Tech Manual Powerline Softener (PS) Series

Transcription

1 Tech Manual Powerline Softener (PS) Series Models: PS 2161 PS 2465 PS 2472 PS 3072 PS 3657 PS 3672 PS 4272 PS 4872

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3 TABLE OF CONTENTS General Information About this Manual...3 The Powerline Product Line...5 System Sizing...5 Equipment Specifications System Configuration...7 Component Functionality...7 Installation Getting Started...11 Pre-installation Review...11 Powerline Installation...12 Unpacking...12 Tank Placement...12 Distributor Assembly...12 Media Loading...13 Control Valve...13 Interconnecting Plumbing...13 Backwash / Brine Flow Control...14 Brine / Drain Line...14 Electrical Service...14 Brine Drum...15 Operation and Maintenance Normal Operating Procedures Pre Start-up Check List...16 Start-up Procedures...16 System Flow Paths...20 Troubleshooting...22 Parts Replacement Parts/Kits Control Valve Control Valve...38 Drawings...46 System Log...48 Page - 2

4 GENERAL INFORMATION About this Manual This manual will cover information needed for the proper installation and operation of your Kinetico Powerline Softener System. We have also included information regarding the frequently asked questions about softening systems. This information may be more technical in nature, but provides further insight to the continued operation of this equipment to its highest standards. This manual will use various icons to help highlight issues that are relevant to the safe operation of this equipment. The following icons will be used as described: General information regarding the application of this product will be highlighted by this icon. This will include technical specifications and expected operational results. Lock out electrical power Use appropriate lockout procedures when servicing. Maintain safe pressure This sign indicates the safe operating pressure range. Consult maintenance section Refer to the maintenance section for specific instructions. Consult equipment specifications section Refer to the equipment specifications section for specific instructions. Consult MSDS sheets A caution icon will be used to present any information that may hold a potential hazard or concern during the installation, use or maintenance of this product. Should this information not be followed, it may result in damage of this equipment and its surroundings. Electrical shock or electrocution hazard Pinch point or crushing hazard Chemical hazard Page - 3

5 The warning icon will be used to present any information that may result in a severe hazard or concern during the installation, use or maintenance of this product. Should this information not be followed, it may result in severe physical harm. Stay clear Do not touch No access Only properly trained and authorized persons can enter area or open panel. Any tools or materials required during the installation, use or maintenance of this equipment will be preceded by this icon. Using these specific tools will minimize time and effort. Not using the proper tool may result in damage to this equipment, its surroundings or even physical harm. If there are any additional questions pertaining to this equipment, please contact your local Kinetico Dealer for further assistance. Page - 4

6 The Powerline Softener Product Line Kinetico s Powerline Softeners are designed to serve both domestic and international customers. As shown in table below, the PS Series is available in both a 50 and 60 Hz configuration. PowerLine Softener - Simplex Fl ow Capacity Part # Model # 15 psi 15 lb. brine 60 Hz 50 Hz PS2162-S5-T2 Simplex Softener, 21" x 61" Media Tank 60 gpm 13.6 M 3 /hr 150,000 grains PS2465-S6-T2 Simplex Softener, 24" x 65" Media Tank 65 gpm 14.8 M 3 /hr 180,000 grains PS2472-S8-T2 Simplex Softener, 24" x 72" Media Tank 70 gpm 15.9 M 3 /hr 240,000 grains PS3072-S12-T2 Simplex Softener, 30" x 72" Media Tank 85 gpm 19.3 M 3 /hr 360,000 grains PS3657-S14-T3 Simplex Softener, 36" x 57" Media Tank 140 gpm 31.8 M 3 /hr 420,000 grains PS3672-S18-T3 Simplex Softener, 36" x 72" Media Tank 150 gpm 34.1 M 3 /hr 540,000 grains PS4272-S26-T3 Simplex Softener, 42" x 72" Media Tank 160 gpm 36.3 M 3 /hr 780,000 grains PS4872-S34-T3 Simplex Softener, 48" x 72" Media Tank 180 gpm 40.9 M 3 /hr 1,020,000 grains Brine Drums Part # Description 68370A 24" x 50" PowerLine Brine Drum, with Air Check (up to 24" x 65" units) 68373A 30" x 48" PowerLine Brine Drum, with Air Check (up to 30" x 72" units) 68371A 50" x 60" PowerLine Brine Drum, with Air Check ( 36" x 72" and larger units) System Sizing In sizing a Powerline softener, the tank size is provided in the model number (i.e. PS2161 = 21 x 61 resin tank). Load Sizing To properly size a Powerline system, the loading to the system must be determined. The load is determined by two factors: the incoming quality of the water and its flow rate. Both these characteristics must be considered when sizing a system. Inlet Quality Although hardness is the most important factor to understand when sizing a softening system, a representative water sample should be taken where a variety of factors are examined. The following parameters are recommended for the full inlet water analysis. Total Suspended Solids (TSS) Total Dissolved Solids (TDS) Conductivity ph Calcium Magnesium Iron Manganese Sodium Chloride Sulfate Total Hardness Total Compensated Hardness Total Alkalinity Average Temperature Flow Rate To determine the required flow rate of the system, there are four common methods: Page - 5

7 Fixture count Inlet main size Usage sizing charts Actual historical data Resin Capacity Based on the volume of resin and concentration of brine regenerant, Powerline systems have a wide range of system capacities. Each system can also operate over a range, allowing for the system to be tailored to the customer s needs. The injectors specified with each Powerline allow the operation between 6 and 15 lb per ft 3 brining through the adjustment of the regeneration sequence and time. Based on the capacity curve shown, the actual capacity can be adjusted to provide the most appropriate sizing for the customer. Grains Removal / ft 3 Resin 40,000 grains 35,000 grains 30,000 grains 25,000 grains 20,000 grains 15,000 grains Resin Capacity For further information regarding these flow method calculations, please contact Kinetico. 10,000 grains 5,000 grains Regenerant Level (pounds/ft 3 of Salt) Page - 6

8 EQUIPMENT SPECIFICATIONS System Configuration Simplex System With a single tank unit (Simplex), a continuous flow of soft water is not possible. During the regeneration process, untreated water is by-passed through the system. For this reason, simplex systems are usually specified in non-critical applications. Inlet Drain By-Pass Outlet System Voltage The system can be designed to accommodate a number of different power supplies, including: 120 VAC, 60 Hz 220 VAC, 50 Hz Brine Tank The system is designed to accommodate different sizes of brine tanks. The brine tank selection should be based on space availability and the frequency of regeneration. Units operating on supplies requiring frequent regeneration should select the largest brine tank that can be accommodated. Powerline Brine Tanks Part N o Description Capacity 68370A 24" x 50" Powerline Brine Drum, with Brine Vlv (up to 24 x 65 media tanks) 850 lbs A 30" x 48" Powerline Brine Drum, with Brine Vlv (up to 30 x 72 media tanks) 2,600 lbs A 50" x 60" Powerline Brine Drum, with Brine Vlv (36 x 72 tanks and larger) 4,500 lbs. Component Functionality The Powerline is comprised of various components. A brief description has been provided for each of these major components. An illustration has been provided to help the operator become familiarized with the parts of the Powerline. Media Tank Tank sizes vary from 21 x 61 to 48 x 72. These sizes only represent the size of the tank; they do not include the base or valve in the height. Upper Diffuser The diffuser prevents channeling of the inlet stream into the top of the resin bed. Two styles of diffusers are used; plastic models that attach to the top of the control valve are used in 2 systems. 3 valve systems use a stainless steel diffuser which sits on the flange adapter inside of the tank. Page - 7

9 Lower Distributors The lower distributors are a hub and lateral design. The high surface area of the laterals minimizes pressure loss through the system. On some laterals there may be slots that are blocked off (not opened fully). This design assures proper flow and even distribution of the water through the resin bed. The polypropylene construction of the distributor assembly gives it excellent durability. 42 and 48 tanks use a two tiered distributor system. Riser Tube A riser tube is used to connect the lower distributor to the control valve. Two different size pipes are used, 1.5" and 3" for the 2900 and 3900 valves respectively. Prior to installation, the riser tube must be trimmed to proper length. Gravel A two-part gravel under-bed is used to provide support to the lower distributor assembly. The under-bed also improves flow distribution and reduces system pressure drop. Media High capacity standard mesh resin is used in the Powerline Softeners. This resin has a bead distribution between 40 and 60 mesh. The resin has a capacity of 30,000 grains per cubic foot when regenerated at a brine setting of 15 lbs./ cubic foot. Control Valve Two different control valves are used with the Powerline Softening Systems: 2900 and 3900 valves. All valves are used in a top-mounting configuration. The 2900 has 2" FNPT inlet/outlet connections and attaches to the resin tank by a 4 threaded adapter included on the valve. The 3900 has 3" FNPT inlet/outlet connections and attaches to the resin tank by a 6 flange. All valves are constructed from lead-free brass and offer a 5 stage, adjustable regeneration cycle Page - 8

10 Injector The injector creates a vacuum during the brine cycle, allowing brine to be drawn into the system. Fluctuations in inlet pressure will significantly affect the rate of draw at the injector. Two different injector assemblies are used with the Powerline, one for the 2900 valve, and one for the 3900 valve. Service Piston The service piston found on 2900 and 3900 can allow for water to be by-passed during regeneration. White pistons designate a hard water by-pass, while black pistons represent a no hard water by-pass. Backwash Flow Control The backwash and fast rinse flow rates are regulated by a flow control attached to the outlet of the drain port. (Arrow shows regulated flow direction.) Brine Refill Flow Control For 3900 valves, an unidirectional external flow control is used to regulate the flow of the brine refill. For model 2900 valves, the flow control is found internally in the injection assembly. During the brine draw stage, the flow control does not restrict the brine flow. (Arrow shows regulated flow direction.) Powerhead In single tank systems, an electromechanical timer is used to provide regeneration control. The timer specifies the number of days between regeneration, with regenerations occurring at 2:00 am of the specified day. Times for each stage of the regeneration sequence are also specified by the number of pins inserted into the regeneration program wheel (located on the back of the timer). Page - 9

11 Brine Tank Although the system can be designed to operate with one brine tank, when working with multiple tank configurations, separate brine tanks are recommended. This practice provides for simpler maintenance and troubleshooting of the system. Brine Valve A brine valve is used in each brine tank. This stops the flow of brine to the control valve when a low level is reached and prevents air from being drawn into the tank. When the bottom check activates, it also marks the beginning of the slow rinse process. The brine valve also has a float cup that is used as a safety to prevent an overflow situation. There is also an overflow elbow that can be connected to the drain. Page - 10

12 INSTALLATION Getting Started The following procedures have been developed to assist during the installation of your Powerline Softener. The installation of this Powerline System should be performed by a qualified service person with an understanding of local and regional codes that may affect the installation requirements. Pre-installation Review Before beginning the installation of the Powerline System, confirm system configuration to be installed and components that have been ordered. Please review Powerline specification sheet which includes required components. A review of the customer s facility is also recommended, especially critical operating data that could affect the operation of the system: Water pressure to the Powerline affects the performance during regeneration. The Powerline System will not operate properly if the inlet pressure fluctuates below a dynamic pressure of 25 psi. This minimum pressure must be maintained to the system at all times. Should the pressure fluctuate below this level, a booster pump may be required. Pressures should not exceed 125 psi. If supply water is above this level, a regulating device is required. Ambient temperature must be maintained above 32 F (0 C). Freezing temperatures will cause breakage of equipment and void all warranties. Inlet water temperature must be maintained between 35 F and 100 F to prevent damage to the system. System Location The Powerline Softener is designed for indoor or outside/protective installation. When reviewing the installation site, please take into account the following factors: Level Dry Access to drain Access to electrical hookup Access to adequate water supply The equipment is not recommended for outdoor installations with direct exposure to the elements. Outdoor installations should be under an awning or some other protective structure. Electrical Service Electrical service must be continuous and should be checked for proper voltage. All electrical connections must be connected according to all local and national codes. Use electrical conduit if applicable. Page - 11

13 Powerline Systems are available in a variety of voltages: 120 VAC, 60HZ 220 VAC, 50HZ Powerline Installation Tools and Installation Materials 18 Pipe Wrench Flathead Screwdriver (medium + small) Torch (Acetylene) Pipe Cutter (PVC and Copper) Flux Solder PVC Cement and Cleaner Pipe Clamps Level Chalk Line Fitting Brush Sand Cloth Needle Nose Pliers Teflon Tape and Paste 2-5/16 Open End Wrenchs Unpack Place all equipment in location including media tanks, brine tanks and remote meters. Unpack media pallet containing gravel, resin, control valve and distributor head. Riser tube will be found packaged in each media tank box. Confirm all equipment has been received. Media Tank(s) Brine Tank(s) Gravel Resin Control Valve(s) Backwash flow restrictor Brine Refill flow restrictor Riser Tube(s) Lower Distributor(s) Tank Placement Place media tanks into tentative positions. Without media or distributors loaded into the tanks, thread the control valve onto the top of the tank. After tightening, rotate the tank so that the valve is facing the right direction. This will help to minimize moving the media tank after it has been loaded. Distributor Assembly After placing the media tanks, prepare the internal distributor assembly. The riser tube and hub are pre-glued, but not cut to length. Insert the riser tube assembly into the tank and center the hub in the bottom of the tank. Mark to cut riser tube and remove from tank. Cut the riser tube based on the tank and valve type. Be sure that the edge that was just cut is chamfered to prevent rolling or cutting of the O-ring. Model Cut tube 3/8" below the top of tank. Model Cut tube flush with top of flange on tank. Assemble the laterals to the hub inside the top opening of the tank. Insert the laterals into the hub and turn them 1/4 turn to lock them in place. After all laterals are locked into place, gently lower the assembly to the bottom of the tank, keeping the hub centered. Page - 12

14 Media Loading Fill the media tank with water, approximately six inches above the laterals. This will prevent damage to the distributor system when adding the gravel and resin. Load the gravel into the tank through the top opening. Use a funnel, and be sure to cap or tape off the opening of the riser tube to prevent material from being loaded into the riser tube. The coarse gravel (part number 61333) is loaded first, followed by the finer gravel (part number 57580). Tanks Size Coarse Gravel Fine Gravel part # 1226 part # /4 x 1/8 gravel 20# gravel 21 x 61 Tanks -- ft ft 3 24 x 65 Tanks 1.0 ft ft 3 24 x 72 Tanks 1.0 ft ft 3 30 x 72 Tanks 1.0 ft ft 3 36 x 57 Tanks 2.0 ft ft 3 36 x 72 Tanks 2.0 ft ft 3 42 x 72 Tanks 3.0 ft ft 3 48 x 72 Tanks 3.0 ft ft 3 After the gravel is loaded, load media into each vessel. In multiple tank systems, be sure to load identical volumes of media into each tank. Check the Data Sheet Chart for the amount of resin for the tank being used. After all media has been loaded, bring the water level in the tank to about three inches from the top of the vessel. Remove the cap from the top of the riser tube to prepare for the control valve installation. Install Control Valve 2900 The 2900 valve mounts to the top of the tank through a 4 thread. Before mounting the valve, clean the tank top and valve bottom. Next, lubricate the distributor O-ring and the valve body O-ring with silicone grease. Position the valve body on the top of the tank. To help prevent cross threading, first turn the valve body counterclockwise until threads have seated properly. Once the valve is seated properly, tighten the valve by turning it clockwise until it is tight The 3900 valve mounts to the top of the tank through a flange connection. Before mounting the valve, clean off the top of the tank and bottom of the valve. Next, lubricate the distributor O-ring and the valve body O-ring with silicone grease. The valve can be placed onto the riser tube now, and the split flange can be placed around the bottom of the valve. The 12 bolts can be inserted through the split flange ring, the flange ring and the tank flange. Thread corresponding nuts onto the bolts, and tighten in an alternating fashion. Interconnecting Plumbing The tank manufacturer recommends that vacuum breakers be installed on the inlet side of the plumbing before the by-pass tee for all equipment. Flex connections may also be required to allow for tank expansion. For systems using multiple tanks, a balanced header is necessary to distribute flow equally to all equipment. It is also strongly recommended each tank have inlet/outlet isolation valves as well as a system by-pass. Page - 13

15 The use of unions on the inlet, outlet and drain line connections are recommended. This will allow for easy access to the valve should maintenance be required. A system by-pass is also recommended. This will allow greater flexibility when servicing the equipment. Backwash Flow Control For all control valves, one backwash flow control is required on the drain line of the unit. The drain line for the 3900 is located on the top of the valve, while the 2900 s drain is on the right side. Single Tank Backwash Flow Control Installation For single tank systems, the backwash flow control can be threaded directly into this port. (Arrow shows flow control direction.) Following the flow control, a union should be used. This will allow easy access to the flow control should cleaning or modification to it be required. Brine Line Flow Control For the 3900 valves, the brine line refill flow control is an additional part. For single tank systems, it can be threaded directly onto the valve s inlet brine line. This flow control is bidirectional, allowing for an unrestricted draw and a throttled refill. As recommended with the backwash flow control, a union following the flow control is recommended to simplify future system maintenance. With the 2900 valve, the brine line refill flow control is incorporated into the valve. For multi-tank systems using the 3900 valve, the brine refill flow control should be mounted on the common brine header at the brine tank. Brine Line It is recommended that a brine tank be used with each control valve. This practice will simplify maintenance and troubleshooting issues with the equipment. If hard plumbing the brine line in PVC or copper, it is recommended that the pipe size be the same as the control valve brine connection. Drain Line Air Gap The drain line should be the same size as the drain line flow control connection. It is recommended that a piece of clear PVC be installed into the drain line. This can assist in system start-up and future maintenance of the system. The clear PVC gives a view of the backwash water, and shows the volume, if any, of media loss during backwash. A 1 ½ air gap should be maintained at the discharge point. If this is hard-plumbed, a union is required close to the valve for serviceability issues. Electrical Service A standard electrical plug is provided with the control valve. Should a long connection be desired, a new plug can be made using 3 conductor #14 SO/SJO cords. Page - 14

16 Brine Drum Connect the ½ brine line to the bulkhead fitting on the brine drum. Connect the overflow fitting on the brine drum to a suitable drain. The float cup on the brine valve is used as a safety only. The Powerline valve controls the amount of water that is filled into the drum. So the safety float cup must be higher than the normal level that is filled in the brine drum. ½ Bulkhead Overflow Safety Float Cup Normal Brine level Page - 15

17 OPERATION AND MAINTENANCE Normal Operating Procedures Pre-Start-up Check List After the installation of the Powerline and all accessory equipment is complete, the system can be commissioned into service. During this first operational run, a few additional steps are required. These procedures both confirm that the installation has been done correctly and adjusts the Powerline to operate in the specific site conditions at the customer s facility. Before starting the system up, review the following items to make sure the system is ready for start-up: Have all installation fittings been properly cured? Have all unions and ball valves been tightened? Confirm voltage of incoming power supply to system wiring. Are brine tank(s) full of softener grade salt? Are all isolation valves closed? After reviewing these conditions, begin the commissioning by energizing power to the Powerline System. Start-up Procedures To start up the equipment, plug in the power cord, remove the valve cover and open the timer assembly housing door. Actuate the unit into a backwash cycle by turning the timer knob clockwise to the first set of pins. The backwash cycle starts when the pins engage the micro-switch. The inlet valve should be partially opened and the outlet valve should be closed. Microswitch Back of Timer Timer Pins If the tank was filled with water earlier, then the flow to the drain should begin almost immediately. Flush the tank at a low flow for at least 10 to 15 minutes. During this time the Home drain flow should be monitored for loss of media. If this Position happens, immediately stop the flow by closing the inlet valve and repeat the above process by flushing the tank at a low flow. After approximately 15 minutes, open the inlet valve fully and continue to monitor the drain flow for media loss. If no media loss has occurred, unplug the unit and let it continue to backwash for another 15 minutes. Once this time has elapsed, plug the unit back into the power source and advance the timer knob to a point just before the home position notch. Repeat this process for additional units if needed. Position Program Wheel Timer Motor After the flushing procedure has been completed and the program wheel is returned to the home position, check all cycles for proper responses: Softener cycles 1. Backwash (upflow) Advance knob to the first set of pins. You ll see a high flow to drain. 2. Brine and slow rinse (downflow) Advance knob to just beyond the last backwash pin. Check for suction and a low flow to drain. Page - 16

18 3. Fast rinse (downflow) Advance knob to the second set of pins. The flow rate to drain will increase. 4. Brine Refill (NHWBP-No hard water by-pass, returns to service position) Advance knob to just beyond the fast rinse pins. Check that water is flowing into the brine tank. 5. Program End The last two (2) pins of the program wheel stop the brine refill. If the time of any cycle needs to be changed, the program wheel can be removed, and the roller pins can be added or removed as needed. The installation should now be complete. The by-pass valve can be closed, and the inlet and the outlet valves opened. Setting the Regeneration Cycle The regeneration cycle program on the valve has been preset; however, portions of the program may be lengthened or shortened in time to suit local conditions. To expose the cycle program wheel, grasp the timer in upper left-hand corner and pull, releasing the snap retainer and swinging the timer to the right. To change the regeneration cycle program, the program wheel must be removed. Grasp the program wheel and squeeze the protruding lugs toward the center, and lift the program wheel off the timer. (Switch arms may require movement to facilitate removal.) The program wheel contains holes for the program pins. As the wheel turns, the micro-switch is activated and deactivated by these pins. Each pin represents two minutes. The time for each stage can be adjusted by the number of pins or spaces associated with that stage. Four stages are directly controlled by the pin and space placement. They are: Backwash Brine and slow rinse Fast rinse Brine refill A final set of two pins is also used to signal the completion of the cycle. Modification of the regeneration cycle should start with the first stage and then move through each subsequent stage. Pins should always be added at the end of the cycle being adjusted. This will affect the length of the next cycle and that cycle may also need to be adjusted. Page - 17

19 Backwash Time The first set of pins represents the backwash time. Standard backwash for all systems is 10 minutes, or five pins. To increase this time, simply add consecutive pins to this stage, to match the desired time. Each pin represents two minutes. A minimum of two pins is required to make sure the cycle begins. Backwash Brine and Slow Rinse Brine and Slow Rinse The empty holes following the backwash pins represent the brine and slow rinse stage. Adding spaces increases the time of this stage. Each empty hole represents two minutes of the stage. A minimum of two spaces is required to make sure the cycle is initiated. Fast Rins Fast Rinse Following the brine and slow rinse stage is a group of pins which represent the fast rinse stage. The cycle time is changed based on the number of pins used. Each pin is two minutes. A minimum of two pins is required to assure that this stage has been activated. Brine Refill The spaces following the fast rinse represent the time of the brine refill. Each space is two minutes. Adding consecutive spaces will lengthen the stage, while removing spaces will shorten the cycle. A minimum of two spaces is required to assure the stage is activated. Refill Cycle End Two final pins are required to signal the end of the regeneration cycle. End Page - 18

20 Recommended Pins / Spaces Brine/Slow Rinse Brine Refill BW SPACES Fast Rinse SPACES End Model PINS 6 lbs. 10 lbs. 15 lbs. PINS 6 lbs. 10 lbs. 15 lbs. PINS PS2161-XX PS2161-XX PS2465-XX PS2465-XX PS2465-XX PS2472-XX PS2472-XX PS2472-XX PS3072-XX PS3072-XX PS3072-XX PS3657-XX PS3657-XX PS3672-XX PS3672-XX PS3672-XX PS4272-XX PS4272-XX PS4872-XX PS4872-XX PS4872-XX Setting the Time of Day Press and hold in the red button to disengage the 24-hour gear. 24 hour gear Turn the 24-hour gear until the actual time of day is at the pointer. Release the red button to again engage the 24-hour gear. Setting the Regeneration Day Rotate the skipper wheel until the number 1 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. The finger at the red pointer is tonight. Moving clockwise from the red pointer, extend or retract fingers to obtain the desired regeneration schedule. Starting a Manual Regeneration Rotate the manual regeneration knob clockwise one click. This will begin the regeneration process. Time of Day Red Button Skipper Wheel Page - 19

21 System Flow Paths Service Hard water enters the unit at the valve inlet and flows down through the resin in the mineral tank. Conditioned water enters the center tube through the bottom distributor, then flows up through the center tube, around the piston and out the side outlet of the valve. Backwash Hard water enters the unit at the valve inlet, flows through the service adapter for the by-pass and up through the coupling to the regenerating valve inlet. It then flows through the regenerating valve piston, down the center tube, through the bottom distributor, up through the resin, around the piston and out the drain line. If optional no hard water by-pass is used, water flow to the outlet is prevented by an extended section of the service piston which closes the outlet port from by-pass water until the end of rapid rinse. Brine and Slow Rinse Hard water enters the unit at the valve inlet, flows up into the injector housing and down through the nozzle and orifice to draw brine from the brine tank. Brine flows down through the resin and enters the center tube through the bottom distributor, flows up through the center tube, around the piston and out through the drain line. After the brine level has fallen below the air check, brine draw stops, and a slow rinse begins. Page - 20

22 Fast Rinse Hard water flows through the regenerating valve, directly down through the resin into the bottom distributor and up through the center tube, around the piston and out the drain line. Brine Refill Hard water flows through the service valve and down through the resin. Conditioned water enters the bottom distributor, flows up the center tube, around the piston, to the outlet. Hard water flows to the regenerating valve through the injector housing and brine valve to fill the brine tank. Page - 21

23 Troubleshooting Equipment will not regenerate Power has been disrupted In-line meter not operational Program wheel may be set incorrectly Timer motor Check the following: fuses, breakers, micro-switches and wiring connections at terminal block and connection at remote meter Check cable connection at meter or clutch, check impeller assembly Reset gallons wheel Inoperative, replace Hard water Water statistics have changed No salt Salt bridged Unit not regenerating Flow to brine tank restricted Not drawing brine Roller pin setting incorrect for draw and refill Brine valve assembly O-ring seal at distributor Riser tube cut incorrectly No hard water by-pass leaking Hard water by-pass piston being used Simplex system Regeneration piston leaking Low flow not being metered Resin low Resin damaged from exposure to chlorine, or other chemicals in water Retest water, adjust program wheel Maintain salt level above water Break up bridge, change type of salt if necessary to a higher grade See section Equipment will not regenerate Brine line flow control blocked Clean injectors Check and reset as needed Clean flow washer or replace O-ring pinched or missing Remove valve, check height, replace riser or cut and couple Check and replace seals, spacers and piston Check end cap assembly. Should be white for hard water passage during regeneration and black for no hard water passage during regeneration Will deliver hard water during regeneration unless using no hard water piston assembly on lower piston assembly Check and replace seals, spacers and piston Make sure units are receiving adequate flow rates. Minimum flow required for 2 meters gpm, for 3 meters gpm Top off, find reason for media loss and correct Replace resin and pretreat water Page - 22

24 Uses too much salt Incorrect times set on program wheel Water usage exceeding estimates Defective air check Excessive water in brine tank Brine line flow control Brine valve Check draw and refill rates and reset for better efficiency Check water meter for gallons used per day, check for leaks Clean or replace Clean injector Clean Clean or replace valve Loss of water pressure Inlet flow restricted Low incoming water pressure May occur during high water usage at facility Check inlet of plumbing and piston chamber of valve Well pump defective, well not providing sufficient water, city water supply insufficient Test pressure at various points down stream of equipment, also while equipment is in regeneration Inlet or outlet valves defective or partially closed Check valves Laterals or hub cracked or crushed Media bed loaded with foreign material Check product water for media or possibly gravel Check bed and replace if necessary Loss of mineral to drain Air in water Pressure regulator defective Well system (pump) drawing air. Check for crack in the well line, defective check valve and O-ring seal for pitless adapter If possible, test pressure after regulator, replace if necessary Iron in conditioned water Check drain line for blockage Check drain flow control for blockage Inlet pressure too low for proper backwash Inlet water exceeds recommended iron level System losing capacity Well or city water stats have changed Clean or replace Clean or replace Test and advise customer Pretreat with filtration Retest water, check for low flows and increase frequency of regeneration. If brine draw and refill times are incorrect, reset. Retest raw water, adjust program Excessive water in brine tank or softener fails to draw brine Drain line flow control plugged Clean or replace Plugged injector Clean or replace Page - 23

25 Brine valve sticking Brine line flow control plugged Air check assembly defective Low pressure Internal valve leak Clean or replace Clean or replace Clean or replace Check inlet pressure, adjust. Advise customer Replace seals, spacers, piston Unit cycles continuously Loose micro-switch Broken piston Timer motor may be burned out Adjust by tightening, or replace Replace seals, spacers and piston Replace Drain flows continuously Broken piston Replace seals, spacers and piston Spacing incorrect between back plate and valve Shimming between backplate and valve body may be body which will cause piston to be out of required synchronization Internal leak Foreign material in valve Replace seals, spacers and piston Check piston chamber and clean, replace seals, spacers and piston if necessary Page - 24

26 PARTS Replacement Parts and Kits Part # Description Pistons, Plugs, Seal/Spacer Kits Piston, 2850, HWBP, PowerLine Kit, Seal & Spacer, 2850, PowerLine Piston, 2850, NHWBP, PowerLine Piston, 2900, Upper, Regen, PowerLine Kit, Seal & Spacer, 2900, PowerLine Kit, Seal & Spacer, 2900, PowerLine Piston, 3150/3900, Upper, PowerLine Piston, 3150, NHWBP, Upper, PowerLine Kit, Seal & Spacer, 3150/3900, Upper PowerLine Kit, Seal & Spacer, 3900, Lower, PowerLine Plug, 2900, Soft Water Regen, PowerLine Plug, 3900, Soft Water Regen, PowerLine Piston, 2900, HWBP Piston, 2900, NHWBP Piston, 3", HWBP, Piston, 3", NHWBP, 3900 Replacement Motor Assemblies Motor, Regen Asy, 2900/2850 (115/60hz) Motor, Lower Asy, 2900, (115/60hz) Motor, Regen Asy, 3900/3150 (115/60hz) Motor, Lower Asy, 3900 (115/60hz) Replacement Brine Assemblies Brine Valve Asy ( ) Brine Injector Asy ( ) Brine Valve Asy ( ) Brine Injector Asy ( ) Fleck Brine Valves and Components Brine Valve Asy w/safety 24x Brine Valve Asy w/safety 30x Brine Valve Asy w/safety 50x Brine Valve, Air Check Brine Valve, Safety Float Brine Valve, Fitting Pack age Brine Valve, Float Clack Style Brine Valve Replacements Brine VLV 24" x 30" (454) Brine VLV 50" (54HF) ASME Tanks Tank, 18x65, 6" TF - 6" BF, PL, NAT, ASME Tank, 24x65, 6" TF - 6" BF, PL, NAT, ASME Tank, 24x72, 6" TF - 6" BF, PL, NAT, ASME Tank, 30x72, 6" TF - 6" BF, PL, NAT, ASME Tank, 36x57, 6" TF - 6" BF, PL, NAT, ASME Tank, 36x72, 6" TF - 6" BF, PL, NAT, ASME Tank, 42x72, 6" TF - 6" BF, PL, NAT, ASME Tank, 48x72, 6" TF - 6" BF, PL, NAT, ASME Closure, Tank, 6" FLG, PL, Plug for Bottom Flange, Tank, 6" FLG to 4" THD, PL Page - 25

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47 DRAWINGS 2900 Control Valve 1-2 Union 2-2 MNPT Adapter 3 - Drain Line Flow Control (DLFC) 1 FNPT x 1 MNPT 4-1 FNPT Adapter 5-1 Union 6 - Brine Line Connection 1/2 Compression Fitting 2 1 In le t 6 In le t 2 1 Drain Flow Control Direction Outlet Page - 46

48 3900 Control Valve 1-3 Union 2-3 MNPT Adapter 3 - Drain Line Flow Control (DLFC) 2 MNPT 4-2 FNPT Adapter 5-2 Union 6 - Brine Line Flow Control (BLFC) 1 FNPT x 1 MNPT 7-1 FNPT Adapter 8-1 Union 4 FlowControl Direction Drain Brine Line FlowControl Direction Outlet 2 1 Inlet Outlet Page - 47

49 SYSTEM LOG Page - 48

50 Date PRESSURE FLOW RATE Hardness Inlet Outlet Feed Outlet Brine Tank Comments Page - 49

51 Date PRESSURE FLOW RATE Hardness Inlet Outlet Feed Outlet Brine Tank Comments Page - 50

52 TECH MANUAL POWERLINE SOFTENER SERIES 2009, Kinetico Incorporated Page - 51