Hydrotech 9500 User Manual
Model 9000/9100/9500
Service Manual
IMPORTANT: Fill in Pertinent Information on Page 3 for Future Reference
Table of Contents
Job Specication Sheet..........................................................................................................................................3
Equipment Conguration........................................................................................................................................4
General and Commercial Installation Checklist......................................................................................................5
Valve to Tank Installation Instructions.....................................................................................................................7
Regeneration Cycle Program Setting Procedure...................................................................................................8
Time Brine Rell and Meter Setting Procedure...................................................................................................... 9
9000/9100/9500 Electro Mechanical Timer Assembly..........................................................................................12
Power Head Assembly......................................................................................................................................... 14
9000 Control Valve Assembly...............................................................................................................................16
9100 Control Valve Assembly...............................................................................................................................18
9500 Control Valve Assembly...............................................................................................................................20
1600 Brine Valve System (for 9500)..................................................................................................................... 22
1700 Brine Valve System (for 9500)..................................................................................................................... 23
9000 Second Tank Assembly...............................................................................................................................24
9100 Second Tank Assembly...............................................................................................................................25
9500 Second Tank Assembly...............................................................................................................................26
3/4” Meter Assembly.............................................................................................................................................27
1” Meter Assembly................................................................................................................................................28
1 1/2” Meter Assembly..........................................................................................................................................29
9000/9100 Bypass Valve Assembly......................................................................................................................30
Bypass Valve Assembly........................................................................................................................................31
1710 Brine Valve System (for 9500)..................................................................................................................... 32
2300 Safety Brine Valve.......................................................................................................................................33
2310 Safety Brine Valve.......................................................................................................................................34
2350 Safety Brine Valve.......................................................................................................................................35
Troubleshooting.................................................................................................................................................... 36
General Hints for Meter Control...........................................................................................................................37
9000/9100/9500 Meter Flow Data........................................................................................................................ 38
9000/9100 Injector Flow Data (1600 Series Injectors).........................................................................................39
9500 Injector Flow Data (1600 & 1700 Series Injectors)......................................................................................40
9000 Control Dimensions..................................................................................................................................... 41
9100 Control Dimensions..................................................................................................................................... 42
9500 Control Dimensions..................................................................................................................................... 43
Water Conditioner Flow Diagrams........................................................................................................................44
9000/9500 Wiring Diagram................................................................................................................................... 46
Service Assemblies.............................................................................................................................................. 47
IMPORTANT PLEASE READ:
The information, specications and illustrations in this manual are based on the latest information available at the time of
•
printing. The manufacturer reserves the right to make changes at any time without notice.
This manual is intended as a guide for service of the valve only. System installation requires information from a number of
•
suppliers not known at the time of manufacture. This product should be installed by a plumbing professional.
This unit is designed to be installed on potable water systems only.
•
This product must be installed in compliance with all state and municipal plumbing and electrical codes. Permits may be
•
required at the time of installation.
If daytime operating pressure exceeds 80 psi, nighttime pressures may exceed pressure limits. A pressure reducing valve must
•
be installed.
Do not install the unit where temperatures may drop below 32°F (0°C) or above 125°F (52°C).
•
Do not place the unit in direct sunlight. Black units will absorb radiant heat increasing internal temperatures.
•
Do not strike the valve or any of the components.
•
Warranty of this product extends to manufacturing defects. Misapplication of this product may result in failure to properly
•
condition water, or damage to product.
A prelter should be used on installations in which free solids are present.
•
In some applications local municipalities treat water with Chloramines. High Chloramine levels may damage valve components.
•
Correct and constant voltage must be supplied to the control valve to maintain proper function.
•
Job Specication Sheet
Job Number: __________________
Model Number: ________________
Water Test: ___________________
Capacity Per Unit: ______________
Mineral Tank Size: ___________ Diameter: ___________ Height: __________
Brine Tank Size & Salt Setting per Regeneration: __________
9000/9100/9500 Control Valve Specications:
. 1... Type of Timer:
A. 82 minute available regeneration time, 1/15 RPM
B. 164 minute available regeneration time, 1/30 RPM
. 2.. Type of Meter:
Mechanical Valves (Gallon Settings)
Meter Standard Range Extended Range
3/4” 125 - 2,125 625 - 10,625
1” 310 - 5,270 1,150 - 26,350
1-1/2” 625 - 10,625 3,125 - 53,125
3. Timer Gallon Setting: _______________ Gallons
.
4. Regeneration Program Setting:
A. Backwash: ____________________ Minutes
B. Brine and Slow Rinse: ___________ Minutes
.
C. Rapid Rinse: __________________ Minutes
.
D. Brine Tank Rell: _______________ Minutes
5. Drain Line Flow Control: ____________ gpm
6. Brine Rell Rate: __________________ gpm
7. Injector Size: _____________________
Page 3
Equipment Conguration
9000/9100 Equipment Conguration
9500 Equipment Conguration
Page 4
General and Commercial Installation Checklist
1. Place the softener tank where you want to install the unit.
. NOTE: Be sure the tank is level and on a rm base.
2. During cold weather it is recommended that the installer warm the valve to room temperature before
operating.
3. Perform all plumbing according to local plumbing codes.
— Use a 1/2” minimum pipe size for the drain.
— Use a 3/4” drain line for backwash ow rates that exceed 7 gpm or length that exceeds 20’ (6 m).
4. Both tanks must be the same height and diameter and lled with equal amounts of media.
5. The distributor tube must be ush with the top of each tank. Cut if necessary. Use only non-aerosol silicone
lubricant.
6. Lubricate the distributor o-ring seal and tank o-ring seal. Place the main control valve on one tank and the
tank adapter on the second tank.
. NOTE: If required, solder copper tubing for tank interconnection before assembling on the main control valve
and tank adapter. Maintain a minimum of 1” distance between tanks on nal assembly.
7. Solder joints near the drain must be done before connecting the Drain Line Flow Control tting (DLFC).
Leave at least 6” (152 mm) between the DLFC and solder joints when soldering pipes that are connected on
the DLFC. Failure to do this could cause interior damage to DLFC.
8. Use only Teon tape on the drain tting.
9. Be sure the oor under the salt storage tank is clean and level.
10. Place approximately 1” (25 mm) of water above the grid plate. If a grid is not utilized, ll to the top of the air
check in the salt tank. Do not add salt to the brine tank at this time.
11. On units with a bypass, place in Bypass position.
— Turn on the main water supply.
— Open a cold soft water tap nearby and let water run a few minutes or until the system is free of foreign
material (usually solder) resulting from the installation. Close the water tap when water runs clean.
12. Place the bypass In Service position and let water ow into the mineral tank. When water ow stops, slowly
open a cold water tap nearby and let water run until air is purged from the unit. Then close tap.
Electrical
13. Make all electrical connections according to codes. Plug the valve into an approved power source. Do not
insert meter cable into the meter yet.
14. Tank one has control valve and tank two has adapter.
15. Look on the right side of the control valve, it has indicators showing which position the control valve is in
during Regeneration and which tank is In Service.
NOTE: Make sure the meter cable is not inserted in the meter dome. Swing the timer out to expose the
program wheel (to swing timer out) grab onto the lower right corner of timer face and pull outward.
Page 5
General and Commercial Installation Checklist
Control Valve Position Indicators
Program Wheel
Timer
16. Cycle timer into backwash position. Turn manual knob so that the micro switch rides on the rst set of pins.
— In this position the tanks switch (lower piston) and the control valve moves to the backwash position
(upper piston).
— Wait until the positioning of upper and lower pistons stops before advancing the timer further. If advanced
too fast the control will not home into the In Service position (it will not advance to any other position). To
correct this, rotate the manual knob back to In Service and start again into backwash.
. NOTE: Once valve positions itself into the backwash cycle, the homing circuit locks in.
17. With all the air backwashed, slowly cycle the timer to the brine position; rapid rinse; and brine tank rell.
Wait for the control drive motor to position itself in each cycle and stop, before advancing on to the next
position.
18. Once back in the In Service position, cycle the control valve again into the backwash position. The tanks
switch again, and air head backwashes out of the other tank. Cycle the control back to the In Service position.
Leave the timer in the open position. DO NOT insert meter cable yet.
NOTE: Two motors are available.
1/15 RPM has 82 minute regeneration time.
1/30 RPM has 164 minute regeneration time.
. .
Page 6
General and Commercial Installation Checklist
WATER PRESSURE: A minimum of 25 pounds of water pressure is required for regeneration valve to operate
effectively.
ELECTRICAL FACILITIES: A continuous 115 volt, 60 Hertz current supply is required. Make certain the current
supply is always hot and cannot be turned off with another switch.
EXISTING PLUMBING: Condition of existing plumbing should be free from lime and iron buildup. Piping that is
built up heavily with lime and/or iron should be replaced. If piping is clogged with iron, a separate iron lter unit
should be installed ahead of the water softener.
LOCATION OF SOFTENER AND DRAIN: The softener should be located close to a drain.
BY-PASS VALVES: Always provide for the installation of a by-pass valve.
Valve to Tank Installation Instructions
Spin the valve onto the tank, ensuring the threads are not cross-threaded..
1.
NOTE: All Fleck® valves are right-hand threads, or clockwise, to install
Rotate the valve freely without using force until it comes to a stop (this position is considered zero).
2.
Rotate the valve clockwise from zero, between ¼ turn and ½ turn (see the diagram below)..
3.
.
NOTE: If lubricant is required, a silicone compound is strongly recommended. Dow Corning
Compound (available from Fleck®), is recommended for best possible results. Dow Corning® 7 Release
Compound is used in the manufacture of Fleck® control valves. The use of other types of lubricants may
attack the control’s plastic or rubber components. Petroleum-based lubricants can cause swelling in rubber
parts, including o-rings and seals. .
Part No. Description
16174 Silicone, 2 oz Tube
16586-8 Silicone, Dow #7 8 LB
®
Silicone
Page 7
Regeneration Cycle Program Setting Procedure
Setting the Regeneration Cycle Program
The Regeneration cycle program on the water conditioner is preset at the factory. However, portions of the cycle
or program time may be lengthened or shortened for local conditions or system design.
1. Expose cycle program wheel by grasping timer in lower right hand corner and pulling. This releases snap
retainer and swings timer to the left
. NOTE: Meter cable must be removed from meter dome before opening timer.
2. Remove the program wheel by grasping program wheel and squeezing protruding lugs towards center.
Lift program wheel off timer.
— Switch arms may require movement to facilitate removal.
3. Return timer to closed position by engaging snap retainer in back plate.
— Make certain all electrical wires locate above snap retainer post.
Changing Length of the Backwash Time
Looking at the numbered side of the program wheel, the group of pins starting at zero determines the length of
time the unit backwashes.
Example: If there are six pins in this section, the time of backwash is 12 minutes (2 minutes per pin). To
change the length of backwash time, add or remove pins as required.
— The number of pins multiplied by two equals minutes of backwash.
Changing Length of Brine and Rinse Time
The group of holes between the last pin in the backwash section and the second group of pins determines the
length of time that a unit will brine and rinse (2 minutes per hole).
To change the length of brine and rinse time, add or remove pins in the rapid rinse group of pins to increase or
decrease the number of holes in the brine and rinse section.
— The number of holes multiplied by two equals minutes of brine and rinse.
Changing Length Of Rapid Rinse
The second group of pins on the program wheel determines the length of time the water conditioner rapid rinses
(2 minutes per pin). To change the length of rapid rinse time, add or remove pins at the higher numbered end of
this section as required.
— The number of pins multiplied by two equals minutes of rapid rinse.
. NOTE: Program wheels with 0–82 minute cycle times, use one minute per pin or hole to set Regeneration
times. The layout of pins and holes on the program wheel follow the same procedure as on this page.
Changing Length of Brine Tank Rell Time
The second group of holes on the program wheel determines the length of time the water conditioner rells the
brine tank (2 minutes per hole).
To change the length of rell time, move the two pins at the end of the second group of holes as required.
The Regeneration cycle is complete when the two pin set at end of the brine tank rell section trips the outer
micro-switch. The program wheel, however, continues to rotate until the inner micro-switch drops into the notch on
the program wheel.
Programming
1. The control valve is set at the factory for backwash; brine and slow rinse; rapid rinse and brine tank ll times.
Change any of these times by repositioning the pins and holes or adding more pins.
. NOTE: Two speed timer motors are available
1/15 RPM has 82 minute Regeneration Time and each pin or hole equals one minute.
1/30 RPM has 164 minute Regeneration Time and each pin or hole equals two minutes.
Page 8
Time Brine Rell and Meter Setting Procedure
2. The control valve has a separate brine tank ll cycle.
— Calculate the desired salt setting using the brine line ow control rate of rell (in gpm) multiplied by the
timer setting. Then, using one gallon of fresh water dissolving approximately 3 lbs salt, calculate the
rell time.
. Example: A desired 30 lbs salt setting:
The unit has a 1.0 gpm rell rate so a 10 gallon ll is required.
10 gallons x 3 lbs/gals = 30 lbs salt
Set the timer rell section at 10 minutes.
10 minutes x 1.0 gpm = 10 gallon ll
. NOTE: There must always be two pins at the end of a rell time to stop the ll cycle. With the Regeneration
times set, place timer back to its original position, making sure the lower right hand corner snaps back into the
backplate and the meter cable slides through the backplate and does not bind.
3. Setting the gallon wheel.
Knowing the amount of resin in each tank and the salt setting per Regeneration, calculate the gallons available,
using the following capacities as a guide:
(capacity per ft3 x ft3 of resin per tank) = gallons available
compensated hardness of H2O
NOTE: Based on tank size:
More resin increases capacity, less resin decreases capacity.
More salt increases capacity, less salt decreases capacity.
Example:
Tank Diameter = 16”
Compensated Hardness = 35 grains per gallon (tested sample)
ft3 Resin (based on ow rate) = 4
lbs of Salt = 8
Capacity per ft
(24,000 x 4 ft3 of resin per tank) = 2,740 gallons available before regeneration
35 grains
DO NOT SET THIS FIGURE - GO TO STEP 4
— Because the control valve regenerates with soft water from the other tank, subtract the water used for
regeneration. Take each regeneration cycle and calculate the water used.
Example: Unit is set for a 16” diameter tank with 4 ft3 of resin and salted at 8 lbs. per ft3, 7 gpm backwash,
#3 injector, 1.0 gpm brine rell, and 60 psi and timer set for 10 min. backwash, 60 min. brine and rinse,
10 min. rapid rinse, 10 min. brine tank ll.
Backwash 10 minutes x 7.0 gpm = 70.0 gallons
Brine and Rinse 60 minutes x 1.0 gpm = 60.0 gallons
Rapid Rinse 10 minutes x 7.0 gpm = 70.0 gallons
Brine Tank Fill 10 minutes x 1.0 gpm = 10.0 gallons
Total Regeneration Water = 210.0 gallons
With the 2740 gallons available calculated in Step 3, subtract the Regeneration water used from the total
water available.
2740 gallons available - 210 gallons used = 2530 gallons
(in Regeneration, Step 4)
3
. = 24,000
Page 9
Time Brine Rell and Meter Setting Procedure
4. Set meter wheel at approximately 2530 gallons. Lift the inner dial of the meter program wheel so that you can
rotate it freely. Position the white dot opposite the 2530 gallon setting.
NOTE: There is a slight delay between the time the meter zeros out and the cycle starts. Units using the:
1/15 RPM motor, 82 minute Regeneration Time has a 9 minute delay
1/30 RPM motor, 180 minute Regeneration Time has an 18 minute delay.
. NOTE: This delay period is not critical on residential equipment. However, take this factor into consideration.
for commercial applications by subtracting continuous ows for 9 minutes or 18 minutes from water available.
5. Insert meter cable into meter.
6. Check bypass.
7. Plug in unit.
Page 10
Notes
Page 11
9000/9100/9500 (3200 Series)
Electro Mechanical Timer Assembly
Page 12
For Service Assembly Numbers, See the Back of this Manual
9000/9100/9500 (3200 Series)
Electro Mechanical Timer Assembly
Item No. Quantity Part No. Description
. 1....................1.....................13870-03..................Housing, Timer, 9000
. 2....................1.....................17870.......................Label, Indicator, 9000 Timer
. 3....................1.....................15465.......................Label, Caution
. 4....................1.....................16930.......................Label, Instruction
. 5....................1.....................15227.......................Plate, Clutch, Actuator
. 6....................1.....................10300.......................Screw, Slot Hex Wsh, 18-8 x 3/8
. 7....................1.....................17513.......................Clip, Spring
. 8....................1.....................15407.......................Washer, Plain, #4
. 9....................1.....................15228.......................Spring, Return
. 10..................1.....................16270-10..................Program Wheel Assy, 9000 3/4
. . . 16270-50..................Program Wheel Assy, 9000/9500
. . . 16270-30..................Program Wheel Assy, 9000, 1” Std
. . . 16270-40..................Program Wheel Assy, 9000, 1” Ext
. . . 16270-50..................Program Wheel Assy, 9000/9500
. . . 16270-60..................Program Wheel Assy, 9500
. 11..................1.....................13806.......................Retainer, Program Wheel
. 12..................1.....................13748.......................Screw, Flt Hd St, 6-20 x 1/2
. 13..................2.....................11999.......................Label, Button
. 14..................1.....................15223.......................Actuator, Cycle
. 15..................1.....................13886.......................Know, 3200
. 16..................4.....................13296.......................Screw, Hex Wsh, 6-20 x 1/2
. 17..................1.....................17724.......................Program Wheel, Pinion Drive
. 18..................1.....................17723.......................Clutch, Drive Pinion
. 19..................1.....................14276.......................Spring, Meter Clutch
. 20..................1.....................14253.......................Retainer, Clutch Spring
. 21..................3.....................14087.......................Insulator
. 22..................1.....................15314.......................Switch, Micro, Modied
. 23..................1.....................15320.......................Switch, Micro, Timer
. 24..................2.....................11413.......................Screw, Pan Hd Mach, 4-40 x 1 1/8
. 25..................1.....................13018.......................Pinion, Idler
. 26..................1.....................18563.......................Spring, Idler Shaft
. 27..................1.....................13017.......................Gear, Idler
. 28..................1.....................13164.......................Gear, Drive
. 29..................1.....................13887.......................Plate, Motor Mounting
. 30..................1.....................18743.......................Motor, 120V, 60 Hz 1/30 RPM, 5600
. . . 18824-1....................Motor, 230V, 50 Hz 1/30 RPM
. . . 19170.......................Motor, 120V 60 Hz 1/15 RPM
. . . 18825.......................Motor, 230V, 50 Hz 1/15 RPM Mallory
. 31..................2.....................13278.......................Screw, Phil Hd Mach, 6-32 x 1/8 Steel Zinc
. 32..................1.....................14265.......................Clip, Spring
. 33..................1.....................15055.......................Timer, Main Drive Gear
. 34..................1.....................19210-02..................Program Wheel Assy, 9000 1/15
. . . 19210-05..................Program Wheel Assy, 9000/3230
. 35..................23...................15493.......................Pin, Spring, 1/16 x 5/8 SS
. 36..................1.....................15203.......................Harness, 9000/9500, Timer
. 37..................2.....................40422.......................Nut, Wire, Tan
Not Shown....1..................... 60320-02..................Switch Kit, 3200/9000 Timer Auxiliary
For Service Assembly Numbers, See the Back of this Manual
Page 13
Power Head Assembly
Page 14
For Service Assembly Numbers, See the Back of this Manual
Power Head Assembly
Item No. Quantity Part No. Description
. 1........................2.........................18728.............................Nut, Tinnerman, U Type, 8-32
. 2........................1.........................11838.............................Power Cord, 6’ Fleck
. . . 11839.............................Power Cord, 12’ Fleck
. . . 40084-12........................Power Cord, 12’ U.S., Round, 120V Sys 5, 6, 7 &
2900/3150/3900 #4
. . . 11545-01........................Power Cord Assy, 4’ Black, Euro w/Terminals
. . . 14678.............................Power Cord, U.S., 220/60
. . . 19303-01........................Power Cord Assy, Australian w/Terminals
. . . 40085-12........................Power Cord, 12’ US, Round, 240V
. . . 19674.............................Transformer, 24V, 9.6VA Residential Valves
. . . 41475.............................Transformer, 24V, 9.6VA, European
. 3........................1.........................15202.............................Harness, 9000/9500, Drive
. . . 14822.............................Harness, 2900
. . . 40041-06........................Harness, Low V, 9000/9500
. 4........................1.........................15134.............................Gear Assy, Drive, 1/2” Stroke 9000/9500
. 5........................1.........................15135.............................Gear, Drive, 9000
. 6........................1.........................14896.............................Wheel, Geneva
. 7........................2.........................40422.............................Nut, Wire, Tan
. 8........................2.........................19367.............................Screw, Designer Cover, Thumb 8-32 Blank UV Stable Material
. 9........................1.........................15175.............................Label, Shaft Position
. 10......................2.........................14917.............................Ring, Retaining
. 11......................1.........................15199.............................Plate, Ground, 9000/9500
. 12......................1.........................14430.............................Screw, Hex Wsh St, 6 x 1/4 Type “B”
. 13......................2.........................19160.............................Screw, Phil Pan, Thread 6-32 x 3/8 Type 23 Zinc
. 14......................1.........................18737.............................Motor, 24V, 50/60 Hz, 1 RPM
. . . 18738.............................Motor, 120V, 50/60 Hz 1 RPM
. . . 18739.............................Motor, 220V, 50/60 Hz 1 RPM
. 15......................1.........................15131.............................Backplate, 9000
. . . 17784-05........................Panel, Control, 9000/9500 ET
. 16......................2.........................15172.............................Screw, Flt Hd Mach, 4-40 x 1 3/8 Steel Zinc Plate
. 17......................2.........................10340.............................Washer, Lock #4, Zinc
. 18.................................................10218.............................Switch, Micro
. 19......................1.........................10339.............................Nut, Hex, 4-40 Zinc Plated
. 20......................1.........................15331.............................Screw, Hex Wsh Mach, 10-24 x 3/4 410 S.S.
. 21......................2.........................15133.............................Gear Assy, Drive, 3/4” Stroke
. 22......................1.........................13547.............................Strain Relief, Flat Cord Heyco #30-1
. 23......................1.........................15810.............................Ring, Retaining
. 24......................1.........................15132.............................Cam, Triple
. . . 17331.............................Cam, 9500
. . . 17765.............................Cam Assy, Aux Switch, 9500
. 25......................1.........................15368.............................Tube, Cable Guide, 2-Tank
. . . 17337.............................Tube, Cable Guide, 9500
. 26......................2.........................15372.............................Washer, Thrust, 3/8
. 27......................1.........................15216.............................Meter Cable Assy, 15.25”
. . . 15425.............................Meter Cable, 13.25”
. . . 17744.............................Meter Cable Assy, 20.75” 1 1/2” Std
. . . 19121-01........................Meter Cable Assy, SE, Paddle 6600/6700
. . . 19121-05........................Meter Cable Assy, ET, 28” 2750/3150 Systemax 4-6
. . . 19791-01........................Meter Cable Assy, Turbine/SE
. 28......................2.........................15692.............................Washer, Plain, 3/8”
. 29......................1.........................16433.............................Switch, Miniature
. 30......................1.........................10302.............................Insulator, Limit Switch
. 31......................2.........................15173.............................Screw, Slot Rd Hd Mach, 5-20 x 3/8
Not Shown
. . 1.........................60232-110......................Cover, Designer, 1 Pc Black
. . 1.........................60232-112......................Cover, Designer, 1 Pc Black w/Left Window
. . 1.........................60320-09........................Switch Assy, 9000, Drive Cam
. . 1.........................60320-10........................Switch Assy, 9500, Drive Cam
For Service Assembly Numbers, See the Back of this Manual
Page 15
9000 Control Valve Assembly
Page 16
For Service Assembly Numbers, See the Back of this Manual
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