SERVICE ASSEMBLIES ...................................................... 46
JOB SPECIFICATION SHEET
Job Number: ________________________________________
Model Number: ______________________________________
Water Test: _________________________________________
Capacity Per Unit: ____________________________________
Mineral Tank Size: ________ Diameter: ______Height: ______
Brine Tank Size and Salt Setting per Regeneration: _________
9000/9100/9500 Control Valve Specifications:
1. Type of Timer:
A. 82 minute available regeneration time, 1/15 RPM
B. 164 minute available regeneration time, 1/30 RPM
2. Meter Size:
A. 3/4- inch Std Range (125 - 2,100 gallon setting)
B. 3/4-inch Ext Range (625 - 10,625 gallon setting)
C. 1-inch Std Range (310 - 5,270 gallon setting)
D. 1-inch Ext Range (1,150 - 26,350 gallon setting)
E. 1-1/2 inches Std Range (625 - 10,625 gallon setting)
F. 1-1/2 inches Ext Range (3,125 - 53,125 gallon setting)
the State of California to cause cancer or
birth defects or other reproductive harm.
®
9000/9100/9500 Service Manual
Figure 2 9500 Equipment Configuration
INSTALLATION & STARTUP
CAUTION
Water Pressure
A minimum of 25 pounds (1.7 bar) 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 filter unit should be installed ahead of the
water softener.
Location Of Softener And Drain
The softener should be located close to a drain to prevent air
breaks and back flow.
Bypass Valves
Always provide for the installation of a bypass valve.
Water pressure is not to exceed 125 psi (8.6 bar),
water temperature is not to exceed 110°F (43°C),
and the unit cannot be subjected to
freezing conditions.
Installation Instructions
1. Place the softener tank where you want to install the unit.
NOTE: Be sure the tank is level and on a firm base.
2. During cold weather, the installer should warm the valve
to room temperature before operating.
3. Perform all plumbing according to local plumbing codes.
• Use a 1/2-inch minimum pipe size for the drain.
• Use a 3/4-inch drain line for backwash flow rates that
exceed 7 gpm or length that exceeds 20 feet (6 m).
4. Both tanks must be the same height and diameter and
filled with equal amounts of media.
5. The distributor tube must be flush 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 inch distance between tanks on final assembly.
7. Solder joints near the drain must be done before
connecting the Drain Line Flow Control fitting (DLFC).
Leave at least 6 inches (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 plumber tape on the drain fitting.
9. Be sure the floor under the salt storage tank is clean
and level.
10. Place approximately 1 inch (25 mm) of water above the grid
plate. If a grid is not utilized, fill 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.
12. Turn on the main water supply.
13. 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.
14. Place the bypass In Service position and let water flow into
the mineral tank. When water flow stops, slowly open a cold
water tap nearby and let water run until air is purged from
the unit. Then close tap.
15. Make all electrical connections according to codes. Plug the
valve into an approved power source. Do not insert meter
cable into the meter yet.
16. Tank one has control valve and tank two has adapter.
17. 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.
Figure 3 Control Valve Position Indicators
61591 Rev A
Figure 4 Timer
FLECK
®
9000/9100/9500 Service Manual • 3
INSTALLATION & STARTUP
Figure 5 Program Wheel
18. Cycle timer into backwash position. Turn manual knob so
that the micro switch rides on the first 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.
19. With all the air backwashed, slowly cycle the timer to the
brine position; rapid rinse; and brine tank refill. Wait for
the control drive motor to position itself in each cycle and
stop, before advancing on to the next position.
20. 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.
CONTINUED
19210 Rev D
Valve To Tank Installation
1. Spin the valve onto the tank, ensuring the threads are not
cross-threaded.
NOTE: All Fleck® valves are right-hand threads, or
clockwise, to install
2. Rotate the valve freely without using force until it comes
to a stop (this position is considered zero).
3. Rotate the valve clockwise from zero, between 1/4-turn
and 1/2-turn (see “Figure 6”).
NOTE: If lubricant is required, a silicone compound
4 • FLECK
is strongly recommended. Dow Corning®
Silicone Compound (available from Pentair), is
recommended for best possible results. Dow
Corning® 7 Release Compound is used in the
manufacture of Pentair 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
16174Silicone, 2 oz Tube
16586-8Silicone, Dow #7
8 lb
®
9000/9100/9500 Service Manual
Figure 6
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.
INSTALLATION & STARTUP
CONTINUED
Changing Length of Brine Tank Refill Time
The second group of holes on the program wheel determines
the length of time the water conditioner refills the brine tank
(2 minutes per hole).
To change the length of refill 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 refill 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 fill times.
Change any of these times by repositioning the pins and
holes or adding more pins.
NOTE: Two 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.
2. The control valve has a separate brine tank fill cycle.
Calculate the desired salt setting using the brine line
flow control rate of refill (in gpm) multiplied by the timer
setting. Then, using one gallon of fresh water dissolving
approximately 3 lbs salt, calculate the refill time.
Example: A desired 30 lbs salt setting:
The unit has a 1.0 gpm refill rate so a 10 gallon fill
is required.
10 gallons x 3 lbs/gals = 30 lbs salt
Set the timer refill section at 10 minutes.
10 minutes x 1.0 gpm = 10 gallon fill
NOTE: There must always be two pins at the end of a refill
time to stop the fill 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:
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-inch diameter tank with 4 ft3 of
resin and salted at 8 lbs. per ft3, 7 gpm backwash,
#3 injector, 1.0 gpm brine refill, and 60 psi and timer
set for 10 min. backwash, 60 min. brine and rinse, 10
min. rapid rinse, 10 min. brine tank fill.
Backwash
Brine and Rinse
Rapid Rinse
Brine Tank Fill
10 min x 7.0 gpm
60 min x 1.0 gpm
10 min x 7.0 gpm
10 min x 1.0 gpm
= 70.0 gal
= 60.0 gal
=
70.0 gal
= 10.0 gal
Total Regeneration Water= 210.0 gal
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)
5. 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 flows for 9 minutes or 18
minutes from water available.
6. Insert meter cable into meter.
7. Check bypass.
8. Plug in unit.
Tank Diameter= 16 inches
Compensated
Hardness
ft3 Resin (based on
flow rate)
lbs of Salt per ft
Capacity per ft
3
3
(24,000 x 4 ft3 of resin
per tank)
35 grains
35 grains per gallon
=
(tested sample)
= 4
= 8
= 24,000
2,740 gallons available
=
before regeneration
Complete step 4 before setting gallons on the meter wheel.