Excalibur CHLOR-A-SOFT Installation And Operaion Manual

Installation and Operation Manual

CHLOR-A-SOFT With Coconut Shell

Carbon

Water Softener

Page 1

220 Bayview Avenue Unit #18

Barrie, Ontario L4N 4Y8

www.excaliburwater.com

Table of Contents

Installation ......................................................................................................................... 3

Bypass Valve ...................................................................................................................... 6

Start-up Instructions ...........................................................................................................7

General Operation...............................................................................................................8

User Displays/Settings ....................................................................................................... 10

Installer Displays/Settings.................................................................................................. 12

Drawing and Part Numbers ................................................................................................ 13

Front Cover and Drive Assembly......................................................................................... 14

Drive cap Assembly, Down flow Piston, Regenerant Piston and Spacer Stack Assembly ........... 15

Injector Cap, Injector Screen, Injector, Plug and O-ring ....................................................... 16

Refill and Refill Port Plug.................................................................................................... 17

Drain Line – ¾” ................................................................................................................ 18

Drain Line – 1”.................................................................................................................. 19

Water Meter & Meter Plug.................................................................................................. 20

Installation Fitting Assemblies ............................................................................................ 21

Bypass Valve .................................................................................................................... 22

WS1 Wrench (order No. V3193) ......................................................................................... 23

Service Instructions........................................................................................................... 24

Troubleshooting................................................................................................................ 29

Warranty.......................................................................................................................... 31

Page 2

Installation

GENERAL INSTALLATION & SERVICE 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.

Do not use Vaseline, oils, other hydrocarbon lubricants or spray silicone anywhere. A silicone
lubricant may be used on black o-rings but is not necessary. Avoid any type of lubricants,

including silicone, on red or clear lip seals.

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 ¼” NPT connection and on the threads for the drain line
connection. Teflon tape is not necessary on the nut connections or caps because o-ring seals are
used. The nuts and caps are designed to be unscrewed or tightened by hand or with the special
plastic Service Wrench, #V3193. If necessary 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.

SITE REQUIREMENTS:

• Water pressure, 20-125 psi • Current draw is 0.25 ampers

• Water temperature (to 30C) or (40 to 100F) • A 15-foot power cord is furnished

• The tank should be on a firm, level surface • The plug-in transformer is for dry locations only

• Electrical: Use a 115/120v, 60Hz uninterrupted

outlet

1. The distance between the drain and the water conditioner should be as short as possible.
All plumbing should be done in accordance with local plumbing codes. NOTE: Maximum
head 15 10’ or 3 meters.

2. Since salt must be periodically added to the brine tank, it should be located where it is
easily accessible.

3. Do not install any water conditioner with less than 10 feet of piping between its outlet
and the inlet of a water heater.

4. Do not locate unit where it or its connections (including the drain and overflow lines) will
ever be subjected to room temperatures under 34F.

Page 3

• Batteries are not used

5. The use of resin cleaners in an unvented enclosure is not recommended.

INLET/OUTLET PLUMBING: Connect to supply line downstream of outdoor spigots.

6.

Install an inlet shutoff valve and plumb to the unit’s bypass valve inlet located at the
right rear as you face the unit. There are a variety of installation fittings available. They
are listed under Installation Fitting Assemblies. When assembling the installation
fitting package (Inlet and Outlet), connect the fitting to the plumbing system first and
then attach the nut, slit 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 getting solder flux,
primer and solvent cement on any part of the o-rings, split rings, bypass valve or control
valve. If the building’s electrical system is grounded to the plumbing, install a copper
grounding strap from the inlet to the outlet pipe. Plumbing must be done in

accordance with all applicable local codes.

DRAIN LINE: First, be sure that the drain can handle the backwash rate of the system.

7.

Solder joints near the drain must be done prior to connecting the drain line flow control
fitting. Leave at least 6” between the drain line flow control fittings and solder joints.
Failure to do this could cause interior damage to the flow control. Install a 1/2” I.D.
flexible plastic tube to the Drain Line Assembly or discard the tubing nut and use the ¾”
NPT fitting for rigid pipe. If the backwash rate is greater than 7 gpm, use a ¾” drain line.
Where the drain line is elevated but empties into a drain below the level of the control
valve, form a 7” loop at the discharge end of the line so that the bottom of the loop is
level with the drain connection on the control valve. This will provide an adequate anti­siphon trap. Where the drain empties into an overhead sewer line, a sink-type trap must
be used. Run drain tube to its discharge point in accordance with plumbing codes. Pay
special attention to codes for air gaps and anti-siphon devices

8. BRINE TANK CONNECTION: Install a 3/8” O.D. polyethylene tube from the Refill
Elbow to the Brine Valve in the brine tank.

9. OVERLOW LINE CONNECTION:

AN OVERFLOW DRAIN LINE RECOMMENDED WHERE A BRINE OVERFLOW COULD
DAMAGE FURNISHINGS OR THE BUILDING STRUCTURE.
Your softener may be equipped with a brine tank safety float which greatly reduces the
chance of an accidental brine overflow. In the event of a malfunction, however, an
OVERFLOW LINE CONNECTION will direct the “overflow” to the drain instead of spilling
on the floor where it could cause considerable damage. This fitting should be on the side
of the cabinet or the brine tank. To connect overflow fitting, locate hole in side of brine
tank. Insert overflow fitting into tank and tighten with plastic thumb nut and gasket from
the inside. Attach a length of 1/2” I.D. tubing (not supplied) to fitting and run to drain.
Do not elevate overflow line higher than 3” below bottom of overflow fitting. Do not “tie”
this tube into the drain line of the control valve. Overflow line must be a direct, separate
line from overflow fitting to drain, sewer, or tub. Allow an air gap as per the drain line
instructions.

IMPORTANT: Never insert a drain line directly into a drain, sewer line, or trap.
Always allow an air gap between the drain line and the wastewater to prevent the
possibility of sewage being back-siphoned into the conditioner.

10. SERIAL NUMBER: Record the serial number on the installer’s and customer’s records.

Bypass Valve

The bypass valve is typically used to isolate the control valve from the plumbing system’s
water pressure in order to perform control valve repairs or maintenance. The WS1 bypass

Page 4

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 positions including a
diagnostic position that allows service personnel to work on a pressurized system while still
providing untreated bypass water to the facility or residence. It’s completely non-metallic, all
plastic design allows for easy access and serviceability without the need for tools.

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 seizing after long periods of
non-use. 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 1)

2. Bypass Position: The inlet and outlet handles point to the centre 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 2)

3. Diagnostic Position: The inlet handle points in the direction of flow and the outlet

handle points to the centre 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 3)

4. Shut Off Position: The inlet handle points to the centre of the bypass valve and the

outlet points to the direction of flow, the water is shut off to the plumbing system. 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 4)

Page 5

Page 6

Page 7

Start-up Instructions

• After installation is completed and checked for leaks, rotate the bypass handles to the
bypass position (see bypass valve diagram page).

• Fully open a cold water faucet.

• Allow water to run until clear to rid pipes of debris, which may have occurred during

installation.

• The system is now ready for testing:

1. With the bypass valve in the bypass position, manually pour enough water into
the brine tank to reach the top of the air check valve.

2. Press and hold the REGEN button for three seconds until the drive motor starts.
Wait until the motor stops and the display reads “Backwash”. The backwash time
will begin to count down.

3. Open the inlet handle of the bypass valve very slightly allowing water to fill the
tank slowly in order to expel air. CAUTION: If water flows too rapidly, there will
be a loss of media out of the drain.

4. When the water is flowing steadily to the drain without the presence of air, press
the REGEN button to advance the control to the brine position. The brine time
will begin to count down.

5. Fully open the inlet bypass valve handle (bypass is now in the diagnostic position)

Check to verify that water is being drawn from the brine tank
There should be a slow flow to the drain
Allow three minutes for the media bed to settle

6. Press the REGEN button again to advance the control to the next position and
allow water to run for 2-3 minutes. Control will transfer and the display will read
backwash or rinse depending on the program used. If backwash is displayed
press the REGEN button to advance the control to the rinse position. Allow water
to run to drain until clear.

7. Press the REGEN button to advance the control to where the display reads fill.
This will allow water to run into the brine tank and prepare it for the next
regeneration. Allow the brine tank to fill automatically.

8. While the brine tank is filling, load it with water softener salt.

9. SANTIZE! For each cubic foot of resin, add two ounces of 6% household chlorine
bleach to the water in the brine tank brine well. Press and hold the REGEN and
DOWN buttons simultaneously for three seconds to begin regeneration. Allow the
system to complete the regeneration automatically. The system will now be
sanitized and producing soft water. Be sure to check for local codes, which may
also specify sanitization methods.

Page 8

General Operation

g

PLEASE NOTE: For complete instructions refer to manual. Hand tighten nuts only.
GENERAL OPERATION

When the system is operating
one of two displays will be
shown: time of day will be one
choice, gallons of treated water
available or days until the next
regeneration will be the other choice.
Pressing NEXT will toggle
between the two choices.

TO SET TIME OF DAY

In the event of a prolonged
power outage, time of day
flashes, indicating that this
needs to be reset. All other
information will be stored in
memory no matter how long
the power outage, Please
complete the steps as shown to
the right. To access this mode,
press “SET CLOCK”.

ADJUST HARDNESS,
DAYS BETWEEN
REGENERATIONS,
OR TIME OF
REGENERATION

For initial set-up or to make
adjustments, please complete
the steps as shown to the right.
Access this mode by pressing
“NEXT” and “” simultaneously.
Note: Hardness display shows
“-NA-“ if used as a filter. If
other displays do not appear
refer to manual.

1. Accessed by pressin
CLOCK

2. Adjust hours with UP and
DOWN arrows. AM/PM
toggles at 12.

3. Press NEXT.

4. Adjust minutes with up
and down arrows.

5. Press “NEXT” to complete
and return to normal
operation

1. Accessed by pressing
“SET CLOCK”.

2. Adjust hardness using
up and down arrows.

3.Press “NEXT”

4. Adjust days between
regenerations using up
and down arrows.

5. Press “NEXT”

6. Adjust time of
regeneration hours with
up and down arrows,
AM/PM toggles at 12.

7. Press “NEXT”

8. Adjust time of
regeneration minutes
with up and down
arrows.

9. Press “NEXT to
complete and return to
normal operation.

SET

Page 9

MANUAL REGENERATION
NOTE: For softeners, if brine tank does not

contain salt, fill with salt and wait at least 2 hours
before regeneration.
If you need to initiate a manual regeneration,
either immediately, or tonight at the
preprogrammed time (typically 2 a.m.). complete
The following steps.
For Immediate Regeneration:
Press and hold REGEN
until valve motor starts (typically 3 seconds)

For Regeneration Tonight:

Press and release “REGEN”(notice that flashing “REGEN)
TODAY” appears).

If the display shows “E1,” “E2” or” E3” (for error), call
a service technician

To shut off water to the system, please position arrow handles as shown in the bypass operation
diagram below. If your valve doesn’t look like the diagram below, contact your service technician
for instructions on how to shut off water.

NOTES:

Page 10

Installation Date:

Injector color
Installed:_________________

Drain Control
Size installed: _____________

Hardness (gpg):__________
Water Pressure:__________
Salt setting:_____________
Iron (ppm):_____________
Manganese (ppm):_______
TDS (ppm):_____________
pH:___________________

User Displays/Settings

General Operation

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 (to the nearest hour).
The second display is the days remaining until the next regeneration. If the
days remaining are equal to one, regeneration will occur at the next preset
regeneration time. The user can scroll between displays as desired.

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 flowing through
The system) the word Softening or Filtering flashes on the display
If a water meter is installed.

Regeneration Mode
Typically a system is set to regenerate 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 provide treated water when the regeneration has been completed.

Manual Regeneration
Sometimes there is need to regenerate the system, sooner than when the system
calls for it, to as a 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 regeneration 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 system will regenerate at the preset delayed 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 not set delayed regeneration time so “REGEN TODAY” will
not activate if “REGEN” button is pressed.

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.

Note: For softeners, if brine tank does not contain salt, fill with salt and wait at least two
hours before regenerating.

Page 11

Set Time of Day

The user can also set time of day. Time of day should only need to
be set after extended power outages or when daylight saving time
begins or ends. If an extended power outage occurs, the time of day
will flash on and off which indicates the time of day should be reset.

STEP 1U – Press SET CLOCK

STEP 2U – Current time: Set the clock to the closest hour by using

UP and DOWN button. AM/PM toggles after 12. Press NEXT to go to
step 3U.

STEP 3U – Current Time (minutes): Set the minutes of the day
using UP or DOWN buttons. Press NEXT to exit SET CLOCK. Press

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.

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.

REGEN to return to previous step.

Page 12

Installers Displays/Settings

STEP 1I – Press NEXT and UP simultaneously for 3 seconds.

STEP 2I – Hardness: Set the amount of hardness in grains of hardness as

calcium carbonate per gallon using the DOWN or UP buttons. 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. This display will show “-NA­“if “FILTER” is selected in Step 2F or if “AUTO” is not selected in Step 6S. Press
NEXT to go to step 3I. Press REGEN to exit Installer Displays/Settings.

STEP 3I – Day Override: When gallon capacity is set to off, sets the number of
days between regenerations. When gallon capacity is set to AUTO or to a
number, sets the maximum
to “OFF” regeneration initiation is based solely on gallons used. If value is set as
a number (allowable range from 1 to28) a regeneration initiation will be called
for on that day even if sufficient number of gallons were not used to call for
regeneration. Set Day Override using down or up buttons:

• Number of days between regeneration (1 to 28); or

• “OFF”.

See table 12 for more detail on softener setup and Table 13 for more detail on
filter setup. Press NEXT to go to step 4I. Press REGEN to return to previous step.

STEP 4I – Next Regeneration Time (hour): Set the hour of day for regeneration
using down or up buttons. AM/PM toggles after 12. The default time is 2:00 a.m.
This display will show “REGEN on 0 GAL” if”on0” is selected in Step 7F. Press
NEXT to go to step 5I. Press REGEN to return to previous step.

STEP 5I – Next Regeneration Time (minutes): Set the minutes of day for
regeneration using down or up 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.

To initiate a manual regeneration immediately, press and hold the “REGEN”
button for three seconds. The system will begin to regenerate immediately. The
control valve may be stepped through the various regeneration cycles by
pressing the “REGEN” button.

Page 13

number of days between regenerations. If value set

Drawings and
Part Numbers

Page 14

Front Cover and Drive Assembly

Drawing

No.

1 CLK V3175TC01 WS1TC Front Cover ASY 1
2 CLK V310701 WS1 Motor 1
3 CLK V310601 WS1 Drive Bracket & Spring Clip 1
4 CLK V3108TC WS1TC PC Board 1
5 CLK V3110 WS1 Drive Gear 12 x 36 3
6 CLK V3109 WS1 Drive Gear Cover 1

CLK V3002TC WS1TC Drive ASY *

Not Shown CLK V3186 WS1 Transformer 110V-12V 1
* Drawing number parts 2 through 6 may be purchased as a complete assembly, part
CLK V3002TC.

Order No. Description Quantity

Page 15

Drawing No. Order No. Description Quantity

1 CLK V3005 WS1 Spacer Stack Assembly 1
2 CLK V3004 Drive Cap ASY 1
3 CLK V3135 O-ring 228 1
4 CLK V3011 WS1 Piston Downflow ASY 1
5 CLK V3174 WS1 Regernerant Piston 1
6 CLK V3180 O-ring 337 1

Page 16

Injector Cap, Injector Screen, Injector, Plug and O-Ring

Drawing No. Order No. Description Quantity

1 CLK V3176 Injector Cap 1
2 CLK V3152 O-Ring 135 1
3 CLK V3177 Injector Screen 1
4 CLK V30101Z WS1 Injector ASY Z Plug 1

CLK V30101A WS1 Injector ASY A BLACK
CLK V30101B WS1 Injector ASY B BROWN
CLK V30101C WS1 Injector ASY C VIOLET
CLK V30101D WS1 Injector ASY D RED
CLK V30101E WS1 Injector ASY E WHITE

5 CLK V30101F WS1 Injector ASY F BLUE 1

CLK V30101G WS1 Injector ASY G YELLOW
CLK V30101H WS1 Injector ASY H GREEN
CLK V30101I WS1 Injector ASY I ORANGE
CLK V30101J WS1 Injector ASY J LIGHT BLUE

CLK V30101K WS1 Injector ASY LIGHT GREEN
Not Shown CLK V3170 O-ring 011 *
Not Shown CLK V3171 O-ring 013 *

* The Injector plug and the injector each contain one 011 (lower) and 013 (upper) o-ring.

NOTE: For down flow, injector is located in the down hole and injector plug in the up hole. For a
filter that only backwashes, injector plugs are located in both holes, and regenerant piston must
be removed.

Page 17

Refill and Refill Port Plug

Drawing

No.

1 CLK V319501 WS1 Refill Port Plug ASY. This part is required for backwash only

2 CLK H4615 Elbow Locking Clip 1
3 CLK JCPP6 Polytube insert 3/8 1
4 CLK JCPG6PBLK Nut 3/8 1
5 CLK H4613 Elbow Cap 3/8 1
6 CLK V3163 O-ring 019 1
7 CLK V316501* WS1 RFC Retainer Asy. 1
8 CLK V3182 WS1 RFC 1

Not

Shown

* Assembly includes WS1 RFC

Order No. Description Quantity

systems

CLK H4650 Elbow ½" with nut and

insert

Option

Page 18

Drain Line – ¾"

Drawing

Order No. Description Quantity

No.

1 CLK H4615 Elbow Locking Clip 1
2 CLK PKP10TS8BU Polytube Insert 5/8 Option
3 CLKV3192 WS1 Nut ¾" Male Asy. Option
4 CLK V315801 WS1 Drain Elbow ¾ Male

1

Asy.
5 CLK V3163 O-ring 019 1
6 CLK V315901 WS1 DLFC Retainer Asy. 1

CLK V3162007 WS1 DLFC 0.7 gpm for ¾"
CLK V3162010 WS1 DLFC 1.0 gpm for ¾"
CLK V3162013 WS1 DLFC 1.3 gpm for ¾"
CLK V3162017 WS1 DLFC 1.7 gpm for ¾" One
CLK V3162022 WS1 DLFC 2.2 gpm for ¾" DLFC
CLK V3162027 WS1 DLFC 2.7 gpm for ¾" must be

7 CLK V3162032 WS1 DLFC 3.2 gpm for ¾" used if

CLK V3162042 WS1 DLFC 4.2 gpm for ¾" ¾"
CLK V3162053 WS1 DLFC 5.3 gpm for ¾" fitting is
CLK V3162065 WS1 DLFC 6.5 gpm for ¾" used
CLK V3162075 WS1 DLFC 7.5 gpm for ¾"
CLK V3162090 WS1 DLFC 9.0 gpm for ¾"
CLK V3162100 WS1 DLFC 10.0 gpm for

¾"

Page 19

Drain Line – 1"

Drawing

Order No. Description Quantity

No.

1 CLK H4615 Elbow Locking Clip 1

2 CLK V300802 WS1 Drain FTG 1 Straight 1
3* CLK V3166 WS1 Drain FTG Body 1 1
4* CLK V3167 WS1 Drain FTG Adapter 1 1
5* CLK V3163 O-ring 019 1
6* CLK V3150 WS1 Split Ring 1
7* CLK V3150 WS1 Nut 1" QC 1
8* CLK V3105 O-ring 215 1

CLK V3190090 WS1 DLFC 9.0 gpm for 1
CLK V3190100 WS1 DLFC 10.0 gpm for 1 One
CLK V3190110 WS1 DLFC 11.0 gpm for 1 DLFC

9 CLK V3190130 WS1 DLFC 13.0 gpm for 1 must be

CLK V3190150 WS1 DLFC 15.0 gpm for 1 used if
CLK V3190170 WS1 DLFC 17.0 gpm for 1 1" fitting
CLK V3190200 WS1 DLFC 20.0 gpm for 1 is used
CLK V3190250 WS1 DLFC 25.0 gpm for 1

* Can be ordered as a set order number CLK V300802, description: WD Drain FTG 1 Straight

Page 20

Water Meter and Meter Plug

Drawing No. Order No. Description Quantity

1 CLK V3151 WS1 Nut 1" QC 1
2 CLK V3105 O-ring 215 1
3 CLK V300301 WS1 Meter Plug Asy. 1

Page 21

Installation Fitting Assemblies

Order No: CLK V3007 Order No: CLK V300701

Description: WS1 Fitting 1" PVC Male NPT Elbow Assembly Description: WS1 Fitting ¼ " & 1" PVC Solvent 90 ASY

Drawing

No.

1 CLK V3151 WS1 Nut 1" Quick

Order No. Description Quantity Drawing

No.

2 1 CLK V3151 WS1 Nut 1" Quick

Connect

Order No. Description Quantity

Connect
2 CLK V3150 WS1 Split Ring 2 2 CLK V3150 WS1 Split Ring 2
3 CLK V3105 O-Ring 215 2 3 CLK V3105 O-Ring 215 2
4 CLK V3149 WS1 Fitting 1 PVC

Mule NPT Elbow

2 4 CLK V3189 WS1 Fitting ¼ & 1

PVC Solvent 90

Order No: CLK V300702 Order No: CLK V300703

Description:WS1 Fitting 1" Brass Sweat Assembly Description: WS1 Fitting ¾ " Brass Sweat Assembly

Drawing

No.

1 CLK V3151 WS1 Nut 1" Quick

2 CLK V3150 WS1 Split Ring 2 2 CLK V3150 WS1 Split Ring 2
3 CLK V3105 O-Ring 215 2 3 CLK V3105 O-Ring 215 2
4 CLK V3188 WS1 Fitting 1 Brass

Order No. Description Quantity Drawing

No.

2 1 CLK V3151 WS1 Nut 1" Quick

Connect

2 4 CLK V318801 WS1 Fitting ¾

Sweat

Order No. Description Quantity

Connect

Brass Sweat

2

2

2

2

Page 22

Bypass Valve

Drawing No. Order No. Description Quantity

1 CLK V3151 WS1 Nut 1"" Quick Connect 2
2 CLK V3150 WS1 Split Ring 2
3 CLK V3105 O-Ring 215 2
4 CLK V3145 WS1 Bypass 1" Rotor 2
5 CLK V3146 WS1 Bypass Cap 2
6 CLK V3147 WS1 Bypass Handle 2
7 CLK V3148 WS1 Bypass Rotor Seal

Retainer
8 CLK V3152 O-Ring 135 2
9 CLK V3155 O-Ring 112 2

10 CLK V3156 O-Ring 214 2

(Not Shown) Order No. CLK V319101, Description: WS1 Bypass Vertical Adapter Assembly

Order No. Description Quantity
CLK V3151 WS1 Nut 1" Quick Connect 2
CLK V3150 WS1 Split Ring 2
CLK V3105 O-Ring 215 2

CLK V319101 WS1 Bypass Vertical Adapter Assembly 2

2

Page 23

Service Wrench

Although no tools are necessary to assemble or disassemble the valve, the WS1 wrench (shown
in various positions on the valve) may be purchased to aid in assembly or disassembly.

Page 24

Service Instructions

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 plug 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 PC board can be removed separately from the drive bracket but it is not recommended. Do
not attempt to remove the display panel from the PC board. Handle the board by the edges. To
remove the PC board from the drive bracket, unplug the power and motor plugs from the PC
board. Lift the middle latch along the top of the drive bracket while pulling outward on the top of
the PC board. The drive bracket has one plastic pin that fits into the hole 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
the pin. To reinstall the PC board, position the lower edge of the PC board so that the hole in the
PC board lines up with the plastic pin. Push the top of the PC board towards the valve. Align the
upper hole on left hand side of PC board with the pin and push in until the PC board snaps under
the middle latch, weave the power wire into the holders and reconnect the motor and power
plugs.

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 plug for the power source.
Unweave the wire 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.

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 back plate. If resistance is felt before latching, then notches are not fully engaged,
the piston rod is not in the hole, the power wire is jammed between the drive bracket and drive
back plate, or the gear is not engaging the drive cap assembly.

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 tilted towards
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 of 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 interfere with pulse counting.

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The drive gear cover only fits on one way, with the large clip tilted 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
board. Move the spring clip loop to the right and hold. Rotate the motor at least a ¼ 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.

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 reinstalling, lift and slightly rotate
motor before reinserting.

Replace the valve cover. After completing any valve maintenance, press and hold SET HOUR and
DOWN buttons for 3 seconds or unplug power source jack (black wire) from the circuit board and
plug back in. This resets the electronics and establishes the service piston position.

Drive Cap Assembly, Main Piston and Regenerant Piston

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 control
valve body and seals with an o-ring. To remove the drive cap assembly use the special plastic
wrench or insert a ¼” to ½” 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.

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The drive cap assembly contains the drive cap, the main drive gear, drive cap spline, piston rod
and various other parts that should not be disassembled 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 and, if
a regenerant 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 bisulfate or vinegar or
replace the regenerant piston if needed. To remove the main 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 bisulfate or vinegar or replace the main piston.

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 he special wrench or a screwdriver as a ratchet until the black o-ring 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.

Reattach the drive assembly to the control valve and connect all plugs. After completing any
valve maintenance, press and hold SET HOUR and DOWN buttons for 3 seconds or unplug power
source jack (black wire) from the circuit board and plug back in. This resets the electronics and
establishes the service piston position.

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 spacer stack assembly may be chemically cleaned (dilute sodium bisulfate or vinegar) or
wiped with a soft cloth.

The spacer stack assembly can be pushed into 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
properly 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.

Reattach the drive cap assembly and piston(s) and the drive assembly.

After completing any valve maintenance, press and hold SET HOUR and DOWN buttons for 3
seconds or unplug power source jack (black wire) from the circuit board and plug back in. This
resets the electronics and establishes the service piston position.

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 is a screen. Remove the screen and clean if fouled.

Page 27

The plug and/or injector can be pried out with a small screwdriver/ the plug can be wiped clean.
If the lug leaks replace the entire plug. The injector consists of a throat and a nozzle. Chemically
clean the injector with vinegar or sodium bisulfate. 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:

a. for down flow systems, the appropriate size injector is located in the “D” hole, a plug is in

the “UP” hole and that the piston is a combination of the down flow main piston and the
regenerant piston; or

b. for backwash only systems, a plug is in the “DN” hole and in the “UP” hole, and that the

piston only has a down flow main piston (the regenerant piston must be removed) and a
plug is in the refill flow control position.

Push the plug(s) and/or injectors firmly in place, replace the screen and hand tighten the injector
cap.

Refill Flow Control Assembly or Refill Port Plug

To clean 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 upwards through the
side slots of the retainer with a small blade flat screwdriver.

Chemically clean the flow control or the white flow control retainer using dilute sodium bisulfate
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.

Reset the flow control so the rounded end is visible in the flow control. Reset the white flow
control retainer by pushing the retainer into the elbow until the o-ring sets. Remove locking clip,
push down on elbow to reset and insert locking clip.

Do not use Vaseline, oils, or other unacceptable lubricants on o-ring. A silicon lubricant may be
used on the o-ring on the elbow or the white retainer.

Meter Plug

This control valve does not come equipped with a meter, instead a plug is installed. The plug
should not need to be serviced.

To remove the meter plug 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 meter plug is visible. Twist a flat blade screwdriver
in the slot between the control valve body and the meter plug. When the meter plug is part way
out it is easy to remove the meter plug from the housing.

Do not use a wire brush to clean. Wipe with a clean cloth or chemically clean in dilute sodium
bisulfate or vinegar.

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Do not use Vaseline, oils, or other unacceptable lubricants on the o-ring. A silicon lubricant
maybe used on the black o-ring.

Reinsert the meter plug into the side slot. Hand tighten the nut. Do not use a pipe wrench to
tighten nut.

Bypass Valve

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.

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.

When reinstalling the red arrow handles be sure that:

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.

After completing any valve maintenance, press and hold SET HOUR and DOWN buttons for 3
seconds or unplug power source jack (black wire) from the circuit board and plug back in. This
resets the electronics and establishes the service piston position.

1. O-rings on both rotors face to the right when being viewed from the front control
valve when the handle pointers are lined up with the control valve body arrows;
or

2. Arrows point toward each other in the bypass position.

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Table 15

Troubleshooting Procedures

Problem Possible Cause Solution

a. Transformer unplugged a. Connect power

1. Timer does not display time
of day
c. Defective transformer c. Replace transformer
d. Defective PC board d. Replace PC board
a. Switched outlet a. Use uninterrupted outlet

2. Timer does not display
correct
time of day c. Defective PC board c. Replace PC board
a. Bypass valve in bypass position a. Put bypass valve in service position

3. No softening/filtering display b. Meter connection disconnected b. Connect meter to PC board
when water is flowing c. Restricted/stalled meter turbine c. Remove meter and check for rotation or foreign

d. Defective meter d. Replace meter
e. Defective PC board e. Replace PC board
a. Power outages a. Reset control valve to correct time of

b. Time of day not set correctly b. Reset to correct time of day

4. Control valve regenerates c. Time of regeneration incorrect c. Reset regeneration time
at wrong time of day d. Control valve set at "on 0"

e. Control valve set at NORMAL

a. Control valve has just been

5. ERROR followed by code
number
Error Code 1001 – Unable to
Recognize start of regeneration
Error Code 1002 – Unexpected
stall
Error 1003 – Motor ran to long,
timed out trying to reach next
cycle
position
Error Code 1004 – Motor ran to
long, timed out trying to reach
home position
f. Drive gear label dirty or

If other Error Codes display
contact the factory
h. PC board is damaged or defective h. Replace PC board
i. PC board incorrectly aligned to

b. No electric power at outlet b. Repair outlet or use working outlet

b. Power outage b. Reset time of day

material

day

d. Check control valve set-up procedure

(immediate regeneration)

+ on 0

serviced

b. Foreign matter lodged in control
valve
c. High drive forces on piston c. Replace piston(s) and spacer stack

d. Control valve piston not in home
position

e. Motor not inserted fully to
engage pinion, motor wires
broken or disconnected, motor
failure

damaged, missing or broken gear
g. Drive bracket incorrectly aligned
to back plate

drive bracket

regeneration time option
e. Check control valve set-up procedure
regeneration time option
a. Press NEXT and REGEN for 3
seconds or unplugged power source
jack (black wire) and plug back in to
reset control valve
b. Check piston and spacer stack
assembly for foreign matter

assembly
d. Press NEXT and REGEN for 3
seconds or unplug power source
jack (black wire) and plug back in to
reset control valve

e. Check motor and wiring. Replace
motor if necessary

f. Replace or clean drive gear

g. Reset drive bracket properly

i. Ensure PC board is correctly snapped
on to drive bracket

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Problem Possible Cause Solution
a. Motor not operating a. Replace motor
b. No electric power at outlet b. Repair outlet or use working outlet

6. Control valve stalled in c. Defective transformer c. Replace transformer
regeneration d. Defective PC board d. Replace PC board
e. Broken drive gear or drive cap

assembly
f. Broken piston retainer f. Replace drove cap assembly
g. Broken main regenerant piston g. Replace main regenerant piston
a. Transformer unplugged a. Connect transformer

7. Control valve does not b. No electric power at outlet b. Repair outlet or use working outlet
regenerate automatically
when
REGEN button is depressed
and held d. Defective PC board d. Replace PC board

8. Control valve does not
regenerate automatically b. Meter connection disconnected b. Connect meter to PC board
But does when REGEN
Button is depressed
d. Defective meter d. Replace meter
e. Defective PC board e. Replace PC board
f. Set-up error f. Check control valve set-up

9. Time of day flashes on and
off

c. Broken drive gear or drive cap

assembly

a. By-pass valve in bypass

position

c. Restricted/stalled meter turbine c. Remove meter and check for

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.

e. Replace drive gear or drive cap
assembly

c. Replace drive gear or drive cap
assembly

a. Put bypass valve in normal
operation position

rotation or foreign matter

procedure
a. Reset the time of day

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