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Fleck 5600 Econominder

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doc0

5600 / 5600 Econominder

Owners Manual
For questions or in case of emergency, please call your local service technician (preferably the one who installed the system).
Product Features, Benets, & Job Specication Sheet
Congratulations on the purchase of your new water treatment system with the 5600 control valve. You will have peace of mind knowing your system will bring you years of treated water use and enjoyment.
Product Features & Benets
Rugged, simple design Non-corrosive, UV-resistant valve body Economical (small annual power consumption) Clogged Plumbing Dissolved Minerals
Eliminate: Stains Scale Deposits Soap Scum
Enjoy: Longer Lasting Appliances (up to 30% longer) Less Detergent/Soap/Cleanser Use Greater Lathering of Soap Cleaner Dishes, Towels, Linens Softer Hands
IMPORTANT: The information, specications and illustrations in this manual are based on the latest information available at the time of printing. The manufacturer reserves the right to make changes at any time without notice.
Setting Time of Day & Initiating a Manual Regeneration

5600 Model

Setting the Time of Day:
To set the time of day, push the red button and spin the 24-hour gear until the present time of day is visible above the time of day arrow.
Forcing a Manual Regeneration:
To manually regenerate the valve, turn the manual regeneration knob clockwise until it reads REGEN.

5600 Econominder Model

Setting the Program Wheel:
To set the program wheel, lift the people dial and rotate it so that the number of people in the household is aligned with the household grains per gallon water hardness. Release the dial and check for rm alignment at the setting. This provides reserve capacity based on 75 gallons per person.
To manually regenerate valve, turn the manual regeneration knob clockwise until it reads REGEN. NOTE: Unit will regenerate tonight when the gallon capacity reaches zero.
Descriptions of Softener & Filter Control Valve Positions

Service:

Hard water enters unit at valve inlet and ows down through the mineral in the mineral tank. Conditioned water enters center tube through the bottom distributor, then ows up through the center tube, around the piston, and out the outlet of the valve.

Preliminary Rinse:

Slow rinse of the resin bed. Water ows down through the resin bed up the bottom distributor and out the drain.

Backwash:

Hard water enters unit at valve inlet, ows through piston, down center tube, through bottom distributor, and up through the mineral, around the piston and out the drain line. Water is passed through the resin bed in the opposite direction of normal ow, which ushes suspended matter out of the resin tank. Backwashing also loosens the resin bed which becomes compacted during the softening (in service) cycle.
Brine/Slow Rinse (Softener Only):
Hard water enters unit at valve inlet, ows up into injector housing and down through nozzle and throat to draw brine from the brine tank, brine ows down through mineral and enters the center tube through bottom distributor and out through the drain line. The resin beads are washed with the strong solution of salt water which is called the brine solution. Since the resin beads prefer calcium and magnesium ions, the slow rinse allows an overwhelming concentration of sodium ions to overpower and force the calcium and magnesium ions off of the resin beads and are then discharged down the drain.

Rapid Rinse:

The resin bed is rinsed to remove excess brine solution from the tank and the resin beads are then ready to produce soft water again. Hard water enters unit at valve inlet, ows through piston, down center tube, through bottom distributor, and up through the mineral, around the piston and out the drain line.

Settling Rinse:

Illustration of Water Flowing Through a System
Brine Tank Rell (Softener Only):
Hard water enters unit at valve inlet, ows up through the injector housing, through the brine valve to rell the brine tank. Valve is now delivering soft water to the home. Raw water is relling the brine tank to make a brine solution for the next regeneration.

Regeneration:

When the valve is in Regeneration, raw water is being passed to service until rapid rinse is complete.
General Residential Checklist & Troubleshooting

Adding Salt

Ensure that the salt level in the brine tank is always above the water line.

Water Pressure

Water pressure range of 20-125 psi is required for regeneration valve to operate effectively.

Electrical Facilities

An uninterrupted alternating current (A/C) supply is required. Please make sure voltage supply is compatible with unit before installation.

Existing Plumbing

Condition of existing plumbing should be free from lime and iron buildup. Replace piping that has heavy lime and/or iron build-up. If piping is clogged with iron, install a separate iron lter unit ahead of the water softener.
Location of Softener, Drain & Brine Tank
Locate the softener close to a clean working drain and connect according to local plumbing codes. The brine tank should be located within 20 feet of the water softener. Drain cannot be elevated more than 36 inches or exceed 20 feet in length.

Bypass Valves

Always provide for the installation of a bypass valve if unit is not equipped with one. If valve is leaking, turn bypass from In Service to the Bypass Position. NOTE: If the valve continues to leak after turning the bypass to bypass position, shut off the main water line and call your local service technician (preferably the one who installed the system) IMMEDIATELY.
Problem Control valve fails to regenerate
Solution Check for power outage and verify unit is plugged in. If this does not work, contact your local water service technician (preferably the one who installed the system). Check salt level in brine tank & maintain salt level above water level. If problem still exists, contact your local water service technician.

Water does not feel or appear soft
Unit uses too much salt Loss of water pressure Iron in conditioned water Excessive water in brine tank Other problems with the water softener Power Outage Reset the Time of Day in the event of a power outage/ failure. See Setting the Time of Day page. Contact your local water service technician.
5600 Time Clock & Econominder Models

5600 Time Clock

5600 Econominder
5600 L-Style Econominder & Time Clock Models

5600 L-Style Econominder

5600 L-Style Time Clock
To Download the Service Manual for this Valve, please visit: www.eckcontrols.com

P/N 42447

Rev. A

doc1

Model 5600 & 5600 Econominder

Service Manual

IMPORTANT: Fill in pertinent information on page 3 for future reference.

Table of Contents

Job Specification Sheet. 3 General Residential Installation Check List. 4 Valve Installation and Start-up Procedures. 5 Model 5600 Installation and Start-up Procedures. 6 Model 5600 Backwash Filter Installation and Start-up Procedures. 7 Model 5600 Econominder Installation and Start-up Procedures. 9 Water Conditioner Flow Diagrams. 10 Service Position. 10 Preliminary Rinse Position. 10 Backwash Position. 11 Brine Position. 11 Slow Rinse Position. 12 Rapid Rinse Position. 12 Settling Rinse Position. 13 Brine Tank Fill Position. 13 Model 5600 Control Valve Drive Assembly. 14 Model 5600 and 5600 Econominder Control Valve Drive Assembly. 16 Model 5600 Econominder Control Valve Drive Assembly. 18 Bypass Valve Assembly, Plastic. 20 Bypass Valve Assembly, Brass. 21 Model 5600 Econominder Meter Assembly. 22 Service Instructions. 23 Replace Time Brine Valve, Injectors and Screen. 23 Replace Timer. 24 Replace Piston Assembly. 25 Replace Seals and Spacers. 26 Replace Meter. 27 Replace Meter Cover and/or Impeller. 28 Model 5600 and 5600 Econominder Troubleshooting. 29 General Service Hints for Meter Control. 30 Model 5600SF Troubleshooting. 31 Service Assemblies. 32

Page 2

Job Specification Sheet
Job Number ___________________________________ Model Number ________________________________ Water Test ____________________________________ Capacity of Unit ________________________ Max. _____________ Per Regeneration Mineral Tank Size: Diameter ___________________ Height _____________________ Brine Tank Size and Salt Setting Per Regeneration: ___________________________________
Control Valve Specifications
Type of Timer: ___ Std. ___ "L" ___ 7-day ___ 12-day ___ Meter, Std. ___ Meter, Ext. Day/Time of Regeneration _____________________________ Drain Line Flow Control _______________________________ gpm Brine Refill Rate _____________________________________ gpm Injector Size ________________________________________ Meter Gallon Setting _________________________________ gal

Tank Size (diameter)

6" 7" 8" 9" 10" 12" 13" 14" 16"

Injector

#0 red #0 red #1 white #1 white #1 white #2 blue #2 blue #3 yellow #3 yellow
Slow Rinse Rate (gpm) @ 40 psi
.31 gpm.31 gpm.45 gpm.45 gpm.45 gpm.84 gpm.84 gpm 1.0 gpm 1.0 gpm
Brine Draw Rate (gpm) @ 40 psi
.28 gpm.28 gpm.38 gpm.38 gpm.38 gpm.56 gpm.56 gpm.63 gpm.63 gpm
.5 gpm.5 gpm.5 gpm.5 gpm.5 gpm 1.0 gpm 1.0 gpm 1.0 gpm 1.0 gpm
1.2 gpm 1.2 gpm 1.5 gpm 2.0 gpm 2.4 gpm 3.5 gpm 4.0 gpm 5.0 gpm 7.0 gpm
NOTE: Due to varying water conditions, tank sizes and water pressures, use the above settings as guidelines only.
BLFC (Brine Line Flow Control), refill rate for filling brine tank. (Drain Line Flow Control), backwash and rapid rinse flow rates.

Page 3

General Residential Installation Check List

Water Pressure

A minimum of 25 psi (1.7 bar) of water pressure is required for regeneration valve to operate effectively.

Electrical Facilities

An uninterrupted alternating current (A/C) supply is required. Please make sure voltage supply is compatible with unit before installation.

Existing Plumbing

Condition of existing plumbing should be free from lime and iron buildup. Replace piping that has heavy lime and/or iron build-up. If piping is clogged with iron, install a separate iron filter unit ahead of the water softener.
Location of Softener and Drain
Locate the softener close to a clean working drain and connect according to local plumbing codes.

Bypass Valves

Always provide for the installation of a bypass valve if unit is not equipped with one.

CAUTION

Do not exceed 120 psi (8.2 bar) water pressure. Do not exceed 110F (43C) water temperature. Do not subject unit to freezing conditions.

Page 4

Valve Installation and Start-up Procedures
1. Place the softener tank where you want to install the unit.
NOTE: Be sure the tank is level and on a firm base.

2. During cold weather it is recommended that the installer warm the valve to room temperature before operating. 3. Perform all plumbing according to local plumbing codes. Use a 1/2" (13 mm) minimum pipe size for the drain. Use a 3/4" (19 mm) drain line for backwash flow rates that exceed 7 gpm (25.6 Lpm) or length that exceeds 20 (6 m). 4. Cut the 1" (25 mm) distributor tube (1.050 O.D.) flush with top of each tank.
NOTE: Only use silicone lubricant.
5. Lubricate the distributor O-ring seal and tank O-ring seal. Place the main control valve on tank. 6. Solder joints near the drain must be done before connecting the Drain Line Flow Control fitting (DLFC). Leave at least 6" (152 mm) between the DLFC and solder joints when soldering pipes that are connected on the DLFC. Failure to do this could cause interior damage to DLFC. 7. Use only Teflon tape on the drain fitting. 8. Be sure the floor under the salt storage tank is clean and level. 9. Place approximately 1" (25 mm) of water above the grid plate. If a grid is not utilized, fill to the top of the air check in the salt tank. Do not add salt to the brine tank at this time. 10. On units with a bypass, place in Bypass position. Turn on the main water supply. Open a cold soft water tap nearby and let water run a few minutes or until the system is free of foreign material (usually solder) resulting from the installation. Close the water tap when water runs clean. 11. Place the bypass in the In Service position and let water flow into the mineral tank. When water flow stops, slowly open a cold water tap nearby and let water run until air is purged from the unit. Then close tap. 12. Plug the valve into an approved power source. When the valve has power it drives to the In Service position.

Page 5

Model 5600 Installation and Start-up Procedures
NOTE: Install the water softener with the inlet, outlet and drain connections made according to manufacturers recommendations and to meet applicable plumbing codes.

Manual Regeneration Knob

24-Hour Gear

Red Time Set Button

Skipper Wheel (shows every other day regeneration)

Time of Day Arrow

Red Pointer
Figure 1 Model 5600 Softener Control 1. Manually index the softener control into the In Service position and let water flow into the resin tank. When the water flow stops, open a softened water tap until all air is released from the lines. Then close tap.
NOTE: Manually dial the various regeneration positions by turning the knob on the front of the control until the indicator shows that the softener is in the desired position.
2. Manually index the control to the Backwash position and allow water to flow at the drain for 3 or 4 minutes. 3. Remove back cover plate. 4. Make sure that the salt dosage is set as recommended by the manufacturer. If necessary, set salt according to the setting instruction sheet. Manually index the control to the Brine Fill position and allow the brine tank to fill to the top of the air check. 5. Manually index the control to the Brine Draw position and allow the control to draw water from the brine tank until it stops. 6. Plug in the electrical cord and look in the sight hole in the back of the motor to see that it is running. Set the days that regeneration is to occur by sliding tabs on skipper wheel outward to expose trip fingers. Each tab is one day. Finger at red pointer is tonight. Moving clockwise from red pointer, extend or retract fingers to obtain the desired regeneration schedule. 7. Manually advance the control to the beginning of the Brine Fill position and allow the control to return to the In Service position automatically. 8. Fill the brine tank with salt. 9. Replace back cover on the control. 10. Make sure that any bypass valving is left in the normal In Service position.

Page 6

Model 5600 Backwash Filter Installation and Start-up Procedures
Skipper Wheel (shows every other day backwash)
Figure 2: Model 5600 Backwash Filter Control
Before Plugging in the Unit
1. Open a treated water tap down stream of the filter. 2. Manually index the filter to the In Service position and allow the mineral tank to fill by slowly opening the main water supply valve. Any bypass should be in the In Service position.
NOTE: The water flowing from the downstream tap is cloudy and/or contains media fines as well as air. Allow the water to run until it appears clean and free of air.
3. When a steady clean flow appears at the tap, close the tap and the main water supply valve and allow the filter media bed to settle for 1520 minutes. 4. Manually index the filter to the Backwash position. 5. To prevent a sudden surge of water and air, partially open the main water supply valve so that the flow at the drain of the filter is approximately 1 gpm (3.7 Lpm). The water at the drain is cloudy again and/or contains media fines as well as air. Allow water to flow at the drain until it appears clean and free of air. 6. Continue to open the water supply valve until it is completely open. Allow water to flow at the drain until all media fines are washed out of the filter. 7. Manually index the filter to the In Service position, and again open the downstream tap. Check to be sure that the water flows clear. If necessary, allow water to flow until all media fines are gone. If the tap is equipped with an aerator check that is not plugged with media fines and pipe scale. 8. Plug in the electrical cord and look in the sight hole on the back of the timer motor to ensure that it is running. Set the days backwashing is to occur by sliding tabs on the skipper wheel outward to expose trip fingers. Each tab is one day. Finger at red pointer is tonight. Moving clockwise from red pointer, extend or retract fingers to obtain the desired backwash schedule. 9. Set time of day by pushing red button and spin the 24-hour gear until the present time of day is visible above the time of day arrow.

Page 7

Model 5600 Backwash Filter Installation & Start-up Procedures (Contd.)
Cycle Times and Flow Diagrams
1. In Service position. See Figure 4, page 10. 2. Preliminary Rinse position. Same as Figure 4, page 10 with standard piston (white end plug) or filter piston (black end plug). Eliminated with low water piston (gray end plug). 3. Backwash position. Same as Figure 6, page 11 with standard piston. 15 minutes with filter piston. 7 minutes with low water piston. 4. Brine Rinse position. Eliminated, resulting in a 50 minute pause, no water flows during this time. 5. Slow Rinse position. Eliminated, resulting in a 50 minute pause, no water flows during this time. 6. Second Backwash position. Same as Figure 9, page 12 with standard piston. 15 minutes with filter piston. 7 minutes with low water piston. 7. Settling Rinse position. Same as Figure 10, page 13 with standard or filter piston. Eliminate with low water piston. 8. Brine Tank Refill position. Eliminated, filter is back in service at this time.

Page 8

Model 5600 Econominder Installation & Start-up Procedures
Manual Regeneration Knob 24-Hour Gear Program Wheel People Dial Red Time Set Button Grains Per Gallon Water Hardness Scale

White Dot

Gallons Label
Figure 3: Model 5600 Econominder 1. Manually index the softener control to the In Service position and let water flow into the resin tank. When the water flow stops, open a softened water tap until all air is released from the lines. Then close tap.
NOTE: The various regeneration positions may be dialed manually by turning the knob on the front of the control until the indicator shows that the softener is in the desired position.
2. Set water usage program wheel using any one of the following procedures: Typical Residential Application To program, just set the time, set the hardness and it automatically monitors system needs and regenerates only when necessary. To set time of day press red time set button and turn 24-hour gear until present time of day is at time of day. Set program wheel by lifting the people dial and rotating it so that the number of people in the household is aligned with the household grains per gallon water hardness. Release the dial and check for firm engagement at setting. This method provides reserve capacity based on 75 gallons per person. Optional Programming Procedures Calculate the gallon capacity of the system, subtract the necessary reserve requirement and set the gallons available at the small white dot on program wheel gear. Note, drawing shows 850 gallon setting. The capacity (gallons) arrow denotes remaining gallons exclusive of fixed reserve. 3. Rotate program wheel counterclockwise until it stops at Regeneration position. 4. Manually index the control to the Backwash position and allow water to flow at the drain for 3 or 4 minutes. 5. Remove back cover plate. 6. Make sure than the salt dosage is set as recommended by the manufacturer. Manually index the control to the Brine Fill position and allow the brine tank to fill to the top of the air check. 7. Manually index the control to the Brine Rinse position and allow the control to draw water from the brine tank until it stops. 8. Plug in the electrical cord and look in the sight hole in the back of the monitor to see that it is running. 9. Manually advance the control to the beginning of the Brine Fill position and allow the control to return to the In Service position automatically. 10. Fill the brine tank with salt. 11. Replace back cover on the control. Be sure cable is not pinched between cover and housing. 12. Make sure that any bypass valving is left in the normal In Service position.

Page 9

Water Conditioner Flow Diagrams

Service Position

Figure 4: Service Position
Preliminary Rinse Position
Figure 5: Preliminary Rinse Position

Page 10

Water Conditioner Flow Diagrams (Contd.)

Backwash Position

Figure 6: Backwash Position

Brine Position

Figure 7: Brine Position

Page 11

Slow Rinse Position
Figure 8: Slow Rinse Position

Second Backwash Position

Figure 9: Second Backwash Position

Page 12

Settling Rinse Position
Figure 10: Settling Rinse Position

Brine Tank Fill Position

Figure 11: Brine Tank Fill Position

Page 13

Model 5600 Control Valve Drive Assembly

1A 39 1A

Figure 12: Model 5600 Control Valve Drive Assembly

Page 14

Item Number

1 1A 29 30s

No. Reqd

(2-3) (3-5) 1

Part Number 14448-001 15494-01 15494-19205-60514 60514-01 60514-40214

Description

Drive Housing, with Pin Drilled for Cover L Housing, with Pin L Housing, with Pin Drilled for Designer Motor Mounting Plate Motor, 120V, 60 Hz Motor, 24V, 60 Hz Screw, Motor Mtg. and Ground Wire Screw, Component Mounting Idler Gear Idler Pinion Spring, Idler Drive Gear Main Gear and Shaft 24-hour Gear Assembly, Silver 24-hour Gear Assembly, Tan Cycle Actuator Gear Knob, Manual Regeneration Ball, 1/4 Dia. Spring, Detent, Skipper Wheel Skipper Wheel Assembly, 12-day Skipper Wheel Assembly, 7-day Skipper Wheel Ring Spring, Compression, 6700 Regeneration Pointer Electrical Cord, Standard Wire Connector (not shown) Strain Relief Back Cover Front Label, Brown on Beige Front Label, Blue/Silver on Black Rear Label, Softener Rear Label, Filter Tape Stripe, Brown on Beige Tape Stripe, Blue on Silver Brine Cam Assembly, 3-18 Brine Cam Assembly, 6-36 Brine Cam Assembly, Minutes Screw-drive Mounting Washer Screw, Knob Valve Position Dial, Standard Valve Position Dial, Low Water Valve Position Dial, Chemical Filter Valve Position Dial, Filter Knob Label, Beige Knob Label, Silver Screw, Brine Cam

34 35s 37 38

39 40s
s Not used when a filter valve

Page 15

Model 5600 and 5600 Econominder Control Valve Drive Assembly
Backwash Filter Injector Option 51
Figure 13: Model 5600 and 5600 Econominder Control Valve Drive Assembly

Page 16

Part Number
17772 61400-12 61400-13446-10 13446-10913U 11981-18706 18706-13918 13857
Adapter Clip (Clock or Meter) Seal Silicone Seal Valve Body Assembly, 1 Dist. Valve Body Assembly, 3/4 Dist. O-ring, Distributor Tube, 1 O-ring, Distributor Tube, 13/16 O-ring, Top of Tank Not Assigned Spacer Piston, Standard Piston, Low Water Piston, Filter Piston Pin Piston Rod Assembly Piston Retainer End Plug Assembly Standard, White End Plug Assembly Filter, Black End Plug Assembly Low Water, Gray Screw, Injector Mounting Adapter Coupling O-ring, Adapter Coupling Screw, Adapter Coupling (Clock or Meter) O-ring, Drain O-ring, Injector O-ring, Brine Spacer O-ring, Injector Cover Injector Body Injector Nozzle, Undrilled Injector Throat, Specify Size Injector Screen Injector Cover Brine Valve Stem Brine Valve Seat Brine Valve Cap Brine Valve Spacer Quad Ring Spring, Brine Valve Washer, Brine Valve Retaining Ring BLFC Fitting Nut BLFC Ferrule BLFC Tube Insert BLFC Button,.25 gpm BLFC Button,.50 gpm BLFC Button, 1.0 gpm O-ring, BLFC BLFC Button Retainer BLFC Fitting, 3/8 DLFC Button, Specify Size DLFC Button Retainer Screen, Brine Line O-ring, DLFC (not shown) Air Disperser End Plug Retainer Screw Washer Screw Yoke, Brass, 1 NPT Yoke, Brass, 3/4 NPT Yoke, Plastic, 1 NPT Yoke, Plastic 3/4 NPT Drain Hose Barb BLFC, Plug Brine Valve, Plug

15 16* 17* 20s 23s 38

39s 50 51A 51B 54s * not used with meter controls s used in backwash filter

Page 17

Model 5600 Econominder Control Valve Drive Assembly

1A 18 21

Figure 14: Model 5600 Econominder Control Valve Drive Assembly

Page 18

1 1A 30

2-3 2-1 1

14488-001 15494-01 15494-19205-60405-60514-01 60514-15151 40214
Drive Housing, with Pin Drilled for Cover L Housing, with Pin L Housing, with Pin Drilled for Designer Motor Mounting Plate Motor, 120V, 60 Hz Motor, 24V, 60 Hz Screw, Motor Mtg. and Ground Wire Screw, Component Mounting Idler Gear Idler Pinion Spring, Idler Drive Gear Main Gear and Shaft 24-hour Gear Assembly, Silver 24-hour Gear Assembly, Tan Cycle Actuator Gear Knob, Manual Regeneration Ball, 1/4 Dia. Spring, Compression, 6700 Screw, Program Wheel Program Skipper Wheel Assembly, Specify Hardness Capacity Program Wheel Retainer Cover Label, Program Wheel Electrical Cord Wire Connector Strain Relief Back Cover not assigned Front Label, Beige Front Label, Silver Rear Label, Softener Rear Label, Filter Tape Stripe, Beige Tape Stripe, Silver Brine Cam Assembly, 3-18 Brine Cam Assembly, 6-36 Brine Cam Assembly, Minutes Screw-drive Mounting Washer Drive Pinion, Program Wheel Clutch, Drive Pinion Spring Retainer Spring Cable Assembly, Standard Cable Assembly, Extended, Right Angle Valve Position Dial, Standard Valve Position Dial, Low Water Valve Position Dial, Filter Knob Label, Beige Knob Label, Silver Screw, Knob Screw, Brine Cam

Page 19

Bypass Valve Assembly, Plastic

10 12A

Figure 15: Bypass Valve Assembly, Plastic Item Number

11 12A 12B

18706-13708NP 13398 13398NP
O-ring, 119 Clip, Mounting Screw, Hex Washer Head, #8-18 x 5/8" Yoke, Plastic 1" NPT Yoke, Plastic 3/4" Yoke, 3/4" Yoke, 3/4" (Nickel-plated) Yoke, 1" Yoke, 1" (Nickel-plated)

Page 20

Bypass Valve Assembly, Brass
Figure 16: Bypass Valve Assembly, Brass Item Number
17290 17290NP 13399 13399NP 11978 13604-11989
Bypass Valve Body, 3/4" Bypass Valve Body, 3/4" Bypass Valve Body, 1" Bypass Valve Body, 1" (Nickel-plated) Seal, Bypass Plug, Bypass Side Cover Label Screw Side Cover Lever, Bypass Screw, Hex Head, 1/4-14

Page 21

Model 5600 Econominder Meter Assembly

2A 2B 4

Figure 17: Model 5600 Econominder Meter Assembly Item Number

1 2A 2B 9

13305 14613
Screw, Meter Cover Assembly Meter Cover Assembly, Standard Meter Cover Assembly, Extended Range (Right Angle) O-ring, Meter Cover Assembly Impeller Screw, Adapter Clip Adapter Clip Meter Body O-ring, Meter Body Flow Straightener

Page 22

Service Instructions
Replace Time Brine Valve, Injectors and Screen
1. Unplug electrical cord from outlet. 2. Turn off water supply to conditioner: If the conditioner installation has a three valve bypass system, first open the valve in the bypass line, then close the valves at the conditioner inlet and outlet. If the conditioner has an integral bypass valve, put it in the Bypass position. If there is only a shut-off valve near the conditioner inlet, close it. 3. Relieve water pressure in the conditioner by putting the control in the Backwash position momentarily. Return the control to the In Service position. 4. Disconnect brine tube and drain line connections at the injector body. 5. Remove the two injector body mounting screws. The injector and brine module can now be removed from the control valve. Remove and discard valve body O-rings. 6. Replace brine valve. Pull brine valve from injector body, also remove and discard O-ring at bottom of brine valve hole. Apply silicone lubricant to new O-ring and reinstall at bottom of brine valve hole. Apply silicone lubricant to O-ring on new valve assembly and press into brine valve hole, shoulder on bushing should be flush with injector body. 7. Replace injectors and screen. Remove injector cap and screen, discard O-ring. Unscrew injector nozzle and throat from injector body. Screw in new injector throat and nozzle, be sure they are seated tightly. Install a new screen. Apply silicone lubricant to new O-ring and install around oval extension on injector cap. 8. Apply silicone lubricant to three new O-rings and install over three bosses on injector body. 9. Insert screws with washers through injector cap and injector. Place this assembly through hole in timer housing and into mating holes in the valve body. Tighten screws. (Be sure to reinstall brass spacers with injector on model 4600 valve.) 10. Reconnect brine tube and drain line. 11. Return bypass or inlet valving to normal In Service position. Water pressure automatically builds in the conditioner.

NOTE: Be sure to shut off any bypass line.
12. Check for leaks at all seal areas. Check drain seal with the control in the Backwash position. 13. Plug electrical cord into outlet. 14. Set time of day and cycle the control valve manually to assure proper function. Make sure control valve is in the In Service position. 15. Make sure there is enough brine in the brine tank. 16. Rotate program wheel counterclockwise until it stops at Regeneration position. 17. Start regeneration cycle manually if water is hard.

Page 23

Service Instructions (Contd.)

Replace Timer

1. Unplug electrical cord from outlet. 2. Turn off water supply to conditioner: If the conditioner installation has a three valve bypass system, first open the valve in the bypass line, then close the valves at the conditioner inlet and outlet. If the conditioner has an integral bypass valve, put it in the Bypass position. If there is only a shut-off valve near the conditioner inlet, close it. 3. Relieve water pressure in the conditioner by putting the control in the Backwash position momentarily. Return the control to the In Service position. 4. Pull cable out of meter cover. Remove the control valve back cover. 5. Remove screw and washer at drive yoke. Remove timer mounting screws. The entire timer assembly now lifts off easily. 6. Put new timer on top of valve. Be sure drive pin on main gear engages slot in drive yoke (rotate control knob if necessary). 7. Replace timer mounting screws. Replace screw and washer at drive yoke. 8. Return bypass or inlet valving to normal In Service position. Water pressure automatically builds in the conditioner.
9. Plug electrical cord into outlet. 10. Set time of day, program wheel, and salt usage. Cycle the control valve manually to assure proper function. Be sure to return the control valve to the In Service position. 11. Replace the control valve back cover. Be sure grommet at cable hole is in place. 12. Make sure there is enough brine in the brine tank. 13. Rotate program wheel counterclockwise until it stops at Regeneration position. 14. Start regeneration cycle manually if water is hard. 15. Plug cable into meter cover, rotate cable to align drive flat if necessary.

Page 24

Replace Piston Assembly
1. Unplug electrical cord from outlet. 2. Turn off water supply to conditioner: If the conditioner installation has a three valve bypass system, first open the valve in the bypass line, then close the valves at the conditioner inlet and outlet. If the conditioner has an integral bypass valve, put it in the Bypass position. If there is only a shut-off valve near the conditioner inlet, close it. 3. Relieve water pressure in the conditioner by putting the control in the Backwash position momentarily. Return the control to the In Service position. 4. Pull cable out of meter cover. Remove the control valve back cover. 5. Remove screw and washer at drive yoke. Remove timer mounting screws. The entire timer assembly now lifts off easily. Remove end plug retainer plate. 6. Pull upward on end of piston yoke until assembly is out of valve. 7. Inspect the inside of the valve to make sure that all spacers and seals are in place, and that there is no foreign matter that would interfere with the valve operation. 8. Take new piston assembly as furnished and push piston into valve by means of the end plug. Twist yoke carefully in a clockwise direction to properly align it with drive gear. Replace end plug retainer plate. 9. Place timer on top of valve. Be sure drive pin on main gear engages slot in drive yoke (rotate control knob if necessary). 10. Replace timer mounting screws. Replace screw and washer at drive yoke. 11. Return bypass or inlet valving to normal In Service position. Water pressure automatically builds in the conditioner.

12. Plug electrical cord into outlet. 13. Set time of day, program wheel, and salt usage. Cycle the control valve manually to assure proper function. Be sure to return the control valve to the In Service position. 14. Replace the control valve back cover. Be sure grommet at cable hole is in place. 15. Make sure there is enough brine in the brine tank. 16. Rotate program wheel counterclockwise until it stops at Regeneration position. 17. Start regeneration cycle manually if water is hard. 18. Plug cable into meter cover. Rotate cable to align drive flat if necessary.

Page 25

Replace Seals and Spacers
1. Unplug electrical cord from outlet. 2. Turn off water supply to conditioner: If the conditioner installation has a three valve bypass system, first open the valve in the bypass line, then close the valves at the conditioner inlet and outlet. If the conditioner has an integral bypass valve, put it in the Bypass position. If there as only a shut-off valve near the conditioner inlet, close it. 3. Relieve water pressure in the conditioner by putting the control in the Backwash position momentarily. Return the control to the In Service position. 4. Pull cable out of meter cover. Remove the control valve back cover. 5. Remove screw and washer at drive yoke. Remove timer mounting screws. The entire timer assembly now lifts off easily. Remove end plug retainer plate. 6. Pull upward on end of piston rod yoke until assembly is out of valve. Remove and replace seats and spacers with fingers.

Page 26

Replace Meter
1. Unplug electrical cord from outlet. 2. Turn off water supply to conditioner: If the conditioner installation has a three valve bypass system, first open the valve in the bypass line, then close the valves at the conditioner inlet and outlet. If the conditioner has an integral bypass valve, put it in the Bypass position. If there is only a shut-off valve near the conditioner inlet, close it. 3. Relieve water pressure in the conditioner by putting the control in the Backwash position momentarily. Return the control to the In Service position. 4. Pull cable out of meter cover. 5. Remove two screws and clips at bypass valve or yoke. Pull resin tank away from plumbing connections. 6. Remove two screws and clips at control valve. Pull meter module out of control valve. 7. Apply silicone lubricant to four new O-rings and assemble to four ports on new meter module. 8. Assemble meter to control valve. Note, meter portion of module must be assembled at valve outlet. 9. Attach two clips and screws at control valve. Be sure clip legs are firmly engaged with lugs. 10. Push resin tank back to the plumbing connections and engage meter ports with bypass valve or yoke. 11. Attach two clips and screws at bypass valve or yoke. Be sure clip legs are firmly engaged with lugs. 12. Return bypass or inlet valving to normal In Service position. Water pressure automatically builds in the conditioner.

13. Check for leaks at all seal areas. 14. Plug electrical cord into outlet. 15. Set time of day. Make sure control valve is in the In Service position. 16. Rotate program wheel counterclockwise until it stops at Regeneration position. 17. Start regeneration cycle manually if water is hard. 18. Plug cable into meter cover. Rotate cable to align drive flat if necessary.

Page 27

Replace Meter Cover and/or Impeller
1. Unplug electrical cord from outlet. 2. Turn off water supply to conditioner: If the conditioner installation has a three valve bypass system, first open the valve in the bypass line, then close the valves at the conditioner inlet and outlet. If the conditioner has an integral bypass valve, put it in the Bypass position. If there is only a shut-off valve near the conditioner inlet, close it. 3. Relieve water pressure in the conditioner by putting the control in the Backwash position momentarily. Return the control to the In Service position. 4. Pull cable out of meter cover. 5. Remove four screws on cover 6. Lift cover off of meter module, discard O-ring. 7. Remove and inspect impeller for gear or spindle damage, replace if necessary. 8. Apply silicone lubricant to new O-ring and assemble to the smallest diameter on meter cover. 9. Assemble cover to meter module. Be sure impeller spindle enters freely into cover. Press firmly on cover and rotate if necessary to assist in assembly. 10. Replace four screws and tighten. 11. Return bypass or inlet valving to normal In Service position. Water pressure automatically builds in the conditioner.
12. Check for leaks at all seal areas. 13. Plug electrical cord into outlet. 14. Set time of day. Make sure control valve is in the In Service position. 15. Rotate program wheel counterclockwise until it stops at Regeneration position. 16. Start regeneration cycle manually if water is hard. 17. Plug cable into meter cover. Rotate cable to align drive flat if necessary.

Page 28

Model 5600 and 5600 Econominder Troubleshooting
PROBLEM Softener fails to regenerate. CAUSE A. Electrical service to unit has been interrupted.
B. C. A. B. Timer is defective. Power failure. Bypass valve is open. No salt in brine tank.
Softener delivers hard water.

B. C. A. B.

C. Injectors or screen is plugged. D. Insufficient water flowing into brine tank. E. Hot water tank hardness. F. Leak at distributor tube.
G. Internal valve leak. 3. 4. Unit uses too much salt. Loss of water pressure. A. B. A. B. Improper salt setting. Excess water in brine tank. Iron build-up in line to water conditioner. Iron build-up in water conditioner.

G. A. B. A. B.

Loss of resin through drain line. Iron in conditioned water.

C. Inlet of control plugged due to foreign material loose from pipes by recent work done on plumbing system. A. Air in water system.
CORRECTION Assure permanent electrical service (check fuse, plug, pull chain or switch). Replace timer. Reset time of day. Close bypass valve. Add salt to brine tank and maintain salt level above water level. Replace injectors and screen. Check brine tank fill time and clean brine line flow control if plugged. Repeated flushings of the hot water tank is required. Make sure distributor tube is not cracked. Check O-ring and tube pilot. Replace seals and spacers and/or piston. Check salt usage and salt setting. See problem number 7. Clean line to water conditioner. Clean control and add resin cleaner to resin bed. Increase frequency of regeneration. Remove piston and clean control.

A. Fouled resin bed.

Excessive water in brine tank. Salt water in service line.
A. Plugged drain line flow control. A. B. C. D. Plugged injector system. Timer not cycling. Foreign material in brine valve. Foreign material in brine line flow control.
A. Assure that well system has proper air elimination control, check for dry well condition. A. Check backwash, brine draw and brine tank fill, increase frequency of regeneration, increase backwash time. A. Clean flow control. A. B. C. D. Clean injector and replace screen. Replace timer. Clean or replace brine valve. Clean brine line flow control.

Page 29

Model 5600 and 5600 Econominder Troubleshooting (Contd.)
PROBLEM Softener fails to draw brine. CAUSE Draw line flow control is plugged. Injector is plugged. Injector screen plugged. Line pressure is too low. CORRECTION Clean drain line flow control. Clean or replace injectors. Replace screen. Increase line pressure (minimum 20 psi (1.3 bar) at all times). Change seals, spacers and/or piston assembly. Replace timer. Remove piston assembly and inspect bore, remove foreign material and check control in various regeneration positions. Replace seals and/or piston assembly. Replace seals and/or piston assembly. Replace timer.

A. B. C. D.

A. B. C. D. E. A. A.
E. Internal control leak. 10. Control cycles continuously. 11. Drain flows continuously. A. Faulty timer mechanism. A. Foreign material in control.

Internal control leak.

B. C. D.
C. Control valve jammed in Brine or Backwash position. D. Timer motor stopped or jammed.
General Service Hints for Meter Control

PROBLEM

A. Reserve capacity has been exceeded.

CORRECTION

A. Check salt dosage requirements and reset program wheel to provide additional reserve. B. Pull cable out of meter cover and rotate manually, program wheel must move without binding and clutch must give positive "clicks" when program wheel strikes regeneration stop (if not, replace timer). C. Check output by observing rotation of small gear on front of timer (program wheel must not be against regeneration stop for this check) each tooth to tooth is approximately 30 gallons (113.5 L) (if not, replace meter).

Program wheel is not rotating with meter output.
C. Meter is not measuring flow.

Page 30

Model 5600SF Troubleshooting
PROBLEM Filter fails to backwash.
CAUSE A. Electrical service to unit has been interrupted.
B. C. A. B. Timer is defective. Power failure. Bypass valve is open. Excessive water usage.
Filter "bleeds" iron.
C. Hot water tank rusty. D. Leak at distributor tube.
E. Defective or stripped filter medium bed. F. Inadequate backwash flow rate.

Loss of water pressure.

A. Iron or turbidity build-up in water filter.
Loss of filter medium through drain line. Drain flows continuously.
B. Inlet plugged due to foreign material broken loose from pipes by recent work done on plumbing system. A. Broken or missing top screen. A. Foreign material in control.
CORRECTION Assure permanent electrical service (check fuse, plug, pull chain or switch). Replace timer. Reset time of day. Close bypass valve. Reduce days between, backwashing (see timer instructions), make sure that there is not a leaking valve in the toilet bowl or sinks. Repeated flushings of the hot water tank is required. Make sure distributor tube is not cracked, check O-ring and tube pilot. Replace bed. Make sure filter has correct drain flow control, be sure flow control is not clogged or drain line restricted, be sure water pressure has not dropped, increase backwash flow rate according to specifications for your unit, see your dealer for recommendations. Reduce days between backwashing so filter backwashes more often, make sure filter is sized large enough to handle water usage. Remove piston and clean control.
A. Replace top screen, must have 0.020" wide slots. A. Remove piston assembly and inspect bore, remove foreign material and check control in various cycle positions. B. Replace seals and/or piston assembly. C. Replace piston, seals and spacers (and drive motor if necessary).
B. Internal control leak. C. Control valve jammed in rinse or backwash.

Page 31

Service Assemblies
Part Number 60102-00 60102-10 60102-60084-XX 60514-01 60514-60087 160136-5600 160135-14381 60405-10 60405-20
Piston, Softener Piston, Filter Piston, Low Water Seal Kit Injector Brine Valve Brine Cam, 3-18 Brine Cam, 6-36 Brine Cam, Minutes Coupling, with Clip and Screws Bypass, Brass 3/4" NPT Bypass, Brass 1" NPT Bypass, Plastic Meter, Standard Meter, Extended Service Kit, Meter Service Kit, Clock Skipper Wheel, 7-day Skipper Wheel, 12-day Meter Program Wheel, Standard Meter Program Wheel, Extended

Page 32

Notes:

Page 33

P/N 40106

Rev. J 03/09

 

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