Installation Instructions - Watts Water Technologies
Contents
1. Brine Tank Fill Position 27 SERVICE ASSEMBLIES Brine Line Flow Controls ProSense 60022 12 cis BLFC 125 GPM 5000 5600 9000 ProSense 60022 50 BLFC 50 GPM 5000 5600 9000 ProSense 60350 Brine Valve 9000 Bypass Assemblies 6004055 Bypass Valve 5600 3 4 6004188 Bypass Valve 5600 1 NPT A acre Bypass Plastic Assy Injector Assemblies ProSense 61794 Injector Assembly specify size of injector Tank Dia Injector DLFC BLFC 61794 0624 8 Brown 000 1 5 0 125 61794 0634 9 Brown 000 2 0 0 125 61794 0644 10 Brown 000 24 0 125 61794 0562 12 Violet 00 3 5 0 5 Meter Assemblies ProSense 15078 01 Adapter 1 Coupling 60080 icis Meter Assy 5600 9000 ProSense 3 4 Std Range AAA Meter Assy 5600 9000 ProSense 3 4 Ext 60389 eee Meter Assy 9000 ProSense 1 60389 Meter Assy 9000 ProSense 1 60389 20 Meter 9000 ProSense 1 BSP Metric COMO Meter Assy 9000 ProSense 1 Ext 60390NP Meter Assy 9000 ProSense 1 Ext N P 60390 20 Meter Assy 9000 ProSense 1 Ext BSP Metric 606122. Meter Assy 9000 ProSense 1 Std Range HW 150 60612 Meter Assy 9000 ProSense 1 Std Range HW 150 NP 14038 Meter Assy AA Meter Cap Assy Ext loci Meter Cap Assy 15219NP iiis Meter Cap Assy Std NP 192397 ines Meter Cap Assy Ext 15237 Meter Cap Assy Ext NP 19509 vie Impeller Meter 13509 01 Impeller Celcon HW 150 28 Piston Seal 8 Spacer Kits 61785 sara ProSense Upper Piston Kit 61 286 ProSense Lower Piston Kit Second Tank Assemblies ProSense 60425 12 Tube Assy ProSense 6 12 Tanks 60425 16 Tube Assy ProSense 13 16 Tanks 14865 Adapter Assy 2nd Tank ProSense 61449 Kit 1 05 Distributor Adapter Tools PU Stuffer Tool Assy 5600 9000 19061 ua Re Puller Assy Port Ring Tool DLFC Retainer Valve Body Assembly ProSense 40688 Valve Assy ProSense 18803 O ring 336 18569 Retainer Tank Seal Cover Assembly ProSense 61787 Cover Assembly ProSense SERVICE ASSEMBLIES continued 29 CALIFORNIA PROPOSITION 65 WARNING WARNING This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive
3. indicates that the time displayed is between 12 00 noon and 12 00 midnight there is no AM indicator PM indicator is not used if clock mode is set to 24 hour 4 When MIN is displayed the value entered is in minute increments 5 When g L is displayed the value for regenerant amount entered is in grams Liter of resin 6 When Kg is displayed the value entered is in kilograms or kilograins 7 Four digits used to display the time or program value Also used for error codes 8 Colon used as part of the time display 9 Locked unlocked indicator In Level Programming this is displayed when the current parameter is locked out It is also used in Level Il Programming to indicate if the displayed parameter is locked icon flashes when controller is in Level 10 When x2 is displayed a second regeneration has been called for 11 The recycle sign is displayed flashing when a regeneration at the next time of regeneration has been called for Also displayed continuous when in regeneration 12 The display cursor is next to SALT AMOUNT when programming the amount of regenerant 13 The display cursor is next to REGENERATION TIME when programming the time of regeneration and the days of regeneration 14 The display cursor is next to TIME DAY when programming the current time and day 15 The hourglass is displayed when the motor is running The camshaft should be turning 16 These cursors appear next t
4. 2 Controller Regeneration starts but control shows Err3 before completing regeneration harness is connected to motor and controller module Verify that Home Switch sensor is connected and in place Verify that motor gear has engaged cam gear If everything is connected try replacing in this order 1 Wire Harness Motor Home Switch Sensor Assy 2 Controller ERR 4 is displayed Hardness front detected with no water flow A ERR 6 is displayed Conductivity sensors reading out of range Check which tank in service and check if the sensors Defective sensors or no sensors are have been connected properly If already connected connected replace conductivity sensor probes with new ones Check Salt Light is displayed Press No regenerant draw or insufficient Ensure salt regenerant is available the regen button to turn off the check regenerant detected during regeneration salt light Check for regenerant draw Inspect regeneration line for leaks 22 ProSense METER FLOW DATA 1 Brass Meter 3 4 Mechanical Meter 1 1 1 1 1 1 1 1 1 4 4 30 ESTAS AI A 25 1 1 O a eee 30 mm Rp 25 35 30 20 15 10 35 Pressure Drop psid Pressure Drop psid 23 ProSense INJECTOR FLOW DATA 1600 SERIES INJECTORS Injector 2 Injector 000 0 50 0 00 20 1 100 PSI
5. External Drive Gear Assembly Upper lin Retaining Ring o Cam Triple ProSense Washer Thrust eri Screw Hex Washer Head iE Screw 6 32 x 3 8 Pan Head Scrw Flat Head 13 23 d 21 T d 16 Lod 40 1 20 ot 9 lt e 3 D 28 AD 5 fi h es A 8 E ji lt 4 7 T ox a 20 g d 7 5 477 2 8 64 4 29 e 22 15 Item No QTY PartNo Description Tiens 10340 Washer Lock 4 Zinc 11 MEME 16433 Switch Micro Low DB e E 10218 APA Switch Micro 20 i 15692 us Washer Plain 3 8 10302 AAA Insulator Limit Switch 22 ehe 12 18737 Drive Motor 24V 50 60 Hz iie 2 us 10339 AAA Nut Hex 4 40 Zinc Plated 24 ats queens 15134 Drive Gear Assembly Lower DO 1252026 43000 2 Cover ProSense 26 122 43035 2T uci 2 17020 Screw STL Hex WSH 6 20 x 3 8 2B css Tus 18547 se Strain Relief Cord nang Maans 42296 10 Plate Adapter Motor Kit 43056 Label ProSense 3d A disc 43112 ns Label Sensor Wires ProSense ProSense CONTROL VALVE ASSEMBLY Description Valve Body Assy ProSense Seal 5600 Spacer Spacer 9000 Screw Hex Washer Head Piston 9000 Upper Retainer Piston Rod Piston Rod Upper Plug End 5
6. SA DAYS Time Day Regeneration Time press Salt Amount then Y 4 Capacity SERES m Hardness Controller programming is complete NOTE If one of the following conditions occur Controller displays Err 3 and goes to home position or Power outage discharges the supercapacitor and when power is restored and the time of day is reset the regen icon will begin flashing This indicates that a delayed regeneration will occur at the next programmed time of regeneration and the system will regenerate by water usage Description Range Resin Volume Cubic feet 0 75 F to Select correct resin volume 4 00 Time of Day 12 hr Set to time of day Note Setting includes PM indicator Day of Week Set to actual day of the week Time of Regeneration Set to desired time of regeneration Days Override Days ys 0 Leave at E to disable Disab b5 to 30 Set to desired days between regeneration Salt Dosage Lbs f 3 Set to desired desired dosage to lbs per cubic feet of resin 15 Capacity Kilograins Capacity calculated by Logix Control Use to OVERRIDE calculated capacity 900 Hardness Grains gal 3 Set to actual water hardness to in grains per gallon 200 PROGRAMMING MODE continued In Service Display SU MO TU WE TH FR SA DAYS Time amp Day Regen Time amp Day Salt Amount Capacity 4 Hardness SU MO TU WE TH FR SA DAYS Time 8 Day Regen Time amp Day Salt Amount Capacity Hardness Figure 6
7. Silicone Compound available from Watts is recommended for best possible results Dow Corning 7 Release Compound is used in the manufacture of this control valve The use of other types of lubricants may attack the control s plastic or rubber components Petroleum based lubricants can cause swelling in rubber parts including O rings and seals Do not exceed water pressure of 125 psi 8 6 bar Do not exceed 110 F 43 3 C Do not subject unit to freezing conditions GENERAL INSTALLATION INSTRUCTIONS 1 Turn off water heater s 2 Turn off the main water supply to the home and open an inside faucet cold and hot to relieve any pressure within the plumbing system 3 Place the system in the desired installation location Make sure that the location is level and sturdy enough to support the weight of the system once it is in operation 4 Place the bypass valve in the bypass position 5 Connect the cold water supply to the inlet of the water softening system While constructing the supply line install a master supply valve user supplied in the supply line and close it 6 Connect the feed water line to the home to the outlet of the system 7 Plumb the drain line to an appropriate drain abiding buy all local city and state codes Use a 3 4 drain line for backwash flow rates that exceed 7 gpm or length that exceeds 20 6 m 8 Connect the brine tank to the water softener control valve brine inlet po
8. The display shows the number of the tank in service small digit next to CPH position The display also alternates between Capacity Remaining and Flow Rate faucet icon for the tank in service NOTE The Regen icon is only on when in regeneration NOTE The faucet icon is displayed on all the ProSense controls when there is flow The ProSense controller will show the faucet icon when the flow rate is displayed even if the flow rate is zero The faucet icon will turn off when the capacity is displayed In service flow rate display can be replaced with a clock display using Level Il Programming Parameter P10 Programming Overview The ProSense controller includes multiple program levels that allow water treatment professionals to customize the system for many water conditions Additionally historical data can be viewed allowing quick and easy troubleshooting In most cases Level Programming is all that is required to set up the water conditioning system for proper operation A brief description of each program level is listed below Level Used to program controller for normal applications Level II P Values Allows the installer to customize programming for non standard applications Level 1 C Values Allows the installer to adjust length of select cycles for non standard applications Level IV History H Values Allows access to historical information for troubleshooting the system NOTE If a button is no
9. Volume Holding SET for 3 seconds will reset control to factory defaults Days since last regeneration 0 256 Current Flow Rate Depends onturbineused H3 Water used today in gallons or m since Time of 0 131 070 or 0 1 310 7 m Regeneration Water used since last regeneration in gallons or m 0 131 070 or 0 1 310 7 m H5 Total water used since reset in 1005 0 999900 gallons or 0 9999m Holding SET key for 3 seconds will reset H5 and H6 to zero H6 Total water used since reset in 1 000 000 4 294 x 105 gal or 4 264 x 10 m Holding SET key for 3 seconds will reset H5 and H6 to zero Hr Average usage for Sunday in galonsorm 0131 070 galons or OA O TO He Average usage for Monday in gallons or mi 0 131 070 gallons or 0 1 310 70m Average usage Tor Tuesday in galons orm 0434070 gallons or 0 1 310 70me Average usage for Wednesday ingallons orm 0431070 gallons 0 131070 Average usage for Thursday in galons orm 0 131 070 gallons or 0 1 310 70m nz Average usage for Friday in galons orm 0434070 gallos or 0 1 310 70me Average usage for Saturday in gallons orm 0434070 gallons 0 1310790 H15 Peak Flow Rate 0 200 gpm or 1000Lpm Holding SET key for 3 seconds will reset H15 to zero Day and Time of Peak Fl
10. forms including tablets and granules These solid materials may be used directly without dissolving before use 1 Dosage A Two grams approximately 0 1 ounce 3 mL per cubic foot 2 Regenerant tank conditioners A Backwash the conditioner and add the required amount of hypochlorite to the well of the regenerant tank The regenerant tank should have water in it to permit the chlorine solution to be carried into the conditioner B Proceed with the normal regeneration 11 WIRING DIAGRAMS Connecting the ProSense Twin Alternating or Parallel Controller The twin sensor and extension cables are used for twin unit parallel and alternating applications Four standard connections are required for operation the power transformer the flow sensor motor optical sensor and the connection between tank 1 and tank 2 controls Figure 7 outlines these standard features TANK TANK 2 EA a rr p Figure 7 12 4 f Hr Tide bed Eo UH gt vege i gt gt 5 i aA __ Y POWERHEAD ASSEMBLY 26 25 30 Item No QTY Description Backplate 9000 T Nut Clip 8 32 Transformer US 24V 9 6VA Gear Drive Wheel Geneva P PER Nut Wire Tan E Screw Designer Cover Thumb Label Shaft Position Retaining Ring
11. harm California law requires this warning to be given to customers in the State of California For more information www watts com prop65 LIMITED WARRANTY Certain Watts products come with a limited warranty from Watts Regulator Co Other products may have no warranty or are covered by the original manufacturer s warranty only For specific product warranty information please visit www watts com or the published literature that comes with your product Any remedies stated in such warranties are exclusive and are the only remedies for breach of warranty EXCEPT FOR THE APPLICABLE PRODUCT WARRANTY IF ANY WATTS MAKES NO OTHER WARRANTIES EXPRESS OR IMPLIED TO THE FULLEST EXTENT PERMITTED BY APPLICABLE LAW WATTS HEREBY SPECIFICALLY DISCLAIMS ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANT ABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND IN NO EVENT SHALL WATTS BE LIABLE IN CONTRACT TORT STRICT LIABILITY OR UNDER ANY OTHER LEGAL THEORY FOR INCIDENTAL INDIRECT SPECIAL OR CONSEQUENTIAL DAMAGES INCLUDING WITHOUT LIMITATION LOST PROFITS OR PROPERTY DAMAGE REGARDLESS OF WHETHER IT WAS INFORMED ABOUT THE POS SIBILITY OF SUCH DAMAGES WWATTS A Watts Water Technologies Company USA Tel 800 659 8400 e www watts com Canada Tel 888 208 8927 e www wattscanada ca IOM WQ PROSENSE 1248 EDP 2915953 O 2013 Watts
12. 600 Retainer End Plug Seal Quad Ring 010 Link Piston Rod Screw 4 40 Screw STL Hex WSH 6 20 x 3 8 Washer Hague Drive Piston Lower ProSense Link Piston Rod 9000 9500 O ring ProSense Drain Body Injector 9000 O ring 011 Screen Injector Nozzle Injector 1 Natural Throat Injector O ring 021 Screw Hex Slotted Screw Hex WSH HD 14 Item No QTY Part No Description vir pM Trets 15348 O ring 563 28 ee 19173 ice Retainer DLFC Button 2O conces 12085 i Washer Flow 1 2 gpm Brine Valve Stem 9000 Seat Brine Valve Spacer Brine Valve Cap Brine Valve Spring Brine Valve Ring Retaining SS diia 16098 Washer Nylon Brine Ji sodas ym TASTE scies O ring 015 13245 Retainer BLFC SOL eres 12085 Washer Flow Control 50 gpm 40 ee Tinna 12550 Quad Ring 009 4 2 ons 13302 O ring 014 A 13244 Adapter BLFC 43 etes 13497 Air Disperser Injector Label Injector Label 5 gpm Spacer 4600 Retainer 32 mm O ring Dist 7000 Mueren 61419 AA Kit 1 05 Distributor Adapter 49 Miss 14906 Plate 9000 DO 14928 Plug End Stub 9000 ES Tn 60285 01 Injector Cap Assy ProSense ProSense SECOND TANK ASSEMBLY 42325 REVA Descrip
13. Body Meter 9000 1 A dinge 14960 Flow Straightener 1 Oii 13309 iii O ring 119 S nsus 25 15078 Adapter 1 Coupling 19250 ceo Clip Mounting Miras 14202 01 Screw Hex Wsh Mach 8 32 x 5 16 PA s Meter Cap Assy Ext Tos 152397 died Meter Cap Assy Ext 17 BYPASS VALVE ASSEMBLY 60040SS REVL 60041SS_REVK Item No QTY PartNo Description By Pass Body 3 4 By Pass Body 3 4 NP 5600 By Pass Body 1 By Pass Body 1 NP Seal By Pass 560CD Plug By Pass w Wax Plate By Pass Top Label By Pass Standard Mount Screw Hex Wsh Hd 10 24 x 1 2 Plate By Pass Bottom Lever By Pass Screw Sltd Indent 1 4 14 x 1 1 2 18 BYPASS VALVE ASSEMBLY Description OO 11 9 Pt 192 Osa Mounting 3 2 13314 Slot Ind Hex 8 18 x 60 4A 1 18706 Yoke 1 NPT Plastic PROBE KIT Item No Part No Description Jpn 30212618 Probe Cable Clips Kit 20 TROUBLESHOOTING 1 Water conditioner fails to regenerate A Electrical service to unit has been A Assure permanent electrical service check fuse interrupted plug pull chain or switch B Timer is defective B Replace timer C Power failure C Reset time of day 2 Hard water A By pass valve is o
14. IOM WQ PROSENSE Instructions for Installing ProSense Twin Alternating Water Softening Systems Service Manual TABLE OF CONTENTS JOB SPECIFICATION SHEET JOB SPECIFICATION SHEET 1 Job No EQUIPMENT CONFIGURATION 1 Modei Ne SAFETY ette 2 est HOW TO USE THIS MANUAL 2 Capacity Per Unit GENERAL AND COMMERCIAL INSTALLATION Mina TRAE INSTRUCTIONS esr iet reete 2 CONTROLLER FEATURES ad 4 Size Diameter Height PLACING WATER CONDITIONING SYSTEM INTO Brine Tank Size and Salt Setting per Regeneration OPERATION saca 5 ProSense Control Valve Specifications PROGRAMMING 6 1 Timer Gallon Setting Gallons DISINFECTION OF WATER CONDITIONING SYSTEMS 11 2 Regeneration Program Setting WIRING DIAGRAMS e ete 12 aves POWERHEAD ASSEMBLY 13 LS b Backwash Minutes ProSense CONTROL VALVE ASSEMBLY 14 bn Rapid Rinse Minutes ProSense SECOND TANK 5 15 i d Brine Tank Refill Minutes 3 4 METER ASSEMBLY 16 1 METER ASSEMBLY 17 3 Drain Line Flow Control ProSense BYPASS VALVE 58 18 4 Brine Refill Rate gpm BYPASS VALVE ASSEMBLY 19 injector cine PROBE KIT ttt 20 TROUBLESHOOTING 21 EQUIPMENT CONFIGURATION ProSense METER FLOW DATA 23 Prose
15. PSI Injector 3 Injector 00 0 60 1 1 1 1 1 1 1 1 1 1 1 1 T 1 1 1 1 1 e Brine Draw PS PSI Injector 4 Injector 0 a Sa inse R 1 0 50 A ia 0 10 0 00 100 120 80 40 20 1 Injector 4 0 80 gt Draw e ra a 0 00 20 40 60 80 100 1 20 PSI 24 PROSENSE CONTROL VALVE DIMENSIONS 1 2 14 NPT DRAIN PORT AF qua OM MA here Mia HI FEE 2 1 2 8 NPSM 0 85 27 81 61500 9100LNE_REVA 25 WATER CONDITIONER FLOW DIAGRAMS Tanks Switching Position Meter Initiated Regeneration In Service Position c oO gt IN de E 3 un Ne o o0 x S 9 zc n 89 N 6 ES c X 8 5 NS 26 WATER CONDITIONER FLOW DIAGRAMS continued Slow Rinse Position Rapid Rinse Position
16. arameters are accessible by pressing and holding the UP and SET buttons until the display shows a C value NOTE The controller must be in the treated water position to change settings Brine Draw 0 200 Ses Notes Automatically calculated from resin volume and salt dosage settings and draw rate Standard Backwash 0 20 7 Flow rate dictated by size of drain line flow controller Standard Fast Rinse 0 200 Rinses residual regenerant from tank Refill 0 200 Ses Notes Automatically calculated from resin volume and salt dosage settings and refill rate C13 Control uses C13 in place of C3 when the Cleaning Backwash 0 200 14 number of standard regenerations is more than or equal to the cleaning cycle interval P19 C1 Control uses C14 in place of C4 when the Cleaning Fast Rinse 0 200 number of standard regenerations is more than or equal to the cleaning cycle interval P19 Cannot be changed in Level Cycle Programming C2 Slow Rinse 0 200 Ses Notes Initial time automatically calculated to provide two bed volumes of rinse 5 4 PROGRAMMING MODE continued Level IV Viewing History H Values Historical information can be viewed by pressing the SET and DOWN buttons simultaneously with the ProSense controller in the home position Release both buttons when the controller displays an H value Press the UP or DOWN buttons to navigate to each setting Osea age mo Initial Setting Value Cubic Feet or Liters Resin
17. be displayed Resin Volume The amount of resin can be determined by the diameter of the tank Tank Diameter Resin Volume inches Cubic Feet 8 0 75 9 1 10 1 5 12 2 PROGRAMMING MODE continued Level Il Programming P Values Level Il Programming parameters can be adjusted to fine tune the conditioner s operation The parameters are accessible by pressing and holding the UP and DOWN buttons until the controller displays a P value NOTE The controller must be in the home position to change settings See Table for Level Il parameters Typically the Level Il parameters will not need to be adjusted as the default settings accommodate most applications Contact your water treatment professional before attempting any programming UnitsofMeasure of Measure JOUS 1 Metrie US 1 7 O US Metric 0 12 hour clock flow rate displayed 1 24 hour clock flow rate displayed Clock Mode 2 12 hour clock Time of Day displayed 3 24 hour clock Time of Day displayed Interval Months 0 Dissabled Number of days per month is fixed at 30 p12 Resin Tank Sensor 60 04 4 20 of Capacity Expressed as a percentage of resin bed capacity Placement remaining after lowest set of pins Disable Resin Tank 0 Resin Tank Sensors Enabled Sensors 1 Resin Tank Sensors Disabled E Rate gpm x 100 Used with salt amount to calculate refill time E Rate gpm x 100 Used with sal
18. be adjusted to a more accurate value Upon start up of a new system this light will stay illuminated until the resin has exhausted a few times Then it will turn off and function normally CONTROLLER FEATURES continued Keypad Buttons Figure 5 1 SET Used to accept a setting that normally becomes stored in memory Also used together with the arrow buttons 2 DOWN arrow Generally used to scroll down or decrement through a group of choices 3 UP arrow Generally used to scroll up or increment through a group of choices 4 REGENERATE Used to command the controller to regenerate Also used to change the lock mode NOTE If a button is not pushed for thirty seconds the controller returns to normal operation mode Pushing the Regenerate button immediately returns the controller to normal operation except when the controller is in regeneration mode or Level Il Programming mode Programming Conventions The ProSense controller is programmed using the buttons on the keypad The programming instructions are described two ways whenever a section has keypad input First a table shows simplified instructions Second text follows that describes the action In each table Action lists the event or action desired Keys are listed as e UP for up arrow 9 DOWN down arrow SET for set REGEN for regeneration Duration describes how long a button is held down P R for press and release HOLD for press and hol
19. d X sec for a number of seconds to press the button and hold it down Display calls out the display icons that are visible SYSTEM PROGRAMMING After you have performed the installation steps the conditioner will need to be programmed Follow these steps carefully as they differ from previous valve instructions NOTE The ProSense controller will be shipped in the service treated water position Do not rotate the camshaft before performing the following steps Power up The Controller Plug the transformer into a non switched outlet The display will show 9100 If this is the first time the control is powered up the display will show ifthe product is for USA otherwise it will show Finish programming the ProSense controller using the Level Programming instructions NOTE Er r3 will be displayed when the controller does not detect the cam at the home position and that the motor is turned on As soon as it detects the cam at the home position the motor will be turned off and error will disappear The camshaft will move to service if not already in service These cam movements may take up to 5 minutes Flowmeter Setting 1 Press UP key and DOWN key and hold for 3 seconds Now the control will enter into the Level Il Programming mode 2 Use DOWN key to scroll to the parameter P16 Flowmeter parameter setting 3 Use SET key to change the parameter value 4 Use UP DOWN key to set the value as per the flow
20. e iron filter unit should be installed ahead of the water softener Location Of Softener And Drain The softener should be located close to a drain Bypass Valves Always provide for the installation of a bypass valve Tank and Probe Assembly Use only 100 silicone lubricant on the probe O rings Figure 2 Do not allow the lubricant to come into contact with the probe pins Install the probe assemblies into the tank and secure with the locking clasp Figure 3 Important The pins on the probes will only fit into the bulkhead fittings one way The pins must go into the matching holes at the bottom of the fitting The probe with the shortest length of wire must be on top NOTE Do not attempt to tighten or loosen the Bulkhead fittings as they are secured with a locking adhesive Probe Pins N Figure 2 Lubricate Bulkhead Fitting Figure 3 Locking Clasp Valve to Tank Installation Instructions 1 Spin the valve onto the tank ensuring the threads are not cross threaded NOTE The main control valve and tank adaptor have right hand threads or clockwise to install 2 Rotate the valve freely without using force until it comes to a stop this position is considered zero 3 Rotate the valve clockwise from zero between turn and 75 turn Figure 4 1 2 Tum a 1 4 Turn Zero Zero Figure 4 NOTE If lubricant is required a silicone compound is strongly recommended Dow Corning
21. edia tank in the upright position Do not turn upside down or drop Turning the tank upside down or laying the tank on its side can cause media to enter the valve Use only regenerants designed for water conditioning Do not use ice melting salt block salt or rock salt During cold weather it is recommended that the installer warm the valve to room temperature before operating Teflon is a trademark of E l duPont de Nemours HOW TO USE THIS MANUAL This installation manual is designed to guide the installer through the process of installing and starting up water conditioning systems featuring the ProSense controller This manual is a reference and will not include every system installation situation The person installing this equipment should have Training on the ProSense control valve Knowledge of water conditioning and how to determine proper control settings Adequate plumbing skills PRE INSTALLATION CONSIDERATIONS Water Pressure A minimum of 25 pounds of water pressure is required for regeneration valve to operate effectively Electrical Facilities A continuous 115 volt 60 Hertz current supply is required Make certain the current supply is always hot and cannot be turned off with another switch Existing Plumbing Condition of existing plumbing should be free from lime and iron buildup Piping that is built up heavily with lime and or iron should be replaced If piping is clogged with iron a separat
22. egeneration The ProSense controller features several options that offer Pressing and releasing the REGEN button while the controller additional flexibility for manually regenerating the softener On is in regeneration will program the control for a delayed second twin tank systems the tank in standby will move to service regeneration A flashing x2 icon next to the regeneration icon Then the tank that was in service will be regenerated will appear indicating a second regeneration will start when the time of day reaches the programmed time of regeneration Delayed Manual Regeneration The delayed second regeneration will be performed on the new Press and release the REGEN button to start a delayed tank in service manual regeneration The Regeneration icon on the display will flash indicating a regeneration will start when the time of Double Immediate Manual Regeneration day reaches the programmed time of regeneration Pressing Back to Back manual regenerations are initiated by pressing the REGEN button again will turn off the regeneration icon and and holding the REGEN button for three seconds while the cancel the delayed regeneration controller is in the regenerating mode A solid x2 icon next to the regeneration icon will appear indicating a second manual regeneration will start immediately after current regeneration is complete 10 DISINFECTION OF WATER CONDITIONING SYSTEMS The materials of construction in the modern water conditioning
23. l B Remove power head assembly and inspect bore Remove foreign material and check control in various regeneration positions C Internal control leak C Replace seals and piston assembly 21 TROUBLESHOOTING continued ProSense Controller Problem Sm ERR 1 is displayed Program settings have been corrupted Press any key and reprogram Level settings ERR 3 is displayed Controller on tank 1 does not know the Wait for two minutes for the controller to return to Home position of the camshaft Camshaft should position The hourglass should be flashing on the be rotating to find Home position display indicating the motor is running Camshaft on tank 1 is not turning during Check that motor is connected Verify that motor wire ERR 3 display harness is connected to motor and controller module Verify that Home switch sensor is connected and in place Verify that motor gear has engaged cam gear If everything is connected try replacing in this order 1 Wire Harness Motor Home Switch Sensor Assy 2 Controller Camshaft on tank 1 is turning more than five Verify that Home Switch sensor is in place and minutes to find Home position connected to wire Verify that camshaft is connected appropriately Verify that no dirt or rubbish is clogging any of the cam slots If motor continues to rotate indefinitely replace the following components in this order 1 Wire Harness Motor Home Switch Sensor Assy
24. meter connected to the system 5 Use SET key to store the modified value Tank In Service Parameter Setting 1 Use DOWN key to scroll to the parameter P18 Tank In Service parameter setting 2 Use SET key to change the parameter value 3 Use UP DOWN key to set the value as per the tank number shown by the indicator lablel on the valve 4 Use SET key to store the modified value and wait for 30 seconds to let the control back to service mode PROGRAMMING MODE Level Programming ProSense Screen Buttons to Press SU MO TU WE TH FR SA DAYS TimelDay Regeneration Time Salt Amount then Y press Hardness SU MO TU WE TH FR SA DAYS Time Day Regeneration Time me press Salt Amount r7 TRU then Y or Cape press Hardness SU MO TU WE TH FR SA DAYS TimelDay Regeneration Time press Salt Amount then 4 or Capacity Hardness press SU MO TU WE TH FR SA DAYS TimelDay Regeneration Time 4 press Salt Amount then a or Capacity Hardness LESS E SU TU WE TH FR SA DAYS Time Day Regeneration Time press m Salt Amount LI then Y or Capacity Hardness p ress SU TU WE FR SA DAYS Time Day Regeneration Time press Salt Amount 4 then Y Capacity press B Hardness SU MO TU WE TH FR SA DAYS Time Day ress Regeneration Time y Salt Ai it 77 to override press Capacity then y or Hardness press SU MO TU WE TH FR
25. ning system Heat can adversely affect the plastic control valve and bypass valve All plastic connections should be hand tightened Teflon tape may be used on connections that do not use an O ring seal Do not use pipe dope type sealants on the valve body Do not use pliers or pipe wrenches Do not use petroleum based lubricants such as Vaseline oils or hydrocarbon based lubricants Use only 100 silicone lubricants Use only the power transformer supplied with this water conditioning system All electrical connections must be completed according to local codes The power outlet must be grounded Install an appropriate grounding strap across the inlet and outlet piping of the water conditioning system to ensure that a proper ground is maintained To disconnect power unplug the AC adapter from its power source Observe drain line requirements Do not support the weight of the system on the control valve fittings plumbing or the bypass Do not allow this water conditioning system to freeze Damage from freezing will void this water conditioning System s warranty Operating ambient temperature 34 to 120 F 1 to 49 C Operating water temperature 34 to 100 F 1 to 38 C Operating water pressure range 25 to 120 psi 1 38 to 8 27 bar In Canada the acceptable operating water pressure range is 25 to 100 psi 1 38 to 6 89 bar Observe all warnings that appear in this manual Keep the m
26. nstallation steps 11 12 13 and 14 of the General Installation Instructions to purge the air from the second tank 16 Check for leaks and repair as needed 17 Installation is now complete and the system is ready for programming and one cycle of brine tank refill so that the correct amount of water is in the brine tank for the first regeneration cycle The brine tank refill must be done after programming the system ProSense Controller Operation Power Loss Memory Retention The ProSense controller features battery free Time of Day and Day of Week retention during temporary loss of power A super capacitor is designed to keep time for 8 to 24 hours depending on the installation If the super capacitor is exhausted the ProSense control will display four dashes immediately upon power up The Time of Day and Day of Week must be reset All other programmed parameters are stored in the static memory and are retained CONTROLLER FEATURES Display Icons amp Cursors 16 7 Time Day ho em Time 15 12 Amount 11 did 26 P 24 14 13 25 NOTE In normal operation and during programming only a few of the icons are actually displayed 1 This cursor is displayed when the days between regeneration are being programmed used with 5 to 30 day regeneration programming 2 One of these cursors is displayed to indicate which day will be programmed into the controller 3 PM
27. o the item that is currently displayed 17 X100 multiplier for large values 18 When Lbs ft3 is displayed the value for regenerant amount entered is in pounds cubic foot of resin 19 Faucet is displayed when the current flow rate is displayed Control may show the faucet and O indicating no flow 20 Maintenance interval display turns on if the months in service exceed the value programmed in P11 21 Displays the tank in service durning normal operating mode Used with 22 23 and 24 in programming mode or regeneration 22 History Values H The number displayed by 23 identifies which history value is currently displayed 23 Parameter P Displayed only in Level Il Programming The number displayed by 21 identifies which parameter is currently displayed 24 Cycle C The number displayed by 21 is the current cycle in the regeneration sequence 25 Hardness setting 26 Capacity display shows estimated system capacity Check Salt Light A check salt LED light indicator is located at the bottom left of the controller keypad buttons This light indicates by illuminating that the conductivity probes did not see a shift in conductivity during the last service cycle before regeneration was called for by the meter This could be an indicator that the brine tank is out of salt It could also indicate that the hardness of the feed water has come down and the hardness value programmed in Level 1 Programming needs to
28. ow Rate Time and day that peak flow occurred 5 7 17 Months since service 0 2184 months Holding SET key for 3 seconds will reset H17 H18 and H19 to zero Number of Low Salt Alarms 0 665636 pu Number of Reduced Capacity Alarms 0 665536 222 Number of regenerations since last serviced 0 65536 Holding Set key for 3 seconds will reset Hrto zero H5 H15 H17 values be reset by pressing and holding for 3 seconds while the value is being displayed Program Reset Immediate Manual Regeneration The ProSense controller can be reset to original factory Pressing and holding the REGEN button for three seconds parameters when viewing the HO parameter Press and hold starts an immediate manual regeneration A solid regeneration the SET button for three seconds while HO is displayed icon will be displayed The controller will immediately begin Release the button All settings except for Time of Day and Day a regeneration on the tank in service To advance to the next of Week will be reset The ProSense controller will now display step in the regeneration cycle press and release the SET and the resin volume Refer to Level Programming UP buttons simultaneously To advance the system through all NOTE After a program reset all programmed values will steps of regeneration and return to service press and hold the reset to default settings SET and UP keys simultaneously for three seconds Manual Regeneration Options Delayed Second R
29. pen A Close by pass valve B No salt is in brine tank B Add salt to brine tank and maintain salt level above water level C Injector screen plugged C Clean injector screen D Insufficient water flowing into brine tank D Check brine tank fill time and clean brine line flow control if plugged E Hot water tank hardness E Repeated flushings of the hot water tank is required F Leak at distributor tube F Make sure distributor tube is not cracked Check O ring and tube pilot bed Increase frequency of regeneration C Inlet of control plugged due to foreign C Remove piston and clean control material broken loose from pipes by recent work done on plumbing system 5 Loss of mineral through drain line A Air in water system A Assure that well system has proper air eliminator control Check for dry well condition B Improperly sized drain line flow control B Check for proper drain rate 6 Iron in conditioned water A Fouled mineral bed A Check backwash brine draw and brine tank fill Increase frequency of regeneration Increase backwash time 9 Control cycles continuously A Misadjusted broken or shorted switch A Determine if switch or timer is faulty and replace it or replace complete power head 10 Drain flows continuously A Valve is not programming correctly A Check timer program and positioning of control Replace power head assembly if not positioning properly B Foreign material in contro
30. rt using the factory supplied fittings and tubing Add enough water to the brine tank so that water covers the top of the air check DO NOT ADD SALT AT THIS TIME 9 Open the user supplied feed water valve Check for leaks and repair as needed 10 Allow the inside hot and cold faucet to remain open until all air has been purged from the plumbing system Then close the faucet 11 Locate Manual Regeneration Options in this manual and follow the steps to initiate an Immediate Manual Regeneration Once you have read that section place the system in backwash and unplug the system from its electrical outlet once it has cycled into the backwash position This will stall the unit is backwash so can be purged from one of the tanks Look on the right side of the control valve it has indicators showing which position the control valve is in during Regeneration and which tank is In Service Tank one has control valve and tank two has adapter 12 Adjust the user supplied feed water valve to 1 4 open and place the bypass valve into the service position 13 Air will come out of the drain line until the tank in backwash is completely purged of air Then water will flow to drain Allow water to flow to drain for 15 minutes or until the water to drain is clear of resin color throw 14 Plug the system back into the electrical outlet and manually cycle it through the remaining regeneration steps until it arrives in the service position 15 Repeat i
31. se Water Softener Configuration ProSense INJECTOR FLOW DATA EM 1600 SERIES 24 Tank2 Tank 1 dad ProSense CONTROL DIMENSIONS 25 WATER CONDITIONER FLOW 26 ne SERVICE ASSEMBLIES 28 Inlet Tank 2 Adapter Bypass Valve Adapter Clips Main Control Valve 42265 REVA Figure 1 WIWATTS SAFETY INFORMATION This water conditioner s control valve conforms to UL CE Standards Generic valves were tested and certified for compliance as verified by the agency listing Please review the entire Installation and Operation Manual before installing the water conditioning system As with all plumbing projects it is recommended that a trained professional water treatment dealer install the water conditioning system Please follow all local plumbing codes for installing this water conditioning system This system will not make microbiologically unsafe water safe Water that is unsafe must be treated separately from this conditioner This water conditioning system is to be used only for potable water Inspect the water conditioning system for carrier shortage or shipping damage before beginning installation Use only lead free solder and flux as required by federal and state codes when installing soldered copper plumbing Use caution when installing soldered metal piping near the water conditio
32. system will not support bacterial growth nor will these materials contaminate a water supply During normal use a conditioner may become fouled with organic matter or in some cases with bacteria from the water supply This may result in an off taste or odor in the water Some conditioners may need to be disinfected after installation and some conditioners will require periodic disinfection during their normal life Depending upon the conditions of use the style of conditioner the type of ion exchanger and the disinfectant available a choice can be made among the following methods Sodium or Calcium Hypochlorite These materials are satisfactory for use with polystyrene resins synthetic gel zeolite and bentonites 5 25 Sodium Hypochlorite These solutions are available under trade names such as Clorox If stronger solutions are used such as those sold for commercial laundries adjust the dosage accordingly 1 Dosage Polystyrene resin 1 2 fluid ounce 35 5 mL per cubic foot Non resinous exchangers 0 8 fluid ounce 23 7 mL per cubic foot 2 Regenerant tank conditioners A Backwash the conditioner and add the required amount of hypochlorite solution to the well of the regenerant tank The regenerant tank should have water in it to permit the solution to be carried into the conditioner B Proceed with the normal regeneration Calcium Hypochlorite Calcium hypochlorite 7096 available chlorine is available in several
33. t amount to calculate draw time a oo 1 1 Autotrol turbine 2 2 Autotrol turbine 3 User defined K factor 4 Fleck 3 4 Paddle 5 Fleck 3 4 Turbine 6 Fleck 1 Paddle 7 Fleck 1 1 1 2 Turbine 8 Fleck 1 1 2 Paddle 9 Meter Factor K factor P16 3 K factor or Pulse 0 01 99 99 equivalent Pulse Equivalent P16 9 Cleaning Cycle Interval 0 100 Number of standard regeneration cycles between cleaning regeneration cycles The controller will automatically adjust the Hardness Setting P8 when the sensors in the resin tank detect a hardness front passing This automatic adjustment to the hardness setting may result in the system passing hard water near the end of the service cycle if the resin tank sensor placement setting P12 is wrong The sensor placement setting P12 must be reduced to eliminate the problem Reducing the Capacity Setting P7 or increasing the Hardness setting P8 will only produce a temporary solution NOTE 1 Default selected with initial setting value 2 Facotry Default is 0 for North America units and 1 for World units PROGRAMMING MODE continued Level Ill Cycle Programming C Values Several Level Ill program parameters can be adjusted to fine tune valve operation for non standard applications Typically these parameters will not need to be adjusted as the default settings accommodate most applications Contact your Water Treatment Professional before attempting any programming The p
34. t pushed for thirty seconds the controller returns to normal operation mode Level I Programming The ProSense controller can be quickly programmed by following the sequential procedure in the section Placing Water Conditioning System Into Operation Level Program parameters are those that can be accessed by pressing the UP or DOWN buttons Step by step instructions are shown on previous page Resin Volume Setting Set to match the volume cubic feet of resin in the mineral tank Time of Day Includes PM indicatior Can be set to display as a 24 hour clock See Level II programming Day of Week Set to actual day of the week Time of Regeneration Fully adjustable Default is 2 00 AM Days Override Range 0 5 to 30 days Leave at 0 to disable Salt Dosage Set at pounds of salt per cubic foot of resin in the conditioner tank NOTE When the controller is set up for a twelve hour clock a PM indicator will illuminate when the displayed time is in the PM hours There is no AM indicator Programming the Lockout Feature All Level parameters can be locked out when the controller is in Level 1 Programming Simply press the REGEN button during Level Il Programming and a lock icon will appear indicating that the specific setting has been locked out When locked out the setting cannot be adjusted in Level Programming To disable the Lock Out feature press the REGEN button when in Level Il The lock icon will not
35. tion 40678 Ring ProSense Yoke Retainer pia 13287 O ring 123 T 14865 Adapter Assy 2nd Tank ProSense 19054 O ring 124 tes 40538 Retainer 32mm O ring Dist 7000 61419 Kit 1 05 Distributor Adapter 18303 O ring 336 are 13255 Clip Mounting Lus 14202 01 Screw Hex Wsh Mach 8 32 x 5 16 3 4 METER ASSEMBLY 42293 REVA Item No QTY PartNo Description 14613 Flow Straightener O 4 12473 cms Screw Hex Wsh 10 24 x 5 8 diosa Maori 14038 Meter Cap Assy r Tasso 13847 O ring 137 Std 560CD Meter clear 18509 Impeller Meter sentes 4 13314 Screw Slot Ind Hex 8 18 60 y c 19255 ite Clip Mounting 4 19905 O ring 119 Duros diss 15150 Meter Cap Assy Ext Mess 15287 Meter Assy Ext 1382 Body Meter 5600 1 METER ASSEMBLY 42294 REVA Item No QTY PartNo Description diia 4 12112 Screw Hex Hd Mach 10 24 x 1 2 2 15218 Meter Cap Assy 15297 nte Meter Cap Assy EXT iaa 1384 cse O ring 137 STD 560CD Meter rr 13509 iine Impeller Meter 13509 01 Impeller Celcon AAA Post Meter Impeller B etes qe 15043
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