchange bed before exhaustion of the resin occurs KFZSD 1 1 5 Manual 01 04 Rev 1 7 2 APPENDIX REPLACEMENT SPARE PARTS LIST PART NUMBER DESCRIPTION 05 900005977NT 1 2750 Valve head with 1600 injector and 3200NT Timer 05 900005987NT 1 5 2850 Valve head with
18. ither receipt nor possession of this manual confers or transfers any right to the client and by its retention hereof the client acknowledges that it will not reproduce or cause to be reproduced in whole or in part any such information except by written permission from USFilter The client shall have the right to use and disclose to its employees the information contained herein for the purpose of operating and maintaining the USFilter equipment and for no other purpose In the event the content of this manual is altered or section items are omitted during a reproduction in whole or in part and instructions or definitions within the reproduction result in personal injury to those who follow the altered instructions the burden of responsibility for personal injury falls solely on the party who affects the reproduction MANUAL USER S GUIDE This manual describes the procedures necessary to install operate and maintain your USFilter Duplex Softener system Please read this manual carefully before installing and operating your equipment The equipment warranty may be voided if installation or operation instructions are not followed correctly Warnings Cautions and Notes are used to attract attention to essential or critical information Warnings and Cautions will appear before the text associated with them and notes can appear either before or after associated text Warnings indicate condition practices or procedures which must be obs
19. nd C m When the softener is returned to Service re open the inlet and outlet valves restore power to the controller and regenerate the unit again US o KFZSD 1 1 5 Manual 01 04 Rev 1 SAMPLING AND TESTING 5 0 SAMPLING AND TESTING This section covers sampling and testing procedures that may apply to your softener Selected sampling and testing procedures should be performed regularly during the operation of this system A well kept logbook of test dates and results and of operator observations is an invaluable tool for troubleshooting future performance problems Any tests used with this system must be performed on a regular basis and must be accurately recorded in a logbook The frequency of sampling and testing is normally at the discretion of the customer 5 1 5 2 GENERAL SAMPLING AND TESTING GUIDELINES A Regular and complete record keeping is critical to maintaining proper operation of a softener B Close monitoring of performance will allow operators to detect operating problems early C The most important operating data is generated during the initial operation of new equipment This point forms a baseline that is used to evaluate all future operation D Always record a complete set of data immediately before and after performing a regeneration E Refer to the remainder of this section for recommended sampling procedures SAMPLING AND TESTING Hardness is the measurement of calcium and magn
20. nto the softener tank Fill the tank with water and soak the resin for at least 2 hours US zz2 2 KFZSD 1 1 5 Manual 01 04 Rev 1 SYSTEM INSTALLATION 2 4 VALVE AND PIPING INSTALLATION CAUTION Before installing the valve remove the tape or cap from the top of the riser pipe NOTE During installation refer to Table 1 1 for injector sizes and DLFC sizes 1600 Injector 1700 Injector n Cover Gasket Cover i Gasket Screen Nozzle Nozzle Screen Injector Body Throat Throat Injector Body Figure 2 6 Injector Components and Assembly A Verify the correct injector assembly is used using the following procedure and referring to Figure 2 6 above Each control valve has been configured for use with a specific diameter tank If a smaller or larger tank is used instead a different injector will need to be used 1 Remove the mounting bolts and lift off the cover and gasket 2 Compare the installed injector nozzle and throat to the specification table in Section 1 4 If the correct color injector is already installed skip to step 6 3 Using a standard screwdriver unscrew the installed injector nozzle from the injector body Unscrew the installed injector throat from the injector body Install the required injector throat and nozzle see Table 1 1 these are included in the supplied kit see Figure 2 1 Screw them into the injector body until snug but do not overtighten US z2 88
21. que Do NOT plug in the power cord at this time Locate the brine tank between the two softeners The brine tank location should be such that it will not interfere with access to the softener control valve or filling the brine tank with salt The brine tank must be placed on a smooth firm foundation Install the piping according to the System 7 Duplex Alternating Installation with Remote Meter Figure 2 8 The brine draw lines from both control valves must be run to the common brine tank Components supplied by the manufacturer are the 3 way solenoid valves and the Normally Open Diaphragm valves Follow all Installation Instructions in the Model 2750 or 2850 Control Valve Service Manual US zf2 T KFZSD 1 1 5 Manual 01 04 Rev 1 SYSTEM INSTALLATION MODEL 2750 amp 2850 SYSTEM 7 DUPLEX ALTERNATOR INSTALLATION WITH A REMOTE METER 1 amp 1 1 2 2 TANKS 1 METER ALTERNATOR SYSTEM ONE UNIT IN SERVICE THE OTHER IS ON STAND BY WHEN THE METER ZEROS OUT THE UNIT IN SERVICE GOES INTO A REGENERATION CYCLE THE STAND BY UNIT GOES INTO SERVICE Figure 2 8 Duplex Alternating Installation with Remote Meter J Loosely thread the supplied tubing fitting onto each valve s brine inlet connection K Cut the supplied brine tubing into 3 6 pieces Run one piece between the air check assembly on the brine tank to the supplied tubing tee and the other two pieces between the tee and each valve s b
22. rine inlet connection Refer to figure 2 9 BRINE TANK WITH COVER Figure 2 9 Brine Tubing Connection L The manufacturer recommends that drain tubing be installed connecting the overflow elbow on the side of the brine tank to an open floor drain Do not run this US z2 8B KFZSD 1 1 5 Manual 01 04 Rev 1 SYSTEM INSTALLATION line overhead it must be to a gravity drain Do not make a direct connection to the floor drain M Install the remote meter in a horizontal portion on the common soft water line Make sure the arrow on the meter s brass casting is pointing the proper direction For ease of service a union should be installed on the meter outlet the inlet has a built in union 2 5 3200NT CONTROLLER WIRING A Transformer Wiring Refer to the 3200NT Timer Service Manual Transformer Installation and 2750 2850 3150 Timer Wiring Diagram These can be found in the 3200NT manual Table of Contents The 3200NT Timer is supplied with a 120VAC to 24VAC transformer that requires wiring into the 3200NT PCB The transformer is wired into P1 of the 3200NT PCB and grounded on the chassis of the 3200NT assembly B Solenoid Valve Wiring Refer to the 3200NT Timer Service Manual 2750 2850 3150 Timer Wiring Diagram A 3 Way Universal 24VAC solenoid valve is supplied for control of the effluent product valve that is utilized in the system The solenoid valve is wired into the 3200NT Timer PCB at terminal
23. s and will eventually require replacement To determine resin capacity or solve any of the resin related problems identified while troubleshooting the resin will have to be sampled and tested using the following procedures NOTE NOTE Before starting this procedure obtain two replacement o rings to put between each tank and its valve These are listed in the spare parts section Disconnect the power and interconnecting wiring to the valve timer Open the valve in the bypass line then close the valves at the softener inlet and outlet Relieve water pressure in the softener by putting the control into regeneration and advancing through each regeneration step waiting each time for the valve to stop moving until the control is back in Service see section 3 3 Disconnect the inlet outlet drain and brine piping tubing at the valve Spin the whole brine valve and timer assembly off of the softener vessel s top flange Discard the two O rings between the valve and the tank To provide the most accurate information on resin condition a resin sample must be representative of the entire bed Use a grain thief or related device to take a core sample of the resin bed refer to Figure 5 1 Do not take a sample by taking resin from only the top of the bed The particulates and resin that normally collect at the top of the bed will not accurately represent the entire bed 1 Insert a clean Y pipe into the softener vessel and t
24. sure other than 35 psig adjust the Brine In and Slow Rinse times using the graphs in Section 8 4 and this formula Cycle time Time shown x Flow at 35 psig Flow at actual psig For tank sizes that are listed with more than one possible resin amount refer to the last letter of the model see above to determine whether to use the minimum Y median X or maximum Z resin volume At higher salt dosages use 70 of salt instead if more salt is loaded the tank may overflow during the Brine Refill step 1 3 KFZSD 1 1 5 Manual 01 04 Rev 1 SYSTEM INSTALLATION 2 0 SYSTEM INSTALLATION 2 1 EQUIPMENT INCLUDED Your system has been shipped to you in the following assemblies Check to make sure that none of these appear damaged or missing Each softener assembly consists of the following components common to all softeners see Figure 2 1 1 Fiberglass vessel with PVC riser tube distributor assembly 1 Control Valve with cover 1 Tank Valve bushing for 16 tanks with 1 valves 1 Drain line flow control DLFC housing 1 Tube fitting for brine inlet line 1 Kit with assorted DLFC injector parts 1 Upper Disperser 1 5 valves only 1 Lot Cation Resin and gravel if necessary 2 Operating Manuals 1 Hardness test kit Injector Nozzles y e DLFC Washers 1 P F 7 6 4 10 gt N gt 1 2 3 4 5 6 7 8 9 1 0 Figure 2 1 Components common to all softeners
25. t present in another substance e g anything in water that is not H20 is a contaminant A complete sequence of operation For instance a complete softener cycle of would involve Service Backwash Brine In Slow Rinse Fast Rinse Brine Tank Refill and back into Service The solution which emerges from a system unit The state in which the resin is no longer capable of removing enough hardness from the feed water Extremely small particles of ion exchange resin The volume of solution which passes through a system within a given time Flow rate is usually expressed in terms of gallons per minute The space provided above the resin bed in an ion exchange column to allow for expansion of the bed during backwash An expression of concentration of material in solution One grain per gallon is equivalent to 17 12 parts per million A unit of weight 0 0648 grams 0 000143 pounds KFZSD 1 1 5 Manual 01 04 Rev 1 HARDNESS INFLUENT ION EXCHANGE ION KILOGRAIN MEDIA MINERAL RAW WATER REGENERATION RESIN RINSE SCALE SOFTENING SPECIFIC GRAVITY TDS THROUGHPUT VOLUME APPENDIX The scale forming and lather inhibiting qualities which water high in calcium and magnesium ions possesses The solution which enters a system unit A process by which certain undesired ions of given charge are removed from solution with an absorbent being replaced in the solution by desirable
26. tep installation instructions If you need technical assistance in operating or maintaining your unit call your local representative If you require further assistance call the Technical Support Department at the phone number provided on the cover of this manual 1 1 SYSTEM FUNCTION The function of your water softener is to reduce the hardness in feedwater using ion exchange resin The water softener vessel contains high quality cation resin in the sodium form that removes hardness Hardness will create scale on reverse osmosis membranes water heaters boilers and other equipment if not removed Calcium magnesium and other cations removed by the resin are replaced with sodium ions The resin has a fixed capacity based on the pounds of salt used per cubic foot of resin during regeneration Flow rate TDS and other factors will dictate the actual capacity of the resin When the capacity is exceeded the resin will allow the hardness ions to pass through the unit Before the capacity is exceeded the unit is removed from service and regenerated with a solution of sodium chloride brine Completion of the regeneration steps allows the water softener to be returned to the service mode 1 2 QUALITY ASSURANCE QUALITY CONTROL We have defined Quality Assurance and Quality Control into a series of engineering and manufacturing practices and control procedures to insure that you receive the finest product available in the world We will continue to up
27. the time of publication However USFilter assumes no responsibility for the technical content of the manufacturer literature This manual should be read fully and understood before installation operation or maintenance of the system is attempted The information in this manual may not cover all operating details or variations or provide for all conditions in connection with installation operation and maintenance Should questions arise which are not answered specifically in this manual contact the USFilter Technical Support Department at the phone number provided on the cover of this manual USFilter reserves the right to make engineering refinements that may not be reflected in these manuals The material in these manuals is for informational purposes and is subject to change without notice and should not be construed as a commitment by USFilter USFilter assumes no responsibility for any errors that may appear in this document This manual is believed to be complete and accurate at the time of publication In no event shall USFilter be liable for incidental or consequential damages in connection with or arising from the use of this manual Copyright 2004 USFilter Printed in the United States of America All rights reserved THIS BOOK OR PARTS THEREOF MAY NOT BE REPRODUCED IN ANY FORM WITHOUT THE WRITTEN PERMISSION OF THE PUBLISHERS PROPRIETARY RIGHTS STATEMENT This manual discloses information in which USFilter has proprietary rights Ne
28. wist it all of the way down to the bottom of the resin bed 2 Plug the top end of the pipe and slowly lift it out of the vessel Empty the plug of resin inside the pipe into a clean container 3 Take enough resin from the bed to fill a one quart jar and contact your dealer to have the sample tested Apply silicone lubricant to the top edge of the riser tube distributor assembly and to two new O rings Reverse steps 1 5 to put the softener back into operation AA s 5 2 so A KFZSD 1 1 5 Manual 01 04 Rev 1 pipe grain thief SR LANUS Riser tube distributor a ssy Softener resin Figure 5 1 Grain thief for resin sampling SAMPLING AND TESTING KFZSD 1 1 5 Manual 01 04 Rev 1 MAINTENANCE 6 1 6 0 MAINTENANCE GENERAL MAINTENANCE GUIDELINES A MAINTENANCE AND SAFETY Before working on this system operators must be familiar with the General Safety Precautions at the beginning of this manual B VESSELS The vessel for this system is fiberglass and requires no maintenance If exposed to freezing temperatures the vessel and its piping must be insulated and heated or shut down and drained C PIPING Operators should check all piping connections periodically for leaks Any flanges used on the piping may require periodic tightening to prevent leaks If the system is operated within the temperature and pressure limits little maintenance is required D MANUAL VALVES Manual
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