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AS0922MP-CL Serial No

1. 7 When all the air is purged from the tank water begins to flow steadily from the drain slowly open the main supply valve all the way Allow the water to run into the drain until the water appears clear Turn off the water supply and wait for a few minutes to allow all trapped air to escape from the tank Then open the inlet valve bypass inlet slowly and allow the backwash to time down 8 Press the regen button and allow valve to position into the draw cycle Once the valve is positioned and display registering a time down then again press regen and allow to advance to rinse Once again when display starts to count down press regen button 9 Display will register a small backwash time and then move down to fill 10 Allow to fill the brine compartment Check that water is slowly flowing into the brine well by lifting up the brine well cap 11 Allow to time out and note water level in brine compartment The compartment should have been prior filled with salt The valve will then go back into the service mode AS0922MP CL Allow the salt to dissolve in the brine compartment for at least 30 minutes Itis recommended to give a new softener a complete regeneration before placing fully into service Press and hold the regen button until the display starts to blink and go into the backwash mode Allow to count down to the draw mode When the valve is in this mode and counting down ch
2. Water Conditioner Regeneration 20 Automatic Regeneration Manual Regeneration Care of Your Water Conditioner 20 General Cleaning the Injector Injector Screen Maintaining the Drain Line Brine Line and Brine Tank Overflow Connection 21 Placing Softener into Operation 22 Valve Manual 6 assa Ese dd adi s agenda dii ae 23 25 Replacement ede noo horno a anna aba rage 26 38 Service InstruCTiO DS ioo oe ean ee eua uo euge eu vMe prex 39 46 Troubleshooting ovaa aaa aa aaa aja asa a aoc aao oen arua neus aida nx 47 49 Alarms Troubleshooting Procedures Glossary of Terms aaa avau dada aja kajaka aka aka da daa kaaa 50 Safety Caution Warning The plug in transformer for this Never attempt o work on this control while equipment is rated for indoor use standing in or near water without only disconnecting electrical power to the control AS0922MP CL Page 15 Introduction The Model E1 Control provides sophisticated demand based water conditioning by incorporating a microprocessor and a water meter to electronically monitor the amount of water used daily The control is factory programmed to regenerate when the volume throughput setting is reached at a present delayed time of 2am It is rec
3. Remai ingM M Days Backwash Draw Rinse Fill be TA TV Rerrainirg M Hor Days se Bakwas Draw x 1000 Rinse Regen RemaningM M Days Set Backwash Tntal gg Draw X 1000 Rinse Regen Fill Hour M Days wm Backwash X 1000 Rinsc Regen Fill NEXT M REGEN M Hour M Days Tima Sel Backwash Total Draw x 1000 c 1 Rise Regen Fit V REGEN Rerraining M Hour M Days imc Daw Rnse Fil Total X 1000 Regen LEAN AS0922MP CL General Display When the system is operating one of four displays may be shown Pressing NEXT will alternate between the displays shown below User 1 Shows volume remaining to regeneration User 3 Displays flow rate M hour User 4 Displays total flow in cubic metres since last reset Can be used to estimate average daily usage PRESS DOWN ARROW FOR 3 SECONDS TO RESENT TO ZERO User 5 Shows current time Setting Time of Day Push NEXT button until time of day screen is displayed Press and hold the V or A arrow until the correct hour is displayed Then press NEXT button The minutes will flash Press the or V arrow until correct minute is displayed Press the NEXT button to return to the display screens If the NEXT button is not pressed hours or minutes will flash for five minutes before ret
4. Failure to do this could cause interior damage to the drain line flow control fitting When assembling the installation fitting package inlet and outlet connect the fitting to the plumbing system first and then attach the nut split ring and o ring Heat from soldering or solvent cements may damage the nut split ring and o ring Solder joints should be cool and solvent cements should be set before installing the nut split ring or o ring Avoid getting primer and solvent cement on any part of the o rings bypass valve or control valve Position the softener within 1 1 metres of a 10 amp GPO The transformer is connected into the plug socket on the back of the valve control panel Do not Page 17 drop the transformer or have the cable too taut The transformer is only suitable for internal use only For full understanding of the water softener we recommend that the instruction manual be fully read before installation and commissioning of the softener by undertaken IMPORTANT A NUMBER OF VALVE COMPONENTS ARE LOCKED INTO POSITION WITH EASILY REMOVABLE CLIPS ENSURE ALL LOCKING CLIPS ARE CORRECTLY IN POSITION BEFORE PRESSURISING THE SOFTENER ENSURE THAT IT IS POINTED OUT TO ALL RELEVANT PERSONNEL THAT THE LOCKING CLIPS MUST NOT BE REMOVED WHILST THE SYSTEM IS UNDER WATER PRESSURE Note All electrical connections must be connected according to local codes Install grounding strap on metal plates Bypass Valve The by
5. Incorrect backwash controller a Contact dealer excessively low or high b Foreign matter affecting controller b Remove backwash controller Clean amp rate operation replace 11 Flowing or dripping water a Internal valve malfunction a Contact dealer at drain line after regeneration AS0922MP CL Page 53 Microprocessor Troubleshooting Procedures Problem Possible Cause Solution a AC Adapter unplugged a Connect power 1 Timer does not display time b No electric power at outlet b Repair outlet or use working outlet of day c Defective AC adapter c Replace AC adapter d Defective PC board d Replace PC board a Switched outlet a Use uninterrupted outlet 2 Timer does not display correct b Power Outage b Reset time of day time of day c Defective PC board c Replace PC board a Bypass valve in bypass position a Put bypass valve in service position 3 No softening filtering display b Meter connection disconnected b Connect meter to PC board when water is flowing c Restricted stalled meter turbine c Remove meter and check for rotation or foreign material d Defective meter d Replace meter e Defective PC board e Replace PC board a power outages a Reset control valve to correct time of 4 Control valve regenerates day at wrong time of day b Time of day not set correctly b Reset to correct time of day c Time of regeneration incorrect c Reset re
6. 0 95 1021pm Volume Range 0 500 250 0 m Totaliser 0 001 9 999 000 gt DIMENSIONS amp WEIGHT Distributor Pilot 1 050 OD Pipe 3 4 NPS Drain Line 3 4 20mm Hose Tail Brine Line 3 8 OD Poly Tube Mounting Base 2 12 8 NPSM Height from Top of Tank 7 3 8 187mm Weight 4 5lbs 2kg Distributor Pilot 12mm Above Tank Top ELECTRICAL SPECIFICATIONS AC Adaptor Supply Voltage 230V AC Supply Frequency 50 Hz Output Voltage 12 16 V AC Output Current 500 mA CYCLES OF OPERATION Range times minutes Factory Set Backwash 1 upflow 1 20 12 Regenerate draw slow rinse downflow 1 99 70 Backwash 2 4 upflow 1 20 or OFF OFF Fast Rinse downflow 1 20 or OFF 10 Regenerant Refill in service with treated water 0 1 99 9 9 Service downflow Noryl is a trademark of General Electric AS0922MP CL Page 12 Table of Contents SPOCHICATIONS MR 10 IntrodU cliOn ea ik ova daza sawed cede ERE e ERRORES RE 12 Special Features General Conditioner Information How Your Conditioner Works Model E1 Control Front Panel Installation important installation details Bypass Valve em Screen Display Information and Programming Instructions 17 19 General Display Status Regeneration and Error Display Status Basic Button Function
7. 2am The control valve is compatible with a variety of resin cleaners The control valve is capable of routing the flow of water in the necessary paths to regenerate water treatment systems The injector regulates the flow of brine The control valve regulates the flow rates for backwashing rinsing and the replenishing of treated water into a regenerant tank The control valve uses no traditional fasteners e g screws instead clips threaded caps nuts and snap type latches are used Caps and nuts only need to be firmly hand tightened because radial seals are used Tools required to service the valve include one small blade screw driver one large blade screw driver pliers and a pair of hands A plastic wrench is available which eliminates the need for screwdrivers and pliers Disassembly for servicing takes much less time than comparable products currently on the market Control valve installation is made easy because the distributor tube can be cut 12 7mm 2 above to 12 7 mm below the top of tank thread The distributor tube is held in place by an o ring seal and the control valve also has a bayonet lock feature for upper distributor baskets The AC adapter power pack comes with a 2 0 meter power cord and is designed for use with the control valve The AC adapter power pack is for dry location use only e Solid state microprocessor with easy access front panel settings Front panel display for time of day volume r
8. AS0922MP CL Page 54 9 Time of day flashes on and off the valve a Power has been out more than two hours the AC adapter was unplugged and then plugged back into the wall outlet the AC adapter plug was unplugged and then plugged back into the board or the NEXT and REGEN buttons were pressed to reset a Reset the time of day Glossary of Terms Alarms Display errors alert you to operating conditions requiring attention The display shows the type of error Refer to the Alarms section in this manual for additional information Backwash An upward flow of water which expands the resin bed to remove foreign particles Brine The salt solution which regenerates the conditioner s resin bed Brine Draw The process of drawing the brine solution from the salt storage tank into the resin tank Fast Rinse Purge A flow of water through the resin bed which propels any remaining brine solution out of the resin tank to the drain AS0922MP CL Hardness A common quality of water containing dissolved calcium magnesium and other elements Water hardness is usually expressed milligrams per litre as calcium carbonate equivalent Manual Regeneration Forces the control to regenerate by pressing the REGEN button Regeneration Includes the backwash brine draw and fresh water rinse steps necessary to prepare the resin bed for conditioning after exhaustion Regeneration Indicator The disp
9. Injector Unscrew the injector cap and lift off Loosen cap with special wrench or pliers if necessary Attached to the injector cap is a screen Remove the screen and clean if fouled The injector can be pried out with a small screwdriver The injector consists of a throat and a nozzle Chemically clean the injector with vinegar The holes can be blown out with air Both pieces have small diameter holes that control the flow rates of water to insure that the proper concentration of regenerant is used Sharp objects which can score the plastic should not be used to clean the injector Scoring the injector or increasing the diameter of the hole could change the operating parameters of the injector Push the injector firmly in place replace the screen and hand tighten the injector cap Two holes are label DN and UP Check for compliance See Compliance table AS0922MP CL Page 45 Compliance Table Application Injector and or Main Regenerant Stack Body Plug s Piston Piston WS1EI Downflow Softener or Injector in DN hole V3011 V3174 V3005 V3001 Regenerating Filter Refill Flow Control Assembly or Refill Port Plug To clean or replace the refill flow control pull out the elbow locking clip and then pull straight up on the elbow Replace the elbow locking clip in the slot so that it is not misplaced Twist to remove the white flow control retainer The flow control can be removed by prying upward th
10. Locate the cabinet softener in an accessible place so that salt can easily be added e Do not install any unit closer than 3m 10ft of piping between the outlet of the water conditioner and the inlet of the water heater Water heaters can transmit heat back down the cold water pipe into the control valve Hot water can severely damage the controller A 3m total pipe run including bends elbows etc is a reasonable distance to prevent hot water damage A positive way to prevent hot water from flowing from a heat source to the conditioner is to install a check valve in the soft water piping from the conditioner If a check valve is installed make sure that the water heating unit is equipped with a properly rated temperature and pressure safety relief valve Always conform to local codes e Do not locate the unit in an area where the temp ever falls below 1 C 34 F or over 49 C 120 F Do not install the unit near acid or acid fumes Do not expose the unit to petroleum products Water Line Connection A bypass valve system must be installed to provide for occasions when the water conditioner must is by passed for hard water or for servicing Bypass offers simplicity and ease of operation These softeners are equipped as standard with a bypass valve See pages 14 and15 Figure 3 Ty Conditioner Drain Line Connection to sewer AS0922MP CL Page 16 The ideal location for the unit is above and not more t
11. SUPPLY WATER CONDITIONED WATER TO TOP CF TANK FROM DISTRIBUTOR flow diagram backwash TO DRAIN PISTON ROD IE a BELOW 2nd SIEP OUT_CT PORT FOR SERVICE WATER BACKWASH WATER SUPPLY WATER TO DRAIN TO DISTRIBUTOR Flow Diagram Downflow AS0922MP CL Page 39 flow diagram downflow brine REGENERANT IN MANIFOLD TC REGENERANT IS SIPHONE2 IN REGENERANT TRAVELS THROUGH MANIFOLD p THE INJECTOR p Vi 2 LY 7 PISTON ROD IS 2 my BELOW 3rd STEP DOWN 24 6 SUFFLY WATER OJ LET SERT FOR 7 SERVICE WATER SUPPLY WATER AND REGENERANT WASTE WATER FROM DISTRIBUTOR 10 OF TANK Flow Diagrams Rinse and Fill AS0922MP CL Page 40 flow diagram rinse TO IKAN PISTON ROD IS dih STEP DOWN A ree e SL Y ZANE SIM WATER I 1 CAL I p ONTI ET PORT FCR SERVIE SUPPLY WATER INLET CONDITIONED WATER STO OF TANK FROM DISTRIBUTOR flow diagram fill CONDITIONED A773 TO REGENERANT TANK M nnm INS SE PISTON ROD IS BELOW tst STEP DOWN SUPPLY T TES a Ge 4 E a WATER Med od Uum f 2 2 JE d JZUILEIFCH FON SERVICE v 1ER CONDITIONE 2 WATER SUPPLY WATER FROM DISTRIBUTOR TO TCP OF TANK WS1 Wrench Order No V31
12. memory except for the current time of day Current time of day When power is restored the display will show zeros and will again register when the current time of day is reset If power is lost during a regeneration cycle the valve will remain operational in the current cycle and will recommence electrically in that cycle when power is restored In long power outages it is advisable to check that the system is not in a regeneration cycle that could be discharging water to drain and in this instance it would be advisable to place the valve in bypass mode until power is restored General Note When changing valve operational cycles the valve control will emit a number of whirring sounds Note The valve cannot be positioned into the regeneration mode without ELECTRIC Power Note It is very important that on commissioning the tank and valve be completely vented of air AS0922MP CL Page 10 MODEL AS0922MP WATER SOFTENER WITH CONTROL VALVE SERIES MODEL WS1EI AS0922MP CL Page 11 GENERAL WS1 CONTROL VALVE SPECIFICATONS Inlet Outlet Fittings 25mm BSP F PVC elbows Cycles 5 Valve Material Noryl 1 or equivalent Regeneration Down flow FLOW RATES Service 215psi 1 bar drop includes bypass amp meter 102 Ipm Backwash 25psi 1 7 bar drop includes bypass 102 Ipm OPERATING PRESSURE Minimum Maximum 330 600 kpa 48 100 psi METER Accuracy 596 Flow Rate Range
13. screw capped bottle Add one 1 tablet to sample shake or crush to disintegrate Repeat until last trace of reddish tinge disappears The final colour is usually blue but with some water a greyish coloured end point is obtained Using 50ml sample Hardness ppm number of tablets x 40 20 LR BW Tablets Directions Take a 100ml sample of water in a screw capped bottle Add one 1 AS0922MP CL tablet to sample shake or crush to disintegrate Repeat until last trace of reddish tinge disappears The final colour is usually blue but with some water a greyish coloured end point is obtained Using 100ml sample Hardness ppm number tablets x 2 1 Contact IBC Water if further details are required Page 7 MODEL AS0922MP CL SOFTENER THE MICROPROCESSOR CONTROL WILL REQUIRE BASIC DATA PROGRAMMING TO SUIT THE RAW WATER HARDNESS AND DESIRED UNIT CAPACITY IMPORTANT IT IS ESSENTIAL THAT YOU READ THE GENERAL CONDITIONER INFORMATION AND CONTROL SETTINGS OF THIS MANUAL BEFORE ATTEMPTING TO SET THE FUNCTIONS OF THIS UNIT THE DEALER OR AGENT CAN SUPPLY THE RAW WATER HARDNESS HOWEVER DO NOT EXCEED THE MAXIMUM THROUGH PUT IN CUBIC METERS BASED ON THE ACTUAL RAW WATER HARDNESS FIGURE IN TABLE 2 SUGGESTED SETTINGS VOLUME THROUGHPUT IN CUBIC METRES Based on Maximum Exchange Capacity TABLE 2 Raw Water Hardness Maximum Program Setting mg L CaCO In Cubic Metres throughput see no
14. the time of regen picis hour Press NEXT to go to Step 51 If the factory ee Fecit default of 2am is to be changed Pier E eL ia A 57 ra f Step 5I Use V or A buttons to set the time of regen minutes Press NEXT to exit installer display v Mersrrg Setting Current Time of Day X eu me Push NEXT button until TIME of day screen is ii displayed ie bar appears under TIME function Press A EAL REGEN and hold the V OR A arrow until a arrow appears against SET and release the button and the hour Exit back to display screen which would normally show display flashes and then set the correct hour Then remaining M Note When in the program mode Step 1 to press the NEXT button The minutes will flash Press the V OR arrow until the correct minutes is displayed Note only press AOR V button NOT both together 5 If it is desired to go back one program step press regen button to return back Rerin De Press the NEXT button to return to the display screens 252 qud If the NEXT button is not pressed hours or minutes will m Rr flash for five minutes before returning to display screen A nese Then using the NEXT button select which screen you wished Recommended to leave on remaining M AS0922MP CL Power outage When electric power is interrupted the microprocessor will hold all relevant information in
15. water mixture ratio over the entire operating pressure range of the control valve The injector provides good performance in a variety of applications The injector fitted has been used to suit a wide range of operating pressures But requires a minimum of 330 kpa to function correctly Injector Order Information Injector order Injector Typical tank number colour Diameter V3010 1B Brown 7 V3010 1D Red g V3010 1E F White Blue 10 V3010 1G Yellow 12 V3010 11 Orange 13 V3010 1K Light Green 14 Will vary with Tank Resin Volume Check with Factory Refill Flow Control Assembly or Refill Port Plug The refill flow control assembly consists of a refill flow elbow refill flow control retainer assembly refill flow control polytube insert and nut assembly The refill flow control retainer fits in the refill elbow The refill Page 27 flow control retainer houses the refill flow control which controls the flow rate when the regenerant tank is being refilled The refill flow control is a flexible washer like part with a small orifice and a precision moulded contour that delivers a steady 1 91pm 0 5 gpm regenerant tank refill rate at varying inlet pressures Refill is accomplished with treated water The refill flow control assembly is installed in an easy to access refill elbow located on top of the control valve The refill flow control assembly is installed in an easy to access refi
16. 8 WS1 Drive Back Plate 1 4 V3011 WS1 Piston Downflow ASY 1 5 V3174 WS1 Regenerant Piston 1 6 V3135 O ring 228 1 7 V3180 O ring 337 1 8 V3105 O ring 215 Distributor Tube 1 Not Shown V3001 WS1 Body ASY Downflow 1 V3011 is labelled with DN AS0922MP CL Page 31 Black Plug Injector Cap Injector Screen Injector Plug and O Ring Drawing No Order No Description Quantity 1 V3176 Injector Cap 1 2 V3152 O ring 135 1 3 V3177 Injector Screen 1 V3010 1A WS1 INJECTOR ASSY BLACK V3010 1B WS1 INJECTOR ASSY BROWN V3010 1C WS1 INJECTOR ASSY VIOLET V3010 1D WS1 INJECTOR ASSY RED 5 V3010 1E WS1 INJECTOR ASSY WHITE 1 V3010 1F WS1 INJECTOR ASSY BLUE V3010 1G WS1 INJECTOR ASSY YELLOW V3010 1H WS1 INJECTOR ASSY GREEN V3010 11 WS1 INJECTOR ASSY ORANGE V3010 1J WS1 INJECTOR ASSY LIGHT BLUE V3010 1K WS1 INJECTOR ASSY LIGHT GREEN Not Shown V3170 O ring 011 i Not Shown V3171 O ring 013 AS0922MP CL Page 32 The injector plug has one 011 lower and 013 upper o ring Refill Flow Control Assembly Drawing No Order No Description Quantity 2 H4615 Elbow Locking Clip 1 3 JCP P 6 Polytube insert 3 8 1 4 JCPG 6PBLK Nut 3 8 1 5 H4613 Elbow Cap 3 8 1 6 V3163 O ring 019 1 7 V3165 01 WS1 RFC Retainer ASY 1 8 V3182 WSC RFC 1 Not Shown H4650 Elbow gt with nut and insert Option Assem
17. 93 01 AS0922MP CL Page 41 Although no tools are necessary to assemble or disassemble the valve the WS1 wrench shown in various positions on the valve may be purchased to aid in assembly or disassembly me Loosens Drain Nut In hf Polytube Applications NS V 4 2 Loosens Injector And Bypass Caps Loosens Quick Connect Nuts Service Instructions AS0922MP CL Page 42 Drive Assembly Remove the valve cover to access the drive assembly Disconnect the power source plug black wire from the PC board prior to disconnecting the motor or water meter plugs from the PC board The power source plug connects to the four pin jack The motor plug connects to the two pin jack on the left hand side of the PC board The water meter plug gray wire connects to the three pin jack on the far right hand side of the PC board The PC board can be removed separately from the drive bracket but it is not recommended Do not attempt to remove the display panel from the PC board Handle the board by the edges To remove the PC board from the drive bracket unplug the power water meter and motor plugs from the PC board Lift the middle latch along the top of the drive bracket while pulling outward on the top of the PC board The drive bracket has two plastic pins that fit into the holes on the lower edge of the PC board Once the PC board is tilted about 45 from the drive bracket it can be lifted off of these pins To reinstall the PC b
18. Pressure kPa BLUE ORDER NO V3010 1F Metric Units AoA ale plane ola 0 5 100 200 300 400 500 600 700 800 900 Pressure kPa Flow Rate lpm L t od YELLOW ORDER NO 3010 16 Metric Units 40 300 amp 550 9 Pressure kia ORANGE ORDER V3010 1l Metric Units 10 200 400 500 900 Pressure kPa LIGHT GREEN ORDER NO V3010 1K Metric Units pus 500 707 Pressure kPa GREEN ORDER NO V3010 1H Metric Units HEHEEEBEEBREHEEEM sd RN UR HRS 1 HE ti Flow Rate e FEAE 0 20 E 4 500 BOO 300 Pressure kPa LIGHT BLUE ORDER NO V3010 1 Metric Units Flow Rate ipm Troubleshooting Your water conditioning system is designed and manufactured for efficient low maintenance service However if problems do occur this section provides a list of possible causes and solutions Alarms The control continuously monitors itself and sends an error to the display if it detects something wrong When the error is sensed the display shows the letters Err with a number from 1 to 4 Refer to microprocessor troubleshooting procedures Refer to table 3 to help identify the cause of a problem You can solve some problems yourself such as low salt in the storage tank or a blown household fuse However some problems require installer or de
19. TH MODEL WS1 VALVE EI CONTROL Check the equipment upon arrival for damage or shortages and report same to our Office or Agent before starting Position the Softener on a firm foundation preferably concrete with sufficient space for operation and maintenance The softener must be within One and a Half metres of a 240V 10 amp Power Outlet The softener MUST be installed under cover and protected from the weather as the Valve control and Transformer are not waterproof STEP 1 The Softener is supplied with the resin preloaded in the tank and the valve bypass assembled on the tank STEP2 Connect the Inlet and Outlet pipes and Drain line to the control valve as per the instruction book installation details Note the directional arrows on the Valve The inlet is on the right hand side facing the front of the valve The drain is from the larger elbow on the top of the valve The valve Inlet and Outlet threads are 25mm BSP Female with a 12mm push on Hose connection for the drain line STEP 3 Remove front lid from the cabinet Then connect cabinet brine overflow drain line to waste trap STEP 4 Load 2 bags of 25kg high purity water softener salt into the brine tank and replace lid STEP 5 Refer to Instruction booklet for start up procedure placing conditioner into Service NOTE The INLET PIPE connection is on the right hand side as viewed from the front of the valve NOTE The POWER connection transformer socket is on the right hand side as
20. WATER SOFTENER WITH MICROPROCESSOR INSTALLATION amp OPERATING INSTRUCTIONS Model AS0922MP CL Serial No Manufacturer and Supplier of IBC FILTRATION amp WATER TREATMENT PRODUCTS lt Mein Se for commercial industrial and residential application Qualit Telephone 07 3219 2233 Facsimile 07 3219 2266 Email sales ibcwater com au Website www ibcwater com au AS0922MP CL Page 1 GENERAL WATER SOFTENER PERFORMANCE DATA SHEET Recommended Approx Maximum Pipe Size Resin Shipping Space Service Flow Volume Weight Required kg Inlet Litres Per Kg metres AS0922MP CL 770 1 4 1540 5 3 16 22 BEBE BRINE CHAMBER POLY MOULDED Capacity amp Salt Automatic Dosage Model No System Operating Pressure 330 690 kPa Temperature 4 x 43 C Electrical 240V 16VAC 50Hz 3 watts maximum Control Valve Series WS1 E1 with bypass valve and installation fittings A pressure reduction valve must be installed in areas of high water pressure above 690kPa A water hammer arrestor must be installed if water hammer prevails between the softener and the closing off device Caution Do not use where water is microbiologically unsafe or with water of unknown quality FAILURE TO OBSERVE WARNINGS WILL VOID WARRANTY AS0922MP CL Page 2 AS0922MP CL Page 3 BASIC INSTALLATION OF IBC CABINET WATER SOFTENER SYSTEM FITTED WI
21. aker open or b Correct the electrical problem circuit switched off 4 Control does not a Transformer unplugged a Plug transformer into outlet plug trans regenerate former cable into control automatically b Defective control b Contact dealer AS0922MP CL Page 52 Table 3 Troubleshooting Procedures cont 6 Control does not draw a Low water pressure a Increase water pressure brine b Restricted drain line b Remove restriction c Injector or injector screen plugged c Clean injector and screen Refer to the Cleaning the Injector Injector Screen section in this manual d Injector defective d Replace injector Contact dealer e Valve general malfunction e Contact dealer f Air check prematurely closed in f Replace or repair air check if needed brine tank Check brine line connections 7 Intermittent or irregular a Low water pressure a Increase water pressure brine draw b Defective injector b Replace both injector and injector cap Contact dealer 8 Brine tank overflow a Airleak in brine line to air check a Check all connections in brine line for leaks b Refill program setting incorrect b Contact dealer 9 System using more or a Inaccurate program setting of brine a Contact dealer less salt than estimated refill b Air check system incorrect b Contact dealer c Defective brine refill operation c Contact dealer control 10 Control backwashes at a
22. aler assistance Caution Service procedures that require the water pressure to be removed from the system are marked with a after the possible cause To remove water pressure from the system put the bypass valve into the shut off position and open the service line valve Restore system water pressure when the service work is completed Table 3 Troubleshooting Procedures Problem Cause Solution 1 Hard water at the tap a Low or no salt in the salt storage a Refill the salt storage tank and manually tank initiate a regeneration Refer to the Manual Regeneration section in this manual b Capacity setting to low to b Reduce the capacity setting Refer to the accommodate water hardness or Capacity Setting section in this manual water usage c Unit did not regenerate c Check power d Plugged injector d Clean injector and screen Refer to the Cleaning the Injector Injector Screen in this manual e Air check valve prematurely closed e Replace brine riser pipe if needed in brine riser pipe Check brine line connection for air tightness 2 Hard water leakage a Improper Regeneration a Check that the correct salt dosage is during service used Repeat regeneration b Internal seal problem b Contact dealer c O ring around riser tube damaged c Contact dealer 3 Loss of power to the a Transformer unplugged a Connect the power System b Fuse blown circuit bre
23. bly includes V3182 WS1 RFC AS0922MP CL Page 33 Water Flow Froper RFC orientation directs refill water flow towards the washer face Haa with rounded edge anc EL E text pe Drain Line 34 Drawing No Order No Description Quantity 1 H4615 Elbow Locking Clip 1 PKP10TS8 2 BULK Polytube insert 5 8 Option 3 V3192 WS1 Nut Drain Elbow Option 4 V3158 01 WS1 Drain Elbow 34 Male 1 5 V3163 O ring 019 1 6 V3159 01 WS1 DLFC Retainer 1 7 V3162 007 WS1 DLFC 0 7 gpm for 34 2 6 lpm One DLFC V3162 010 WS1 DLFC 1 0 gpm for 34 3 8 lpm must be V3162 013 WS1 DLFC 1 3 for 4 4 9 Ipm used if 34 V3162 017 WS1 DLFC 1 7 gpm for 34 6 5 Ipm fitting is V3162 022 WS1 DLFC 2 2 gpm for 4 8 8 Ipm used V3162 027 WS1 DLFC 2 7 gpm for 4 10 2 Ipm V3162 032 WS1 DLFC 3 2 gpm for 4 12 1 Ipm V3162 042 WS1 DLFC 4 2 gpm for 4 16 lpm V3162 053 WS1 5 3 gpm for 4 20 Ipm V3162 065 WS1 DLFC 6 5 gpm for 4 24 7 Ipm V3162 075 WS1 DLFC 7 5 gpm for 4 28 5 Ipm V3162 090 WS1 DLFC 9 0 for 4 34 2 Ipm AS0922MP CL Page 34 V3162 100 WS1 DLFC 10 0 for 34 38 lpm Softeners are supplied with a 20mm Push ON Hose Connection as standard the illustrated Nut and 5 8 Tube Insert are only supplied as an option Flow Proper DLFC orientation directs water flow towards the washer face with rounded edge Water Met
24. d To remove the water meter assembly unscrew the meter cap on the left side of the control valve Pliers may be used to unscrew the nut if necessary With the nut removed a slot at the top of the water meter is visible Twist a flat blade screwdriver in the slot between the control valve body and the meter When the meter is part way out it is easy to remove the water meter from the housing Once the water meter is removed from the control valve body gently pull forward on the turbine to remove it from the shaft Do not use a wire brush to clean the turbine Wipe with a clean cloth or chemically clean in vinegar The turbine can be immersed in the vinegar Do not immerse electronics If the turbine is scored or damaged or the bearings on the turbine are worn replace the turbine Do not lubricate the turbine shaft The turbine shaft bearings are pre lubricated Do not use Vaseline oils or other unacceptable lubricants on the o ring A silicone lubricant may be used on the black o ring Snap the turbine on the shaft and reinsert the water meter into the side slot Hand tighten the nut Do not use a pipe wrench to tighten nut AS0922MP CL Page 46 Bypass Valve The working parts of the bypass valve are the rotor assemblies that are contained under the bypass valve caps Before working on the rotors make sure the system is depressurized Turn the red arrow shaped handles towards the centre of the bypass valve and back several times to ensur
25. ditioner has reached the throughput setting volume capacity e The REGEN button was pressed Automatic Regeneration The control makes regeneration decisions based on the amount of water that has flowed through the conditioner and the programmed throughput figure The factory setting for Time of Regeneration is 2 00 AM You can change this time Refer to the Customer Installer Programming Instructions section in this manual for additional information Manual Regeneration To force the control to perform a regeneration press the REGEN push button This button is located on the front of the control When you press the REGEN button the control performs a full regeneration of the conditioner You can use this feature if you need a large amount of conditioned water but the capacity remaining is low Note If you press this button once and release immediately regeneration will occur at the delayed time setting i e 2am If an immediate regeneration is required then hold in the button for 3 seconds Care of Your Water Conditioner General Check the salt level in the salt storage tank regularly Always maintain the salt level above the water level for a consistent salt dosage and proper water conditioner operation Don t allow the conditioner to run out of salt before refilling When refilled the salt storage tank contains enough salt to support numerous resin bed regenerations It is recommended to utilise a high grade wa
26. e regeneration cycle Figure 1 2 Bypass Position The inlet and outlet handles point to the centre of the bypass the control valve is isolated from the water pressure contained in the plumbing system Untreated water is supplied to the plumbing system Figure 2 3 Diagnostic Position The inlet handle points in the direction of flow and the outlet handle points to the centre of bypass valve system water pressure is allowed to the control valve and the plumbing system while not allowing water to exit from the control valve to the plumbing Figure 3 4 Shut Off Position The inlet handle points to the centre of the bypass valve and the outlet handle points in the direction of flow the water is shut off to the plumbing system i e plumbing connection somewhere in the building bypasses the system Figure 4 Page 16 Vigure 1 NORMAL OPERATION TREATED SUPALY WATER WATER EXITS l A 7 2 un ayy RES 4 ligure 3 DIAGNOSTIC MODE SUPPLY SUPP_Y WATER WATER EXITS ENTERS ie s 7 I AS0922MP CL 0 4 ea Figure 2 BYPASS OPERATION SUPPL SUPPLY WATER WATER FXITS FNTFAS Figure 4 SHUT OFF MODE NO WATER SUPPLY WATER IS 8HJI OFF EXITS FROM THE HOUSE AND THE VALVE Page 19 WS1EI Screen Display Information And Programming Instructions AS0922MP CL Page 20 General Operation
27. e exciting current constant and moving a permanent magnet near the semiconductor produces a voltage output proportional to the movement of the magnet Hall effect devices provide a high speed response excellent temperature stability and no physical contact Installation Fitting Assemblies The installation fittings are used to connect the bypass to the plumbing system Standard fittings supplied are a 22mm BSP female PVC elbow assembly Both elbow fittings have a unique drill out feature to allow a 4 NPT connection to the inlet and or outlet which can be used for a RO feed test ports pressure tap ports etc Page 26 SPARE PARTS AND SERVICING INSTRUCTIONS AS0922MP CL Page 29 WS1E1 Front Cover and Drive Assembly Drawing No Order No Description Quantity 1 V3175EI 01 WS1EI Front Cover Assembly 1 2 V3107 01 WS1 Motor 1 3 V3106 01 WS1 Drive Bracket amp Spring Clip 1 4 V3408E1 WS1 5 PC Board El 1 5 V3110 WS1 Drive Gear 12x36 3 6 V3109 WS1 Drive Gear Cover 1 V3002El WS1EI Drive ASY Not Shown V3186 01 WS1 AC ADAPTER CORD ONLY 1 Drawing number parts 2 through 6 may be purchased as a complete assembly part V3002EI AS0922MP CL Page 30 WE1EI Drive Cap Assembly Downflow Piston Regenerant Piston and Spacer Stack Assembly Drawing No Order No Description Quantity 1 V3005 WS1Spacer Stack Assembly 1 2 V3004 Drive Cap ASY 1 3 V317
28. e hole could change the operating parameters of the injector Push the injector firmly in place replace the screen and hand tighten the injector cap 5 Close off the tap in service line and reposition bypass valve back into service position Maintaining the Drain Line The drain line discharges and brine during the regeneration cycle Typically the line drains into a sewer connection The installer should plumb the drain line according to local codes leaving a one or two inch air gap between the end of the drain line and the drain opening Be sure that the drain line remains unrestricted so the regeneration water and brine can flow freely to the drain Do not set objects on the drain line that could crimp the line and restrict flow PES Right Way Brine Line Connection The brine line comprises a pick up air check assembly installed in the brine wall in the cabinet and connected by tubing to the brine elbow on top of the valve Note Make sure that all fittings and connections are tight so that premature checking does not take place Premature checking occurs when the ball in the air check seals before all brine is drawn out of the brine tank Refer to the Troubleshooting section in this manual for additional information Brine Tank Overflow Line Connection In the event of a malfunction the tank overflow connection directs overflow to the drain instead of spilling on the floor where it could cause water damage Complete t
29. e rotor is turning freely The nuts and caps are designed to be unscrewed or tightened by hand if necessary a pliers can be used to unscrew the nut or cap Do not use a pipe wrench to tighten or loosen nuts or caps Do not place screwdriver in slots on caps and or tap with a hammer To access the rotor unscrew the cap and lift the cap rotor and handle out as one unit Twisting the unit as you pull it out will help to remove it more easily There are three o rings one under the rotor cap one on the rotor stem and the rotor seal Replace worn o rings Clean rotor Reinstall rotor When reinstalling the red arrow handles be sure that 1 The handle pointer are lined up with the control valve body arrows and the rotor seal o ring and retainer on both rotors face to the right when being viewed from the front of the control valve or 2 Arrows point toward each other in the bypass position Since the handles can be pulled off they could be accidentally reinstalled 180 from their correct orientation To install the red arrow handles correctly keep the handles pointed in the same direction as the arrows engraved on the control valve body while tightening the bypass valve caps After completing any valve maintenance press and hold NEXT and REGEN buttons for 3 seconds or unplug power source jack black wire at the circuit board and plug back in This resets the electronics and establishes the service piston position The display should flash all
30. eck to see that brine is being drawn out of the cabinet into the valve The brine draw is very slow and all brine will be drawn out until the air check on the brine riser tube shuts off The system will then remain in the draw cycle to slowly rinse And regenerate the brine through the resin Allow the system to complete a full regeneration and return to the service position This will take a few hours When the unit has returned to the service position with the normal display then open the bypass valve outlet valve slowly to enable water to enter the treated water line ensure that the bypass valve is correctly in Normal Operation position Open a tap in the treated water and allow to run to drain for a few minutes Then check the harness of the water with the supplied test kit If not soft allow to run to drain for 5 minutes and recheck the hardness Refer to troubleshooting section if the water is still hard Page 25 WS1EI Manual Control Valve Function and Cycles of Operation This glass filled or equivalent fully automatic control valve is designed as the primary control center to direct and regulate all cycles of a water softener The control valve can be set to regenerate on demand consumption of a predetermined amount of water and or as a time clock passage of a particular number of days The control valve is factory set to regenerate on demand consumption with a delay regeneration set for
31. emaining current flow rate and total volume used Totalizer e Four methods to initiate regeneration meter immediate meter delayed time clock delayed or pressure differential e Optional double backwash feature offers optimum regeneration cleaning ability and efficiency AS0922MP CL e Fully adjustable 6 cycle control delivers controlled backwash downflow brining slow rinse second backwash fast rinse refill and downflow service e Downflow regeneration e 12 volt output AC Adapter provides safe and easy installation Control valve design provides optimum service and backwash rates e Treated water regenerant refill e Reliable and proven DC Drive General Factory set up is for M throughput regeneration with 2 AM delayed regeneration and No second Backwash Manual Initiated Regeneration The user can initiate manual regeneration The user has the option to request the manual regeneration at the delayed regeneration time of 2am or to have the regeneration occur immediately 1 Pressing and releasing immediately the REGEN button E will flash towards regen on the display and regeneration will occur at 2am the delayed regeneration time The user can cancel the request by pressing and releasing the REGEN button 2 Pressing and holding the REGEN button for approximately 3 seconds will immediately start the regeneration The user cannot cancel this request except by resetting the control by pressing NEXT a
32. er and meter Plug Drawing No Order No Description Quantity 1 V3151 WS1 Nut 1 QC 1 2 V3003 WS1 Meter ASY 1 3 V3118 01 WS1 Turbine ASY 1 4 V3105 O ring 215 1 Order number V3003 includes V3118 01 WS1 Turbine Assy and V3105 O ring 215 AS0922MP CL Page 35 Installation Fitting Assembly Order No V3007 01 Description WS1 Fitting 34 amp 1 PVC Solvent 90 ASY Drawing No Order No Description Quantity 1 V3151 WS1 Nut 1 Quick Connect 2 2 V3150 WS1 Split Ring 2 3 V3105 O Ring 215 2 4 V3189 WS1 Fitting 34 amp 1 PVC Solvent 90 2 AS0922MP CL Page 36 Bypass Valve Drawing No Order No Description Quantity 1 V3151 WS1 Nut 1 Quick Connect 2 2 V3150 WS1 Split Ring 2 3 V3105 O ring 215 2 4 V3145 WS1 Bypass 1 Rotor 2 5 V3146 WS1 Bypass Cap 2 6 V3147 WS1 Bypass Handle 2 7 V3148 WS1 Bypass Rotor Seal Retainer 2 8 V3152 O ring 135 2 9 V3155 O ring 112 2 AS0922MP CL Page 37 10 V3156 O ring 214 2 Flow Diagrams Service and Backwash flow diagram service AS0922MP CL Page 38 LLL 27227227208 i i 7 ETE MARIA Ihm SE 1 07 os L M IVI TT PISTON ROO 15 BOTTGHEC ff e Lk CUT IN HOME POSITION TA iz rm 29 MN SUTLET FORT FOR SERVICE WATER pe SUPPLY WATER INLET
33. generation time d Control valve set at on O d Check control valve set up procedure immediate regeneration regeneration time option a Control valve has just been serviced a Press NEXT and REGEN for 3 seconds or unplug power source jack black wire 5 Err followed by code number and plug back in to reset control valve Error Code 1001 Unable to recognize start of regeneration Error Code 1002 Unexpected stall Error Code 1003 Motor ran too long timed out trying to reach next cycle position Error 1004 Motor ran too long timed out trying to reach home position If other Error Codes display contact the factory Foreign matter is lodged in control valve o Check piston and spacer stack assembly for foreign matter high drive forces on piston Replace piston s amp spacer stack assembly Control valve piston not in home position c Press NEXT and RGEN for 3 seconds or unplug power source jack black wire and plug back in to reset control valve Motor not inserted fully to engage pinion motor wires broken or disconnected motor failure e Check motor and wiring Replace motor if necessary Drive gear label dirty or damaged missing or broken gear f Replace or clean drive gear Drive bracket incorrectly aligned to back plate 9 Reseat drive bracket properly PC board is damaged or defective h Replace PC board PC board incorrectl
34. han 6 1m 20ft from the drain For such installations using the appropriate adaptor fitting supplied connect 12mm 1 2 plastic tubing to the drain line connection located on the top of the valve pe Righ Way Figure 5 Air Gap Installation If the unit is located more than 6 1m 20ft from the drain use 20mm tubing for runs up to 12 0m You may elevate the line up to 1 8m providing the run does not exceed 4 5m and the water pressure at the conditioner is not less than 280kPa 40psi You may elevate an additional 500mm for each additional 70kPa 10psi of water pressure When the drain line is elevated and empties into a drain which is below the level of the control valve form a 170mm 7 inch loop at the drain end of the line so that the bottom of the loop is level with the drain line connection This provides an adequate siphon trap If the drain empties into an overhead sewer line a sink type trap must be used Caution Never connect the drain line into a drain sewer line or trap Always allow an air gap between the drain line and the wastewater to prevent the possibility of sewage being back siphoned into the conditioner ot In Bypass In Bypass AS0922MP CL Important Installation Details The control valve fittings and or bypass are designed to accommodate minor plumbing misalignments but are not designed to support the weight of the system or the plumbing Do no use Vaseline oils other
35. he following steps to connect the overflow fitting to the brine tank 1 Locate the fitting overflow on the side of the brine tank 2 Attach a length of 1 2in 1 3cm tubing not supplied to the fitting and run to the drain Note Do not elevate the overflow line higher than 3in 7 6cm below the bottom of the overflow fitting Do not tie into the drain line of the control unit The overflow line must be a direct separate line from the overflow fitting to the drain sewer or tube Allow an air gap as in the drain line connection Overtlow Fitting installed Arne Tank Connect 1 7 inch 1 3 cm LD Tubing or Hose and Run 1p Drain Overflow Line Connection AS0922MP CL Page 24 Placing Softener into Operation Initial Start Up 1 Mains water turned off to unit or bypass valve in shut off mode Connect transformer to power point and turn on 2 3 Program controller as per Customer Install Programming Instructions 4 Press the Regen button in and hold for 3 to 5 seconds 5 6 The softener will advance to the backwash position and start counting down Slowly open the inlet valve or the bypass valve into the Diagnostic Mode approximately one quarter of t a turn and allow the mineral tank to slowly fill up with water Caution If the water supply valve is opened too rapidly or too far resin may be lost In the BACKWASH position you should hear air escaping slowly from the drain line
36. he necessary flow passage for water during the different cycles The all plastic spacer stack assembly U S Patent 6402944 is a one piece design which allows the stack to be removed using your fingers The exterior of the stack is sealed against the body bore with self lubricating EPDM o rings while the AS0922MP CL interior surface is sealed against the piston using slippery self cleaning silicone lip seals The lip seals are clear in colour and have a special slippery coating so that the piston does not need to be lubricated Injector Cap Screen Injector Plug and Injector The screen injector and or injector plug s are installed under the injector cap in an easy to access location on top of the valve The injector cap contains four slots so no water accumulates in the cap The injector cap is designed to be hand tightened Under the injector cap there is an easy to clean removable screen to prevent fouling of the injector There are two holes under the injector cap labelled DN and UP The injector is in the DN hole and the Up hole is plugged The injector lets water pass through the pathway The self priming injector increases the velocity of the water creating a zone of negative pressure that draws in the concentrated liquid regenerant sodium chloride brine The regenerant blends with the stream of water which passes through the media to regenerate the resin bed The injector provides a consistent regenerant
37. hydrocarbon lubricants or spray silicone anywhere A silicone lubricant may be used on black o rings but is not necessary Avoid any type of lubricants including silicone on the clear lip seals The nuts and caps are designed to be unscrewed or tightened by hand or with the special plastic wrench Do not use a pipe wrench to tighten or loosen nuts or caps Do not place a screwdriver in the slots on caps and or tap with a hammer Do not use pipe dope or other sealant on threads Use teflon tape on threaded inlet outlet and drain fittings Teflon tape is not necessary on the nut connection or caps because of o ring seals After completing any valve maintenance involving the drive assembly of the drive camp assembly and pistons press and hold NEXT and REGEN buttons for 3 seconds or unplug power source jack from the printed circuit board black wire and plug back in This resets the electronics and establishes the service piston position The display should flash all wording then flash the software version and then reset the valve to the service position All plumbing should be done in accordance with local plumbing codes The pipe size for the drain line should be a minimum of 12mm Solder joints near the drain must be done prior to connecting the drain line flow control fitting Leave at least 150mm 6 between the drain line control fitting and solder joints when soldering pipes that are connected on the drain line control fitting
38. ive cap assembly and piston The spacer stack assembly can be removed easily without tools by using thumb and forefinger Inspect the black o rings and clear lip seals for wear or damage Replace the entire stack if necessary Do not disassemble the stack The spacer stack assembly may be chemically cleaned with vinegar or wiped with a soft cloth The spacer stack assembly can be pushed in to the control valve body bore by hand Since the spacer stack assembly can be compressed it is easier to use a blunt object 15 9mm 5 8 to 28 6 mm 1 1 8 in diameter to push the centre of the assembly into the control valve body The assembly is properly seated when at least four threads are exposed approximately 15 89 mm 5 8 Do not force the spacer stack assembly in The control valve body bore interior can be lubricated with silicone to allow for easy insertion of the entire stack Do not use silicone or any other type of lubricant on the clear lip seals or the piston Reattach the drive cap assembly and piston s and the drive assembly IMPORTANT NOTE After completing any valve maintenance press and hold NEXT and REGEN buttons for 3 seconds or unplug power source jack black wire at the circuit board and plug back in This resets the electronics and establishes the service piston position The display should flash all wording then flash the software version and then reset the valve to the service position Injector Cap Screen Injector Plug and
39. lay arrow which indicates the regeneration cycle status Resin Bed The supply of synthetic organic exchange material used in water conditioners This material is subject to degradation and will need to be renewed Resin replacement normally varies between 3 to 7 years Page 55
40. ll elbow located on top of the control valve The refill flow control assembly is attached to the control valve with a locking clip The locking clip allows the elbow to rotate 270 degrees so the outlet can be orientated towards the regenerant tank The control valve has a standard refill elbow to which a 3 8 flexible tube can be connected Always utilise the supplied Tube insert Drain Line Flow Control and Fitting Assembly The drain line flow control assembly includes a drain line flow control and a fitting The drain line flow control allows proper media bed expansion by regulating the flow rate to the drain The drain line flow control is a flexible washer like part with an orifice and a precision moulded contour The flow rates are within 1096 over the pressure range of 1 4 bar 20 psi to 8 6 bar 125 psi The drain line flow control and fitting are located on top of the control valve and replaceable without the use of special tools The drain line flow control can be installed in the standard 34 drain line elbow which accommodates 5 8 polytube or pipe 20mm threaded drain line connections The optional nut and polytube insert for the drain line elbow is designed for use with flexible polytube only The drain line elbow can be rotated 180 degrees so the outlet can be orientated to the nearest drain This model softener is fitted with a 20mm push on hose elbow Water Meter or Meter Plug The water meter is installed on
41. ly The drive bracket is properly seated when it snaps under the latches on the drive back plate If resistance is felt before latching then notches are not fully engaged the piston rod is not in hold the wires are jammed between the drive bracket and drive back plate or the gear is not engaging the drive cap assembly To inspect the drive gears the drive gear cover needs to be removed Before trying to remove the gear cover the drive bracket must be removed from the drive back plate Refer to the instructions above regarding removing the drive bracket from the drive back plate The drive gear cover can be removed from the drive bracket without removing the motor or the PC board The drive gear cover is held in place on the drive bracket by three clips The largest of the three clips is always orientated to the bottom of the drive bracket With the PC board facing up push in and down on the large clip on the drive gear cover Handle the cover and the gears carefully so that the gears do not fall off of the pegs in the cover Replace broken or damaged drive gears Do not lubricate any of the gears Avoid getting any foreign matter on the reflective coating because dirt or oils may interfere with pulse counting The drive gear cover only fits on one way with the large clip orientated towards the bottom If all three clips are outside of the gear shroud on the drive bracket the drive gear cover slips easily into place The drive bracket does not
42. nd REGEN buttons simultaneously for 3 seconds However this may totally clear all the pre programmed in functions and is not recommended The WS1EI control valve consist of the following components Drive Assembly 2 Drive Cap Assembly Main Piston and Regenerant Piston Spacer Stack Assembly Injector Cap Screen Injector Refill Flow Control Assembly Drain Line Flow Control and Fitting Assembly Water Meter Bypass Valve Installation Fitting Assemblies php OND OA Drive Assembly The drive assembly consists of the following parts Drive Bracket Printed Circuit PC Board Motor Drive Gears Drive Gear Cover Page 26 The drive bracket holds the PC board the motor the drive gears and the drive gear cover in place The PC board receives and retains information displays the information determines when to regenerate and initiates regeneration The display show different types of information in the initial system set up installer display settings diagnostics or user display settings The PC board powers the motor The PC board s two prong jack connects wires to the direct current DC motor The motor is held in place on the drive bracket by a spring loaded clip and a small bulge in the plastic which fits in one of the slots on the motor housing The motor turns drive gears that drive the piston to cycle positions for backwashing regeneration rinsing refill or service The motor is fully
43. need to be removed from the drive plate if the motor needs to be removed To remove the motor disconnect the power and motor plugs from the jacks on the PC board Move the spring clip loop to the right and hold Rotate the motor at least a 1 4 turn in either direction so the wires are vertical up amp down before gently pulling on the wire connectors to remove the motor Pulling directly on the wires without rotating the motor may break the wires off the motor Replace the motor if necessary Do not lubricate the motor or the gears To reinstall the motor move the spring clip loop to the right and hold Gently turn the motor while inserting so that the gear on the motor meshes with the gears under the drive gear cover Release the spring clip loop and continue to rotate the motor until the wires are horizontal and the motor housing engages the small plastic bulge inside the drive AS0922MP CL Page 43 bracket motor retainer Reconnect the motor plug to the two pronged jack on the lower left hand side of the PC board If the motor will not easily engage with the drive gears when reinstalling lift and slightly rotate the motor before reinserting Reconnect the power plug Replace the valve cover After completing any valve maintenance press and hold NEXT and REGEN buttons for 3 seconds or unplug power source jack black wire at the circuit board and plug back in This resets the electronics and establishes the service piston position The display
44. oard position the lower edge of the PC board so that the holes in the PC board line up with the plastic pins Push the top of the PC board towards the valve until it snaps under the middle latch weave the power and water meter wires into the holders and reconnect the motor water meter and power plugs The drive bracket must be removed to access the drive cap assembly and pistons or the drive gear cover It is not necessary to remove the PC board from the drive bracket to remove the drive bracket To remove the drive bracket start by removing the plugs for the power source and the water meter Un weave the wires from the side holders Two tabs on the top of the drive back plate hold the drive bracket in place Simultaneously lift the two tabs and gently ease the top of the drive bracket forward The lower edge of the drive bracket has two notches that rest on the drive back plate Lift up and outward on the drive bracket to disengage the notches To reassemble seat the bottom of the drive bracket so the notches are engaged at the bottom of the drive back plate Push the top of the drive bracket toward the two latches The drive bracket may have to be lifted slightly to let the threaded piston rod pass through the hole in the drive bracket Maintain a slight engaging force on top of the drive bracket while deflecting the bracket slightly to the left by pressing on the side of the upper right corner This helps the drive gears mesh with the drive cap assemb
45. ommended to de rate the throughput setting by one days general usage to ensure soft water is available on the day of regeneration However in instances where this is not desired the control can be reprogrammed so that a regeneration can be initiated immediately on reaching the throughput setting The control provides efficient trouble free soft water The Series WS1 El valve combines design simplicity with glass reinforced NORYL plastic construction to provide an uncommonly reliable appliance If maintenance becomes necessary the Model WS1 water Conditioner System has the capability for quick repairs NORYL is a trademark of GE Plastics Special Features e Memory Retention During a power outage critical operating information in the control s memory is stored in a special electronic device called a NOVARAM This information includes the time of day water usage amounts all programming data When power is restored the information is returned to the microprocessor and operation resumes as if an outage never occurred The time of day will be late by the length of the power outage Because most power outages are less than one minute in duration it may be months or years before the time display requires resetting If an outage of one or more hours occurs the time of day should be reset but no other reprogramming is necessary Design Reliability Solid state electronics assure many years of trouble free performance The me
46. or upflow piston fully extend the piston rod and then unsnap AS0922MP CL Page 44 the main piston from its latch by pressing on the side with the number Chemically clean in vinegar or replace the main piston Reattach the main piston to the drive cap assembly Reattach the regenerant piston to the main piston Do not lubricate the piston rod main piston or regenerant piston Lubricant will adversely affect the clear lip seals Reinsert the drive cap assembly and piston into the spacer stack assembly and hand tighten the drive cap assembly Continue to tighten the drive cap assembly using a screwdriver as a ratchet until the black o ring on the spacer stack assembly is no longer visible through the drain port Excessive force can break the notches moulded into the drive back plate Make certain that the main drive gear still turns freely The exact position of the piston is not important as long as the main drive gear turns freely Reattach the drive assembly to the control valve and connect all plugs After completing any valve maintenance press and hold NEXT and REGEN buttons for 3 seconds or unplug power source jack black wire at the circuit board and plug back in This resets the electronics and establishes the service piston position The display should flash all wording then flash the software version and then reset the valve to the service position Spacer Stack Assembly To access the spacer stack assembly remove the drive assembly dr
47. oughput in cubic metres from Table 2 2 Current time of day NOTE All other parameters have been factory pre set DO NOT CHANGE AS0922MP CL Page 8 CUSTOMER INSTALLER PROGRAMING INSTRUCTIONS The WS1 E1 has been factory programmed with the majority of the commands and parameters installed It is necessary on commissioning of the softener to program in the M throughput and if desired another time of day when regeneration is to proceed or accept the factory default of 2am and to set up the clock to register the current time of day The transformer plugs into the socket mounted on the back face of the front panel of the valve The procedure is as follows Plug in the transformer into the mains and turn on valve will sequence to the service position Step 11 To enter installer display press the NEXT and A buttons simultaneously for 5 seconds and release Display flashes De JATV WE Step 21 Using the V A keys input desired pup Mfg volumetric throughput capacity table 2 in cubic E are meters Adjustable from 0 5 250 0 It is suggested pus 500 Rie the value entered be equal to the actual volumetric capacity minus a 1 day s estimated water usage 8 A Gi E Press NEXT to go to Step 3l Remaitens Jatkeash Step Use V or A buttons to Set to OFF d WE Press NEXT to go to Step 4l Ud EA ETATEM Step 41 Use V or buttons to set
48. pass valve is typically used to isolate the control valve from the plumbing system s water pressure in order to perform control valve repairs or maintenance The WS1 bypass valve is particularly unique in the water treatment industry due to its versatility and state of the art design features The full flow bypass valve incorporates four positions including a diagnostic position that allows service personnel to work on a pressurised system while still providing untreated bypass water to the facility or residence Its completely non metallic all plastic design allows for easy access and serviceability without the need for tools AS0922MP CL The bypass body and rotors are glass filled Noryl or equivalent and the nuts and caps are glass filled polypropylene All seals are self lubricating EPDM to help prevent valve seizing after long periods of non use Internal o rings can easily be replaced if service is required The bypass consists of two interchangeable plug valves that are operated independently by red arrow shaped handles The handles identify the flow direction of the water The plug valves enable the bypass valve to operate in four positions 1 Normal Operation Position The inlet and outlet handles point in the direction of flow indicated by the engraved arrows on the control valve Water flows through the control valve during normal operation and this position also allows the control valve to isolate the media bed during th
49. r the resin cannot remove any more minerals This resin state is called exhaustion and indicates that the resin needs to be regenerated The regeneration process restores the conditioner s ability to soften water The control monitors the amount of water that flows through the conditioner and automatically calculates when to regenerate the resin bed Model E1 Control Front Panel Figure 1 The main components of the model E1 Control front panel are e Main Display Screen with Cycle Time Remaining e Display screen set as remaining or time of day e Display can indicate Rate of Flow e Four Digit Display Programming Push Buttons Page 14 REGEN Push Button Five cycle operation provides for downflow condi tioned water upflow backwash downflow brining and slow rinse downflow fast rinse and refill of the brine tank Optional second backwash available System operation cannot get out of phase or sequence The control always returns to a fixed conditioned water position after regeneration e Bypass untreated water is automatically available during regeneration AS0922MP CL Page 15 Installation All plumbing and electrical connections must conform to local codes Inspect the unit carefully for carrier shortage or shipping damage Location Selection e Locate unit as close to a drain as possible If supplementary water treating equipment is required make sure that adequate additional space is available
50. reversible turns both ways and changes direction of rotation to change the direction of piston motion The motor is easily replaced if necessary There are three drive gears held in place by the drive gear cover All three drive gears are the same size A reflective coating is applied to the gears As the centre drive gear turns a light shines on the coating and a light sensing diode determines if a light pulse was returned The PC board counts the pulses and determines when to stop driving the motor Drive Cap Assembly Main Piston and Regenerant Piston The drive gears turn the main gear of the drive cap assembly which moves the piston The screw driven horizontally moving piston stops at specific positions to direct the flow of water to backwash regenerate rinse or refill The PC board determines the position of the piston by counting pulses produced when the piston is moved An optical sensor looking at one of the reduction drive gears generates these pulses Each cycle position is defined by a number of pulses The counter is zeroed each time the valve goes to the service position The PC board finds the service position by noting the increase in current delivered to the motor when the mechanical stop at the service position is reached This method of controlling the piston position allows for greater flexibility and requires no switches or cams U S Patent 6 444 127 Spacer Stack Assembly The spacer stack assembly provides t
51. rough the side slots of the retainer with a small flat blade screwdriver Chemically clean the flow control or the white flow control retainer using vinegar Do not use a wire brush If necessary replace the flow control o ring on the flow control retainer or the o ring on the elbow Reseat the flow control so the rounded end is visible in the flow control Reseat the white flow control retainer by pushing the retainer into the elbow until the o ring seats Remove locking clip push down on elbow to reseat and insert locking clip Do not use Vaseline oils or other unacceptable lubricants on o rings A silicone lubricant may be used on the o ring on the elbow or the white retainer Water Meter or Meter Plug The water meter assembly is connected to the PC board by a cable If the entire water meter assembly is to be replaced remove the control valve cover and disconnect the power source and water meter plugs from the PC board Unlatch the drive assembly and lean it forward Unthread the water meter wire from the side of the drive assembly and through the drive back plate To reinstall rethread the water meter wire through the drive back plate and the side of the drive assembly Reattach the drive assembly and the water meter and power plugs If no water meter wire is visible then a plug is installed not a water meter The water meter cable does not need to be removed from the PC board if the water meter is only being inspected and cleane
52. should flash all wording then flash the soft ware version and then rest the valve to the service position Drive Cap Assembly Main Piston and Regenerant Piston The drive assembly must be removed to access the drive cap assembly The drive cap assembly must be removed to access the piston s The drive cap assembly is threaded into the control valve body and seals with an o ring To remove the drive cap assembly use the special plastic wrench or insert a 4 to 5 flat blade screwdriver into one of the slots around the top 2 of the drive cap assembly so it engages the notches moulded into the drive back plate around the top 2 of the piston cavity The notches are visible through the holes Lever the screwdriver so the drive cap assembly turns counter clockwise Once loosened unscrew the drive cap assembly by hand and pull straight out The drive cap assembly contains the drive cap the main drive gear drive cap spline piston rod and various other parts that should not be dissembled in the field The only replaceable part on the drive cap assembly is the o ring Attached to the drive cap assembly is the main piston downflow and if a regenerant is used a regenerant piston The regenerant piston the small diameter one behind the main piston is removed from the main piston by pressing sideways and unsnapping it from its latch Chemically clean in vinegar or replace the regenerant piston if needed To remove the main downflow
53. te 60 25 5 80 19 0 100 15 0 120 12 5 140 11 0 160 9 5 180 8 5 200 7 5 250 6 0 Important Note To provide uninterrupted soft water supply to the end of the service and just before a regeneration is due it is strongly recommended to de rate the throughput setting by the average daily usage Eg If the setting is elected at 15 0 then deduct a figure of one days usage Note Estimated daily consumption per person is 300 litres or O 3Cubic Metres for people 0 9cubic metres Deduct One Cubic Metre For Commercial applications it will be necessary to determine the daily water usage figure For other raw water hardness multiply the throughput at 100 hard i e 15 0 by the ratio of 100 divided by the desired hardness e g for 50 hard e g for 170 hard 15 0 x 100 30 00 50 15 0 x 100 8 8 input 8 5 170 Note The program for M input will only accept the inputting of a whole or half a number e g If the calculated throughput is say 9 75m then what can be programmed in is 9 5 or 10 0 However always select the lower figure i e 9 5 in this example Above 50M the program will only accept increments in 2 5 therefore only input a lower figure eg Calculation gives 58 33 therefore input 57 5 Note The chart is based on low to medium total dissolved solids water consult IBC Water for using the softener for waters above 250 mg L hardness Programming Parameters to be input at commissioning 1 Thr
54. ter softener salt like IBC premium grade Do not use a fine grade of salt Have the salt storage tank serviced once a year to remove accumulated sediment that may impede brine draw Cleaning the Injector Injector Screen AS0922MP CL The injector is the component which creates the vacuum necessary to draw the brine into the water conditioner Clean the injector and the injector screen once a year in order to maintain proper water conditioning Some locations may require more frequent injector and screen servicing Complete the following steps to clean the injector and the injector screen 1 Unplug the wall mount transformer 2 Shut off the water supply or put the bypass valve into the bypass position 3 Depressurise the pipework by opening a tap in the service line 4 Unscrew the injector cap large top slotted cap and lift off Loosen cap with special plastic wrench or pliers if necessary Attached to the injector cap is a screen Remove the screen and clean if fouled The injector can be pried out with a small screwdriver The injector consists of a throat and nozzle Chemically clean the injector with vinegar The holes can be blown out with air Both pieces have small diameter holes that control the flow rates of water to insure that the proper concentration of regenerant is used Sharp objects which can score the plastic should not be used to clean the injector Scoring the injector or increasing the diameter of th
55. tering system has only one moving part a rotating turbine that measures water usage e Time and Capacity Display During normal conditioning operation the correct time of day and capacity can be accessed on the display The capacity value is the number of cubic metres of water that the unit can condition before another regeneration is needed e Flow indicator The display can access the actual flow rate through the system e Throughput and Capacity Setting Once the capacity setting is entered the information cannot AS0922MP CL be lost due to a power outage so reprogramming is not necessary e Guest Cycle An extra regeneration can be achieved at any time by pressing the REGEN button on the front panel It takes a few minutes for the regeneration to start The unit completes the regeneration in about two hours This feature is beneficial when you expect to use more than the normal amount of water for example guest visits or an extra heavy laundry day The manual can be set for immediate regeneration of delayed regeneration at 2am General Conditioner Information How Your Conditioner Works In general your water conditioner works in the follow ing manner Hard water flows into the conditioner and through the resin bed where calcium and magnesium hardness minerals are exchange The conditioned water flows out of the resin bed into your plumbing system After a certain amount of hard water has passed through the conditione
56. the outlet side of the control valve The water meter uses a turbine to measure cubic metres of treated water The turbine rotates with the flow of water and reports its rate of rotation through Hall effect circuitry to the printed circuit PC board This rotation permits the PC board to record the total volume of treated water and the flow rate The small centrally located magnet is shielded from water which substantially reduces iron fouling problems with the turbine AS0922MP CL The turbine is accurate to within 596 over a wide operating flow rate range 0 95 lpm 0 25 gpm up to control valve maximums and has a very low pressure drop Water used for regeneration is not metered If the control valve is in regeneration mode e g a backwash cycle and there is a water demand that water usage is not metered When facing the front of the control valve the water meter is positioned on the left hand side of the control valve Allow sufficient clearance to clean and repair the water meter without disconnecting the plumbing or disassembling any other parts of the control valve Water Meter Hall Effect Explanation 3 Some semiconductor materials exhibit a phenomenon in the presence of a magnetic field that is adaptable to sensing devices When a current is passed through one pair of wires attached to a semiconductor will develop a voltage proportional to the magnetic field present and the current in the other pair of wires Holding th
57. urning to display screens Page 21 General Regeneration Error Screens Status Remaining M Hour M Days Regen Screen Backwash Displays the time remaining inthe Bg Draw curent cycle Pressing REGEN Rinse advances to the next cycle Fill ee i uw l mmen i NEXT SEI MLOGCN 4 te Error Screen P Altsrmuted flashing Err and vreur code every 3 seconds Clear by 4 1 cGasconnecting the power supply at tac PC board and revenncting be press the and REGEN buttons sitrintaneously For 2 seconds Button Operation and Function NEXT Scrolls to the nesl display Pressing vuce and releasing will schedule regenerition the present delayed regeneration time Pressing again amt releasing will cancel the regeneration REGEN Pressing and holding or 3 seconds will initiate an immediate regenerution Pressing while in regeneration wil advance to the nesi cycle Pressing in fhe program levels will go backwards to thv previous sereen Changes variable being displayed Key sequenze to luck and anlock NEXT REGEN program settings Holding for 3 scconds tntitiules control reset The software NEXT REGEN version is displayed and the piston rcturns tu the heme survice position resynchbronizing the valve AS0922MP CL Page 22 Water Conditioner Regeneration Your water conditioner regenerates for one of two reasons e The control determines that the con
58. viewed from the front of the valve at the back of the control Table 3 MODEL RESIN LITRES BRINE TANK SALT LOADING KG AS0922MP CL AS0922MP CL Page 4 AS0922MP CL Page 5 WS1 MP VALVE Top Strainer Note Never Shorten the Riser Pipe installed inside the tank AS0922MP CL Page 6 WATER HARDNESS TEST METHOD Water to be tested should be taken from a tap after the water softener Measure 10ml of water into plastic bottle supplied approximately 1 3 full Add one Yes No tablet to sample water replace cap and shake until tablet has completely dissolved NOTE do not handle Yes No tablet with fingers The final colour to be obtained for soft water is green Note The shade of green may vary If the colour turns red the water is above 20 mg l hardness therefore another regeneration is recommended However if the raw water is very high in hardness it may not be possible to achieve a reduction in hardness below 20mg l but the softener is still working correctly Consult IBC Water for further clarification Rinse plastic bottle after each test has been completed When used as above the tablets change the colour from green to red at a hardness of approximately 20ppm based on a sample volume of 10mls Other hardness test kits are available for more accurate testing eg Hardness Tablets Directions Take a 50ml sample of water in a
59. wording then flash the software version and then reset the valve to the service position AS0922MP CL Page 47 Order No V3009 Description WS1 Auxiliary Micro Switch Assembly Order No V3009 Description WS1 Auxiliary Microswitch Assembly Drawing No Order No Description Quantity 1 V3301 WS1 MICROSWITCH 1 2 V3302 WS1 MOLEX CONNECTOR 1 Not Shown V3303 WS1 MOLEX TERMINAL 3 3 V3304 WS1 SCREWS 4 40 X 5 8 2 4 V3305 WS1 RETAINING RING SS 1 5 V3306 WS1 WASHER ID 0 257 OD 0 640 1 Slip the washer and retaining ring on to the end of the piston rod Attach the microswitch to the drive bracket using the screws Attach the connector to the microswitch Attach the terminals to wires and connect AS0922MP CL Page 46 Flow Rate arn INJECTOR PERFORMANCE CURVES BLACK ORDER NO V3010 1A Metric Units 2 20 40 500 5 Pressure kPa VIOLET ORDER NO V3010 1C Metric Units 9 4 10 200 40 EDJ 700 Pressure kPa WHITE ORDER NO V3010 1E Metric Units M ch Fow Rate lpm m o A tt e th a a 0 5 100 200 200 400 oco BW BIO 907 Pressure kPa Flew Rate lprn BROWN ORDER NO V3010 1B Metric Units 20 200 40 500 70 900 Pressure kPa RED ORDER NO V3010 1D Metric Units Flow Rate 100 20 300 400 50 00
60. y aligned to drive bracket i Ensure PC board is correctly snapped on to drive bracket Motor not operating a Replace motor b No electric power at outlet b Repair outlet or use working outlet 6 Control valve stalled in c Broken drive gear or drive cap c Replace AC adapter regeneration assembly d Defective PC board d Replace PC board e Broken drive gear or drive cap e Replace drive gear or drive cap assembly assembly f Broken piston retainer f Replace piston retainer g Broken main or regenerant piston g Replace main or regenerant piston 7 Control valve does not regenerate a AC adapter unplugged a Connect AC adapter automatically when REGEN button b No electric power at outlet b Repair outlet or use working outlet is depressed and held c Broken drive gear or drive cap c Replace drive gear or drive cap assembly assembly d Defective PC board d Replace PC board 8 Control valve does not a Bypass valve in bypass position a Put bypass valve in normal operation Regenerate automatically but does when REGEN button is depressed position Meter connection disconnected b Connect meter to PC board Restricted stalled meter turbine c Remove meter and check for rotation or foreign matter d Defective meter d Replace meter e Defective PC board e Replace PC board f Set up error f Check control valve set up procedure

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