Manual: 4650 Service - Current (40261)
Contents
1. Brine Cam Assembly Minutes Support Bracket Hot water Only CONTROL DRIVE ASSEMBLY FOR CLOCK Item No QTY Part No jm 2 N25 TT cci D sirs Bis 18242 Desa jg roc rn ee ee rere to Seal 4650 HW Chloramine resistant T 1 40319 Valve Body O ring Distributor Tube 1 O ring 121 560CD HW O ring Top of Tank O ring 231 560CD HW Stand Off Spacer Hot Water Spacer Cold Water Piston Standard Piston Pin Piston Rod Assembly Piston Retainer End Plug Assembly Brass Hot Water j PRAE 19446 ion ees End Plug Assembly Std White Cold Water 13 4 13387 nu Screw Injector Mounting dis 1 13315 ies Screw Injector Mounting n 2 ds 19228 nisu Adapter Coupling O ring Adapter Coupling Screw Adapter Coupling O ring Drain O ring 013 560CD Injector HW O ring Injector O ring 011 560CD HW O ring Brine Spacer Hot Water O ring Brine Spacer Cold Water O ring Injector Cover O ring 021 560CD HW 22 rss 1 13163 Injector Body PP 1 10225 xx Injector Nozzle Hot Water dcus 10913350 Injector Nozzle Cold Water BR61500 4650 Rev A Item No QTY Part No Description 280 es 10226 xx Injector Throat Specify Size Hot Water o 10914 xx Injector Throat Specify Size Cold Water 25 202i t pie 10227 Injector Screen A inui 191066 nm I2. Fleck 4650 Service Manual TABLE OF CONTENTS JOB SPECIFICATION SHEET reet n 1 INSTALLATION AND START UP PROCEDURE 1 CONTROL VALVE DRIVE ASSEMBLY 2 CONTROL DRIVE ASSEMBLY FOR CLOCK 3 BYPASS VALVE ASSEMBLY 4 rtt e tg 4 WATER CONDITIONER FLOW DIAGRAMS 5 SERVICE INSTRUCTIONS iiie intend eee eade dida 7 TROUBLESHOOTING iii 9 SERVICE ASSEMBLY sse 10 JOB SPECIFICATION SHEET Job Number Model Number Water Test Capacity Per Unit Max Per Regeneration Mineral Tank Size Diameter Height Brine Tank Size and Salt Setting per Regeneration 1 Type of Timer A L B 7 Day C 12 Day 2 Day Time of Regeneration 3 Drain Line Flow Control gpm 4 Brine Refill Rate gpm 5 Injector Size INSTALLATION AND START UP PROCEDURE The water softener should be installed with the inlet outlet and drain connections made in accordance with manufacturer s recommendations and to meet applicable plumbing codes Manual Red Time Regeneration Set Button Knob 24 GR Gear Skipper Wheel Shows every other day regeneration Red Pointer BR61501 4650 Rev A Time of Day Arrow Figure 1 1 Manually index the softener control into the service position and let water flow into the resin tank When the water flow Stops open a softened water tap until all air is release
3. K SALT LEVEL Hard water enters the unit at the valve inlet flows around the lower piston groove down thru the top of tank passage downward thru the resin up the distributor tube thru the center hole in the piston over the top edge of the piston and out the drain line 8 Brine Tank Fill Position 4 to 24 Minutes Adjustable Cycle VALVE DRIVE ASSEMBL BRINE VALVE FLOW CONTROL Lm DIS a OUTLET BRINE TANK SALT LEVEL Hard water enters the unit at the valve inlet flows around the lower piston groove thru the injector throat thru the brine valve and flow control to fill the brine tank Hard water also flows around the lower piston groove thru the passage to the top of tank down thru the resin and enters the distributor as conditioned water The conditioned water flows up thru the center tube to the valve outlet SERVICE INSTRUCTIONS A TO REMOVE TIME BRINE VALVE INJECTORS AND SCREEN 1 2 10 11 12 13 14 15 16 17 Unplug electrical cord from outlet Turn off water supply to conditioner a If the conditioner installation has a three valve bypass system first open the valve in the bypass line then close the valves at the conditioner inlet and outlet b If the conditioner has an integral bypass valve put itin the bypass position c If there is only a shut off valve near the conditioner inlet close it Relieve water pressure in the condition
4. RINE TANK SALT LEVEL PAL PLIS LT TELL TTL LIL TL SL TL IS TA TL IL ISLE LE ETS DLL Hard water enters the unit at the valve inlet flows around the lower piston groove thru the injector nozzle and orifice to draw brine from the brine tank The brine flows down thru the resin into the distributor up thru the center tube thru the center hole in the piston and out the drain line Fleck 4650 AP10 5 WATER CONDITIONER FLOW DIAGRAMS continued 5 Slow Rinse Position Last Portion of 50 Minute Fixed Cycle VALVE DRIVE ASSEMBL BRINE VALVE FLOW CONTROL INLET es OUTLET BRINE TANK After all the brine has been drawn from the brine tank hard water continues to enter thru the valve inlet flows around the lower piston groove thru the nozzle and orifice down thru the resin and into the distributor up thru the center tube thru the center hole in the piston and out the drain line 6 Second Backwash Position 10 Minutes VALVE DRIVE ASSEMBL BRINE VALVE FLOW CONTROL Hard water enters the unit at the valve inlet flows around the lower piston groove and lower piston land down thru the center tube and out the distributor up thru the resin thru the top of tank passage around the upper piston groove and out the drain line 6 AP10 Fleck 4650 7 Settling Rinse Position 5 Minutes VALVE ASSEMBU VALVE DRIVE ASSEMBU BRINE VALVE FLOW CONTROL BRINE TAN
5. XXXX Injector Cold Water See Parts List RE Injector Hot Water 60032 Brine Valve Cold Water 60032 001 Brine Valve Hot Water 60514 3 nis Brine Cam 3 18 60514 01 Brine Cam 6 36 60514 02 Brine Cam Minutes GOSTO nirisan Coupling with Clip and Screws 60040 Bypass Brass 3 4 NPT Cold Water 6004 aus Bypass Brass 1 NPT Hot Water 14860 Skipper Wheel 7 Day 14381 esr Skipper Wheel 12 Day Flow Control Washers 19153 ideas 0 6 gpm 19152 ire ae 0 8 gpm 1 0 gpm 12085 ini 1 2 gpm 19150 ats 1 3 gpm 12086 un 1 5 gpm 19149 oim 1 7 gpm 12081 ng 2 0 gpm 12088 ici 2 4 gpm 12089 iine tus 3 0 gpm 12090 3 5 gpm 12091 n 4 0 gpm 19147 4 5 gpm 12092 662220 niinus 5 0 gpm W1 c 6 0 gpm 12408 n 7 0 gpm Hot water injector components are listed separately 10 AP10 Fleck 4650 Fleck 4650 AP10 11 2010 Pentair Residential Filtration LLC 40261 RevC AP10
6. ace brine valve Foreign material in brine line flow control Clean brine line flow control Softener fails to draw brine Drain line flow control is plugged Clean drain line flow control Injector is plugged Injector screen plugged Line pressure is too low Clean or replace injectors Replace screen Increase line pressure Line pressure must be at least 20 psi at all times Internal control leak Change seals and spacers and or piston assembly Control cycles continuous Faulty timer mechanism Replace timer Drain flows continuously Foreign material in control Internal control leak Control valve jammed in brine or backwash position Remove piston assembly and inspect bore remove foreign material and check control in various regeneration positions Replace seals and or piston assembly Replace seals and or piston assembly Timer motor stopped or jammed Replace timer Fleck 4650 AP10 9 SERVICE ASSEMBLY 6010200 ss Piston Assembly Cold Water Softener 60102 10 Piston Assembly Cold Water Feeder Filter 60102 20 Piston Assembly Cold Water Low Water 60102 031 Piston Assembly Hot Water Softener 60102 231 Piston Assembly 4650 560CD CW HW Softener 60125 Seal Kit Cold Water 60125 05 Seal Kit Hot Water 60084
7. cal cord from outlet Turn off water supply to conditioner a If the conditioner installation has a three valve bypass system first open the valve in the bypass line then close the valves at the conditioner inlet and outlet b If the conditioner has an integral bypass valve put itin the bypass position c If there is only a shut off valve near the conditioner inlet close it Relieve water pressure in the conditioner by putting the control in the backwash position momentarily Return the control to the service position Remove the control valve back cover Remove screw and washer at drive yoke Remove timer mounting screws The entire timer assembly will now lift off easily Remove end plug retainer plate Pull upward on end of piston rod yoke until assembly is out of valve Remove and replace seats and spacers with fingers TROUBLESHOOTING Problem Softener fails to regenerate Possible Cause Electrical service to unit has been interrupted Solution Ensure permanent electrical service check fuse plug pull chain or switch Timer is defective Replace timer Power failure Reset time of day Softener delivers hard water Unit uses too much salt Loss of water pressure Loss of resin through drain line Bypass valve is open Close bypass valve No salt in brine tank Add salt to brine tank and maintain salt level above water level Injectors or screen plugged R
8. cessary Replace timer mounting screws Replace screw and washer at drive yoke Return bypass or inlet valving to normal service position Water pressure should now be applied to the conditioner and any bypass line shut off Plug electrical cord into outlet Set time of day program wheel and salt usage Cycle the control valve manually to ensure proper function Make sure the control valve is returned to the service position Replace the control valve back cover Be sure grommet at cable hole is in place Make sure there is enough brine in the brine tank Rotate program wheel counterclockwise until it stops at regeneration position Start regeneration cycle manually if water is hard Fleck 4650 AP10 7 SERVICE INSTRUCTIONS continued C TO REPLACE PISTON ASSEMBLY 1 2 10 11 12 13 14 15 16 17 Unplug electrical cord from outlet Turn off water supply to conditioner a If the conditioner installation has a three valve bypass system first open the valve in the bypass line then close the valves at the conditioner inlet and outlet b If the conditioner has an integral bypass valve put itin the bypass position c If there is only a shut off valve near the conditioner inlet close it Relieve water pressure in the conditioner by putting the control in the backwash position momentarily Return the control to the service position Remove the control valve back cover R
9. d from the lines then close the tap Note The various regeneration positions may be dialed manually by turning the knob on the front of the control until the indicator shows that the softener is in the desired position 2 Manually index the control to the backwash position and allow water to flow at the drain for 3 or 4 minutes 3 Remove back cover plate 4 Make sure that the salt dosage is set as recommended by the manufacturer Manually index the control to the brine fill position and allow the brine tank to fill to the top of the air check 5 Manually index the control to the brine draw position and allow the control to draw water from the brine tank until it stops 6 Plug in the electrical cord and look in the sight hole in the back of the motor to see that it is running Set the days that regeneration is to occur by sliding tabs on skipper wheel outward to expose trip fingers Each tab is one day Finger at red pointer is tonight Moving clockwise from red pointer extend or retract fingers to obtain the desired regeneration schedule 7 Manually advance the control to the beginning of the brine fill position and allow the control to return to the service position automatically 8 Fill the brine tank with salt 9 Replace back cover on the control 10 Make sure that any bypass valving is left in the normal service position BR40261 Rev C AP10 CONTROL VALVE DRIVE ASSEMBLY Item No QTY Part No Descript
10. emove screw and washer at drive yoke Remove timer mounting screws The entire timer assembly will now lift off easily Remove end plug retainer plate Pull upward on end of piston yoke until assembly is out of valve 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 yoke carefully in a clockwise direction to properly align it with drive gear Replace end plug retainer plate Place timer on top of valve Be sure drive pin on main gear engages slot in drive yoke Rotate control knob if necessary Replace timer mounting screws Replace screw and washer at drive yoke Return bypass or inlet valving to normal service position Water pressure should now be applied to the conditioner and any bypass line shut off Plug electrical cord into outlet Set time of day Cycle the control valve manually to ensure proper function Make sure the control valve is returned to the service position Replace the control valve back cover Be sure grommet at cable hole is in place Make sure there is enough brine in the brine tank Rotate program wheel counterclockwise until it stops at regeneration position Start regeneration cycle manually if water is hard 8 AP10 Fleck 4650 D TO REPLACE SEALS AND SPACERS Unplug electri
11. eplace injectors and screen Insufficient water flowing into brine tank Check brine tank fill time and clean brine line flow control if plugged Hot water tank hardness Repeated flushings of the hot water tank is required Leak at distributor tube Internal valve leak Improper salt setting Excess water in brine tank Iron buildup in line to water conditioner Make sure distributor tube is not cracked Check O ring and tube pilot Replace seals and spacers and or piston Check salt usage and salt setting See problem Excessive water in brine tank below Clean line to water conditioner Iron buildup in water conditioner Inlet of control plugged due to foreign material broken loose from pipes by recient work done on plumbing system Air in water system Clean control and add resin cleaner to resin bed Increase frequency of regeneration Remove piston and clean control Ensure that well system has proper air eliminator control Check for dry well condition Iron in conditioned water Fouled resin bed Check backwash brine draw and brine tank fill increase frequency of regeneration Increase backwash time Excessive water in brine tank Plugged drain line flow control Clean flow control Salt water in service line Plugged injector system Clean injector and replace screen Timer not cycling Replace timer Foreign material in brine valve Clean or repl
12. er by putting the control in the backwash position momentarily Return the control to the service position Disconnect brine tube and drain line connections at the injector body Remove the two injector body mounting screws The injector and brine module can now be removed from the control valve Remove and discard valve body O rings To replace brine valve a Pull brine valve from injector body also remove and discard O ring at bottom of brine valve hole b Apply silicone lubricant to new O ring and reinstall at bottom of brine valve hole c Apply silicone lubricant to O ring on new valve assembly and press into brine valve hole shoulder on bushing should be flush with injector body To replace injectors and screen a Remove injector cap and screen discard O ring Unscrew injector nozzle and throat from injector body b Screw in new injector throat and nozzle Be sure they are seated tightly Install a new screen c Apply silicone lubricant to new O ring and install around oval extension on injector cap Apply silicone lubricant to three new O rings and install over three bosses on injector body Insert screws with washers through injector cap and injector Place this assembly through hole in timer housing and into mating holes in the valve body Tighten screws Be sure to reinstall brass spacers with injector on Model 4600 valve Reconnect brine tube and drain line Return bypass or inlet valving to normal ser
13. ion jm Tus 15494 01 L Housing w Pin VI Vas T3175 Motor Mounting Plate Duos le 18743 1 Motor 120V 60 Hz 1 30 rpm dues 18752 1 Motor 100V 50 Hz 1 30 rpm 18824 1 Motor 23V 50 Hz 1 30 rpm dace 18826 1 Motor 24V 50 Hz 1 30 rpm dieses 19659 1 Motor 24V 60 Hz 1 30 rpm les 19660 1 Motor 230V 60 Hz 1 30 rpm ch 11384 Screw Motor Mtg amp Ground Wire SPA EE ch 13296 Screw Component Mounting SH LE 13017522 Idler Gear Tas 12s 13018 Idler Pinion Sissies Tae 19912 Spring Idler Oreste Ales 13164 Drive Gear NOs i eres 40214 Screw Brine Cam 14 onde Tires 13170 Main Gear amp Shaft 12 in Tusc 19205 01 24 Hour Gear Assembly Silver IS ID 13011 Cycle Actuator Gear dite Tissa T4177 Knob Manual Regeneration 15 nus Au 13300 Ball 1 4 Dia 2 AP10 Fleck 4650 BR61501 4650 Rev A Description Spring Detent Skipper Wheel Knob Label Silver Valve Position Dial Standard Skipper Wheel Assembly 12 Day Skipper Wheel Assembly 7 Day Skipper Wheel Ring Spring Detent Main Gear Regeneration Pointer Electrical Cord Standard Wire Connector Not Shown Strain Relief Screw Knob Front Label Silver on Black Washer Screw Drive Mounting Brine Cam Assembly 3 18 Brine Cam Assembly 6 36
14. is 60041SS Bypass Valve 5600 1 NPT BIk Grip Lever SS 4 AP10 Fleck 4650 WATER CONDITIONER FLOW DIAGRAMS 1 Service Position VALVE ASSEMBLY VALVE DRIVE ASSEMBLY BRINE VALVE FLOW CONTROL Hard water enters the unit at the valve inlet flows around the lower piston groove thru the passage to the top of tank down thru the resin and enters the distributor as conditioned water The conditioned water flows up thru the center tube to the valve outlet 2 Preliminary Rinse Position 5 Minutes VALVE ASSEMBLY VALVE DRIVE ASSEMBLY BRINE VALVE FLOW CONTROL Hard water enters the unit at the valve inlet flows around the lower piston groove down thru the top of tank passage downward thru the resin up the distributor tube thru the center hole in the piston over the top edge of the piston and out the drain line 3 Backwash Position 10 Minutes VALVE ASSEMBLY VALVE DRIVE ASSEMBLY BRINE VALVE FLOW CONTROL BRINE TANK SALT LEVEL Hard water enters the unit at the valve inlet flows around the lower piston groove and lower piston land down thru the center tube and out the distributor up thru the resin thru the top of tank passage around the upper piston groove and out the drain line 4 Brine Position First Portion of 50 Minute Fixed Cycle VALVE ASSEMBLY e VALVE DRIVE ASSEMBLY BRINE VALVE FLOW CONTROL B
15. njector Cover Lr 131 2 03 Brine Valve Stem Assembly Hot Water HP 198172 02 Brine Valve Stem Assembly Cold Water 29 iniiiesee ares 19165 Brine Valve Cap E O 1910766 Brine Valve Spacer Ds reves 12550 01 iiss Quad Ring Hot Water ls 12550 es Quad Ring Cold Water SN EI Ts 119 3 ttes Spring Brine Valve s issue 16008 5er Washer Brine Valve Retaining Ring BLFC Fitting Nut BLFC Ferrule BLFC Tube Insert BLFC Button Specify Size O ring BLFC O ring 015 560CD HW BLFC Button Retainer BLFC Fitting DLFC Button Specify Size DLFC Button Retainer Screen Brine Valve O ring DLFC not shown 46 1 13A97 Air Disperser End Plug Retainer End Plug Retainer Hot Water Screw Washer Screw Yoke Brass 1 NPT Yoke Brass 3 4 NPT Fleck 4650 AP10 3 BYPASS VALVE ASSEMBLY 60040SS Rev T 60041SS Rev U Item No QTY Part No Description o iie Ta x c 40614 Bypass Body 3 4 iis 40634 Bypass Body 1 SS VEN p Tusc 14105 s Seal Bypass 560CD ES T ass 11972 5 Plug Bypass AZ issues jm 11978 Side Cover De Tus 13604 03 Label Bus 15721 Screw i issues 12 11986 iiis Side Cover Oa dearest 1 1197 Lever Bypass n n ng lasse 11989 5n Screw Hex Head 1 4 14 10 diesem 60040SS Bypass Valve 5600 3 4 NPT BIk Grip Lever SS d
16. vice position Water pressure should now be applied to the conditioner and any bypass 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 ensure proper function Make sure the control valve is returned to the service position Make sure there is enough brine in the brine tank Rotate program wheel counterclockwise until it stops at regeneration position Start regeneration cycle manually if water is hard B TO REPLACE TIMER 1 2 11 12 13 14 Unplug electrical cord from outlet Turn off water supply to conditioner a If the conditioner installation has a three valve bypass system first open the valve in the bypass line then close the valves at the conditioner inlet and outlet b If the conditioner has an integral bypass valve put itin the bypass position c If there is only a shut off valve near the conditioner inlet close it Relieve water pressure in the conditioner by putting the control in the backwash position momentarily Return the control to the service position Remove the control valve back cover Remove screw and washer at drive yoke Remove timer mounting screws The entire timer assembly will now lift off easily Put new timer on top of valve Be sure drive pin on main gear engages slot in drive yoke rotate control knob if ne
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