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OPERATING MANUAL
LIGHT COMMERCIAL WATER SOFTENER LCTA 150 SERIES
With 9500 Twin Alternating-Top Mount Control Valve

MODEL NO.

Meter

C ONTENTS S

S EC C TION I Introduction
Tenergy Water Light Commercial water softeners are assembled of the highest quality parts available. The LCTA 150 Series is a twin tank, single controller, metered system available with 1-1/2 connections, with different size units to meet your needs. The Mineral Tank is a noncorrosive fiberglass tank with a one-piece thermoplastic inner liner in compliance with FDA under 21 CFR Part 177. The tank has a working pressure of 150 PSI, or maximum temperature of 120F. The exchange media is a polystyrene strong acid cation resin in the sodium form. It has a maximum exchange capacity of 30,000 grains per cubic feet, when regenerated with 15 lbs. salt. The valve body is constructed of high quality brass to assure long life. The piston is Teflon coated to prevent wear and allow foreign particles to pass without damage to the piston. The unit is a twin alternating system, where one unit is in service and the other unit regenerated and in standby. Regeneration cycle is fully adjustable to meet your changing needs. Regeneration on the LCTA 150 Series is initiated by the 9500 Econominder Water Meter. Once a preset number of gallons flow through the system, and the meter zeroes out, the unit in service starts to regenerate and the unit in standby is put into service. Once the unit completes its regeneration cycle, it automatically goes into standby.

Section 1 2

Description

Page

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . .2 PRINCIPLES OF Softening - Ion Exchange . . . . . . . . . . . . . . . . .3 Regeneration Steps and Purpose . . . . . . . . . .3 SPECIFICATIONS Specification Sheet . . . . . . . . . . . . . . . . . . . . .4 Softener Specification . . . . . . . . . . . . . . . . . . .5 Softener Data . . . . . . . . . . . . . . . . . . . . . . . . .5 Tenergy Brand Resin Data . . . . . . . . . . . . . . . .6 Exchange Capacity Data . . . . . . . . . . . . . . . . .6 Eductor & Flow Control Data . . . . . . . . . . . . . .6 Brine (Salt) Data . . . . . . . . . . . . . . . . . . . . . . .6 INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . .7 START-UP INSTRUCTIONS Meter Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 PROGRAM SETTING PROCEDURE How to Set the Regeneration Cycle . . . . . . . . .9 Manual Regeneration . . . . . . . . . . . . . . . . . . .10 MEDIA LOADING . . . . . . . . . . . . . . . . . . . . . . . . .10 PARTS LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 1-1/2 Meter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .see Model 9500 Service Manual, pg. 19 Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .see Model 9500 Service Manual, pg. 13 Timer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .see Model 9500 Service Manual, pg. 21 Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . .see Model 9500 Service Manual, pg. 15 1700 Brine System Assembly . . . . . . . . . . . . . . . . . . . .see Model 9500 Service Manual, pg. 17 1600 Brine System Assembly . . . . . . . . . . . . . . . . . . . .see Model 9500 Service Manual, pg. 16 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . .12-13 DRAWINGS Electrical Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . .see Model 9500 Service Manual, pg. 26 Valve Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .see Model 9500 Service Manual, pg. 26 Typical Piping . . . . . . . . . . . . . . . . . . . . . . .back Optional-Duplex Piping Assembly . . . . . . . .back Brine Tank Assemblies . . . . . . . . . . . . . . . .back

4 5 6

7 8

9 10

LCTA 150 SERIES TWIN ALTERNATING WATER SOFTENER

Copyright 2000 by TENERGY WATER, LLC. All rights reserved. Except as permitted under the United States Copyright Act of 1976, no part of this publication may be reproduced or distributed in any form or by any means, stored in a data base or retrieval system, without the prior written permisssion of TENERGY WATER, LLC.

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S EC C TION 2

Principles of Softening Ion Exchange

Softening of water by the ion exchange process involves the exchange or substitution of the hardness minerals, chiefly calcium and magnesium, for sodium minerals. The exchange is made possible because the minerals are ionic in nature (often called ionized impurities), which means they have an electrical charge. The ion exchange process is based on the fact that like charges repel one another, and unlike charges attract. Calcium and magnesium ions in water are actually dissolved rock. They have been dissolved by water, the universal solvent. As the water trickles down through strata of rock and soil it dissolves the calcium and magnesium deposits. This dissolved rock eventually finds its way into an underground aquifer and when water from the aquifer is pumped to the surface, it contains the dissolved hardness minerals of calcium and magnesium and is said to be hard water. An ion exchange softener exchanges the hardness minerals, calcium and magnesium, for sodium, from the softener resin. Sodium is less objectionable because it does not build up on surfaces as scale deposits. All three minerals are positively charged ions called cations. The exchange takes place by passing water containing hardness minerals over a man-made ion exchange resin contained in a suitable tank. The resin, polystyrene divinyl benzene in most modern softeners, consists of millions of tiny plastic beads, all of which contain many negatively charged exchange sites attracting positive cations. When the resin is in the regenerated state these negatively charged exchange sites hold positively charged sodium cations. As the calcium and magnesium contact the resin beads in their travel through the resin tank, they displace the sodium ions from the exchange sites. During the ion exchange process, relatively small amounts of other strongly charged cations such as iron and manganese are also removed along with the calcium and magnesium. Ion exchange is possible for two reasons: (1) All cations do not have the same strength of positive charge and (2) the resin prefers the more strongly charged cations calcium and magnesium than it does the weaker sodium cations. The exchanged sodium cations pass downward through the resin bed and out the softener outlet; thus, the softener delivers soft water. Eventually, all of the resin exchange sites are occupied by calcium and magnesium and no further exchange can take place. The resin is said to be exhausted and must be regenerated.
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The softener resin is regenerated with a dilute brine solution of sodium chloride (common salt) and water. During regeneration the flow of service water from the softener is first stopped. Brine is drawn from the brine tank mixing with a separate stream of water. The brine solution flows downward through the resin, contacting the resin beads loaded with calcium and magnesium ions. Even though the calcium and magnesium are more strongly charged than the sodium, the concentrated brine solution contains literally billions of the more weakly charged sodium ions which have the power to displace the smaller number of calcium and magnesium ions. When the calcium and magnesium ions are displaced, the positive sodium ions are attracted to the negative exchange sites. Eventually, all sites are filled by sodium ions and the resin is said to be regenerated and ready for the next softening cycle.

REGENERATION STEPS AND PURPOSE Tank Switching When unit in service depletes the pre-set volume of water and regeneration is initiated, the service flow automatically switches from the unit exhausted to the unit that was in standby. Backwash Flow through the resin bed is reversed. Water flows upward, expanding and agitating the resin bed. This action loosens sediment that may have collected on the resin during service and is flushed to drain. Resin fines which developed during service are also removed. Brine In Brine is educted from the brine tank, passes through the resin during service, and is flushed to drain. Resin fines, which developed during service, are also removed. Slow Rinse After the brine has been introduced, brine air check is closed, allowing water to flow through eductor at a slow rate, displacing the brine remaining in the resin bed. This insures good utilization of the brine. Fast Rinse The resin is now flushed downward at a set flow rate. This resettles the bed and rinses out any remaining brine left in the resin bed. Brine Fill Brine tank is refilled with a preset amount of water to dissolve salt for the next regeneration. After the brine fill step the unit is ready for service, thus completing the regeneration cycle. The unit then places itself into the standby mode.
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S EC C TION 3

Specifications
SPECIFICATIONS SHEET (to be filled out by installer) Job No. Model No. Water Test Capacity Per Unit Gallons Per Regeneration Mineral Tank Size: Diameter Brine Tank Size & Salt Setting Per Regeneration Control Valve Specifications 1. Type of Timer Meter Initiated 2. Timer Program Settings a) Backwash b) Brine & Slow Rinse c) Rapid Rinse d) Brine Tank Refill 3. Drain Line Flow Controller 4. Brine Line Flow Controller 5. Injector Size # min. min. min. min. gpm gpm Reserve Gallons Height

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SOFTENER SPECIFICATIONS
PIPE MODEL # SIZE 4 MINERAL TANK UNDERBED TANK RESIN SIZE 4 CU. FT. 1/4x1/8 #20 BRINE TANK SALT SIZE 4 FILL SOFTENING CAPACITY 1 MAX MIN3 LBS. SALT PER REGENERATION 2 MAX MIN
FLOW RATE & PRESSURE

SERV GPM

DROP BKW PSI GPM

SPACE REQUIRED 4 FLOOR HEIGHT

TT60F TT90F TT120F TT150F TT180F TT210F TT240F TT300F

1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2

12x52 14x65 16x65 20X62 21x62 21x62 24x72 24x72

2 3 4 5 6 7 8 10

100 100

30 60 80 100 100 100 100 100

24x41 24x41 24x41 24X50 24x50 24x50 30x48 39x48

600 600 600 800 800 800 1200 2000

60K 90K 120K 150K 180K 210K 240K 300K

40K 60K 80K 100K 120K 140K 160K 200K

30 45 60 75 90 105 120 150

12 18 24 30 36 42 48 60

25/33 26/37 29/40 37/48 35/47 34/46 37/49 35/47

15/25 15/25 15/25 15/25 15/25 15/25 15/25 15/25

5 7 9 12 12 15 15 15

24x42 24x44 24X46 24x50 24x52 24x52 30x69 39x69

63 76 76 73 65 71 83 83

Above information subject to change or correction as required by the manufacturer. KEY TO THE NOTATIONS ABOVE: 1. Capacities are based on resin manufacturers data and are dependent upon influent water TDS, temperature, bed depth, pressure, and flow rates. The raw water is to be free of oil, color, and turbidity. 2. All units from Tenergy Water are set at minimum salt settings. 3. Use the minimum capacity when sizing units. 4. Duplex systems require approximately twice the floor length space.

SOFTENER DATA - Commercial

PART # M2218 M2220 M2222 M2224 M2226 M2228 M2230 M2235 DESCRIPTION TT60F95 Twin Alt Softener TT90F95 Twin Alt Softener TT120F95 Twin Alt Softener TT150F95 Twin Alt Softener TT180F95 Twin Alt Softener TT210F95 Twin Alt Softener TT240F95 Twin Alt Softener TT300F95 Twin Alt Softener PIPE SIZE 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 WEIGHT 370 550 720 900 1115 1215 1535 1750

9500 Twin/Alt 1-1/2 Meter

RANGES: 1-1/2 Meter: Standard Range = 10,625 Gallons 1-1/2 Meter: Extended Range = 53,125 Gallons

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TENERGY BRAND SOFTENER RESIN DATA

GENERAL DESCRIPTION Ionic form, as delivered Functional Group Matrix Structure Appearance PHYSICAL AND CHEMICAL PROPERTIES Bead Size (U.S. Standard Mesh) min. 90% Bead Size Range mm Uniformity coefficient Maximum Bead Integrity min. % Whole Beads Bulk Density ( 5%) lbs/ft3 True Density approx. g/ml Water Retention % wt. Total Capacity min. eq/l Volume Change Na max. % TYPICAL OPERATING PARAMETERS Operating Temperature max. F Operating pH Range Bed Depth min. inches Pressure drop (59F) per gpm/ft 2 Approx. psi/ft Flow Velocity service up to gpm/ft 2 Flow Velocity backwash (68F) gpm/ft 2 Flow Velocity type Regenerant level approx. lbs/ft3 Regenerant concentration % Flow Velocity regeneration gpm/ft3 Flow Velocity rinsing approx. gpm/ft3 Rinse Water Requirement approx. gal/ft 3 resin Bed Expansion approx. % per gpm/ft3 (68F) Freeboard (as % of resin volume) Na+ Sulfonic Acid Polystyrene - DVB Gel Dark

EXCHANGE CAPACITY DATA

20,000 grain approx. per cu. ft. 6 lbs. salt-sodium chloride 25,000 grain approx. per cu. ft. 8 lbs. salt-sodium chloride 27,000 grain approx. per cu. ft. 10 lbs. salt-sodium chloride 30,000 grain approx. per cu. ft. 15 lbs. salt-sodium chloride

16-50 0.41-0.51 1.7 95 53 1.29 42-46 2.0 5-10

248 0-14 24 0.16 16 6-7 NaCl 6-15 10 0.50-1 1-5 20-40 10 50-100

Note: To convert parts per million (ppm) or milligrams per liter (mpl) to grains divide by 17.1. Example: Water Hardness of 250 ppm (250 ppm 17.1 ppm/gr) = 14.6 gr.

EDUCTOR AND FLOW CONTROL DATA

MODEL # TT 60F95 TT 90F95 TT120F95 TT 150F95 TT 180F95 TT 210F95 TT 240F95 TT 300F95 INJECTOR #3 Yellow #3 Yellow #3 Yellow #3C Yellow #3C Yellow #4C Green #4C Green #4C Green RATE 1.10 gpm 1.10 gpm 1.10 gpm 1.30 gpm 1.30 gpm 1.79 gpm 1.79 gpm 1.79 gpm SLOW RINSE B.L.F.C.1 D.L.F.C.2 1.0 gpm 5.0 gpm 1.0 gpm 5.0 gpm 1.0 gpm 7.0 gpm 2.0 gpm 12.0 gpm 2.0 gpm 12.0 gpm 2.0 gpm 12.0 gpm 2.0 gpm 15.0 gpm 2.0 gpm 15.0 gpm

BRINE (SALT) DATA

TANK DIA. (IN.) 18 20 24 30 36 42 48 54 60 66 72 TANK BRINE PER AREA INCH OF HEIGHT (SQ. FT.) (GALLONS)* 1.76 1.10 2.16 1.33 3.14 1.95 4.90 3.04 7.06 4.40 9.62 5.97 12.57 7.8 15.90 9.9 19.63 12.2 23.76 14.7 28.27 17.5 SALT PER INCH SATURATED BRINE SOLUTION (LBS) 2.86 3.48 5.07 7.90 11.4 15.5 20.2 25.2 31.8 38.2 45.5

KEY TO THE NOTATIONS ABOVE: 1. Brine Line Flow Control (Refill Brine Tank) 2. Drain Line Flow Control (Backwash and Rapid Rinse Flow Rate) Due to varying water conditions, tank sizes, and water pressures, the above settings should be used only as a guideline.

*without salt in tank - brine only It is recommended that a good grade of solar or pellet salt be used. One gallon warm water (80F) will dissolve a maximum of 2.6 lbs. of salt. One gallon colder water will dissolve a maximum of 2.4 lbs. of salt One gallon of saturated brine weighs 10.74 lbs.

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S EC C TION 4

Installation Instructions
Conduct a visual check of all equipment for any damage that may have occurred during shipping. NOTE: If there is obvious damage to any equipment, it must be noted on the carriers Bill of Lading. Open and inspect the contents of all closed crates, cartons, etc. and inspect for concealed damage. The manufacturer is not liable for any damage during transit. Position the equipment in its proper location, setting on a flat surface. Level equipment as required; both tanks must be at the same weight. Equipment out of plumb can exhibit poor flow characteristics which will affect the performance and regeneration of the system. Load media if required. (See Section 7 Media Loading) NOTE: Units 12 and smaller are shipped with media (resin and gravel), distribution tube, and control valve installed. Warning: If new distribution tube is to be installed, it must be cut 1/16 below top of tank (valve) mounting. Unit should be positioned with the valve control facing forward. Install 1-1/2 copper interconnecting pipe. Check the main line war pressure. The softener is designed for a minimum of 30 psi and a maximum of 120 psi working pressure. If the line pressure exceeds this limit, a pressure-reducing valve should be installed. NOTE: Injector flow rates are based on approximately 40 to 60 psi working pressure. Maximum allowable water temperature of 120F. A 120 Vac, 60cycle electrical source must be available for operation of the control timer. Connect raw water supply line to the inlet valve connection. Connect treated water outlet to service line. It is suggested that pipe sizes be equal to or one size larger than the valve connection. Warning: When piping with copper, solder all piping as subassemblies before installing. Internal valve damage can result from the high heat of the torch. It is recommended that manual isolation valves be installed on the inlet and outlet piping along with a system bypass valve. This will isolate the unit when service is required. (See Section 10 Typical Piping Arrangement Drawing) Connect Drain to a sump, drain trench or other open drain. Open drains are required for taking samples and allowing a visual check. Avoid overhead pipe runs to drain facility, as undue back pressure will affect the operation of injectors. NOTE: All piping is to meet your state and local code. Position brine tank approximately 6 from the softener tank on a level smooth surface. Connect the brine air check assembly in the salt/brine tank to the brine suction (eductor) connection. If brine tank is located more than six feet from softener tank, use one size larger tubing. Tubing 5/8 may be installed from the brine tank overflow to drain. This is a gravity drain designed to divert brine overflow to the drain in the event of a malfunction which could cause overflow of the brine tank. Be sure inlet/outlet isolation valves are closed and by-pass valve is open.

PROGRAM WHEEL FOR CONTROL OF REGENERATION CYCLE

BRINE TANK REFILL FIELD ADJUSTED (16 MIN. SHOWN) (2 MIN. PER HOLE) FAST RINSE 10 MINUTE (2 MIN. PER PIN) BRINE & RINSE 60 MINUTE (2 MIN. PER HOLE) BACKWASH 60 MINUTE (2 MIN. PER

CLOSE-UP VIEW OF PROGRAM WHEEL (see Section 6 for its location and use)
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S EC C TION 5

Start-Up Instructions
The start-up of this system is relatively simple and should be easily accomplished. It is suggested that the start-up procedure be reviewed thoroughly until each step is fully understood. Tank #1 will have control valve. Tank #2 will have tank adapter. Remove Control Box Cover. Notice the indicator located on right side of housing with two arrows that tell you the control valve position during regeneration and which tank is in service. Do not plug unit into electrical outlet yet. On units without bypass lever, close inlet/outlet isolation valves and open bypass valve and flush piping. Once piping has been flushed, open inlet/ outlet isolation valves and close bypass valve. Let water flow into the mineral tank. When water flow stops, open cold water tap nearby and let run until system is relieved of air pressure.

INDICATOR

Next, plug unit into electrical outlet. DO NOT INSERT METER CABLE YET. Turn manual regeneration knob so that indicator mentioned above shows valve is in backwash position (See Section 6 Manual Regeneration) to relieve any air from the vessel. With a water hose, fill the brine tank with approximately 6 of water. Let cycle timer automatically switch to second position brine in/slow rinse. Observe brine (water) draw from brine tank. Once water drops to a certain level a ball check in the brine well closes, thus not allowing air in the system. Move manual regeneration knob to the next position fast rinse. Allow water to go to drain. Water color should be clear at the end of step 10 minutes. Timer will automatically move to next position brine refill. Once brine refill step is complete, check water in brine tank. Water level should be approximately 1 above grid plate. If not, adjust brine refill time accordingly. (See Section 6 How to Change Regeneration Cycle Times) Allow timer to return to home (Service) position automatically. Once back in the service position, cycle the control valve again into the backwash position. The tanks will switch and relieve any air from the other vessel. Slowly cycle the control valve back to the service position. (See Section 6 Manual Regeneration) Unplug unit from electrical outlet when setting the gallon wheel. Knowing the amount of resin per each tank and the salt setting per regeneration, calculate the gallons available. (See Section 3 Exchange Capacity Data)

TIMER FACE ILLUSTRATION

LOWER WHEEL HAS/IS REGENERATION KNOB

The 9500 valve regenerates with soft water from the other tank. Water used for regeneration must be subtracted from total gallons available. (See Section 3 Eductor and Flow Control Data) Example: 20 Diameter Tank A. Backwash . . . . . . . . . . . . . . . .(10 min) (12 gpm) = 120.0 gal. B. Brine In/Slow Rinse . . . . . . . . (42 min) (1.95 gpm) = 81.9 gal. C. Rapid Rinse . . . . . . . . . . . . . .(10 min) (12 gpm) = 120.0 gal. D. Brine Fill . . . . . . . . . . . . . . . . . (10 min) (2.0 gpm) = 20.0 gal. Regeneration Water Used 341.9 gal. Subtract 342 from total gallons available.

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S EC C TION 6

Program Setting Procedure

SET GALLONS CALCULATED Lift (pull hub toward you) the gallon label wheel (the inner dial of the meter program wheel) so you can rotate meter program wheel freely. Position the white dot on the meter program wheel opposite the approximate number of gallons calculated. NOTE: There is a slight delay time from the time the meter zeros out and when the cycle starts. Units using the 1/15 rpm motor, 82 minute regeneration time available (tanks 6 thru 12) have a 9 minute delay. Units using the 1/30 rpm motor, 180 minute regeneration time available (tanks 13 and larger) have an 18 minute delay. Typically on residential equipment this delay period is not critical. On commercial applications, this must be taken into consideration and continuous flows for 9 minutes or 18 minutes should be subtracted from water available. NOTE: If during the setting of your meter wheel, or your water usage is such that the capacity of the in-service unit is exhausted before the timer is back into service; the trip arm will advance past the position shown and the Meter Reset Stop will stall in the 12:00 position. No regenerations will be initiated. To get unit back to proper position: 1st turn manual regeneration knob into backwash, and 2nd lift the reset plate up and allow the meter program wheel to reset itself. Insert meter cable into meter and controller. Check that both inlet/outlet isolation valves are open and the bypass valve is closed. Check that system bypass valve is in the service position. Plug unit in electrical outlet. Unit is ready for service. HOW TO SET THE REGENERATION CYCLE PROGRAM The regeneration cycle program on your water conditioner has been factory preset; however, portions of the cycle or program may be lengthened or shortened in time to suit local conditions. The timer face plate is hinged. To expose cycle program wheel, grasp timer in lower right-hand corner and pull, releasing snap retainer and swinging timer to the left. To change the regeneration cycle program, the program wheel must be removed. Grasp program wheel and squeeze protruding lugs towards center; lift program wheel off timer. (Switch arms may require movement to facilitate removal). Return timer to closed position engaging snap retainer in back plate. Make certain all electrical wires locate above snap retainer post. How to Change the Length of the Backwash Time: The program wheel as shown in the drawing is in the service position. As you look at the numbered side of the program wheel, the group of pins starting at zero determines the length of time your unit will backwash. FOR EXAMPLE: If there are six pins in this section, the time of backwash will be 12 min. (2 min. per pin). To change the length of backwash time, add or remove pins as required. The number of pins times two equals the backwash time in minutes.

TENERGY WATER 2001

How to Change the Length of Brine and Rinse Time: The group of holes between the last pin in the backwash section and the second group of pins determines the length of time that your unit will brine and rinse (2 min. per hole). To change the length of brine and rinse time, move the rapid rinse group of pins to give more or fewer holes in the brine and rinse section. Number of holes times two equals brine and rinse time in minutes. How to Change the Length of Rapid Rinse: The second group of pins on the program wheel determines the length of time that your water conditioner will rapid rinse (2 min. per pin). To change the length to rapid rinse time, add or remove pins at the higher numbered end of this section as required. The number of pins times two equals the rapid rinse time in minutes. How to Change the Length of Brine Tank Refill Time: The second group of holes on the program wheel determines the length of time that your water conditioner will refill the brine tank (2 min. per hole). To change the length of refill time, move the two pins at the end of the second group of holes as required. The regeneration cycle is complete when the outer micro-switch is tripped by the two pin set at end of the brine tank refill section. The program wheel, however, will continue to rotate until the inner micro-switch drops into the notch on the program wheel. MANUAL REGENERATION Turn the manual regeneration knob clockwise until the service position indicator is in the 3:00 position. This slight movement of the Manual Regeneration Knob engages the program wheel and starts the reset motor. The black center knob will make one revolution. Warning: When you manually move cycle timer to different regeneration steps you must wait until positioning of upper and lower piston has stopped before advancing to next step. If advanced too fast the control will not advance to the service position or to any other position. To correct this, rotate the manual knob back to service and start again. When manual regeneration is engaged, position of regeneration cycle is shown by the arrow on the position indicator.

S EC C TION 7

Media Loading
Media loading or replacement is sometimes required for units in the field. Replacement of media is relatively simple, if the following procedure is followed: Replacement of Media Close inlet/outlet isolation valve of unit to be rebedded. Manually turn timer dial to backwash position (See Section 6 Manual Regeneration) to relieve vessel pressure. Unplug electrical connection of unit. Disconnect inlet, outlet, drain, and brine lines. Unscrew valve head from tank. Remove distribution tube from tank and visually inspect for any damage or wear replace if necessary. Warning: If new distribution tube is to be installed, it must be cut 1/16 below top of tank (valve) mounting connection. Empty tank into resin trap/strainer, holding the resin/gravel and allowing water to flow to drain. Dispose of used media. Relocate tank in original location. NOTE: Disposal of resin must meet local and state regulations.
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Loading of Media Install distribution tube in mineral tank. Place a cap or tape over the open end of distributor to prevent any media from entering. Fill tank with approximately one-third water to act as a buffer. Slowly pour the required amount of media in each vessel: Gravel to be loaded first Resin to be loaded second Multiple tank system, divide the gravel and resin quantities equally per number of vessels. Clean top of tank and tank threads of any resin or gravel. Remove cap or tape from distribution tube and clean. Visually check and clean valve and distribution O Ring of any foreign matter and lubricate with silicone or soap. NOTE: Do not use Vaseline or grease. Locate control valve on tank making certain riser tube is located properly. Tighten valve to tank. Reposition and level tank if necessary to assure proper alignment. Connect inlet, outlet, drain, and brine connections. The unit is ready for start-up. (See Section 5)
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S EC C TION 8 UNIT ASSEMBLY

ITEM NO. NO. REQD PART NO. DESCRIPTION

1 2 3 4 5

6 7

8 9 10 11 12 13

1 Specify Specify Specify 2 2 2 2 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1

K4028 A4000 A7005 A7006 C2020-4 C2023 C2025 C2026 C2028 C2029 C1031 D5007 G2002 G2003 G2004 G2007 H1072 H1075 H1040-36 H1071 H1015 H1024 H1018 K4560366 V2003-A

9500 Control Valve w/1-1/2 Meter C1 Dark softener Resin #20 Flint Gravel 1/4 x 1/8 Gravel 12 x 52 - 4 PI Blue Tank w/RB 14 x 42 - 4 PI Blue Tank w/RB 16 x 65 - 4 PI Blue Tank w/RB 20 x 62 - 4 PI Blue tank w/RB 22 x 54 - 4 PI Natural Tank w/Base 22 x 60 - 4 Pl Natural Tank w/Base 24 x 72 - 4 1-1/2 - 72 w/R2A-2 Screen (cut to fit) 18 x 40 Blue Tank 24 x 41 Black Tank 24 x 50 Black Tank 30 x 48 Black Tank TP500 Grid Plate 24 Grid Plate 3-1/2 Brine Well x 36 6 Well x 48 H. 3-1/2 Brine Well Cap 6 Brine Well Cap Overflow Set Brine Assembly 1 F x 3/4 F Brass Flow Control 1 PVC Flow Control

BRINE PICKUP SYSTEM ASSEMBLY

ITEM NO. NO. REQD PART NO. DESCRIPTION

1 1A

H7076-28 H7076-36

1B 1C 1D 1E 1F 1G 1H 1J 1K 1L 1M 1N 1P 2

I4366J

Brine Assembly 33 Tank Brine Assembly 40 Tank 3/8 X 28 Rigid PVC (for 28 brine wells) 3/8 x 30 Rigid PVC (for 30 brine wells) 3/8 x 36 Rigid PVC (for 36 brine wells) Body, Drilled Less Ball Quad Ring Float Rod - 14 Float Rod - 24 Float Grommet (2 required) Bell Type Float Guide, Lock, Adaptor Washer Crown Nut Ball Cage Air Check Ball Quad Cup Seat Stem Spool Seat 3/8 x 3/8 Union Elbow

NOTE: Brine System Sold as Assemblies Only.

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S EC C TION 9

Troubleshooting
PROBLEM 1. LOSS OF RESIN 2. SOFTENER FAILS TO REGENERATE CAUSE A. Broken distribution tube B. Inlet/outlet connection reversed A. Electrical service to unit interrupted. B. Timer defective C. Power failure A. Bypass valve open B. No salt in brine tank C. Injector screen plugged D. Insufficient water flowing into brine tank E. Hot water tank hardness F. Leak at distributor tube G. Internal valve leaking 4. UNIT USED TOO MUCH SALT 5. LOSS OF WATER PRESSURE A. Improper salt setting B. Excessive water in brine tank A. Iron buildup in line to water conditioner B. Iron buildup in water conditioner CORRECTION A. Replace distribution tube. B. Reconnect inlet/outlet connection properly. A. Assure permanent electrical service (check fuse, plug, pull chain, or switch). B. Replace timer. C. Reset time of day. A. Close bypass valve. B. Add salt to brine tank and maintain salt level above water level. C. Clean injector screen. D. Check brine tank fill time and clean brine line flow control if plugged. E. Repeated flushing of the hot water tank is required. F. Make sure distributor tube is not cracked. Check O Ring and tube pilot. G. Replace seals and spacers and/or piston. A. Check salt usage and salt setting. B. See Problem No. 8. A. Clean line to water conditioner. B. Clean control and add mineral cleaner to mineral bed. Increase frequency of regeneration. C. Remove piston and clean control.

3. HARD WATER

C. Inlet of control plugged due to foreign material broken loose from pipes by recent work done on plumbing system 6. LOSS OF MINERAL THROUGH DRAIN LINE 7. IRON IN CONDITIONED WATER A. Air in water system

A. Assure that well system has proper air eliminator control. Check for dry well condition. A. Check backwash, brine draw, and brine tank fill. Increase frequency of regeneration. Increase backwash time. A. B. C. D. E. Clean flow control. Clean injector and screen. Replace timer. Replace brine valve seat and clean valve. Clean brine line flow control.

A. Fouled mineral bed

8. EXCESSIVE WATER IN BRINE TANK

A. Plugged drain line flow control B. Plugged injector system C. Injector screen plugged D. Foreign material in brine valve E. Foreign material in brine line flow control

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Troubleshooting
PROBLEM 9. SOFTENER FAILS TO DRAW BRINE CAUSE A. Drain line flow control plugged B. Injector plugged C. Injector screen plugged D. Line pressure too low E. Internal control leak A. Broken or shorted switch A. Valve not programming correctly

continued
CORRECTION A. B. C. D. E. Clean drain line flow control. Clean injector. Clean screen. Increase line pressure to 20 P.S.I. Change seals, spacers, and piston assembly.

10. CONTROL CYCLES CONTINUOUSLY 11. DRAIN FLOWS CONTINUOUSLY

A. Determine if switch or timer is faulty and replace it, or replace complete power head. A. Check timer program and positioning of control. Replace power head assembly if not positioning properly. B. Remove power head assembly and inspect bore. Remove foreign material and check control in various regeneration positions. C. Replace seals and piston assembly. A. Replace drain line. B. Replace seals in piston assembly.

B. Foreign matter in control

C. Internal control leak 12. BRINE TANK FILLS DURING BRINE DRAW STEP OPTIONAL WATER METER 13. SOFTENER DELIVERS HARD WATER A. Reserve capacity exceeded B. Program wheel not rotating with meter output A. Clogged drain B. Internal piston seal leaks

C. Meter not measuring flow

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 it does not, replace timer. C. Check flow output by observing rotation of small gear on front of timer. Each tooth to tooth is approximately 30 gallons; if not, replace meter. NOTE: Program wheel must not be against regeneration stop for this check.

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S EC C TION 1 0

OPTIONAL

INSTALLATION
TYPICAL PIPING

DUPLEX INSTALLATION
TYPICAL PIPING

TYPICAL INSTALLATION

TYPICAL INSTALLATION

BRINE TANK ASSEMBLY

(18 Diameter)

BRINE TANK ASSEMBLY

(24 Diameter and Larger)

DISTRIBUTED BY:

Manufactured by: Tenergy Water, LLC, New Britain, Connecticut

PN-X0S9500