Pentair FLECK 3900 Service Manual

FLECK® 3900

service manual

TABLE OF CONTENTS

JOB SPECIFICATION SHEET ............................................... 2

INSTALLATION .....................................................................3

START-UP INSTRUCTIONS..................................................3

3200 TIMER SETTING PROCEDURE ....................................4

3210 & 3220 TIMER SETTING PROCEDURE ....................... 4

3200, 3210, 3220, 3230 REGENERATION CYCLE SETTING

PROCEDURE .......................................................................5

3200 TIME CLOCK TIMER ASSEMBLY ................................. 6

3210 METER DELAYED TIMER ASSEMBLY .........................8

3220 METER IMMEDIATE TIMER ASSEMBLY ...................10

3230 REMOTE START TIMER ASSEMBLY .........................12

CONTROL DRIVE ASSEMBLY ............................................ 14

ADAPTER CONTROL DRIVE LOWER

POWERHEAD .....................................................................16

CONTROL VALVE ...............................................................18

1800 SERIES BRINE SYSTEM AND DRAIN LINE FLOW

CONTROL ASSEMBLY ........................................................ 20

3-INCH METER ASSEMBLY ...............................................24

SERVICE VALVE OPERATOR ASSEMBLY ..........................25

2350 SAFETY BRINE VALVE ..............................................26

TROUBLESHOOTING ..........................................................27

GENERAL SERVICE HINTS FOR METER CONTROL .......... 28

WATER CONDITIONER FLOW DIAGRAMS .........................28

FLOW DATA & INJECTOR DRAW RATES ..........................30

DIMENSIONAL DRAWING 3900 TOP MOUNT ....................31

DIMENSIONAL DRAWING 3900 SIDE MOUNT ..................32

TYPICAL INSTALLATIONS .................................................33

VALVE WIRING ...................................................................34

SERVICE ASSEMBLIES ......................................................39

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3900 Service Manual

JOB SPECIFICATION SHEET

Job Number: ______________________________________________

Model Number: ____________________________________________

Water Hardness: __________________________________ ppm or gpg

Capacity Per Unit: __________________________________________

Mineral Tank Size: ___________ Diameter: ________Height: ________

Salt Setting per Regeneration: ________________________________

1. Type of Timer:

A. 7 Day or 12 Day

B. Meter Initiated

2. Downflow: Upflow Upflow Variable

3. 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 inch Std Range (625 - 10,625 gallon setting)

F. 1-1/2 inch Ext Range (3,125 - 53,125 gallon setting)

G. 2-inch Std Range (1,250 - 21,250 gallon setting)

H. 2-inch Ext Range (6,250 - 106,250 gallon setting)

I. 3-inch Std Range (3,750 - 63,750 gallon setting)

J. 3-inch Ext Range (18,750 - 318,750 gallon setting)

K. Electronic ____Pulse Count ___ Meter Size ____________

4. System Type:

A. System #4: 1 Tank, 1 Meter, Immediate, or Delayed Regeneration

B. System #4: Time Clock

C. System #4: Twin Tank

D. System #5: 2-5 Tanks, Interlock Mechanical 2-4 Tanks, Interlock Electronic Meter per unit for Mechanical and Electronic

E. System #6: 2-5 Tanks, 1 Meter, Series Regeneration, Mechanical 2-4 Tanks, 1 Meter, Series Regeneration, Electronic

F. System #7: 2-5 Tanks, 1 Meter, Alternating Regeneration,

Mechanical 2 Tanks only, 1 Meter, Alternating Regeneration, Electronic

G. System #9: Electronic Only, 2-4 Tanks, Meter per Valve, Alternating

H. System #14: Electronic Only, 2-4 Tanks, Meter per Valve. Brings units on and offline based on flow.

5. Timer Program Settings:

A. Backwash: ______________________________ Minutes

B. Brine and Slow Rinse:_____________________ Minutes

C. Rapid Rinse: ____________________________ Minutes

D. Brine Tank Refill: ________________________ Minutes

E. Pause Time: ____________________________ Minutes

F. Second Backwash: _______________________ Minutes

6. Drain Line Flow Control: gpm

7. Brine Line Flow Controller: gpm

8. Injector Size#:

9. Piston Type:

A. Hard Water Bypass

B. No Hard Water Bypass

INSTALLATION

CAUTION

Water Pressure

A minimum of 20 pounds (1.4 bar) of water pressure is required for regeneration valve to operate effectively.

Electrical Facilities

An uninterrupted alternating current (A/C) supply is required.

NOTE: Other voltages are available. Please make sure your

voltage supply is compatible with your unit before installation.

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.

By-Pass Valves

Always provide for the installation of a by-pass valve if unit is not equipped with one.

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 making sure the unit is level and on a firm base.

2. During cold weather, the installer should warm the valve to room temperature before operating.

3. All plumbing should be done in accordance with local plumbing codes. The pipe size for residential drain line should be a minimum of 1/2 inch (13 mm). Backwash flow rates in excess of 7 gpm (26.5 Lpm) or length in excess of 20 feet (6 m) require 3/4 -inch (19 mm) drain line. Commercial drain lines should be the same size as the drain line flow control.

4. Refer to the dimensional drawing for cutting height of the distributor tube. If there is no dimensional drawing, cut the distributor tube flush with the top of the tank.

5. Lubricate the distributor o-ring seal and tank o-ring seal. Place the main control valve on tank.

NOTE: Only use silicone lubricant.

6. Solder joints near the drain must be done prior to connecting the Drain Line Flow Control fitting (DLFC). Leave at least 6 inches (15 cm) between the DLFC and solder joints when soldering pipes that are connected on the DLFC. Failure to do this could cause interior damage to the DLFC.

7. Plumber tape is the only sealant to be used on the drain fitting. The drain from twin tank units may be run through a common line.

8. Make sure that the floor is clean beneath the salt storage tank and that it is level.

9. 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 (Figure 1) in the salt tank. Do not add salt to the brine tank at this time.

10. On units with a by-pass, place in by-pass position. Turn on the main water supply. Open a cold soft water tap nearby and let run a few minutes or until the system is free from foreign material (usually solder) that may have resulted from the installation. Once clean, close the water tap.

11. Slowly place the by-pass in service position and let water flow into the mineral tank. When water flow stops, slowly open a cold water tap nearby and let run until the air is purged from the unit.

12. Plug unit into an electrical outlet.

NOTE: All electrical connections must be connected according

to local codes. Be certain the outlet is uninterrupted.

60002 Rev E

Figure 1 Residential Air Check Valve

STARTUP INSTRUCTIONS

The water softener should be installed with the inlet, outlet, and drain connections made in accordance with the manufacturer’s recommendations, and to meet applicable plumbing codes.

1. Turn the manual regeneraton knob slowly in a clockwise direction until the program micro switch lifts on top of the first set of pins. Allow the drive motor to move the piston to the first regeneration step and stop. Each time the program switch position changes, the valve will advance to the next regeneration step. Always allow the motor to stop before moving to the next set of pins or spaces.

NOTE: For electronic valves, please refer to the manual

2. Position the valve to backwash. Ensure the drain line flow

3. Position the valve to the brine / slow rinse position. Ensure

4. Position the valve to the rapid rinse position. Check the

regeneration part of the timer operation section. If the valve came with a separate electronic timer service manual, refer to the timer operation section of the electronic timer service manual.

remains steady for 10 minutes or until the water runs clear (see above).

the unit is drawing water from the brine tank (this step may need to be repeated).

drain line flow, and run for 5 minutes or until the water runs clear.

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3900 Service Manual • 3

5. Position the valve to the start of the brine tank fill cycle. Ensure water goes into the brine tank at the desired rate. The brine valve drive cam will hold the valve in this position to fill the brine tank for the first regeneration.

6. Replace control box cover.

7. Put salt in the brine tank.

NOTE: Do not use granulated or rock salt.

3200 TIMER SETTING PROCEDURE

How To Set Days On Which Water Conditioner Is To Regenerate (Figure 2)

Rotate the skipper wheel until the number “1” is at the red pointer. Set the days that regeneration is to occur by sliding tabs on the skipper wheel outward to expose trip fingers. Each tab is one day. Finger at red pointer is tonight. Moving clockwise from the red pointer, extend or retract fingers to obtain the desired regeneration schedule.

How To Set The Time Of Day

1. Press and hold the red button in to disengage the drive gear.

2. Turn the large gear until the actual time of day is at the time of day pointer.

3. Release the red button to again engage the drive gear.

How To Manually Regenerate Your Water Conditioner At Any Time

1. Turn the manual regeneration knob clockwise.

2. This slight movement of the manual regeneration knob engages the program wheel and starts the regeneration program.

3. The black center knob will make one revolution in the following approximately three hours and stop in the position shown in the drawing.

4. Even though it takes three hours for this center knob to complete one revolution, the regeneration cycle of your unit might be set for only one half of this time.

5. In any event, conditioned water may be drawn after rinse water stops flowing from the water conditioner drain line.

How to Adjust Regeneration Time

1. Disconnect the power source.

2. Locate the three screws behind the manual regeneration knob by pushing the red button in and rotating the 24 hour dial until each screw appears in the cut out portion of the manual regeneration knob.

3. Loosen each screw slightly to release the pressure on the time plate from the 24-hour gear.

4. Locate the regeneration time pointer on the inside of the 24-hour dial in the cut out.

5. Turn the time plate so the desired regeneration time aligns next to the raised arrow.

6. Push the red button in and rotate the 24-hour dial. Tighten each of the three screws.

7. Push the red button and locate the pointer one more time to ensure the desired regeneration time is correct.

8. Reset the time of day and restore power to the unit.

61502-3200 Rev A

Figure 2

3210 & 3220 TIMER SETTING PROCEDURE

Typical Programming Procedure

Calculate the gallon capacity of the system, subtract the necessary reserve requirement and set the gallons available opposite the small white dot on the program wheel gear (Figure 3).

NOTE: Drawing shows 8,750 gallon setting. The capacity

(gallons) arrow (15) shows zero gallons remaining. The unit will regenerate tonight at the set regeneration time.

How To Set The Time Of Day

1. Press and hold the red button in to disengage the drive gear.

2. Turn the large gear until the actual time of day is opposite the time of day pointer.

3. Release the red button to again engage the drive gear.

How To Manually Regenerate Your Water Conditioner At Any Time

1. Turn the manual regeneration knob clockwise.

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3900 Service Manual

2. This slight movement of the manual regeneration knob engages the program wheel and starts the regeneration program.

3. The black center knob will make one revolution in the following approximately three hours and stop in the position shown in the drawing.

4. Even though it takes three hours for this center knob to complete one revolution, the regeneration cycle of your unit might be set for only one half of this time.

5. In any event, conditioned water may be drawn after rinse water stops flowing from the water conditioner drain line.

Immediate Regeneration Timers

These timers do not have a 24-hour gear. Setting the gallons on the program wheel and manual regeneration procedure are the same as previous instructions. The timer will regenerate as soon as the capacity gallons reaches zero.

NOTE: The program wheel to the left may be different than

the program wheel on the product.

NOTE: To set meter capacity rotate manual knob one - 360°

revolution to set gallonage.

Timer Setting Procedure

How To Change The Length Of The Backwash Time

The program wheel as shown in the drawing is in the service position. As you look at the numbered side of the program wheel, the group of pins starting at zero determines the length of time your unit will backwash.

For example, if there are six pins in this section, the time of backwash will be 12 min. (2 min. per pin). To change the length of backwash time, add or remove pins as required. The number of pins times two equals the backwash time in minutes.

How To Change The Length Of Brine And Rinse Time

1. The group of holes between the last pin in the backwash section and the second group of pins determines the length of time that your unit will brine and rinse (2 min. per hole).

2. To change the length of brine and rinse time, move the rapid rinse group of pins to give more or fewer holes in the brine and rinse section. Number of holes times two equals brine and rinse time in minutes.

How To Change The Length Of Rapid Rinse

1. The second group of pins on the program wheel determines the length of time that your water conditioner will rapid rinse (2 min. per pin).

2. 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 times two equals the rapid rinse time in minutes.

61502-3200 Rev A

Figure 3

3200, 3210, 3220, 3230 REGENERATION CYCLE SETTING PROCEDURE

How To Set The Regeneration Cycle Program

The regeneration cycle program on your water conditioner has been factory preset, however, portions of the cycle or program may be lengthened or shortened in time to suit local conditions.

3200 Series Timers (Figure 4)

1. To expose cycle program wheel, grasp timer in upper left-hand corner and pull, releasing snap retainer and swinging timer to the right.

2. To change the regeneration cycle program, the program wheel must be removed. Grasp program wheel and squeeze protruding lugs toward center, lift program wheel off timer. Switch arms may require movement to facilitate removal.

3. Return timer to closed position engaging snap retainer in back plate. Make certain all electrical wires locate above snap retainer post.

How To Change The Length Of Brine Tank Refill Time

1. The second group of holes in the program wheel determines the length of time that your water conditioner will refill the brine tank (2 min. per hole).

2. To change the length of refill time, move the two pins at the end of the second group of holes as required.

3. The regeneration cycle is complete when the outer microswitch is tripped by the two pin set at end of the brine tank refill section.

4. The program wheel, however, will continue to rotate until the inner micro switch drops into the notch on the program wheel.

61502-3210 Rev A

Figure 4

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3900 Service Manual • 5

3200 TIME CLOCK TIMER ASSEMBLY

38

37

36

615023200 Rev A

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3200 TIME CLOCK TIMER ASSEMBLY

continued

Item No. QTY Part No. Description

1 ..............1 ...... 13870 ..............Housing, Timer, 3200

2 ..............1 ...... 14265 ..............Clip, Sping

3 ..............3 ...... 14087 ..............Insulator

4 ..............1 ...... 10896 ..............Switch, Micro

5 ..............1 ...... 15320 ..............Switch, Micro, Timer

6 ..............2 ...... 11413 ..............Screw, Pan Hd Mach,

4-40 x 1-1/8

7 ..............1 ...... 13886 ..............Knob, 3200

8 ..............5 ...... 13296 ..............Screw, Hex Wsh, 6-20 x 1/2

9 ..............1 ...... 11999 ..............Label, Button

10 ............1 ...... 13018 ..............Pinion, Idler

11 ............1 ...... 13312 ..............Spring, Idler Shaft

12 ............1 ...... 13017 ..............Gear, Idler

13 ............1 ...... 13164 ..............Gear, Drive

14 ............1 ...... 13887 ..............Plate, Motor Mounting

15 ............1 ...... 18743-1 ..........Motor, 120V, 60Hz,

1/30 RPM

....... 18752-1 ..........Motor, 100V, 50Hz,

1/30 RPM

....... 18824-1 ..........Motor, 230V, 50Hz,

1/30 RPM

....... 18826-1 ..........Motor, 24V, 50Hz, 1/30 RPM

....... 19659-1 ..........Motor, 24V, 60Hz, 1/30 RPM

....... 19660-1 ..........Motor, 230V, 60Hz,

1/30 RPM

16 ............2 ...... 13278 ..............Screw, Sltd Fillister Hd

6-32 x .156

17 ............1 ...... 15424 ..............Spring, Detent, Timer

18 ............1 ...... 15066 ..............Ball, 1/4-inch, Delrin

19 ............1 ...... 15465 ..............Label, Caution

20 ............1 ...... 19210 ..............Program Wheel Assy

21 ............1 ...... 13911 ..............Gear, Main Drive, Timer

22 ...........17 ..... 41754 ..............Pin, Spring, 1/16 x 5/8 SS,

Timer

23 ............1 ...... 13011 ..............Arm, Cycle Actuator

24 ............1 ...... 13864 ..............Ring, Skipper Wheel

Item No. QTY Part No. Description

25 ............2 ...... 13311 ..............Spring, Detent, Timer

26 ............2 ...... 13300 ..............Ball, 1/4-inch, SS

27 ............1 ...... 14381 ..............Skipper Wheel Assy, 12 Day

....... 14860 ..............Skipper Wheel Assy, 7 Day

28 ............1 ...... 13014 ..............Pointer, Regeneration

29 ............1 ...... 40096-24 .........Dial, 12 AM Regen Assy,

Black

....... 40096-02 .........Dial, 2 AM Regen Assy, Black

30 ............1 ...... 13881 ..............Bracket, Hinger Timer

31 ............2 ...... 11384 ..............Screw, Phil, 6-32 x 1/4 Zinc

32 ............1 ...... 13902 ..............Harness, 3200

33 ............2 ...... 40422 ..............Nut, Wire, Tan

34 ............1 ...... 15354-01 .........Wire, Ground, 4 inches

35 ............1 ...... 14007 ..............Label, Time of Day

36 ............1 ...... * ......................Complete 3200 Time Clock

Timer Assembly

37 ..................... 60320-02 .........Switch Kit, 3200/9000 Timer

Auxiliary, Optional

38 ..................... 61420-03 .........Program Wheel, Gear Assy,

Filter 2 Min Per Pin

....... 61420-04 .........Program Wheel, Gear Assy,

Softener, 2 Min Per Pin *Call your distributor for Part Number

FLECK

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3900 Service Manual • 7

3210 METER DELAYED TIMER ASSEMBLY

41

43

40

42

61502-3210 Rev A

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3210 METER DELAYED TIMER ASSEMBLY

continued

Item No. QTY Part No. Description

1 ..............1 ...... 13870 ..............Housing, Timer, 3200

2 ..............1 ...... 13802 ..............Gear, Cycle Actuator

3 ..............1 ...... 40096-02 .........Dial 2 AM Regen Assy,

Black

4 ..............1 ...... 13886 ..............Knob, 3200

5 ..............4 ...... 13296 ..............Screw, Hex Wsh, 6-20 x 1/2

6 ..............2 ...... 11999 ..............Label, Button

7 ..............1 ...... 13803 ..............Gear, Program Drive Wheel

8 ..............1 ...... 13806 ..............Retainer, Program Wheel

9 ..............1 ...... 13748 ..............Screw, Flat Head St,

6-20 x 1/2

10 ............1 ...... 14265 ..............Clip, Spring

11 ............1 ...... 15424 ..............Spring, Detent, Timer

12 ............1 ...... 15066 ..............Ball, 1/4-inch Delrin

13 ............1 ...... 13018 ..............Pinion, Idler

14 ............1 ...... 13312 ..............Spring, Idler Shaft

15 ............1 ...... 13017 ..............Gear, Idler

16 ............1 ...... 13164 ..............Gear, Drive

17 ............1 ...... 13887 ..............Plate, Motor Mounting

18 ............1 ...... 18743-1 ..........Motor, 120V, 60Hz

1/30 RPM

....... 18752-1 ..........Motor, 100V, 50Hz,

1/30 RPM

....... 18824-1 ..........Motor, 230V, 50Hz,

1/30 RPM

....... 18826-1 ..........Motor, 24V, 50Hz, 1/30 RPM

....... 19659-1 ..........Motor, 24V, 60Hz, 1/30 RPM

....... 19660-1 ..........Motor, 230V, 60Hz,

1/30 RPM

19 ............1 ...... 13278 ..............Screw, Fillister Hd,

6-32 x .156

20 ............1 ...... 13830 ..............Pinion, Program Wheel

Drive

21 ............1 ...... 13831 ..............Clutch, Drive Pinion

22 ............1 ...... 14276 ..............Spring, Meter, Clutch

23 ............1 ...... 14253 ..............Retainer, Clutch Spring

24 ............3 ...... 11384 ..............Screw, Phil, 6-32 x 1/4

25 ............1 ...... 13881 ..............Bracket, Hinge Timer

26 ............3 ...... 14087 ..............Insulator

27 ............1 ...... 10896 ..............Switch, Micro

28 ............1 ...... 15320 ..............Switch, Micro, Timer

29 ............2 ...... 11413 ..............Screw, Pan Hd Mach,

4-40 x 1 1/8

30 ............1 ...... 14198 ..............Label, Indicator

Item No. QTY Part No. Description

31 ............1 ...... 15465 ..............Label, Caution

32 ............1 ...... 14007 ..............Label, Time of Day

33 ............1 ...... 14045 ..............Label, Instruction

34 ............1 ...... 13902 ..............Harness, 3200

35 ............2 ...... 40422 ..............Nut, Wire, Tan

36 ............1 ...... 15354-01 .........Wire, Ground, 4 inches

37 ............1 ...... 19210 ..............Program Wheel Assy

38 ...........17 ..... 41754 ..............Pin, Spring, 1/16 x 5/8 SS,

Timer

39 ............1 ...... 13911 ..............Gear, Main Drive, Timer

40 ............1 ...... * ......................Complete 3210 Meter

Delayed Timer Assembly

41 ..................... 60405-80 .........Program Wheel, w/3-inch STD

Label 63,750 gal

....... 60405-90 .........Program Wheel, w/3-inch EXT

Label 320,000 gal

42 ..................... 60320-02 .........Switch Kit, 3200/9000 Timer

Auxiliary, Optional

43 ..................... 61420-03 .........Program Wheel, Gear Assy,

Filter 2 Min Per Pin

....... 61420-04 .........Program Wheel, Gear Assy,

Softener, 2 Min Per Pin

Not Shown:

3

....... 25141 ..............Label, STD M

, Gallon

240, 3-inch

....... 25142 ..............Label, EXT M3, Gallon

1200, 3-inch

*Call your distributor for Part Number

FLECK

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3900 Service Manual • 9

3220 METER IMMEDIATE TIMER ASSEMBLY

31

33

1

30

27

2

3

32

9

1

29

28

6

4

5

10

11

36

35

34

17

18

19

20

12

21

22

23

24

23

25

23

26

13

14

21

15

40

4

16

7

8

5

38

39

37

61502-3220 Rev B

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3220 METER IMMEDIATE TIMER ASSEMBLY

Item No. QTY Part No. Description

1 ..............1 ...... 13870 ..............Housing, Timer

2 ..............1 ...... 15431 ..............Gear, Cycle Actuator,

3 ..............1 ...... 13886 ..............Knob, 3200

4 ..............4 ...... 13296 ..............Screw, Hex Wsh, 6-20 x 1/2

5 ..............2 ...... 11999 ..............Label, Button

6 ..............1 ...... 13807 ..............Gear, Program Drive Wheel

7 ..............1 ...... 13806 ..............Retainer, Program Wheel

8 ..............1 ...... 13748 ..............Screw, Flt Hd St, 6-20 x 1/2

9 ..............1 ...... 14265 ..............Spring Clip

10 ............1 ...... 13018 ..............Pinion, Idler

11 ............1 ...... 18563 ..............Idler Shaft Spring

12 ............1 ...... 13017 ..............Gear, Idler

13 ............1 ...... 13164 ..............Drive Gear

14 ............1 ...... 13887 ..............Plate, Motor Mounting

15 ............1 ...... 18743-1 ..........Motor, 120V, 60 Hz,

....... 18752-1 ..........Motor, 100V, 50Hz,

....... 18824-1 ..........Motor, 230V, 50Hz,

....... 18826-1 ..........Motor, 24V, 50Hz, 1/30 RPM

....... 19659-1 ..........Motor, 24V, 60Hz, 1/30 RPM

....... 19660-1 ..........Motor, 230V, 60Hz,

16 ............2 ...... 13278 ..............Screw, Sltd Fillister Hd

17 ............1 ...... 14502 ..............Pinion, Program Wheel

18 ............1 ...... 14501 ..............Clutch, Drive Pinion

19 ............1 ...... 14276 ..............Meter Clutch Spring

20 ............1 ...... 14253 ..............Retainer, Clutch Spring

21 ............3 ...... 11384 ..............Screw, Phil, 6-32 x 1/4 Zinc

22 ............1 ...... 13881 ..............Bracket, Hinge Timer

23 ............3 ...... 14087 ..............Insulator

24 ............1 ...... 15414-00 .........Micro Switch

25 ............1 ...... 15320 ..............Switch, Micro, Timer

26 ............2 ...... 11413 ..............Screw, Pan Hd Mach,

27 ............1 ...... 14198 ..............Label, Indicator

continued

System #5

1/30 RPM

4-40 x 1-1/8

Item No. QTY Part No. Description

28 ............1 ...... 15465 ..............Label, Caution

29 ............1 ...... 14007 ..............Label, Time of Day

30 ............1 ...... 15148 ..............Label, Instruction

31 ............1 ...... 40617 ..............Harness, 3220

32 ............2 ...... 40422 ..............Nut, Wire, Tan

33 ............1 ...... 15354-01 .........Wire, Ground, 4 inches

34 ............1 ...... 19210-05 .........Program Wheel Assembly,

9000/3230

35 ...........17 ..... 41754 ..............Pin, Spring, 1/16 x 5/8

Stainless Steel, Timer

36 ............1 ...... 15055 ..............Gear, Main Drive

37 ............1 ...... * ......................Complete 3220 Meter

Immediate Timer Assembly

38 ..................... 60405-80 .........Program Wheel, w/3-inch STD

Label 63,750 gal

....... 60405-90 .........Program Wheel, w/3-inch EXT

Label 320,000 gal

39 ..................... 60320-02 .........Switch Kit, 3200/9000 Timer

Auxiliary, Optional

40 ..................... 61420-06 .........Program Wheel, Gear Assy,

Softener Immediate 2 Min

Per Pin

....... 61420-42 .........Program Wheel, Gear Assy,

Filter Immediate 2 Min Per

Not Shown:

3

....... 25141 ..............Label, STD M

240, 3-inch

....... 25142 ..............Label, EXT M3, Gallon

1200, 3-inch

*Call your distributor for Part Number

, Gallon

FLECK

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3900 Service Manual • 11

3230 REMOTE START TIMER ASSEMBLY

25

1

24

23

24

26

27

10

11

3

4

3

5

17

22

7

8

9

28

2

20

30

18

21

13

14

8

12

3

6

8

24

15

29

16

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61502-3230R REV A

3230 REMOTE START TIMER ASSEMBLY

continued

Item No. QTY Part No. Description

1 ..............1 ...... 13870 ..............Housing, Timer

2 ..............1 ...... 14265 ..............Spring Clip

3 ..............3 ...... 14087 ..............Insulator

4 ..............1 ...... 15314 ..............Micro Switch

5 ..............1 ...... 15320 ..............Switch, Micro, Timer

6 ..............2 ...... 11413 ..............Screw, Pan Hd Mach,

4-40 x 1-1/8

7 ..............1 ...... 13886 ..............Knob, 3200

8 ..............4 ...... 13296 ..............Screw, Hex Wsh, 6-20 x 1/2

9 ..............1 ...... 11999 ..............Label, Button

10 ............1 ...... 13018 ..............Pinion, Idler

11 ............1 ...... 18563 ..............Idler Shaft Spring

12 ............1 ...... 13017 ..............Gear, Idler

13 ............1 ...... 15055 ..............Drive Gear

14 ............1 ...... 13887 ..............Plate, Motor Mounting

15 ............1 ...... 18743-1 ..........Motor, 120V, 60 Hz, 1/30 RPM

....... 18752-1 ..........Motor, 100V, 50Hz, 1/30 RPM

....... 18824-1 ..........Motor, 23V, 50Hz, 1/30 RPM

....... 18826-1 ..........Motor, 24V, 50Hz, 1/30 RPM

....... 19659-1 ..........Motor, 24V, 60Hz, 1/30 RPM

....... 19660-1 ..........Motor, 230V, 60Hz, 1/30 RPM

16 ............2 ...... 13278 ..............Screw, Sltd Fillister Hd

17 ............1 ...... 15313 ..............Label, Caution

18 ............1 ...... 19210-05 .........Program Wheel Assembly,

3200

20 ............1 ...... 15055 ..............Main Drive Gear

21 ...........17 ..... 41754 ..............Pin, Spring, 1/16 x 5/8

Stainless Steel, Timer

22 ............1 ...... 13011 ..............Cycle Actuator Arm

Item No. QTY Part No. Description

23 ............1 ...... 13881 ..............Bracket, Hinge Timer

24 ............3 ...... 11384 ..............Screw, Phil, 6-32 x 1/4 Zinc

25 ............1 ...... 16336 ..............Harness, 3230R

26 ............2 ...... 40422 ..............Nut, Wire, Tan

27 ............1 ...... 15354-01 .........Wire, Ground, 4 inches

28 ..................... 60320-02 .........Switch Kit, 3200/9000 Timer

Auxiliary, Optional

29 ..................... * ......................3230 Timer Assy

30 ..................... 61420-06 .........Program Wheel, Gear Assy,

Softener Immediate 2 Min

Per Pin

....... 61420-42 .........Program Wheel, Gear Assy,

Filter Immediate 2 Min

Per Pin *Call your distributor for Part Number

FLECK

®

3900 Service Manual • 13

CONTROL DRIVE ASSEMBLY

11

39

40

45

44

9

46 41

42

3

1

38

37

36

47

35

34

48

21

8

5

28

15

7

6

14

4

33

32

30

31

29

20

13

43

25 26 27

17

16

18

15

12

19

22

24

23

2

61501-3150 Rev B

14 • FLECK

®

3900 Service Manual

CONTROL DRIVE ASSEMBLY

Item No. QTY Part No. Description

1 ..............1 ...... 19304-04 .........Backplate, 3150/3900,

Upper, NEMA 3R

2 ..............1 ...... 15120-01 .........Bracket, Motor Mtg,

3150/3900 Environmental

3 ..............2 ...... 16346 ..............Nut, Hex, Jam, 5/16 - 18

4 ..............1 ...... 40392 ..............Motor, Drive, 115V, 50/60

Hz, Sp

....... 40390 ..............Motor, Drive, 220V, 50 Hz,

Sp, Fam 3

....... 42581 ..............Motor, Drive, 24VAC/DC,

50-60 Hz, Fam 3

5 ..............1 ...... 17797 ..............Bracket, Switch Mounting,

3150/3900

6 ..............4 ...... 10302 ..............Insulator, Limit Switch

7 ..............3 ...... 10218 ..............Switch, Micro

8 ..............1 ...... 17845-03 .........Pin, Hinge, 3150/3900, Env

9 ..............4 ...... 11235 ..............Nut, Hex, 1/4 -20, Mach

Screw, Zinc

10 ............2 ...... 13365 ..............Washer, Lock, #4, External

11 ............2 ...... 40080 ..............Screw, Rd Hd, 4-40 x

1-1/2 inch

12 ............1 ...... 16053 ..............Bracket, Brine Side

13 ............2 ...... 40133 ..............Screw, Pan Hd,

4-40 x 1/4-inch

14 ............2 ...... 40133 ..............Screw Pan HD,

4-40 x 1/4-inch

15 ............2 ...... 16052 ..............Bushing, 3150/3900

16 ............1 ...... 16059 ..............Washer, SS, .88, 3150/3900

17 ............1 ...... 16051 ..............Ring, Retaining, Bowed

18 ............2 ...... 10300 ..............Screw, Slot Hex Wsh,

18-8 x 3/8

19 ............4 ...... 10231 ..............Screw, Slot Hex,

1/4 - 20 x 1/2

20 ............2 ...... 14202-01 .........Screw, Hex Wsh Hd,

8 x 5/16

21 ............1 ...... 10475-01 .........Wire, Ground

22 ............1 ...... 16494-03 .........Cam Assy, 3150/3900

Signal After Brine Fill

....... 16494-05 .........Cam Assy, 3150/3900

Upper Signal After Rapid

Rinse

....... 16494-06 .........Cam Assy, 3150/3900,

Upper, Upflow, Signal After

Rapid Rinse

23 ............4 ...... 11224 ..............Screw, Hex Hd,

5/16 - 18 x 5/8

24 ............1 ...... 60240-02 .........Cover Assy, 3150/3900 Env,

Black, NEMA 3R

25 ............5 ...... 41084 ..............Terminal Block, Segment,

Gray

26 ............1 ...... 41085 ..............Endplate, Terminal Bloack,

Gray

27 ............1 ...... 40174 ..............Terminal Block, Green/

Yellow

28 ............1 ...... 16046 ..............Gear, Drive

29 ............1 ...... 16050 ..............Ring, Retaining

30 ............1 ...... 11774 ..............Ring, Retaining

continued

Item No. QTY Part No. Description

31 ............1 ...... 16047 ..............Link, Drive

32 ............1 ...... 11709 ..............Pin, Drive Link

33 ............1 ...... 16048 ..............Bearing, Drive Link

34 ............1 ...... 11898 ..............Clip, 3150/3900

35 ............1 ...... 16045 ..............Pinion, Drive

36 ............1 ...... 11381 ..............Pin, Roll, 2900/3900

37 ............1 ...... 11080 ..............Screw, Flt Hd Mach,

38 ............3 ...... 10872 ..............Screw, Hex Wsh,

39 ............1 ...... 40084-12 .........Power Cord, 12 feet US,

....... 40085-12 .........Power Cord, 12 feet US,

....... 11545 ..............Power Cord, 4 feet European,

....... 19303 ..............Power Cord, 8 feet,

....... 19885 ..............Power Cord, Japanese,

40 ............1 ...... 17967 ..............Fitting Assy, Liquid Tight, Blk

41 ............1 ...... 19691 ..............Plug, .750 Dia, Recessed,

42 ............3 ...... 19591 ..............Plug, .8750 Hole, Recessed,

43 ............2 ...... 15250 ..............Label, Terminal Strip

44 ...........10 ..... 19800 ..............Plug, .140 Dia, White

45 ............1 ...... 15806 ..............Plug, Hole, Heyco #2693

46 ............1 ......

47 ..................... 60057-01 .........Drive Assy, 3150, 120V, SYS 5

....... 60057-03 .........Drive Assy, 3150, 24V, 3900

....... 60057-11 .........Drive Assy, 3150, 120V, 3900

....... 60057-21 .........Drive Assy, 3150, 120V,

48 ..................... * ......................3150 Powerhead Assembly

Not Shown

1 ...... 17470 ..............Cable Guide Assy, 2850/3150

1 ...... 19856 ..............Ring, Retaining (Used on

1 ...............................Timer (See Timer Section)

1 ...... 16427-04 .........Wire, Lead, 12 inches, White

1 ...... 40396 ..............Harness, Drive,

1 ...... 14924 ..............Strain Relief Heyco #1247

1 ...... 15513 ..............Meter Cable, 17.5 inches, 2

1 ...... 15216 ..............Meter Cable, 15.25 inches,

1 ...... 18585 ..............Harness, 3900, Aux Switch

*Call your distributor for Part Number

17421 ..............Plug, 1.20 Hole

8-32 x 3/8

8-32 x 17/64

Round, 120V

Round, 240V

Black

Australian

110V/120V

Black

& 7, Signal After Brine Tank Fill

Upper, SYS #5 or SYS #7

Upper, SYS #4 or SYS #6

Upflow, 3900 Upper, SYS 5 or SYS 7, Brine Draw First

Cover)

Environmental

inches

1.5 inches

®

FLECK

3900 Service Manual • 15

ADAPTER CONTROL DRIVE LOWER POWERHEAD

4

5

6

7

8

9

10

6

11

12

13

14

15

16

17

1

2

3

15

34

28

29

40

38

39

37

36

34

35

32

33

31

27

30

26

25

24

18

21

20

22

23

16 • FLECK

®

3900 Service Manual

ADAPTER CONTROL DRIVE LOWER POWERHEAD

Item No. QTY Part No. Description

1 ..............1 ...... 19305 ..............Back Plate, 3900 Lower,

2 ..............1 ...... 16086 ..............Bracket - Motor Mounting

3 ..............2 ...... 16346 ..............Nut

4 ..............1 ...... 40392 ..............Drive Motor - 115 V.

....... 40390 ..............Drive Motor - 220 V.

....... 42581 ..............Drive Motor - 24 VAC/DC

5 ..............2 ...... 18692 ..............Washer, Sealing

6 ..............2 ...... 18691 ..............Connector, Conduit

7 ..............1 ...... 17797 ..............Bracket - Switch Mounting

8 ..............1 ...... 18693 ..............Conduit, lnterdrive

9 ..............4 ...... 11235 ..............Nut, 1/4-20

10 ............1 ...... 17845-03 .........Pin, Hinge

11 ............1 ...... 10218 ..............Switch

12 ............2 ...... 10302 ..............Insulator - Switch

13 ............4 ...... 10231 ..............Screw - Hex Head, 1/4-20 x

14 ............1 ...... 16053 ..............Bracket - Brine Side

15 ............2 ...... 16052 ..............Bushing

16 ............1 ...... 16059 ..............Washer

17 ............1 ...... 16051 ..............Retaining Ring - Bowed “E”

18 ............2 ...... 11805 ..............Screw, RD HD, 4-40 x 5/8-

20 ............2 ...... 17567 ..............Screw - Hex Head, WSH, 8

21 ............2 ...... 12288 ..............Washer, Lock, Internal #8

22 ............1 ...... 16495 ..............Cam Assembly

23 ............4 ...... 11224 ..............Screw - Hex Head,

24 ............1 ...... 19813/41536 ...Screw O-ring, Cover

25 ............1 ...... 60240-22 .........Cover, Black, Lower,

continued

Enviromental

50/60 Hz.

1/2, 18-8 S.S.

inch, Type 1, Steel/Zinc

x 1/2, Type B, 18-8, S.S.

5/16-18 x 5/8, S.S.

Environmental

Item No. QTY Part No. Description

26 ..............................................Includes Item No: 2, 4, 7, 11,

12, 15, 18, 20, 21, 22, 23, 28, 29, 30, 31, 32, 33, 34, 35, 36,

37, 38, 39, 40

....... 60058-01 .........Lower Drive Assy, 3900, 120V

....... 60058-03 .........Lower Drive Mtr Assy, 3900,

24V

27 ..................... * ......................3900 Lower Powerhead Assy

28 ............1 ...... 16048-01 .........Bearing - Drive Link

29 ............2 ...... 11080 ..............Screw - Flt HD Mach, 8-32 x

3/8, Steel Zinc

30 ............1 ...... 16046 ..............Drive Gear

31 ............1 ...... 16050 ..............Retaining Ring

32 ............2 ...... 11774 ..............Retaining Ring - “E”

33 ............1 ...... 19315 ..............Indicator

34 ............4 ...... 10872 ..............Screw - Hex Head, 8-32 x

17/64, Steel/Trivalent Zinc

35 ............1 ...... 18726 ..............Space, Indicator

36 ............1 ...... 11709 ..............Pin - Drive Link

37 ............1 ...... 16047 ..............Drive Link

38 ............1 ...... 11898 ..............Clip

39 ............1 ...... 16045 ..............Drive Pinion

40 ............1 ...... 11381 ..............Roll Pin

Not Shown

1 ...... 40405 ..............Wire Harness, Environmental,

System 4, Lower *Call your distributor for Part Number

FLECK

®

3900 Service Manual • 17

CONTROL VALVE

37

38

39

21

22

8

9

19

6

20

12

10

11

1

5

6

7

28

13

2

3

2

4

3

14

15

2

4

2

3

32

29

40

16

17

18

43

42

16

36

17

35

26

23

24

27

24

25

29

41

24

30

31

33

34

18 • FLECK

®

3900 Service Manual

61500-3900

CONTROL VALVE

Item No. QTY Part No. Description

1 ..............1 ...... 15114 ..............Valve Body

2 ..............8 ...... 11720 ..............Seal

....... 11720-02 .........Seal, Silicone

3 ..............5 ...... 10369 ..............Spacer - Port

4 ..............2 ...... 10368 ..............Spacer

5 ..............1 ...... 16130 ..............Piston

6 ..............2 ...... 14818 ..............Clip - Piston Rod

7 ..............1 ...... 15125 ..............Piston Rod

8 ..............1 ...... 14922 ..............O-ring -035

9 ..............1 ...... 16398-01 .........End Plug Assembly

10 ............2 ...... 40118 ..............Screw - Hex Head

11 ............1 ...... 16078 ..............O-ring - 149

12 ............1 ...... 16074 ..............Coupling

13 ............1 ...... 16077 ..............O-ring - 140

14 ............1 ...... 15112 ..............Seal

15 ............1 ...... 16067-02 .........3-inch Adapter Body

16 ............4 ...... 16068 ..............Seal

....... 41534 ..............Seal, 3900, 558 BP

17 ............2 ...... 16069 ..............Spacer - Narrow

18 ............1 ...... 16070 ..............Spacer - Wide

19 ............1 ...... 16071 ..............Piston

....... 16082 ..............Piston - No Hard Water

20 ............1 ...... 16072 ..............Piston Rod

21 ............1 ...... 16076 ..............O-ring - 042

22 ............1 ...... 16399-01 .........End Plug Assy - White

....... 16399-11 .........End Plug Assy - Black,

23 ............1 ...... 16800 ..............O-ring - 238

24 ............2 ...... 16345 ..............O-ring - 362

25 ............1 ...... 16255 ..............Tank Adapter - 6-inch -8

26 ............2 ...... 16257 ..............Flange Segment

27 ...........12 ..... 11238 ..............Screw - Hex Head

28 ............1 ...... 16088 ..............Pipe Plug - 2-inch NPT

35 ............1 ...... 16258 ..............Flow Disperser

37 ..................... 60106-00 .........Piston Assy, 3900/3150 STD

....... 60106-10 .........Piston Assy, 3150, Upflow

38 ..................... 60131 ..............Seal & Spacer Kit, 3900

....... 60131-10 .........Seal & Spacer Kit, Silicone,

39 ..................... 60107-00 .........Piston Assy, 3900, HWBP,

continued

Bypass

NHWB-P

Upper, 3150

Chemical Resistent, 3900 Upper, 3150

Lower

Item No. QTY Part No. Description

....... 60107-10 .........Piston Assy, 3900, NHWBP,

Lower

40 ..................... 60132 ..............Seal & Spacer Kit, 3900,

Lower

....... 60132-10 .........Seal & Spacer Kit, 3900,

558BP Chemical Resistent,

Lower

41 ..................... 60190 ..............Flange Kit, Park &

Structural, 09/05 and After

....... 60191 ..............Flange Kit, Park, 08/05 and

Prior

42 ..................... 60193 ..............Flange Kit, 6-inch Thread

43 ..................... 60192 ..............Flange Kit, Welded

Options

29 ............2 ...... 16482 ..............Flange Segment

30 ............1 ...... 16483 ..............Flange Ring

31 ............1 ...... 16484 ..............O-Ring -442

32 ...........12 ..... 16517 ..............Screw, Park Tank

....... 19592 ..............Screw, Structural Tank

33 ...........12 ..... 18619 ..............Washer

34 ...........12 ..... 16346 ..............Nut

36 ............1 ...... 18584 ..............Adapter, Side Mount

FLECK

®

3900 Service Manual • 19

1800 SERIES BRINE SYSTEM AND DRAIN LINE FLOW CONTROL ASSEMBLY

18

19

23

28

26

25

21

15

16

40

41

34

33

32

39

20

38

37

36

35

27

22

24

42

20 • FLECK

®

3900 Service Manual

30

31

29

50

49

48

50

47

45

49

48

44

46

43

44

45

60036 Rev C

1800 SERIES BRINE SYSTEM AND DRAIN LINE FLOW CONTROL ASSEMBLY

Item No. QTY Part No. Description

1 ..............1 ...... 16340 ..............Body, Injector, 1800 D/F

....... 16340-20 .........Body, Injector, 1800,

Downflow, Metric

....... 16340-01 .........Body, Injector, 1800 Upflow

....... 16340-21 .........Body, Injector, 1800,

Upflow, Metric

2 ..............1 ...... 15128-xx .........Injector Nozzle

....... 15128-04 .........#4 Green

....... 15128-05 .........#5 Red

....... 15128-06 .........#6 White

....... 15128-07 .........#7 Blue

....... 15128-08 .........#8 Yellow

....... 15128-09 .........#9 Violet

....... 15128-10 .........#10 Black

3 ..............1 ...... 15127-xx .........Injector Throat

....... 15127-04 .........#4 Green

....... 15127-05 .........#5 Red

....... 15127-06 .........#6 White

....... 15127-07 .........#7 Blue

....... 15127-08 .........#8 Yellow

....... 15127-09 .........#9 Violet

....... 15127-10 .........#10 Black

4 ..............3 ...... 15246 ..............O-ring, -116

5 ..............1 ...... 16341-01 .........Cap, Injector, 1800

6 ..............8 ...... 12473 ..............Screw, Hex Wsh,

10-24 x 5/8

7 ..............1 ...... 16341-02 .........Plug, Injector, 1800

8 ..............1 ...... 19054 ..............O-ring, -021, 560CD

9 ..............1 ...... 16497-01 .........Stem Assy, 1800, Brine

Valve

10 ............1 ...... 18713 ..............Brine Valve Body, 1800

11 ............1 ...... 11772 ..............Spring, 3150 Brine Valve

12 ............1 ...... 11774 ..............Ring, Retaining

13 ............1 ...... 16498-01 .........Stem Guide Assy, Brine

14 ............1 ...... 16387 ..............Plug, Pipe, 1/2-inch NPT

continued

Item No. QTY Part No. Description

15 ............2 ...... 18702 ..............Fitting, Tube, 1/2 NPT 5/8

16 ............1 ...... 18703 ..............Tube, Brine, 5/8 OD Annealed

....... 18703-01 .........Tube, Brine, 5/8 OD, Short,

Upflow

17 ............1 ...... 60009-00 .........Air Check, #900, Commercial

Less Fittings

....... 60009-01 .........Air Check, #900,

Commercial, HW Less Fittings

18 ..................... 60277-04 .........Injector Assy, 1800, #4,

Downflow

....... 60272-04 .........Injectory Assy, 1800, #4,

Upflow

....... 60277-05 .........Injectory Assy, 1800 #5,

Downflow

....... 60272-05 .........Injector Assy, 1800, #5,

Upflow

....... 60277-06 .........Injector Assy, 1800, #6,

Downflow

....... 60277-07 .........Injector Assy, 1800, #7,

Downflow

FLECK

®

3900 Service Manual • 21

1800 SERIES BRINE SYSTEM AND DRAIN LINE FLOW CONTROL ASSEMBLY

Item No. QTY Part No. Description Item No. QTY Part No. Description

....... 60272-07 .........Injector Assy, 1800, #7,

Upflow

....... 60277-08 .........Injector Assy, 1800, #8,

Downflow

....... 60277-09 .........Injectory Assy, 1800 #9,

Downflow

....... 60277-10 .........Injectory Assy, 1800 #10,

Downflow

19 ..................... 60036-02 .........Brine Valve, 1800, Design 3

....... 60276-01 .........Brine Valve, 1800, Retrofit

Kit, Downflow 1800 Injector

and Brine Valve, Update to

Design 3

20 ..................... 60734 ..............Regulator, 3150/3900,

Pressure, Upflow

21 ..................... 60711-000 .......DLFC, 2-inch NPT, Less

BTTNS, w/4 HLS

....... 60711-00 .........DLFC, 2-inch NPT, Less

BTTNS, W/2 HLS

....... 60711-01 .........DLFC, 2-inch NPT, Less

BTTNS, W/1 HLS

....... 60711-20 .........DLFC, 2-inch NPT, 20 gpm

....... 60711-25 .........DLFC, 2-inch NPT, 25 gpm

....... 60711-30 .........DLFC, 2-inch NPT, 30 gpm

....... 60711-35 .........DLFC, 2-inch NPT, 35 gpm

....... 60711-40 .........DLFC, 2-inch NPT, 40 gpm

....... 60711-45 .........DLFC, 2-inch NPT, 45 gpm

....... 60711-50 .........DLFC, 2-inch NPT, 50 gpm

....... 60711-55 .........DLFC, 2-inch NPT, 55 gpm

....... 60711-60 .........DLFC, 2-inch NPT, 60 gpm

....... 60711-65 .........DLFC, 2-inch NPT, 65 gpm

....... 60711-70 .........DLFC, 2-inch NPT, 70 gpm

....... 60711-75 .........DLFC, 2-inch NPT, 75 gpm

....... 60711-80 .........DLFC, 2-inch NPT, 80 gpm

....... 60711-85 .........DLFC, 2-inch NPT, 85 gpm

....... 60711-90 .........DLFC, 2-inch NPT, 90 gpm

....... 60711-95 .........DLFC, 2-inch NPT, 95 gpm

....... 60711-100 .......DLFC, 2-inch NPT, 100 gpm

....... 60812-30 .........DLFC, 2-inch BSP/Metric,

30 gpm

....... 60812-35 .........DLFC, 2-inch BSP/Metric,

35 gpm

....... 60812-45 .........DLFC, 2-inch BSP/Metric,

45 gpm

....... 60812-50 .........DLFC, 2-inch BSP/Metric,

50 gpm

....... 60812-55 .........DLFC, 2-inch BSP/Metric,

55 gpm

....... 60812-70 .........DLFC, 2-inch BSP/Metric,

continued

70 gpm

....... 60812-75 .........DLFC, 2-inch BSP/Metric,

75 gpm

....... 60812-80 .........DLFC, 2-inch BSP/Metric,

80 gpm

....... 60812-90 .........DLFC, 2-inch BSP/Metric,

90 gpm

....... 60812-95 .........DLFC, 2-inch BSP/Metric,

95 gpm

....... 60812-100 .......DLFC, 2-inch BSP/Metric,

100 gpm

22 ............2 ...... 27913-21 .........Housing, Flow Control,

2-inch BSP

23 ..................... 16804 ..............O-ring, -150

24 ............1 ...... 16649 ..............Holder, DLFC Button

25 ............1 ...... 16650 ..............Cover Plate DLFC

26 ............1 ...... 13898 ..............Screw, Flat HD, Phil, Steel

27 ............6 ...... 13386 ..............Screw, Hex HD MACH, 1/4-20

x 1 OR Slot Hex Cap Screw

18-8 S.S.

....... 17976 ..............Screw, Hex HD, M6 x 25 mm

28 ..................... 16529 ..............Washer, Flow, 10.0 gpm

....... 16736 ..............Washer, Flow, 15.0 gpm

....... 16528 ..............Washer, Flow, 20.0 gpm

....... 16737 ..............Washer, Flow, 25.0 gpm

29 ............1 ...... 19089 ..............Body Regulator 3150

30 ............1 ...... 10242 ..............Fitting, Nipple, 1/2-inch,

Close

31 ............1 ...... 19091 ..............Pin, Regulator 3150

32 ............1 ...... 19093 ..............Stand-Off Regulator 3150

33 ............1 ...... 19095 ..............Diaphragm, Regulator 3150

34 ............1 ...... 19094 ..............Washer, Regulator 3150

35 ............1 ...... 19092 ..............Retainer, Regulator 3150

36 ............1 ...... 19101 ..............Spring, Regulator 3150

37 ............1 ...... 19399 ..............Washer, Calibration 3150

38 ............1 ...... 19090 ..............Cap, Regulator 3150

39 ............1 ...... 19278 ..............Fitting, Tube, 90 Deg

40 ............1 ...... 19693 ..............Pressure Gauge

41 ............1 ...... 41232 ..............Bushing Reducer 1/4 x 1/8

42 ..................... 60710-1.2 ........BLFC, 1-inch F x 1-inch M,

NPT, 1.2 gpm

....... 60710-2.0 ........BLFC, 1-inch F x 1-inch M,

NPT, 2.0 gpm

....... 60710-2.4 ........BLFC, 1-inch F x 1-inch M,

NPT, 2.4 gpm

....... 60710-3.0 ........BLFC, 1-inch F x 1-inch M,

NPT, 3.0 gpm

....... 60710-3.5 ........BLFC, 1-inch F x 1-inch M,

22 • FLECK

®

3900 Service Manual

1800 SERIES BRINE SYSTEM AND DRAIN LINE FLOW CONTROL ASSEMBLY

Item No. QTY Part No. Description

NPT, 3.5 gpm

....... 60710-4.0 ........BLFC, 1-inch F x 1-inch M,

NPT, 4.0 gpm

....... 60710-5.0 ........BLFC, 1-inch F x 1-inch M,

NPT, 5.0 gpm

....... 60710-7.0 ........BLFC, 1-inch F x 1-inch M,

NPT, 7.0 gpm

43 ..................... 60710-9.0 ........BLFC, 1-inch F x 1-inch M,

NPT, 9.0 gpm

....... 60710-10 .........BLFC, 1-inch F x 1-inch M,

NPT, 10 gpm

....... 60710-12 .........BLFC, 1-inch F x 1-inch M,

NPT, 12 gpm

....... 60710-15 .........BLFC, 1-inch F x 1-inch M,

NPT, 15 gpm

....... 60710-20 .........BLFC, 1-inch F x 1-inch M,

NPT, 20 gpm

....... 60710-25 .........BLFC, 1-inch F x 1-inch M,

NPT, 25 gpm

44 ..................... 16530 ..............Housing, BLFC, 1"M x 1"F

45 ..................... 19292 ..............O-ring, -020

46 ..................... 19279 ..............Retainer, Flow Control,

Flow 9.0 - 25 gpm

47 ..................... 19053 ..............Retainer, Flow Control,

Flow 2.0 - 7.0 gpm

48 ..................... 12085 ..............Washer, Flow, 1.2 gpm

....... 12087 ..............Washer, Flow, 2.0 gpm

....... 12088 ..............Washer, Flow, 2.4 gpm

....... 12089 ..............Washer, Flow, 3.0 gpm

....... 12090 ..............Washer, Flow, 3.5 gpm

....... 12091 ..............Washer, Flow, 4.0 gpm

....... 12092 ..............Washer, Flow, 5.0 gpm

....... 12408 ..............Washer, Fow, 7.0 gpm

....... 17944 ..............Washer, Flow, 9.0 gpm

....... 16529 ..............Washer, Flow, 10.0 gpm

....... 16735 ..............Washer, Flow, 12.0 gpm

....... 16736 ..............Washer, Flow, 15.0 gpm

....... 16528 ..............Washer, Flow, 20.0 gpm

....... 16737 ..............Washer, Flow, 25.0 gpm

49 ..................... 16738 ..............Retainer,Flow Control

50 ..................... 16805 ..............Ring, Retaining

Not Shown - Option Without Brine Valve

1 ...... 16605 ..............Retainer Plate

1 ...... 19860 ..............Fitting, Brine Valve, 1800

continued

FLECK

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3900 Service Manual • 23

3INCH METER ASSEMBLY

14

12

13

8

6

15

4

5

7

5

3

11

9

2

10

1

5

8

9

10

Item No. QTY Part No. Description

1 ..............1 ...... 16254 ..............Meter Body

2 ..............1 ...... 16279 ..............Impeller Shaft

3 ..............1 ...... 16575 ..............Impeller Assembly

4 ..............1 ...... 16400 ..............Meter Cover Assembly -

Standard

....... 16401 ..............Meter Cover Assembly -

Extended Range

5 ..............3 ...... 15707 ..............O-Ring - 236

6 ..............6 ...... 12112 ..............Screw - Hex Head

....... 15886 ..............Screw - Hex Head (Metric)

7 ..............1 ...... 16280 ..............Flow Straightener

8 ..............2 ...... 16328 ..............Connecting Flange

9 ..............8 ...... 40118 ..............Screw - Hex Head

....... 17122 ..............Screw - Hex Head (Metric)

10 ............8 ...... 16386 ..............Nut - 1/2-13

24 • FLECK

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3900 Service Manual

60608

Item No. QTY Part No. Description

11 ............1 ...... 16574 ..............Stainless Steel Washer

12 ............1 ...... 16401 ..............Meter Cap, 3-inch, EXT, BRS,

PDL

13 ............1 ...... 15707 ..............O-ring - 236

14 ..................... 60608-02 .........Meter Assy, 3-inch

Inline, NPT, EXT, Brass,

Paddlewheel

....... 60608-22 .........Meter Assy, 3-inch

Inline, BSP/Metric, EXT,

Paddlewheel

15 ..................... 60608-01 .........Meter Assy, 3-inch

Inline, NPT, STD, Brass,

Paddlewheel

....... 60608-21 .........Meter Assy, 3-inch

Inline, BSP/Metric, STD,

Paddlewheel

SERVICE VALVE OPERATOR ASSEMBLY

16

Item No. QTY Part No. Description

1 ..............1 ...... 15074 ..............Body, SVO

2 ..............1 ...... 16065 ..............Piston & Stem, SVO

3 ..............1 ...... 10141 ..............O-ring, -010

4 ..............2 ...... 14835 ..............Seal, 3150

5 ..............1 ...... 14834 ..............Spacer, Softwater Fill

6 ..............1 ...... 16509 ..............Plug, End, SVO

7 ..............1 ...... 12977 ..............O-ring, -015

8 ..............1 ...... 15965 ..............Fitting, Bias

9 ..............1 ...... 10249 ..............Spring, Brine Valve

10 ............1 ...... 10250 ..............Ring, Retaining

11 ............1 ...... 16498-02 .........Stem Guide Assy, SVO

12 ............3 ...... 10332 ..............Fitting, Insert, 3/8

13 ............3 ...... 10330 ..............Fitting, Sleeve, 3/8 Celcon

14 ............3 ...... 10329 ..............Fitting, Tube, 3/8 Nut, Brass

15 ............1 ...... 16503 ..............Fitting, Elbow, 90 Deg.

16 ............1 ...... 60150-3150 .....SVO Assy, 3150/3900

(Includes Items 1-15)

Not Shown

................1 ...... 16511 ..............Tube, 3150, PVC, SVO

BR60150-3150REVA

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3900 Service Manual • 25

2350 SAFETY BRINE VALVE

Item No. QTY Part No. Description

1 ..............1 ...... 60038 ..............Safety Brine Valve, 2350

1A ............1 ...... 61024 ..............Actuator Assy, 2350 Brine

2 ..............1 ...... 60028-30 .........Float Assy, 2350, 30-inch Wht

....... 60026-30SAN .Float Assy, 2350, 30-inch Hot

Water

3 ..............1 ...... 60009-00 .........Air Check, #900, Commercial

Less Fittings

....... 60009-01 .........Air Check, #900,

Commercial, Hot Water Less Fittings

Not Shown

................1 ...... 18603 ..............Fitting Assy, 900 Air Check

2350

................1 ...... 18602 ..............Fitting Assy, 900 Air Check

26 • FLECK

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3900 Service Manual

TROUBLESHOOTING

Problem Cause Correction

Water conditioner fails to regenerate.

Hard water. By-pass valve is open. Close by-pass valve.

Unit used too much salt. Improper salt setting. Check salt usage and salt setting.

Loss of water pressure. Iron buildup in line to water conditioner. Clean line to water conditioner.

Loss of mineral through drain line.

Iron in conditioned water. Fouled mineral bed. Check backwash, brine draw, and brine tank fill.

Excessive water in brine tank.

Softener fails to draw brine. Drain line flow control is plugged. Clean drain line flow control.

Control cycles continuously. Misadjusted, broken, or shorted switch. Determine if switch or timer is faulty and replace

Drain flows continuously. Valve is not programming correctly. Check timer program and positioning of control.

Electrical service to unit has been interrupted

Assure permanent electrical service (check fuse, plug, pull chain, or switch)

Timer is defective. Replace timer.

Power failure. Reset time of day.

No salt is in brine tank. Add salt to brine tank and maintain salt level above

water level.

Injector screen plugged. Clean injector screen.

Insufficient water flowing into brine tank. Check brine tank fill time and clean brine line flow

control if plugged.

Hot water tank hardness. Repeated flushings of the hot water tank is

required.

Leak at distributor tube. Make sure distributor tube is not cracked. Check

o-ring and tube pilot.

Internal valve leak. Replace seals and spacers and/or piston.

Excessive water in brine tank. See "Excessive water in brine tank".

Iron buildup in water conditioner. Clean control and add mineral cleaner to mineral

bed. Increase frequency of regeneration.

Inlet of control plugged due to foreign

Remove piston and clean control. material broken loose from pipes by recent work done on plumbing system.

Air in water system. Assure that well system has proper air eliminator

control. Check for dry well condition.

Improperly sized drain line flow control. Check for proper drain rate.

Increase frequency of regeneration. Increase

backwash time.

Plugged drain line flow control. Clean flow control.

Plugged injector system. Clean injector and screen.

Timer not cycling. Replace timer.

Foreign material in brine valve. Replace brine valve seat and clean valve.

Foreign material in brine line flow control. Clean brine line flow control.

Injector is plugged. Clean injector

Injector screen plugged. Clean screen.

Line pressure is too low. Increase line pressure to 20 psi

Internal control leak Change seals, spacers, and piston assembly.

Service adapter did not cycle. Check drive motor and switches.

it, or replace complete power head.

Replace power head assembly if not positioning

properly.

Foreign material in control. Remove power head assembly and inspect bore.

Remove foreign material and check control in

various regeneration positions.

Internal control leak. Replace seals and piston assembly.

FLECK

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3900 Service Manual • 27

GENERAL SERVICE HINTS FOR METER

WATER CONDITIONER FLOW DIAGRAMS

CONTROL

Problem: Softener delivers hard water Reason: Reserve capacity has been exceeded. Correction: Check salt dosage requirements and reset

program wheel to provide additional reserve.

Reason: Program wheel is not rotating with meter output. Correction: Pull cable out of meter cover and rotate manually.

Program wheel must move without binding and clutch must give positive clicks when program wheel strikes regeneration stop. If it does not, replace timer.

Reason: Meter is not measuring flow. Correction: Check meter with meter checker.

1 Service Position

Service Outlet

Inlet

Drain

Inlet

Hard water enters at valve inlet and flows down thru mineral to the bottom distributor. Conditioned water flows up thru the distributor tube, around the piston and out the outlet.

Regeneration Valve

Service Valve

2 Backwash Position

No Hard Water Bypass

Service Outlet

Drain

Inlet

Hard water enters at valve inlet – flows thru service adapter piston for by-pass, and up thru coupling to regeneration valve inlet. Flow continues thru the regeneration valve piston – down the distributor tube – thru the bottom distributor and up thru the mineral – around the piston and out the drain. If optional no hard water by-pass piston is used, water flow to service outlet is prevented by an extension on the service outlet until the end of the rapid rinse cycle or brine tank refill cycle, depending on options chosen.

28 • FLECK

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3900 Service Manual

WATER CONDITIONER FLOW DIAGRAMS

continued

3 Brine Position

Drain

Inlet

Hard water enters at valve inlet – flows thru injector nozzle and throat to draw brine from the brine tank. Brine flows down thru the mineral – into the bottom distributor – up the distributor tube – around the piston and out the drain.

4 Slow Rinse Position

5 Rapid Rinse Position

Drain

Inlet

Hard water enters at valve inlet – flows thru the regeneration valve directly down thru the mineral – into the bottom distributor – up the distributor tube – around the piston and out the drain.

6 Brine Tank Refill Position

Drain

Inlet

Hard water enters at valve inlet – flows thru injector nozzle and throat – down thru the mineral – into the bottom distributor – up the distributor tube – around the piston and out the drain.

Service Outlet

Inlet

Drain

Inlet

Hard water enters at valve inlet – flows thru nozzle and thru throat to brine valve to refill the brine tank. Inlet flow also continues down thru mineral to the bottom distributor. Conditioned water flows up thru the distributor tube, around the piston and out the outlet. Note: An option is available to keep service valve in by-pass position until the end of brine tank refill cycle.

FLECK

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3900 Service Manual • 29

FLOW DATA & INJECTOR DRAW RATES

30 • FLECK

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3900 Service Manual

DIMENSIONAL DRAWING 3900 TOP MOUNT

17.81 452.4

DRAIN

2.58 65.5

7.40 188.1

DRAIN

INLET

5.48 139.2

DRAIN

12.46 316.4

2.59 65.8

15.51 394

OUTLET

4.08 103.7

16.16 410.5

7.08 179.8

OUTLET

2.00 50.8

7.50 190.4

INLET

1.01 25.7

5.18 131.6

INLET

5.50 139.7

FLECK

8.12 206.2

®

3900 Service Manual • 31

DIMENSIONAL DRAWING 3900 SIDE MOUNT

45°

4.95 125.7

INLET

DRAIN

45°

OPTIONAL

EITHER SIDE

6.95 176.5

OUTLET

16.16 410.5

5.38 136.7 8.12 206.2

DRAIN

21.70 551.2

OUTLET

2.00 50.8

12.46 316.4

INLET

TOP

BOTTOM

6.75 171.5

OUTLET

4.62 117.3

INLET

32 • FLECK

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3900 Service Manual

TYPICAL INSTALLATIONS

System #4 - Typical Single Tank Installation with Optional Meter

Optional 3900 Meter

Drain

Brine Line

Brine Tank

Out

In

Manual Shut-Off

3 Wire Power Cord

Resin Tank

System #5 Interlock - Typical Twin Tank Installation with Optional Meter Interlock and No Hard Water Bypass

Out

Manual ShutOff

Optional 3900 Meter

Drain

Brine Line

System #6 Interlock - Typical Twin Tank Installation with Optional Meter Interlock and No Hard Water Bypass

Out

Meter

Manual ShutOff

In

3 Wire Power Cord

Resin Tank Unit 1

Electrical Interlock Cord

Brine Tank

Resin Tank Unit 2

Drain

Brine Line

Brine Tank

Electrical Interlock Cord

In

3 Wire Power Cord

Resin Tank Unit 1

Resin Tank Unit 2

Brine Tank

FLECK

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3900 Service Manual • 33

VALVE WIRING

System #4

System #4 with Remote Meter

34 • FLECK

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3900 Service Manual

VALVE WIRING

System #5

continued

FLECK

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3900 Service Manual • 35

VALVE WIRING

System #6

continued

36 • FLECK

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3900 Service Manual

VALVE WIRING

System #7

continued

FLECK

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3900 Service Manual • 37

VALVE WIRING

continued

System #7 Multivalve

38 • FLECK

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3900 Service Manual

SERVICE ASSEMBLIES

60036-02 1800 Brine Valve:

11772 �� Spring 11774 �� Retaining Ring 18713 �� Brine Valve Body 16497-01 �� Brine Stem Assembly 16498-01 �� Stem Guide Assembly

60277-xx 1800 Injector Assembly:

12473 �� Screw - Hex Head 15127-xx �� Injector Throat 15128-xx �� Injector Nozzle 15246 �� O-ring -116 16340 �� Injector Body 16341-01 �� Injector Cover

-xx Specify Size

60160-00 3900 Upper Piston Assembly:

14818 �� Clip Piston Rod 14922 �� O-ring -035 15125 �� Piston Rod 16130 �� Piston 16389-0 �� End Plug Assembly

60107-00 3900 Lower Piston - Hard Water

Bypass:

14818 �� Clip Piston Rod 16071 �� Piston 16072 �� Piston Rod 16076 �� O-ring -042 16399-01 �� End Plug Assembly - White

60107-10 3900 Lower Piston - No Hard Water

Bypass:

14818 �� Clip Piston Rod 16082 �� Piston - No Hard Water Bypass 16072 �� Piston Rod 16076 �� O-ring -042 16399-11 �� End Plug Assembly - Black

60058-01 3900 Lower Drive Motor Assembly -

115 V System #4:

10302 �� Insulator - Switch 10872 �� Screw - Hex Head 11080 �� Screw - Flat Head 10218 �� Switch 10300 �� Screw - Hex Head 11805 �� Screw - Pan Head 40392 �� Drive Motor - 115V� 50/60 Hz 17797 �� Bracket - Switch Mounting 16086 �� Bracket - Motor Mounting

60131-10 3900 Upper Seal Kit:

10368 �� Spacer 10369 �� Spacer 11720-02 �� Seal, 1-1/2-inch, Silicone

60132-10 3900 Lower Seal Kit:

41534 �� Seal, 3900, 558 Bypass 16069 �� Spacer, 3900 16070 �� Spacer, 3900

60038 Safety Brine Valve, 2350:

60028-30 �� Float Assembly, White 60009-00 �� #900 Air Check, Less Fittings 18602 �� Kit, Fitting, 1700 Brine, 900 Air Check 18603 �� Kit, Fitting, 1700 Brine, 2350 Safety

61417 Adapter Assy, Side Mount, 3900:

18584-02 �� Adapter, 3900 Side Mount 16257 �� Segment, Flange 11238 �� Screw, Hex, 5/16-18 x 1, 18-8 Stainless

Steel 16345 �� O-ring, 362 16800 �� O-ring, 238 11533 �� Plug, Pipe 1/4-inch

60150-3150 SVO, Assembly, 3150/3900

60131 3900 Upper Seal Kit:

10368 �� Spacer 10369 �� Spacer - Port 11720 �� Seal

60132 3900 Lower Seal Kit:

16068 �� Seal 16069 �� Spacer - Narrow 16070 �� Spacer - Wide

60057-01 3900 Upper Drive Motor Assembly -

115 V:

10302 �� Insulator - Switch 10872 �� Screw - Hex Head 11080 �� Screw - Flat Head 10218 �� Switch 10300 �� Screw - Hex Head 15120 �� Bracket - Motor Mounting 40392 �� Drive Motor - 115 V� 50/60 Hz 16052 �� Blushing 17797 �� Bracket - Switch Mounting 12624 �� Screw - Pan Head

FLECK

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3900 Service Manual • 39

SERVICE ASSEMBLIES

WARNING:

continued

CALIFORNIA PROPOSITION 65 WARNING

Drain Line Flow Controls (DLFC):

60711-00 �� 2-inch NPT, Less BTTNS, w/2 Holes 60711-000 �� 2-inch NPT, Less BTTNS, w/3 Holes 60711-01 �� 2-inch NPT, Less BTTNS, w/1 Hole 60711-20 �� 2-inch NPT, 20 gpm 60711-25 �� 2-inch NPT, 25 gpm, Brass 60711-30 �� 2-inch NPT, 30 gpm 60711-35 �� 2-inch NPT, 35 gpm 60711-40 �� 2-inch NPT, 40 gpm 60711-45 �� 2-inch NPT, 45 gpm 60711-50 �� 2-inch NPT, 50 gpm 60711-55 �� 2-inch NPT, 55 gpm 60711-60 �� 2-inch NPT, 60 gpm 60711-65 �� 2-inch NPT, 65 gpm 60711-70 �� 2-inch NPT, 70 gpm 60711-75 �� 2-inch NPT, 75 gpm 60711-80 �� 2-inch NPT, 80 gpm 60711-85 �� 2-inch NPT, 85 gpm 60711-90 �� 2-inch NPT, 90 gpm 60711-95 �� 2-inch NPT, 95 gpm 60711-100 �� 2-inch NPT, 100 gpm 60812-30 �� 2-inch BSP/ Metric, 30 gpm 60812-35 �� 2-inch BSP/ Metric, 35 gpm 60812-45 �� 2-inch BSP/ Metric, 45 gpm 60812-50 �� 2-inch BSP/ Metric, 50 gpm 60812-55 �� 2-inch BSP/ Metric, 55 gpm 60812-70 �� 2-inch BSP/ Metric, 70 gpm 60812-75 �� 2-inch BSP/ Metric, 75 gpm 60812-80 �� 2-inch BSP/ Metric, 80 gpm 60812-90 �� 2-inch BSP/ Metric, 90 gpm 60812-95 �� 2-inch BSP/ Metric, 95 gpm 60812-100 �� 2-inch BSP/ Metric, 100 gpm

This product contains chemicals known to the

State of California to cause cancer or birth defects or other reproductive harm.

40 • FLECK

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3900 Service Manual

FLECK

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3900 Service Manual • 41

42 • FLECK

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3900 Service Manual

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3900 Service Manual • 43

FILTRATION & PROCESSING SOLUTIONS

5730 NORTH GLEN PARK ROAD, MILWAUKEE, WI 53209

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Pentair FLECK 3900 Service Manual

Specifications and Main Features

Frequently Asked Questions

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