INSTALLATION
INSTRUCTIONS & PARTS
HOBART
WATER SOFTENING
SYSTEM
WS-500
A product of HOBART TROY, OHIO 45374
F25405 (March 2011)
TABLE OF CONTENTS
INSTALLATION ............................................................................ 2
DISC SELECTION ......................................................................... 15
REPLACEMENT PARTS .................................................................... 15
© HOBART 2011
INSTALLATION
SAVE THESE INSTRUCTIONS
1. Determine location to install equipment. Make
sure the unit will be on a flat surface.
2. If sand, silt, or turbidity is present, install a
separate prefilter.
NOTE: Sediment filtration is recommended before
the water softener, particularly in areas with known
sediment issues or on a private water supplies.
NOTE: If the peak flow rate required is unknown, a
prefilter with a minimum of 1.25" connections should
be used. Filters with 5 micron nominal ratings should
be considered the standard in food service
applications.
By-Pass Valve Kit Installation
3. If the optional by-pass valve kit is being
installed, continue with steps listed below. If bypass valve kit is not being installed - proceed to
step 24.
4. To install by-pass valve determine which port on
the by-pass valve (Port A or Port B) to plumb
the raw water connection to.
5. Determine which port on the by-pass valve (Port
C or Port D) to connect the softener.
F25405 (March 2011) Page 2 of 20
6. Verify the by-pass valve is in the by-pass
position. Turn by-pass handle to reveal yellow
by-pass segment.
7. Remove the by-pass valve handle by pulling it
away from the by-pass valve body.
9. Locate patch decal provided with by-pass valve
kit.
10. Remove patch decal from paper lining and
apply to body of the by-pass valve based on the
specific installation using Table 1.
NOTE: For use in A-D or B-D configuration, it will be
necessary to cut patch.
8. The five position valve has two installation
configuration options. Photo below shows the
crossover and parallel configurations as the
valve is shipped.
F25405 (March 2011)Page 3 of 20
Table 1
MODE RAW
INLET
A-C A C PARALLEL 2
B-C B C CROSSOVER 3
A-D A D CROSSOVER 4
B-D B D PARALLEL 5
SOFTENER
INLET
INSTALL
CONFIGURATION
FIG
F25405 (March 2011) Page 4 of 20
11. Align the handle with the shaft until handle
slides onto shaft. Push down on handle until it
snaps into place.
NOTE: The handle is keyed allowing it to go on the
shaft only one way. Failing to perform above
procedure can result in breaking the shaft inside the
handle. Do not force handle onto shaft.
17. Apply a liberal amount of silicone to the four Orings and install on the two end spaces on both
Port C and Port D.
NOTE: When installing a plastic component in line, it
is recommended that grounding straps be put in
place before the lines are actually cut to ensure the
ground is never broken.
12. Prepare plumbing by roughing in.
13. Connect the inlet/outlet adapters to the
plumbing. Solder or glue adapters to pipe as
applicable.
NOTE: Do not solder adapters while in the by-pass
valve.
NOTE: Care should be taken during the installation
process to assure that solder flux does not come in
contact with the media tanks, the control module,
and related components.
14. After all plumbing is completed and before
connecting any equipment, flush both inlet and
outlet lines by opening the raw water inlet valve
and allowing water to rinse out and debris in the
line.
15. Close the raw water line when complete.
16. Locate from the by-pass kit the two elbows,
four O-rings, two E-Clips and silicone packet.
18. Insert mesh screens into left and right elbows.
19. Locate from the by pass kit the four O-rings, two
E-Clips and silicone packet
F25405 (March 2011)Page 5 of 20
20. Apply a liberal amount of silicone to the four Orings and install them on the two outermost
groves on both elbows
NOTE: Elbows are marked left (L) and right (R).
When applying to by-pass valve be certain to install
in correct location based on left/right orientation.
By-Pass Valving Installation
NOTE: If optional by-pass valve kit is not installed - it
is recommended that by-pass valving be installed.
To install by-pass valving - follow steps listed below.
24. Determine location to install equipment. Make
sure the unit will be on a flat surface.
25. If sand, silt, or turbidity is present, install a
separate prefilter.
NOTE: Sediment filtration is recommended before
the water softener, particularly in areas with known
sediment issues or on a private water supplies.
NOTE: If the peak flow rate required is unknown, a
prefilter with a minimum of 1.25" connections should
be used. Filters with 5 micron nominal ratings should
be considered the standard in food service
applications.
26. Install by-pass valving. Be certain to note the
inlet and outlet arrows on the valve head.
27. Connect the inlet/outlet adapters leading to the
softener using the proper size plumbing.
28. Plumb as necessary to accommodate the bypass valving and to complete the installation.
NOTE: Make sure to align the center slot (the slot
with the small triangle underneath it) with the outside
of the by pass valve.
21. Connect elbows from the by-pass valve to
softener using E-clips. Press E-clips until they
securely snap in place.
22. Connect the by-pass valve to the inlet/outlet
adapters. Press E-clips until they securely snap
in place.
23. Plumb as necessary to accommodate the bypass valve and to complete the installation.
Proceed to step 31.
NOTE: Actual installation of by-pass valving may
vary from installation to installation. Be sure to follow
state and local codes.
NOTE: When installing a plastic component in line, it
is recommended that grounding straps be put in
place before the lines are actually cut to ensure the
ground is never broken.
NOTE: Do not solder brass adapters while inserted
in the module base. Damage to plastic and ruber
parts may result due to the heat. In addition, the
materials used in the soldering process may attack
certain types of plastics.
NOTE: Care should be taken during the installation
process to assure that solder flux do not come in
contact with the media tanks, the control module,
and related components.
F25405 (March 2011) Page 6 of 20
29. After all plumbing is completed, but before
connecting equipment, flush both the inlet and
outlet lines by opening the by-pass valve and
allowing water to rinse out any debris in the
lines.
30. Connect the main tank with softener valve to the
inlet/outlet adapter. The inlet/outlet adapter is
inserted into the control valve and locked in
place by the plastic E-clips.
31. Locate enclosed kit containing four O-rings, two
pipes with O-rings, and the silicone packet.
Apply a liberal amount of silicone to the four Orings and the O-rings in the two pipes. Install
the four O-rings to the inlet/outlet adapters.
32. NOTE: Be certain the E-clips are fully inserted
into the valve. Check to make sure that all three
tabs on the E-clips are fully inserted.
F25405 (March 2011)Page 7 of 20
F25405 (March 2011) Page 8 of 20
F25405 (March 2011)Page 9 of 20
Tank Connection
Brine Drum
33. Connect the remote tank to the main tank using
connector pipes, connector links and connector
pins.
NOTE: Always use both links and pins.
34. Run a drain line to the discharge point.
NOTE: Follow state and local codes.
35. Before connecting unit, check for obstructions
or kinks. Apply Teflon tape to pipe threads on
side of softener valve, and install the two fittings
supplied. Connect drain line to valve.
36. Position the brine drum.
NOTE: Brine drum should be conveniently
positioned to allow salt to be added.
NOTE: An air gap must be provided for all drain
lines. Check state and local plumbing codes for
proper setup of drain line air gaps.
NOTE: On drain lines that must travel more than 8
feet up and 30 feet over, it is best to take the 5/8"
drain line that fits the valve and attach it in a larger
diameter line or pipe.
NOTE: In Hobart Softeners, the brine drum mixes
and stores a solution of salt for regeneration of the
softener media. During the brine rinse cycle, this
solution is drawn from the brine drum and through
the media to regenerate it.
The brine drum contains an adjustment to draw the
correct amount of salt (brine) solution for each cycle.
This adjustment is made in two places, the adjuster
tube and the float cup.
NOTE: The adjuster tube measures the amount of
solution that is drawn from the brine drum into the
softener during the brine rinse cycle. The float cup
height determines how much softened water flows
back into the brine drum to prepare for the next
regeneration.
The adjuster tube is set by cutting and removing tabs
on both sides of the tube. Cut across each tab
horizontally, following the channel in the plastic.
Break off each tab individually until the proper setting
is reached. The remaining number or letter imprinted
on the tab determines the correct setting.
F25405 (March 2011) Page 10 of 20
NOTE: The float cup height determines how much
softened water flows back into the brine drum to
prepare for the next regeneration.
The float cup is set by adjusting its height above the
bottom of the Brine Valve Assembly. By removing
the brine valve assembly and resting it on a flat
surface, the height of the float cup can be measured
with a ruler.
The height is measured from the base of the brine
valve assembly to the top of the float cup.
NOTE: Standard settings are defined by markings on
the rod of the brine valve assembly. Where the
predefined settings are not adequate, the actual float
cup height must be measured and the setting must
be measured and set according to the measured
float cup height.
Determining the correct brine valve setting for a
particular application is a three step process:
1. Determine the compensated hardness. This
requires a hardness test and an iron test on raw
water at the application site. Compensated
hardness is calculated by multiplying the ferrous
iron (in ppm) by 3 and adding it to the grains of
hardness.
F25405 (March 2011)Page 11 of 20
2. To test the water supply, use the water analysis
test kit available through Pro Products Inc. The
recommended kit is #2404 Deluxe Field
Analysis Kit. To order the test kit contact Pro
Products at 800-285-9176 or visit
www.ProProducts.com.
3. Set the adjuster tube and float cup. Use the
brine drum specifications for the WS-500 to
determine the correct settings for both the
adjuster tube and the float cup height.
Brine Valve Settings for WS-500
24 x 40 Brine Valve Adjustment
Salt Setting
Adjuster Tube
Float Cup
NOTE: Do not drop the brine valve into the drum.
Dropping may lower the float cup, resulting in an
improper setting.
After the adjustments have been made to the
adjuster tube and the float cup, the brine valve
assembly must be installed in the brine drum. Locate
the brine valve in the brine well so the 3/8" bent tube
is along the back of the brine well away from the
brine drum wall. The 3/8" bent tube snaps into a
notch and extends from the brine drum about 1 inch.
NOTE: The WS-500 comes with a #4 meter disc
installed at the factory. If this is not the correct disc
for a given application, locate the meter disc kit and
install the correct disc.
Disc Selection
36. To change disc, remove screws and cap cover
from level one.
25 lbs.
K
12"
38. Remove balance piston o-ring and balance
piston spring.
39. Remove meter drive pawl.
37. Remove balance piston.
F25405 (March 2011) Page 12 of 20
40. Remove meter disc.
41. Install correct meter disc and reassemble in
reverse order.
NOTE: Make certain all components are correctly
installed.
NOTE: Be certain to start cap screws by hand
rotating backwards until screw drops into thread then
tighten. An alternating, crossing pattern should be
used while tightening cap screws to ensure correct
cap fit.
Salt Alarm Installation
47. To install salt alarm system - remove paper
lining from back of salt alarm sensor.
Add a clean grade of salt at this time. Higher grades
of Pelletized Salt for impurities and solubility should
be used.
NOTE: Do not use rock salt or solar salt.
NOTE: On iron-bearing water, a salt that contains
resin cleaning additives is recommended.
42. Open the inlet valve slowly and allow the tanks
to fill slowly with water. Water will run at the
drain until unit is full and pressurized.
43. With the unit in service and under pressure,
allow the brine drum to fill with water until the
brine valve shuts off.
44. After the unit is fully pressurized, purge air form
the lines by opening soft water outlet.
NOTE: When brine drum overflow could cause
damage, a ½" I.D. overflow line must be installed on
the barbed overflow fitting on drum and connected to
a drain. Make sure drain is not higher than barbed
fitting. FOLLOW STATE AND LOCAL CODES.
45. Check for plumbing leaks.
46. Check unit for proper operation.
48. Remove plastic lining from Velcro
®
backing
located on back of salt alarm controller.
49. Remove four screws securing back cover to salt
alarm controller.
F25405 (March 2011)Page 13 of 20
50. Install three (3) AA batteries into salt alarm
controller.
NOTE: When installing batteries - be certain to
inspect connector to ensure it is secure.
51. Re-install back cover to salt alarm controller.
52. Using the adhesive backing on both devices place alarm controller and salt alarm sensor in a
position that will allow salt alarm controller to be
seen and heard when it is activated.
54. Check for proper operation by pressing the
recessed red button on bottom of salt alarm
controller. If controller is operating properly the indicator light will flash and an audible tone
will be heard.
53. Insert phone cable into salt alarm sensor and
salt alarm controller.
NOTE: Salt alarm controller can be mounted up to
100 feet from salt alarm connector box using
standard phone cable from local retailers (7 foot
cable is provide with kit).
F25405 (March 2011) Page 14 of 20
DISC SELECTION
Using the full louver nozzle, the amount of hardness removed (in compensated gpg) will be based on the amount
of brine and the meter disc selected.
OVERDRIVE OPERATION
Setting Capacity Efficiency Dosing Meter
Disc
3
3
1234567 8
Disc
7 142128344045 51
20 20 20 20 15.7 12.4 10.0 8.3
*Compensated hardness in gpg = Hardness + (3 x Fe in mg/l)
25 lbs. 70,000 grains 2,800 gr./lb. 10.0 lbs./ft
Peak flow during regeneration:
ALTERNATING OPERATION
Setting Capacity Efficiency Dosing Meter
25 lbs. 70,000 grains 2,800gr./lb. 10.0 lbs./ft
Flow during regeneration (@ 15 psig)
Gallons/Regeneration: 8,922 4,461 2,974 2,231 1,784 1,487 1,275 1,115
REPLACEMENT PARTS
Disc Selection
(Compensated Hardness*)
1 2 3 4 5678
6 12 16 20 24303540
28.0 28.0 28.0 20.7 15.7 12.4 10.0 8.3
*Compensated hardness in gpg = Hardness + (3 x Fe in mg/l)
Disc Selection
(Compensated Hardness*)
Item
Number
1 00-913091-130 Cord Phone 7ft. 1
2 00-913091-129 Sensor Salt Alarm 1
3 00-913091-128 Salt Alarm Assy. 1
Part Number Description Qty.
F25405 (March 2011)Page 15 of 20
F25405 (March 2011) Page 16 of 20
Item
Number
1 00-913091-00067 Cap Screw 8
2 00-913091-00068 Cap 1
3 00-913091-00069 O-Ring (Actuator) 1
4 00-913091-00071 Seal - Cap 1
5 00-913091-00070 Actuator 1
6 00-913091-00072 Meter Disc 1 1
7 00-913091-00073 Meter Disc 2 1
8 00-913091-00074 Meter Disc 3 1
9 00-913091-00075 Meter Disc 4 1
10 00-913091-00076 Meter Disc 5 1
11 00-913091-00077 Meter Disc 6 1
12 00-913091-00078 Meter Disc 7 1
13 00-913091-00079 Meter Disc 8 1
14 00-913091-00048 O-Ring (Balance Piston) 1
15 00-913091-00008 Piston - Balance 1
16 00-913091-00010 Spring (Balance Piston) 1
17 00-913091-00049 Control Disc (Tan) 1
18 00-913091-00012 Pawl (No Back) 1
19 00-913091-00013 Pawl - Meter Drive 1
20 00-913091-00014 Spring (Meter Drive Pawl) 1
21 00-913091-00015 Pawl - Regen Start 1
22 00-913091-00081 Eccentric Pin 1
23 00-913091-00061 Filter 1
24 00-913091-00016 Pawl - Regen Drive 1
25 00-913091-00081 Eccentric Pin 1
26 00-913091-00084 O-Ring (Regen) 1
27 00-913091-00083 Pin - Support 1
28 00-913091-00085 Screw (Level 1) 8
29 00-913091-00017 Seal - Red (Level 1) 1
30 00-913091-00047 Level 1 Assy. (Incls. Items 1 thru 29) 1
31 00-913091-00020 Level 2 1
32 00-913091-00100 Tube - Vent 1
33 00-913091-00050 Brine Flow Control (0.7 GPM) 1
34 00-913091-00023 Seal - Red (Level 2) 1
35 00-913091-00051 Level 3 Assy. 1
36 00-913091-00087 Elbow - Brine 1
37 00-913091-00086 Elbow - Drain 1
38 00-913091-00097 Regeneration Flow Control 1
39 00-913091-00025 Seal - Red (Level 3) 1
40 00-913091-00052 Venturi Throat (Yellow) 1
41 00-913091-00055 Control Valve (With Quad Ring) 1
42 00-913091-00102 Quad Ring (Control Valve) 1
43 00-913091-00094 Main Piston (Incls. Item 44) 4
44 00-913091-00095 Quad Ring (Main Piston) 4
45 00-913091-00096 Valve Seat - Main (Incls. Item 46) 4
46 00-913091-00093 Seal - Main Valve 4
47 00-913091-00056 Backwash Flow Control 1
48 00-913091-00103 Seal - Control Valve 1
Part Number Description Qty.
Page 17 of 20
F25405 (March 2011)
Item
Number
49 00-913091-00054 Level 4 1
50 00-913091-00053 Level 4 Assy. (Incls. Items 41 thru 49 & 51) 1
51 00-913091-00031 Seal - Red (Level 4) 1
52 00-913091-00058 Drain Valve (With Quad Ring) 1
53 00-913091-00035 Interlock 1
54 00-913091-00057 Level 5 1
55 00-913091-00059 Seal - Drain Valve 1
56 00-913091-00039 Seal - Main Base (Level 6) 1
57 00-913091-00040 Check Stems 2
58 00-913091-00060 Level 6 1
59 00-913091-00101 Ring - Main Base 1
60 00-913091-00062 Upper Distributor 1
61 00-913091-00063 Brine Valve Assy. 1
62 00-913091-00064 E-Clip (In/Out) 2
63 00-913091-00110 Nozzle (Full Louver) 1
64 00-913091-00111 Pin - Connector 2
65 00-913091-00112 O-Ring (Connector) 4
66 00-913091-00113 Pipe - Connector 2
67 00-913091-00114 Link - Connector 2
---- 00-0913091-00046 Complete Head Assy. (WS-500) 1
---- 00-913091-00098 Drain Tube AR
---- 00-913091-00099 Brine Tube AR
Part Number Description Qty.
F25405 (March 2011)
Page 18 of 20
Item
Number
1 00-913091-127 Kit, Bypass Valve with Install Elbow 1
2 00-913091-132 Screens for In/Out 20 Mesh 1
3 00-913091-131 Kit, Elbow 1.25" 2
Part Number Description Qty.
F25405 (March 2011)Page 19 of 20
- N O T E S -
F25405 (March 2011) Printed in U.S.A.Page 20 of 20
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