Service Manual IMPORTANT: Fill in pertinent information on page for future reference.
Job Specification Sheet * JOB NO. * MODEL NO. * WATER TEST * CAPACITY PER UNIT * MINERAL TANK SIZE DIA. HEIGHT * BRINE TANK SIZE & SALT SETTING PER REGENERATION: * 850 CONTROL VALVE SPECIFICATIONS Type of Timer (see pages 0,, and ) A) day B) * to 40 m meter or * to 00 m meter * Other C) Meter Wiring Package ) System #4 - tank; meter; immediate or delayed regeneration ) System #5 - tanks; meters; interlock ) System # - tanks; meter; series regeneration 4) System #7 - tanks; meter; alternator Timer Program Settings (see pages 0,, and ) A) Backwash min. B) Brine & Slow Rinse min. C) Rapid Rinse min. D) Brine Tank Refill min. Drain Line Flow Control gpm 4 Brine Line Flow Controller gpm 5 Injector Size # Service Valve Operation Units (SVO) Size of Service Valve Page
General Commercial Pre-Installation Check List WATER PRESSURE: A minimum of 5 pounds of water pressure is required for regeneration valve to operate effectively. ELECTRICAL FACILITlES: A continuous 5 volt, 0 Hertz current supply is required. Make certain the current supply is always hot and cannot be turned off with another switch. EXISTlNG PLUMBING: Condition of existing plumbing should be free from Iime and iron buildup. Piping that is built up heavily with Iime and/or iron should be replaced. If piping is clogged with iron, a separate iron filter unit should be installed ahead of the water softener. LOCATION OF SOFTENER AND DRAIN: The softener should be located close to a drain. BY-PASS VALVES: Always provide for the installation of a by-pass valve. CAUTION: Water pressure is not to exceed 0 p.s.i., water temperature is not to exceed 00 F, and the unit cannot be subjected to freezing conditions. Installation Instructions. Place the softener tank where you want to install the unit making sure the unit is Ievel and on a firm base. (Maximum 4 feet apart for twin units.). All plumbing should be done in accordance with Iocal plumbing codes. The pipe size for the drain Iine should be the same size as the drain Iine flow control connection. Water meters are to be installed on soft water outlets. Twin units with () one meter shall be installed on common soft water outlet of units.. Solder joints near the drain must be done prior to connecting the Drain Line Flow ControI fitting. Leave at Ieast " between the DLFC and solder joints when soldering when the pipes are connected on the DLFC. Failure to do this could cause interior damage to the DLFC. 4. Teflon tape is the oniy sealant to be used on the drain fitting. The drain from twin units may be run through a common Iine. 5. Make sure that the floor is clean beneath the sait storage tank and that it is Ievel.. Place approximately " of water above the grid plate (if used) in your sait tank. Salt may be placed in the unit at this time. 7. Place in by-pass position. Turn on the main water supply. Open a cold soft water tap nearby and let run a few minutes or until the system is free from foreign material (usually solder) that may have resulted from the installation. 8. Place the by-pass in service position. 9. Manually index the softener control into service position and Iet water flow into the mineral tank. When water flow stops, close inlet valve, piace control in backwash position to relieve head of air, then gradually open inlet valve to purge remain ing air in tank. Return control to service position. 0. Electrical: All electrical connections must be connected according to codes. Use electrical conduit if applicable. Plug into power supply. Page
Assembly Drawings and Part Numbers F40 Control Valve Assembly FILTER PARTS RWB PISTON ASSEMBLY 7 BLOCK-A 8 9 4 0 4 BLOCK-B 5 NRWB PISTON ASSEMBLY 5 4 4 7 9 0 4 8 BLOCK-C BLOCK-B 4 Page 4 9 0
Assembly Drawings and Part Numbers F40 Control Valve Assembly Parts List Item No. 4 5 7 8 9 0 4 5 7 8 9 0 4 Quantity 5 Part No. 00-0004-00 00-000-00 05-00-00 05-0005-00 00-0004-00 05-0005-00 05-00-00 0-0005-00 05-00005-00 05-0005-00 05-0005-00 099-0079-00 0-0004-00 05-00-00 00-0008-00 05-00099-00 05-004-00 05-00-00 05-0004-00 05-0008-00 0-000-00 05-005-00 05-0044-00 00-00040-00 05-00044-00 0-00054-00 Description Riser O-Ring - AS Valve-Tank O-Ring- AS40 Adapter-Top Mount F40(US) Adapter-Top Mount F40(Metric) Valve-Tank Adapter Seal Valve Body(NPT) Valve Body(BSP) Screw,ch,Mx0mm,A-70 Piston(RWB) Piston Rod(RWB) Connecting Link Pin End Plug Assembly Screw,ch,Mxmm,A-70 Brine Tube(RWB) Seal-Valve Assembly Spacer-Valve Assembly Piston(NRWB) Piston Assembly(NRWB) Piston Rod(NRWB) Spacer(NRWB) Screw,ch,Mx5mm,A-70 Brine Tube(NRWB) Retainer Injector Body Gasket Injector Cover Screw,ch,M5x0mm,A0-70 Bold faced items are recommended spare parts. Page 5
Control Drive Assembly (For F0 & F40 Mechanical Clock) FOR SM 0 9-9- - - 7 5 8 4 Page 4
Control Drive Assembly (For F0 & F40 Mechanical) Item No. Quantity Part No. Description 05-0004-00 Motor Assembly 0V 05-00084-00 Brine Valve Cam 08-0000-00 Roll Pin- Drive Assembly 4 099-0075-00 Drive Cam Assembly 5 05-00049-00 Insulator -Drive Assembly 04-00000-00 Switch 7 0-00000-00 Screw,tcp,NO.4-40x.5,b,Zn,0 8 05-0009-00 Back Plate with Thumb Screws 9-047-00004-00 Line Group 9-047-00005-00 Line Group-SM 0 04-0000-00 Power Cord(Obligue-Flat(Inverted V)) 078-004-00 Strain Relief 047-0000-00 Line Group-Motor - 099-0004-00 Timer Assembly(0V/50HZ) - 099-0088-00 Timer Assembly(0V/50HZ)-SM 4 05-00098-00 Cover Assembly Bold faced items are recommended spare parts. Page 7
Timer Assembly (For Mechanical Clock) 4 5 0 9 8 7 4 7 8 5 9 0 4 4 5 7 8 7 9 7 Page 8 0
Timer Assembly (For Mechanical Clock) Item No. Quantity Part No. Description 05-00078-00 Timer Housing 09-0080-00 Decal- Instructions 05-00074-00 Cycle Actuator Arm 4 099-0077-00 4 Hour Gear Assembly 5 05-00089-00 Knob 4 0-0000-00 Screw,tchw,NO.-0x/,b,black,Zn,0 7 09-0079-00 Button Decal 8 099-007-00 Skipper Wheel Assembly 9 078-00008-00 Ball 0 058-0000-00 Spring Detent- Skipper Wheel 09-008-00 Decal- Time of Day 05-000-00 Spring Clip 058-0000-00 Spring- Denent- Main Gear 4 05-0008-00 Plastic Ball-0.5inch Dia. 5 057-000-00 Main Drive Gear 099-0078-00 Program Wheel(ST) Assembly 7 057-000-00 Idler Pinion 8 058-0000-00 Spring- Idler 9 057-0004-00 Idler Gear 0 057-000-00 Driver Gear 05-0004-00 Motor Mounting Plate 05-000-00 Motor Assembly(0V/50HZ) 0-0000-00 Screw,ccch,NO.-x/8,Zn,0 4 0-000-00 Screw,ccch,NO.-UNCx/4,Zn,0 5 05-0004-00 Hinge Bracket 0-000-00 Screw,tchw,NO.8-8x/8,Zn,0 7 05-00048-00 Insulator- Drive Assembly 8 04-0000-00 Switch 9 04-0000-00 Switch 0 0-00055-00 Screw, tcp, NO. M-4x.5,b,Zn,0 05-00070-00 Skipper Wheel Ring 05-0007-00 Regeneration Pointer Bold faced items are recommended spare parts. Page 9
MODEL 00 & 0 TIMER SERIES Regeneration Cycle program Setting Procedure Even though it takes three hours for this center knob to complete one revolution, the regeneration cycle of your unit might be set for only one half of this time. Typical Programming Procedure Calculate the gallon capacity of the system, subtract the necessary reserve requirement and set the gallons required by Iifting the gallon dial and rotating it so that the number of gallons required is aligned with the white dot on program wheel gear. Release and check for firm engagement with gear. In any event, conditioned water may be drawn after rinse water stops flowing from the water conditioner drain Iine. Immediate Regeneration Timers: Note: To set meter capacity at initial start-up, either:. Rotate manual regeneration knob one full revolution. or. Rotate program wheel manually clockwise and align white dot with capacity arrow. These timers do not have a 4 hour gear. Setting the gallons on the program wheei and manual regeneration procedure are the same as previous instructions. This procedure must be followed any time the program wheel setting is changed. How To Set The Time Of Day: Press and hold the red button in to disengage the 4 hour gear. Manual Regeneration Knob 4 HR. Gear Turn the 4 hour gear until the actual time of day is at the time of day pointer. Release the red button to again engage the 4 hour gear. How To Manually Regenerate Your Water Condition At Any Time: Turn the manual regeneration knob clockwise one click. This slight movement of the manual regeneration knob engages the program wheel and starts the regeneration program. TO SET TIME OF DAYPRESS RED BUTTON AND TURN LARGE AIAL UNTIL TIME IS AT ARROW. TO MANUALLY START CYCLETURN KNOB CLOCKWISE. Service Position Indicator CAPACITE CAPACITY KAPAZITAT CAPACITA CAPACIDAD M Capacity (M Remaining) White Dot (M Capacity) Red Time Set Button The black center knob will make one revolution in the following approximately three hours and stop in the position shown in the drawing. CAUTION ALWAYS REMOVE CABLE FROM METER BEFORE SWINGING TIMER OPEN. Program Wheel Page 0 M Label
MODEL 00 & 0 TIMER SERIES Timer Setting Procedure Service Position Indicator How To Set Days On Which Water Conditioner Is To Regenerate: Rotate the skipper wheel until the number is at the red pointer. Set the days that regeneration is to occur by sliding tabs on the skipper wheel outward to expose trip fingers. Each tab is one day. Finger at red pointer is tonight. Moving clockwise from the red pointer, extend or retract fingers to obtain the desired regeneration schedule. Manual Regeneration Knob TO SET TIME OF DAYPRESS RED BUTTON AND TURN LARGE DIAL UNTIL TIME IS AT ARROW. TO MANUALLY START CYCLE TURN KNOB CLOCKWISE. Red Pointer How To Set The Time Of Day: Press and hold the red button in to disengage the drive gear. Turn the Iarge gear until the actual time of day is at the time of day pointer. Release the red button to again engage the drive gear. How To Manually Regenerate Your Water Conditioner At Any Time: Turn the manual regeneration knob clockwise. This slight movement of the manual regeneration knob engages the program wheel and starts the regeneration program. The black center knob will make one revolution in the following approximately three hours and stop in the position shown in the drawing. Even thought it takes three hours for this center knob to complete one revolution, the regeneration cycle of your unit might be set only one half of this time. In any event, conditioned water may be drawn after rinse water stops flowing from the water conditioner drain Iine. How to Adjust Regeneration Time:. Disconnect the power source.. Locate the three screws behind the manual regeneration knob by pushing the red button in and rotating the 4 hour dial until each screw appears in the cut out portion of the manual regeneration knob.. Loosen each screw slightly to release the pressure on the time plate from the 4 hour gear. 4. Locate the regeneration time pointer on the inside of the 4 hour dial in the cut out. 5. Turn the time plate so the desired regeneration time aligns next to the raised arrow.. Push the red button in and rotate the 4 hour dial. Tighten each of the three screws. 7. Push the red button and Iocate the pointer one more 4 HR. Gear E Y A TIMF D O Red Time Set Button Skipper Wheel, Day (Shows Every Other Day Regeneration) time to ensure the desired regeneration time is correct. 8. Reset the time of day and restore power to the unit. IMPORTANT SALT LEVEL MUST ALWAYS BE ABOVE WATER LEVEL ln BRINE TANK. Page
MODEL 00 & 0 TIMER SERIES Regeneration Cycle program Setting Procedure How To Set The Regeneration Cycle Program: The regeneration cycle program on your water conditioner has been factory preset, however, portions of the cycle or program may be lengthened or shortened in time to suit local conditions. 00 & 0 Series Timers (Figure to Right) To expose cycle program wheel, first pull cable out of meter dome of 0 timers, grasp timer in upper Ieft-hand corner and pull, releasing snap retainer and swinging timer to the right. To change the regeneration cycle program, the program wheel must be removed. Grasp program wheel and squeeze protruding Iugs toward center, Iift program wheel off timer. (Switch arms may require movement to facilitate removal.) Return timer to closed position engaging snap retainer in back plate. Make certain all electrical wires Iocate above snap retainer post. Reconnect meter cable. Timer Setting Procedure for 00 and 0 Timer How To Change The Length Of The Backwash Time: The programwheel as shown in the drawing is in the service position. As you Iook at the numbered side of the program wheel, the group of pins starting at zero determines the Iength of time your unit will backwash. FOR EXAMPLE: If there are six pins in this section, the time of backwash will be min. ( min. per pin). To change the Iength of backwash time, add or remove pins as required. The number of pins times two equals the backwash time in minutes. How To Change The Length Of Rapid Rinse: The second group of pins on the program wheel determines the Iength of time that your water conditioner will rapid rinse. ( min. per pin.) To change the Iength of rapid rinse time, add or remove pins at the higher numbered end of this section as required. The number of pins times two equals the rapid rinse time in minutes. How To Change The Length Of Brine Tank Refill Time: The second group of holes in the program wheel determines the length of time that your water conditioner will refill the brine tank. ( min. per hole.) To change the Iength of refill time, move the two pins at the end of the second group of holes as required. The regeneration cycle is complete when the outer microswitch is tripped by the two pin set at end of the brine tank refill section. The program wheel, however, will continue to rotate until the inner micro-switch drops into the notch on the programwheel. BACKWASH SECTION (MIN. PER PIN) PIN STORAGE PROGRAM WHEEL FOR REGENERATION CYCLE BRINE & RINSE (MIN.PER HOLE) RAPID RINSE SETION (MIN. PER PIN) How To Change The Length Of Brine And Rinse Time: The group of holes between the Iast pin in the backwash section and the second group of pins determines the Iength of time that your unit will brine and rinse ( min. per hole.) BRINE TANK To change the Iength of brine and rinse time,move the rapid rinse group of pins to give more or fewer holes in the brine and rinse section. Number of holes times two equals brine and rinse time in minutes. Page
Assembly Drawings and Part Numbers Medium Brining System Assembly 7 a.brine Tube(NRWB) b.brine Tube(RWB) 8 9 BLOCK-A 0 4 5 7 BLOCK-C Fittings for medium (" to /") brining system 4 8 9 5 BLOCK-B 0 Fittings for /" BV 7 Page 4 5
MODEL 00 & 0 TIMER SERIES Assembly Drawings and Part Numbers Medium Brining System Assembly Parts List Item No. Quantity Part No. 05-00000-00 End Plug-Brine System Assembly 00-0004-00 O-Ring- AS00 00-00050-00 RFC Washer-5.0 gpm 4 05-00-0 Flow Control Retainer 5 05-00-00 Piston- Brine System Assembly 05-000-00 Piston Rod- Brine System Assembly 7 00-0009-00 O-Ring- AS0 8 05-00-00 Spacer- Brine System Assembly 9 05-00054-00 Brine Valve Body 0 05-00045-00 Insert sleeve 05-0008-00 Retainer 05-000-00 Nut 00-000-00 Quad Ring- ASQ009 4 058-00008-00 Spring- Brine Valve 5 08-0009-00 Retaining Ring d 05-0000-0 Stem Guide 7 0-000-00 Screw,ch,M5x70mm,A-70 8 05-00044-00 Injector Cover 9 00-0009-00 Injector Cover Gasket 05-0089-00 5# Injector Nozzle 05-000-00 # Injector Nozzle 075-0000-00 Injector Screen 05-000-00 Injector Body 05-0090-00 5# Injector Throat 05-0007-00 # Injector Throat 4 05-0009-00 Water Disperser 5 00-00040-00 Injector Body Gasket 05-00058-00 Elbow Fitting 7 05-009-00 Air Check 0 Description Bold faced items are recommended spare parts. Page 4
Assembly Drawings and Part Numbers.5" Flow Meter Assembly Mechanical Meter Cover Assembly Electronic Meter Cover Assembly 5 7 4 8 9 0 4 Page 5
Assembly Drawings and Part Numbers.5" Flow Meter Assembly Parts List Item No. Quantity Part No. 0-0000-00 Meter Cable Assembly(.5 ) 4 0-00048-00 Screw,ch,M5x5mm,A-70 099-0095-00 Meter Cover Assembly 4 0-000-00 Screw,tchw,NO.8-8x/8,Zn,0 047-0009-00 Meter Cable Assembly(5 ) 047-000-00 Meter Cable Assembly(99.5 ) 099-0088-00 Meter Cover Assembly 7 00-000-00 O-Ring- AS7 8 05-0005-00 Impeller 9 05-0000-00 Post, Impeller 05-00055-00 Meter Body(NPT) 05-005-00 Meter Body(BSP) 05-0009-00 Flow Straightener 00-00009-00 O-Ring- AS 05-00004-00 Nipple -Quick Connect(NPT) 05-005-00 Nipple-Quick Connect(BSP) 05-00057-00 Nut- Quick Connect 5 0 4 Bold faced items are recommended spare parts. Page Description
Dimensional Drawing )F40 Valve RWB 45mm (9.7") " " 0mm (4") /" " 0mm (9.") 0mm (.") 8mm (7.") 4" UN NRWB 58mm (0.") " " 0mm (4") /" " 0mm (9.") 0mm (.") 94mm (7.") 4" UN Page 7
Assembly Kits )For F40 Valve Piston Kits 00-00007-00 Piston Kits-NRWB 00-00008-00 Piston Kits-RWB Adapters 00-0000-00 Fittings for medium ( to ½ brining system 00-0007-00 Fittings for / BV Seals & Spacers 00-00050-00 F40 Spacers & Seals Injector 00-000-00 #5 Injector Assembly 00-000-00 # Injector Assembly Meter(.5" Electronic Flow Meter) 00-0008-00 5" Cable 00-00005-00 99.5" Cable Meter(.5" Extended Mechanical Flow Meter) 00-0000-00 Medium ½ Brine Valve 00-000-00 Brine Valve Assembly RFC Washers 00-0000-00 5.0G RFC Housing Assembly 00-004-00 7 5H OO )ORZ &RQWURO ZLWK JSP washer 00-0044-00 % 5H OO )ORZ &RQWURO ZLWK JSP washer Drive Cam Assembly 00-000-00 Drive Cam Assembly BWFC Washers 00-0007-00 0G 00-008-00 9G 00-00-00 0G 00-009-00 G 00-000-00 5G 00-000-00 0G 00-00047-00 5G BWFC Housing Assembly 00-004-00 NPT 0G 00-005-00 BSP 0G 00-008-00 NPT 5G 00-009-00 00-000-00 00-004-00 00-0049-00 00-005-00 00-0050-00 00-005-00 Page 8 BSP 5G NPT 5G BSP 5G NPT 50G BSP 50G NPT 00G BSP 00G
Service Instructions PROBLEM. Softener fails to regenerate. CAUSE A. Electrical service to unit has been interrupted. B. Timer is defective. Hard water. A. Assure permanent electrical service (check fuse, plug, pull chain or switch). B. Replace timer. C. Power failure.. CORRECTION C. Reset time of day. A. By-pass valve is open. A. Close by-pass valve. B. No salt in brine tank. C. Injector screen plugged. D. Insufficient water flowing into brine tank. B. Add salt to brine tank and maintain salt Ievel above water Ievel. C. Clean injector screen. E. Hot water tank hardness. D. Check brine tank fill time and clean brine line flow control if plugged. F. Leak at distributor tube. E. Repeated flushings of the hot water tank is required. G. Internal valve Ieak. F. Make sure distributor tube is not cracked. Check O-ring and tube pilot. G. Replace seals and spacers and/or piston.. 4. Unit used too much salt. Loss of water pressure. A. Improper salt setting. A. Check salt usage and salt setting. B. Excessive water in brine tank. B. See problem no. 7 A. Iron buildup in Iine to water conditioner. A. Clean Iine to water conditioner. B. lron buildup in water conditioner. B. Clean control and add mineral cieaner to mineral bed. lncrease frequency of regeneration. C. Inlet of control plugged due to foreign material broken Ioose from pipes by recent work done on plumbing system. 5. Loss of mineral through drain Iine. A. Air in water system. B. Improperly sized drain line flow control.. Iron in conditioned water. A. Fouled mineral bed. C. Remove piston and clean control. A. Assure that well system has proper air eliminator control. Check for dry well condition. B. Check for proper drain rate. A. Check backwash, brine draw and brine tank fill. Increase frequency of regeneration. lncrease backwash time. A. Clean flow control. 7. Excessive water in brine tank. A. Plugged drain Iine flow control. B. Plugged injector system. B. Clean injector and screen. C. Replace timer. D. Replace brine vaive seat and ciean valve. C. Timer not cycling. D. Foreign material in brine valve. E. Foreign material in brine iine flow control. Page 9 E. Clean brine Iine flow control.
Service Instructions CAUSE PROBL EM 8. Softener fails to draw brine. A. Drain Iine fiow controi is piugged. A. Clean drain Iine flow control. B. Injector is plugged. B. Clean injector. C. Injector screen plugged. C. Clean screen. D. Line pressure is too low. F. Service adapter did not cycle. Control cycles continuously. 0. Drain flows continuously. D. lncrease Iine pressure to 0 P.S.I. E. Change seals, spacers and piston assembly. E. InternaI control Ieak. 9. CORRECTION F. Check drive motor and switches. A. Missadjusted, broken or shorted switch. A. Determine if switch or timer is faulty and replace it, or replace complete power head. A. Valve is not programing correctly. A. Check timer program and positioning of control. Replace power head assembly if not positioning properly. B. Foreign material in control. B. Remove power head assembly and inspect bore. Remove foreign material and check control in various regeneration positions. C. Replace seals and piston assembly. C. InternaI control Ieak. General Service Hints For Meter Control Problem: Softener Delivers Hard Water. Cause couid be that... Reserve Capacity Has Been Exceeded. Correction: Check salt dosage requirements and reset program wheel to provide additional reserve. Cause could be that... Program Wheel Is Not Rotating With Meter Output. Correction: Pull cable out of meter cover and rotate manually. Program wheel must move without binding and clutch must give positive clicks when program wheel strikes regeneration stop. lf it does not, repiace timer. Cause could be that... Meter Is Not Measuring Flow. Correction: Check meter with meter checker. Page 0
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