SERVICE MANUAL - Softenerparts.com
Contents
1. See Symptom Cause 1 See Symptom Cause 4 Retest the water Verify that the distributor tube is seated correctly and is not cracked Verify that the distributor tube is seated correctly and is not cracked Verify the backwash flow Clean or replace the drain plunger assembly Follow the procedure detailed in the Parts Replacement section of this manual Replace the clock motor Follow the procedure detailed in the Parts Replacement section of this manual Verify backwash flow rate and or backwash more frequently Replace the basket and verify that the distributor is cut 1 2 inch below the top of the tank threads Parts Replacement General Information Familiarize yourself with the parts replacement procedures and component parts thoroughly before attempting any repair Insure that the unit is in the bypass position and relieve the system pressure before attempting any repair procedure WARNING Disconnect all electrical power to the unit before attempting any repair procedure Required Tools The following tools are required to perform routine maintenance on this control valve Phillips Screwdriver Needle Nose Pliers Adjustable Wrench Small Standard Screwdriver Timer Head Replacement Te Disconnect all electrical power to the control 2 Place the bypass valve into the bypass position 3 Remove the front dust cover from the timer assembly 4 Relieve the system pressure 5 Remove the four 42. The timing mark furthest from the set screw will provide 22 minutes of backwash Note The alignment mark must be located on or between the black timing marks 4 Tighten set screw and install dust cover ELECTROMECHANICAL POWER HEAD PARTS LIST ITEM P N DESCRIPTION QTY dE 15 76 Screw t Ze 529 309 Time Dial 1 3 525 303 Spring Washer Small 1 4 52 308 Locating Dial 1 5A 529 232 1 Gear Time of Day 12 Day 1 5B 529 232 2 Gear Time of Day 7 Day 1 6 19 3 C clip 1 U 529 218 Actuator 1 8 529 212 Spindle Actuator 1 9 529 333 1 Housing Power Head 1 10 15 185 10 Screw Day Selector Wheel 1 11A 525 274 1 Washer Day Indicator 12 Day 1 11B 525 274 2 Washer Day Indicator 7 Day 1 12A 525 241 2 Day Selector Wheel 12 Day 1 12B 525 241 4 Day Selector Wheel 7 Day 1 13 525 205 Spring Washer Large 1 14 15 87 Screw Head Mount 4 15 529 245 Cycle Cam amp Knob Assembly 1 16 529 219 3 Drain Plunger Assembly 1 17 401 7 Return Spring Drain Plunger 1 18 185 0221 1 O ring Plunger Cap 1 19 529 286 Plunger Cap 1 20 529 280 Retainer Drain Plunger 1 1 15 92 2 Screw Retainer it 22 15 76 Screw Timer Motor 2 23 30 77 _ Timer Motor 1 24 516 221 Return Spring Main Diaphragm 1 25 15 185 10 Screw Ratchet 1 26 14 11 Washer Ratchet 1 et 525 260 Ratchet 1 28A 525 254 2 Gear Ratchet 12 Day 1 28B 525 254 5 Gear Ratchet 7 Day 1 29 529 234 _ Front Cover 1 30A 529 220 1 Rear Cover Gray 1 30B 529 220
3. assembly
4. 2 F Rear Cover White 1 31 28 8 28 Strain Relief 1 32 28 142 2 Power Cord 120 Volt 1 Indicate Voltage Indicate Opaque or Clear VALVE BODY PARTS LIST ITEM P N DESCRIPTION its 15 88 Screw Backcap 541 207 Backcap 3 Cycle 3 541 206 Seal Backcap 4 541 325 Gasket Injector 5 428 _ Injector Specify Size 6 541 221 Cover Plate Injector T 15 89 Screw Injector Mount 8 413 13 Filter Screen Injector 9 541 254 Spring Clip 10 186 111 N O Ring Plug T 541 273 Plug 12 19 19 C Clip Backwash Flow Adjuster 13 541 243 Backwash Flow Adjuster w o rings 14 529 244 Gasket Cross Over Port 15 541 244 Body Stem Assembly 16 185 024 1 O Ring Small Seat Insert 17 541 204 Seat Insert 18 185 028 12 O Ring Large Seat Insert 19 541 256 Main Diaphragm 20 19 3 C Clip Main Diaphragm Zt 516 221 Return Spring Main Diaphragm 22 19 90 Screw Adapter Ring 23A 185 231 1 O Ring Structural Tank 23B 186 105 O Ring Park Tank 24 541 232 Adapter Ring 25A 185 211 1 O Ring 13 16 Riser Adapter 25B 185 214 1 O Ring 1 050 Riser Adapter 26A 541 205 13 16 Riser Adapter 26B 541 218 1 050 Riser Adapter ake 185 029 1 O Ring Outside Riser Adapter 28 541 257 1 Valve Body amp Seal nn AS AS B Troubleshooting Guide ds Symptom Cause Unit Fails To Cycle A Faulty electrical circuit B Defective clock motor C Low inlet pressure D Drain line is restricted E A
5. adjusted between 14 to 22 minutes Factory Default Setting The factory default cycle setting is preset into the control valve MODEL 2 Cycle Backwash 14 Minutes Set Time of Regeneration 1 Remove the front dust cover from the timer assembly 2 Rotate the Time of Regeneration plate A until the desired time appears in the window Note A M or P M Set Time of Day 1 Remove the front dust cover from the timer assembly 2 Turn the Timer Knob B until the alignment mark located on the Time Of Day Gear C points directly to the correct time of day Note A M or P M Set Backwash Frequency 1 Remove the front dust cover from the timer assembly 2 Pull all skipper wheel tabs up 3 Rotate skipper wheel D until the number one tab aligns with the DAY mark E 4 Starting with the number one tab push down the tabs to determine the days on which regeneration is required Backwash Cycle Settings Adjusting the backwash cycle can be accessed according to the following procedure A Loosen the screw located on top of the timer cover remove front dust cover from timer assembly 2 Turn timer knob B until set screw on the time cam is visible On the upper timing cam two 2 black timing marks will appear 3 Loosen the set screw and position the alignment mark F located on the lower cam on or between the timing marks The timing mark closest to the set screw will provide 14 minutes of backwash
6. head mounting screws 6 Lift the timer assembly away from the valve body Follow these step in reverse to reinstall the timer assembly Note Prior to re installment insure the main return spring is centered over the main diaphragm Timer Motor Replacement Y Disconnect all electrical power to the control 2 Remove both the front dust cover and rear timer cover 3 Disconnect the two 2 wire nuts from the timer motor leads 4 Remove the two 2 motor mount screws 5 Lift the motor away from the timer assembly Follow these steps in reverse to re install the timer motor Main Diaphragm Replacement 1 Disconnect all electrical power to the control 2 Place the bypass valve into the bypass position 3 Remove the front dust cover from the timer assembly 4 Relieve the system pressure 5 Remove the four 4 head mounting screws 6 Lift the timer assembly away from the valve body 7 Remove the c clip from the center of the diaphragm 8 Lift the diaphragm away from the body stem assembly 9 Follow these steps in reverse to re install the main diaphragm Note Prior to re installment insure the main return spring is centered over the main diaphragm and the outside edges of the main diaphragm are tucked into the valve body Drain Plunger Replacement 1 Disconnect all electrical power to the control 2 Place the bypass valve into the bypass position 3 Remove the front
7. 542 009 VALVE SERVICE MANUAL Assembly 1 Cut the top of the distributor tube 1 2 inch below the top of the resin tank threads Chamfer the top of the tube to prepare it for insertion into the control valve Verify that the control is equipped with the proper voltage tank o ring and injector Install the control valve onto the distributor tube Grip the_control valve body and turn control into the resin tank installation General Information 4 5 When facing the front of the control the inlet is to the right and the outlet is to the left The system pressure must be between 20 psi and 120 psi If the system pressure is greater than 120 psi a pressure reducing valve must be installed The unit must be installed in accordance with local codes Do not over tighten connections Drain Line Connection 3 The drain line 1 D must be at least 1 2 inch a Teflon tape should be used when installing the drain fitting into the control valve The drain line must be free of kinks Fitting Kit Connection i DO NOT use Teflon tape when connecting the fitting kits to the control valve If the fitting kit provides a sweat connection care must be taken to prevent the Noryl nut from melting Place a wet rag over the copper tube and the Noryl nut prior to heating the tube Start Up Insure that the bypass is secured in the bypass position Verify that the control valve is in the s
8. dust cover from the timer assembly 4 Relieve the system 5 Remove the retainer screw located below the Time Of Day gear 6 Lift the retainer down and away from the timer assembly 7 Press down on the drain plunger to remove it from the valve body 8 Inspect the plunger o rings and center cup for wear 9 Clean out the plunger orifice in valve body 10 Use a Dow 111 Silicone based lubricant to lightly lubricate the plunger o rings and the valve body orifice 11 Follow these steps in reverse to re install drain plunger Backwash Adjustment Valve Replacement t 2 oN p o 10 11 12 Place the bypass valve into the bypass position Relieve the system pressure Remove the four 4 head mounting screws Lift the timer assembly away from the valve body Remove the c clip from the center of the diaphragm Lift the diaphragm away from the body stem assembly Remove the seat assembly Disconnect the large c clip located on top of the backwash adjustment valve Press the backwash adjustment valve down and out through the valve body assembly Inspect the o rings on the valve for wear Clean or replace the valve assembly if necessary Lightly lubricate the o rings with a Dow 111 Silicone based lubricant Follow these steps in reverse to re install the backwash adjustment valve Riser Replacement Ma ro N E Mo Ber 11 Disconnect all electrical power to the control Place the by
9. ervice position Open all plumbing connections to allow the free flow of water to the unit Slowly shift the bypass valve to the service position Allow the water to completely fill the resin tank Open a tap and allow the water to run until all of the air is removed from the system Once all of the air is removed close the tap Manually advance the control valve to the backwash position and allow water to flow to drain Manually return the control valve back to the service position Cycle Flow Diagrams CONTROL INLET VALVE SERVICE The service cycle position directs untreated water to flow down through the filter media in the mineral tank and up through the riser tube The water is conditioned when passing through the media Kk BRINE LEVEL BACKWASH The backwash cycle position directs water to flow down through the riser tube and up through the filter media and to drain Foreign material and media fines are flushed from the mineral tank during this cycle to prepare the media for filtering Programming General Information The control valve is designed to initiate regeneration according to pre set factory parameters Following the instructions contained in this section will allow the installer to customize the program for the users exact needs The backwash cycle time is controlled by the time cam located on the front of the timer assembly The backwash cycle length can be
10. ll skipper tabs in the out position F Main diaphragm is torn G Timer Knob out of alignment with Time Gear H Body stem assembly worn Unconditioned Water To Service The bypass valve is open or faulty Excessive water usage Unit not cycling Loss of filter media Change in raw water Leak at the distributor tube nmponn Loss Of Resin A Leak at the distributor tube B Backwash control improperly adjusted Continuous Flow To Drain A Drain plunger stuck open B Clock motor stalled Loss Of Water Pressure A Media Bed Fouled B Lower distributor basket crushed Solution Verify electrical service fuse circuit breaker light switch pull chain power cord Replace the clock motor Follow the procedure outlined in the Parts Replacement section of this manual C Verify that the service inlet pressure is a mnmoon gt minimum of 20 psi Insure that the drain line is free of kinks Cycle the control to backwash and verify flow rate Push desired number of skipper tabs to the in position Replace the diaphragm Follow the procedure detailed in the Parts Replacement section of this manual Realign the Knob and Gear Follow the procedure outlined in the Parts Replacement section of this manual Replace body stem assembly Follow the procedure detailed in the Parts Replacement section of this manual Close the bypass valve Check regeneration frequency
11. pass valve into the bypass position Relieve the system pressure Disconnect the unit from the bypass connections Remove the unit from the resin tank Turn out the upper distributor basket from the unit adapter ring Remove the two 2 adapter hold down screws and lift away the adapter ring Separate the riser assembly from the valve body Clean the riser o rings and wipe out the valve body cavity Use a Dow 111 Silicone based lubricant to lightly lubricate the riser o rings and the valve body cavity Follow these steps in reverse to re install the riser assembly Body Stem Assembly Replacement i Disconnect all electrical power to the control Place the bypass valve into the bypass position Remove the front dust cover from the timer assembly 10 14 15 en Relieve the system pressure Remove the four 4 head mounting screws Lift the timer assembly away from the valve body Remove the c clip from the center of the diaphragm Lift the diaphragm away from the body stem assembly Remove the seat assembly Lift out the body stem assembly Inspect the center check disc rubber seal for wear Clean or replace if necessary Re install the body stem assembly Lightly lubricate the seat assembly o rings with a Dow 111 Silicone based lubricant Re install the seat assembly insure that one of the two 2 flats is facing towards the top of the valve body Re install main diaphragm and timer
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