®
OPERATING MANUAL
WATER QUALITY & CONDITIONING PRODUCTS
WATER CONDITIONER
with WM100SM valve
INTRODUCTION
and establishes the service piston positions. The display
General Warnings
The control valve, fittings and, or bypass are designed to
accommodate minor plumbing misalignments but are not
designed to support the weight of a system or the
plumbing.
should flash all wording, then flash the software version (e.g.
154) and then reset the valve to the service position.
All plumbing should be done in accordance with local plumb-
ing codes. The pipe size for the drain line should be a mini-
mum of 1/2". Backwash flow rates in excess of 7 gpm or
length in excess of 20' require 3/4" drain line.
Do not use Vaseline, oils, other hydrocarbon lubricants or
spray silicone anywhere. A silicon lubricant may be used on
black o-rings but is not necessary. Avoid any type of lubri-
cants, including silicone, on red or clear lip seals.
Solder joints near the drain must be done prior to connect-
ing the drain line flow control fitting. Leave at least 6"
between the drain line control fitting and solder joints when
soldering pipes that are connected on the drain line control
fitting. Failure to do this could cause interior damage to the
drain line flow control fitting.
The nuts and caps are designed to be unscrewed or tight-
ened by hand or with the special plastic wrench. If necessary
a pliers can be used to unscrew the nut or cap. Do not use
a pipe wrench to tighten or loosen nuts or caps. Do not place
screwdriver in slots on caps and/or tap with a hammer.
When assembling the installation fittings package (inlet and
outlet), connect the fitting, to the plumbing system first and
then attach the nut, split ring and o-ring. Heat from soldering
or solvent cements may damage the nut, split ring or o-ring.
Solder joints should be cool and solvent cements should be
set before installing the nut, split ring, and o-ring. Avoid get-
ting primer and solvent cement on any part of the o-rings,
split rings, bypass valve or control valve.
Do not use pipe dope or other sealants on threads, Teflon
tape must be used on the threads of the 1" NPT elbow or the
1/4" NPT connection and on the threads for the drain line
connection. Teflon tape is not necessary on the nut connec-
tion or caps because of o-ring seals.
After completing any valve maintenance involving the drive
assembly or the drive cap assembly and pistons, press the
NEXT and REGEN buttons for 3 seconds or unplug power
source jack from the printed circuit board (black wire) and
plug back in. This resets the electronics
Plug into an electrical outlet. Note: All electrical connections
must be connected according to local codes. (Be certain the
outlet is uninterrupted.)
Install grounding strap on metal pipes.
Principles of Softening and Ion-Exchange
Softening of water by the exchange process involves the
exchange or substitution of the hardness minerals, chiefly calci-
um 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.
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 stronger charged cations calcium and magnesium
than it does the weaker sodium cations.
Calcium and magnesium ions in water are actually dissolved
rock. They have been dissolved by water, the “universal solvent”,
as it trickles down through strata of rock and soil it dissolves cal-
cium 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 dissolve
hardness minerals of calcium and magnesium and is said to be
hard water.
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 calci-
um and magnesium and no further exchange can take place.The
resin is said to be exhausted and must be regenerated.
An ion exchange softener exchanges the hardness minerals, cal-
cium, and magnesium, for sodium, from the softener resin.
Sodium is less objectionable because it does not build up on sur-
faces as scale deposits.
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 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 weaker 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
is said to be regenerated and ready for the next softening cycle.
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, consist of millions of tiny plastic beads, all of
which contain many negatively charged exchange sites to attract
the positive cations. When the resin is in the regenerated state
these negatively charged exchange sites hold positively charged
sodium cations.
3
INTRODUCTION
Specifications TABLE I
Minimum/Maximum Operating Pressures
Minimum/Maximum Operating Temperatures
Current Draw & Voltage
20 psi (138 kPa) -125 psi (862 kPa)
40°F (4°C) -110°F (38°C)
0.5 Amperes 110 Volts Other options available
Table 2 contains a summary of specifications for the control valve and bypass valve.
Quick Reference Specifications TABLE 2
Service flowrate (includes bypass)
Backwash flowrate (includes bypass)
Minimum/Maximum Operating Pressures
Minimum/Maximum Operating Temperatures
Current Draw & Voltage
27 gpm (102.2 lpm) @ 15 psig (103 kPa) drop
27 gpm (102.2 lpm) @ 25 psig (172 kPa) drop
20 psi (138 kPa) -125 psi (862 kPa)
40°F (4°C) - 100°F (38°C)
0.5 Amperes110 Volts Other options available
0.5 gpm (1.9 lpm)
Regenerant Refill Rate
Injectors
See Injector Graphs
Drain Line Flow Controls
See Table 11
Inlet/Outlet Fitting Options
(a) 1" NPT elbow which has a unique drill out feature to
allow a 1/4" NPT connection to the inlet and/or outlet
(b) 3/4" & 1" PVC solvent weld fitting
(c) 1" straight brass sweat fitting
(d) 3/4" straight brass sweat fitting
Distributor Tube Opening
Tank Thread
1.05" Diameter (3/4" U.S. PVC Pipe Size)
2-1/2" - 8 NPSM
Control Valve Weight
PC Board Memory
4.5 lbs 2.0 kg
Nonvolatile EEPROM
(Electrically erasable programmable read only memory)
Compatible with regenerants/chemicals
Sodium chloride, potassium chloride, potassium
permanganate, sodium bisulfite, sodium hydroxide,
hydrochloric acid, chlorine and chloramines
SOFTENING
CAPACITY
LBS. SALT
PER REGEN
FLOW RATE &
PRESSURE
MINERAL TANK
BRINE TANK
MODEL
PIPE
SIZE
TANK
SIZE
RESIN
CU. FT.
SIZE
SALT
FILL
SERV DROP
BKW
GPM
MAX
MIN
MAX MIN
GPM
PSI
M3011-W100SM
M3013-W100SM
M3015-W100SM
M3017-W100SM
M3019-W100SM
M3021-W100SM
1"
1"
1"
9 X 48
10 X 54
12 X 52
13 X 65
16 X 65
21 X 62
1
1.5
2
3
4
18 X 36
18 X 36
18 X 36
18 X 36
18 X 36
24 X 41
300
300
300
300
300
600
30K
45K
60K
90K
120K
210K
20K
30K
40K
60K
80K
140K
15
22
30
45
60
6
9
12
18
24
42
15
16
20
21
22
24
15
15
15
15
15
15
2.0
2.7
3.2
5.3
7.5
1.25/1.5
1.25/1.5
1.25/1.5
7
105
11.0
4
CONTROL VALVE FUNCTIONS
Control Valve Function and Cycles of Operation
This glass filled Noryl fully automatic control valve is designed
The transformer power pack comes with a 15-foot power cord
and is designed for use with the control valve. The transformer
power pack is for dry location use only. The control valve remem-
bers all settings for two hours if the power goes out. After two
hours the only item that needs to be reset is the time of day, all
other values are permanently stored in the nonvolatile memory.
The control valve does not need batteries.
as the primary control center to direct and regulate all cycles of
a water softener. The control valve can be set to regenerate on
demand (consumption of a predetermined amount of water)
and/or as a time clock (passage of a particular number of days).
The control valve is compatible with a variety of regenerants
andresin cleaners. The control valve is capable of routing the
flow, of water in the necessary paths to regenerate or backwash
water treatment systems. The injector regulates the flow of brine
or other regenerants. The control valve regulates the flow rates
for backwashing rinsing and the replenishing of treated water into
a regenerant tank.
When the control valve is used as a down flow softener, two
backwashes always occur. The softener will start regenerant
prefill before regeneration, the prefill starts two hours before the
regeneration time set. During the 2-hour period in which the brine
is being made, treated (softened) water is still available. For
example:regeneration time = 2:00 am, prefill option selected,
downflow softener. Fill occurs at 12:00 a.m., start of backwash
cycle occurs at 2:00 a.m.
The control valve is designed to deliver high service (27 gpm @
15 psig) and backwash (27 gpm @ 25 psig) flow rates when the
bypass has straight fittings. The control valve uses no traditional
fasteners (e.g. screws), instead clips, threaded caps and nuts
and snap type latches are used. Caps and nuts only need to be
firmly hand tightened because radial seals are used. Tools
required to service the valve include one small blade screwdriv-
er, one large blade screwdriver, pliers and a pair of hands. A
plastic wrench is available which eliminates the need for screw-
drivers and pliers. Disassembly for servicing takes much less
time than comparable products currently on the market.
The softener will adjust the backwash and rinse cycles automat-
ically when the salt dosage is changed . Backwashes can
be set to be NORMAL or LONGER. The option selected will
apply to all backwashes. Tables 4 and 5 show the length of the
cycles when the valve is set up as a softener.
REGENERATION STEPS AND PURPOSE:
EXCHANGE CAPACITY DATA
Brine fill – Brine tank is filled to dissolve salt for next
regeneration.
20,000 grain approx. per cu. Ft.
6 lbs. salt-sodium chloride
Backwash – Flow through the resin bed is reversed.
Water flows upward expanding and agitating the resin bed.
25,000 grain approx. per cu. Ft.
8 lbs. salt-sodium chloride
Brine in – Brine is educted from the brine tank and pass-
es through the resin bed in a downward flow, thus remov-
ing calcium and magnesium that has accumulated on the
resin beads and is flush to drain.
30,000 grain approx. per cu. Ft.
15 lbs. salt-sodium chloride
Note: To convert parts per million (PPM) or milligrams per
liter (mpl) to grains divide by 17.1
Backwash – A second backwash is performed
Example: Water hardness of 250 PPM
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.
(250 PPM divided by 17.1 PPM/gr.) equals 14.6 gr.
It is recommended that a good grade of solar or pellet salt
be used.
One-gallon water will dissolve approximately 3.0 lbs. of salt
One gallon of saturated brine weighs 10.74 lbs.
Service – Softener goes back into service and ready to
soften water.
5
INSTALLATION
Installation Preview
Conduct a visual check of all equipment for any damage that
Note: Softener to be located at least 10 feet away from hot
may have occurred during shipment.
waterheater to protect against hot water back-up.
Note: If there is obvious damage to any equipment, it should
be noted on the carrier’s Bill Of Lading. Open and inspect the
contents of all closed crates, cartons, etc. and inspect for con-
cealed damage. The manufacturer is not liable for any dam-
age during transit.
Warning: When piping with copper, solder all piping as sub-
assemblies before installing. Internal damage can result from
the high heat of the torch.
It is recommended that manual isolating valves be installed
on the inlet and outlet piping along with a system bypass
valve. This will isolate the unit when service is required.
Run drain line 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 backpressure will affect the operation of injectors.
Position the equipment in its proper location, setting on a flat
surface. Level equipment as required. Equipment out of
plumb can exhibit poor flow characteristics, which will affect
the performance of the system.
Note: Units are shipped with media (resin & gravel), distribu-
tions tube, and control valve installed. Double-check the valve
installation on the tank. Tighten if necessary.
Note: All piping is to meet your local and state code. AVOID
CROSS CONNECTIONS!
Unit should be positioned with the valve control facing forward.
Position brine tank approximately 6" from the softener tank on
a smooth surface.
Check the main line water pressure. The softener is designed
for a minimum of 20 psi and a maximum of 125 psi working
pressure. If the line pressure exceeds this limit, a pressure-
reducing valve should be installed.
Connect the brine air check assembly in the salt/brine tank to
the brine suction (eductor) connection. If brine tank is located
more than 6 feet from softener tank, use one size larger tub-
ing. Tubing 5/8" should be installed from the brine tank over-
flow to drain. This is a gravity drain designed to divert brine to
the drain in the event of a malfunction, which would cause
overflow of the brine tank.
Maximum allowable water temperature is 40°F (4°C) – 110°F
(38°C). A 120vac 60 cycle electrical source must be available
for operation of the controller.
Connect raw water supply line to the inlet valve connection.
Connect treated water outlet to service line. It is suggested that the
pipe size be equal or one size larger than the valve connection.
Be sure inlet/outlet isolating valves are closed and bypass
valve is open.
Installation
STEP 1: Select Location
STEP 2: Install a bypass
Locate main water supply for all faucets and appliances in
home (if possible outside faucets should be separate so not
to waste soft water).
Note: Always install a bypass, either a 3-way valve system
or the standard bypass for the valve you have.This will allow
you to shut off the water supply to the softener, but still have
water in the house if the softener is in need of repair.
Select location that is easily accessible to 110vac power. A
15-foot power cord is provided.
After a location has been determine install bypass onto the
control valve. (Figures 1 and 3 show standard bypass on
valve.) (Figures 2 and 4 show 3-way by pass plumbing.)
You will also need a drain close by for disposal of regenerat-
ed wastewater.
Note: If installing a 3-way bypass valve, do so now.
Close main water supply valve, at the well or at the water meter.
Shut off electrical or fuel supply to the water heater.
Open all faucets to drain pipes.
Leave enough room between walls so you can easily add salt
when needed.
Locate the water softener at least 10 feet away from the hot
water heater so that hot water does not backup and damage
the softener.
Note: If installing standard bypass, move to step 3.
Make sure water softener is in a level spot. You may be
required to put the softener on a platform, such as a piece of
3/4” plywood and shimmed to become level.
The bypass (provided) easily connects to the valve body
using nuts that only require hand tightening. The split ring
retainer design holds the nut on and allows load to be spread
over the entire nut surface area reducing the chance for leak-
age. Make certain the nut is placed on first, then the split
retainer ring, followed by the o-ring to make the seal. A silicon
lubricant may be used on the black o-ring seals. This design
allows for an approximate 2-degree misalignment of the
plumbing. This design will allow for minor plumbing misalign-
ments, but should never handle the weight of the plumbing
system.
Make sure softener is behind any other water conditioning
systems installed in series, except a system that is for taste
and odor or a Reverse Osmosis system.
Select a location were water damage will be least likely to
occur if a leak should develop.
If installing the softener in an outside location make sure
to protect from the elements, such as rain, sunlight, and
contamination.
6
INSTALLATION
Figure 2: Plumbing with 3-way b pass.
Figure 1: Plumbing with by pass (Standard).
Figure 4: 3-way bypass plumbing.
Figure 3: Bypass (standard).
When installing sweat copper follow state and
federal codes by using a lead free solder and
flux. Use a joint compound to seal threaded pipe.
Some homes use the cold water pipes for an elec-
trical ground (metal only). Whenfinished with
plumbing, a ground wire should bre connected
to the copper pipes to complete the ground cur-
cuit. Use two clamps and #4 copper wire for this.
Figure 5:
Figure 6:
7
INSTALLATION
STEP 3:
Note: When assembling the installation fitting
package, connect the fitting to the plumbing
system first and then attach the nut, split ring
and o-ring. Heat from soldering or solvent
cements may damage the nut, split ring, and
o-ring. Make sure solder joints are cool
before assemble is started.
Move softener
into place
Make sure floor is level.
Install shims if needed.
Measure, cut, and install
pipe and fittings to the
bypass valve (dry fit only
to make sure you have a
proper fit) inlet and out-
let side. Be sure hard
water is supplied to the
inlet side. Trace pipe to
be sure.
joints should be cool and solvent cements should be set
before installing the nut, split ring, and o-ring. Avoid get-
ting primer and solvent cement on any part of the o-
rings, split rings, and bypass valve or control valve.
Solvent cements and primers should be used in accor-
dance with the manufacturer’s instructions.
Slip the nut onto the fitting first, then the split ring second
and the o-ring last. Hand tighten the nut. If the fitting is
leaking tightening the nut will not stop the leak. Remove
the nut, remove the fitting, and check for damage or mis-
alignment of the o-ring.
The installation fittings connect to the control valve or the
bypass valve using nuts that only require hand tightening.
Hand tighten nut connections between control valve and
installation fittings, control valve and bypass valve, and
bypass valve and installation fittings allow for easy serv-
iceability. Do not use a pipe wrench to tighten nuts on
installation fittings. Hand tighten only.
Do not use pipe dope or other sealant on threads. Teflon
tapemust be used on the threads of the 1" NPT elbow
and the 1/4" NPT connection and on the threads for the
drain line connection.Teflon tape is not necessary on the
nut connection or caps because of o-ring seals.
1” PVC MALE NPT ELBOW
3/4” x1” PVC SOLVENT ELBOW
STEP 4: Move brine
tank next to softener
and connect brine
draw line to value.
1” BRASS SWEAT
3/4” BRASS SWEAT
With brine tank next to the soft-
ener tank connect the brine
drawline to valve body.
Control valves that use a regen-
erant, come equipped with a
3/8" refill flow control assembly.
To complete the regenerant line connections orientate the
outlet in the desired direction and push the plastic insert into
the poly tube. Push the poly tube into the nut. Do not use
pipe dope or other sealant on threads. The threads for the
compression nut do not need Teflon tape. Tighten the nut
securely to create a pressure tight connection. A pliers or
crescent wrench may be used to tighten or unscrew the nut.
The nut, gripper and retainer sleeve is a 3-piece assembly
that can come apart if removed from the elbow body. Parts
must be reassembled exactly as shown in refill flow con-
trol assembly drawing to function properly. If the nut is
completely removed from the body, slip the nut, plastic
gripper and retainer sleeve on to the tube then tighten on
to the fitting. Complete the connection by installing the
loose end of the tubing to the brine valve in the salt tank.
Figure 8: Four types of installation fittings.
Split ring retainer design holds the nut on and allows load
to be spread over the entire nut surface area reducing the
chance for leakage. The split ring design, incorporated into
the installation fittings allows approximately 2 degrees off
axis alignment to the plumbing system. The installation fit-
tings are designed to accommodate minor plumbing mis-
alignments but are not designed to support the weight of a
system or the plumbing.
When assembling the installation-fitting package, connect
the fitting to the plumbing system first and then attach the
nut, split ring and o-ring. Heat from soldering or solvent
cements may damage the nut, split ring, or o-ring. Solder
8
INSTALLATION
STEP 5: Connect the Drain Line
If the drain line is a 5/8" flexible poly tube, slide the nut onto
the poly tube, then place the poly tube insert into the end of
the poly tube and tighten the nut on to the 3/4" drain line fit-
ting. The nut is only designed for use with flexible poly tube.
Use other nuts if attaching different materials. Run line to a
drain. Making sure you have a 1 1/2" airgap. You may use a
floor drain, standpipe or any open type drain (see Fig 10).
Do not use Vaseline, oils, or other unacceptable lubricants on
o-rings. A silicon lubricant may be used on the black o-ring.
Use a pliers or crescent wrench to tighten or unscrew the nut.
Do not use a pipe wrench to tighten or loosen nut. Do not use
pipe dope or other sealant on threads. Use Teflon tape on the
threads of the drain line control fitting when installing 3/4"
NPT or 1" straight fitting.
Figure 9: Brine Draw Connection.
Figure 11: Drain Line Connection
Figure 10: Also be sure drain line has an air gap.
STEP 5: Start-up
Place the bypass valve in the “bypass” position or mode
(see figures 12-14 below.)
This will put the valve in manual mode. Now press the Regen
button twice.This will put the system in backwash. Slowly open the
inlet valve. (Open the valve a little at a time, pausing several times
to allow the unit to fill slowly and expel air.) When the tank has filled
and a steady flow to the drain is achieved, let the system run until
clear water can be seen coming from the drain line. When water is
clear press the regen button 4 times. This will take the valve back
to service position. Open several cold water and hot water faucets
and let run until hot water heater is full and cold water faucets have
expelled trapped air. Turn electrical power back on or re-light the
hot water heater. Now continue with control valve setup.
Open the main water supply valve.
Open a couple of cold water faucets that are to be conditioned
and let run until air is expelled and pipes are full.
Open the outlet valve of the bypass.
Close the bypass valve.
Press and hold the regen button on the keypad for 3 seconds.
Figure 12: Operating Mode
Figure 13: Bypass Mode
Figure 14: Bypass Mode
9
CONTROL PROGRAMMING
FILTER
SETTINGS*
TIME
CLOCK
DIR
RESERVE CAPACITY
SOFTENER
BACKWASH
ONLY
DAY
GALLON
REGENERANT
OVERRIDE
CAPACITY
Yes
Yes
Automatically Calculated Yes Off Auto
Yes
Yes
Off
Off
Auto
If desired enter a value less
than estimated capacity
Yes
Yes
Any Number
Yes
Yes
Yes
Yes
Automatically calculated
Yes
Yes
Any Number
Auto
If desired enter a value less
than estimated capacity
Yes
Yes
Yes
Yes
Any Number Any Number
Yes
None
Yes
Any Number
Off
* Day override AND Gallon Capacity cannot be set to "off" at the same time
DIR/TIME CLOCK
OPTIONS
FACTORY DEFAULT PROGRAMMING
To change press and hold NEXT & ▼
For DIR Softeners, there are two
options for setting the Gallons
Capacity. The Gallons Capacity
1. Configuration . . . . . . . . . . . . . . . . . . . . .Softener
2. Grain Capacity . . . . . . . . . . . . . . . . . . . . . . . . .*
3. Pounds of salt per regeneration . . . . . . . . . . . .*
4. Backwash Duration . . . . . . . . . . . . . . . . .Normal
5. Gallons Capacity . . . . . . . . . . . . . . . . . . . . .Auto
6. Brine Refill . . . . . . . . . . . . . . . . . . . . . . . . . .Pre
7. Regenerant Flow . . . . . . . . . . . . . . . . . . . . . .dn
8. Regeneration Initiation . . . . . . . . . . .Normal +0
is automatically calculated if set
to AUTO. Reserve Capacity, is
Figure 15: Key Pad
automatically estimated based on water usage if AUTO is used.
The other option is to set the Gallons Capacity to a specific
number. If a specific number is set, reserve capacity is zero,
unless the value is manually set (i.e. the manufacturer inten-
tionally sets the gallon capacity number below the calculated
capacity of the system).
Installer Setup: Press NEXT & ▲
This control valve is set up in the AUTO mode; it can also be set
to regenerate immediately or at the next regeneration time by
changing the Regeneration Time Option. There arc three choic-
es for settings:
1. Hardness . . . . . . . . . . . . . . . . . . . . . . . .“grains”
2. Calendar Override . . . . . . . . . . . . . . . . . . . . . . .
3. Time of Regeneratiuon (hour) . . . . . . . .2:00AM
4. Time of Regeneratiuon (minute) . . . . . .2:00AM
1. “NORMAL” means regeneration will occur at the pre
set regeneration time.
Diagnostics: Press ▼ & ▲
2. “On 0” means regeneration will occur when the gallons
1. Number of days since last regeneration
2. Number of gallons since last regeneration
3. Reserve capacity gallons used in last 7 days
4. Daily gallon usage for last 64 days
5. Current flow rate
capacity reaches zero.
3. “NORMAL” and “on 0” means the regeneration will occur at
the preset regeneration time unless the gallons capacity
reaches zero. If the gallon capacity reaches zero, the
regeneration will begin 10 minutes after no water usage.
6. Maximum flow rate in the last seven days
7. Total gallons since the last reset
8. Number of days since last reset
9. Number of regenerations since the last reset
The user can initiate manual regeneration.The user has the option
to request the manual regeneration at the delayed regeneration
time or to have the regeneration occur immediately:
1. Pressing and releasing the REGEN button. “Regen t o d a y ”
will flash on the display and the regeneration will occur at
the delayed regeneration time. The user can cancel the
request by pressing and releasing the REGEN button. This
method of manually initiating regeneration is not allowed
when the system is set to immediately regenerate when the
capacity reaches zero.
Valve History: Press ▼ & ▲ then ▼ & ▲
1. Software version
2. Maximum flow rate since start-up
3. Total number of gallons since start-up
4. Total number of days since start-up
5. Total Number of regenerations since start-up
6. Number of error occurences since start-up
2. Pressing and holding the REGEN button for approximately
3 seconds will immediately start the regeneration. The user
cannot cancel this request, except by resetting the control
by pressing NEXT and REGEN buttons simultaneously for
3 seconds.
* Refer to specification table 2 page 4.
10
CONTROL PROGRAMMING
Press NEXT to go to step 4I. Press REGEN to
return to previous step.
INSTALLER (I) Displays/Settings
STEP 1I – Press NEXT and arrow up simulta-
STEP 4I – Next Regeneration Time (hour): Set
the hour of day for regeneration using down or up
arrow buttons. AM/PM toggles after 12. The
default time is 2:00 am. This display shows
“REGEN on 0 GAL” if “on 0” is selected in Step
9S or Step 7F. Press NEXT to go to step 5I.
Press REGEN to return to previous step.
neously for 3 seconds.
STEP 2I – Hardness: Set the amount of hard-
ness in grains of hardness as calcium carbonate
per gallon using, arrow down or arrow up but-
tons. The default is 20 with value ranges from 1
to 150 in 1 grain increments. Note the grains per
gallon can be increased if soluble iron needs to
be reduced. Press NEXT to go to step 3I. Press
REGEN to exit Installer Displays/Settings.
STEP 5I – Next RegenerationTime (minutes):
Set the minutes of day regeneration using the
arrow buttons. This display will not be shown if
“on 0” is selected in Step 9S or Step 7F. Press
NEXT to exit Installer Displays/ Settings. Press
REGEN to return to previous step.
STEP 3I – Day Override: When gallon capacity
is set to off, sets the number of days between
regeneration’s. When gallon capacity is set to
AUTO or to a number sets the maximum number
of days between regenerations. If value set to
“off” regeneration initiation is based solely on
gallons used. If value is set as a number (allow-
able range from 1 to 28) a regeneration initiation
will be called for on that day even if sufficient
number of gallons were not used to call for a
regeneration. Set Day Override using arrow
buttons to days between regeneration
To initiate a manual regeneration immediately,
press and hold the “REGEN” button for three
seconds. The system will beam to regenerate
immediately. The control valve may be stepped
through the various regeneration cycles by
pressing the “REGEN” button.
(1 to 28); or OFF.
REGENERATION MODE
Typically a system is set to regener-
ate at a time of low water usage. An
example of a time with low water
usage is when a household is asleep.
If there is a demand for water when the system is regenerating,
untreated water will be used.
When the system begins to regenerate, the display will change
to include information about the step of the regeneration process
and the time remaining for that step to be completed.The system
runs through the steps automatically and will reset itself to pro-
vide treated water when the regeneration has been completed.
General Operation
MANUAL
User (U) Displays/Settings
REGENERATION
Sometimes there is a
When the system is operating one of two displays will be
shown. Pressing NEXT will alternate between the displays.
One of the displays is always the current time of day. The
second display is one of the following: days remaining or
gallons remaining. Days remaining are the number of days
left before the system goes through a regeneration cycle.
Capacity remaining is the number of gallons that will be treat-
ed before the system goes through a regeneration cycle. The
user can scroll between the displays as desired.
need to regenerate
the system, sooner
than when the system calls for it, usually referred to as manual
regeneration. There may be a period of heavy water usage
because of guests or a heavy laundry day.
To initiate a manual regeneration at the preset delayed regener-
ation time, when the regeneration time option is set to “NORMAL”
or “NORMAL + on 0”, press and release “REGEN”. The words
“REGEN TODAY” will flash on the display to indicate that the sys-
tem will regenerate at the preset delayed regeneration time. If
you pressed the “REGEN” button in error, pressing the button
again will cancel the request. Note: If the regeneration time
option is set to “on 0” there is no set delayed regeneration time
so “REGEN TODAY” will not activate if “REGEN” button is
pressed.
If the system has called for a regeneration that will occur at
the preset time of regeneration, the words REGEN TODAY
will appear on the display.
When water is being treated (i.e. water is flowing through the
system) the word “Softening” flashes on the display.
Note: If brine tank does not contain salt, fill with salt
and wait at least two hours before regenerating.
To initiate a manual regeneration immediately, press and hold the
“REGEN” button for three seconds. The system will begin to
regenerate immediately. The request cannot be cancelled.
PROGRAMMING (NOTE)
SANITIZING THE SYSTEM
1. At completion of softener
SET TIME OF DAY
installation you should
The user can also set the time
of day. Time of day should only
need to be set after extended
power outages or when day-
light savings time begins or
ends. If an extended power
outage occurs, the time of day
will flash on and off which indi-
cates the time of day should
be reset.
sanitize the system.
2. Take the lid off of the salt
tank and then take the
cap off of the brine well.
Pour about 3/4 to 1 1/2
ounce of 5.25% common
household bleach into
the brine well. Replace
cap and lid. (This can be
done with or without salt
in tank.)
STEP 1U – Press SET CLOCK.
STEP 2U – Current Time (hour): Set the hour of the day
using down or up arrow buttons. AM/PM toggles after 12.
Press NEXT to go to step 3U.
3. Press and hold regenera
tion button to start the
regeneration process
immediately.
STEP 3U – Current Time (minutes):Set the minutes of
the day using down or up arrow buttons. Press NEXT to
exit Set Clock. Press REGEN to returnto previous step.
Each water softener is
handled in a manner to
keep clean and sanitary.The
materials used will not con-
taminate your water supply
or cause bacteria to grow.
However, during shipping,
storage, installation, and
operation, bacteria growth
could develop. Some water
supplies may require periodic
disinfecting.
POWER LOSS If the power goes out for less than two
hours, the system will automatically reset itself. If an
extended power outage occurs, the time of day will flash
on and off which indicates the time of day should be reset.
The system will remember the rest.
Figure 16:
The Brine System
ERROR MESSAGE If the word “ERROR” and a number
are alternately flashing on the display contact the OEM
for help. This indicates that the valve was not able to
function properly.
SYSTEM COMPONENTS DESCRIBED
The drive bracket holds the PC board, the motor, the drive
gears and the drive gear cover in place.
Components:
The control valve consists of the following components
1. Drive Assembly
The PC board receives and retains information, displays the
information,determines when to regenerate and initiates
regeneration.The display shows different types of information
in the initial system set up (for softeners or filters), installer
displays/settings, diagnostics, and valve history or user dis-
plays/settings.
2. Drive Cap Assembly, Main Piston and
Regenerant Piston
3. Spacer Stack Assembly
4. Injector Cap, Screen, Injector Plug and Injector
5. Refill Flow Control Assembly or Refill Port Plug
6. Drain Line Flow Control and Fitting Assembly
7. Water Meter or Meter Plug
8. Installation Fitting Assemblies
9. Bypass Valve (optional)
The PC board’s two-prong jack connects wires to the direct
current (DC) motor. The motor is held in place on the drive
bracket by a spring-loaded clip and a small bulge in the plas-
tic, which fits in one of the slots on the motor housing. The
motor turns drive gears that drive the piston to cycle positions
for backwashing, regeneration, rinsing, refill or service. The
motor is fully reversible (turns both ways) and changes direc-
tion of rotation to change the direction of piston motion. The
motor is easily replaced if necessary.
DRIVE ASSEMBLY
The drive assembly consists of the following parts:
There are three drive gears held in place by the drive gear
cover. All three drive gears are the same size. A reflective
coating is applied to the gears. As the center drive gear turns
a light shines on the coating and a light sensing diode deter-
mines if a light pulse was returned. The PC board counts the
pulses and determines when to stop driving the motor.
•
•
•
•
•
Drive Bracket
Printed Circuit (PC) Board
Motor
Drive Gears
Drive Gear Cover
12
CONTENTS
TABLE 10: Injector Order Information
DRIVE CAP ASSEMBLY
Main Piston and Regenerant Piston
PART #
COLOR
TANK DIA.
KC11V3010-1D
KC11V3010-1E
KC11V3010-1F
KC11V3010-1G
KC11V3010-1J
KC11V3010-1K
RED
WHITE
BLUE
YELLOW
LT BLUE
LT GREEN
9"
The drive gears turn the main gear of the drive cap assembly,
which moves the piston. The screw-driven, horizontally mov-
ing piston stops at specific positions to direct the flow of water
to backwash, regenerate, rinse or refill. The PC board deter-
mines the position of the piston by counting pulses produced
when the piston is moved. An optical sensor looking at one of
the reduction drive gears generates these pulses. Each cycle
position is defined by a number of pulses. The counter is
zeroed each time the valve goes to the service position. The
PC board finds the service position by noting the increase in
current delivered to the motor when the mechanical stop at
the service position is reached.This method of controlling pis-
ton position allows for greater flexibility and requires no
switches or cams.
10"
12"
13"
16"
21"
through the media to regenerate the bed.
The injector provides a consistent regenerant/water mixture ratio
over the entire operating pressure range of the control valve. The
injector provides good performance in a variety of applications,
which may involve elevated drain lines and long regenerant draw
lenghts. Injectors are chosen by knowing the type, amount, and
regenerant flow rate for a particular type of media. The color-
coded injectors give different regenerant draw, slow rinse and total
flow rates over the pressure range. See Table 10 for color codes.
One of two main pistons is always used:
1. The down flow piston which is used when the control
valve is used as a down flow softener, regenerating
filter or nonregenerating filter: or
2. The up flow piston, which is used when the control valve
is used as an up flow softener.
REFILL FLOW CONTROL Assembly
The refill flow control assembly consists of a refill flow elbow, refill
flow control retainer assembly, refill flow control, poly tube insert
and nut assembly. The refill flow control retainer fits in the refill
elbow. The refill flow control retainer houses the refill flow control,
which controls the flow rate when the regenerant tank is being
refilled. The refill flow control is a flexible washer-like part with a
small orifice and a precision molded contour that delivers a
steady 0.5 gpm regenerant tank refill rate at varying inlet
pressures. Refill is accomplished with treated water.
If the control valve is used as a softener or a regenerating
filter, a regenerant piston must be attached to the main piston.
If the control valve is to be used on system that does not
require a regenerant to be added the regenerant piston must
be removed.
SPACER STACK ASSEMBLY
The refill flow control assembly is installed in an easy to access
refill elbow located on top of the control valve. The refill flow con-
trol assembly is attached to the control valve with a locking clip.
The locking clip allows the elbow to rotate 270 degrees so the
outlet can be orientated towards the regenerant tank.
The spacer stack assembly provides the necessary flow pas-
sage for water during the different cycles.The all-plastic spac-
er stack assembly (patent pending) is a one-piece design,
which allows the stack to be removed using your fingers.
The exterior of the stack is sealed against the body bore with
self-lubricating EPDM o-rings while the interior surface is
sealed against the piston using slippery self cleaning direc-
tional (oneway) silicone lip seals.The lip seals are red or clear
in color and have a special slippery coating so that the piston
does not need to be coated or lubricated.
DRAIN LINE FLOW CONTROL/Fitting
The drain line flow control assembly includes a drain line flow
control and a fitting. The drain line flow control allows proper
media bed expansion by regulating the flow rate to the drain.
The drain line flow control is a flexible washer-like part with an
orifice and a precision molded contour. The flow rates are
within +- 10% over the pressure range of 1-0 psi to 125 psi.
The flexible washer-like parts are identified with three num-
bers, which correspond to the flow rate in gallons per minute.
See Table 11.
INJECTOR
T
he screen, injector and/or injector plug(s) are installed under
the injector cap in an easy to access location on top of the valve.
The injector cap contains four slots so no water accumulates
in the cap. The injector cap is designed to be hand tightened.
The drain line flow control and fitting are located on top of the
control valve and replaceable without the use of special tools.
Under the injector cap there is an easy to clean removable
screen to prevent fouling of the injector. There are two holes
under the injector cap labeled “DN” and “UP”. The holes will be
filled with a plug or an injector.
TABLE 11: Drain Line Flow Control (3/4" Fitting)
PART #
Number on Backwash Flow Rate
Fitting
GPM
The plug (#KC113010-IZ) prevents water from traveling through
the pathway. The injector lets water pass through the pathway.
The self-priming injector increases the velocity of the water, cre-
ating a zone of negative pressure that draws in the concentrated
liquid regenerant, such as sodium chloride (brine), potassium
permanganate, sodium hydroxide, hydrochloric acid, etc. The
regenerant blends with the stream of water, which passes
KC11V3162-022
KC11V3162-027
KC11V3162-03
KC11V3162-053
KC11V3162-075
22
27
32
53
75
2.2
2.7
3.2
5.3
7.5
KC11V3190-110
110
11
13
CONTENTS
The drain line flow control can be installed in the standard
used for a RO feed, test ports, pressure tap ports, etc.
1/4" drain line elbow, which accommodates 5/8" poly tube or
3/4" NPT drain line connections. The optional nut and poly
tube insert for the 3/4" drain line elbow is designed for use
with flexible poly tube only. The 3/4" drain line elbow can be
rotated 180 degrees so the outlet can be orientated to the
nearest drain. The same retainer is used for all drain line flow
controls for the 3/4" fitting.
The installation fitting assemblies are sold in pairs and
consist of two fittings, two nuts, two split rings and two o-
rings. The installation fitting assemblies and the bypass valve
are sold separately from the control valve.
Bypass Valve
The bypass valve is typically used to isolate the control valve
from the plumbing system’s water pressure in order to per-
form control valve repairs or maintenance. The W100SM
bypass valve is particularly unique in the water treatment
industry due to its versatility and state of the art design
features. The 1" full flow bypass valve incorporates four posi-
tions including a diagnostic position that allows service per-
sonal to work on a pressurized system while still providing
untreated bypass water to the facility or residence. Its
completely non-metallic, all plastic design allows for easy
access and serviceability without the need for tools.
Water Meter or Meter Plug
The water meter is installed on the outlet side of the control
valve. The water meter uses a turbine to total gallons of treat-
ed water. The turbine rotates with the flow of water and
reports its rate of rotation through Hall-effect 8 circuitry to the
printed circuit (PC) board. This rotation permits the PC board
to record the total volume of treated water and the flow rate.
The small centrally located magnet is shielded from water,
which reduces substantially iron-fouling problems with the
turbine. The turbine is accurate to within 5% over a wide
operating flow rate range (0.25 gpm up to control valve max-
imums) and has a very low pressure drop. Water used for
regeneration is not metered. If the control valve is set to pre-
fill the regenerant, water used between the prefill cycle up to
the start of the regeneration cycle is metered. If the control
valve is in regeneration mode (e.g. a backwash cycle) and
there is a water demand that water usage is not metered.
The bypass body and rotors are glass filled Noryl and the
nuts and caps are glass filled polypropylene. All seals are
self-lubricating EPDM to help prevent valve seizing after long
periods of nonuse. Internal o-rings can easily be replaced if
service is required.
The bypass consists of two interchangeable plug valves that
are operated independently by red arrow shaped handles.
The handles identify the flow direction of the water. The plug
valves enable the bypass valve to operate in four positions.
1. Normal Operation Position: The inlet and outlet handles
point in the direction of flow indicated by the engraved
arrows on the control valve. Water flows through the
control valve during normal operation and this position
also allows the control valve to isolate the media bed
during the regeneration cycle. (See Figure 17)
2. Bypass Position: The inlet and outlet handles point to the
center of the bypass, the control valve is isolated from the
water pressure contained in the plumbing system.
Untreated water is supplied to the plumbing system.
(See Figure 18)
3. Diagnostic Position: The inlet handle points in the direction
of flow and the outlet handle points to the center of bypass
valve, system water pressure is allowed to the control
valve and the plumbing system while not allowing water
to exit from the control valve to the plumbing.
(See Figure 19)
4. Shut Off Position: The inlet handle points to the center of
the bypass valve and the outlet handle points in the
direction of flow, the water is shut off to the plumbing
systems. If water is available on the outlet side of the
softener it is an indication of water bypass around the
system (i.e. a plumbing connection somewhere in the
building bypasses the system). (See Figure 20)
When facing the front of the control valve, the water meter is
positioned on the left-hand side of the control valve. Allow
sufficient clearance to clean and repair the water meter with
out disconnecting the plumbing or disassembling any other
parts of the control valve.
A unique feature of this control valve is the ability to display
actual water usage for the last 63 days.The values are initially
stored as "_" because it is is unknown. As days pass values
are stored as “O” for no flow or the actual number of galons.
The counting of the gallons starts at the regeneration
time. If no regeneration time can be set (i.e. when the valve is
set for immediate regeneration) the counting, of gallons starts
at 12 a.m. Day 1 is yesterday, day 2 the day before yesterday,
etc. As new values are added the oldest history disappears.
Another unique feature is that the valve automatically calcu-
lates a reserve capacity when set up as a softener with
“Gallons Capacity” set to “AUTO”. The reserve capacity for a
given day of the week is the middle value stored for the last
three non-trivial water usages (i.e. less than 20 gallons day)
in seven-day intervals which is then adjusted either upward or
downward depending upon the difference between today’s
water usage and the estimated reserve capacity.
Installation Fitting Assemblies
The installation fittings are used to connect the optional
bypass or the control to the plumbing system. There are four
installation-fitting assemblies available:
1. 1" NPT elbow
2. 3/4" & 1" PVC solvent weld elbow fitting
3. 1" straight brass sweat fitting **
4. 3/4" straight brass sweat Fitting **
Both elbow fittings have a unique drill out feature to allow a
1/4" NPT connection to the inlet and/or outlet which can be
* Some semiconductor materials exhibit a phenomenon in the presence of a magnetic
field that is adaptable to sensing devices. When a current is passed through one pair of
wires attached to a semiconductor, another pair of wires properly attached and orient-
ed with respect to the semiconductor will develop a voltage proportional to the magnet-
ic field present and the current in the other pair of wires. Holding the exiting current
constant and moving a permanent magnet near the semiconductor produces a voltage
output proportional to the movement of the magnet. Hall-effect devices provide a
high-speed response, excellent temperature stability and no physical contact.
** Has not been tested for compliance with California Proposition 65 so this
fitting should not be installed in California.
14
SYSTEM COMPONENTS DESCRIBED
Figure 17:
Figure 18:
Figure 19
Figure 20::
SYSTEM COMPONENTS DESCRIBED
Service Instructions
To reassemble seat the bottom of the drive bracket so the
notches are engaged at the bottom of the drive back plate.
Push the top of the drive bracket towards the two latches.The
drive bracket may have to be lifted slightly to let the threaded
piston rod pass through the hole in the drive bracket. Maintain
a slight engaging force on top of the drive bracket while
deflecting the bracket slightly to the left by pressing on the
side of the upper right corner. This helps the drive gears
mesh with the drive cap assembly. The drive bracket is
properly seated when it snaps under the latches on the drive
back plate. If resistance is felt before latching, then notches
are not fully engaged, the piston rod is not in hole, the wires
are jammed between the drive bracket and drive back plate,
or the gear is not engaging the drive cap assembly.
DRIVE ASSEMBLY
Remove the valve cover to access the drive assembly.
Disconnect the power source plug (black wire) from the PC
board prior to disconnecting the motor or water meter plugs
from the PC board. The motor plug connects to the two-pin
jack on the left-hand side of the PC board. The power source
plug connects to the four-pin jack. The four-pin jack is
between the two-pin and three-pin jacks. The water meter
plug (gray wire) connects to the three.
The PC board can be removed separately from the drive brack-
et but it is not recommended. Do not attempt to remove the dis-
play panel from the PC board. Handle the board by the edges.
To remove the PC board from the drive bracket, unplug the
power, water meter and motor plugs from the PC board. Lift the
middle latch along the top of the drive bracket while pulling out-
ward on the top of the PC board. The drive bracket has two
plastic pins that fit into the holes on the lower edge of the PC
board. Once the PC board is tilted about 45˚ from the drive
bracket it can be lifted off of these pins. To reinstall the PC
board, position the lower edge of the PC board so that the
holes in the PC board line up with the plastic pins. Push the top
of the PC board towards the valve until it snaps under the
middle latch, weave the power and water meter wires into the
holders and reconnect the motor water meter and power plugs.
To inspect drive gears, the drive gear cover needs to be
removed. The drive gear cover is held in place on the drive
bracket by three clips. The largest of the three clips is always
orientated to the bottom of the drive bracket. Before trying to
remove the drive gear cover, the drive bracket must be
removed from the drive back plate. The drive gear cover can
be removed from the drive bracket without removing the
motor or the PC board. Simultaneously, push in and down on
the large clip at the bottom and the clip on the left-hand side
of the drive bracket behind the PC board. Keep your other
fingers behind the drive gear cover so the drive gears do not
drop on the ground. Replace broken or damaged drive gears.
Do not lubricate any of the gears. Avoid getting any foreign
matter on the reflective coating because dirt or oils may inter-
fere with pulse counting.
The drive bracket must be removed to access the drive cap
assembly and pistons or the drive gear cover. It is not
necessary to remove the PC board from the drive bracket to
remove the drive bracket.To remove the drive bracket start by
removing the plugs for the power source and the water meter.
Unweave the wires from the side holders. Two tabs on the
top of the drive back plate hold the drive bracket in place.
Simultaneously lift the two tabs and gently ease the top of
the drive bracket towards your body. The lower edge of
the drive bracket has two notches that rest on the drive
back plate. Lift up and outward on the drive bracket to
disengage the notches.
The drive gear cover only fits on one way, with the large clip
orientated towards the bottom. If all three clips are outside of
the gear shroud on the drive bracket the drive gear cover slips
easily into place.
The drive bracket does not need to be removed from the drive
plate if the motor needs to be removed. To remove the motor,
disconnect the power and motor plugs from the jacks on the PC
15
SERVICE INSTRUCTIONS
board. Move the spring clip loop to the right and hold. Rotate the
vinegar or replace the main piston.
motor at least a 1/4 turn in either direction before gently pulling
on the wire connectors to remove the motor. Pulling directly on
the wires without rotating the motor may break the wires off the
motor.
Reattach the main piston to the drive cap assembly. Reattach
the regenerant piston (if needed) to the main piston. Do not
lubricate the piston rod, main piston or regenerant piston.
Lubricant will adversely affect the red or clear lip seals. Reinsert
the drive cap assembly and piston into the spacer stack
assembly and hand tighten the drive cap assembly. Continue to
tighten the drive cap assembly using a screwdriver as a ratchet
until the black oring on the spacer stack assembly is no longer
visible through the drain port. Excessive force can break the
notches molded into the drive back plate. Make certain that the
main drive gear still turns freely. The exact position of the piston
is not important as long as the main drive gear turns freely.
Replace the motor if necessary. Do not lubricate the motor or the
gears. When reinstalling the motor gently turn the motor while
inserting so that the gear on the motor meshes with the gears
under the drive gear cover and the small plastic bulge engages
one of the slots on the motor housing. Reconnect the motor plug
to the two-pronged jack on the lower left-hand side of the PC
board. If motor will not easily engage with drive gear when rein-
stalling, lift and slightly rotate motor before reinserting.
Replace the valve cover. After completing any valve mainte-
nance, press and hold NEXT and REGEN buttons for 3 seconds
or unplug power source jack (black wire) and plug back in. This
resets the electronics and establishes the service piston position.
The display should flash all wording, then flash the software ver-
Reattach the drive assembly to the control valve and connect all
plugs. After completing any valve maintenance, press and hold
NEXT and REGEN buttons for 3 seconds or unplug power
source jack (black wire) and plug back in. This resets the elec-
tronics and establishes the service piston position. The display
should flash all wording, then flash the software version (e.g.
154) and then reset the valve to the service position.
sion (e.g. 154) and then reset the valve to the service position
.
DRIVE CAP ASSEMBLY, MAIN PISTON
AND REGENERANT PISTON
SPACER STACK ASSEMBLY
To access the spacer stack assembly remove the drive
assembly, drive cap assembly and piston. The spacer stack
assembly can be removed easily without tools by using thumb
and forefinger. Inspect the black o-rings and red or clear lip seals
for wear or damage. Replace the entire stack if necessary. The
spacer stack assembly has been 100% tested at the factory to
insure proper orientation of one-way seals. Do not disassemble
the stack.
The drive assembly must be removed to access the drive cap
assembly. The drive cap assembly must be removed to access
the piston(s). The drive cap assembly is threaded into the con-
trol valve body and seals with an o-ring.To remove the drive cap
assembly, use the special plastic wrench or insert a 1/4" to 1" flat
bladed screwdriver into one of the slots around the top 2" of the
drive cap assembly so it engages the notches molded into the
drive back plate around the top 2" of the piston cavity. See
Figure 5. The notches are visible through the holes. Lever the
screwdriver so the drive cap assembly turns counter clockwise.
Once loosened unscrew the drive cap assembly by hand and
pull straight out.
The spacer stack assembly may be chemically cleaned (dilute
sodium bisulfite or vinegar) or wiped with a soft cloth.
The spacer stack assembly can be pushed in to the control valve
body bore by hand. Since the spacer stack assembly can be
compressed it is easier to use a blunt object (5/8" to 1-1/8" in
diameter) to push the center of the assembly into the control
valve body. The assembly is property seated when at least four
threads are exposed (approximately 5/8"). Do not force the
spacer stack assembly in. The control valve body bore interior
can be lubricated with silicone to allow for easy insertion of the
entire stack. Do not use silicone or any other type of lubricant on
the red or clear lip seals or the piston.
The drive cap assembly contains the drive cap, the main drive
Missing Photo
Figure 21: To
Reattach the drive cap assembly, and piston(s) and the drive
assembly.
remove drive cap
After completing any valve maintenance, press and hold NEXT
and REGEN buttons for 3 seconds or unplug power source jack
(black wire) and plug back in. This resets the electronics and
establishes the service piston position. The display should flash
all wording, then flash the software version (e.g. 154) and then
reset the valve to the service position.
gear, drive cap spline, piston rod and various other parts that
should not be dissembled in the field. The only replaceable part
on the drive cap assembly is the o-ring. Attached to the drive cap
assembly is the main piston (downflow or upflow) and if a regen-
erant is used, a regenerant piston.
The regenerant piston (the small diameter one behind the main
piston) is removed from the main piston by unsnapping it from
its latch. Chemically clean in dilute sodium bisulfite or vinegar or
replace the regenerant piston if needed. To remove the main-
downflow or upflow piston fully extend the piston rod and then
unsnap the main piston from its latch by pressing on the side
with the number. Chemically clean in dilute sodium bisulfite or
INJECTOR CAP, SCREEN, INJECTOR
PLUG AND INJECTOR
Unscrew the injector cap and lift off. Loosen cap with special
plastic wrench or pliers if necessary. Attached to the injector cap
is a screen. Remove the screen and clean if fouled.
16
CONTENTS
The plug and/or injector can be pried out with a small
water meter.
screwdriver. The plug can be wiped clean. If the plug leaks
replace the entire plug. The injector consists of a throat and a
nozzle. Chemically clean the injector with vinegar or sodium
bisulfite. The holes can be blown out with air. Both pieces have
small diameter holes that control the flow rates of water to insure
that the proper concentration of regenerant is used. Sharp
objects, which can score the plastic, should not be used to clean
the injector. Scoring the injector or increasing the diameter of the
hole could change the operating parameters of the injector.
Two holes are labeled DN and UP. Check for compliance with
one of the following:
The water meter wire does not need to be removed from the PC
board if the water meter is only being inspected and cleaned.
To remove the water meter assembly, unscrew the meter cap on
the left side of the control valve. Pliers may be used to unscrew
the nut if necessary.
With the nut removed, a slot at the top of the water meter is
visible. Twist a flat blade screwdriver in the slot between the
control valve body and the meter. When the meter is part way
out it is easy to remove the water meter from the housing.
Once the water meter is removed from the control valve body,
use your fingers to gently pull forward on the turbine to remove
it from the shaft.
a. For downflow systems, the appropriate size injector is
located in the “DN” hole, a plug is in the “UP” hole and
the piston is a combination of the downflow main piston and
the regenerant piston;
b. For upflow systems, the appropriate size injector is located
in the “UP” hole, a plug is in the “DN” hole and the piston
is a combination of the upflow main piston and the regenerant
piston; or
c. For backwash only systems, a plug is in the “DN” hole and
in the “UP” hole, and the piston only has a downflow
main piston (the regenerant piston must be removed) and a
plug is in the refill flow control position.
Do not use a wire brush to clean. Wipe with a clean cloth or
chemically clean in dilute sodium bisulfite or vinegar. The turbine
can be immersed in the chemical. Do not immerse electronics. If
the turbine is scored or damaged or the bearings on the turbine
are worn replace the turbine.
Do not lubricate the turbine shaft. The turbine shaft bearings are
pre-lubricated. Do not use Vaseline, oils or other unacceptable
lubricants on the o-ring. A silicon lubricant may be used on the
black o-ring.
Snap the turbine on the shaft and reinsert the water meter into
the side slot. Hand tighten the nut. Do not use a pipe wrench to
tighten nut.
Push the plug(s) and/or injectors firmly in place, replace the
screen and hand tighten the injector cap.
BYPASS VALVE
REFILL FLOW CONTROL ASSEMBLY
OR REFILL PORT PLUG
The working parts of the bypass valve are the rotor assemblies
that are contained under the bypass valve caps. Before working
on the rotors, make sure the system is depressurized. Turn the
red arrow shaped handles towards the center of the bypass valve
and back to the arrow direction several times to ensure rotor is
turning freely.
To clean or replace the refill flow control, pull out the elbow-
locking clip and then pull straight up on the elbow. Replace the
elbow-locking clip in the slot so that it is not misplaced. Twist to
remove the white flow control retainer. The flow control can be
removed by prying upward through the side slots of the retainer
with a small blade flat screwdriver.
The nuts and caps are designed to be unscrewed or tightened
by hand. If necessary a pair of pliers can be used to unscrew the
nut or cap. Do not use a pipe wrench to tighten or loosen nuts or
caps. Do not place screwdriver in slots on caps and/or tap with a
hammer. To access the rotor, unscrew the cap and lift the cap,
rotor and handle out as one unit. Twisting the unit as you pull it
out will help to remove it more easily.There are three o-rings: one
under the rotor cap, one on the rotor stem and the rotor seal.
Replace worn o-rings. Clean rotor. Reinstall rotor.
Chemically clean the flow control or the white flow control
retainer using dilute sodium bisulfite or vinegar. Do not use a
wire brush. If necessary, replace the flow control o-ring on
the flow control retainer, or the o-ring on the elbow.
Reseat the flow control so the rounded end is visible in the flow
control. Reseat the white flow control retainer by pushing the
retainer into the elbow until the o-ring seats. Remove locking clip,
push down on elbow to reseat and insert locking clip.
When reinstalling the red arrow handles be sure that:
1. O-rings on both rotors face to the right when being viewed
from the front of the control valve when the handle pointers
are lined up with the control valve body arrows; or
Do not use Vaseline, oils, or other unacceptable lubricants on
o-rings. A silicon lubricant may be used on the o-ring on elbow or
the white retainer.
2. Arrows point toward each other in the bypass position.
WATER METER OR METER PLUG
Since the handles can be pulled off, they could be accidentally
reinstalled 180° from their correct orientation. To install the red
arrow handles correctly, keep the handles pointed in the same
direction as the arrows engraved on the control valve body while
tightening the bypass valve caps.
The water meter assembly is connected to the PC board by a
wire. If the entire water meter assembly is to be replaced, remove
the control valve cover and remove the power source and water
meter plugs from the PC board. Unlatch the drive assembly and
lean it forward. Unthread the water meter wire from the side of the
drive assembly and through the drive back plate. To reinstall,
rethread the water meter wire through the drive back plate and
the side of the drive assembly. Reattach the drive assembly
and the water meter and power plugs.
After completing, any valve maintenance, press and hold NEXT
and REGEN buttons for 3 seconds or unplug power source jack
(black wire) and plug back in. This resets the electronics and
establishes the service piston position. The display should flash
all wording then flash the software version (e.g. 154) and then
reset the valve to the service position.
If no water meter wire is visible, then a plug is installed not a
17
DRAWING AND PART NUMBERS
BRINE TANK AND SOFTENER TANK
Figure 17
Figure 18
FRONT COVER AND DRIVE ASSEMBLY
Drawing No.
Order No.
Description
Qty.
1
2
3
KC11V317501 W100SM Front Cover ASY 1
KC12V3107-0
1
W100SM Motor
W100SM Drive Bracket
& Spring Clip
1
1
KC12F3106-01
4
5
6
KC12V3108
KC12V3110
KC12V3109
KC12V3002
KC11V3186
W100SM PC Board
1
3
1
*
W100SM Drive Gear 12x36
W100SM Drive Gear Cover
W100SM Drive ASY
Not Shown
W100SM Transformer 110V-12V
1
*Drawing number parts 2 through 6 may be purchased as a complete assembly,
part V3002.
18
CONTENTS
DRIVE CAP ASSEMBLY, DOWNFLOW PISTON, UPFLOW PISTON,
REGENERANT PISTON AND SPACER STACK ASSEMBLY
Drawing No.
Order No.
Description
Qty.
1
KC12V3005 W100SM Spacer Stack Assembly
1
2
3
4
5
6
KC12V3004 Drive Cap ASY
KC12V3135 O-ring 228
KC12V3011 W100SM Piston Downflow ASY
KC12V3174 W100SM Regenerant Piston
KC12V3180 O-ring 337
1
1
1
3
1
Note: The regenerant piston is not used in backwash only applications.
INJECTOR CAP, INJECTOR SCREEN, INJECTOR, PLUG AND O-RING
Drawing No.
Order No.
KC12V3176
KC12V3152
KC12V3177
KC12V3010-12
KC12V3010-10
KC12V3010-IE
KC12V3170
KC12V3171
Description
Injector Cap
O-ring 135
Injector Screen
W100SM Injector ASY Z Plug
W100SM Injector ASY D Red
W100SM Injector ASY E White
O-ring 011
Qty.
1
1
1
1
1
1
*
*
1
2
3
4
5
Not Shown
Not Shown
O-ring 013
*The injector plug and the injector each contain one 011 (lower)
and one 013 (upper) o-ring.
Note: For upflow position, injector is located in the up hole and injector
plug in the down hole. For a filter that only backwashes injector plugs
are located in both holes.
19
DRAWING AND PART NUMBERS
Drawing No.
Order No.
KC12V3195-01
KC12H4615
Description
Qty.
**
1
1
2
3
4
5
6
7
8
W100SM Refill Port Plug ASY
Elbow Locking Clip
Polytube insert 3/8
Nut 3/8
KC12JCP-P-6
KC12JCPG-6PBLK
KC12H4613
1
1
Elbow Cap 3/8
1
KC12V3163
O-ring 019
1
KC12V3165-01
KC12V3182
W100SM RFC Retainer ASY
W100SM RFC
1
1
*Assembly includes WS1 RFC.
**This part is required for backwash only systems.
DRAIN LINE - 3/4"
Drawing No.
Order No.
KC12H4615
Description
Elbow Locking Clip
Qty.
1
1
2
3
4
5
6
7
KC12PKP10T58 Polytube insert 5/8
KC12V3192
Option
W100SM Nut 3/4 Drain Elbow
Option
KC12V3158-01 W100SM Drain Elbow 3/4 Male ASY
1
1
1
*
KC12V3163
O-ring 019
KC12V3159-01 W100SM DLFC Retainer ASY
KC12V3162-022 W100SM DLFC 2.2 gpm for 3/4
KC12V3162-027 W100SM DLFC 2.7 gpm for
20
DRAWING AND PART NUMBERS
WATER METER AND METER PLUG
Drawing No.
Order No.
KC12V3151
KC12V3003
Description
W100SM Nut 1” QC
W100SM Meter ASY
Qty.
1
1
2
3
4
5
1
KC12V3118-01 W100SM Turbine ASY
KC12V3105 O-ring 215
KC12V3003-01 W100SM Meter Plug ASY
1
1
1
* Order number KC12V3003 includes KC12V3118-01 and KC12V3105.
INSTALLATION FITTING ASSEMBLIES
Drawing No. Order No.
Description
Qty.
Drawing No.
Order No.
Description
Qty.
1
2
3
4
KC12V3151 W100SM Nut 1” Quick Connect
KC12V3150 W100SM Split Ring
2
2
2
2
1
2
3
4
KC12V3151 W100SM Nut 1” Quick Connect
KC12V3150 W100SM Split Ring
2
2
2
2
KC12V3105 O-ring 215
KC12V3105 O-ring 215
KC12V3149 W100SM Fitting 1” PVC Male NPT Elbow
KC12V3189 W100SM Fitting 3/4” & 1” PVC Solvent 90
Drawing No. Order No.
Description
Qty.
Drawing No.
Order No.
Description
Qty.
1
2
3
4
KC12V3151 W100SM Nut 1” Quick Connect
KC12V3150 W100SM Split Ring
2
2
2
2
1
2
3
4
KC12V3151 W100SM Nut 1” Quick Connect
KC12V3150 W100SM Split Ring
2
2
2
2
KC12V3105 O-ring 215
KC12V3105 O-ring 215
KC12V3188 W100SM Fitting 1” Brass Sweat
KC12V3188-01 W100SM Fitting 3/4” Brass Sweat
21
DRAWING AND PART NUMBERS
BYPASS VALVE
Drawing No.
Order No.
Description
Qty.
2
1
2
KC12V3151 W100SM Nut 1” Quick Connect
KC12V3150 W100SM Split Ring
KC12V3105 O-ring 215
2
3
2
4
KC12V3145 W100SM Bypass 1” Rotor
KC12V3146 W100SM Bypass Cap
KC12V3147 W100SM Bypass Handle
KC12V3148 W100SM Bypass Rotor Seal Retainer
KC12V3152 O-ring 135
2
5
2
6
2
7
2
8
2
9
KC12V3155 O-ring 112
2
10
KC12V3156 O-ring 214
2
(Not Shown) Order No.KC12 V3191-01. Description: WS100sm Bypass Vertical Adapter Assembl
Order No.
KC12V3151
KC12V3150
KC12V3105
KC11V3191-01
Description
Qty.
1
W100SM Nut 1” Quick Connect
W100SM Split Ring
O-ring 215
1
1
W100SM Bypass Vertical Adaper
Assembly
1
W100SM WRENCH
(Order No. KC12V3193)
Although no tools are necessary to assemble or
disassemble the valve, the WS100SM wrench
(shown in various positions on the valve) may be
purchased to aid in assemble or disassembly.
22
DRAWING AND PART NUMBERS
flow diagram...service
flow diagram...rinse
flow diagram...backwash
flow diagram...fill
flow diagram...downflow brine
23
TROUBLESHOOTING
System Troubleshooting
PROBLEM
CAUSE
CORRECTION
1. Loss of Resin
A. Broken distribution tube
A. Replace distribution tube.
B. Inlet/Outlet connection reversed.
B. Reconnect inlet/outlet
connection properly.
2. Softener fails to regenerate.
A. Electrical service to unit has
been interrupted.
A. Assure permanent electrical service
(check fuse, plug, pull chain or switch.
B. Timer is defective.
C. Power failure.
B. Replace timer.
C. Reset time of day.
A. Close bypass valve.
3. Hard Water
A. Bypass valve is open.
B. No salt in brine tank.
B. Add salt to brine tank and maintain
salt level abovewater level.
C. Injector screen plugged.
C. Clean injector screen.
D. Insufficient water flowing
into brine tank.
D. Check brine tank fill time and clean
brine line flow control if plugged.
E. Hot water tank hardness,
F. Leak at distributor tube.
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. Internal valve leaking.
G. Replace seals and spacers and or
piston.
4. Unit used too much salt.
5. Loss of water pressure.
A. Improper salt setting.
A. Check salt usage and sat setting.
B. See Problem No. 8.
B. Excessive water in brine tank.
A. Iron buildup in line to
water conditioner.
A. Clean line to water conditioner.
B. Iron buildup in water
conditioner.
B. Clear control and add mineral cleaner and
increase regeneration frequency.
C. Inlet of control plugged due
to foreign material broken loose
from pipes by recent work done
on plumbing system.
C. Remove piston and clean control.
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. Fouled mineral bed.
A. Check backwash, brine draw,
and brine tank fill. Increase
frequency of regeneration.
Increase backwash time.
24
TROUBLESHOOTING
System Troubleshooting (continued)
PROBLEM
CAUSE
CORRECTION
8. Excessive water in brine tank.
A. Plugged drain line flow control.
B. Plugged injector system.
C. Foreign material in brine valve.
D. Defectie controller.
A. Clean flow control.
B. Clean injector and screen.
C. Replace timer.
D. Replace controller.
E. Foreign material in brine
E. Clean brine line flow control.
line flow control.
9. Softener fails to draw brine.
A. Drain line flow control is plugged.
B. Injector is plugged.
A. Clean drain line flow control
B. Clean injector.
C. Injector screen plugged.
D. Line pressure is too low.
E. Internal control leak.
C. Clean screen.
D. Increase line pressure to 20 P.S.I.
E. Change seals, spacers, and
piston assembly.
10. Control cycles continuously.
11. Drain flows continuously.
A. Broken or shorted switch,
A. Determine if switch or timer
is faulty and replace it, or replace
complete power head.
A. Piston is not positioned
correctly when in service.
A. Check timer program and positioning
of control. Replace power head
assembly if not positioning properly.
B. Foreign material in control.
B. Remove power head assembly
and inspect bore. Remove foreign
material and check control in
various regeneration positions.
C. Internal control leak
A. Clogged drain.
C. Replace seals and piston assembly.
A. Replace drain line.
12. Brine tank fills during brine step.
B. Internal piston seal leaks.
B. Replace seals in piston assembly.
See
Troubleshooting
Programming
(next page)
25
TROUBLESHOOTING
Troubleshooting Programming
PROBLEM
POSSIBLE CAUSE
SOLUTION
1. Timer does not display time of day
a. Transformer unplugged
b. No electric power at outlet
c. Defective transformer
d. Defective PC board
a. Switched outlet
a. Connect power
b. Repair outlet or use working outlet.
c. Replace transformer
d. Replace PC board
a. Use uninterrupted outlet
b. Reset time of day
2. Timer does not display
correct time of day
b. Power outage
c. Defective PC board
c. Replace PC board
3. No softening display when
water is flowing
a. Bypass valve in bypass position
c. Restricted/stalled meter turbine
a. Put bypass valve in service position
c. Remove meter and check for
rotation or foreign material
d. Defective meter
d. Replace meter
e. Defective PC board
a. Power outages
e. Replace PC board
4. Control valve regenerates at
wrong time of day of day
a. Reset control valve to correct time
b. Reset to correct time of day
c. Reset regeneration time
b. Time of day not set correctly
c. Time of regeneration incorrect
d. Control valve set at “on 0”
(immediate regeneration)
d. Check control valve set-up
procedure regeneration time option
e. Control valve set at NORMAL on 0
e. Check control valve set-up
procedure regeneration time option
a. Control valve has just been serviced a. Press NEXT and REGEN for
3 seconds or unplug power source
Jack (black wire) and plug back in
to reset control valve
5. ERROR followed by code number
b. Foreign matter is lodged in control
b. Check piston and spacer stack
valve.
assembly for foreign matter.
Error Code 1001 -Unable to recognize
start of regeneration
c. High drive forces on piston
c. Replace piston(s) and spacer
stack assembled.
Error Code 1002 - Unexpected stall
d. Control valve piston not in home
position
d. Press NEXT and REGEN for
3 seconds or unplug power source
jack (black wire) and plug back in
to reset control valve
Error Code 1003 - Motor ran to long,
timed out trying to reach next cycle
position
e. Motor not inserted fully to engage
pinion, motor wires broken or
disconnected, motor failure
e. Check motor and wiring.
Replace motor if necessary
Error Code 1004 - Motor ran to long,
timed out trying to reach home
position
f. Drive gear label dirty or damaged
missing or broken gear
f. Replace or clean drive gear
g. Reseat drive bracket properly
h. Replace PC board
If other Error Codes display contact
the factory.
g. Drive bracket incorrectly aligned
to back plate
h. PC board is damaged or defective
i. PC board incorrectly aligned to
drive bracket
i. Ensure PC board is correctly
snapped on to drive
26
CONTENTS
Troubleshooting Programming (continued)
PROBLEM
POSSIBLE CAUSE
SOLUTION
6. Control valve stalled in regeneration
a. Motor not operating
a. Replace motor
b. No electric power at outlet
c. Defective transformer
d. Defective PC board
b. Repair outlet or use working outlet
c. Replace transformer
d. Replace PC board
e. Broken drive gear or drive cap
assembly
e. Replace drive gear or drive cap
assembly
f. Broken piston retainer
f. Replace drive cap assembly
g. Replace main or regenerant piston
a. Connect transformer
g. Broken main or regenerant piston
a. Transformer unplugged
7. Control valve does not regenerate
when REGEN button is pressed.
b. No electric power at outlet
b. Repair outlet or use working outlet
c. Broken drive gear or drive cap
c. Replace drive gear or drive cap assembly
d. Defective PC board
d. Replace PC board
a. By-pass valve in bypass position
b. Meter connection disconnected
c. Restricted/stalled meter turbine
a. Put control valve in service position
b. Connect meter to PC board
8. Control valve does not regenerate
automatically but does when
REGEN button is depressed
c. Remove meter and check for
rotation or foreign matter
d. Defective meter
e. Defective PC board
f. Set-up error
d. Replace meter
e. Replace PC board
f. Check control valve set-up
procedure
9. Time of day flashes on and off
a. Power has been out more than
two hours, the transformer was
unplugged and then plugged back
into the wall outlet, the transformer
plug was unplugged and then
plugged back into the board or the
NEXT and REGEN buttons were
pressed to reset the valve.
a. Reset the time of day
27
DISTRIBUTED BY:
Manufactured by Watts Water Quality & Conditioning Products, 13700 Highway 90 W., San Antonio, TX, USA
FORM: 0500-200 P/N: XOSW100SM
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