AS1029-E - IBC Water
Contents
1. Water Conditioning Control System Installation Operating and Maintenance Manual AS1029 E Page 8 Cycle Flow Diagrams 4 a RS asin eL mr Iu a jJ TANT ve SERVICE The service cycle position directs untreated water to flow down through the resin bed in the mineral tank and up through the riser tube The water is conditioned when passing through the resin A SLOW RINSE The slow rinse cycle position directs a slow flow of water down through the riser tube and up through the resin bed to drain This slow flow of water pushes the brine solution through the resin bed AS1029 E Rare FD BACKWASH The backwash cycle position directs water to flow down through the riser tube and up through the resin bed and to drain Foreign material and resin fines are flushed from the mineral tank during this cycle to prepare the resin bed for brining wrr L FAST RINSE The fast rinse cycle position directs water to flow down through the riser tube and up through the media bed and to drain Foreign material is flushed from the mineral tank during this cycle FNNA tei H po Em RAKT LEVEL 25 BRINE In brine draw concentrated salt brine is drawn from the brine tank and directed to flow down through the riser tube and up through the resin bed to the drain Brine is drawn until the air c2. 1 Disconnect all electrical power to the control 2 Place the bypass valve into the bypass position 3 Remove the front dust cover from the timer assembly 4 Relieve the system pressure by using a screwdriver to press down on the drain plunger opening the drain 5 Remove the three 3 screws from the triangular cover plate 6 Lift away the cover plate 7 Remove the injector from valve body and separate the gasket from the injector 8 Inspect the injector cavities for blockage 9 Remove the filter screen from the valve body and inspect the screen for dirt Replace if necessary 10 Follow these steps in reverse to re install the riser assembly Note After backing out the drain seat the seat may still require minor adjustment to eliminate leaks Turn the seat in or out until the leak to drain stops Riser Replacement 1 Disconnect all the electrical power to the control Place the bypass valve into the bypass position 3 Relieve the system pressure 4 Disconnect the unit from the bypass connections 5 Remove the unit from the resin tank 6 Turn out the upper distributor basket from the unit adapter ring 7 Remove the two 2 adapter hold down screws and lift away the adapter ring 8 Separate riser assembly from valve body 9 Clean the riser o rings and wipe out the valve body cavity 10 Use the Dow 111 Silicone based lubricant to lightly lubricate the riser o rings and the valve bod
3. pressure by using a screw driver to press down on the drain plunger opening the drain line 5 Disconnect the solenoid cable from the solenoid coil 6 Remove the four 4 head mounting screws 7 Lift the timer assembly away from the valve body 8 Remove the c clip from the centre of the diaphragm 9 Lift the diaphragm away from the body stem assembly 7 Follow these steps in reverse to reinstall the timer assembly Note Prior to re instalment insure that the main return spring is centred over the main diaphragm and that the outside edges of the main diaphragm are tucked into the valve body Drain Plunger Replacement _ Disconnect all electrical power to the control 2 Place the bypass valve into bypass position 3 Remove the front dust cover from the timer assembly 4 Relieve the system pressure by using a screwdriver to press down on the drain plunger opening the drain line 5 Remove the retaining screw located below the Time of Day gear 6 Lift the retainer down and away from the timer assembly 7 Press down on the drain plunger to remove it from the valve body 8 Inspect the plunger o rings and centre cup for wear 9 Clean out the plunger orifice in valve body 10 Use a Dow 111 Silicone based lubricant to lightly lubricate the plunger o rings and the valve body orifice 11 Follow these steps in reverse to re install drain plunger Page 16 Injector and Filter Screen Replacement
4. unit before attempting and repair procedure Required Tools The following tools are required to perform routine maintenance on this valve Phillips Screwdriver Needle Nose Pliers Adjustable Wrench Small Standard Screwdriver Timer Assembly Replacement 1 Disconnect all electrical power to the control 2 Place the bypass valve into bypass position 3 Remove the front dust cover from the timer assembly 4 Relieve the system pressure by using a screwdriver to press down on the drain plunger opening the drain line 5 Disconnect the solenoid cable from the solenoid coil 6 Remove the four 4 head mounting screws 7 Lift the timer assembly away from the valve body 8 Follow these steps in reverse to reinstall the timer assembly Note Prior to re instalment insure that the main return spring is centred over the main diaphragm Timer Motor Replacement 1 Disconnect all electrical power to the control Remove both the front dust cover and the rear timer cover 3 Disconnect the two 2 wire nuts from the timer motor leads Remove the two 2 motor mount screws Lift the motor away from the timer assembly Follow these steps in reverse to reinstall the timer assembly oos AS1029 E Main Diaphragm Replacement mk Disconnect all electrical power to the control 2 Place the bypass valve into the bypass position 3 Remove the front dust cover from the timer assembly 4 Relieve the system
5. 0mm AS0922 E 200mm AS1029 E 260mm Adjustment of Softener Brine Valve 1 Lift float rod to full up position 2 Set float to distance shown Measure from the top of the crown nut to the bottom of the float
6. Brine injector undersized correctly and properly c Verify proper injector selection 6 Control fails to draw a Brine injector plugged a Clean and replace injector brine b Filter screen plugged b Clean and replace screen C Loose brine line connection c Verify that all the brine line connections are tight d Drain line is restricted d Insure that the drain line is not kinked or plugged e Lowinlet pressure e Verify that the service inlet pressure is a minimum of 20 psi f Main diaphragm is torn f Replace diaphragm g Solenoid plunger stuck open g Clean or replace the solenoid plunger assembly 7 Continuous flow to a Drain plunger stuck open a Clean or replace the drain plunger drain b Clock motor stalled assembly b Replace the clock motor 8 Loss of water pressure a Iron build up in mineral tank a Increase salt dosage or regenerate more frequently b Lower distributor basket crushed b Replace basket and verify that the distributor is cut 1 2 inch below the top of the tank threads c Resin has lost mechanical strength c Replace resin AS1029 E Page 15 Parts Replacement General Information Familiarise yourself with the parts replacement procedures and component parts thoroughly before attempting any repair Insure that the unit is in the bypass position and relieve the system pressure before attempting any repair procedure WARNING Disconnect all electrical power to the
7. Disconnect the solenoid cable from the solenoid coil 6 Remove the four 4 head mounting screws Lift the timer assembly away from the valve body 8 Remove the c clip from the centre of the diaphragm 9 Lift the diaphragm away from the body stem assembly 10 Remove the seat assembly 11 Lift out the body stem assembly 12 Inspect the centre check disc rubber seal for wear Clean or replace if necessary 13 Re install the body stem assembly 14 Lightly lubricate the seat assembly o rings with a Dow 111 Silicone based lubricant Page 17 15 16 17 12 Follow these steps in reverse to re install the backwash adjustment valve Re install the seat assembly insure that one of the two 2 flats is facing towards the top of the valve body Re install the main diaphragm and the timer assembly It is now necessary to reseat the rear check disc Refer to the Check Disc Replacement procedure Backwash Adjustment Valve Replacement 1 2 10 11 Place the bypass valve into the bypass position Relieve the system pressure Remove the four 4 head mounting screws Lift the timer assembly away from the valve body Remove the c clip from the centre of the diaphragm Lift the diaphragm away from the body stem assembly Remove the seat assembly Disconnect the large c clip located on top of the backwash adjustment valve Press the backwash adjustment valve down and out through the valve
8. Indicator 12 Day Washer Day Indicator 7 Day Day Selector Wheel 12 Day Day Selector Wheel 7 Day Spring Washer Large Screw Head Mount Cycle Cam 8 Knob Assembly Drain Plunger Assembly return Spring Drain Plunger O ring Plunger Cap Plunger Cap Retainer Drain Plunger Screw Retainer Switch 8 Terminal Assembly Screw Switch Screw Timer Motor Timer Motor Return Spring Main Diaphragm Screw Ratchet Washer Ratchet Ratchet Gear Ratchet 12 Day Gear Ratchet 7 Day Front Cover Rear Cover Gray Rear Cover White Solenoid Cord Strain Relief Power Cord 120 Volt Qty Aba dl dl dl do do de AA dl M O N A dl dl dl de Page 11 AS1029 E Page 12 Valve Body Parts List ltem P N 1 15 88 2 15 90 3 413 134 4 413 60 413 58 6 413 62 7 413 61 8 413 59 9 541 208 2 10 541 206 11 541 239 12 541 246 13 541 325 14 428 15 541 221 16 15 89 17 413 13 18 541 254 21 19 19 22 541 243 23 529 244 24 541 244 25 185 024 1 26 541 204 27 185 028 12 28 541 256 29 19 3 30 516 221 31 19 90 32A 185 231 1 32B 186 105 33 541 232 37 541 257 1 Indicate Voltage AS1029 E Description Screw Backcap Screw Solenoid Mount Solenoid Coil Specify Voltage Spacer Guide Spring Plunger Plunger Solenoid Diaphragm Solenoid Backcap 5 Cycle Fast Rinse Seal Backcap Return Spring Check Disc Ch
9. body assembly Inspect the o rings on the valve for wear Clean or replace the valve assembly if necessary Lightly lubricate the o rings with a Dow 111 Silicone based lubricant Follow these steps in reverse to re install the backwash adjustment valve Solenoid Assembly Replacement 1 2 10 11 Disconnect all electrical power to the control Place the bypass valve into the bypass position Relieve the system pressure Disconnect the solenoid cable from the solenoid coil Remove the one 1 solenoid mounting screw Lift away the solenoid coil Test coil and replace if necessary Remove the three 3 remaining screws which hold down the solenoid plunger retainer Place a hand under the plunger retainer while lifting away the retainer assembly Verify that the plunger moves back and forth against the return spring without sticking Clean or replace if necessary Separate the solenoid diaphragm from the valve body Verify that the diaphragm cavity in the valve body is free of debris Inspect the diaphragm for rips or tears The diaphragm should have a hole in the centre and a smaller pin hole off centre AS1029 E Page 18 1029 rl i ii FA I mC Ines we om BRINE VALVE ASSEMBLY Detailed Assembly Information Drawing Order Number Numlter Description Low 91396 um 3 8 x WR union elbow must he purcnased separalely 2 81187 ne 3 8 pol
10. e factory setting for the actual time of regeneration is 3am The tables below are based on an average daily water usage of 250 litres per person and using the maximum salt dosage to provide maximum capacity The tables indicate a suggested number of regenerations per 12 day period The tabs selected will have to suit the suggested number eg For 6 regenerations select tabs 1 3 5 7 9 11 From the left column locate the number in the family reading along and down from the hardness column where the column intersect gives the number of regenerations for every 12 days MODEL AS0715 E No Hardness MG L family 50 100 150 200 250 300 350 400 450 500 1 1 1 1 1 1 1 2 2 2 2 2 1 1 1 2 2 3 3 3 3 3 1 1 2 2 3 3 4 4 4 6 4 1 2 2 3 3 4 6 6 6 6 5 1 2 3 3 4 6 6 6 6 1 2 3 4 6 6 MODEL AS0922 E No m Hardness MG L CACOs family 50 100 150 200 250 300 350 400 450 500 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 2 1 2 2 2 2 2 3 1 1 1 2 2 2 3 3 3 3 4 1 1 2 2 2 3 3 4 4 4 5 1 1 2 2 3 3 4 4 6 6 6 1 2 2 3 3 4 6 6 6 6 MODEL AS1029 E Hardness MG L family 50 100 150 200 250 300 350 400 450 500 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 2 2 2 3 1 1 1 1 2 2 2 2 3 3 4 1 1 1 2 2 2 3 3 3 4 5 1 1 2 2 2 3 3 4 4 4 6 1 1 2 2 3 3 4 4 6 6 AS1029 E Page 7 541 030
11. eck Disc Gasket Injector Injector Specify Size Cover Plate Injector Screw Injector Mount Filter Screen Injector Spring Clip O ring Brine Fitting Brine Fitting C Clip Backwash Flow Adjuster Backwash Flow Adjuster w o rings Gasket Cross Over Port Body Stem Assembly O ring Small Seat Insert Seat Insert O ring Large Seat Insert Main Diaphragm C clip Main Diaphragm Return Spring Main Diaphragm Screw Adapter Ring O ring Structural Tank O ring Park Tank Adapter Ring O ring 13 16 Riser Adapter O ring 1 050 Riser Adapter Power Cord 120 Volt 13 16 Riser Adapter 1 050 Riser Adapter Valve Body amp Seal Qty AA dl dl do do do do do do do do do do dl dd O dl ld dl do do do do do do do dd dd od Page 13 1029 Page 14 Troubleshooting Guide Problem Cause Solution 1 Unit fails to regenerate a Faulty electrical circuit b Defective clock motor c Low inlet pressure Verify electrical service fuse circuit breaker light switch pull chain power cord Replace the clock motor Verify that the service inlet pressure is a minimum of 20 psi d Drain line restricted d Insure the drain line is free of kinks e All skipper tabs in the out position e Push desired number of skipper tabs to the in position f The brine injector is plugged f Clean or replace injector g Main diaphra
12. gm is torn g Replace diaphragm h Timer knob out of alignment with h Realign the Knob and Gear Time Gear i Defective solenoid coil i Test and replace the solenoid coil 2 Hard water to service a The bypass valve is open or faulty a Close bypass valve b No salt in storage tank b Add salt c Not enough water in the storage tank c Verify that the safety float is properly set d Unit fails to draw brine d See symptom cause 6 e Excessive water usage e Check regeneration frequency f Unit not regenerating f Seesymptom cause 1 g Loss of resin g See symptom cause 4 h Change in raw water hardness h Test water hardness i Leakatthe distributor tube i Verify that the distributor tube is seated correctly and is not cracked 3 Excessive salt usage a Excessive water in storage tank a Verify that the safety float is properly set b Regeneration is taking place too b Check regeneration frequency frequently c Faulty safety float c Replace safety float 4 Loss of resin a Faulty air check in storage tank a Clean or replace air check b Leak at the distributor tube b Verify that the distributor tube is seated correctly and is not cracked c Backwash flow improperly adjusted c Verify the backwash flow 5 Salt water to service a Brine slow rinse cycle time set too a Verify cycle time short b Excessive water in the storage tank b Verify that the safety float is adjusted c
13. heck in the brine tank closes Page 9 Programming General Information The control valve is designed to initiate regeneration according to pre set factory parameters Following the instructions contained in this section will allow the installer to customise the program for the users exact needs The regeneration cycle is controlled by the time cam located on the front of the timer assembly The brine 8 slow rinse cycle can be adjusted from 50 minutes to 95 minutes in 5 minute increments The backwash and fast rinse cycles are not adjustable Factory Default Settings The following default cycle settings are preset into the control valve Cycles Backwash 11 1 2 minutes Brine Slow Rinse 70 minutes Fast Rinse 4 1 2 minutes Set Time of Regeneration 1 Remove the front dust cover from the timer assembly 2 Rotate the Time of Regeneration plate A until the desired time appears in the window Note A M or P M 1029 Set Time of Day 1 Remove the front dust cover from the timer assembly 2 Turn the Timer Knob B until the alignment mark located on the Time of Day Gear C points directly to the correct time of day Note A M or P M Set Regeneration Frequency 1 Remove the front dust cover from the timer assembly 2 Pull all skipper wheel tabs up 3 Rotate skipper wheel D until the number one tab aligns with the DAY mark E 4 Starting with the number one tab push down the tabs to determi
14. lue but with some water a greyish coloured end point is obtained Using 50ml sample Hardness ppm number of tablets x 40 20 LR BW Tablets Directions Take a 100ml sample of water in a screw capped bottle Add one 1 tablet to sample shake or crush to disintegrate Repeat until last trace of reddish tinge disappears The final colour is usually blue but with some water a greyish coloured end point is obtained Using 100ml sample Hardness ppm number tablets x 2 1 Contact IBC Water if further details are required AS1029 E Page 2 WATER SOFTENER CALCULATIONS MODEL AS1029 E To ascertain DAYS between regeneration periods the following data or estimations are required Let N be the number of days to be calculated 1 6 Water Hardness in mg l call H 2 6 Water Softener Hardness Removal Capacity from Table 1 in grams call 6 Daily Water Usage in litres call D For household situations allow 250 litres per person per day CALCULATION N 1000 x C DxH Select nearest lower whole number If necessary consult your dealer or IBC Water Treatment for advice on setting up the softener EXAMPLE Household use for 4 people on 220 mg l hard water using Model AS1029 E at 2030 grams capacity N 1000 x 2030 1000 x 220 9 2 days 9 days AS1029 E Page 3 10 11 12 Note 13 14 LOCATION 8 INSTALLATION The softener should be located indoors or protected fr
15. m follower G has fully depressed drain valve stem H Water will run from drain line and water in the salt storage tank will be lowered approximately to the centre of the brine valve air shut off assembly Let water run about 5 minutes longer or until water is clear and then turn timer knob B counter clockwise until cam follower G springs back into position again allowing the drain valve stem H to return to the shut off position Open installed outlet valve and be sure that the installed by pass valve is closed BRINE TANK 1 Place at least 25kg of a coarse refined grade of salt Water Softener Salt in the brine tank and always maintain dry salt above the water level The tank can hold up to 50kg of coarse salt 2 Periodically it will be necessary to allow the salt to run out and clean out the brine tank of accumulated silt and insoluble material REGENERATION This automatic water softener is designed for a minimum complete regeneration time of 70 minutes Under normal conditions the regeneration cycle should be set to 70 minutes However if the pressure is low the time may have to be increased to 90 minutes AS1029 E Page 5 REGENERATION FREQUENCY The softener can be set to regenerate from once per day up to once per 12 days To determine the correct number of regenerations refer to the Tables below for the model softener installed The skipper wheel tabs are pushed in fully for the days selected for regeneration Th
16. ne the days on which regeneration is required Regeneration Cycles The backwash and fast rinse cycles are non adjustable Adjusting the brine and slow rinse cycle can be accessed according to the following procedure 1 Loosen the screw located on top of the timer cover remove front dust cover from timer assembly 2 Tum Timer Knob B until setscrew on the time cam is visible 3 Loosen setscrew and using the alignment mark F located on the lower cam move timing cam to the desired length of time 4 Tighten setscrew and install dust cover Page 10 Electromechanical Power Head Parts List P N 3 15 76 529 309 525 303 52 308 529 232 1 529 232 2 19 3 529 218 529 212 529 333 1 10 15 185 10 11A 525 274 1 11B 525 2742 12A 525 2412 12B 525 241 4 13 525 205 14 15 87 15 529 239 1 16 529 219 3 OONDAAKRWN 17 401 7 18 185 0221 1 19 529 286 20 529 280 21 15 92 2 22 525 279 4 23 15 185 10 24 15 76 25 30 77 26 516 221 27 15 185 10 28 14 11 29 525 260 30A 525 2542 30B 525 254 5 31 529 234 32A 529 220 1 32B 529 2202 33 529 290 14BK 34 28 8 28 35 28 142 2 Indicate Voltage Indicate Opaque or Clear 1029 Description Screw Time Dial Spring Washer Small Locating Dial Gear Time of Day 12 Day Gear Time of Day 7 Day C clip Actuator Spindle Actuator Housing Power Head Screw Day Selector Wheel Washer Day
17. om the weather The softener requires an inlet water pressure between 140kPa 20psi and 690kPa 100psi and 240 volt 10 amp electric power supply The softener should service all water lines in the house except the toilet and outside taps The softener should be positioned on a level flat surface close to a drain or any other properly trapped waste outlet The brass adaptors supplied are suitable for 20mm 3 4 female fittings and the softener should be connected to the supply with raw water to the inlet connector and softened water lines to the outlet as indicated on the valve If soldering fittings are used the adaptors should be removed from the valve whilst the fittings are being soldered When facing the front of the control the inlet is to the right and the outlet is to the left The system pressure must be between 140 kPa and 690 kPa psi If the system pressure is greater than 690kPa psi a pressure reducing valve must be installed The unit must be installed in accordance with local codes Do not over tighten connections Drain line ID must be at least 12mm Teflon tape should be used when installing he drain fitting into the control valve The drain line must be free of kinks A safety float with an air check is installed Insure all connections are tight DO NOT use teflon tape when connecting the fitting kits to the control valve There are two drain lines one from the brine tank and one from the softener valve these line
18. s must have an air gap of at least 40mm or twice the pipe diameter at the drain entrance The drain line from the brine tank is gravity fed and hence the drain is required to be below the outlet elbow on the tank The drain line from the softener valve is under pressure during regeneration but for correct operation a maximum of 2 4m of 15NB pipe with no rises can be connected A manual Bypass should be installed AS1029 E 4 PLACING THE SOFTENER IN SERVICE 1 Depress all Skipper Wheel Tabs 2 Turn knob B counter clockwise until cam follower G has fully depressed drain valve stem H 3 Ensure the power is turned off at this stage Open the installed inlet valve slightly and slowly fill the mineral tank with water Air and water will be expelled from drain line during the filling process When the mineral tank is full and the stream of water from the drain line is steady with no air bubbles turn knob B counter clockwise until cam follower G springs back into position allowing the drain valve stem H to return to the shut off position Open the inlet valve fully The salt storage tank will automatically fill to the proper level To check the level remove the cabinet cover plate If for any reason it does not fill to this level the bribe valve float must be raised or lowered as required This level will ensure the softener is set to produce maximum hardness removal 4 Again turn knob B counter clockwise until ca
19. water WATER SOFTENER SERIES 500 12 DAY TIMER INSTALLATION 8 OPERATING INSTRUCTIONS Model AS1029 E Serial Manufacturer and Supplier of i FILTRATION amp WATER TREATMENT PRODUCTS gt Water for commercial industrial and residential application Quality STS SFR Telephone 07 3219 2233 Facsimile 07 3219 2266 Email sales ibcwater com au Website www ibcwater com au AS1029 E Page 1 HARDNESS TEST 1 Water to be tested should be taken from a tap after the water softener 2 Measure 10ml of water into plastic bottle supplied approximately 1 3 full 3 Add one Yes No tablet to sample water replace cap and shake until tablet has completely dissolved NOTE do not handle Yes No tablet with fingers 4 The final colour to be obtained for soft water is green Note The shade of green may vary If the colour turns red the water is above 20 mg l hardness therefore another regeneration is recommended 5 Rinse plastic bottle after each test has been completed 6 When used as above the tablets change the colour from green to red at a hardness of approximately 20ppm based on a sample volume of 10mls Other hardness test kits are available for more accurate testing eg Hardness Tablets Directions a 50ml sample of water in a screw capped bottle Add one 1 tablet to sample shake or crush to disintegrate Repeat until last trace of reddish tinge disappears The final colour is usually b
20. y cavity 11 Follow these steps in reverse to re install the riser assembly AS1029 E Check Disc Replacement _ Disconnect all electrical power to the control 2 Place the bypass valve into the bypass position 3 Relieve system pressure 4 Disconnect the solenoid cable from the solenoid coil 5 Remove the four 4 screws from the backcap 6 Place a hand under the backcap and remove the backcap The check disc return spring will fall into your hand 7 Remove the check disc from the back of the body stem assembly 8 Inspect the rubber seal on the check disc for wear Clean or replace if necessary 9 Re install the check disc on body stem assembly 10 Place a small amount of Dow 111 silicone based lubricant on the back cap centre post 11 Insure that the back cap gasket is properly seated in Backcap 12 Install check disc return spring into centre post 13 Align the mark on top of the back cap with the mark on the valve body and carefully direct open end of return spring into centre post of the check disc 14 Install the four 4 back cap screws 15 Pressurise system and check for leaks Body Stem Assembly Replacement 1 Disconnect all electrical power to the control 2 Place the bypass valve into the bypass position 3 Remove the front dust cover from the timer assembly 4 Relieve the system pressure by using a screw driver to press down on the drain plunger to the open drain line 5
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