A-Star 2018 ED Installation Programming Troubleshooting

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Water softening system

Installation

Programming

Troubleshooting

Version 05-2006

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SAFETY GUIDES

• FOLLOW THE INSTALLATION INSTRUCTIONS CAREFULLY. FAILURE TO INSTALL THE
SOFTENER PROPERLY VOIDS THE WARRANTY.

• BEFORE YOU BEGIN INSTALLATION, READ THIS ENTIRE MANUAL. THEN, OBTAIN ALL
THE MATERIALS AND TOOLS YOU WILL NEED TO MAKE THE INSTALLATION.

• CHECK LOCAL PLUMBING AND ELECTRICAL CODES. THE INSTALLATION MUST
CONFORM TO THEM. IF IN DOUBT, CONTACT YOUR LOCAL DEALER OUR PLUMBER.

• USE ONLY LEAD-FREE SOLDER AND FLUX FOR ALL SWEAT-SOLDER CONNECTIONS,
AS REQUIRED BY YOUR COUNTRY CODES.

• USE CARE WHEN HANDLING THE SOFTENER. DO NOT TURN UPSIDE DOWN, DROP,
OR SET ON SHARP PROTRUSIONS.

• DO NOT LOCATE THE SOFTENER WHERE FREEZING TEMPERATURES OCCUR. DO
NOT ATTEMPT TO TREAT WATER OVER 49°C. FREEZING, OR HOT WATER DAMAGE
VOIDS THE WARRANTY.

• AVOID INSTALLING IN DIRECT SUNLIGHT. EXCESSIVE SUN HEAT MAY CAUSE
DISTORTION OR OTHER DAMAGE TO NON-METALLIC PARTS.

• THE SOFTENER IS NOT DISINGED FOR OUTSIDE INSTALLATION; IF INSTALLING IN AN
OUTSIDE LOCATION, YOU MUST TAKE THE STEPS NECESSARY TO ASSURE THE
SOFTENER, INSTALLATION PLUMBING, WIRING, ETC; ARE AS WELL PROTECTED
FROM THE ELEMENTS (SUNLIGHT, RAIN, WIND, HEAT, COLD), CONTAMINATION,
VANDALISM, ANIMALS, RODENDS, ETC AS WHEN INSTALLED INDOORS;

• THE SOFTENER REQUIRES A MINIMUM WATER FLOW OF 11 LITERS PERMINUTE AT
THE INLET. MAXIMUM ALLOWABLE INLET WATER PRESSURE IS 8.5 BAR. IF DAYTIME
PRESSURE IS OVER 5.6 BAR, NIGHTTIME PRESSURE MAY EXCEED THE MAXIMUM.
USE A PRESSURE REDUCING VALVE IF NECESSARY. (ADDING A PRESSURE
REDUCING VALVE MAY REDUCE THE FLOW.)

• THE SOFTENER WORKS ON 24 VOLT-50 Hz ELECTRICAL POWER ONLY. BE SURE TO

USE THE INCLUDED TRANSFORMER, AND PLUG IT INTO A NOMINAL 220V, 50 CYCLE
HOUSEHOLD OUTLET THAT IS GROUNDED AND PROPERLY PROTECTED BY A
OVERCURRENT DEVICE SUCH AS A CIRCUIT BREAKER OR FUSE. IF TRANSFORMER
IS REPLACED, USE ONLY THE AUTHORIZED SERVICE CLASS II, 24 VOLT
TRANSFORMER. THIS SOFTENER IS NOT INTENDED TO BE USED FOR TREATING
WATER THAT IS MICROBIOLOGICALLY UNSAFE OR OF UNKNOWN QUALITY WITHOUT
ADEQUATE DISINFECTION BEFORE OR AFTER THE SOFTENER.

RECYCLE

European Directive 2002/96/EC requires all electrical and electronic equipment to be disposed
of according to Waste Electrical and Electronic Equipment (WEEE) requirements. This
directive or similar laws are in place nationally and can vary from region to region. Please

refer to your state and local laws for proper disposal of this equipment.

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UNPACKING / INSPECTION

The softener is shipped in one master carton. The softeners are completely assembled
at the factory, except as required at installation. Be sure to check the entire softener for
any shipping damage or parts loss. Also note damage to the shipping cartons. Contact
the transportation company for all damage and loss claims. The manufacturer is not
responsible for damages in transit. Small parts, needed to install the softener, are in
parts bag. To avoid loss of the small parts, keep them in the parts bag until you are
ready to use them.

TABLE OF CONTENTS

PAGE N°

SAFETY GUIDES 2
SPECIFICATIONS, DIMENSIONS 4
BEFORE STARTING INSTALLATION 5 - 6
TYPICAL INSTALLATION ILLUSTRATION 6
INSTALLATION STEPS 7- 10
PROGRAMMING THE TIMER 11 - 13
SANITIZING PROCEDURES 14
WATER AND WATER CONDITIONING 15 - 16
HOW THE WATER SOFTENER WORKS 16 - 17
GENERAL WATER SOFTENER MAINTENANCE & TROUBLESHOOTING 18 - 20
AUTOMATIC ELECTRONIC DIAGNOSTICS 20
SERVICE CHECKOUT PROCEDURES, WIRING SCHEMATIC 21 - 23
WATER FLOW THROUGH VALVE 24 - 25
REPAIR PARTS 26 - 30

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SPECIFICATIONS AND DIMENSIONS

52 @ 0.8
86 @ 1.7

Rated Capacities @ salt dose (°Fm³@Kg)

122 @ 4.6

Resin Quantity (Liters) 18

Rated Service Flow (L/min) 26

pressure drop @ service flow (BAR) 0.6

Max Flow rate to the drain (l/min) 11

Max hardness (°F) 162

Max Clear water Iron ( PPM) 5

Tank Size ( inch) 10*21

Valve connections (inch) 3/4

Capacity salt tank (Kg) 45

Operating water pressure limits (Bar)) 1.4 to 8.6

Operating Water temp limits (°C) 4-49

electrical rating Transformer 240 VAC to 24 V AC

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BEFORE STARTING INSTALLATION

WHERE TO INSTALL THE SOFTENER

o Place the softener as close as possible to the pressure tank (well system) or

water meter (city water).

o Place the softener as close as possible to a floor drain, or other acceptable drain

point (laundry tub, sump, standpipe, etc.).

o Connect the softener to the main water supply pipe BEFORE or AHEAD OF the

water heater. DO NOT RUN HOT WATER THROUGH THE SOFTENER.

Temperature of water passing through the softener must be less than 49°C
(120°F).

o Keep outside faucets on hard water to save soft water and salt.
o Do not install the softener in a place where it could freeze. Damage caused by

freezing is not covered by the warranty.

o Put the softener in a place water damage is least likely to occur if a leak

develops. The manufacturer will not repair or pay for water damage.

o A 220 volt 50 Hz electric outlet, to plug the included transformer into, is needed

within 2 meters of the softener. The transformer has a 2 meters power cable. Be

sure the electric outlet and transformer are in an inside location, to protect
from wet weather.

o If installing in an outside location, you must take the steps necessary to assure

the softener, installation plumbing, wiring, etc., are as well protected from the
elements, contamination, vandalism, animals, rodents etc., as when installed
indoors.

o Keep the softener out of direct sunlight. The sun’s heat will melt plastic parts.

TOOLS, PIPE and FITTINGS, OTHER MATERIALS YOU WILL NEED

o In and out pipes to the softener must be at least 3/4” size. Some local codes

require a minimum of 1” pipe size. To plumb with 1” pipes, buy adaptors to fit the
1” pipe threads on the installation adaptors or bypass valve (see page 5). You

should maintain the same, or larger, pipe size as the water supply pipe, up to the
softener inlet and outlet.

o Use copper, brass, or galvanized pipe and fittings. Some codes may also allow

CPVC plastic pipe.

o ALWAYS install a bypass valve or valves. Either use the optional valve (included

with some models), or 3 shut-off valves. Bypass valves let you turn off water to
the softener for repairs if needed, but still have water in the house pipes.

o Drain hose (3/8” or 7/16” inside diameter) is needed for valve and salt tank

drains. You can buy good quality, thick-wall, flexible hose at most hardware
stores.

o If a rigid valve drain is needed, to comply with plumbing codes, you can buy the

parts needed (see page 8) to connect a 1/2 in. copper tubing drain.

o Nugget or pellet water softener salt is needed to fill the brine tank (see page 10

and 118).

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PLAN HOW YOU WILL INSTALL THE SOFTENER

You must first decide how to run in and out pipes to the softener. Look at the house main
water pipe at the point where you will connect the softener. Is the pipe soldered copper,
glued plastic, or threaded galvanized? What is the pipe size? Now look at the typical
installation illustration below. Use it as a guide when planning your particular installation.

Be sure to direct raw, hard water to the softener valve inlet fitting.

The valve is marked IN and OUT.

Typical Installation Illustration

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INSTALLATION STEPS

NOTE:

For easier installation, remove the top cover

cover forward and lift up.

1. INSTALL BYPASS VALVE:

o Remove the plastic shipping plug and wire from valve outlet.
o Push the bypass valve (lubricate o--ring seals)into

both ports of the valve...Figures 3A.

o Snap the two large plastic clips in place, from the

top, down...Figures 3A and 3B. Be sure they snap

into place. Pull on the adaptors, or bypass valve,
to make sure they held securely in place.

2. INSTALL THE BRINE TANK OVERFLOW FITTINGS:

o Insert the rubber grommet into the 3/4” diameter

hole in the brine tank sidewall...see page 9.

o Push the barbed end of the hose adaptor elbow

into the grommet.

3. MOVE THE SOFTENER ASSEMBLY INTO INSTALLATION POSITION:

o Be sure the installation surface is level and smooth. If needed, place the tank on

a section of 2 cm thick (min.) plywood. Then, place shims under the plywood as
needed to level the softener.

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4. INSTALL GROUNDING CLAMPS AND WIRE (Recommended):

o To maintain electrical ground continuity in the

house cold water piping, install the ground clamps
(not included) as shown. Be sure the pipes are clean,
under the clamps, to assure good contact.
NOTE: A 3-valve bypass system maintains ground
continuity.

5. PLUMB IN AND OUT PIPES TO AND FROM SOFTENER:

CAUTION: Observe all of the following cautions as you connect inlet and outlet

plumbing.

o Turn off the house water supply valve and open faucets to relieve pressure

in the pipes.

o BE SURE RAW,

HARD WATER IS DIRECTED TO THE VALVE INLET

PORT.

o Be sure to use bypass valve(s).
o If making a soldered copper installation, do all sweat soldering before

connecting pipes to the softener fittings. Torch heat will damage plastic parts.

o Put grounding clamps (see step 4) on copper tubes before soldering.
o When turning threaded pipe fittings onto plastic fittings, use care not to cross-

thread.

o Use pipe joint compound on all external pipe threads.
o Support inlet and outlet plumbing in some manner (use pipe hangers) to keep the

weight off of the valve fittings.

6. CONNECT AND RUN THE VALVE DRAIN HOSE: (figure 4)

o Take a length of 3/8” or 7/16” inside diameter hose and attach to the valve

drain fitting. So water pressure does not blow the hose off, use a hose clamp
to secure in place.

o Locate the other end of the hose at a suitable drain point...floor drain, sump,

laundry tub, etc. Check and comply with local codes.

IMPORTANT: Use high quality, thick-wall hose that will not easily kink or collapse.

The water softener will not work if water cannot exit this hose during regenerations.

o Tie or wire the hose in place at the drain point.

Water pressure will cause it to whip during the
backwash and fast rinse cycles of regeneration.
Also provide an air gap of at least 4 cm between
the end of the hose and the drain point.
An air gap prevents possible siphoning of sewer
water, into the softener, if the sewer should ‘‘back-up’’.

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o If raising the drain hose overhead is required to

get to the drain point, do not raise higher than

2.4 meters above the floor. Elevating the hose

may cause a back-pressure that could reduce brine
draw during regenerations.

CONNECTING A RIGID VALVE DRAIN TUBE

o To adapt a copper drain tube to the softener,

use a hacksaw to cut the barbed end from the
drain fitting as shown in Fig. 4A. Rotate the drain
fitting so the cutting blade clears the valve housing
to prevent damage to valve. Buy a compression
fitting (1/4″ female pipe thread x 1/2″ O.D. tube)
and needed tubing from your local hardware store.

7. CONNECT AND RUN THE BRINE TANK OVERFLOW HOSE :

o Attach a length of 3/8” or 7/16” I.D. hose to the

drain elbow, installed in step 2, page 7. Use a
hose clamp to hold it in place.

o Locate the other end of the hose at the drain point.

DO NOT ELEVATE THIS HOSE HIGHER THAN
THE ELBOW ON THE BRINE TANK. DO NOT TEE

THIS HOSE TO THE VALVE DRAIN HOSE.

NOTE: This drain is for safety only. If the brine tank should over-fill
with water, the excess is carried to the drain.

8. FLUSH PIPES, EXPEL AIR FROM SOFTENER, AND TEST YOUR

INSTALLATION FOR WATER LEAKS:

CAUTION: To avoid water or air pressure damage to softener inner parts, be sure
to do the following steps exactly as listed.
A. Fully open two cold, soft water faucets nearby the softener.
B. Place bypass valve(s) in ‘‘bypass’’ position. On a single valve, slide the stem into

BYPASS. On a 3-valve system, close the inlet and outlet valves,
and open the bypass valve...see page 6.

C. Fully open the house main water pipe shutoff valve. Observe a steady flow from both

opened faucets.

D. Place bypass valve(s) in ‘‘service”, EXACTLY as follows. KEEP SOFTWATER
FAUCETS OPEN.

1. SINGLE BYPASS VALVE: SLOWLY, slide the valve stem toward ‘‘service’’, pausing

several times to allow the softener to pressurize slowly.

2. 3--VALVE BYPASS: Fully close the bypass valve and open the outlet valve.

SLOWLY, open the inlet valve, pausing several times to allow the softener to pressurize
slowly.

E. After about three minutes, open a HOT water faucet for one minute, or until all air
is expelled, then close.
F. Close both cold water faucets.