CS-2003
Contents
1. reset back wash flow rate and or adjust time 7 Excessive water in brine Plugged Drain Line A Check flow to drain Clean tank and or salty water flow control to service Dirty or damaged brine valve B Clean or replace brine valve C Plugged Injector C Clean injector and replace screen D Low inlet pressure D Increase pressure to allow injector to perform properly 20psig minimum Excessive brine refill cycle time E Reset brine refill cycle time 8 Softener fails to use salt Check items listed in 1 Improper control valve programming Check and reset programming Plugged restricted drain line Clean drain line and or flow control Injector is plugged Clean or replace injector and screen Nowater in brine tank Check for restriction in BLFC Ensure safety float is not stuck Check brine tank for leaks Water pressure is too low Line pressure must be at least 20 psi Brine line injects air during brine draw Check brine line for air leaks Internal control leak Call dealer Check piston seals and spacers for scratches and dents 9 Control cycles continuously A Faulty circuit board A Replace circuit board 10 Continuous flow to drain A Foreign material in control A Call dealer Clean valve rebuild unit B Internal control leak B Same as above C Valve jammed in backwash brine or C Same as above rapid rinse position D Motor stopped or jammed D Repl2. CORRECTION Connect to constant power source Reconnect cable Reset program settings Replace power supply Replace or Repair Check motor operation by activating the service button on back of motor Reset time of day programming and install 9 volt battery Reset Regeneration time programming Reset unit to the new capacity Keep brine tank full of salt at all times Clean it yearly Salt may be bridged If using a salt grid plate ensure refill water is over it Call dealer find out how to confirm it clean the resin and prevent future fouling Call dealer Check distibutors and backwash flow Call dealer Replace spacers seals and or piston Call dealer Check for resin oxidation caused by Chlorine Mushy resin Call dealer Check for correct bed depth Broken distibutors Air or gas in bed Well gas eliminator Loose brine line Close by pass valve Check for too slow or high service flow Check for media fouling Adjust brine tank refill time See symptom No 7 Indicates plumbing leak ie toilet tank Reset programming CS 2003 Troubleshooting Guide Cont d SYMPTOM PROBABLE CAUSE CORRECTION 6 Loss of water pressure A Scaling Fouling of inlet pipe A Clean or replace pipeline Pretreat to prevent Fouled resin B Clean resin Pretreat to prevent Improper backwash C Too many resin fines and or sediment Call dealer
3. 2 13 Inspect the inside of the valve to make sure that all spacers and seals are in place and that there is no foreign matter that would interfere with the valve operation Take new piston assembly as furnished and push piston into valve by means of the end plug Twist drive yoke carefully in a clockwise direction to properly align it with drive gear Reinstall piston retaining plate screws Place powerhead on top of valve Be sure drive pin on main gear engages slot in drive yoke wide side of drive yoke upright must face to the left away from the motor Replace powerhead mounting screws Replace screw and washer at drive yoke Reconnect brine tube and drain line Return by pass or inlet valving to normal service position Water pressure should now be applied to the conditioner and any by pass line shut off Replace the control valve back cover Follow Steps A 9 through A 13 D TO REPLACE SEALS AND SPACERS 1 2 3 Follow Steps A 1 through A 3 Remove the control valve back cover Disconnect the meter signal wire from the meter Remove screw and washer at drive yoke Remove powerhead mounting screws The entire powerhead assmebly will now lift off easily Remove piston retaining plate screws Pull upward on end of piston rod yoke until assembly is out of valve Remove and replace seals and spacers Take piston assembly and push piston into valve by means of the end plug Twist yoke carefully in a clockwise dir
4. 201 Valve Body Only ete End Spacer Spacer WA Seal Seal amp Spacer Kit Includes 1 Ref 2 4 Ref 3 amp 5 Ref 4 DownFlow Piston Piston Rod Retainer End Plug Assembly Hex Washer HD 10 24 X 13 16 Screw Piston Assembly Includes 1 Ref 5 1 Ref 6 1 Ref 7 amp 1 Ref 9 singa Brine Valve Stem Brine Valve Seat EE een Brine Valve Spacer MR EE Ouad Ring O Ring Brine Valve Cap Brine Valve Spring Plain Nylon Washer Retaining Ring Brine Assembly Includes Ref 10 Thru 18 O Ring 20001X210 20251X254 20251X266 Flow Control Button 1 5 GPM 20251X267 Flow Control Button 2 0 GPM 20251X268 Flow Control Button 2 4 GPM 20251X269 Flow Control Button 3 0 GPM 20251X270 Flow Control Button 3 5 GPM 20251X27 f names Flow Control Button 4 0 GPM 20251X272 Flow Control Button 5 0 GPM 20251X274 Flow Control Button 7 0 GPM Plastic Flow Control Housing Flow Control Assembly Specify GPM on Order Includes 1 19 1 20 1 21 amp 1 39 20251X256 Flow Control Assembly 1 5 GPM PVC 20251X257 REAGEER Flow Control Assembly 2 0 GPM PVC 20251X258 Flow Control Assembly 2 4 GPM PVC 20251X259 Flow Control Assembly 3 0 GPM PVC 20251X260 Flow Control Assembly 3 5 GPM PVC 20251X261 Flow Control Assembly 4 0 GPM PVC 20251X262 Flow Control Assembly 5 0 GPM PVC 20
5. 251X264 20001X214 20561X204 O Ring 20001X215 O Ring NSR EE IE O Ring NS es EER RE SV SeSe LS RES ee Injector Plug O Ring Injector Plug amp O Ring Assembly Includes 1 25 1 26 amp 1 27 Flow Control Assembly 7 0 GPM PVC Drain Retainer 20001X217 NIS Injector Throat N S Injector Nozzle N S Vortex Generator 20001X219 esse ees Injector Assembly Specify Size Includes 1 Each of Ref 25 27 28 29 amp 30 20001X222 Injector Screen 20001X224 Injector Seal 20001X223 Injector Cap 20001X226 10 24 X 1 Hex Washer HD Screw 20001X220 Injector Kit Specify Size Includes 1 Each of Ref 30A 31 32 33 amp 2 of Ref 34 20561X239 O Ring 20561X240 BLFC Button Retainer 20251X318 5 GPM BLFC Button 20561X241 BLFC Adapter 20001X228 BLFC Assembly 5 GPM Includes 1 Each of Ref 35 36 37 amp 38 20251X255 ur Drain Line Fitting 90 Degree Elbow 1 2 NPT X 1 2 Tubing Items 45 Thru 48 Used Only With Clock Regen Hans N S Adapter Coupling EN 20561X216 O Ring 2056 1X215 ee EES nasse Adapter Coupling amp O Ring Assembly Includes Ref 1 45 amp 2 46 frites 20561X201 oo Mounting Clip st 20561X217 esse 8 18 X 5 8 Hex Washer HD Screw N S Non Stocked Item Bold Ref No Indicates Assembly or Kit 10 CS 2003 3 4 Turbine Meter Assmebly N Ref No Ouantity Pa
6. CS 2003 Control Start Up Procedures Final Set Up With Proper Valve Operation Verified 1 Add water to the top of the air check Manually step the valve to the Brine Draw Position and allow the valve to draw water from the brine tank until it stops Note The air check will check at approximately the mid point of the screened intake area 2 Next manually step the valve to the Brine Refill Position and allow the valve to return to Service automatically 3 With the valve in Service check that there is about 3 0 to 5 0 of water above the grid in the brine tank if used 4 Fill the brine tank with salt 5 Set Up is now finished the control can now be left to run automatically Error Codes There are four 4 error codes that could indicate a possible problem with the control valve Error 2 Homing slot expected Valve will start looking for home Normal operation continues Error 3 Encoder is not sending a signal Valve reguires service to continue Error 4 Unable to find homing slot Valve reguires service to continue Error 5 Motor overload stalled position or shorted motor Valve reguires service to continue CS 2003 Valve Powerhead Assembly CS 2003 Valve Powerhead Assembly Parts List Ref No Ouantity Part No Diners EEE 20001X100 Dash Me 20002X100 Ori Rene 20003X100 Oran lies 20003X101 Dress ls 20005X100 Aires d
7. CS 2003 Service Manual B689 HA EEA E43 Regeneration Cycles h Step 3 Rapid Rinse IL1839 Your new CS 2003 Valve is capable of high flow rates with simple to use electronics 95 North Oak Street Kendallville IN 46755 Phone 800 345 9422 Fax 800 848 2535 1 FW1742 A CS 2003 Control Start Up Procedures Main Menu MENU Menu Enter ENTER Button SET Set Change OHANGEJ Button 1 To Enter Main Menu Press the Menu Enter Button Time of Day will Flash 2 To Set Time of Day Press the Set Change Button First Digit will begin to Flash Example 12 00 To Change Digit Value Press the Set Change Button To Accept the Digit Press the Menu Enter Button Next Digit will Flash Once hours is accepted all digits will Flash 3 With all Digits Flashing Press the Menu Button to Set A M or P M To Change Digit Value Press the Set Change Button Example A To Accept the Digit Press the Menu Enter Button Once A M P M is Accepted the Next Menu Item will Flash 4 Metered Version To Set the Hardness Press the Set Change Button To Change Digit Value Press the Set Change Button Example H 10 To Accept the Digit Press the Menu Enter Button Next Digit Will Flash Once the Last Digit is Accepted all Digits will Flash Note One cycle must be completed before new setting will be accepted 5 To Exit Menu Press the Menu Enter Button Note If no Buttons are
8. Operation Once the Power is Restored CS 2003 Control Start Up Procedures Starting Extra Regeneration Cycle 1 Starting Delayed Extra Cycle If Gallons Remaining is not Already at 0 Press and Hold the Set Change Button After 3 Seconds the Gallons Remaining Display will Read 0 Example 0000 Regeneration Cycle will be Initiated at the Next Designated Regeneration Time 2 Starting Immediate Extra Cycle First Complete Above Delayed Cycle Steps With Gallons Remaining at 0 Press and Hold the Set Change Button After 3 Seconds the Regeneration Cycle will Begin 3 Fast Cycling Thru Regeneration First Complete Above Immediate Cycle Steps Press and Hold the Set Change Button After 3 seconds the Valve will Start to Advance to the Next Step CS 2003 Control Start Up Procedures Sample Regeneration Cycle Displays Step 1 Less Than 9 Minutes Step 2 Less Than 59 Minutes Remaining in the Backwash Step Remaining in the Brine Rinse Step For Filters amp Reactr this is a Rest Period 4 13 ES Step 3 Less Than 9 Minutes Step 4 Less Than 11 Minutes Remaining in the Rapid Rinse Step Remaining in the Brine Refill Step For Filters this Step is Skipped Notes When the Valve is Between Positions the Display will Flash the Number of the Step it is Moving towards Step 5 Valve is In Service To Fast Cycle Thru Regeneration Press and Hold the Set Change Button Until the Valve Starts to Advance to the Next Step
9. Pressed for 60 Seconds or Longer the Menu will Automatically be Exited CS 2003 Control Start Up Procedures Normal Operation 1 Metered Version Normal Display Alternates Between Time of Day and Gallons of Treated Water Remaining When the display is Showing Gallons Remaining and there is Water Flow the Upper and Lower Colon Lights will Alternate As Treated Water is Used the Gallons Remaining Display will Count Down from a Maximum Value to O Once the Count Reaches 0 a Regeneration Cycle will be Initiated at the Next Designated Regeneration Time 2 Battery Back Up This Unit Uses a Standard 9 volt Alkaline Battery Installing the Battery To Install the Battery the Back Cover Must be Removed by Removing the Two Back Cover Screws Next Insert the Battery into the Battery Holding Clip and Snap the 9 volt Battery Connector onto the Battery Replace Back Cover Features of Battery Back Up The Battery Back Up Maintains the Time of Day During Power Failures The Battery Back Up Continues to Count Down Gallons Remaining During Power Failure Metered Version Note During Power Failure to Conserve Battery Power the Display is turned off However to Confirm that the Battery is Working you can Press Either Button and the Display will Turn on for Five Seconds Menus can not be Accessed During Power Failure Ifa Power Failure Occurs while the Valve is in Regeneration the Regeneration will Resume
10. ace motor 16
11. ck for leaks at all seal areas 12 Follow steps A 9 through A 13 TO CHECK DRIVE MOTOR OPERATION 1 Remove the control valve back cover 2 To verify drive motor operation push service button located on back of motor Motor should run Release button After 1 minute the control should automatically advance to Rapid Rinse cycle 3 Position It will remain in Rapid Rinse for 5 minutes and then advance to Service Position CS 2003 Troubleshooting Guide SYMPTOM 1 Softener fails to regenerate automatically 2 Regeneration at wrong time 3 Loss of capacity 4 Poor water guality 5 High salt usage PROBABLE CAUSE Power supply plugged into intermittent or dead power source Disconnected meter cable Improper control valve programming Defective power supply Defective circuit board or meter Defective drive motor Time of day improperly set due to power failure Regeneration time set improperly Increased raw water hardness Brine concentration and or guantity Resin fouling Poor distribution Channeling uneven bed surface Internal valve leak Resin age Resin Loss Check items listed in 1 2 amp 3 Bypass valve open Channeling High salt setting Excessive water in brine tank Constant flow through the unit Improperly set hardness Regeneration freguency or regeneration day override programming 15
12. ection to properly align it with drive gear Reinstall piston retaining plate SCrews Place powerhead on top of valve Be sure drive pin on main gear engages slot in drive yoke wide side of drive yoke upright must face to the left away from motor Replace powerhead mounting screws Replace screw and washer at drive yoke Return by pass or inlet valving to normal service position Water pressure should now be applied to the conditioner and any by pass line shut off Replace the control valve back cover Follow Steps A 9 through A 13 TO REPLACE METER 1 Follow Steps A 1 through A 3 2 Remove two screws and clips at by pass valve or yoke Pull resin tank away from plumbing connections 3 Remove signal wire from meter 4 Remove two screws and clips at meter and pull the meter out of the control valve 5 Apply silicone lubricant to four new O rings and assemble to four ports on new meter 6 Assemble meter to control valve Note meter portion of module must be assembled at valve outlet Install two screws and clips 7 Install signal wire into new meter 8 Push resin tank back to the plumbing connections and engage meter ports with by pass valve or yoke 9 Attach two clips and screws at by pass valve or yoke Be sure clip legs are firmly engaged with lugs 10 Return by pass or inlet valving to normal service position Water pressure should now be applied to the conditioner and any by pass line shut off 11 Che
13. if water is hard B To Replace Powerhead 1 4 5 6 Remove the control valve back cover Remove the three screws along the outer edge of the back plate and remove the front cover Disconnect the power supply and the circuit board signal wire from the motor and feed them back through the control Disconnect the optical sensor signal wire Disconnect the meter signal wire from circuit board and feed back through the control Remove screw and washer at drive yoke Remove powerhead mounting screws The entire powerhead assembly will now lift off easily Put new powerhead on top of the valve Be sure the drive pin on main gear engages slot in drive yoke wide side of drive yoke upright must face to the left away from the motor Replace powerhead mounting screws Replace screw and washer at drive yoke Reconnect meter signal optical sensor power supply and circuit board signal wires Reinstall front cover and back cover C To Replace Piston Assembly 1 2 3 as Follow Steps A 1 through A 3 Remove control valve back cover Disconnect the meter signal wire from the meter Remove screw and washer at drive yoke Remove powerhead mounting screws The entire powerhead assembly will now lift off easily Remove piston retaining plate screws Pull upward on end of piston yoke until assembly is out of valve CS 2003 Service Instructions Cont d TO REPLACE PISTON ASSEMBLY Cont d 6 9 10 11 1
14. in 20001X101 fans lies NIS mmmh naat AE EE Dinda NIS Ea nenen Sa esta lee NIS na EE AR see EES 20001X106 Daan uan liese 20001X109 Oinin EES 20001X110 TA ESE le 20001X111 Dire Sie 20001X112 OR pena part ER 20001X113 TO EE ee dun 20001X114 see EE 20001X116 VD sise ss 20001X118 l EER io 20001X119 Tenan EE 20001X120 sho Sere N RS 20001X121 om ie sana 20001X1272 EEN os lens 20001X124 ERA rene 20001X125 N S Non Stocked Item Bold Ref No Indicates Assembly or Kit Net maan anta Circuit Board Kadann Screw EE sr Front Cover and Label RE Rear Cover MERE N a Indicator Dial Ee Hayco Fitting RR Screw Description Powerhead Assembly Complete Timeclock Softener Powerhead Assembly Complete Filter Powerhead Assembly Complete Metered Softener w meter Powerhead Assembly Complete Metered Softener w o meter Powerhead Assembly Complete Reactr Circuit Board Assembly Includes 1 Ref 1 5 Ref 2 amp 1 Ref 3 EE Main Gear A Encoder Wheel hate Brine Cam AR TE Encoder LE Power Supply not pictured CS 2003 Control Valve Assembly CS 2003 Control Valve Assembly Parts List Ref No Quantity Part No Description 20001X200 ee Valve Body Complete 20001X
15. jector body also remove and discard O ring at bottom of brine valve hole 5 Apply silicone lubricant to new O ring and reinstall at bottom of brine valve hole 6 Apply silicone lubricant to O ring on new Brine valve assembly and press into brine valve hole shoulder on bushing should be flush with injector body 5B To Replace Injectors and Screen 1 Remove injector cap screws remove cap amp discard gasket Remove vortex generator from end of the injector assembly 2 Remove injector assembly Apply silicone lubricant to new injector assembly o rings and install Be sure to push injector assembly in tightly so o rings are seated Replace vortex generator Install a new screen 3 Apply silicone lubricant to new gasket and install around oval extension on injector cap 9 10 11 12 13 Insert screws thru injector cap and into mating holes in the valve body Tighten screws Reconnect brine tube and drain line Return by pass or inlet valving to normal service position Water pressure should now be applied the conditioner and any by pass line shut off Check for leaks at all seal areas Check drain seal with the control in the backwash position Plug electrical cord into outlet Set time of day and cycle the control valve manually to assure proper function Make sure control valve is returned to the service position Make sure there is enough salt in the brine tank Start regeneration cycle manually
16. rt No Description LA EE AE TERE 20564X200 Meter Assembly Turbine Complete CS 2003 By Pass Valve Assembly Stainless Steel sil Parts List Ref No Quantity Part No Description las lasse 2056 1X270 i aveia Bypass Valve Stainless Steel SEDES 1 20561X283 esse Bypass Valve 1 Stainless Steel CS 2003 Service Instructions A To REPLACE BRINE VALVE INJECTORS AND SCREEN 1 3 4 Turn off water supply to conditioner a If the conditioner installation has a three valve by pass system first open the valve in the by pass line then close the valves at the conditioner inlet and outlet b If the conditioner has an integral by pass valve put it in the by pass position c If there is only a shut off valve near the conditioner inlet close it Relieve water pressure in the conditioner by stepping the control into the backwash position momentarily Return the control to the service position Unplug electrical cord from outlet Disconnect brine tube and drain line connections at the injector body 5A To Replace Brine Valve 1 Remove the control valve back cover Disconnect the meter signal wire from the meter 2 Remove screw and washer at drive yoke Remove powerhead mounting screws The entire powerhead assembly will now lift off easily 3 Remove piston retaining plate screws and Pull upward on end of piston yoke until assembly is out of valve 4 Pull brine valve from in
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