Service Manual 09/2013 (Rev. A)
Contents
1. HOBART SERVICE MANUAL SERVICE WS 500 Water Softening System Installation Instructions WS 500 4 H 19981 NOTICE This Manual is prepared for the use of trained Hobart Service Technicians and should not be used by those not properly qualified This manual is not intended to be all encompassing If you have not attended a Hobart Service School for this product you should read in its entirety the repair procedure you wish to perform to determine if you have the necessary tools instruments and skills required to perform the procedure Procedures for which you do not have the necessary tools instruments and skills should be performed by a trained Hobart Service Technician The reproduction transfer sale or other use of this Manual without the express written consent of Hobart is prohibited This manual has been provided to you by ITW Food Equipment Group LLC ITW FEG without charge and remains the property of ITW FEG and by accepting this manual you agree that you will return it to ITW FEG promptly upon its request for such return at any time in the future A product of Hobart Service 701 S Ridge Ave Troy OH 45374 F25405 Rev A 0913 WS 500 Water Softening System Installation Instructions TABLE OF CONTENTS GENERAL INFORMATION WS 500 ooococcococcococco e enna 3 GENERAL WS 900 gt cional iia nadal all ias gual wetted eee atada a 3 BY PASS OPTIONS ai cue Noah oot a ABN Se a o ARN a2. Instructions DISC REPLACEMENT DISC REPLACEMENT DISC REPLACEMENT WS 500 NOTE The WS 500 comes with a 4 meter disc installed at the factory If this is not the correct disc for a given application locate the meter disc kit and install the correct disc 1 To change disc remove screws and cap cover from level one Fig 29 4 Remove meter drive pawl Fig 27 2 Remove balance piston Fig 30 5 Remove meter disc METER DISC Fig 28 3 Remove balance piston o ring and balance piston spring Fig 31 F25405 Rev A 0913 e Page 14 of 16 WS 500 Water Softening System Installation Instructions DISC REPLACEMENT 6 Install correct meter disc and reassemble in reverse order NOTE Make certain all components are correctly installed NOTE Be certain to start cap screws by hand rotating backwards until screw drops into thread then tighten An alternating crossing pattern should be used while tightening cap screws to ensure correct cap fit Add a clean grade of salt at this time Higher grades of Pelletized Salt for impurities and solubility should be used NOTE Do not use rock salt or solar salt NOTE On iron bearing water a salt that contains resin cleaning additives is recommended 7 Open the inlet valve slowly and allow the tanks to fill slowly with water Water will run at the drain until unit is full and pressurized 8 With the unitin service and under pressure allow the br
3. valve kit is not being installed proceed to BY PASS VALVING WS 500 Page 3 of 16 lt n F25405 Rev A 0913 WS 500 Water Softening System Installation Instructions BY PASS OPTIONS BY PASS OPTIONS BY PASS VALVE KIT WS 500 44 WARNING Disconnect the electrical power to the machine and follow lockout tagout procedures 1 To install by pass valve determine which port on the by pass valve Port A or Port B to plumb the raw water connection to PORT A gt EER a 23314 Fig 1 2 Determine which port on the by pass valve Port C or Port D to connect the softener PORT C gt lt ___ PORT D ai 23315 Fig 2 3 Verify the by pass valve is in the by pass position Turn by pass handle to reveal yellow by pass segment F25405 Rev A 0913 YELLOW BY PASS SEGMENT ey a 23316 Fig 3 4 Remove the by pass valve handle by pulling it away from the by pass valve body BY PASS VALVE gt HANDLE 23317 Fig 4 5 The five position valve has two installation configuration options Photo below shows the crossover and parallel configurations as the valve is shipped NOTE When installing the five position valve be certain to select the proper mode and install configuration parallel or crossover Page 4 of 16 WS 500 Water Softening System Installation Instructions BY PASS OPTIONS Fig 5 6 Locate patch decal provided with by pass valve kit 7 Remove patch dec
4. 00 24 x 40 Brine Valve Adjustment Al2318 Fig 26 NOTE Determining the correct brine valve setting for a particular application is a three step process 1 Determine the compensated hardness This requires a hardness test and an iron test on raw water at the application site Compensated hardness is calculated by multiplying the ferrous iron in ppm by 3 and adding it to the grains of hardness 2 To test the water supply use the water analysis test kit available through Pro Products Inc The recommended kit is 2404 Deluxe Field Analysis Kit To order the test kit contact Pro Products at 800 285 9176 or visit www ProProducts com 3 Set the adjuster tube and float cup Use the brine drum specifications for the WS 500 to determine the correct settings for both the adjuster tube and the float cup height Brine Valve Settings for WS 500 24 x 40 Brine Valve Adjustment Page 13 of 16 NOTE Do not drop the brine valve into the drum Dropping may lower the float cup resulting in an improper setting NOTE After the adjustments have been made to the adjuster tube and the float cup the brine valve assembly must be installed in the brine drum Locate the brine valve in the brine well so the 3 8 bent tube is along the back of the brine well away from the brine drum wall The 3 8 bent tube snaps into a notch and extends from the brine drum about 1 inch F25405 Rev A 0913 WS 500 Water Softening System Installation
5. 4 BY PASS VALVE KIT WS 900 ifsc en ee a a a AN A a as 4 BY PASS VALVING WS 900 saie co incomoda retarted aia AR E ie aoe nia alas a 8 INSTALLATION cosita asia art tb a 10 INSTALLATION WS 500 ici rai a dl att hd aed ta 10 BRINE DRUM SETTINGS FOR WS 500 0 2 rr 12 DISC REPLACEMENT scott aio o A a de andesite 14 DISC REPLACEMENT WS 500 20000 a a aa a a a 14 DISC SELECTION icacnavarsnsza paid as rtorras 16 DISC SELECTION WS 900 anartre eai iiaa ioten iodo ta dada load aaa 16 HOBART SERVICE 2013 F25405 Rev A 0913 _ Page 2 of 16 WS 500 Water Softening System Installation Instructions GENERAL INFORMATION WS 500 GENERAL INFORMATION WS 500 GENERAL WS 500 44 WARNING Disconnect the electrical power to the machine and follow lockout tagout procedures 1 Determine location to install equipment Make sure the unit will be on a flat surface 2 If sand silt or turbidity is present install a separate prefilter NOTE Sediment filtration is recommended before the water softener particularly in areas with known sediment issues or on a private water supplies NOTE If the peak flow rate required is unknown a prefilter with a minimum of 1 25 connections should be used Filters with 5 micron nominal ratings should be considered the standard in food service applications 3 Ifthe optional by pass valve kit is being installed follow steps listed under BY PASS VALVE KIT WS 500 If bypass
6. al from paper lining and apply to body of the by pass valve based on the specific installation using BY PASS VALVE DECAL TABLE NOTE For use in A D or B D configuration it will be necessary to cut patch 23319 Patch Decal 8 Align the handle with the shaft until handle slides onto shaft Push down on handle until it snaps into place NOTE The handle is keyed allowing it to go on the shaft only one way Failing to perform above procedure can result in breaking the shaft inside the handle Do not force handle onto shaft Page 5 of 16 23320 Fig 7 NOTE When installing a plastic component in line it is recommended that grounding straps be put in place before the lines are actually cut to ensure the ground is never broken 9 Prepare plumbing by roughing in 10 Connect the inlet outlet adapters to the plumbing Solder or glue adapters to pipe as applicable NOTE Do not solder adapters while in the by pass valve NOTE Care should be taken during the installation process to assure that solder flux does not come in contact with the media tanks the control module and related components 11 After all plumbing is completed and before connecting any equipment flush both inlet and outlet lines by opening the raw water inlet valve and allowing water to rinse out and debris in the line 12 Close the raw water line when complete 13 Locate from the by pass kit the two elbows four O rings two E Clips an
7. arm controller NOTE When installing batteries be certain to inspect connector to ensure it is secure Page 11 of 16 23294 Fig 22 9 Re install back cover to salt alarm controller 10 Using the adhesive backing on both devices place alarm controller and salt alarm sensor in a position that will allow salt alarm controller to be seen and heard when it is activated 11 Insert phone cable into salt alarm sensor and salt alarm controller NOTE Salt alarm controller can be mounted up to 100 feet from salt alarm connector box using standard phone cable from local retailers 7 foot cable is provide with kit Fig 23 12 Check for proper operation by pressing the recessed red button on bottom of salt alarm controller If controller is operating properly the indicator light will flash and an audible tone will be heard F25405 Rev A 0913 WS 500 Water Softening System Installation Instructions INSTALLATION RECESSED BUTTON 23295 Fig 24 BRINE DRUM SETTINGS FOR WS 500 NOTE In Hobart Softeners the brine drum mixes and stores a solution of salt for regeneration of the softener media During the brine rinse cycle this solution is drawn from the brine drum and through the media to regenerate it NOTE The brine drum contains an adjustment to draw the correct amount of salt brine solution for each cycle This adjustment is made in two places the adjuster tube and the float cup NOTE The ad
8. closed kit containing four O rings two pipes with O rings and the silicone packet Apply a liberal amount of silicone to the four Orings and the O rings in the two pipes Install the four O rings to the inlet outlet adapters NOTE Be certain the E clips are fully inserted into the valve Check to make sure that all three tabs on the E clips are fully inserted Typical Installation Untreated Water Soft Water Untreated Water Soft Water Al3176 Fig 13 Page 7 of 16 Typical Installation x g y a e UA Q X 1 d Dasara YF Su I Al3177 Fig 14 F25405 Rev A 0913 WS 500 Water Softening System Installation Instructions BY PASS OPTIONS Figure 2 Figure 3 A C B C lo gt a amp 7 2 Figure 4 Figure 5 A D B D Al3175 BY PASS VALVE DECAL TABLE INSTALL move RAW INLET SOFTENER INLET CONFIGURATION D Bce B o A BY PASS VALVING WS 500 NOTE If optional by pass valve kit is not installed it is recommended that by pass valving be installed To install by pass valving follow steps listed below 1 Install by pass valving Be certain to note the inlet and outlet arrows on the valve head 2 Connect the inlet outlet adapters leading to the softener using the proper size plumbing 3 Plumb as necessary to accommodate the bypass valving and to complete the installation NOTE Actual installation of by
9. d silicone packet F25405 Rev A 0913 WS 500 Water Softening System Installation Instructions BY PASS OPTIONS O RINGS 5 SILICONE gt 23298 Fig 8 14 Apply a liberal amount of silicone to the four Orings and install on the two end spaces on both Port C and Port D of the By Pass Valve Fig 9 15 Insert mesh screens into left and right elbows SCREENS 23296 Fig 10 16 Locate from the by pass kit the four O rings two E Clips and silicone packet F25405 Rev A 0913 O RINGS 3 gt car SILICONE 3 gt 23321 Fig 11 17 Apply a liberal amount of silicone to the four Orings and install them on the two outermost groves on both elbows NOTE Elbows are marked left L and right R When applying to by pass valve be certain to install in correct location based on left right orientation LEFT RIGHT Fig 12 NOTE Make sure to align the center slot the slot with the small triangle underneath it with the outside of the by pass valve 18 Connect elbows from the by pass valve to softener using E clips Press E clips until they securely snap in place 19 Connect the by pass valve to the inlet outlet adapters Press E clips until they securely snap in place 20 Plumb as necessary to accommodate the bypass valve and to complete the installation Page 6 of 16 WS 500 Water Softening System Installation Instructions BY PASS OPTIONS 21 Locate en
10. ine drum to fill with water until the brine valve shuts off 9 After the unit is fully pressurized purge air form the lines by opening soft water outlet NOTE When brine drum overflow could cause damage a Y I D overflow line must be installed on the barbed overflow fitting on drum and connected to a drain Make sure drain is not higher than barbed fitting 10 Check for plumbing leaks 11 Check unit for proper operation Page 15 of 16 F25405 Rev A 0913 WS 500 Water Softening System Installation Instructions DISC SELECTION DISC SELECTION DISC SELECTION WS 500 Using the full louver nozzle the amount of hardness removed in compensated gpg will be based on the amount of brine and the meter disc selected Specifications WS 500 Overdrive Operation Alternating Operation Salt usage generation 25 Ibs Efficiency 2 800 gr Ib 12 Float cup setting 12 OVERDRIVE OPERATION WS 500 Disc Selection Se o os E Peak Flow During Regeneration Compensated hardness in gpg Hardness 3 x Fe in ppm ALTERNATING OPERATION WS 500 Disc Selection Pe 1 O OA EE Compensated Hardness 7 a Gallons Reiween 8 922 aot aot 2 974 2 231 1 784 1 487 1 275 Mas 115 Regeneration Regeneration Gallons Per Minute 15 psig Compensated hardness in gpg Hardness 3 x Fe in ppm F25405 Rev A 0913 Page 16 of 16
11. juster tube measures the amount of solution that is drawn from the brine drum into the softener during the brine rinse cycle The float cup height determines how much softened water flows back into the brine drum to prepare for the next regeneration NOTE The adjuster tube is set by cutting and removing tabs on both sides of the tube Cut across each tab horizontally following the channel in the plastic Break off each tab individually until the proper setting is reached The remaining number or letter imprinted on the tab determines the correct setting F25405 Rev A 0913 Adjuster Tube AI2317 Fig 25 NOTE The float cup height determines how much softened water flows back into the brine drum to prepare for the next regeneration NOTE The float cup is set by adjusting its height above the bottom of the Brine Valve Assembly By removing the brine valve assembly and resting it ona flat surface the height of the float cup can be measured with a ruler The height is measured from the base of the brine valve assembly to the top of the float cup NOTE Standard settings are defined by markings on the rod of the brine valve assembly Where the predefined settings are not adequate the actual float cup height must be measured and the setting must be measured and set according to the measured float cup height Page 12 of 16 WS 500 Water Softening System Installation Instructions INSTALLATION Brine Valve Settings for WS 5
12. ollow lockout tagout procedures 1 Connect the remote tank to the main tank using connector pipes connector links and connector pins CONNECTOR y LINK NOTE Always use both links and pins 2 Runadrain line to the discharge point NOTE Follow state and local codes 3 Before connecting unit check for obstructions or kinks Apply Teflon tape to pipe threads on side of softener valve and install the two fittings supplied Connect drain line to valve NOTE An air gap must be provided for all drain lines Check state and local plumbing codes for proper setup of drain line air gaps NOTE On drain lines that must travel more than 8 feet up and 30 feet over it is best to take the 5 8 drain line that fits the valve and attach it in a larger diameter line or pipe 4 Position the brine drum NOTE Brine drum should be conveniently positioned to allow salt to be added F25405 Rev A 0913 Fig 18 5 Toinstall salt alarm system remove paper lining from back of salt alarm sensor REMOVE PAPER 7 LINING 23290 Fig 19 Page 10 of 16 WS 500 Water Softening System Installation Instructions INSTALLATION 6 Remove plastic lining from Velcro backing located on back of salt alarm controller REMOVE PLASTIC LINING 23291 Fig 20 7 Remove four screws securing back cover to salt alarm controller SCREWS 23293 Fig 21 8 Install three 3 AA batteries into salt al
13. pass valving may vary from installation to installation Be sure to follow state and local codes NOTE When installing a plastic component in line it is recommended that grounding straps be put in place before the lines are actually cut to ensure the ground is never broken F25405 Rev A 0913 CROSSOVER CROSSOVER NOTE Do not solder brass adapters while inserted in the module base Damage to plastic and ruber parts may result due to the heat In addition the materials used in the soldering process may attack certain types of plastics NOTE Care should be taken during the installation process to assure that solder flux do not come in contact with the media tanks the control module and related components Page 8 of 16 WS 500 Water Softening System Installation Instructions BY PASS OPTIONS BY PASS VALVES Fig 16 4 After all plumbing is completed but before connecting equipment flush both the inlet and outlet lines by opening the by pass valve and allowing water to rinse out any debris in the lines 5 Connect the main tank with softener valve to the inlet outlet adapter The inlet outlet adapter is inserted into the control valve and locked in place by the plastic E clips Page 90f16_ F25405 Rev A 0913 WS 500 Water Softening System Installation Instructions INSTALLATION INSTALLATION INSTALLATION WS 500 44 WARNING Disconnect the electrical power to the machine and f
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