Aqua-Pure AWS 100M, AWS 150M, AWS 200M, AWS 250M, AWS 300M Metered Water Softeners Installation and operating instructions
Below you will find brief information for AWS 100M, AWS 150M, AWS 200M, AWS 250M. These metered water softeners are designed to automatically regenerate based on water usage, saving you salt and water. The instructions cover installation, programming, and maintenance procedures for these models.
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MODELS:
AWS100M
AWS150M
AWS200M
AWS250M
AWS300M
INSTALLATION AND OPERATING
INSTRUCTIONS
METERED WATER SOFTENERS
Installer, please leave with homeowner.
Homeowner, retain for future reference.
INSTR2198 0709 a 3M company
CUNO Incorporated
400 Research Parkway
Meriden, CT 06450 U.S.A.
SAFETY INFORMATION
Read, understand, and follow all safety information contained in these instructions prior to installation and use of the Aqua-Pure AWS
Series Residential Water Softener. Retain these instructions for future reference. Failure to follow installation, operation and maintenance instructions may result in property damage and will void warranty.
Intended use:
The Aqua-Pure AWS Series Residential Water Softener is intended for use in softening water in homes and has not been evaluated for other uses. The system must be installed indoors near the point of entry of a home water line, and be installed by qualifi ed professional installers according to these installation instructions.
EXPLANATION OF SIGNAL WORD CONSEQUENCES
Indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury and/or property damage.
CAUTION
Indicates a potentially hazardous situation, which, if not avoided, may result in property damage.
WARNING
To reduce the risk associated with choking:
• Do not allow children under 3 years of age to have access to small parts during the installation of this product.
To reduce the risk associated with ingestion of contaminants:
• Do not use with water that is microbiologically unsafe or of unknown quality without adequate disinfection before or after the system.
To reduce the risk of physical injury:
• Shut off inlet water supply and depressurize system as shown in manual prior to service.
To reduce the risk associated with a hazardous voltage:
• If the home electrical system requires use of the cold water system as an electrical safety ground, a jumper must be used to ensure a suffi cient ground connection across the fi lter installation piping — refer installation to qualifi ed personnel.
• Do not use the system if the power cord is damaged — contact qualifi ed service personnel for repair.
To reduce the risk associated with back strain due to the heavy weight of the various system components:
• Follow safe lifting procedures.
CAUTION
To reduce the risk associated with property damage due to water leakage:
• Read and follow Use instructions before installation and use of this water treatment system.
• Installation and use MUST comply with existing state or local plumbing codes.
• Protect from freezing. Relieve pressure and drain system when temperatures are expected to drop below 33° F (1° C).
• Do not install systems in areas where ambient temperatures may go above 110° F (43.3° C).
• Do not install on hot water supply lines. The maximum operating water temperature of this fi lter system is 110°F (43.3°C).
• Do not install if water pressure exceeds 100 psi. If your water pressure exceeds 80 psi (552 kPa), you must install a pressure limiting valve. Contact a plumbing professional if you are uncertain how to check your water pressure.
• Do not install where water hammer conditions may occur. If water hammer conditions exist you must install a water hammer arrester. Contact a plumbing professional if you are uncertain how to check for this condition.
• Where a backfl ow prevention device is installed on a water system, a device for controlling pressure due to thermal expansion must be installed.
• Do not use a torch or other high temperature sources near fi lter system, cartridges, plastic fi ttings or plastic plumbing.
• On plastic fi ttings, never use pipe sealant or pipe dope. Use PTFE thread tape only, pipe dope properties may deteriorate plastic.
• Take care when using pliers or pipe wrenches to tighten plastic fi ttings, as damage may occur if over tightening occurs.
• Do not install in direct sunlight or outdoors without adequate protection from the elements.
• Mount system in such a position as to prevent it from being struck by other items used in the area of installation.
• Ensure all tubing and fi ttings are secure and free of leaks.
• SHUT OFF FUEL OR ELECTRIC POWER SUPPLY TO WATER HEATER after water is shut off.
• Do not install system where water lines could be subjected to vacuum conditions without appropriate measures for vacuum prevention.
• Do not apply heat to any fi tting connected to Bypass or Control Valve as damage may result to internal parts or connecting adapters.
• Install on a fl at/level surface. It is also advisable to sweep the fl oor to eliminate objects that could pierce the brine tank.
To reduce the risk associated with property damage due to plugged water lines:
• Pay particular attention to correct orientation of control valve. Water fl ow should match arrow on control valve. The Inlet and Outlet of other water treatment equipment products will vary depending on the control valve brand used.
IMPORTANT NOTES
• The system should be installed on cold water lines only.
• Failure to follow installation, operation and maintenance instructions will void warranty.
TABLE OF CONTENTS
SECTION DESCRIPTION
4
5
SERVICE INSTRUCTIONS & MAINTENANCE
PERFORMANCE DATA SHEET
SECTION 1: BEFORE INSTALLATION
CAUTION
To reduce the risk associated with property damage due to water leakage:
• Read and follow Use instructions before installation and use of this water treatment system.
• Installation and use MUST comply with existing state or local plumbing codes.
ELECTRICAL
There are no user-serviceable parts in the AC adapter, motor, or controller. In the event of a failure, these should be replaced.
1) All electrical connections must be completed according to local codes.
2) Use only the power AC adapter that is supplied.
3) The power outlet must be grounded.
4) To disconnect power, unplug the AC adapter from its power source.
MECHANICAL
1) Do not use petroleum based lubricants such as Vaseline, oils, or hydrocarbon based lubricants. Use only 100% silicone lubricants.
2) All plastic connections should be hand tightened. Thread tape may be used on connections that do not use an o-ring seal. Do not use pliers or pipe wrenches.
3) All plumbing must be completed according to local codes.
4) Soldering near the drain line should be done before connecting the drain line to the valve. Excessive heat will cause interior damage to the valve.
5) Observe drain line requirements.
6) Do not use lead-based solder for sweat solder connections.
7) The drain line must be a minimum of 1/2 inch diameter. Use 3/4 inch pipe if the backwash fl ow rate is greater than 7 gpm (26.5 lpm) or the pipe length is greater than 20 ft (6 m).
8) Do not support the weight of the system on the control valve fi ttings, plumbing or the bypass.
9) It is not recommended to use sealants on the threads. Use thread tap on the threads of the 1 inch NPT elbow, the drain line connections, and other NPT threads.
1-1
GENERAL
1) Observe all warning and caution statements that appear in this manual.
2) Keep the media tank in the upright position. Do not turn upside down or drop. Turning the tank upside down will cause media to enter the valve.
3) Operating temperature is between 34°F (1°C) and 110°F (43.3°C).
4) Rated water pressure range is 20 - 100 psi.
CAUTION
To reduce the risk associated with property damage due to water leakage:
• Installation and use MUST comply with existing state or local plumbing codes.
• Do not install on hot water supply lines. The maximum operating water temperature of this fi lter system is 110°F (43.3°C).
• Do not install if water pressure exceeds 100 psi. If your water pressure exceeds 80 psi (552 kPa), you must install a pressure limiting valve. Contact a plumbing professional if you are uncertain how to check your water pressure.
5) Use only regenerant salts designed for water softening.
IMPORTANT NOTE
SODIUM INFORMATION: Water softeners using sodium chloride for regeneration add sodium to the water. Persons who are on sodium restricted diets should consider the added as part of their overall sodium intake.
6) Follow state and local codes for water testing.
WARNING
To reduce the risk associated with ingestion of contaminants:
• Do not use with water that is microbiologically unsafe or of unknown quality without adequate disinfection before or after the system.
7) When installing the water connections (bypass or manifold) connect to the plumbing system fi rst. Allow heated parts to cool and cemented parts to be set before installing any plastic parts. Do not get primer or solvent on o-rings, nuts or the valve.
IMPORTANT NOTE
If sediment is present, the installation of a sediment pre-fi lter is recommended. Even if sediment is not currently present or at a level high enough to be objectionable, a pre-fi lter can increase the effi ciency of the softener and reduce the amount of maintenance required.
LOCATION SELECTION
Location of a water treatment system is important. The following conditions are required:
CAUTION
To reduce the risk associated with property damage due to water leakage:
• Do not install on hot water supply lines. The maximum operating water temperature of this fi lter system is 110°F (43.3°C).
• Do not install if water pressure exceeds 100 psi. If your water pressure exceeds 80 psi (552 kPa), you must install a pressure limiting valve. Contact a plumbing professional if you are uncertain how to check your water pressure.
• Do not install where water hammer conditions may occur. If water hammer conditions exist you must install a water hammer arrester. Contact a plumbing professional if you are uncertain how to check for this condition.
• Mount system in such a position as to prevent it from being struck by other items used in the area of installation.
• Do not install system where water lines could be subjected to vacuum conditions without appropriate measures for vacuum prevention.
• Install on a fl at/level surface. It is also advisable to sweep the fl oor to eliminate objects that could pierce the brine tank.
1) Level platform or fl oor.
2) Room to access equipment for maintenance and adding regenerant (salt) to tank.
3) Temperatures over 34°F (1°C) and below 110°F (43.3°C).
4) Water pressure below 100 psi and above 20 psi.
5) Constant electrical supply to operate the controller.
6) Total minimum pipe run to water heater of 10 ft (3 m) to prevent backup of hot water into system.
7) Local drain for discharge as close as possible.
8) Water line connections with shut-off or bypass valves.
9) Must meet any local and state codes for site of installation.
10) Valve is designed for minor plumbing misalignments. Do not support weight of systems on the plumbing.
11) Be sure all soldered pipes are fully cooled before attaching plastic valve to the plumbing.
1-2
SECTION 2: INSTALLATION
WATER LINE CONNECTION
A bypass valve system should be installed on all water conditioning systems. Bypass valves isolate the conditioner from the water system and allow unconditioned water to be used. Service or routine maintenance procedures may also require that the system is bypassed.
CAUTION
To reduce the risk associated with property damage due to water leakage:
• Installation and use MUST comply with existing state or local plumbing codes.
• Do not use a torch or other high temperature sources near fi lter system, cartridges, plastic fi ttings or plastic plumbing.
• On plastic fi ttings, never use pipe sealant or pipe dope. Use PTFE thread tape only, pipe dope properties may deteriorate plastic.
• Take care when using pliers or pipe wrenches to tighten plastic fi ttings, as damage may occur if over tightening occurs.
To reduce the risk associated with property damage due to plugged water lines:
• Pay particular attention to correct orientation of control valve. Water fl ow should match arrow on control valve. The Inlet and Outlet of other water treatment equipment products will vary depending on the control valve brand used.
DRAIN LINE CONNECTION
NOTE: Standard commercial practices are expressed here. Local codes may require changes to the following suggestions. Check with local authorities before installing a system.
1) The unit should be above and not more than 20 ft (6.1 m) from the drain. Use an appropriate adapter fi tting to connect
1/2 inch (1.3 cm) plastic tubing to the drain line connection of the control valve.
2) If the backwash fl ow rate exceeds 5 gpm (22.7 lpm) or if the unit is located 20 - 40 ft (6.1 - 12.2 m) from drain, use
3/4 inch (1.9 cm) tubing. Use appropriate fi ttings to connect the 3/4 inch tubing to the 3/4 inch NPT drain connection on valve.
3) The drain line may be elevated up to 6 ft (1.8 m) providing the run does not exceed 15 ft (4.6 m) and water pressure at the conditioner is not less than 40 psi. Elevation can increase by 2 ft (61 cm) for each additional 10 psi of water pressure at the drain connector.
4) Where the drain line is elevated but empties into a drain below the level of the control valve, form a 7 inch (18 cm) loop at the far end of the line so that the bottom of the loop is level with the drain line connection. This will provide an adequate siphon trap. Where the drain empties into an overhead sewer, a sink-type trap must be used. Secure the end of the drain line to prevent it from moving.
Drain Line Connection
IMPORTANT NOTE
Never insert drain line directly into a drain, sewer line or trap. Always allow an air gap between the drain line and the wastewater to prevent the possibility of sewage being back-siphoned into the conditioner.
In the event of a malfunction, the BRINE TANK OVERFLOW will direct “overfl ow” to the drain instead of spilling on the fl oor. This fi tting is located on the side of the brine tank.
Do not elevate overfl ow line higher than overfl ow fi tting.
Do not tie into drain line of control unit. Overfl ow line must be a direct, separate line from overfl ow fi tting to drain, sewer or tub. Allow an air gap as per drain line instructions.
2-1
BRINE LINE CONNECTION
The brine line to the brine tank connects to the valve. Make the connections and tighten. Be sure that the brine line is secure and free from air leak. Even a small leak may cause the brine line to drain out, and the conditioner will not draw brine from the tank. This may also introduce air into the valve causing problems with valve operation.
ELECTRICAL CONNECTION
All AWS controllers operate on 12-volt alternating current power supply. This requires use of the supplied AC adapter.
Make sure power source matches the rating printed on the AC adapter.
AC ADAPTERS
IMPORTANT NOTE
The power source should be constant. Be certain the AC adapter is not on a switched outlet. Power interruptions longer than 8 hours may cause the controller to lose the time and day settings. When power is restored, the day and time settings must then be reentered.
CAMSHAFT
The front end of the camshaft has an indicator cup. The cup has slots in the outer periphery and numbers on the inside face.
The numbers can be seen with the cover off, from the front over the top of the controller. The number at the top indicates which regeneration cycle is currently in progress.
CAMSHAFT FRONT END
The corresponding slot for the number is positioned at the optical sensor which is approximately 90 degrees out of phase.
Regeneration Cycle Indicators
C0 = Treated Water - normal operation mode
C1 = Backwash Cycle
C2 = Brine Draw Cycle
C3 = Slow Rinse Cycle
C4 = System Pause
C5 = Fast Rinse Cycle 1
C6 = Backwash Cycle 2
C7 = Fast Rinse Cycle 2
C8 = Brine Refi ll
POWER LOSS MEMORY RETENTION
The AWS series controllers feature battery-free time and date retention during the loss of power. This is designed to last a minimum of 8 hours depending on the installation. The controller will continue to keep time and day in dynamic memory while there is no AC power.
The controller will not track water usage on volumetric demand controls in the event of a power failure.
All programmed parameters are stored in the static memory and will not be lost in the event of a power failure. These settings are maintained separately from the time and day settings.
MOTOR
The controller uses a standard 12-volt AC motor that works with either 50 Hz or 60 Hz. The same motor is used worldwide and does not need to be changed for different power conditions.
Information entered or calculated by the controller is stored in two different ways:
A static memory will store:
Time of regeneration
Days between regeneration
2-2
A dynamic memory with 8 hour retention will store:
Current day of week
IMPORTANT NOTE
Water fl ow to the valve can be turned on or bypassed when the controller is powered up for the fi rst time.
VARIABLE RESERVE FUNCTION
The AWS metered-demand volumetric controllers are designed to have a variable reserve feature. This feature automatically adjusts the reserve to the end-user’s water usage schedule.
A variable reserve saves salt and water by only regenerating when absolutely necessary, and ensures enough soft water for typical high-water usage days.
Each day of regeneration the controller reviews the last four weeks of water usage for the same day of the week to determine if the remaining capacity is adequate for the next day of the week. If not, it will initiate an automatic regeneration.
DISPLAY ICONS
IMPORTANT NOTE
In normal operation and during programming, only a few of the icons will actually be displayed.
1) Days of the week. The fl ag immediately below the day will appear when that day has been programmed as a day the system should regenerated (used with
7-day timer programming).
2) See #3
3) This cursor is displayed when the days between regeneration are being programmed (used with .5 to 99 day regeneration programming).
4) One of these cursors will be displayed to indicate which day will be programmed into the controller
5) “PM” indicates that the time displayed is between 12:00 noon and 12:00 midnight (there is no AM indicator). PM indicator is not used if clock mode is set to
24-hour.
6) When “MIN” is displayed, the value entered is in minutes increments.
7) When “LBS” is displayed, the value entered is in pounds.
8) When “Kg” is displayed, the value entered is in kilograms or kilograins.
9) Four digits used to display the time or program value. Also used for error codes.
10) Colon fl ashes as part of the time display. Indicates normal operation.
11) Locked/unlocked indicator. In Level I programming this is displayed when the current parameter is locked-out. It is also used in Level II programming to indicate if the displayed parameter will be locked (icon will fl ash) when controller is in Level I.
12) When “x2” is displayed, a second regeneration has been called for.
13) The recycle sign is displayed (fl ashing) when a regeneration at the next time of regeneration has been called for. Also displayed (continuous) when in regeneration.
14) The display cursor is next to “SALT” when programming the amount of regenerant.
15) The display cursor is next to “REGEN TIME & DAY” when programming the time of regeneration and the days of regeneration.
16) The display cursor is next to “TIME & DAY” when programming the current time and day.
17) The hourglass is displayed when the motor is running. The camshaft should be turning.
18) These cursors will appear next to the item that is currently displayed.
19) X100 multiplier for large values.
20) Not used.
21) Shows when water is fl owing through the valve.
2-3
22) Used with #23, #24, #25. Displays a sequence number or a value.
23) History Values. The number displayed by #22 identifi es which history value is currently displayed.
24) Parameter. Displayed only in Level II Programming. The number displayed by #22 identifi es which parameter is currently displayed.
25) Cycle. The number displayed by #22 is the current cycle in the regeneration sequence.
26) Hardness setting.
27) Capacity display — shows estimated system capacity.
KEYPAD - BUTTONS
1) DOWN arrow. Generally used to scroll down or increment through a group of choices.
2) SET. Used to accept a setting that normally becomes stored in memory. Also used together with the arrow buttons.
3) UP arrow. Generally used to scroll up or increment through a group of choices.
4) Regenerate. Used to command the controller to regenerate. Also used to change the lock mode.
PROGRAMMING CONVENTIONS
The controller is programmed using the buttons on the keypad. The programming instructions will be described two ways whenever a section has keypad input.
First, a table shows simplifi ed instructions. Second, text follows that describes the action. In each table:
“Action” lists the event or action desired.
“Keys” are listed as:
UP for up arrow
DOWN for down arrow
SET for set
REGEN for regeneration
“Duration” describes how long a button is held down:
P/R for press and release
HOLD for press and hold
X sec for a number of seconds to press the button and hold it down
“Display” calls out the display icons that are visible.
2-4
REGENERATION MODES
The AWS series controllers can be regenerated either automatically or manually. During a regeneration, the total time remaining of the regeneration, the total time remaining of the regeneration will be displayed on the controller. The current cycle is shown in the lower left of the display.
C0 = Treated Water - normal operation mode (not displayed)
C1 = Backwash Cycle
C2 = Brine Draw Cycle
C3 = Slow Rinse Cycle
C4 = System Pause
C5 = Fast Rinse Cycle 1
C6 = Backwash Cycle 2
C7 = Fast Rinse Cycle 2
C8 = Brine Refi ll
Regeneration Cycle Indicators
Advancing the Regeneration Cycles
Action
Show current cycle
Show regen time remaining
Advance to next cycle
Key
SET
SET
SET and UP
Duration
HOLD
HOLD
HOLD
Cx
Time
Cx
Display
To advance cycles during a regeneration (manual or automatic):
• Press and hold the SET button. The current cycle number, (Ex. C1) will be displayed along with the time remaining for that individual cycle.
• When holding the SET button, simultaneously press the UP button, and release to advance to the next cycle. While the motor is running, an hourglass icon will be displayed.
• Repeat this process for each cycle until the system is back into the treated water mode.
IMPORTANT NOTES
• When the controller gets to cycle C4 (Pause cycle), there may be a slight delay before the controller can be advanced onto cycle C5.
• Not all regeneration cycles may be used. A cycle will be skipped if it is not required by the current program.
Cancelling a Regeneration
Cancel regen
Action Key
SET and UP 5 sec.
Duration Display
Hourglass starts to fl ash
To cancel a regeneration (either manual or automatic):
• Press and hold the SET button and UP buttons simultaneously and hold until the hourglass icon starts fl ashing (approximately 5 seconds).
• The regeneration is cancelled.
• The camshaft rotates to the treated water position (may take up to 2 min.)
• Hourglass fl ashes while motor runs.
If a second regeneration was programmed (display shows a 2X by the regeneration icon) both regenerations must be cancelled separately.
IMPORTANT NOTES
• Cancelling a regeneration may cause undesirable or salty water to go into the plumbing. Only use this function when absolutely necessary.
• If the regeneration cycle is cancelled after the brine draw cycle (C2), check the water level in the brine tank. It must be refi lled to the proper level.
2-5
Action
Regen at next time of regen
Cancel regen
Immediate regen
Immediate double regen
Key
REGEN
REGEN
REGEN
REGEN
MANUAL REGENERATION
Duration
P/R
P/R when recycle icon is fl ashing
5 sec.
5 sec. when immediate manual regen has started
Display
Recycle icon fl ashes
Recycle icon disappears
Recycle icon appears
X2 icon appears
The controller can be manually instructed to perform a regeneration. There are two (2) choices: The controller will perform a delayed regeneration at the next time of regeneration (ex. 2:00 AM that night), or regenerate immediately.
For a delayed regeneration (at the next set time of regeneration):
• Push the REGEN button once. The recycle symbol will be fl ashing on the display. Push the REGEN button again to cancel.
For an immediate regeneration:
• Push and hold the REGEN button for fi ve (5) seconds. The display will show the regeneration symbol. The camshaft will start rotating to cycle C1.
For an immediate, double regeneration:
• After an immediate manual regeneration has begun, and the camshaft has rotated to cycle C1, you can initiate a second immediate manual regeneration.
• Press and hold the REGEN button for 5 seconds once the camshaft has begun cycle C1.
• The display will show a x2 icon indication that a second manual regeneration will occur after the current regeneration is completed.
2-6
STARTUP
IMPORTANT NOTE
The control valve can be started-up even if power is not yet available to the controller. The valve must be connected to water supply. The motor can be unmounted from the valve, and the camshaft can be indexed manually counterclockwise by hand. This will allow the tank to be fi lled and allows regenerant draw to be tested.
See Motor Removal in Maintenance and Service of this manual for further instructions.
1) Remove the cover from the valve. Removing the cover will allow you to see that the camshaft is turning, and in which cycle the camshaft is currently positioned.
2) With the supply water for the system still turned off, position the bypass valve to the “not in bypass” (normal operation) position.
3) Hold the REGEN button on the controller down for 5 seconds. This will initiate a manual regeneration.
The controller will indicate that the motor is turning the camshaft to the cycle C1 (Backwash) position by fl ashing an hourglass. The controller will display the total regen time remaining.
If you press and hold the SET button, the controller will indicate the time remaining in the current cycle.
4) Fill the media tank with water.
A) While the controller is in cycle C1 (Backwash), open the water supply valve very slowly to approximately the 1/4 open position
IMPORTANT NOTE
If opened too rapidly or too far, media may be lost out of the tank into the valve or the plumbing. In the 1/4 open position, you should hear air slowly escaping from the valve drain line.
B) When all of the air has been purged from the media tank (water begins to fl ow steadily from the drain line), open the main supply valve all of the way.
This will purge the fi nal air from the tank.
C) Allow water to run to drain until the water runs clear from the drain line. This purges any refuse from the media bed.
D) Turn off the water supply and let the system stand for about fi ve minutes. This will allow for any air trapped to escape from the tank.
5) Add water to the brine tank (initial fi ll).
A) With a bucket or hose, add approximately 2 gallons (8 liters) of water to the regenerant tank.
If the tank has a salt platform in the bottom of the tank, add water until the water level is approximately 1 inch (25 mm) above the platform.
IMPORTANT NOTE
We recommend that you do not put salt into the tank until after the control valve has been put into operation. With no salt in the tank, it is much easier to view water fl ow and motion in the tank.
Action
Display current cycle
Advance to next cycle
Advance to CO
SET
SET and UP
SET and UP
Key
5 Sec
P/R
5 Sec
Duration
Current Cycle
Next Cycle
CO
Display
6) Engage the refi ll cycle to prime the line between the brine tank and the valve.
A) Slowly open the main water supply valve again, to the fully open position. Be sure not to open too rapidly as that would push the media out of the media tank.
B) Advance the controller to the Refi ll Position. From cycle C1 (Backwash), press and hold the SET button. This will display the current cycle.
While pressing the SET button, press the UP arrow to advance to the next cycle. Continue to advance through each cycle until you have reached cycle C8 (Refi ll).
2-7
IMPORTANT NOTE
As you advance through each cycle there will be a slight delay before you can advance to the next cycle. The hourglass icon will light while the camshaft is indexing. There may be a pause at cycle C4 (System Pause). This cycle allows the water/air pressure to equalize on each side of the valve discs before moving on.
The hourglass will not be visible indicating that the system is paused.
C) With the water supply completely open, when you arrive at cycle C8 (Refi ll), the controller will direct water down through the line to the brine tank. Let the water fl ow through the line until all air bubbles have been purged from the line.
D) Do not let the water fl ow down the line to the tank for more than one to two minutes, or the tank may overfi ll.
E) Once the air is purged from the line, press the SET button and the UP button simultaneously to advance to cycle C0 (Treated Water) position.
7) Draw water from the brine tank.
Action
Advance to C1
Advance to C2
Key
REGEN
SET and UP
Duration
5 Sec
P/R
Display
REGEN icon steady, C1 and time remaining
REGEN icon steady, C2 and time remaining.
A) From the treated water position (cycle C0), advance the valve to the brine draw position. Hold the REGEN button down for 5 seconds.
The controller will begin a manual regen, and advance the control valve to the cycle C1 (Backwash). Press the SET and UP button to advance to cycle C2
(Draw).
B) With the controller in this position, check to see that the water in the brine tank is being drawn out of the tank. The water level in the tank should recede very slowly.
C) Observe the water being drawn from the tank for at least three minutes. If the water level does not recede, or goes up, reference the Troubleshooting section.
8) If the water level is receding from the tank you can then advance the controller back to the treated water (C0) position by pressing SET and the UP buttons simultaneously to advance the controller to the C0 position.
9) Before loading salt add enough water back to the brine tank to cover the salt grid by approximately one (1) inch. Then add initial salt fi ll to brine tank, and one cup full of unscented laundry bleach to the brine well.
10) Put softener through a complete regeneration - to sanitize the system before use (refer to previous section for instructions on manual regeneration).
11) Finally, after the regeneration is complete, turn on a faucet plumbed after the water conditioner. Run the faucet until the water runs clear.
Installation is now complete, and your water softener is now ready for service!
2-8
SECTION 3: PROGRAMMING
THINGS YOU MIGHT NEED TO KNOW
• When the controller is fi rst plugged in, it may display a fl ashing hourglass and the message Err 3, this means that the controller is rotating to the home position.
If the Err 2 is displayed, check that the incoming power frequency matches the controller. See the Troubleshooting section of this manual.
• The preset default time of regeneration is 2:00 AM. If you want to change it, see the Level II Programming section.
• The controller can be programmed to regenerate on specifi c days of the week. See Level II Programming section.
• If electrical power is not available, the camshaft can be rotated to the left by hand if the motor is removed. See Motor Removal in the Maintenance section.
• The controller sends commands to the motor for camshaft movement. However, water pressure/fl ow are required during the regeneration cycle for backwash, purge and refi ll, and brine draw to actually take place.
• Make sure control power source is plugged in. The transformer should be connected to a non-switched power source.
PROGRAMMING
The controller is designed to operate by only setting the time of day and the day of the week. The remaining settings have been set at the factory. These default settings will work for most applications.
The controller menu has three levels:
Level I Basic — This level is easily accessed by the user. The settings can be changed and saved as long as they are not locked.
Level II Professional — This level allows the installer to lock settings. The locked settings are viewable in the basic level but cannot be changed.
History Level — The operation history and the program are viewable. This information is used to troubleshoot and maintain the system.
BASIC PROGRAMMING
IMPORTANT NOTES
If a button is not pushed for thirty seconds, the controller returns to normal operation mode. Pushing the regenerate button immediately returns the controller to normal operation.
Any setting that is a time display will not show “AM” for times between 12:00 midnight and 12:00 noon. “PM” is displayed to the right of the time for times between 12:00 noon and 12:00 midnight. When using the 24 hour clock “PM” is not displayed.
3-1
To change a setting:
Action
Enter basic programming
Move to desired display
Key
SET
UP and DOWN arrows
Enable setting to be changed
Change setting
SET
UP and DOWN arrows
Save setting SET
Return to operation REGEN
This level of programming is accessible by pressing the SET button.
The UP and DOWN arrows will step through the settings.
Time of day
Day of week
Time of regeneration
Number of days between regeneration (99 day calendar override timer)
Amount of salt used per regeneration
Duration
P/R
P/R
P/R
P/R
P/R
P/R
Display
Will show day of week
Will increment through the displays
Display will fl ash
Value changes and
Display stops fl ashing
Normal operation display
Hardness
To make changes:
• Time of day
When the Time of Day is displayed, push SET. The time will fl ash. Use the arrow buttons to increase/decrease the time. Push SET to enter the selection.
• Days of the week
The day of the week does not have a default setting. It is entered at Power-up. To change the current day, push SET when day of week is displayed. A fl ag will fl ash beneath the current day. Use the arrow buttons to change. Push SET to enter the selection.
• Time of Regeneration
This is set for 2:00 AM as the default. The controller does not account for daylight savings time.
To change this setting, push SET. Use the arrow buttons to increase/decrease the time. Push SET to enter the selection.
3-2
• Calendar override
The controller can be programmed to regenerate automatically from a 1/2 day to a 99 day frequency.
The 1/2 day regeneration mode will regenerate at the “time of regeneration,” as well as 12 hours opposite from that time. For example, the controller will regenerate at 2:00 AM and at 2:00 PM on the same day.
The default setting is 12 days. To change, push SET when this setting is displayed. Use the arrow buttons to increase/decrease. Push SET to enter the selection.
IMPORTANT NOTES
Setting days between regeneration to zero will cause the system to not regenerate. This setting is used for selecting regeneration on specifi c days or to use with a remote regeneration input. See below.
Regeneration on specifi c day is used to provide regeneration when water demands are not steady. Example: If the weekdays have low usage and the weekend is high, then regeneration every three days will not meet the requirements.
• Amount of salt used per regeneration
The controllers are setup to automatically calculate the capacity of the system by multiplying the resin/media volume that was entered earlier into the controller, with the salt amount entered by the dealer/installer. This eliminates the need for salting effi ciency tables.
The default setting is L (Low Salt).
To enable the most simple programming possible, the dealer/installer has three salt amount options to choose from. These are set up to give the installation the maximum performance based on the inputs by the dealer/installer. The three salt options are:
High Salt — This setting gives the installation the highest capacity possible for that resin volume. This is a great setting for applications with very high hardness, many occupants or for applications where the dealer wants to provide that the application supplies soft water. This setting may tend to use less water over the course of a year, because it generally needs to be regenerated less often. This setting is displayed as an “H”.
Standard Salt — This setting fi ts most applications around the world. It gives you an effi cient use of salt, while maintaining a large enough capacity to regenerate every three days for most applications. This setting is displayed as an “S”.
Low Salt — This setting is provided to give your installation the maximum effi ciency of salt usage, as measured in grains of hardness softened per pound of salt used
(grains of CaCo3 reduced per pound of salt used). This setting is useful for markets where highly effi cient conditioners are expected or required by the consumers or law. This setting is displayed as an “L”.
IMPORTANT NOTE
SODIUM INFORMATION: Water softeners using sodium chloride for regeneration add sodium to the water. Persons who are on sodium restricted diets should consider the added as part of their overall sodium intake.
3-3
The following tables show the estimated salt amount for each setting, as well as the estimated capacity of that salt setting for each resin amount.
Media Volume
1.0
1.5
2.0
2.5
3.0
Salt Setting
L (Low)
S (Standard)
H (High)
L (Low)
S (Standard)
H (High)
L (Low)
S (Standard)
H (High)
L (Low)
S (Standard)
H (High)
L (Low)
S (Standard)
H (High)
L = Low salt, approximately 3.3 lbs. per cu. ft. of media
S = Standard salt, approximately 9 lbs. per cu. ft. of media
Total Salt Amount per Regeneration (lbs)
3.5
9
15
5
13.5
22.5
6.5
18
30
6.5
18
30
10
27
45
H = High salt, approximately 15 lbs. per cu. ft. of media
To program the salt amount, press the SET button to enter the change mode. The L default will begin to fl ash. Use the UP and DOWN arrow keys to scroll through the three settings. Press the SET button to enter the amount.
• Capacity
The controller is designed to estimate capacity of the system by multiplying the initial resin/media volume by the regenerant amount programmed in under “Amount of regenerant used per regeneration.”
An estimated total system capacity is displayed in kilograins (kilograms CaCO3) that could be removed by the fully regenerated media bed. This value is derived by standard water treatment industry norms. The system capacity is displayed merely for the installers reference when determining regeneration frequency.
NOTE: Capacity is the result of the amount of media in the tank and the salt setting. The default capacity will be changed by selecting a different salt setting.
• Hardness setting
The hardness setting is set in grains per gallon (CaCO3). The hardness is divided into the total capacity setting, giving a total volume of water that can be conditioned before a regeneration is needed. To set, press SET when P8 is displayed, and use the UP or DOWN buttons to increment. Press SET again to accept the setting.
HISTORY LEVEL
This level displays settings and usage information that can be used to diagnose and troubleshoot the system.
To enter the history level:
Enter data mode
Action
Scroll through history
Reset value to factory default
Key
DOWN arrow and SET
UP and DOWN arrows P/R
SET
Duration
5 sec.
P/R
5 secs. with value is displayed
Display
Value for H0
Next history value
Original factory default
3-4
H6
H7
H8
H9
H10
H11
H12
H13
H3
H4
H5
H0
H1
H2
History Data
Description
Resin volume initial setting value
Days since last regeneration
Current fl ow rate
Water used today in gallons since Time of Regeneration
Water used since last regeneration in gallons
Total water used since reset in 100s
Total water used since reset in 1,000,000
Average usage for Sunday in gallons
Average usage for Monday in gallons
Average usage for Tuesday in gallons
Average usage for Wednesday in gallons
Average usage for Thursday in gallons
Average usage for Friday in gallons
Average usage for Saturday in gallons
Range cubic feet
0-255
0-47 gpm
0-65536 gallons
0-65536 gallons
0-65536 gallons
0-65536 gallons
0-65536 gallons
0-65536 gallons
0-65536 gallons
0-65536 gallons
0-65536 gallons
0-65536 gallons
0-65536 gallons
When in history values mode a small “H” will be displayed in the lower left corner of the display. Next to the “H” will be the number that applies to the history value.
H0 — System Resin Volume Setting
The history value H0 displays the initial resin volume setting (programmed when the system was fi rst set up). If the value is incorrect and needs to be reset, press and hold the SET button for fi ve seconds to reset the controller.
IMPORTANT NOTE
Resetting the resin volume resets the entire controller back to the factory default. Only use if absolutely necessary. The control will need to be completely reprogrammed.
3-5
SECTION 4: SERVICE INSTRUCTIONS & MAINTENANCE
VALVE SERVICE
COVER
The cover provides protection for the controller, wiring, and other components. This cover will be removed for most service and maintenance.
When installed, the cover provides NEMA 3 water protection. This protects from falling water up to 30 degrees from vertical.
To remove cover:
1) Grasp side edges toward rear of the valve.
2) Pull outwards until the slots in the cover clears the projections on the top plate.
3) Lift up on the rear and pull forward to clear the control module.
To install cover:
1) Position cover to be low in front and under the bottom edge of the control module.
2) The cover will hook on the bottom of the controller and drop down over the camshaft.
3) To fi nish, grasp the side edges and pull outward to clear the projections on the top plate.
4) Drop down until the cover snaps in place.
ELECTRONIC CONTROL MODULE
The purpose of the electronic control module is to control the regeneration cycle. The control module has several variations. When replacing the controller, use the same model or some functions may not work. This is an electronic controller that is programmable and uses input/output signals.
To remove control module:
1) Disconnect power to the unit.
2) Remove valve cover.
3) Press trip lever to release module from top plate.
4) Pivot the top forward and up.
5) Remove any wire connections. Wire connections have a locking tab that must be squeezed before removing.
NOTE: There is no need to label the wires. The keyed connectors will only plug back into one site.
To install control module:
1) Be sure the power is disconnected.
2) Check model.
3) Check routing of wires and plug them into the controller. Connectors will snap in place. Be sure that wires are properly managed through the clips on top plate.
This will prevent the wires from being caught in the camshaft.
4) Place bottom of module in position. The bottom will fi t into a clip.
5) Pivot the top into position and snap in place. The controller should be secure.
If you are ready to program the controller, then power can be applied by plugging in transformer.
4-1
DRIVE MOTOR
The drive motor is open loop and receives commands from the control module. The motor has a pinion gear that meshes with the camshaft gear to drive (rotate) the camshaft.
During operation, rotation forces the motor into its mounting position and screws or bolts are not needed.
NOTE: Some units will have a shipping peg in the top motor mount. The peg can be removed and discarded. This peg is not required for motor operation.
To remove motor:
1) Disconnect power to the unit.
2) Remove cover.
3) Pull off wiring connector.
4) Grasp the motor body and rotate to the left.
5) Pull motor out.
To install motor:
1) Insert gear through hole on top plate
2) With motor ears fl at to the rear of the top plate, rotate to the right until mounting tabs are engaged in slots.
3) Reconnect wires.
NOTE: It is not necessary to pre-position the camshaft or the motor. When the controller is powered up the camshaft will be rotated to the “home” position.
OPTICAL SENSOR
The optical sensor is mounted to the top plate. The camshaft cup rotates through the sensor and the slots are detected. A signal is sent to the controller for each slot.
IMPORTANT NOTE
Damaged sensors should be replaced. Sensors may be cleaned with compressed air or a soft brush.
To remove optical sensor:
1) Disconnect power to the unit.
2) Remove cover.
3) Remove controller.
4) From the controller side, pinch the legs of the sensor holder in the top plate.
5) Pull the holder away from the mounting surface.
6) Remove wires.
To install optical sensor:
1) Attach wires. Wires should point away from camshaft.
2) Place leading edge of sensor holder into opening.
3) Pivot holder into place. Legs should enter slots and snap in place.
IMPORTANT NOTE
The optical sensor legs are fragile and may break. If the optical sensor legs break or crack, we recommend replacement. A damaged sensor may result in improper regeneration.
4-2
CAMSHAFT
The camshaft has several lobes that push open the valve discs as the camshaft rotates. Rotation is controlled by a drive motor that drives a gear at the rear of the camshaft. The front end has a cup with markings and slots.
IMPORTANT NOTE
The camshaft slots are molded to exact dimensions. Do not attempt to modify the cam cup slots. Improper regen will occur!
The outside surface of the cup has an arrow mark. When the arrow is at top center, the camshaft is in the loading position. 90 degrees to the right on the cup an optical sensor is mounted to the top plate. This sensor reads the slots as they pass through.
The largest slot is “Home” and the remaining slots are positioned to signal the regeneration cycles.
When looking at the end of the camshaft, numbers are visible in the hollow of the cup. An arrow on the top plate points to the current marking. The numbers represent regeneration cycles as follows:
C0 = Treated water - normal operation mode
C1 = Backwash
C2 = Brine draw
C3 = Slow Rinse
C4 = System pause
C5 = Fast rinse cycle 1
C6 = Backwash cycle 2
C7 = Fast rinse cycle 2
C8 = Brine refi ll
These numbers are offset rotationally 90 degrees from the matching slot. The offset enable the service person to view the number at the top of the cup and determine which slot is at the optical sensor.
IMPORTANT NOTE
If any part of the camshaft is broken or damaged the camshaft should be replaced. Do not repair or modify damaged cam lobes, gears or timing cup.
To remove camshaft:
1) Disconnect power to the unit.
2) Remove cover.
3) Remove motor.
4) Camshaft should be in the treated water position. Rotate to the left as needed.
5) Use a screwdriver to hold open the #1 valve disc.
IMPORTANT NOTE
When replacing/removing camshaft, make sure not to damage or misalign the optical sensor. Hold the sensor in position while removing camshaft.
6) Move the camshaft backwards, away from the controller.
7) Lift the loose front end up and out.
To install camshaft:
1) Check that the optical sensor is in position.
2) Position camshaft above the valve discs. The arrow on the cup should be up.
3) Slide the rear of the camshaft into place.
4) Pivot the camshaft close to its fi nal position. The camshaft will push on one or more valve discs. You will feel resistance as you complete the installation.
5) Move the camshaft down and into position. Force valve discs to move as needed.
6) Move the camshaft forward. Check that the optical sensor is in position.
7) Install motor.
NOTE: The camshaft will position itself to C0 (treated water) when the controller is powered up.
4-3
WIRING HARNESSES
The wiring harnesses are designed to fi t one way. The connectors are unique to the port they plug into. The wires are held in place by clips and the connectors latch in place.
To remove a wiring harnesses:
1) Disconnect power to the unit.
2) Remove cover.
3) Remove controller.
4) Remove connections by squeezing the latch on the connector and pulling out.
5) Pull the harness out of the clips on the top plate.
To install a wiring harness:
IMPORTANT NOTE
Start at the back of the valve and work toward the controller. This will place any slack behind the controller. Slack or loose wires can become tangled in the camshaft.
1) Depending on which harness is being installed, plug the connector into the motor or turbine.
2) Route the harness through the opening at the back of the top plate.
3) Place the harness into the clips on the top plate. Do not leave any slack. Put the motor wire in fi rst, then the turbine sensor cable second.
4) Feed the wire through the opening on the front of the top plate.
5) If installing the motor harness the connector to the optical sensor can be clipped in place.
6) Connect the harness to the back of the controller.
NOTE: If using both a motor and turbine cable harness, install the smaller motor cable fi rst. Install the larger turbine cable second. This will lock the motor cable beneath in the wire management clips.
4-4
SPRING (VALVE DISCS)
This spring is a one-piece metal spring that applies pressure to the valve discs holding them closed. The rotating camshaft overcomes this pressure to open the valve discs as needed. The shape of the spring is critical for proper operation.
IMPORTANT NOTE
Do not attempt to straighten or repair this spring. If this spring is damaged, valve discs may not operate correctly.
To remove spring:
1) Disconnect power to the unit.
2) Remove cover.
3) Remove motor.
4) Remove camshaft.
5) Place unit in bypass.
6) Release water pressure by pushing the last valve discs open with a screwdriver.
7) Locate valve discs 3, 4 and 5.
8) Position yourself on the spring side of the valve discs.
9) Place two (or more) fi ngers on the fl at part of the spring.
10) Move the fi ngers toward the valve discs and into the spring valley between the previously located valve discs.
11) By pulling back and up on the spring, the spring will pop out of the valley.
12) Pull back further to remove the spring.
To install spring:
1) Inspect the spring for damage. Do not attempt to repair a bent spring.
2) Position yourself on the spring side of the valve discs.
3) Position the spring over the valve body close to fi nal position. The wide spring segments will be located at the wide valve discs. The curve of the spring will be down into the valve.
The long fl at close edge is inserted fi rst. This edge slides into a channel on the valve body.
The spring will slide off the top of the valve disc downward. The small projection on the end of the spring will drop into the hole in the valve disc to provide secure positioning. Repeat for all spring segments.
NOTE: If a spring segment goes beyond the locating hole, it can be pulled back using a small fl at blade screwdriver.
NOTE: In high pressure (80 psi and higher) applications, the standard single valve disc springs can be installed on top of the one piece spring.
4) Rock the spring back and place the fl at edge into the channel.
5) Lower the springs until they rest on top of the valve discs.
A tool (Phillips screwdriver) will be needed to push the springs in place.
The spring posts will guide the spring into place.
6) Hold the fl at part down with one hand.
7) Spread your fi ngers apart to cover the length and push down.
8) With the other hand use the tool to push down in the valley of each spring segment.
4-5
TOP PLATE
The top plate holds the valve discs in place during operation. This plate is removed to allow cleaning and replacing the valve discs.
IMPORTANT NOTE
The valve discs are made from a chloramine resistant severe service rubber. The valve discs will usually not need to be changed. Before removing the top plate for valve disc service be certain that one of the discs is not operating correctly.
To remove top plate:
1) Disconnect power to unit.
2) Remove cover.
3) Remove motor.
4) Remove camshaft.
5) Place unit in bypass.
6) Release water pressure by pushing the last valve disc open with a screwdriver.
7) Any optional items may be removed.
8) Wiring harnesses should be removed.
9) Remove valve disc spring.
10) Use a Phillips screwdriver to remove the screws from the top plate.
11) Lift the top plate off. All the valve discs can be pulled straight out.
Inspect valve discs for wear. The sealing surface is the raised ridge on the underside of the top shoulder.
Check each valve disc cavity in the valve for debris. Remove any foreign objects before replacing the valve disc.
To install valve discs:
NOTE: If the valve disc fi ts properly in the cavity, it will work correctly.
1) Put the valve disc into the correct (based on shoulder size) valve port cavity. The metal end without rubber coating should be visible.
2) Push down on the shoulder to position the valve disc completely into the port cavity.
The metal portion will be positioned straight up and the top of the shoulder will be level with the valve.
To install the top plate:
NOTE: All valve discs should be in position. Use the same screws that were removed to reassemble the top plate.
IMPORTANT NOTE
Follow the procedure to engage the screws with the existing threads. If the same threads are not used, the holding power of the screw is lost. Under pressure the valve can leak. Screws that have the same diameter but have different threads should not be used.
1) Position the top plate on top of the valve and over the valve discs.
2) Insert a screw at one of the corner positions.
IMPORTANT: This procedure for reinserting screws must be followed to ensure proper holding strength of the screws.
A. Drop screw of same size and thread into the hole.
B. Use a Phillips screwdriver and lightly rotate the screw backwards
C. When the thread of the screw and thread of the hole match, the screw will “click” and slightly drop down.
D. The threads are lines up. Lightly rotate the screw to tighten and engage threads.
E. Once the threads have engaged the screw can be tightened. Minimal resistance will be present as the screw is turned in. Resistance indicates new threads are being formed. Back the screw out and rematch the threads.
3) Turn the screw in but do not tighten.
4-6
4) Place a second screw into the hole diagonally opposite the fi rst screw and turn in but do not tighten.
5) Insert another screw into one of the remaining corners and turn it in.
6) The fourth screw goes into the hole diagonally opposite. Turn it in.
7) Put the remaining screws in following the same crisscross pattern working from the ends toward the center. When all the screws are in place they can be tightened down.
8) Start at the corner of the screw pattern and tighten that screw. Work the same pattern from the ends toward the center and crisscrossing as each screw is tightened. Check that each valve disc moves smoothly before replacing the spring and camshaft.
9) Replace spring.
10) Replace camshaft and motor.
11) Replace controller and wiring harnesses.
MAINTENANCE
IMPORTANT NOTE:
Many of the maintenance procedures involve o-rings. When reassembling two parts with an o-ring seal, care must be taken with the placement of the o-ring. To properly install o-rings, they should be lightly lubricated with silicone. Place the o-ring over the part feature that will be inserted into the hole. Do not start the assembly with the o-ring in the hole.
PREVENTIVE MAINTENANCE
Injector Screen and Injector
Inspect and clean brine tank and screen fi lter on end of brine pickup tube once a year or when sediment appears in the bottom of the brine tank.
Clean injector screen and injector once a year.
1) Unplug the wall-mount transformer.
2) Remove cover. Shut off water supply or put bypass valve(s) into bypass position.
3) Relieve system and valve pressure by using a screwdriver to press valve disc #7 slightly open. The pressure will escape quickly.
4) Using a T-50 torx driver (recommended), or large fl at blade screwdriver, remove injector screen and injector cap.
5) Clean injector screen using a fi ne brush. Flush under running water until clean.
6) Using a needle-nose pliers, pull injector straight out.
7) Flush water into the injector screen recess of the valve body to fl ush debris out through the injector recess.
8) Clean and fl ush the injector with water. Inspect for any debris in the venturi.
9) Lubricate the o-rings on the injector, injector cap and injector screen with silicone lubricant only!
10) Reinstall the injector, injector cap and injector screen. Be careful not to crimp or bend the o-rings.
CAUTION
To reduce the risk associated with property damage due to water leakage:
• Do not use a torch or other high temperature sources near fi lter system, cartridges, plastic fi ttings or plastic plumbing.
• On plastic fi ttings, never use pipe sealant or pipe dope. Use PTFE thread tape only, pipe dope properties may deteriorate plastic.
• Take care when using pliers or pipe wrenches to tighten plastic fi ttings, as damage may occur if over tightening occurs.
11) Plug the wall-mount transformer into outlet; reset clock if necessary.
12) Slowly open water supply valve or return bypass valve(s) to the “service” position.
4-7
WATER METER MAINTENANCE
Demand Systems
The valve metering devices are used with the demand controls, and may require simple maintenance. In rare instances, the turbine wheel of the water meter can collect small particles of oxidized iron, eventually preventing the wheel from turning.
1) Shut off the water supply or put the bypass valve(s) into the bypass position.
2) Relieve pressure by opening the backwash drain valve (the seventh back from the controller) with a screwdriver.
3) Loosen and remove the pipe/tube adapters or bypass from the inlet and outlet of the valve body.
4) Using a needle-nose pliers, remove the turbine from the outlet housing. Grasp one of the four vanes of the outer gland and pull straight out to remove turbine assembly from the outlet of the valve.
5) Carefully remove the turbine wheel from the housing. Use a toothbrush to lightly scrub debris or iron off the magnet. Iron build-up on the surfaces can be reduced by soaking the wheel in mild sodium hydrosulfi te (such as Iron-X) solution for a few minutes. Flush thoroughly with water.
6) Carefully reinstall the turbine wheel into the turbine cage housing. Make sure that the shaft of the wheel seats into the bearing of the cage. Reassemble the turbine cage and check that the wheel rotates freely.
7) Reinstall the turbine cage into the outlet of the valve.
8) Reinstall the pipe/tube adapters or bypass to the inlet and outlet of the valve.
9) Turn on the water supply or put the bypass valve(s) into the service position and purge the air out of the system.
10) The system will require the startup procedure to be performed in order to operate appropriately.
CHECK TURBINE OPERATION
After the turbine has been cleaned, verify that the turbine is accurately working. Repressurize the conditioner system, and verify that the controller is plugged in.
Completely turn on a faucet that is plumbed after the conditioning system. After a few seconds, the display should be fl ashing a small faucet icon with water drops.
If this is fl ashing, the turbine is operating properly.
If the faucet icon does not fl ash, then the system may have a faulty turbine probe cable wire harness. Replace that harness and repeat the steps above for checking for turbine operation.
REFILL FLOW CONTROL
If the brine tank is not refi lling correctly (too much or too little water) the refi ll fl ow control should be cleaned and inspected.
To clean the refi ll fl ow control:
1) Place unit in bypass. Relieve water pressure by pushing open one of the last two valve discs.
2) Remove cap.
3) Pull refi ll fl ow control parts out.
4) Inspect parts for damage.
5) Flush with water and clean with soft brush.
6) Replace refi ll fl ow control parts.
7) Replace cap (hand tight).
DRAIN FLOW CONTROL
If the unit is not supplying conditioned water for as long as when it was fi rst setup, then the drain fl ow control should be cleaned.
To clean the drain fl ow control:
1) Place unit in bypass. Relieve water pressure by pushing open one of the last two valve discs.
2) Remove the drain fl ow control and ball.
3) Inspect parts for damage.
4) Flush with water and clean with soft brush.
5) Orifi ce should be open not plugged.
6) Replace ball and drain fl ow control (hand tight).
4-8
AFTER SERVICE START-UP
Whenever the controller is unplugged or the system is put in bypass for maintenance, a start-up is required. This start-up is not normally as extensive as the new system start-up procedure needs to be followed.
The initial power-up procedure should be used if a new controller or a new valve has been installed. This procedure is explained in the users manual.
The following service start-up procedure can be used when the controller was programmed prior to servicing the unit and removing power. The unit should be fully assembled with the cover off.
To start-up after service:
1) Plug the transformer into the controller. Resin/media volume should not need to be entered. If the display is fl ashing three dashes and a decimal point, contact the factory.
2) Set time of day and day of week if necessary.
NOTE: Time of day and day of week settings are stored in a temporary memory and will be maintained at least 8 hours.
The display will fl ash four dashes and a colon if the time of day needs to be set. If the display shows the correct time, proceed to step 5.
3) The UP and DOWN arrows are used to set the time of day. When the correct time is displayed push SET. If using the 12 hour setting PM will be displayed behind the time. AM is not designated.
4) Use the UP and DOWN arrow buttons to move a small fl ag (box) at the top of the display under the day of the week. When the correct day is fl agged push SET.
The controller is ready to operate. The media tank should be ready for operation.
5) Hold the REGEN button on the controller down for fi ve seconds. This will initiate a manual regeneration. The controller will indicate that the motor is turning the camshaft to the C1 cycle (Backwash) position. The display will show the total regen time remaining and the hourglass will fl ash when the motor is running.
6) Open the supply valve to the 1/4 open position. Any air in the media tank and valve will escape from the valves’ drain line.
7) Open supply valve to full open.
8) Advance the controller to the Refi ll Position. From cycle C1 (Backwash), press and hold the SET button. This will display the current cycle. Press the UP arrow to advance to the next cycle.
Continue to advance through each cycle until you have reached cycle C9 (Refi ll).
NOTE: As you advance through each cycle there will be a slight delay before you can advance to the next cycle. The hourglass icon will fl ash while the camshaft is indexing to each cycle. There may be a pause at cycle C4 (System Pause). This cycle allows the water pressure to equalize on each side of the valve discs before moving on to the next cycle. The hourglass will fl ash indicating that the system is paused.
9) Allow a small amount of water to fl ow into the brine tank. Press SET and UP buttons simultaneously to advance to the treated water position.
10) Turn on a faucet and run the water until it is clear.
The unit is ready for operation.
4-9
SECTION 5: PERFORMANCE DATA SHEET
M O D E L
Rated Service Flow Rate
Pressure Drop at Rated Service Flow Rate (psi)
Rated Softening Capacity (Grains / Pounds of Salt)
Low Salt Setting
Standard Salt Setting
High Salt Setting
Efficiency at factory (Low) Salt Setting
11.2
15
A W S 1 0 0 M
15,115 @ 3.5#
27,403 @ 9#
29,456 @ 15#
4,319
14
15
A W S
22,053 @ 5#
41,432 @ 13.5#
44,536 @ 22.5#
4,411
1 5 0 M
Water Softeners
15
A
12.7
W S 2 0 0 M
28,864 @ 6.5#
55,243 @ 18#
59,381 @ 30#
4,441
14
15
A W S 2 5 0 M
31,059 @ 6.5#
61,044 @ 18#
71,640 @ 30#
4,778
A
17
15
W S 3 0 0 M
44,106 @ 10#
82,864 @ 27#
89,072 @ 45#
4,411
Minimum / Maximum Working Pressure (PSI)
Minimum / Maximum Operating Temperature (°F)
Maximum Flow Rate (gpm) to Drain During
20 – 100
34 – 100
20 - 100
34 -100
20 - 100
34 – 100
20 - 100
34 - 100
20 - 100
34 - 100
1.6 2.5 2.5 3.5 4.8
Regeneration Cycle
Nominal amount of High Capacity Resin (Cu. Ft.) 1
Mineral Tank Dia. x H, in (cm) 8 x 44
(20 x 112)
Overall Height D x H with valve, in. (cm)
Brine Tank, W x D x H, in. (cm)
15 x 51
(38 x 130)
15 x15 x 34
(38 x 38 x 86)
Approx. Salt Storage, lbs. (kg)
With Salt Grid Leg Extensions
Without Salt Grid Leg Extensions
135 (61)
180 (81)
1 ½
10 x 44
(25 x 112)
15 x 51
(38 x 130)
15 x15 x 34
(38 x 38 x 86)
135 (61)
180 (81)
2
10 x 54
(25 x 137)
15 x 51
(38 x 130)
15 x15 x 34
(38 x 38 x 86)
135 (61)
180 (81)
2 1/2
12 x 54
(30 x 137)
15 x 61
(38 x 155)
15 x15 x 34
(38 x 38 x 86)
135 (61)
180 (81)
3
14 x 65
(36 x 165)
15 x 72
(38 x 183)
18 x 33
(46 x 84)
300 (136)
300 (136)
Approx. Ship Weight, lbs., (kg) 102 (46) 130 (59) 130 (59) 193 (87) 284 (129)
This softener has been tested and certified by the Water Quality Association according to NSF/ANSI 44 for the specified performance claims as verified and substantiated by test data. These models are efficiency rated. The efficiency rating is valid only at the stated salt dose and flow rate. They have demand initiated regenerated (DIR) feature that complies with specific performance specifications intended to minimize the amount of regenerant brine and water used in their operation. These softeners have a rated efficiency of not less than 3350 grains of total hardness exchange per pound of salt (based on sodium chloride) and shall not deliver more salt than their listed ratings. The rated salt efficiency is measured by laboratory test described in NSF/ANSI Standard 44. These tests represent the maximum possible efficiency that the systems can achieve. Operational efficiency is the actual efficiency after the system has been installed. It is typically less than the efficiency due to individual application factors including water hardness, water usage and other contaminants that reduce the softener’s capacity. These systems are not intended for use with water that is microbiologically unsafe or of unknown quality without adequate disinfection before or after the system. For best results, use any type of salt made for a water softener, with the exception of block salt. Refer to other sections in the manual for warranty details on installation, parts and service, maintenance and further restrictions or limitations to the use of the product.
Tested and Certified by the Water Quality Association according to NSF / ANSI Standard 44
5-1
SECTION 6: TROUBLESHOOTING
1.
2.
3.
4.
PROBLEM
ERR 1 displayed
ERR 2 displayed
ERR 3 displayed
Brine tank overfl ow.
CAUSE
A.
Controller power has been connected and the control is not sure of the state of operation.
A.
Controller power does not match 50 or 60 Hz.
A.
SOLUTION
Press the UP arrow and the control should reset.
A.
Controller does not know the position of the camshaft. Camshaft should be rotating to fi nd home position.
A.
Camshaft is not turning during ERR 3 display
A.
Disconnect and reconnect the power.
B.
If problem persists, obtain the appropriate controller for either 50 or 60 Hz power.
A.
Wait for 2 minutes for the controller to return to HOME position.
The hourglass should be fl ashing on the display indicating the motor is running.
A.
Check that motor is connected
A.
If camshaft is turning for more than 5 minutes to fi nd HOME position.
B.
Verify that motor wire harness is connected to motor and the controller module.
C.
Verify that optical sensor is connected and in place.
D.
Verify that motor gear has engaged cam gear.
E.
If everything is connected, try replacing in this order:
- Wire harness
- Motor
- Optical sensor
- Controller
A.
Verify that optical sensor is in place and connected to wire.
B.
Verify that camshaft is connected appropriately. Verify that no dirt or rubbish is clogging any of the cam slots.
C.
If motor continues to rotate indefi nitely, replace the following components in this order:
- Optical sensor
- Wire Harness
- Motor
- Controller
A.
Remove brine control to clean ball and seat.
A.
Uncontrolled brine refi ll fl ow rate.
B.
Air leak in brine line to air check.
B.
Check all connections in brine line for leaks. Refer to instructions.
C.
Drain control clogged with resin or other debris.
C.
Clean drain control.
A.
Valve stem return spring weak.
A.
Replace spring.
5.
Flowing or dripping water at drain or brine line after regeneration.
6.
Hard water leakage after regeneration.
A.
Improper regeneration.
7.
8.
Control will not draw brine.
Clock does not display time of day.
B.
F.
A.
B.
C.
Leaking of external bypass valve.
C.
O-ring around riser pipe damaged.
A.
Low water pressure.
B.
Restricted drain line.
C.
Injector plugged.
D.
Possible problem with injector.
E.
Air check valve closes prematurely.
Valve disc 2 and/or 3 not closed.
Transformer cord unplugged.
Problem with transformer.
Problem with circuit board.
A.
Repeat regeneration after making certain correct salt dosage was set.
B.
Replace bypass valve.
C.
Replace o-ring.
A.
Set pump to maintain 20 psi at softener.
B.
Change drain to remove restriction.
C.
Clean injector and screen.
D.
Replace injector.
E.
Put control momentarily into brine/slow rinse. Replace or repair air check if needed.
F.
Remove foreign matter from disc and check disc for closing by pushing in on stem. Replace if needed.
A.
Connect power.
B.
Replace transformer.
C.
Replace timer.
6-1
9.
10.
Clock does not display correct time of day.
No water fl ow display when water is fl owing.
A.
B.
Electrical outlet operated by switch.
Incorrect voltage or frequency (Hz).
C.
Power outages.
A.
Bypass valve in bypass.
B.
Meter probe disconnected or not fully connected to meter housing.
C.
Restricted meter turbine rotation due to foreign material in meter.
D.
Problem with meter probe.
E.
Problem with circuit board.
A.
Electrical cord or transformer unplugged.
B.
Problem with motor.
A.
Use electrical outlet not controlled by switch.
B.
Replace timer with one of correct voltage and frequency (Hz)
(Contact Dealer).
C.
Reset clock.
A.
B.
Shift bypass valve to not-in-bypass position.
Fully insert probe into meter housing.
C.
Remove meter housing, free up turbine and fl ush with clean water. Turbine should spin freely, if not, replace meter.
D.
Replace harness.
E.
Replace timer.
A.
Connect power.
B.
Replace motor.
11.
Control will not regenerate automatically or when button is pressed.
12.
Control regenerates at wrong time of day.
13.
Intermittent or irregular brine draw.
14.
15.
16.
17.
System using more or less salt than salt control is set for.
No conditioned water after regeneration
Control will not regenerate automatically but will regenerate when button is pushed.
Run out of soft water between regenerations
A.
Power outages.
B.
Clock set incorrectly.
A.
Low water pressure.
A.
No salt in brine tank.
B.
Injector plugged.
C.
Air check valve closes prematurely.
A.
Reset clock to correct time of day.
B.
Reset clock to correct time of day.
A.
Set pump to maintain 20 psi at softener.
B.
Possible problem with injector.
A.
Inaccurate setting.
B.
Replace injector and cap.
A.
Make correct setting.
B.
Foreign matter in controller causing incorrect fl ow rates.
C.
Problem with controller.
B.
Remove salt controller and fl ush out foreign matter. Manually index control to brine/slow rinse and allow unit to proceed through complete regeneration.
C.
Replace part.
A.
B.
C.
Add salt to brine tank.
Clean injector and injector screen.
Put control momentarily into refi ll to free air check. Replace or repair air check if needed.
D.
Check for power.
A.
Same as Problem 10.
D.
Unit did not regenerate.
A.
If water fl ow display is not operative, refer to
Problem 10.
B.
Problem with circuit board.
C.
Incorrect hardness and capacity settings.
A.
Improper regeneration.
B.
C.
D.
Incorrect salt settings.
Incorrect hardness.
Water hardness has increased.
E.
Restricted meter turbine rotation due to foreign material in meter.
B.
Replace timer.
C.
Set to correct values.
A.
Repeat regeneration, making certain that correct salt dosage is used.
B.
Set control to proper level. See Specifi cations.
C.
Set to correct values.
D.
Set hardness to new value.
E.
Remove water housing, free up turbine and fl ush with clean water. Turbine should spin freely; if not, replace meter.
6-2
6
7
8
9
4
5
2
3
REF
1
DESCRIPTION
Control Valve, Timer & Cover (AWS-M)
Adapter Assy., Flg-Thrd (incl. Ref. 4)
O-ring
Clamp Assy. (Incl. Ref. 5)
Latch, Clamp
Tank Jacket Cap
Tank Jacket, White
Media Tank w/Base (Incl. Ref. 11)
Media
11 Tank Base
12 Brine Line Tubing
13 Brine Tank, Complete
14 Overfl ow Fitting
15 Brine Tank Shell w/Cover
16 Brine Well w/Cap
17 Grid Plate
18 Safety Brine Valve, Complete
19 Safety Brine Valve
20 Float Assembly
21 Air Check Assembly
22 Bypass Valve (Incl. Ref. 24)
23 Bypass Drain Ftg, 3/4” Barb x FPT
SECTION 7: PARTS
COMPONENT PARTS LIST
METERED SOFTENER MODELS (AWS SERIES)
AWS100M
VAM-X-7SB-C
FA45TX
ORG-234
FC45XX
FC45C
T40BK-8
T40WH0844P
MTP0844FB
H-10P
C04N-44
T06-8P
13000X
BT1534X
BT16
BT1534L
BT15BW
BT15GP
10002X
60014
60068X
60002
1040930
1002449
AWS150M
VAM-X-5SB-C
FA45TX
ORG-234
FC45XX
FC45C
T40BK-10
T40WH1044P
MTP1044FB
H-010P & H-050P
C04N-44
T06-10P
13000X
BT1534X
BT16
BT1534L
BT15BW
BT15GP
10002X
60014
60068X
60002
1040930
1002449
AWS200M
VAM-X-5SB-C
FA45TX
ORG-234
FC45XX
FC45C
T40BK-10
T40WH1054P
MTP1054FB
H-10P (x2)
C04N-54
T06-10P
13000X
BT1534X
BT16
BT1534L
BT15BW
BT15GP-EXT
10002X
60014
60068X
60002
1040930
1002449
NOTE: When ordering components, always specify model number.
AWS250M
VAM-9SB-C
FA45TX
ORG-234
FC45XX
FC45C
T40KB-12
T40WH1254P
MTP1254FB
H-10P (x2) & H-050P
C04N-54
T06A-12P
13000X
BTCS33BK
BT16
BT1833BK
H1030-28
BTCS12-18
10002X
60014
60068X
60002
1040930
1002449
AWS300M
VAM-X-8SB-C
--
--
--
--
T40BK-14
T40WH1465P
MTP1465B
H-10P (x3)
T04N-65
T06A-14F
13000X
BTCS33BK
BT16
BT1833BK
B1030-28
BTCS12-18
10002X
60014
60068X
60002
1040930
1002449
7-1
VALVE EXPLODED VIEW
VALVE PARTS LIST
ONLY THOSE PARTS REFERENCED IN DRAWING ARE STOCK ITEMS
ALL OTHERS ARE SPECIAL ORDER, NON-RETURNABLE
7
8
9
REF
1
4
5
2
3
6
PART NO.
DESCRIPTION
1035807 Valve Assembly w/o Flow Controls
1235338 Top Plate (Not Shown)
1235339 Valve Disc Spring, One Piece
1236246 Valve Cover
1235352 Cam, STD, Black
25F-8
25F-10
25F-12
25F-14
Drain Control Assembly:
No. 8 (1.6 gpm; 6.1 lpm)
No. 10 (2.5 gpm; 9.5 lpm)
No. 12 (3.5 gpm; 13.2 lpm)
No. 14 (4.8 gpm; 18.2 lpm)
1235269 Motor/Optical Cable Assembly
1000226 Screen/Cap Assembly w/O-ring Injector
(High Effi ciency) Options
1030410
1030412
1035736
“G” Injector (High Effi ciency) - Tan
“J” Injector (High Effi ciency) - Lt. Blue
“L” Injector (High Effi ciency) - Orange
REF
10
11
12
13
14
15
Ref.
16
17
18
19
20
PART NO.
DESCRIPTION
1243510 Regenerant Refi ll Controller
1030502 Ball, Refi ll Flow Control
1002449 Drain Fitting Elbow (3/4 inch hose barbed)
1010428 O-ring
1000269 Injector Cap with O-ring
1035622 Tank Ring
104117 Valve Disc Kit: Standard (Not Shown)
1001670 1 inch Copper Tube Adapter Kit (Incl. Adapters,
Gasket and Nuts)
1235373 Module, Sensor, Photo Interrupter
1235361 Motor w/Spacer and Pinion, 12V, 50/60 Hz
1242163 Controller
1000812 Transformer
7-2
WARRANTY
For any warranty questions, please refer to the enclosed warranty card or call 1-800-222-7880 or mail your request to:
CUNO Incorporated
400 Research Parkway
Meriden, CT 06450
CUNO and Aqua-Pure are trademarks of 3M Company used under license.
3M is a trademark of 3M Company.
Tested and Certifi ed Under Industry Standards is a trademark of Water Quality Association.
© 2009 3M Company. All rights reserved.

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Key features
- Automatic regeneration based on water usage
- Salt and water saving design
- Easy to install and program
- Detailed instructions for installation, programming, and maintenance