PRINTERSErie 2401S Installation.qxd
Contents
1. 8 Cycle 2 The control will display Press the UP ARROW or DOWN ARROW to set the length of the brine slow rinse cycle from 0 to maximum 99 minutes Note In most applications the factory settings are adequate and will not need adjustments Press the SCROLL amp button to advance to the next setting 9 Cycle 3 The control will display Press the UP ARROW or DOWN ARROW to set the length of the fast rinse brine refill cycle from 0 to maximum 99 minutes The time of the fast rinse brine refill cycle with the brine refill flow control will determine the quantity of refill to the brine tank independent of the inlet pressure Note This setting will need adjustments in most applications For brine refill flow con trol information and salt settings see page 19 Press the SCROLL button the control will display Press the UP ARROW or DOWN ARROW to exit the Installer s Level IMPORTANT NOTE In order for these new settings to become active it is necessary for you to execute a complete regeneration After you step scroll through a manual regeneration the new settings will become active If you choose not to manually regenerate the system the settings will not become active until the unit has completed its next scheduled regeneration Capacity Volume Setting 2 Reset Flow Note This function is not available if the control was programmed for No Meter in the Manu facturer s lev2. Unit uses too much salt Salt water to service Loss of resin through drain line Loss of water pressure 1 CAUSE Excessive water in brine tank Unit regenerates too frequently Excessive water in brine tank Low water pressure Improper brine slow rinse time setting Improper fast rinse brine refill time setting Excessive backwash fast rinse flow Lower and or upper distributor damaged Leak between riser tube and upper distributor Mineral or iron build up in resin tank Plugged lower and or upper distributor Crushed lower and or upper distributor Plugged outlet manifold 1 SOLUTION Refer to symptom Excessive water in brine tank Check capacity reserve capacity and calendar override Refer to symptom Excessive water in brine tank Check injector selection and adjust rinse time Verify that the brine slow rinse time corresponds to the proper salt level and the proper amount of resin Verify that the fast rinse brine refill time corresponds to the proper salt level and amount of resin See page 19 Verify that the backwash flow control is installed and sized correctly Replace distributor s Verify that the riser tube is seated correctly and not cracked Clean the resin bed and control valve increase the regeneration frequency Verify that the distributor s are free of debris Replace di
3. 24015 Installation amp Service Manual Water Treatment Controls A Division of Aquion Partners L P Table of Contents Installation Instructions 3 5 Important Control Information 5 7 Programming Instructions for the Installer s BM 8 10 Capacity Program Volume Setting 11 12 System Program Hardness Setting Programming Instructions for the Manufacturer s 13 14 Programming Instructions for the End User s s 15 Checking the Diagnostics 16 Start Up System Check Instructions 17 Injector and Flow Control Information 18 19 Cycles of the System ssss 20 Water Flow Diagrams 21 Troubleshooting sess 22 25 Rotary Valve Exploded View 26 Rotary Valve Parts List ssssssse 27 Control Exploded View ssss 28 Control Pans List uu s a ie nets 29 Wiring DIBOEATEU 2 oc aote oat sect otto on 30 Disassembly Instructions 31 42 Synchronizing the Valve Body and Control Control Specifications Agency Approvals The control complies with the rules of the FCC applicable to residential water softeners The control meets UL and CSA requirements for residential wate
4. Both English US and Metric units can be programmed into the control When the manufacturer selects English US units the volume is displayed by GL gallons and the flow rate is indicated by GPM gallons per minute GL d gallons per day indicates the average volume and the time is displayed in a 12 hour AM PM format When the manufacturer selects Metric units the volume is displayed by L liters and the flow rate is indicated by L m liters per minute The average volume is indicated by L d liters per day and the time is displayed in a 24 hour format Flow Input Meters Standard Meter The meter produces 108 pulses per one gallon of flow and 29 pulses per liter of flow The maximum pulse rate is 54 per second corresponding to a maximum flow rate of 30 GPM Secondary Meter The control can be programmed for a non standard meter this is a non Hall effect type meter and is called a volume pulse setting on the control 100 gal per pulse Note The factory selects a M factor for the meter For English US the K factor defines the number of gallons per pulse For Metric the K factor defines the number of liters per pulse The default setting is 100 Holiday Mode Regeneration is not allowed when the control is in the holiday mode The word HOLIDAY will blink when scrolled to on the control board After sixty seconds the unit will enter the holiday mode The only way the unit will exit the
5. 19 One of the rectangular openings on the injector should be facing directly towards the center of the valve body 18 Push the injector 19 down firmly Reinstall the seal disk 12 into the valve body 18 with the green side facing up Reinstall the rotor assembly 11 10 9 and 8 into the valve body 18 ensuring that the arrow on the worm gear 8 is pointing directly towards the second tooth on the worm drive shaft 30 facing the front of the control valve The 2 holes in the rotor assembly should now be exactly aligned with the corresponding holes in the seal disk 12 Center the washer 6 onto the worm gear 8 Make sure the valve cover O ring 5 is clean and securely installed around the raised rib on the valve cover Z4 Lower the valve cover 4 straight down onto the valve body 18 and press down firmly and evenly to seat the valve cover 4 Reinstall the 6 bolts 3 and nuts 22 and tighten them in a cross pattern Reinstall the drain hose to the drain line elbow 1 PARI n 2 gt 7 Io e A o rO UEM ae QU Q 9 Worm Drive Shaft Replacement FOR STEPS 1 3 PLEASE REFER TO THE CONTROL PARTS LIST FOR REPLACEMENT PART NUMBERS 1 2 3 FOR STEPS 4 13 PLEASE REFER TO THE ROTARY PARTS LIST FOR REPLACEMENT PART NUMBERS 4 5 6 10 11 11 12 13 Disconnect all electrical power to the unit Remove the screw holding the flow meter sensor
6. 4 in place and remove the flow meter sensor 4 Remove the 2 base mounting screws 10 and take away the control head assembly Unscrew the packing gland nut 34 Remove the packing gland nut 34 worm drive shaft 30 from the valve body 18 Separate the packing gland nut 34 from the worm drive shaft 30 Inspect the worm drive shaft 30 The threads on the worm drive shaft 30 should not be deformed or damaged replace if necessary Check the worm drive shaft washer 31 for wear and or damage replace if necessary Lubricate the O rings 32 Install the worm drive shaft 30 into the valve body by turning it clockwise as far as possible Install the packing gland nut 34 over the worm drive shaft 30 and screw it into the valve body 18 Reinstall the control head assembly onto the valve body and tighten the 2 base mounting screws 10 Reinstall the flow meter sensor 4 It is now necessary to check the Synchronization of the Valve Body and Control Head refer to Impeller Replacement PLEASE REFER TO THE ROTARY PARTS LIST FOR REPLACEMENT PART NUMBERS 1 Remove the bypass valve assembly from the control valve 2 Using a slot screwdriver separate the impeller assembly 56 from hub 55 The impeller hub 55 will remain pressed into the valve body 18 3 Inspect the impeller assembly 56 replace if necessary 4 Reverse the procedure for reassembly Riser Replacement PLEASE REFER TO THE ROTARY PA
7. holiday mode is when a flow rate greater than 1 5 gallons per minute has been detected or if an immediate regeneration has been started You may also manually scroll out of the holiday mode as the last way to exit After exiting the holiday mode the unit will go into an immediate regeneration Override Counter If the override parameter is set to OFF the days to override counter will not be used to initiate regeneration The days to override counter is always used to initiate regeneration when No Meter has been selected If days to override is programmed with a meter the over ride will only initiate regeneration if the meter has not recorded enough water usage Regeneration Level When a regeneration in progress is aborted the valve is cycled to the service position If the aborted regeneration was initiated by the control not manually initiated the regeneration is restarted after a 60 second delay Example A power outage is an aborted regeneration If a manual regeneration is aborted there is no back up regeneration Regeneration Once an immediate regeneration is requested a complete regeneration must occur to clear the request Once regeneration starts it must finish or the board will not clear If the regeneration is aborted and the request is not cleared another immediate regeneration will occur Manually walk scroll the control through a regeneration to clear the board High Speed Motor Operation in the
8. operating properly The corrupt memory registers and records this error to the non volatile memory Non Volatile Memory The computer board configuration parameters are saved in non volatile E7PROM memory that has a minimum of 100 000 erase write cycle capability The non volatile memory is used for storage of information The storage of information will stay in memory in the event of a power outage Example The Hardness Capacity or Volume settings are the types of settings stored in the non volatile memory In the occurrence of a power outage the non volatile memory will hold this important setting information The time of day however will need to be reset if the power interruption has lasted longer than two hours The non volatile memory is not programmed to store the time of day and in most cases the super capacitor will last only two hours Corrupt Manufacturer s Mode Installers Mode and Diagnostic Mode Parameters This corrupt mode signifies that somehow the board received an incorrect signal and rejected that signal The board is now put on notice that there was a mistake made The corrupt mem ory will register and record the error to the non volatile memory If any of the parameters except Valve Type Meter Type or Duplex Type become corrupt the default for the corrupted parameter will also be saved in the non volatile memory The number of corruptions can be read in the Diagnostic Level Measurement Units
9. 0 d To adjust the reserve press the SCROLL button Press the UP ARROW or DOWN ARROW to set the reserve capacity in incre ments of 10 gallons up to 40 capacity of the system If a Variable Reserve is desired press the UP ARROW or DOWN ARROW The control will display The reserve capacity will be calculated automatically based on the registered daily water consumption The default setting is 2596 of the capacity 75 gallons Press the SCROLL button to advance to the next setting 5 Time of Regeneration The control will display Regen 2 00 am Press the UP ARROW or DOWN ARROW to set the time of regeneration Press the SCROLL amp button to advance to the next setting 6 Days Override The control will display Press the UP ARROW or DOWN ARROW to set the maximum number of days between regenerations from OFF to 30 days max limit Press the SCROLL button to advance to the next setting The Installer s Level continued 7 Cycle 1 The control will display BACK WAG 10 min Press the UP ARROW or DOWN ARROW to set the length of the backwash cycle from 0 to maximum 99 minutes When iron or hardness is present the backwash time should be extended 5 to 15 minutes based on experience Note In most applications the factory settings are adequate and will not need adjustments Press the SCROLL button to advance to the next setting
10. 7 Use a silicone base lubricant to lubricate the green side of the seal disk 12 8 Remove the insert plate 13 from the valve body 18 Inspect the insert plate 13 make sure the ribs are intact Replace the insert plate if necessary 9 Remove the gasket 14 from the valve body 1 X e I Ms fo J aj 1 ININA Ia jo 0 Lan MI Y I YES OA AO oO JS Wr 18 Inspect the gasket 14 for wear or 13 damage replace if necessary 10 Using needle nose pliers grasp one side of the CC 4 injector 19 and pull it straight out of the valve M m body 18 9 9 45 11 Clean the surface of the valve body 18 amp Tn 12 Lift the float valve 16 straight out of the 20 j 16 float valve chamber of the valve body 18 C gt gt 13 Remove the spring 15 from the float valve gt 17 shaft 14 Clean all sealing surfaces inside the float chamber 15 Make sure the float valve 16 is straight up in the float chamber of the valve body 18 Instructions continued on page 39 Rotor Seal Disk Float Valve Gasket and Injector Replacement continued 16 17 18 19 20 21 22 23 24 25 Reinstall the gasket 14 and insert plate 13 into the valve body 18 Lightly lubricate the O rings 20 and 21 of the new injector with a soapy water solution Install the injector
11. BERS 1 2 3 Make sure the arrow on the worm gear 8 is Make sure the valve cover O ring 5 is clean and see fig 1 If this is not the case please refer to Drive Motor Replacement on pages 33 34 Remove the drain hose from the drain elbow 1 Remove the 6 bolts 3 and nuts 22 holding the valve body 18 and cover 4 together Lift the valve cover 4 away from the valve body 18 pointing directly towards the second tooth on the worm drive shaft 30 facing the front of the control valve see fig 2 The 2 holes in the rotor assembly should now be exactly aligned with the corresponding holes in the seal disk 12 installed securely around the raised rib on the valve cover Z4 Lower the valve cover 4 straight down onto the valve body 18 and press down firmly and evenly to seat the valve cover Reinstall the 6 bolts 3 and nuts 22 and tighten them in a cross pattern Reinstall the drain hose to the drain line elbow 1 Erie Water Treatment Controls A Division of Aquion Partners L P 2080 East Lunt Avenue Elk Grove Village Illinois 60007 Tel 847 758 5953 Fax 847 354 6911 www eriewatertreatment com 2003 Erie Water Treatment Controls Part 68027 Rev A 5 03
12. Displays the amount of hardness programmed into the control Note Will not display when control is programmed for Volume Rsrv Displays whether the control is programmed for Fixed or Variable Reserve Note Will not display when programmed for Immediate Regeneration Regen Displays the time of day the unit will regenerate Override Displays the override mode by reading OFF or the number of days program med into the control Backwashi Displays the minutes of backwash programmed into the control If the control is programmed for Metric units this position will display as CYCLE 1 BRN RNS Displays the minutes of brine and rinse programmed into the control If the control is programmed for Metric units this position will display as CYCLE 2 FILL RNS Displays the minutes of fast rinse programmed into the control If the control is programmed for Metric units this position will display as CYCLE 3 Units Displays the mode of measurement ENGLISH US or METRIC Meter Displays whether the control is programmed as a Standard Meter No Meter or Volume Pulse setting Capacity Volume Hardness Displays whether the control is programmed for a Capacity Volume or Capacity Hardness setting Regen Displays the programmed regeneration type Delayed Immediate or Delayed Immediate Valve Type Displays the type of valve the factory programmed into the control M P Resets Displays how many times the programs
13. ELF THREADING 4 1 70980 FLOW METER SENSOR HOUSING POTTED CABLE ASSEMBLY 5 1 72134 70873 HEYCO BUSHING SR 5P 4 HEYCO PLUG DP 500 6 1 70971 POWER LEAD 7 1 70312 HEYCO BUSHING SR 2P 4 8 1 70962 ELECTRONIC CONTROL BACKPLATE 9 3 71502 SCREW 8 18 X 3 8 LG SELF THREADING 10 4 71497 SCREW 10 16 X 1 LG TYPE BT SS SELF THREADING 11 1 70720 DRIVE SHAFT 12 1 71656 MOTOR 24VCD WITH INTERNAL CAPACITORS 13 1 71677 DRIVE MOTOR EMC CIRCUIT ASSEMBLY MASTER 14 1 71075 WORM 15 1 70668 RETAINING RING 16 1 72049 POSITION INDICATING BOARD amp MICROSWITCH ASSEMBLY 17 2 70622 SCREW 2 28 X 3 4 LG SELF THREADING 18 1 71185 BRACKET 19 1 71106 HUB AND GEAR 20 1 70625 SCREW 6 32 X 7 16 LG 21 1 70965 CAM SHAFT 22 1 71679 MOTOR LEAD 23 1 70970 CAM SWITCH ASSEMBLY LEAD 24 1 72138 TRANSFORMER 120VAC 5A Wiring Diagram POSITION SWITCHES CONTROL PAD Disassembly Instructions Before Servicing the Equipment Make sure the control valve is in the service position The control will display the time of day and gallons remaining Disconnect all electrical power to the unit Bypass or disconnect the water supply Relieve the water pressure Familiarize yourself with the part replacement procedures and components before attempting any repairs Required Tools Phillips screwdriver Needle nose pliers Adjustable wrench Small standard screwdriver 3 8 Allen wrench Important Notes Brine Refill Flow Control If th
14. ISER INSERT GASKET 25 1 71118 RISER INSERT 26 1 70662 RISER TUBE O RING 27 1 70663 TANK O RING 28 1 71010 ADAPTER RING 29 2 71512 SCREW 6 20 X 21 32 LG SS 30 1 71060 WORM DRIVE SHAFT 31 1 70616 WORM DRIVE SHAFT WASHER 32 2 70666 WORM DRIVE SHAFT O RING 33 1 70661 PACKING GLAND O RING 34 1 71069 PACKING GLAND NUT 35 1 71124 BRINE REFILL ELBOW 36 1 70667 O RING 37 1 71961 REFILL ELBOW CHECKBALL 1 4 DIA 38 1 70984 REFILL ELBOW SPRING 39 2 13490 COMPRESSION NUT FOR 3 8 TUBE JACO 0 6 40 1 71184 BRINE REFILL FLOW CONTROL 41 1 71728 FLOW CONTROL WASHER 25 GPM 70994 FLOW CONTROL WASHER 0 5 GPM 70995 FLOW CONTROL WASHER 1 0 GPM 42 1 71129 BRINE TEE 43 1 70659 O RING 44 1 70871 BRINE TEE CHECK BALL 3 8 DIA 45 2 12625 3 8 TUBE SUPPORT 46 1 13604 BRINE REFILL TUBE 3 8 O D X 250 I D X 12 L 48 1 70797 COMPRESSION NUT FOR 3 8 TUBE JACO PG 6 50 1 70932 UMBRELLA CHECK VALVE OPTIONAL FOR OVERHEAD DRAINS 55 1 72050 IMPELLER HUB 56 1 70469 IMPELLER ASSY 57 1 70621 SCREW 4 20 X 3 16 LG 1 70980 SENSOR HOUSING POTTED CABLE ASSY Control Exploded View Control Parts List Item Qty Aquion Part Description 1 1 72252 FRONT COVER SUBASSEMBLY 2 1 70966 BOARD ASSEMBLY NGC DRIVE MOTOR PROGRAMMED Softener demand Program Code R1SDa Aquion factory programmed board part 72264 Filter Demand Program Code R1FDa Aquion factory programmed board part 72265 3 1 70618 SCREW 4 24 X 3 8 LG S
15. LET pipe connection of the bypass To empty the hot water heater of untreated valve When looking at the front of the unit water run hot water in the bathtub until the the OUTLET is the pipe connection on the water runs cold PODES Ute valve 10 Test Hot and Cold Water ES Test hot and cold water for hardness Older hot water heaters may have calcium deposits in them which could affect your test results If only hot water is treated test the water at the drain valve installed between the unit and the hot water tank 11 Install Drain Line and Air Gap air gap not included with unit Connect the drain line to the drain outlet on the left side of the valve This connection C is a 1 2 inch female pipe thread To l attach a drain line a fitting is needed to If treating only hot water install a drain connect from the female connection to the valve between the conditioner tank and hot drain line Note This line operates under water heater so that the water can be pressure so it may be installed higher than tested for hardness before entering the hot the conditioner 8 Turn on the Water and Test for Leaks Close all faucets that were opened in Step 5 Turn the water back on at the water meter DRAIN or pressure tank STACK Check for leaks AIR GAP If there is a leak drain the plumbing again before soldering STAND PIPE FOR WASHER ETC Test to confirm that the u
16. Plugged injector Plugged injector filter Restricted drain line Restricted brine line Leak in brine line Not enough water in the brine tank Defective or shorted microswitch es Valve fails to draw brine Improper fast rinse brine refill time setting Improper or missing brine refill flow control Leak between the rotor and seal disk Blockage in brine line or brine valve Improper fast rinse brine refill time setting Improper refill flow control Plugged refill flow control OO N 7 1 2 3 4 1 2 SOLUTION Verify operating pressure Clean injector Clean injector filter Check drain line for kinks or restrictions Verify backwash flow control is free of debris Check brine line for kinks or restrictions Check brine line and connections for air leakage Refer to the symptom Valve fails to refill brine tank Replace microswitch es Refer to symptom Valve fails to draw brine Verify that fast rinse brine refill time corresponds to the proper salt level and amount of resin Verify that the flow control is installed and properly sized Verify or replace rotor and seal disk Remove blockage Verify that the fast rinse brine refill time corresponds to salt level and amount of resin Verify that the flow control is properly sized Verify that the flow control is free of debris Troubleshooting continued SYMPTOM
17. RTS LIST FOR REPLACEMENT PART NUMBERS CONDO OO RON e Place the bypass valve into the bypassed position Relieve the system pressure Disconnect the unit from the bypass connections Remove the unit from the resin tank Note Do not use the control assembly as a handle while rotating the valve Remove the two adapter screws 29 and remove the adapter ring 28 Separate the riser assembly 24 25 26 and 27 from the valve body 18 Clean the 2 riser O rings 26 and 27 and wipe out the valve body cavity Use Dow 111 Silicone based lubricant or equivalent to lightly lubricate the riser O rings 26 and 27 and the valve body cavity 18 Reverse the procedure for reassembly Synchronizing the Valve Body and Control Head To ensure the proper operation of the control valve the valve body and control head should be synchronized in the service position Proceed as follows Step 1 Control Head PLEASE REFER TO THE CONTROL HEAD PARTS LIST FOR REPLACEMENT PART NUMBERS 1 Make sure that the control valve is in the service mode if the control valve is in regeneration push the scroll button to manually advance the unit through the regeneration cycles until the display shows the time of day and gallons remaining 2 The flat side on the drive shaft 11 should be pointing down mark on the drive shaft pointing up Step 2 Valve Body PLEASE REFER TO THE ROTARY PARTS LIST FOR REPLACEMENT PART NUM
18. Regeneration Mode High speed motor operation is achieved while stepping the control through the regeneration cycle Pressing the scroll button a second time while in regeneration activates the higher speed Programming the Control ffr 23 POWER o WS Key Buttons SCROLL UP ARROW DOWN ARROW The manufacturer of the system will program the control to either a Hardness or Volume setting To change this setting or any of the system defaults see pages 13 14 for factory program ming information If you are unsure of which setting the manufacturer has chosen Hardness or Volume the following steps will help you to determine which programming pages to use Enter the Installer s Level by pressing and holding the DOWN ARROW for 5 seconds The control will display System Check Within 10 seconds enter the Installer s access code DOWN ARROW DOWN ARROW SCROLL BUTTON DOWN ARROW If the control displays System the control is programmed for a Hardness setting See pages 8 10 for programming If the control displays Capacity the control is programmed for a Volume setting See pages 11 12 for programming The Installer s Level System Hardness Setting Verify that the control valve is in the Service Mode The control will display Tim
19. SCROLL button to advance through the different settings Programming options menu 1 Units The control will display Units Holic tS Press the UP ARROW or DOWN ARROW to program the control from English US Gallons to Metric Liters Press the SCROLL amp button to advance to the next setting 2 Flow Meter Type Standard meter This is the standard Erie meter No meter When no meter is selected the installer must activate the calendar override The calendar override will be used as a day set ting for regeneration Volume Pulse setting Whenever a non Erie meter is used the pulse factor must be pro grammed in this field The control will display Std Meter To program no meter or choose a pulse factor for a non Erie meter continue below Press the UP ARROW or DOWN ARROW to program the flow meter from Std Meter to No Meter or Vol Pulse If Vol Pulse is selected push the UP ARROW or DOWN ARROW to program the pulse factor from 1 to 1000 The control will display Vol Pulse 100 Press the SCROLL button to advance to the next setting 3 Capacity Note The hardness function is not program mable if Metric was selected in Step 1 The control will display Volume Capacity Press the UP ARROW or DOWN ARROW to program the capacity from a volume to a hardness setting II Volume is selected the installer will pro gram the amount of water to be used N
20. ackplate mounting screws 10 and take away the control head assembly 1 4 Loosen the 3 front cover screws 9 and remove the front cover 1 Disconnect the wires 22 and 23 from the drive motor assembly 12 and microswitch assem bly 16 At the back of the backplate 8 remove the 2 screws 10 holding the drive motor assembly 12 in place and remove the microswitch assembly 16 and drive motor assembly 12 Remove the retaining ring 15 securing the worm 14 and remove the worm 14 from the drive shaft 11 Pull the drive shaft 11 out of the drive motor assembly 12 To replace the cam shaft 21 and or hub gear 19 loosen screw 20 and lift out and remove 21 and 719 Instructions continued on page 34 Note The small PCB board 13 is soldered onto the drive motor assembly 12 Drive Motor Replacement continued 10 To replace the microswitch assembly 16 remove the 1 small screw on the bottom of the assembly 11 Reverse the procedure to reassemble the cam shaft 21 hub gear 19 and microswitch assembly 16 12 Reinstall the drive shaft 11 into the drive motor assembly 12 with the flat side on the drive shaft pointing down mark on the drive shaft pointing up 13 Reinstall the worm 14 on the drive shaft 11 and install the retaining ring 15 to secure the worm 14 14 Put the microswitch assembly 16 onto the drive motor assembly 12 make sure the micro Switch assembly and cam shaft are in the servi
21. age displays in the window of the control a fault has occurred on the board also know as a corrupt signal In most cases reprogramming the board will clear this message from the window If the screen does not clear other checks must be made to the Switches boards and parts Important Control Information continued Blinking Digits or Message Digits or a message blinking at the rate of 0 5 seconds ON and 0 5 seconds OFF indicates that these digits can be changed edited A message flashing at a rate of 1 second ON and 1 second OFF cannot be changed Pressing and releasing the UP ARROW or DOWN ARROW can change the blinking digits or the message The user can increase or decrease the values by using the two arrow keys Real Time Clock A real time clock maintains the time of the day when line power is applied to the control The time of day is maintained by a super capacitor for a minimum of 2 hours following the loss of line power Corrupt Memory registers and records this error to non volatile memory Corrupt Real Time Clock If line power is lost for an extended period the super capacitor will lose its charge and the real time clock will stop operating When line power returns the clock will blink indicating that the clock needs to be set to the correct time The clock will activate from 8 00 AM until the clock is set to the correct time After the time has been set the colon flashes to indicate that the clock is
22. alve in regeneration Excessive water use Change in raw water hardness o a A QO Unit fails to regenerate T Valve fails to draw brine 8 Decreasing exchange capacity of resin 9 No salt in brine tank 10 Leak at riser tube 11 Leak between rotor and seal disk 12 Valve body and timer out of synchronization 1 Faulty electrical supply 2 Control not set properly 3 Defective drive motor 4 Defective flow meter 5 Defective computer board 6 Defective microswitch es SOLUTION 1 Close or verify bypass 2 Refer to symptom Loss of Resin Wait for regeneration to complete Check regeneration frequency Adjust programming accordingly o oO A CO Refer to symptom Unit fails to regenerate 7 Refer to symptom Valve fails to draw brine 8 Clean or replace resin bed 9 Add salt 10 Verify that the riser tube is seated correctly and is not cracked 11 Verify or replace rotor and seal disk 12 Synchronize valve body and timer 1 Verify electrical service fuse transformer 2 Verify the correct regeneration schedule and reset the control Replace drive motor Clean and or replace flow meter Replace computer board o a A9 O Replace microswitch es SYMPTOM Valve fails to draw brine Valve cycles con tinuously Excessive water in brine tank Valve fails to refill brine tank 1 OO N 1 AR CAUSE Low operating pressure
23. ce position 15 Install the microswitch assembly 16 and drive motor assembly 12 on the backplate 8 and secure it with the 2 screws 17 16 Connect the wires 22 and 23 to the drive motor assembly 12 and microswitch assembly 16 refer to the wiring diagram on page 30 for proper connection 17 It is now necessary to check the synchronization of valve body and control head refer to Synchronizing the Valve Body and Control Head on page 43 18 Reverse the remaining steps for reassembly Note The small PCB board 13 is soldered onto the drive motor assembly 12 Backwash Flow Control Replacement PLEASE REFER TO THE ROTARY PARTS LIST FOR REPLACEMENT PART NUMBERS 1 Remove the drain hose from the drain elbow 1 and unscrew and remove the drain elbow 1 2 Unscrew the backwash flow control 2 using a 3 8 Allen wrench 3 Reverse the procedure for reassembly Brine Refill Flow Control Replacement PLEASE REFER TO THE ROTARY PARTS LIST FOR REPLACEMENT PART NUMBERS 1 Remove the spring clip 23 securing the brine refill elbow 35 2 Remove the brine refill flow control 40 from the brine refill elbow 35 Inspect the flow control 40 and flow control washer 41 for blockage and or debris Clean or replace if necessary Note If the spring clip 23 seems loose after installation remove the clip 23 and squeeze it back on with pliers to create a secure fit 3 Reverse the procedure
24. day and gallons remaining before regeneration Time of Day GL Remaining Press the SCROLL button to advance to the next setting Available Programming Parameters 1 Time of Day Setting The control will display Time of Day Press the UP ARROW or DOWN ARROW to program the time of day Press the SCROLL amp button to advance to the next setting 2 Holiday Mode The control will display Time When the control valve is left in this position for 60 seconds the holiday mode will become active and the unit will not regenerate The holiday program ends when a flow rate greater than 1 5 gallons is measured with the meter or when the SCROLL button is pushed In either case the unit will start an immediate regeneration Press the SCROLL amp button to advance to the next setting 3 Immediate Regeneration Mode The control will display If the control valve is left in this position the timer will countdown to 0 starting a regeneration at 0 To avoid an Immediate Regeneration push the SCROLL button before the timer has reached O Press the SCROLL button to advance to the next setting 4 Delayed Regeneration Mode Note This function will not be available if the control was programmed for Immediate in the Manufacturer s level The control will display the programmed regeneration time Regen current setting If the control valve is left in this position the u
25. e of Day GL Remaining Press the DOWN ARROW and hold it for 5 seconds until the control display shows System Check Within 10 seconds enter the Installer s access code by pressing in the following key sequence DOWN ARROW DOWN ARROW SCROLL BUTTON DOWN ARROW The control is now in the Installer s Level Use the SCROLL button to advance through the different settings Programming options menu 1 System The control will display System 24000 Gm Press the UP ARROW or DOWN ARROW to set the softening capacity between regenerations in increments of 1000 Grn Press the SCROLL amp button to advance to the next setting 2 Hardness Enter the customer s current water hardness Note The hardness function is not programma ble if Metric was selected in the Manufac turer s Level The control will display VI ater Herd 24 Gm Press the UP ARROW or DOWN ARROW to set the water hardness between 0 and 99 grains Press the SCROLL button to advance to the next setting 3 Reset Flow Note Not available if No Meter was selected in the Manufacturer s Level The control will display To select YES use the UP ARROW or DOWN ARROW The peak flow rate is set to 0 and the average volume per day is set to 2596 of the capacity Press the SCROLL amp button to advance to the next setting 4 Reserve Capacity The control will display Rarv 2
26. e spring clip seems loose after installation remove the clip and squeeze it back on with pliers to create a secure fit Annual Maintenance Clean out the injector Clean the brine refill flow control Clean the backwash flow control Verify that the flow meter is functioning correctly Clean the impeller if necessary Verify the programming of the control Reprogram the control if necessary Verify the minimum and maximum pressure Install a pressure reducer if necessary Computer Board Replacement PLEASE REFER TO THE CONTROL PARTS LIST FOR REPLACEMENT PART NUMBERS 1 NOOB WD Disconnect all electrical power to the unit Loosen the 3 front cover screws 9 and remove the front cover 1 with computer board 2 Disconnect all wire connections from the computer board 2 Remove the clear zebra strip from the push in connection on the computer board 2 Remove the one screw 3 holding the computer board in place Push aside the clips holding the computer board 2 in place and remove the computer board 2 Reverse the procedure for reassembly refer to the wiring diagram on page 30 for proper lead connections Drive Motor Replacement PLEASE REFER TO THE CONTROL PARTS LIST FOR REPLACEMENT PART NUMBERS 1 2 5 Disconnect all electrical power to the unit Remove the screw holding the flow meter sensor 4 in place and remove the flow meter sensor 4 3 Remove the 2 b
27. el Press the DOWN amp ARROW and hold it for 5 seconds until the control displays Press the UP or DOWN ARROW to If YES is selected the control will reset to O The peak flow rate is set to 0 and the average volume per day is set to 2596 of the Verify that the control valve is in the Service Mode The control will display Within 10 seconds enter the Installer s access code by pressing in the following key sequence capacity DOWN ARROW DOWN ARROW Press the SCROLL button to advance to the next SCROLL amp BUTTON setting DOWN ARROW The control is now in the Installer s Level 3 Reserve Capacity use the SCROLL button to advance Phe contor wl display through the different settings Programming options menu To adjust the reserve press the SCROLL button Press the UP ARROW or DOWN ARROW to set the reserve The control will display capacity in increments of 10 gallons up to 40 capacity of the bed 1 Capacity Capacity 2058 CL If a Variable Reserve is desired press the UP ARROW or DOWN ARROW Press the UP ARROW or DOWN ARROW to set the volume of softened water between The control will display regenerations in increments of 100 gallons This can be programmed from 100 to 999 999 gallons See pages 18 19 for more information The reserve capacity will be calculated Press the SCROLL button to advance to the next automatically based on t
28. eneral tank sizes Tank Backwash Flow Control inch mm Gal min L min 7 178 E 1 6 6 1 8 203 E 1 6 6 1 9 229 G 2 0 7 6 10 254 J 2 6 9 8 12 305 K 35 13 2 13 330 L 4 0 15 1 14 356 M 5 0 18 9 16 406 N 6 0 22 7 Brine Refill Flow Control Selection Your system will come with one of the following flow controls 0 25 GPM A Each minute in the refill cycle is equal to 0 75 pounds of salt 0 5 GPM B Each minute in the refill cycle is equal to 1 5 pounds of salt 1 0 GPM D Each minute in the refill cycle is equal to 3 0 pounds of salt To verify the size of your flow control put scroll the unit into the refill cycle and measure the refill flow rate Note The fast rinse brine refill cycle can only be set in increments of one minute Note One gallon of water will dissolve three pounds of salt The amount of water in the tank will determine the amount of salt that the system will use during each regeneration Note The following flow control recommendations are based on general tank sizes Tank Brine Refill Flow Control inch 7 A B 8 A B 9 B 10 B D 12 D 13 D 14 D Cycles of the System 1 SERVICE Untreated water flows down through the resin bed and up through the riser tube the water is conditioned when passing through the resin The throughput is dependent on the maximum permissible pressure drop for the complete water softener and the maximum permissible specific load of the res
29. for reassembly D ey ny a P a an NS Q Brine Tee Replacement PLEASE REFER TO THE ROTARY PARTS LIST FOR REPLACEMENT PART NUMBERS 1 Remove the compression nut 39 and brine refill tube 46 from the brine tee 42 2 Remove the brine tee 42 by turning it counter clockwise 3 Remove the brine tee retainer 42 O ring 43 and check ball 44 from the brine tee 42 Inspect the parts for wear and or debris replace if necessary 4 Reverse the procedure for reassembly Rotor Seal Disk Float Valve Gasket and Injector Replacement PLEASE REFER TO THE ROTARY PARTS LIST FOR REPLACEMENT PART NUMBERS 1 Remove the drain hose from the drain elbow 1 2 Remove the 6 bolts 3 and nuts 22 holding the valve body 18 and cover 4 together 3 Lift the valve cover 4 away from the valve body 18 4 Remove the worm gear 8 and cam shaft 9 from the valve cover 4 the white Teflon O ring LL 8 7 will remain in the valve cover 4 C SM 5 Remove the rotor plate 11 from the valve body Es TN 18 and inspect the surface The rotor plate s 20 11 surface should be smooth and free of any circular grooves or scratches replace if necessary 6 Remove the seal disk 12 from the valve body 18 Inspect the seal disk 12 make sure the raised ribs are intact The green Teflon coating may be worn off of the ribs but this will not affect the sealing performance of the disk Replace the seal disk if necessary
30. have been reset Corrupt Memory For factory information only 4000 VTL REV For factory information only To exit the diagnostic level press the up or down arrow at the exit display Start Up System Check Instructions 1 Turn the main shutoff valve until it is just barely open this will allow the unit to release the air trapped inside without agitating the mineral when you manually regenerate the system 2 Verify that the control is in the service position The control will display the time of day and gallons remaining 3 Manually advance scroll the control to the regeneration position The display will count down from 10 to 0 The first step will be back wash Allow the water to flow from the drain until all the air has purged After all the air has purged open the main valve 4 Advance scroll the control valve to the brine cycle The system will draw water from the brine tank Remove the brine line and check for suction If no suction occurs refer to the troubleshooting section on page 23 5 Advance scroll the control to fill rinse Allow the system to fill the brine tank 6 Use the scroll button to advance the control back to the service position 7 The installation is now complete Please refer to pages 8 15 for programming informa tion IMPORTANT SANITIZING WATER CONDITIONERS IS RECOMMENDED BY THE WATER QUALITY ASSOCIATION After the installation is complete including set ting the compu
31. he registered daily setting water consumption The default setting is 25 of the capacity 75 gallons Press the SCROLL button to advance to the next setting The Installer s Level continued 4 Time of Regeneration The control will display Regen 2 00 am Press the UP ARROW or DOWN ARROW to set the time of regeneration Press the SCROLL button to advance to the next setting 5 Days Override The control will display Press the UP ARROW or DOWN ARROW to set the maximum number of days between regenerations from OFF to 30 days max limit Press the SCROLL button to advance to the next setting 6 Cycle 1 The control will display BACK WAG 10 min Press the UP 0 ARROWOr DOWN ARROW 1 set the length of the backwash cycle from 0 to maximum 99 minutes When iron or high hardness is present the backwash time should be extended 5 to 15 minutes based on experience Note In most applications the factory settings are adequate and will not need adjustments Press the SCROLL button to advance to the next setting 7 Cycle 2 The control will display Press the UP ARROW or DOWN ARROW to set the length of the brine slow rinse cycle from 0 to maximum 99 minutes Note In most applications the factory settings are adequate and will not need adjustments Press the SCROLL button to advance to the next setting 8 Cycle 3 The control will dis
32. in 2 BACKWASH Water flows down through the riser tube and up through the resin bed to drain the resin bed is fully expanded and all foreign materials are thoroughly washed from the resin allowing a good brine cycle to occur 3 BRINE Salt brine drawn from the brine tank by the injector slowly flows down through the resin bed and up through the riser tube to drain the resin is being regenerated when the salt brine passes through the bed The brine cycle is terminated when the air check seats in the brine valve 4 SLOW RINSE Slow rinse continues for the remainder of the brine cycle the water slowly flows down through the resin bed and up through the riser tube to drain slowly washing the brine from the resin tank 5 FAST RINSE BRINE REFILL Water flows to the brine tank and at the same time down through the resin bed and up through the riser tube to drain ensuring that all traces of brine are washed out and that the resin bed is compacted The resin bed is now ready for the next service cycle l ea LH aie FAST RINSE BRINE REFILL Water Flow Diagrams DA AN DOCCT OO UN ti SERVICE BACKWASH BRINE SLOW RINSE FAST RINSE BRINE REFILL L SOFT WATER BRINE RINSE WATER L HARD WATER Troubleshooting SYMPTOM CAUSE Hard untreated 1 Open or defective bypass water to service Unit fails to regenerate Loss of Resin V
33. nit is softening the water Note A suitable air gap should be used between the end of the drain line and the drain to prevent possible back siphoning The air gap should always be a minimum of two times the diameter of the drain line Be sure to check local plumbing codes area regulations may differ Important Control Information Program Levels To enter any of the program levels featured on the 24015 the control must display the time of day and gallons remaining Service Mode The 2401S has four program levels available 1 The Installer s Level The Installer s Level is for trained personnel only To access this level you must provide the five key sequence code located on page 8 Please refer to pages 8 12 for programming information 2 The Manufacturer s Level The Manufacturer s Level is for trained person nel only To access this level you must provide the six key sequence code located on page 13 Please refer to pages 13 14 for programming information 3 The End User s Level This level does not require a special code to access Please refer to page 15 for program ming information 4 The Diagnostic Level To access this level press and hold the up arrow for five seconds Please refer to page 16 for information on the Diagnostic Level Power On LED A green LED near the keypad is ON when power is applied to the control and the micro processor is operating properly Service Required If this mess
34. nit will regenerate at the programmed time The display will remain in the delayed regeneration mode until the regeneration has started To cancel this mode push the SCROLL amp button The Diagnostic Level Checking the Diagnostics Viewing Only Press the UP ARROW and hold it for 5 sec onds The diagnostics menu will display REGEN DAYS AGO Use the SCROLL button to advance to each diagnostic If no button is pressed within 60 seconds the display will return to the time of the day Service Mode Regen _ Days Ago Displays how many days ago the unit last regenerated In Srvc Displays how many days the control has been in service of Regens Displays the number of regenerations that have taken place since the control was installed Tot Vol Displays the total volume of water used since installation Last Rgn Displays the amount of water used before the last regeneration Peak Flow Displays the peak flow rate since the last regeneration This function resets back to 0 after every regeneration Note Will not display when control is programmed for Volume Pulse Avg Vol Displays the average daily water consumption Capacity System If the control is program med for Volume the display will read CAPACITY along with the maximum volume of water to be used When the control is programmed for Hardness the display will read SYSTEM along with the maximum grain capacity of the system Hardness
35. ote This is the only option as a capacity set ting if Metric was selected in Step 1 The Manufacturer s Level continued If Hardness is selected the installer will pro gram the capacity in grains and hardness amount Note To activate any change with either volume or hardness advance scroll the control through a manual regeneration The program change will take affect after the unit has completed a full regeneration Press the SCROLL button to advance to the next setting 4 Regeneration Type Delayed Immediate In this program the unit will regenerate immediately if the capacity reaches 0 If the system still has a reserve capacity the regeneration will be delayed until the pro grammed regeneration time Immediate In this program the unit will regener ate immediately if the capacity reaches 0 Delayed In this program the unit will not regen erate when the capacity reaches 0 The unit will wait until the programmed regeneration time Note If No Meter was selected in Step 2 delayed regeneration is the only option The control will display Press the UP ARROW or DOWN ARROW to program the regeneration type from Delayed to Dlyd Immd or Immediate Press the SCROLL button the control will display Press the UP ARROW or DOWN ARROW to exit the Manufacturer s Level The End User s Level Verify the control valve is in the Service Mode The control will display the time of
36. play Press the UP ARROW or DOWN ARROW to set the length of the fast rinse brine refill cycle from 0 to maximum 99 minutes The time of the fast rinse brine refill cycle with the brine refill flow control will determine the quantity of refill to the brine tank independent of the inlet pressure Note This setting will need adjustments in most applica tions For brine refill flow control information and salt settings see page 19 Press the SCROLL amp button the control will display Press the UP ARROW or DOWN ARROW to exit the Installer s Level IMPORTANT NOTE In order for these new settings to become active it is necessary for you to execute a complete regeneration After you step scroll through a manual regeneration the new settings will become active If you choose not to manually regenerate the system the settings will not become active until the unit has completed it s next scheduled regeneration The Manufacturer s Level Verify the control valve is in the Service Mode The control will display the time of day and gallons remaining Time of Day G Remaining Press the DOWN ARROW and hold it for 5 seconds until the control displays System Check Within 10 seconds enter the Manufacturer s access code by pressing in the following key sequence DOWN ARROW SCROLL amp BUTTON UP ARROW UP ARROW SCROLL amp BUTTON The control is now in the Manufacturer s Level Use the
37. r softeners Power Requirements The control receives power from an external wall mount or plug in transformer The factory or the manufacturer will supply the transformer Voltage The voltage supplied to the control is 24V AC Frequency Line frequency is 50 Hz or 60 Hz Temperatures Operating Range The ambient air around a computer board must not exceed 50 C 122 F The computer board operates down to 0 C 32 F Storage Range The control can be stored at temperatures from 20 C 4 F to 70 C 158 F Humidity The control operates properly with relative humidity from 10 to 95 non condensing Environmental Requirements EMC The control meets international standards for electromagnetic compatibility EMC It has been tested by an independent laboratory to be in compliance with CE requirements It is resis tant to electrical noise and will not emit levels of RFI Radio Frequency Interference that could disturb nearby electronic devices Location The water softener and control cannot be exposed to outdoor elements such as direct sunlight or atmospheric precipitation The system may be installed in a covered open air structure such as a carport residential or commercial building Weather covers are also available through the Order Department part number 72370 Installation Instructions 1 Before You Begin Read these instructions from beginning to end before proceeding with installation Maximum wo
38. rking temperature is 100 F Use a hand truck to transport the unit To prevent accident or injury do not hoist the unit over your shoulder Do not lay the unit on its side Wear safety glasses and work gloves 2 Test Raw Water Test the customer s raw water for hard ness iron pH and or any other element contaminant that could affect this system s performance 3 Check the Water Pressure Use a pressure gauge to confirm that the water pressure does not exceed 100 psi If the water pressure exceeds this limit install a pressure regulator on the inlet pipe of the unit The minimum pressure for a conditioner is 25 psi 60 psi is the optimum operating pressure 4 Locate a Site for the Unit There are two primary needs for a site the main water source and a drain Locate the conditioner as close to the main water source as possible so that you do not miss any water outlets If possible bypass any outside faucets The drain may be a floor drain a sewer trap utility sink vent stack dry well etc depending on local plumbing codes Place the unit in the desired location on a level smooth clean surface If located outdoors protect the unit from direct sun or freezing temperatures which can damage the unit 5 Turn off the Water and Drain the Pipes Turn off the water at the meter or the pressure tank Drain all pipes Do not sweat pipes with water in them steam will damage the plastic pa
39. rts in the valve To drain the plumbing system open all faucets in the house including the toilets This will allow air to enter the plumbing system The water will drain out of the lowest faucet or outlet 6 Bypass the Outside Faucets Install plumbing pipes to bypass outside faucets if the customer requests This may not be possible in a slab home where the plumbing is buried in the foundation If it is not possible provide an untreated hose bib on the inlet pipe 7 Connect the Plumbing to the Bypass Valve and Brine Tank Do not point the soldering torch directly at the system The material will last many years within normal operating tempera tures but will melt in a torch flame To prevent hot water from backing up in the conditioner avoid short connections of pipe between the conditioner and the hot water heater If you can t avoid a short connec tion move the equipment to another location As a last resort install a check valve If this causes water hammer install a water hammer suppressor Connect the raw water pipe to the INLET 9 Run the Remaining Hard Water from pipe connection of the bypass valve When the Plumbing looking at the front of the unit the INLET is the pipe connection on the left side of the To flush out the pipes turn on all the faucets valve in the house and flush the toilets approxi mately two to three minutes per faucet Connect the treated water pipe to the OUT
40. stributor s Remove and clean outlet SYMPTOM Constant flow to the drain CAUSE SOLUTION 1 Drive motor failure 1 Replace drive motor 2 Defective computer board 2 Replace computer board 3 Defective microswitch es 3 Defective microswitch es 4 Valve body and timer out of 4 Synchronize valve body and timer synchronization 5 Leak between the rotor and seal disk 5 Verify or replace rotor and seal disk Valve Exploded View Rotary Parts List Item Qty Aquion Part Description 1 1 70793 1 4 NPTF TO 1 2 I D HOSE MALE DRAIN ELBOW 2 1 71099 72173 72175 BACKWASH FLOW CONTROL 3 0 10 0 2 0 3 5 75050 75053 BACKWASH FLOW CONTROL 1 6 1 8 2 2 2 6 75074 75078 75265 BACKWASH FLOW CONTROL 5 0 6 0 7 0 8 0 9 0 4 0 3 6 71070 HEX HEAD BOLT 5 16 18 X 2 LG SS 4 1 71083 VALVE BODY COVER 5 1 70658 VALVE COVER O RING 6 1 72327 WASHER 7 1 70665 TEFLON O RING 8 1 71089 WORM GEAR 9 1 71087 71088 STANDARD CAM SHAFT tse with 70932 of SPOKELESS CAM SHAFT 10 1 70656 ROTOR O RING 11 1 71132 ROTOR PLATE COATED 12 1 71084 SEAL DISK COATED 13 1 71182 INSERT PLATE 14 1 71183 GASKET 15 1 71006 FLOAT VALVE SPRING 16 1 71127 FLOAT VALVE 17 1 70660 FLOAT VALVE O RING 18 1 71202 VALVE BODY 19 1 71063 71064 INJECTOR 2 3 71067 71068 INJECTOR 4 5 20 1 70655 INJECTOR O RING LOWER 21 1 70664 INJECTOR O RING UPPER 22 6 71071 HEX NUT 5 15 18 SS 23 1 71947 SPRING CLIP 24 1 71344 R
41. ter and putting water in the brine tank the following procedure can be used to sanitize the water conditioner Mix about a 3 4 cup of common unscented 5 2596 household bleach with about 1 quart of water and pour this solution into the brine well Note Do not pour undiluted bleach into the water conditioner Initiate a manual regeneration The bleach solution will be drawn into the water conditioner during the regeneration process When the regeneration process is complete the water conditioner has been sanitized Note The unit may he sanitized with or without salt in the brine tank Injector Selection Injector The injector determines the brine concentration ratio between brine suction and rinse water and the brine flow through the resin bed Injector performances vary significantly with inlet pressure Note The following table is only an indication and is valid for an inlet pressure of 40 psi 3 bar with a bed depth of 30 inches Note The following injector recommendations are based on general tank sizes Tank Injector inch mm Color 7 178 4 PURPLE 8 203 4 PURPLE 9 229 4 PURPLE 10 254 1 4 RED PURPLE 12 305 1 RED 13 330 1 RED 14 356 2 1 YELLOW RED 16 406 5 2 GREEN YELLOW Flow Control Selection Backwash Flow Control The backwash flow control determines the resin bed expansion during the backwash indepen dent of the inlet pressure Note The following flow control recommendations are based on g
Download Pdf Manuals
Related Search