(TTLX) X-Factor Twin Tank Softener Manual
Contents
1. NOT SHOW 1 THIS WATER METER SHOULD NOT BE USED AS THE PRIMARY MONITORING DEVICE FOR CRITICAL OR HEALTH EFFECT APPLICATIONS REFILL FLOW CONTROL ASSEMBLY H4612 Nut3a8 1 __ 1 0ringolg9 _V3165 01 Retainer Assy 1 V8182 RFC Assembly includes V3182 RFC Flow Proper RFC orientation directs refill water flow towards the washer face with rounded edge and text PAGE 14 V4017 01 TT Interconnect Fitting Assembly up to 10 tanks V4052 01 TT Interconnect Fitting Assembly for 12 to 21 Tanks 5 cut to length Description WS1 NUT 1 QUICK CONNECT WS1 SPLIT RING O RING 215 WS1 FITTING 1148116 PVC SOLVENT PIPE PVC SCH 80 17 X 2 D1400 1191 In Out Head Fitting Installation Instructions Installation fittings are designed to accommodate minor plumbing misalignments but are not designed to support the weight of a system or the plumbing e Slide nut on first then the split ring and o ring e Hand tighten the nut only The V401 7 01 twin tank control valve interconnect kit can be used on tanks up to 10 in diameter and is packed in with control valve If using 12 diameter tanks or larger order optional kit number V4052 01 twin taniceontrol valve interconnect Kit for 12 thru 21 diameter tanks V3180__ O RING 337 V3105 O RING 215 DISTRIBUTOR TUBE PAGE 15 DRAIN LINE 3 4 H4615 Elbow Locking C2. Drop will flash while water is being treated RIME OF DAY A 635 Contact Screen 555 9222229 REMAINING CAPACITY 650 SET TIME OF DAY Current time of day needs to be entered during initial installation and adjusted when daylight saving time begins or ends If an extended power outage occurs and depletes the on board non rechargeable coin cell battery when power resumes the time of day should be reset and battery replaced STEP 1 Press STEP 2 Current Time hour Set the hour of the day using j or buttons AM PM toggles after 12 Press C to go to Step 3 STEP 3 Current Time minutes Set the minutes of the day using 4 or iv buttons Press NEXT to exit Set Time of Day Press to return to previous step RETURN TO NORMAL MODE ADJUST HARDNESS DAYS BETWEEN REGENERATIONS OR TIME OF REGENERATION MEN STEP 1 Press C and simultaneously for 3 seconds to access Installer Display Settings E 4 an Ll STEP 2 STEP 2 Hardness Set the amount of hardness in grains of hardness as calcium carbonate per gallon using the Or iv buttons The default is 20 with value ranges from 1 to 150 in 1 grain Ar increments Note The grains per gallon can be increased if soluble iron needs to be reduced Press to go to step 3 Press to exit Installer Display Settings STEP Day Override Set the maximum number of days between regenerations If value set to O
3. INSTALLATION OPERATING AND SERVICE MANUAL TWIN TANK WATER SOFTENER WITH THE X FACTOR CONTROL VALVE 7 TTLX 150 7 T TLX 200 7 1 TLX 3800 7 1 TLX 400 7 T TLX 600 7 TTFESLX 60 7 TTFESLX 90 7 TTFESLX 120 7 TTFESLX 180 Congratulations on purchasing your new Lancaster Water Softener This unit is designed to give you many years of trouble free service When installed in accordance with the following instructions and if given reasonable care clear soft water will be the result For servicing and future inspection purposes please file this booklet with your important documents In the event that you need assistance for servicing your water softener please first contact the professional contractor who installed the system TABLE OF CONTENTS Job Specifications 4 Pre Installation Review pp General Installation and Service Warnings scccccseeceeceeeeeecesececeeeeeeeseceeseueeesseaeeesseeeeesseeeeeas Bybass valve msialausomnmsiucuonsagrams sasasi aaa aa OE Placing SOTOMCr MANO ga baga are saa General Operation sae es E DET SG Adjust Hardness Days Between Regenerations or Time of Regeneration LOW BANO PIN ERREUR Contact Screen Programming TER SDGCINCQUOEIS Sanan aana a ga aa ven orbi a aa ai E a aan an a amet NSO SENICE SCION cedem nag daa aa E cestode aaa Ba a a NA Kaga an A aan TOUDE STOO ING kaake
4. please press and hold the NEXT amp the REGEN buttons simultaneously for 3 to 5 seconds to perform a soft reset which will synchronize the control valves positions PAGE 27 TROUBLESHOOTING Possible Cause Solution a No power at electric outlet a Repair outlet or use working outlet b Control valve Power Adapter not plugged b Plug Power Adapter into outlet or into outlet or power cord end not connect power cord end to PC Board connected to PC board connection connection 1 No Display on PC Board c Improper power supply c Verify proper voltage is being delivered to PC Board d Defective Power Adapter d Replace Power Adapter e Defective PC Board e Replace PC Board a Power Adapter plugged into electric outlet a Use uninterrupted outlet controlled by light switch b Tripped breaker switch and or tripped GFI b Reset breaker switch and or GFI switch c Power outage c Reset time of day If PC Board has battery back up present the battery may be depleted See Front Cover and Drive Assembly drawing for instructions connection on PC Board labeled METER on PC Board 3 Display does not indicate that water is flowing foreign material Refer to user instructions for how the display c Meter wire not installed securely into c Verify meter cable wires are installed indicates water is flowing three pin connector securely into three pin connector labeled METER d Defective meter d Replace meter e Defective PC Board e R
5. the cable Position the large white drive gear with the A pointing toward the 1 o clock position and then press it onto the stainless steel drive shaft make sure it snaps amp locks into position NOTE The white A text orientated i i i towards 1 o clock drive gear is splined to the drive shaft and will only assemble in one orientation Because of this it is not necessary that the discs and gear be exactly positioned the positioning needs to be Splines can only fit one direction approximate but they have to fit on the shaft on shaft Next install the larger black reducing gear onto the stainless steel shaft then install the remaining smaller reducing gears from left to right Re install the grey reducing gear cover over the gears and affix with the 3 stainless steel screws Now you can re install the drive motor by pressing the spring clip loop to the right then rotate the motor as you are inserting it so the gear of the motor meshes properly with the reducing gears Release the spring clip loop and rotate the motor untill the motor housing engages with the plastic nub inside the housing that holds the motor in place and make sure that the top of the motor is flush with the top of the grey gear housing Press the drive motor wires down into the strain relief of the drive cap now you can re install the cover assembly After completing any valve maintenance involving the valve drive assembly or the transfer drive assembly
6. application needs 9 Control valve uses too much regenerant c Control valve regenerates frequently c Check for leaking fixtures that may be exhausting capacity or system is undersized a Low water pressure a Check incoming water pressure water pressure must remain at minimum of 25 psi 10 Residual regenerant being delivered to service b Incorrect injector size b Replace injector with correct size for the application c Restricted drain line c Check drain line for restrictions or debris and clean a Improper program settings a Check refill setting b Plugged injector b Remove injector and clean or replace c Drive cap assembly not tightened in c Re tighten the drive cap assembly properly 11 i d Damaged seal stack assembly d Replace seal stack Excessive water in regenerant tank e Restricted or kinked drain line e Check drain line for restrictions or f Plugged backwash flow controller f Remove backwash flow controller and clean or replace d Drain line restriction or debris cause d Inspect drain line and clean to correct 12 Control valve fails to draw in regenerant excess back pressure restriction e Drain line too long or too high e Shorten length and or height f Low water pressure f Check incoming water pressure water pressure must remain at minimum of 25 psi a Power outage during regeneration a Upon power being restored control will finish the remaining regeneration time
7. b Check piston and seal stack assembly check reduction gears check drive bracket and main drive gear interface Press NEXT and REGEN buttons for 3 seconds to resynchronize software 15 E2 Err 1002 Err 102 Control valve with piston position or disconnect motor ran too short and was unable to find the power supply from PC Board for 5 next cycle position and stalled seconds and then reconnect c Main drive gear too tight c Loosen main drive gear Press NEXT and REGEN buttons for 3 seconds to resynchronize software with piston position or disconnect power supply from PC Board for 5 seconds and then reconnect d Improper voltage being delivered to PC d Verify that proper voltage is being Board supplied Press NEXT and REGEN buttons for 3 seconds to resynchronize software with piston position or disconnect power supply from PC Board for 5 seconds and then reconnect a Motor failure during a regeneration a Check motor connections then Press NEXT and REGEN buttons for 3 seconds to resynchronize software with piston position or disconnect power supply from PC Board for 5 seconds and then reconnect b Foreign matter built up on piston and b Replace piston and stack assemblies stack assemblies creating friction and Press NEXT and REGEN buttons for drag enough to time out motor 3 seconds to resynchronize software with piston position or disconnect power supply from PC Board for 5 seconds and then reconnect 16 E3 E
8. banner text Phone Number Set phone number using the Or 7 arrow Press C to forward to the next digit Press to return to previous digit Banner Text Set the banner text up to a maximum of 44 characters Use the or 4 to select letters of the alphabet numbers ampersand amp or a space in the banner text Press C to forward to the next character or to exit the Installer Display Settings PAGE 8 MODEL NUMBER Service Flow GPM at 15 PSI Pressure Drop Resin Tank Size Diameter x Height inches Resin Cu Ft each tank Brine Tank Size inches Brine Tank Capacity Lbs NaCl Drain Line Flow Control GPM Brine Line Re Fill Flow Control GPM Injector color MODEL NUMBER Service Flow GPM at 15 PSI Pressure Drop Resin Tank Size Diameter x Height inches Resin Cu Ft each tank Cabinet Size including top cover W x L x H Cabinet Capacity with grid Los NaCl Drain Line Flow Control GPM Brine Line Re Fill Flow Control GPM Injector color X FACTOR SERIES TTLX SPECIFICATIONS 7 TTLX 150 7 TTLX 200 7 TTLX 300 7 TTLX 400 13 17 16 18 8 x 44 10 x 40 10 x 54 12 x 48 0 75 1 1 5 2 15 17 36 15 17 36 15 17 36 18 40 275 275 275 450 1 0 1 7 1 7 2 7 0 5 0 5 0 5 0 5 1C Violet 1E White 1E White 1F Blue X FACTOR SERIES TTLXC SPECIFICATIONS 7 TTLXC 150 18 10 x 35 0 75 13 5 x 22 5 x 44 225 17 0 5 1E White P
9. flow control retainer assembly refill flow control polytube insert and nut assembly The refill flow control retainer fits in the refill elbow The refill 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 molded contour that delivers a steady 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 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 An optional elbow can be ordered which accommodates a 72 flexible tube for a high regenerant draw rate situation G injectors and larger Both elbows use the same refill flow control and retainer If the control valve is to be used as a non regenerant filter control valve the refill elbow is removed and replaced with a refill port plug P N V3195 01 PAGE 20 DRAIN LINE FLOW CONTROL AND FITTING ASSEMBLIES The drain line flow control assembly includes a drain line flow control and a fitting The drain line flow control allows proper
10. 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 OPERATION NORMAL OPERATION BYPASS OPERATION 1 Normal Operation Position The inlet and outlet TREATED SUPPLY WATER SUPPLY 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 the regeneration cycle see figure 1 2 Bypass Position The inlet and outlet handles point to the center of the bypass the control valve is isolated from the water pressure contained in the plumbing system Untreated water is supplied to the SUPPLY WATER ENTERS plumbing system see figure 2 figure 1 figure 2 3 Diagnostic Position The inlet handle points in the direction of flow and the outlet handle points to DIAGNOSTIC MODE SHUT OFF MODE the center of bypass valve system water pressure is EL allowed to the control valve and the plumbing system ROTE EAS EMEN while not allowing water to exit from the control valve to the plumbing see figure 3 4 Shut Off Position The inlet handle
11. is now in the REGENERANT DRAW position Momentarily press again Valve is now in the BACKWASH position If using optional bypass SLOWLY turn bypass valve to DIAGNOSTIC position See figure 3 on page 4 or slowly open inlet valve to allow water to slowly enter Softener When water is flowing steadily to drain without the presence of air momentarily press again Display will read RINSE Open the outlet valve of the softener or if using optional bypass place to NORMAL OPERATION MODE see figure 1 on page 4 Allow control to finish the RINSE cycle Allow the control to automatically advance to the FILL position Close inlet valve then repeat above steps for the second softener tank When the FILL cycle is reached press to advance the SOFTENING position Now load the brine tank with salt Solar Salt is recommended The brine tank level should be checked every couple of weeks to determine salt usage Keeping the brine tank salt level at least 1 2 full is recommended SANITIZING Use 2 oz of 5 4 unscented household chlorine bleach for each cubic foot of resin Pour bleach directly into the 4 diameter white brine well located inside the brine tank Press and hold the for 5 6 seconds until the motor starts running Allow system to complete the regeneration automatically Check for other local ant state codes which may also specify sanitation methods Note The first step of the regeneration process is to fill the brine tank with
12. 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 molded contour The flow rates are within 10 over the pressure range of 20 psi to 125 psi 1 4 bar to 8 6 bar See table for flow rate information DRAIN LINE FLOW CONTROL AND FITTING ASSEMBLY INFORMATION Fitting Control Order No Line Flow Control gpm lpm V3162 010 V3162 013 V3162 017 V3162 022 V3162 027 V3162 032 V3162 042 V3162 053 V3162 065 V3162 075 V3162 090 V3162 100 V3190 090 V3190 100 V3190 110 V3190 130 V3190 150 V3190 170 V3190 200 V3190 250 250 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 77 drain line elbow which accommodates 5 8 polytube or 94 NPT drain line connections The optional nut and polytube insert for the 34 drain line elbow is designed for use with flexible polytube only The 74 drain line elbow be rotated 180 degrees so the outlet can be orientated to the nearest drain The same retainer is used for all drain line flow controls for the 74 fitting Drain line flow controls designed for the 3 4 fitting are available for flow rates ranging from 0 7 to 10 gpm 2 6 to 37 9 Ipm An optional 1 straight drain line fitting is available to accommodate drain line flow rates rangin
13. points to the center of the bypass valve and the outlet handle points in the direction of flow the water is shut off to the plumbing system If water is available on the outlet side of the softener it is an indication of water bypass around the system i e a plumbing connection somewhere in the building bypasses the system see figure 4 figure 3 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 center of the bypass valve and back several times to ensure rotor is turning freely The nuts and caps are designed to be unscrewed or tightened by hand If necessary a pliers or the service spanner wrench 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 Refer to page 19 for bypass valve parts diagram and service spanner wrench information 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 pointers are lined up with the control valve bod
14. 1 Body Assy Downflow After completing any valve maintenance involving the drive assembly or the drive cap assembly and pistons unplug power source jack from the printed circuit board black wire and plug back in or press and hold awar and buttons for 3 seconds This reseis the electronics and establishes the service piston position The display should flash the software version and then reset the valve to the service position V3010 1A INJECTOR ASSY A BLACK V3010 1B INJECTOR ASSY B BROWN V3010 1C INJECTOR ASSY C VIOLET 5 1 The injector plug and the injector each contain one 011 lower and 013 upper o ring The nut and caps are designed to be unscrewed or tightened by hand or with the service spanner wrench see page 19 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 a screwdriver in slots on caps and or tap with a hammer PAGE 12 Twin Transfer CAR Ji IN AS JAIN T A 227 AL 0 J PAGE 13 Twin Transfer 6 yv40o4 TI TRANSFER SPRING SUPPORT __8 __ V83105 O RING 215 DISTRIBUTOR TUBE 9 oORNG37 0 0 1 10 V40f6 TITRANSFERSEAL 6 11 vso3l TIBODYSFTWIRREGEN 1 12 yv4023 TI TRANSFER DRIVE SHAFTASY 1 13 V328 ORINGIIO 2 14 04006 01 TI TRANSFERDRIVECAPASY 1
15. 4 V3352 Fitting 174 amp 1v2 PVC 2 Fitting 1 Plastic Male Order No V3007 09 Order No V3007 12 Order No V3007 13 Description Fitting 114 amp 172 Brass Sweat Description Fitting 3 4 Brass SharkBite Description Fitting 1 Brass SharkBite Assembly Assembly Assembly Drawing Order Description Quantity Drawing Order Description Quantity No No No No V3151 Nut 1 Quick Connect V3151 Nut 1 Quick Connect V3151 Nut 1 Quick Connect V3150 Split Ri V3150_ Split Ring V3150 Split Ring V3105 O Ring 21 2 V3105 O Ring 215 v3628 Fig 3 4 Brass Shark v3629 1 Brass Sharks gt H H 1 1 4 V3375 Fitting 114 amp 117 Bite Bite Brass Sweat a a N Drawing Order ue Order No V3007 15 Description Fitting 3 4 John Guest QC Elbow Assembly Description Nut 1 Quick Connect Split Ring O Ring 215 Fitting Elbow 3 4 Quick Connect w Stem Must be special ordered Minimum quantity of 24 PAGE 18 The WS1TT control valves consist of the following components 1 Drive Assembly 6 Drain Line Flow Control and Fitting Assembly 2 Drive Cap Assembly Main Piston and Regenerant Piston 7 Water Meter 3 Spacer Stack Assembly 8 Twin Transfer Valve 4 Injector Cap Screen Injector Plug and Injector 5 Refill Flow Control Assembly or Refill Port Plug DRIVE ASSEMBLY The drive assembly consists of the following parts e Drive Bracket e Printed Circuit PC Board e Mo
16. AGE 9 7 TTLX 600 19 14 x 65 24 Dia x 50 900 4 2 0 5 1H Green SOFTENER ASSEMBLY 1 LXCV1TT detailed components shown in this manual Metered Control Valve Twin Tank 2 D1203 Top Distributor FG844VT 01130 12 Ft cut for 44 R DIP1050 Tank Pipe Connector Assy for Model 7 TTLX 150 FG1040VT D1130 12 Ft cut for 40 in R DIP1050 Tank Pipe Connector Assy for Model 7 TTLX 200 in A2Ft i BRINE ASSEMBLY Description L56 50A 24 x 50 L56 40A 18x40 Brine Tank with Cover for Model 7 TTLX 400 Brine Tank Assy G2162 24x50 Brine Tank with Cover for Model 7 TTLX 600 H1031 4x28 Slotted Brine Well for Model 7 TTLX 150 200 300 H1042 4x46 Slotted Brine Well for Model 7 TTLX 600 H7016 4 inch Brine Well Cap for Model 7 LX 150 200 300 600 3 8 Brine Valve Assembly 4 4740 using 1 2 24 long air check assy for Model 7 TTLX 150 200 300 using 1 2 43 long air check assy for Model 7 TTLX 600 H1018 Two Piece Overflow Set 1640N Nylon Screw only for Model 7 TTLX 600 6785N Nylon Nut only for Model 7 TTLX 600 H1023 3 8 0 6 Ft Poly Tubing J 952 15 x 17 x 36 Brine Tank Assy cC Pin Air Check Assembly uncut length see brine tank assy for cut length H4500 48 1 PAGE 10 X FACTOR FRONT COVER AND DRIVE ASSEMBLY Drawing No Description 1 V3692 02LW LP F
17. E FOR CRITICAL OR HEALTH EFFECT APPLICATIONS OPERATING PRESSURES 20 PSI MINIMUM 125 PSI MAXIMUM OPERATING TEMPERATURES 40 F MINIMUM 110 F MAXIMUM If no water meter wire is visible then a plug is installed not a water meter The water meter wire does not need to be removed from the PC board if the water meter is only being inspected and cleaned 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 dilute sodium bisulfite or vinegar The turbine can be immersed in the chemical 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 prelubricated Do not use Vaseline oils or other unacceptable lubricants on the o ring A silicone lubricant may be used on the black o ring Reinsert the water meter into the side slot Hand tighten the nut Do not us
18. FF regeneration initiation is based solely on volume used If value is set as a number allowable DET range from 1 to 28 a regeneration initiation will be called for on that day even if sufficient volume of atta water were not used to call for a regeneration Set Day Override using Or buttons e number of days between regeneration 1 to 28 or Cm OFF i Press awa to go to step 4 Press to return to previous step STEP 4 Press C to go to Step 5 Press to return to previous step REGEN IMMEDIATE ON ZERO RETURN TO NORMAL MODE PAGE 7 LOW BATTERY Anon rechargeable coin cell battery is located on the circuit board used only to maintain the time of day during power outages all other information will be stored in memory no matter how long the power outage The screen displays LOW BATTERY when the battery needs to be replaced The screen will remain illuminated solid blue when LOW BATTERY is displayed Initially LOW BATTERY display will alternate with the User display finally displaying only LOW BATTERY User displays are still accessible by pressing CONTACT SCREEN PROGRAMMING STEP 1 Press C and simultaneously for 3 seconds to access Installer Display Settings STEP 2 Press C to go to step 3 SET 20 GR um EEUU STEP 3 Press wer to go to step 4 DN ZERO From Step 4 Press and hold both the and 4 button to change phone number and
19. Reset time of day 13 Water running to drain b Damaged seal stack assembly b Replace seal stack assembly c Piston assembly failure c Replace piston assembly d Drive cap assembly not tightened in d Re tighten the drive cap assembly properly PAGE 29 Possible Cause Solin a Motor not inserted full to engage pinion a Disconnect power make sure motor is motor wires broken or disconnected fully engaged check for broken wires make sure two pin connector on motor is connected to the two pin connection on the PC Board labeled MOTOR Press NEXT and REGEN buttons for 3 seconds to resynchronize software with piston position or disconnect 14 E1 Err 1001 Err 101 Control unable to power supply tom Board iors sense motor movement seconds and then reconnect b PC Board not properly snapped into drive b Properly snap PC Board into drive bracket bracket and then Press NEXT and REGEN buttons for 3 seconds to resynchronize software with piston position or disconnect power supply from PC Board for 5 seconds and then reconnect c Missing reduction gears c Replace missing gears a Foreign material is lodged in control valve a Open up control valve and pull out piston assembly and seal stack assembly for inspection Press NEXT and REGEN buttons for 3 seconds to resynchronize software with piston position or disconnect power supply from PC Board for 5 seconds and then reconnect b Mechanical binding
20. e 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 board 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 Unweave 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
21. e a pipe wrench to tighten nut PAGE 25 SERVICING TRANSFER CAP ASSEMBLIES Release locking tabs The control valves backplate must be removed from each side to sieve back pele first to allow access to removing the transfer cap assembly NOTE Hold slight downward pressure on the top left corner of the backplate while using a thin flat screwdriver or knife blade to push in on the locking tabs this will release the backplate and it will twist to the left off of the valve body For removal of the drive motor side you will need to remove the drive cover assembly to access the motorized drive The drive motor can be removed by pressing the spring clip loop to the right then rotate the motor a 1 4 turn and pull outward to remove the motor from the reducing gear cover assembly Remove the three Phillips head stainless 4 steel screws that retain the reducing gear cover to the drive cap Once the cover is removed you have access to the reducing drive gears simply slide them off of the gear axles with your fingers to inspect check them there are 3 small black gears with foil decals and 1 larger black reducing gear Remove the large white drive gear from the stainless steel drive shaft To remove the large white transfer drive gear firmly grab the outside edge of the gear with your fingers and pull it outward away from the control valve assembly Now you can use a 5 32 or 4mm allen wrench to remove the 14 20 screws that retain the transfer dr
22. e software with piston position or disconnect power supply from PC Board for 5 seconds and then reconnect b Check piston and seal stack assembly check reduction gears drive gear interface and check MAV NHBP black drive pinion on motor for being jammed into motor body Press NEXT and REGEN buttons for 3 seconds to resynchronize software with piston position or disconnect power supply from PC Board for 5 seconds and then reconnect NOTES eR UE A Division OF C B TOOL CO 1340 MANHEIM PIKE LANCASTER PA 17601 3196 TEL 717 397 3521 FAX 717 392 0266 www lancasterwatertreatment com e E mail info lancasterpump com 5 15
23. e tank 7 Connect the brine line polytubing found with the brine tank to the brine connection on the control valve The control valve has a standard refill elbow to which a 3 8 flexible tube can be connected see below One polytube insert is shipped on the brine line elbow s locking clip Remove this white polytube insert and replace the locking clip The second polytube insert is taped to the top of the brine well cap in the brine tank Press the polytube inserts into each end of the provided brine tubing press the polytube with insert into the nut on the brine fitting Tighten nut securely to create a pressure tight connection The nut gripper and retainer sleeve is a three piece assembly that can come apart from the elbow body Parts must be reassembled exactly as shown to function properly If the nut is completely removed from the body slip the nut plastic gripper and retainer sleeve on to the tube then tighten on to the fitting Make sure the floor is clean beneath the brine tank and that it is level and smooth Install brine tubing to the brine tank using the above instructions 8 A 1 2 inside diameter not provided gravity drain line should be connected to the overflow fitting on the side of the brine tank This overflow is in case of a malfunction in the brine shut off If the unit is installed where water may flow in the event of an overflow and cause water damage connect a length of flexible tubing and run to a drain below t
24. eplace PC Board a Power outage a Reset time of day If PC Board has battery back up present the battery may be depleted See Front Cover and Drive Assembly drawing for instructions 4 Control valve regenerates at wrong time of day b Time of day not set correctly b Reset to correct time of day C Time of regeneration set incorrectly c Reset regeneration time 2 PC Board does not display correct time of day d Control valve set at on 0 immediate d Check programming setting and reset regeneration to NORMAL for a delayed regen time e Control valve set at NORMAL on 0 e Check programming setting and reset delayed and or immediate to NORMAL for a delayed regen time a Power outage a Reset time of day If PC Board has battery back up present the battery may be depleted See Front Cover and Drive Assembly drawing for instructions a Broken drive gear or drive cap assembly a Replace drive gear or drive cap 6 Control valve does not regenerate automatically assembly when the REGEN button is depressed and held b Broken Piston Rod b Replace piston rod c Defective PC Board c Defective PC Board a Meter is not connected to meter a Connect meter to three pin connection connection on PC Board labeled METER on PC Board b Restricted stalled meter turbine b Remove meter and check for rotation or foreign material 7 Control valve does not regenerate automatically c Incorrect programming c C
25. g from 9 to 25 gpm 34 1 to 94 6 lpm This fitting is straight but still connects to the control valve using the same locking clip The drain line flow control is located between two fitted parts i e the fitting acts as the retainer The nut is unscrewed to access the drain line flow control PAGE 21 SERVICE INSTRUCTIONS Disconnect from electrical power prior one to servicing the valve When servicing the valve water may leak from the valve Water from the valve may create a slip hazard Clean up water spills 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 th
26. he level of the overflow Do not connect the tubing to the drain line on the control valve Do not run tubing above overflow height at any point 2nd Tank TUBE UN RETAINER SLEEVE Connection A M Port Treated e M Water Im Outlet A Ne Y BUS GRIPPER BRINE LINE FITTING CONNECTIONS TUBE INSERT NUT In Out Head oe Connection DRAIN LINE FITTING CONNECTION USING 5 8 POLY TUBE Port a Untreated 2nd Tank m xL Water Inlet PAGE 5 PLACING SOFTENER INTO SERVICE Do not add salt to the brine tank yet Do not plug the transformer into the receptacle yet Make sure inlet and outlet valves are to their closed positions If using optional bypass place in bypass position Turn on main water supply Open a cold water faucet This will clear the line of any debris solder pipe dope etc that may be in the line Let water run at faucet for a couple minutes or until clear Turn off faucet Manually add 1 72 gallons of water to the brine tank Now plug the transformer into a 120 volt receptacle be certain the receptacle is uninterrupted Within 5 seconds the control display and buttons will illuminate and the time of day screen will appear Press and hold the button for approximately 5 seconds until the motor starts Wait until display reads BACKWASH and numbers start counting down Momentarily press again Valve
27. heck for programming error but does when the REGEN button is depressed and held d Meter wire not installed securely into d Verify meter cable wires are installed 5 Time of day flashes on and off three pin connector securely into three pin connector labeled METER e Defective meter e Replace meter f Defective PC Board f Replace PC Board PAGE 28 Possible Cause Solution a Media is exhausted due to high water a Check program settings or diagnostics usage for abnormal water usage b Meter not registering b Remove meter and check for rotation or foreign material c Water quality fluctuation c Test water and adjust program values accordingly d No regenerant or low level of regenerant d Add proper regenerant to tank in regenerant tank 8 Hard or untreated water is being delivered e Control fails to draw in regenerant e Refer to Trouble Shooting Guide number 12 f Insufficient regenerant level in regenerant f Check refill setting in programming tank Check refill flow control for restrictions or debris and clean or replace g Damaged seal stack assembly g Replace seal stack assembly h Control valve body type and piston type h Verify proper control valve body type mix matched and piston type match i Fouled media bed i Replace media bed a Improper refill setting a Check refill setting b Improper program settings b Check program setting to make sure they are specific to the water quality and
28. ional treatment equipment may be needed to treat water having special characteristics such as ferric hydroxide iron iron bacteria low pH tastes and odors etc Consult your dealer if you have any questions This water softener is not to be used for treating water that is microbiologically unsafe or of unknown quality without adequate disinfection before or after treatment WATER PRESSURE A minimum of 20 pounds of water pressure psi is required for regeneration Maximum 100 psi CAUTION the softener cannot be subject to a vacuum due to loss of pressure such as a water main break or submersible well pump check valve failure WATER TEMPERATURE The range of water temperature is 35 F to 100 F DO NOT install any water softener with less than 10 feet of piping between its outlet and the inlet of a water heater AMBIENT TEMPERATURE DO NOT locate softener where it or its connections including the drain and overflow lines will ever be subject to room temperatures under 33 F ELECTRICITY An uninterrupted 120 volt 60Hz source is required Make sure electrical source is not on a timer or switch All electrical connections must be connected according to local codes The plug in transformer is for dry locations only Surge protection is recommended with all electrical connections DRAIN All plumbing should be done in accordance with local plumbing codes The distance between the drain and the water softener should be as short as possib
29. ith the stream of water which passes through the media to regenerate the bed The injector provides a consistent regenerant water mixture ratio over the entire operating pressure range of the control valve The injector provides good performance in a variety of applications which may involve elevated drain lines and long regenerant draw lengths Injectors are chosen by knowing the type amount and regenerant flow rate for a particular type of media Guidelines can be found in the media manufacturer s literature The color coded injectors give different regenerant draw slow rinse and total flow rates over the pressure range See injector graphs pages 10 13 for total slow rinse and draw flow rates The control valve has been manufactured to be one of the following e regeneration downflow WS1TT for softeners or regenerating filters install injector in DN location plug in UP location regeneration upflow WS1TT upflow option is for softeners only which are not EA EE or El control valves Install injector in UP location plug in other hole location e WS1TT both the DN and UP holes have injector plugs installed and plug installed for the refill elbow NOTE It is okay to field convert valves from upflow to downflow and vice versa with the WS1TT valve as long as software supports upflow brine REFILL FLOW CONTROL ASSEMBLY OR REFILL PORT PLUG The refill flow control assembly consists of a refill flow elbow refill
30. ive cap assemblies on both sides of the valve NOTE Once the screws are removed from retaining the inlet side transfer valve cap and the outlet drive motor transfer cap from the control valve the cap will spring out away from the valve body At this point the transfer discs may be removed by pulling the discs outward off of the shaft away from the valve body with your hand With the disc out you can inspect the flat surface area to be sure it s clean and smooth free of any debris or scratches Note that the disc is keyed to the drive shaft so that it will only assemble in one orientation The transfer discs may be chemically cleaned with a dilute sodium bisulfate solution vinegar or just wiped with a soft clean cloth To remove seals gently pull out on the outer lip of the seal to lift the seal out from its cavity being careful not to damage the face surface of the seal To reassemble re seat seals into the seal cavity of the control valve body being sure that the lip of the seal is facing outward With seals in place put a thin film of Dow 7 on the tops of the seals and the flat surface of the discs Prior to reinstalling the discs the drive shaft should be removed and the O rings cleaned inspected and lubricated with Dow 7 The shaft can then be installed into the disc prior to installation With the outlet disc assembled to the shaft the orientation of the shaft to inlet disc can be assured by installing the set with the through ho
31. le The pipe size for the drain line should be a minimum of 1 2 inside diameter of pipe SOFTENING It is recommended that the softener be installed to soften both the hot and cold water supply A separate hard water faucet may be plumbed for drinking purposes if desired Outside faucets should be left on hard water BYPASS A bypass valve optional accessory should be installed so that water will be available if it should be necessary to shut off the pressure in order to service the softener GENERAL INSTALLATION AND SERVICE WARNINGS The control valve fittings and or bypass are designed to accommodate minor plumbing misalignments but are not designed to support the weight of a system or the plumbing HYDROCARBONS SUCH AS KEROSENE BENZENE GASOLINE ETC MAY DAMAGE PRODUCTS THAT CONTAIN O RINGS OR PLASTIC COMPONENTS EXPOSURE TO SUCH HYDROCARBONS MAY CAUSE THE PRODUCTS TO LEAK DO NOT USE THE PRODUCT S CONTAINED IN THIS DOCUMENT ON WATER SUPPLIES THAT CONTAIN HYDROCARBONS SUCH AS KEROSENE BENZENE GASOLINE ETC THIS WATER METER SHOULD NOT BE USED AS THE PRIMARY MONITORING DEVICE FOR CRITICAL OR HEALTH EFFECT APPLICATIONS Do not use Vaseline oils other hydrocarbon lubricants or spray silicone anywhere A silicone lubricant may be used on black o rings but is not necessary The nuts and caps are designed to be unscrewed or tightened by hand or with the special plastic wrench If necessary a pliers can be used to unsc
32. le on the outlet disc at the 6 o clock position The easiest thing would be to remove both disc drives and assemble the outlet side first Then each disc could be fitted on the shaft individually At this point the transfer valve cap assemblies can be reinstalled PAGE 26 Note That both transfer caps only mount in one orientation Prior to installation of cap assembly be sure to check that the stainless steel spring and the plastic spring support Is in place attached to the inside of the c assembly Next you can wipe the outside edge of the O ring on the cap and the inside mating area of the valve with a clean cloth amp re apply a thin layer of silicone lubricant like Dow 7 BE SURE NOT TO USE ANYTHING HYDROCARBON BASED SUCH AS VASELINE OR PETROLEUM JELLY TO LUBRICATE PLASTIC COMPONENTS OR O RINGS AS THEY WILL BE DAMAGED BY THE HYDROCARBONS AND POTENTIALLY CAUSE FAILURES THAT CAN RESULT WITH LEAKS Noting the one possible orientation of the transfer drive cap use one hand to press in and support the transfer drive cap while using the opposing hand to start two screws in one on the top and one opposing on the bottom Tighten the screws in evenly so the cap seats the O ring without getting pinched or damaged Screws should only be hand tightened with a 5 32 or 4mm allen wrench DO NOT OVER TIGHTEN SCREWS NOTE be careful and make sure the meter cable doesn t get under the drive cap while tightening as it will result in damaging
33. lip 4 Op Op O ring 019 One DLFC must be Water 7 DLFC 3 2 gpm for 34 used Flow if acis water towards fitting tes eer is DLFC 7 5 gom for 34 used 4 and 6 can be ordered as a complete assembly V3331 Drain Elbow and Retainer Assy Do not use pipe dope or other sealants on threads Teflon tape must be used on threads of 3 4 NPT connection unless using 5 8 polytubing Do not use Vaseline oils other hydrocarbon lubricants or spray silicone anywhere A silicone lubricant may be used on black o rings but is not necessary INSTALLATION FITTING ASSEMBLIES Order No V3007 Standard Order No V3191 01 Optional Description Fitting 1 PVC Male NPT Elbow Description Fitting Vertical Adapter Assembly Assembly Drawing Order Description Quantity Drawing Order No No 2 vaso SptRng 2 Fitting 1 PVC Male V3149 NPT Elbow D O Do not use pipe dope or other sealants on threads Teflon tape must be used on threads of 1 NPT connection Teflon tape is not necessary on the nut connection nor caps because of o ring seals The nut and caps are designed to be unscrewed or tightened by hand or with the service spanner wrench see page 17 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 a screwdriver in slots on caps and or tap with a hammer Do not use Vaseline oils other h
34. n tee gan a NA E TTE JOB SPECIFICATIONS MODEL NO INSTALLATION DATE SERIAL NUMBER INSTALLER NAME _ PHONE ADDRESS WATER TEST AT TIME OF INSTALLATION Hardness CaCo gpg Other sr Iron ppm pH SIZING INFORMATION All Water is Softened Except Hear Hose Bib Other Front Hose Bib Kitchen Cold Toilets All Cold The average family uses 50 gallons per person daily for all water uses in the home Daily Water Usage Gallons Person X Family Size Number of people in family Total Gallons Per Day X Grains Per Gallon of hardness Note Add 4 grains per gallon of hardness for each ppm iron for total compensated hardness Total Grains per Day PAGE 2 PRE INSTALLATION REVIEW WATER QUALITY If sand or sediment is present in the water supply a sediment filter should be installed ahead of the water softener Your water softener has been designed to adequately reduce hardness from levels up to 100 grains per gallon Ferrous bicarbonate iron levels up to 0 5 ppm can also be reduced This is iron that is dissolved in water and not visible to the eye in a freshly drawn sample After standing in contact with air the ferrous iron will become oxidized to the ferric state and start to precipitate as a reddish brown floc It can be seen and may cause discolored water Air must not come in contact with water until after it has passed through the water softener In some cases addit
35. nerant 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 dilute sodium bisulfite or vinegar or replace the regenerant piston if needed To remove the main piston fully extend the piston rod and then unsnap the main piston from its latch by pressing on the side with the number Chemically clean in dilute sodium bisulfite or vinegar or replace the main piston Reattach the main piston to the drive cap assembly Reattach the regenerant piston if needed to the main piston 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 molded 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 involving the drive assembly or the drive cap assembly and pistons unplug power source jack from the printed circuit board black wire and plug back in or press and hold NEXT and REGEN buttons for 3 seconds This resets the electronics and establishes the service pist
36. oard black wire and plug back in or press and hold NEXT and REGEN buttons for 3 seconds 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 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 74 to 77 flat blade screwdriver into one of the slots around the top 2 of the drive cap assembly so it engages the notches molded 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 TITEL 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 or upflow and if a regenerant is used a regenerant piston Upflow is not applicable to EA EE or El control valves PAGE 23 The rege
37. on gears d Foreign matter built up on piston and stack assemblies creating friction and drag enough to time out motor a Foreign material is lodged in MAV NHBP valve b Mechanical binding PAGE 31 a Snap drive bracket in properly then Press NEXT and REGEN buttons for 3 seconds to resynchronize software with piston position or disconnect power supply from PC Board for 5 seconds and then reconnect a Press NEXT and REGEN buttons for 3 seconds to resynchronize software with piston position or disconnect power supply from PC Board for 5 seconds and then reconnect Then re program valve to proper setting b Connect MAV NHBP motor to PC Board two pin connection labeled DRIVE Press NEXT and REGEN buttons for 3 seconds to resynchronize software with piston position or disconnect power supply from PC Board for 5 seconds and then reconnect c Properly insert motor into casing do not force into casing Press NEXT and REGEN buttons for 3 seconds to resynchronize software with piston position or disconnect power supply from PC Board for 5 seconds and then reconnect d Replace piston and stack assemblies Press NEXT and REGEN buttons for 3 seconds to resynchronize software with piston position or disconnect power supply from PC Board for 5 seconds and then reconnect a Open up MAV NHBP valve and check piston and seal stack assembly for foreign material Press NEXT and REGEN buttons for 3 seconds to resynchroniz
38. on 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 drive 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 dilute sodium bisulfite or 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 5 8 to 1 1 8 in diameter to push the center of the assembly into the control valve body The assembly is properly seated when at least four threads are exposed approximately 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 Reattach the drive cap assembly and piston s and the drive assembly After completing any valve maintenance involving the drive assembly or the drive cap assembly and pistons unplug power source jack from the printed circuit board black wire and plug back in or press and hold NEXT and REGEN buttons for 3 seconds This resets the electronics and establi
39. outside of the gear shroud on the drive bracket the drive gear cover slips easily into place The drive bracket does not 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 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 PAGE 22 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 bracket motor retainer Reconnect the motor plug to the two pronged jack on the lower left 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 involving the drive assembly or the drive cap assembly and pistons unplug power source jack from the printed circuit b
40. pacer stack assembly provides the 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 interior surface is sealed against the piston using slippery self cleaning directional one way silicone lip seals The lip seals are clear in color and have a special slippery coating so that the piston does not need to be lubricated INJECTOR CAP SCREEN INJECTOR PLUG amp 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 labeled DN and UP The holes will be filled with a plug or an injector The plug Order V3010 1Z prevents water from traveling a certain pathway 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 such as sodium chloride brine potassium permanganate etc The regenerant blends w
41. rew the nut or cap 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 sealants on threads Use Teflon tape on the 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 or the drive cap assembly and pistons unplug power source jack from the printed circuit board black wire and plug back in or press and hold NEXT and REGEN buttons for 3 seconds 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 1 Backwash flow rates in excess of 7 gpm 26 5 Ipm or length in excess of 20 6 1m require 34 drain line Solder joints near the drain must be done prior to connecting the drain line flow control fitting Leave at least 6 between the drain line control fitting and solder joints when soldering pipes that are connected on the drain line control fitting 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
42. ront Cover Assembly V3107 01 Motor Drive Bracket amp Spring Clip PC Board Drive Gear 12x36 Drive Gear Cover When replacing the battery align itives and push down to fully seat a positives and push down to fully seat Battery PE Orientation 3 volt lithium coin cell lt gt Battery Fully Seated type 2032 AC Adapter Not shown Order No V3186 After completing any valve maintenance involving the drive assembly or the drive cap assembly and pistons unplug power source jack from the printed circuit board black wire and plug back in or press and hold C and buttons for 3 seconds This resets the electronics and establishes the service piston position The display should flash the software version and then reset the valve to the service position PAGE 11 DRIVE CAP ASSEMBLY DOWNFLOW PISTON REGENERANT PISTON AND SPACER STACK ASSEMBLY Drawing Order No Description Qty Do not use Vaseline oils other hydrocarbon lubricants No or spray silicone anywhere A silicone lubricant may be used on black o rings but is not necessary Avoid any V3005 Spacer Stack Assembly type of lubricants including silicone on the clear V3004 Drive Cap Assy lip seals V3178LP Back Plate V3011 Piston Downflow Assy V3174 Hegenerant Piston 6 3135 O ring 228 V3180 O ring 337 8 V3105 Octing 215 Distributor Tube Not Shown V300
43. rr 1003 Err 103 Control valve motor ran too long and was unable to find the next cycle position c Drive bracket not snapped in properly c Snap drive bracket in properly then and out enough that reduction gears and Press NEXT and REGEN buttons for drive gear do not interface 3 seconds to resynchronize software with piston position or disconnect power supply from PC Board for 5 seconds and then reconnect PAGE 30 Possible Cause Solution 17 Err 1004 Err 104 Control valve motor ran too long and timed out trying to reach home position 18 Err 1006 Err 106 Err 116 MAV SEPS NHBP AUX MAV valve motor ran too long and unable to find the proper park position Motorized Alternating Valve MAV Separate Source SEPS No Hard Water Bypass NHBP Auxiliary MAV AUX MAV 19 Err 1007 Err 107 Err 117 MAV SEPS NHBP AUX MAV valve motor ran too short stalled while looking for proper park position Motorized Alternating Valve MAV Separate Source SEPS No Hard Water Bypass NHBP Auxiliary MAV AUX MAV a Drive bracket not snapped in properly and out enough that reduction gears and drive gear do not interface a Control valve programmed for ALT A or b nHbP SEPS or AUX MAV with out having a MAV or NHBP valve attached to operate that function b MAV NHBP motor wire not connected to PC Board c MAV NHBP motor not fully engaged with reducti
44. s with a 15 foot power cord and is designed for use with the control valve The power adapter is for dry location use only The control valve remembers all settings until the battery power is depleted if the power goes out After the battery power is depleted the only item that needs to be reset is the time of day other values are permanently stored in the nonvolatile memory The control valve battery is not rechargeable but is replaceable No user serviceable parts are on the PC board the motor or the power adapter The means of disconnection from the main power supply is by unplugging the power adapter from the wall PAGE 3 BYPASS VALVE The bypass 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 X Factor bypass valve is particularly unique in the water treatment industry due to its versatility and state of the art design features The 1 full flow bypass valve incorporates four positions including a diagnostic position that allows service personal to work on a pressurized system while still providing untreated bypassed water to the facility or residence Its completely non metallic all plastic design allows for easy access and serviceability without the need for tools 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
45. shes 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 Injector Unscrew the injector cap and lift off Loosen cap with special plastic wrench or pliers if necessary Attached to the injector is a screen Remove the screen and clean if fouled The plug and or injector can be pried out with a small screwdriver The plug can be wiped clean If the plug leaks replace the entire plug The injector consists of a throat and a nozzle Chemically clean the injector with vinegar or sodium bisulfite 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 Two holes are labeled DN and UP Check for compliance Refer to Valve Body Compliance Table at the begining of this manual Push the plug s and or injectors firmly in place replace the screen and hand tighten the injector cap PAGE 24 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
46. slightly to the left by pressing on the side of the upper right corner This helps the drive gears mesh with the drive cap assembly 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 hole 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 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
47. that it is not misplaced Twist to remove the white flow control retainer The flow control can be removed by prying upward through the side slots of the retainer with a small flat blade screwdriver Chemically clean the flow control or the white flow control retainer using dilute sodium bisulfite or 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 The water meter assembly is connected to the PC board by a wire 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 THIS WATER METER SHOULD NOT BE USED AS THE PRIMARY MONITORING DEVIC
48. 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 or o ring Solder joints should be cool and solvent cements should be set before installing the nut split ring and o ring Avoid getting primer and solvent cement on any part of the o rings split rings bypass valve or control valve Plug into an electrical outlet Note All electrical connections must be connected according to local codes Be certain the outlet is uninterrupted Install grounding strap on metal pipes This glass filled Noryl or equivalent fully automatic control valve is designed as the primary control center to direct and regulate all cycles of a water softener or filter The control valve is compatible with a variety of regenerants and resin cleaners The control valve is capable of routing the flow of water in the necessary paths to regenerate or backwash water treatment systems The injector regulates the flow of brine or other regenerants The control valve regulates the flow rates for backwashing rinsing and the replenishing of treated water into a regenerant tank when applicable Control valve installation is made easy because the distributor tube can be cut 77 above to 77 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 power adapter come
49. the proper amount of water The brine tank will only have a very slight amount of water in it after the regeneration cycles are completed GENERAL OPERATION Note As an energy saving feature the control will automatically turn off all SOLID BLUE or SOLID GREEN display illumination and keypad illumination after about 5 minutes of the last keypad button push Any further keypad touch will cause the re illumination of the display and keypad and re activate keypad control User Displays When the system is in normal service mode one of up to five available User Displays will be shown Pressing will alternate between the following displays Current time of day Treated water flow rate Service contact name and phone number if entered Remaining Capacity of treated water available Pressing the X3 button while in the Capacity Remaining or Days Remaining displays will decrease the capacity remaining in ten gallon increments or the days remaining in one day increments To clear the Service Call reminder press the 4 and buttons simultaneously while the number and banner text screen is displayed If the system has called for a regeneration that will occur at the preset time of regeneration the words REGEN TODAY will alternate with the header on the display Utilizing the control valve s built in water meter a water drop flashes on the display when water is being treated i e water is flowing through the system PAGE 6
50. tor e Drive Gears e Drive Gear Cover 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 shows different types of information in the initial system set up for softeners or filters installer display settings diagnostics valve history 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 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 center 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 amp REGENERANT PISTON _ The drive gears
51. 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 piston position allows for greater flexibility and requires no switches or cams U S Patent 6444127 One of two main pistons is always used 1 A1 25 diameter downflow piston is used when the WS1TT control valve is used as a downflow softener regenerating filter or non regenerating filter 2 1 25 diameter upflow piston is used when the WS1TT control valve is used as an upflow softener Upflow option not applicable for EA EE or El control valves If the control valve is used as a softener or a regenerating filter a regenerant piston must be attached to the main piston If the control valve is to be used on a system that does not require a regenerant to be added the regenerant piston must be removed PAGE 19 SPACER STACK ASSEMBLY The s
52. und wire should be installed between the inlet and outlet pipe whenever the metallic continuity of a water distribution piping system is interrupted Install grounding strap on metal pipes 5 The drain connection may be made using either 5 8 polytube see below or a 3 4 female adapter The polytube insert is shipped attached to the drain line elbow s locking clip Press the insert into the drain line tubing tubing not provided Loosen the nut of the drain line elbow Press the 5 8 polytube with insert into the drain line elbow until it seats on the back of the fitting Tighten the nut If soldering joints near the drain must be done prior to connecting the drain line flow control fitting Leave at least 6 between the drain line control fitting and solder joints when soldering pipes that are connected on the drain line control fitting Failure to do this could cause interior damage to the drain line flow control fitting Never insert a 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 softener 6 The brine 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 attached to the control valve with a locking clip The locking clip allows the elbow to rotate 270 degrees so the outlet can be oriented towards the brin
53. y 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 PAGE 4 INSTALLATION INSTRUCTIONS All electrical amp plumbing should be done in accordance to all local codes 1 Place the softener where you want to install it making sure it is on a clean level and firm base 2 Do all necessary plumbing inlet to inlet outlet to outlet and drain line to drain The control valve fittings and or bypass are designed to accommodate minor plumbing misalignments but are not designed to support the weight of a system or the plumbing 3 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 or o ring Solder joint should be cool and solvent cements should be set before installing the nut split ring and o ring Avoid getting primer and solvent cement on any part of the o rings split rings bypass valve or control valve 4 A jumper gro
54. ydrocarbon lubricants or spray silicone anywhere A silicone lubricant may be used on black o rings but is not necessary PAGE 16 BYPASS VALVE Order No BP2000 6 vaia7 BypassHande 2 vaise J2 vas Orione TT JAN Ale Vat ad SERVICE SPANNER WRENCH Order No V3193 Although no tools are necessary to assemble or disassemble the valve the wrench shown in various positions on the valve may be purchased to aid in assembly or disassembly Loosens Injector And Bypass Caps PAGE 17 OPTIONAL INSTALLATION FITTING ASSEMBLIES Order No V3007 01 Order No V3007 02 Order No V3007 03 Description Fitting 34 amp 1 PVC Solvent 90 Description Fitting 1 Brass Sweat Description Fitting 34 Brass Sweat Assembly Assembly Assembly 1 V3151 Nut 1 Quick 2 Connect Drawing Order V3151 Nut 1 Quick Connect 2 V3151 Nut 1 Quick Connect Fitting 34 amp 1 PVC Fitting 1 Brass Sweat 3189 Solvent 90 ES Assembly Do not install in California itti 3 4 3188 01 Fitting 34 Brass 5 Sweal Do not install in California 2 Order No V3007 04 Order No V3007 05 uu Order No V3007 07 Description Fitting 1 Plastic Male NPT Description Fitting 1 74 Plastic Male NPT Description Fitting 174 amp 172 PVC Solvent Assembly Assembly Assembly Drawing Order Description Quantity No No BN Nut 1 Quick Connect Fitting 1 74 Plastic
Download Pdf Manuals
Related Search