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MODEL 2500 & 1500 - Donamarc Water Systems Co.
Contents
1. Sos Injector Body Plastic 1483 Injector Body Brass 102277 Injector Screen Meds 10914 Injector Throat Specify Size 10226555 Injector Throat Stainless Steel Specify Size TOONS Injector Nozzle Specify Size 10225 Injector Nozzle Stainless Steel Specify Size ean Gees 10229 Injector Cover Gasket ee 10228 Injector Cover Brass Body ee ee ee 11893 Injector Cover Plastic Body i gt eee 10692522 Injector Body Screw i ote TITE Flow Control Retainer Screw OAE Flow Control Washer Specify Flow Rate G P M ores Tr koe a Reston ee TABS ane ek ets Seal O Ring 113850 Flow Control Housing EE 11385 03 Flow Control Housing Brass 11385 13 Flow Control Housing Brass Bored Bac ons 10244 Inside Tube O Ring 24 OR 066 125701 Tank O Ring Park NOTE For Flat Cap Backwash Filter Valve Less Items 12 thru 18 17893 Flat Cap shown peers Screw Flat not shown Page 15 Printed in U S A MODEL
2. 2500 amp 1500 Service Manual IMPORTANT Fill in pertinent information on page 2 for future reference MODEL 2500 amp 1500 Job Specification Sheet JOB NO MODEL NO WATER TEST CAPACITY PER UNIT MAX PER REGENERATION MINERAL TANK SIZE DIA HEIGHT BRINE TANK SIZE amp SALT SETTING PER REGENERATION CONTROL VALVE SPECIFICATIONS 1 Type of Timer A 7 day 12 day Regeneration Cycle A Separate Time Fill B Rapid Rinse Regeneration Program Settings see pages 6 amp 7 A Backwash min B Brine amp Slow Rinse min D C Rapid Rinse min Brine Tank Refill min Drain Line Flow Controller gpm Brine Refill Rate Injector Size Page 2 Printed in U S A MODEL 2500 amp 1500 Installation Instructions The water softener should be installed with the inlet outlet and drain connections made in accordance with manufacturer s recommendations and to meet applicable plumbing codes 1 10 11 12 13 Remove control box cover Make Time of Day setting and set Skipper Wheel See time control instructions Observe regeneration cycle settings These are factory preset and need no adjustment Add three inches of water to brine tank NOTE To set the control to the various positions noted below turn the manual regeneration knob slowly in a clockwise direction until the drive mot
3. 10250 Retaining Ring 60050 2500 2750 Drive Assy 10329 3 8 Brass Nut STF 120V 32 eee Micro Switch 2 10332 3 8 Sleeve Peete taste 10250 Retaining Ring 1 11749 B V Stem Guide 10302 Insulator Limit Switch Decne Pipe Bing Brine 10338 Pin Roll 3 32 7 8 eee tee ge 12552 1600 Brine Valve Stem 10621 Link 2500 1 12626 Shut Off Valve Seat 10769 Motor Drive 120V 60HZ 1 12748 Brine Valve Body 10774 Bracket Motor Drive Side 1 12550 Quad Ring 10872 Screw Hex Washer 60080 1600 Injector Assembly 8 32 x 5 16 For Illustration 11667 Wire Harness Drive Motor See Page 12 amp 14 okt 11826 10227 Injector Screen eek 12576 Cam Drive STE 15442 11893 Injector Cam Shut Off Valve Wi 10229 Injector Cover Gasket 1 ea 13366 Bearing Drive 2500 ed 10328 90 Elbow 1 4 NPT x 3 8 Tube nese 149232 is Screw Pan HD Mach 4 40 x 1 10692 Screw 17904 Bushing 1 2 10913 Injector Nozzle 60407 Power Head Assy 10914 Injector Throat
4. Drive Gear 20 13887 25 ete coe eas Motor Mounting Plate Th 18743 Motor 120V 60 Hz 19659 Motor 24V 60 Hz ODE Picts te 13278 Screw Motor Mounting 11384 ate Screw Timer Hinge amp Ground Wire 2425 Soh ies cata 1388422 eke aes Hinge Bracket are eta Oot eee 140877 eS Insulator 26 1708966 Switch ees Ay Sv Ph evo 15320 Switch 280 HAI s Screw Switch Mounting 29 T A raaa 14007 Decal Time of Day 14045 Decal Instructions tate We anata Gi beatae ete 13864 Skipper Wheel Ring ak Taste 15066 lt Ball 1 4 in Dia Main Gear Not Shown 1 1390252 Not Shown 2 T2681 ein d Bhatt Wire Connector Not Shown 1 15354 01 Ground Wire Page 17 Printed in U S A 1600 Series Brine System Assembly PARTS LIST No Quantity Part No Description octet at ETET 10328 90 Elbow 1 4 Pipe to 3 8 Tube Ws os etait Brine Line Screen 10332 5 Insert Sleeve 3 8 Tube B
5. f MUU 2 Page 10 Printed in U S A MODEL 2500 amp 1500 Control Valve Drive Assembly Parts List Item No Quantity Part No Description Tsay ase ort 14884 Back Plate Stainless Steel 11209 Back Plate Slant Front not shown UU Asche Es 3200 3000 Timer 7 or 12 Day Sioa ted eera 11838 13547 Strain Relief 11667 Wire Harness N Not Assigned TOB 72 Screw Motor Mounting Bitte Meath Son eho ia aes oh clo alent ae te Not Assigned ck heats Not Assigned TOig TOTTA Bracket Motor Mounting atte ete E 10231 Screw Drive Mounting TA riras beia 10302 22 Aeterna Insulator 1 tats Sot nen 10218 Switch 10909 Connecting Link Pin 10250 5 Retaining Ring 10621 yra VA Bs Connecting Link 12576 Drive Cam STE Black 121027 Drive Cam RR White reas 0338 aha dass Roll Pin tes Ve ey Be ei 133667 sane gd Drive
6. 11893 Screw Flat Page 13 Printed in U S A MODEL 1500 amp 1500 SM Control Valve Assembly See opposite page for parts list mf Page 14 Printed in U S A MODEL 1500 amp 1500 SM Control Valve Assembly Parts List Item No Quantity Part No Description beams peat 107295455 dee aes Valve Body Side Mount 10680 Valve Body Mtg 2 1 2 8 Thd E AE a N End Spacer We eins ve 10757 End Spacer Hot Water 10545 2 2 Seal Ring VA DUS heed alee Silicone Cee rae De tx eves Spacer D gt Rah 16589 Spacer Hot Water Ti tk heel Gee 15168 Piston acs IN cence colts 14309 Piston Rod Retainer T TOGO es Goats Piston Rod Retainer Hot Water 1744529 See Piston Rod ee EUAS 10209 Seal Quad Ring A 10234 2 tant Seal O Ring End Plug 10598 End Plug Assembly 10598 01 End Plug Assembly Hot Water TAA koe dette Injector Body Gasket
7. Bearing 14923 Sat aie Screw Switch Mounting 21 VOLO i Motor 11826 3 Bracket Brine Valve Side E Brine Valve Cam STE Black 108152 tes Brine Valve Cam RR White hak 10300 Screw Timer Mounting not shown TOAT Hole Plug not shown 26 tees conti viel 17904 Hole Plug shown COVER MOUNTING HARDWARE Stainless Steel Back Plate 2 19367 Screw Slant Front Back Plate 4 103002 sent aoe ware Screw Page 11 Printed in U S A MODEL 2500 Control Valve Assembly See opposite page for parts list 23 22 29 20 N S Page 12 Printed in U S A MODEL 2500 Control Valve Assembly Parts List Item No Quantity Part No Description ey dee ee Ty dete eee 11212 ie Valve Body 1076 End Spacer Ta ee 10757B End Spacer Hot Water Sie ee Seal Ring eae es Bos date adits doe Seco Spacer 16589 Spacer Hot Water Boe Soe ed 1 nose ee 19168 weer
8. Piston ede ees 14309 Piston Rod Retainer 16590 Settee hi Piston Rod Retainer Hot Water a 14452 2222255 Piston Rod Ohta a Wa sane 10209 ger See ees Seal Quad Ring dates ered 10209 01 Seal Quad Ring Hot Water Owe es 40078 Seal O Ring End Plug 1 10598 End Plug Assembly eee 10598 01 End Plug Assembly Hot Water Injector Body Gasket Bee Injector Body Plastic 11483 Injector Body Brass Ay oe ee 10227 eee ee Injector Screen pa palate Pata 10914 anda Injector Throat Specify Size Woes Fe ects 10226 eae Seca hs Injector Throat Stainless Steel Specify Size es aca eens 10913 Injector Nozzle Specify Size 10225 eaea Injector Nozzle Stainless Steel Specify Size Wh ner Stee ee 10229 Injector Cover Gasket WEG tax cei 10228 Injector Cover Brass Body 11893 Injector Cover Plastic Body 18 10692 Injector Body Screw 112802 Flow Control Retainer Screw 20 shot 4 Te ped oe PA ee Re e
9. equals brine and rinse time in minutes BRINE amp RINSE PROGRAM SECTION WHEEL FOR 2 MIN PER HOLE CONTROL OF REGENERATION CYCLE STORAGE RAPID RINSE amp BRINE TANK REFILL SECTION 2 MIN PER PIN BACKWASH SECTION 2 MIN PER PIN How To Change The Length Of Rapid Rinse And Brine Tank Fill Time The second group of pins on the program wheel determines the length of time that your water conditioner will rapid rinse and brine tank fill 2 min per pin To change the length of rapid rinse and brine tank fill time add or remove pins at the higher numbered end of this section as required The number of pins times two equals the rapid rinse and brine tank fill time in minutes The regeneration cycle is complete when the outer micro switch drops off the last pin in the rapid rinse and brine tank fill group of pins The program wheel however will continue to rotate until the inner micro switch drops into the notch on the program wheel Return timer to closed position engaging snap retainer in back plate Make certain all electrical wires locate above snap retainer post IMPORTANT SALT LEVEL MUST ALWAYS BE ABOVE WATER LEVEL IN BRINE TANK Page 5 Printed in U S A MODEL 3200 TIMER Regeneration Cycle Program Setting Procedure Brine Tank Refill Separate From Rapid Rinse STF Black Drive Cam and Brine Valve Cam How to Set The Regeneration Cycle Program T
10. 3200 TIMER Timer Assembly See opposite page for parts list Page 16 Printed in U S A MODEL 3200 TIMER Timer Assembly Parts List Item No Quantity Part No Description nets 13870 Timer Housing date eo T3077 ie Stet ea as Cycle Actuator Arm E 40096 24 24 Hour Gear Assembly 12 Midnight 40096 02 24 Hour Gear Assembly 2 a m 13886 01 Knob Lo ee bia 13296 3k Screw Timer Knob and Motor Mtg Plate he eat 11999 ees Button Decal ea ts Sant 14381 Skipper Wheel Assembly 12 Day 14860 bosch tod ng deed Skipper Wheel Assembly 7 Day ore 1304 Sees Regeneration Pointer ees re 14265 52 ERS Spring Clip Spring Skipper Wheel Detent Pay 13300 29 Ball 1 4 in Dia Skipper Wheel 1 hos a 15424 02 3 Spring Main Gear Detent erage set 13911 oo hated es Main Drive Gear i eee Users 19210 here het Program Wheel 15493 Roll Pin feet Ai Share Real bse 13018 Idler Shaft T3392 Spring Idler 8 130177 wasnt Bed Idler Gear TO a ee Tess tear se 18164
11. ANT SALT LEVEL MUST ALWAYS BE ABOVE WATER LEVEL IN BRINE TANK Page 6 Printed in U S A MODEL 2500 amp 1500 Water Conditioner Flow Diagrams 1 SERVICE POSITION Hard water enters unit at valve inlet and flows down thru the mineral in the mineral tank Conditioned water enters center tube thru the bottom distributor then flows up thru the center tube around the piston and out the top outlet of the valve BRINE TANK BRINE VALVE FLOW CONTROL MINERAL TANK BRINE VALVE FLOW CONTROL Hard water enters unit at valve inlet flows thru piston down center tube thru bottom distributor and up thru the mineral around the piston and out the drain line 3 BRINE VALVE FLOW CONTROL Hard water enters unit at valve inlet flows up into injector housing and down thru nozzle and orifice to draw brine from the brine tank brine flows down thru mineral and enters the center tube thru bottom distributor flows up thru center tube around the piston and out thru the drain line Page 7 Printed in U S A MODEL 2500 amp 1500 Water Conditioner Flow Diagrams 4 SLOW RINSE POSITION BRINE VALVE FLOW CONTROL MINERAL TANK Hard water enters unit at valve inlet flows up into injector housing and down thru nozzle and orifice around the piston down thru mineral enters center tube thru bottom distributor flows up thru center tub
12. Push the tool tight against the spacer and push the button in see Fig 3 When the button is pushed in the pins are pushed out to engage the 1 4 dia holes in the spacer Remove the tool from the valve body The spacer will be on the end Pull the center button back the pins will be retracted and the spacer can be removed from the spacer tool Page 21 Printed in U S A MODEL 2500 amp 1500 Seal and Spacer Replacement Cont d Special Tool To Remove Spacers Special Tool To Replace Spacers And Seals Spacer Removing Spacer From Replacing Spacer Valve Body FIGURE 3 In Valve Body FIGURE 4 9 Alternately remove the remaining seals and spacers in accordance with steps No 6 and 8 10 The last or end spacer does not have any holes for the pins of the spacer tool to engage therefore if the end spacer does not come out on the first try try again using the wire hook with the finger loop 11 To replace seals spacers and end ring use special tool with the brass sleeve on one end This is a double purpose tool See Fig 4 The male end acts as a pilot to hold the spacers as they are pushed into the valve body and the brass female end is used to insert the seals into the valve body 12 To restuff a valve body first take the end ring the plastic or brass ring without holes then with your thumb press the button on the brass sleeve end the large dia inner portion is now exposed See Fig 4 Place the end ring on this pilot
13. See Parts Price List Wao Ae vo wits Injector Body Gasket 60303 XX Timer 3200 7 Day Vis wowed 17776 Injector Body See Parts Price List 60090 60304 XX Timer 3200 12 Day See Page 12 amp 14 See Pans Price 10209 Quad Ring 010 60135 2500 Tere tey 10234 O Ring 024 he she 10598 End Plug Assembly Terenie 10909 Pin Link ye eee 15168 Piston 2500 esd wen 14452 Piston Rod 2500 14309 Retainer Piston Rod 60091 Piston Assembly Hot Water For Illustration See Page 12 amp 14 60121 Seal and Spacer Kit Page 27 Printed in U S A P N 15856 Rev 1 1 99 Printed 7 99
14. ad te 10329 Fitting Nut 3 8 Tube 10330 22 52 2 Delrin Sleeve 3 8 Tube WS ces Brine Valve Tube eel 60002 Air Check Assembly Brea Sen ees 12794 90 Elbow 3 8 Tube to 3 8 Tube Not Supplied Brine Line Tube 3 8 Flexible Tube TO hee uel sitet Wis Jeet a aie haa 0250 Retaining Ring Te ees aati ee 11749 Stem Guide E IEA A Not Assigned ied Sted ele dalla adie a Not Assigned VA et Seatac 10249 Brine Valve Spring A Des che 12550 ise Quad Ring Pe ete act le cats 12748 eee Brine Valve Body 15902 Brine Valve Body 1500SM lA 2552 Ase Brine Valve Stem 8 1262635 2 ck a Brine Valve Seat alan etek 11982 O Ring 12747 Flow Control Fitting an ec Flow Control Label Specify Flow Rate MO he Sf es Flow Control Washer Specify Flow Rate e Sone 12098 Flow Control Retainer These Parts Are Furni
15. e around piston and out thru drain line FOR SEPARATE 6 RAPID RINSE BRINE VALVE FLOW CONTROL me MINERAL TANK 4 Hard water enters unit at valve inlet flows up thru injector housing and thru brine valve to fill brine tank hard water also flows directly from inlet down thru mineral into center tube bottom distributor and up thru center tube around piston and out thru the drain line Page 8 Cont d 5 RAPID RINSE amp BRINE TANK FILL BRINE VALVE FLOW CONTROL ESS MINERAL TANK BRINE TANK Hard water enters unit at valve inlet flows up thru injector housing and thru brine valve to fill brine tank hard water also flows directly from inlet down thru mineral into center tube bottom distributor and up thru center tube around piston and out thru the drain line TIME FILL ONLY 7 BRINE TANK FILL POSITION BRINE VALVE FLOW CONTROL 4 MINERAL TANK Hard water enters unit at valve inlet flows up thru the injector housing thru the brine valve to fill the brine tank Printed in U S A Notes Page 9 Printed in U S A MODEL 2500 amp 1500 Control Valve Drive Assembly See opposite page for parts list eo
16. e ee ES Flow Control Washer Specify Flow Rate in G P M ON cect ae 14783 te wanted ek aye Seal O Ring 22 dell eee 11389 see eee Flow Control Housing 11385 03 Flow Control Housing Brass ean 11385 13 Flow Control Housing Brass Bored 2 12338 ii 1 2 Pipe 1 2 Hose x 90 Drain Fitting Qe bes oP 10244 Josie oe Inside Tube O Ring PBa Vian fined fate ores 11208 Seal O Ring d o ee Ty Aas ead a T1143 ee ee Valve Body Adapter For 2 1 4 16 Thd 12 Valve Body Adapter For 1 2 8 Thd went 11966 20 1 3 1 Distributor Tube Pilot Assembly 13 16 1 14673 Distributor Tube Pilot Assembly 13 16 Hot Water 28 a tase 10207 Tank O Ring For 2 1 4 16 Thd 10361 Tank O Ring For 2 1 2 8 Thd 12570 Tank O Ring Park 29 11224 11206 Fitting Gasket 11205 eerie peed Sede Tube Fitting Special i Big 11207228 ae ei ie Sis Special Nut NOTE For Flat Cap Backwash Filter Valve Less Items 12 thru 18 Ce Tees eee ee
17. he regeneration cycle program on your water conditioner has been factory preset however portions of the cycle or program may be lengthened or shortened in time to suit local conditions To expose cycle program wheel grasp timer in upper left hand corner and pull releasing snap retainer and swinging timer to the right To change the regeneration cycle program the program wheel must be removed Grasp program wheel and squeeze protruding lugs towards center lift program wheel off timer Switch arms may require movement to facilitate removal How To Change The Length Of The Backwash Time The program wheel as shown in the drawing is in the service position As you look at the numbered side of the program wheel the group of pins starting at zero deter mines the length of time your unit will backwash FOR EXAMPLE If there are six pins in this section the time of backwash will be 12 min 2 min per pin To change the length of backwash time add or remove pins as required The number of pins times two equals the backwash time in minutes Note Do not add pins before 0 minutes designation How To Change The Length Of Brine And Rinse Time The group of holes between the last pin in the backwash section and the second group of pins determines the length of time that your unit will brine and rinse 2 min per hole To change the length of brine and rinse time move the rapid rinse group of pins to give more or fewer h
18. iston Check salt usage and salt setting See problem no 7 Clean line to water conditioner Clean control and add mineral cleaner to mineral bed Increase frequency of regeneration Remove piston and clean control Assure that well system has proper air eliminator control Check for dry well condition Check backwash brine draw and brine tank fill Increase frequency of regeneration Increase backwash time Page 19 MODEL 2500 amp 1500 Service Instructions Cont d PROBLEM 7 Excessive water in brine tank 8 Softener fails to draw brine 9 Control cycles continuously 10 Drain flows continuously Page 20 00D gt gt CAUSE Plugged drain line flow control Plugged injector system Timer not cycling Foreign material in brine valve Foreign material in brine line flow control Drain line flow control is plugged Injector is plugged Injector screen plugged Line pressure is too low Internal control leak Broken or shorted switch Valve is not programing correctly Foreign material in control Internal control leak Printed in U S A gt moO WB gt CORRECTION Clean flow control Clean injector and screen Replace timer Replace brine valve seat and clean valve Clean brine line flow control Clean drain line flow control Clean injector Clean screen Increase line pressure to 20 5 1 Change seals s
19. n factory preset however portions of the cycle or program may be lengthened or shortened in time to suit local conditions To expose cycle program wheel grasp timer in upper left hand corner and pull releasing snap retainer and swinging timer to the right To change the regeneration cycle program the program wheel must be removed Grasp program wheel and squeeze protruding lugs towards center lift program wheel off timer Switch arms may require movement to facilitate removal How To Change The Length Of The Backwash Time The program wheel as shown in the drawing is in the service position As you look at the numbered side of the program wheel the group of pins starting at zero deter mines the length of time your unit will backwash FOR EXAMPLE If there are six pins in this section the time of backwash will be 12 min 2 min per pin To change the length of backwash time add or remove pins as required The number of pins times two equals the backwash time in minutes Note Do not add pins before 0 minutes designation How To Change The Length Of Brine And Rinse Time The group of holes between the last pin in the backwash section and the second group of pins determines the length of time that your unit will brine and rinse 2 min per hole To change the length of brine and rinse time move the rapid rinse group of pins to give more or fewer holes in the brine and rinse section Number of holes times two
20. obtain the desired regeneration schedule How To Set The Time Of Day Press and hold the red button in to disengage the drive gear Turn the large gear until the actual time of day is at the time of day pointer Release the red button to again engage the drive gear How To Manually Regenerate Your Water Conditioner At Any Time Turn the manual regeneration knob clockwise This slight movement of the manual regeneration knob engages the program wheel and starts the regeneration program The black center knob will make one revolution in the following approximately three hours and stop in the position shown in the drawing Even though it takes three hours for this center knob to complete one revolution the regeneration cycle of your unit might be set only one half of this time In any event conditioned water may be drawn after rinse water stops flowing from the water conditioner drain line SERVICE POSITION 24 HR GEAR INDICATOR MANUAL REGENERATION KNOB TO SET TIME OF DAY BUTTON AND TURN L RO RED TIME SKIPPER WHEEL SET BUTTON SHOWS EVERY OTHER DAY REGENERATION IMPORTANT SALT LEVEL MUST ALWAYS BE ABOVE WATER LEVEL IN BRINE TANK Page 4 Printed in U S A MODEL 3200 TIMER Regeneration Cycle Program Setting Procedure Rapid Rinse White Drive Cam and Brine Valve Cam How to Set The Regeneration Cycle Program The regeneration cycle program on your water conditioner has bee
21. old the back plate with one hand and guide the piston into the valve body with the other hand then grasp the back plate on both sides and slowly push the piston assembly and end plug assembly into the valve See Fig 1 Replace the two capscews to hold the back plate to the valve and tighten securely Connect the brine line from the injector housing to the brine valve if your unit has timed brine tank fill Set the time of day dial to the correct time Replace the electrical plug in the outlet Turn on water supply Cycle control and check for proper function Check by pass valve Page 23 Printed in U S A 2500 amp 1500 Piston Assembly Replacement On fF WO DP 11 12 13 14 15 16 17 18 19 LINE TO BRINE VALVE PISTON ASSEMBLY END PLUG PISTON ROD 2 3 Ze lt lt SPECIAL SPRING ROLL PIN CAPSCREWS Turn off water supply to the valve and relieve water pressure Cycle the valve until the piston is in the service position piston rod all the way out Remove electrical plug from outlet Remove two capscrews holding back plate to valve Disconnect brine line from injector housing to brine valve at the brine valve if your unit has timed brine tank fill Grasp the back plate on both sides and slowly pull end plug and piston assembly out of the valve body Pull out the roll or special spring pin that connects the piston rod to the c
22. oles in the brine and rinse section Number of holes times two equals brine and rinse time in minutes How To Change The Length Of Rapid Rinse The second group of pins on the program wheel determines the length of time that your water conditioner will rapid rinse 2 min per pin BRINE amp RINSE PROGRAM SECTION WHEEL FOR 2 MIN PER HOLE CONTROL OF REGENERATION CYCLE RAPID RINSE SECTION 2 MIN PER PIN BRINE TANK REFILL SECTION 2 MIN PER HOLE BACKWASH SECTION 2 MIN PER PIN To change the length of rapid rinse time add or remove pins at the higher numbered end of this section as required The number of pins times two equals the rapid rinse time in minutes How To Change The Length Of Brine Tank Refill Time The second group of holes on the program wheel deter mines the length of time that your water conditioner will refill the brine tank 2 min per hole To change the length of refill time move the two pins at the end of the second group of holes as required The regeneration cycle is complete when the outer micro switch is tripped by the two pin set at end of the brine tank refill section The program wheel however will continue to rotate until the inner micro switch drops into the notch on the program wheel Return timer to closed position engaging snap retainer in back plate Make certain all electrical wires locate above snap retainer post IMPORT
23. onnecting link and remove the complete end plug and piston assembly Take the new piston assembly as furnished pass thru the back plate and motor support and fasten piston rod to the connecting link with special spring pin Inspect the inside of the valve to make sure that all seals and spacers are in place 10 Spread or spray silicone lubricant on the piston and on the seals inside the valve body While holding the back plate on the side with one hand start the piston into the valve by guiding it with the other hand Then grasp the back plate on both sides and slowly push the piston and then the end plug into the valve Replace the two valve body capscrews and tighten Connect the brine line to the brine valve if used Place electrical plug in outlet Set time of day Turn on water supply Cycle control and check for proper function Make sure that valve is in service position piston rod all the way out Check by pass valve Page 24 Printed in U S A MODEL 2500 amp 1500 Typical Top Mounting Installation MANUAL SHUTOFF TYPICAL CONTROL VALVE INFORMATION Slow Rinse Brine Draw Tank Size Rate gpm Rate SPM Dia Injector 40 PSI 40 PSI D L F C 6 0 Red 31 28 1 2 gom 7 0 31 gpm 28 1 2 8 1 5 9 2 0 10 2 4 12 3 5 13 Blue 4 0 14 5 0 16 Yellow 7 0 gpm Note Due to
24. or runs and positions the valve drive shaft located in the lower center of the control box Control Valve Positions see pages 8 and 9 Service Drive shaft out Backwash Drive shaft in Brine and Rinse Drive shaft 1 2 way out Brine Tank Fill Drive shaft out but brine cam holds brine valve stem in Run water through softener with control in service position for at least three 3 minutes to settle bed Position valve to backwash and check to make sure that drain line flow remains steady for ten 10 minutes Position valve to brine tank fill and check to see if tank is filling Position valve to brine position and check suction Position valve to start of brine tank fill cycle Brine valve drive cam will hold valve in at this position to fill the brine tank for the first regeneration Replace control box cover Check power cord connection Note Make sure control is plugged into a non interrupted electrical circuit Put salt in brine tank Do not use granulated salt Page 3 Printed in U S A MODEL 3200 TIMER Timer Setting Procedure How To Set Days On Which Water Conditioner Is To Regenerate Rotate the skipper wheel until the number 1 is at the red pointer Set the days that regeneration is to occur by sliding tabs on the skipper wheel outward to expose trip fingers Each tab is one day Finger at red pointer is tonight Moving clockwise from the red pointer extend or retract fingers to
25. pacers and piston assembly Determine if switch or timer is faulty and replace it or replace complete power head Check timer program and positioning of control Replace power head assembly if not positioning properly Remove power head assembly and inspect bore remove foreign material and check control in various regeneration positions Replace seals and piston assembly MODEL 2500 amp 1500 Seal and Spacer Replacement 1 Remove electrical plug from outlet turn off water supply to valve and relieve water pressure 2 Remove control box cover 3 Disconnect the brine line from the injector housing to the brine valve if your unit has timed brine tank fill 4 Remove the two capscrews that hold the back plate to the valve 5 Grasp the back plate on both sides and slowly pull end plug and piston assembly out of the valve body See Fig 1 and lay aside Line To Brine Valve Back Plate Piston Wire Hook Remove Seals Removing Power Head Removing Seal From And Piston Assembly FIGURE 1 Valve Body FIGURE 2 6 Remove the seal first using the wire hook with the finger loop see Fig 2 7 The spacer tool use only for removing the spacers has three retractable pins retained by a rubber ring at one end they are retracted or pushed out by pulling or pushing the center button on the opposite end 8 Insert the pin end of the spacer tool into the valve body with the pins retracted button pulled back
26. shed Assembled Together As A Brine Line Flow Control BLFC Page 18 Printed in U S A MODEL 2500 amp 1500 Service Instructions PROBLEM 1 Softener fails to regenerate 2 Hard water 3 Unit used too much salt 4 Loss of water pressure 5 Loss of mineral through drain line 6 Iron in conditioned water gt CAUSE Electrical service to unit has been interrupted Timer is defective Power Failure By pass valve is open No Salt in Brine Tank Injector screen plugged Insufficient water flowing into brine tank Hot water tank hardness Leak at distributor tube Internal valve leak Improper salt setting Excessive water in brine Tank Iron buildup in line to water conditioner Iron buildup in water conditioner Inlet of control plugged due to foreign material broken loose from pipes by recent work done on plumbing system Air in water system Fouled mineral bed Printed in U S A CORRECTION Assure permanent electrical service check fuse plug pull chain or switch Replace timer Reset Time of Day Close by pass valve Add salt to brine tank and maintain salt level above water level Clean injector screen Check brine tank fill time and clean brine line flow control if plugged Repeated flushing of the hot water tank is required Make sure distributor tube is not cracked Check O Ring and tube pilot Replace seals and spacers and or p
27. varying water conditions tank sizes water pressures the above settings should be used only as a guideline 1B L F C Brine Line Flow Control Refill Rate for Filling Brine Tank D L F C Drain Line Flow Control Backwash and Rapid Rinse Flow Rates Page 25 Printed in U S A MODEL 2500 amp 1500 Wiring Diagram for Valve Drive Motor and Timer VALVE MOTOR TIMER MOTOR i PROGRAM WHEEL PROGRAM WITCH DRIVE SWITCH 3 53 BLUE RED SERVICE CAM RAPID RINSE SWITCH SERVICE Ss gt RAPID RINSE SERVICE TIA FILL 0 BRINE amp RINSE E RINSE lt DRIVE _ BACKWASH 7 BACKWASH ae BLACK 2 BLACK m am m M e BLUE PROGRAM SWITCH iiil PLUG 12 V A C 60 CYCLE WHITE Page 26 Printed in U S A MODEL 2500 amp 1500 Service Assemblies 60020 25 BLFC 25 GPM 10545 01 Seal Piston 60020 50 50 10757 a 60020 100 BLFC 1 0 GPM Bese 11451 arse Spacer 12 Hole For Illustration See Page 20 60122 Seal and Spacer Kit Hot Water 60029 1600 Brine Valve 6 10545 Seal Piston Hot Water For Illustration See Page 20 10757B End Spacer Hot Water 10249 Brine Valve Spring ED isa Spacer Hot Water
28. with the lip on the end ring facing the tool and push the tool into the valve body bore until it bottoms While the tool is in the valve body take a seal and press it into the inside diameter of the exposed brass female end See Fig 5 13 Remove the tool turn it end for end and insert it into the valve body bore While holding the large dia of the tool slide it all the way into the valve body bore until it bottoms then push the center button to push the seal out of the tool and leave it in place in the valve body See Fig 6 14 Remove the tool from the valve body and push the center on the brass female end to expose the pilot on the opposite end Place a spacer on this end and insert the spacer and tool into the valve Page 22 Printed in U S A 2500 amp 1500 Seal and Spacer Replacement Cont d Special Tool Placing Seal In Brass Sleeve Removing Special Tool From Valve Of Special Tool FIGURE 5 Body After Inserting Seal FIGURE 6 15 16 17 18 19 20 21 22 23 24 25 26 While the tool is still in the valve press another seal into the inside diameter of the exposed brass sleeve end Remove the tool turn it end for end and insert it into the valve body bore Alternately repeat steps No 13 and 14 until all seals and spacers have been pushed into the valve See valve cross section of your valve Place silicone lubricant on the piston and inside the valve H
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