Pentair FLECK 7000XTR Service Manual

FLECK 7000XTR

SERVICE MANUAL

www.pentairaqua.com

TABLE OF CONTENTS

WARNING:

JOB SPECIFICATION SHEET ................................................3

WATER SOFTENER CONTROL VALVE .................................. 4

VALVE INSTALLATION AND START-UP PROCEDURES .......4

TIMER OPERATION ..............................................................5

MASTER PROGRAMMING MODE FLOW CHART .................. 6

MASTER PROGRAMMING MODE ......................................... 8

USER PROGRAMMING MODE FLOW CHART ..................... 10

USER PROGRAMMING MODE ............................................ 10

DIAGNOSTIC PROGRAMMING MODE FLOW CHART ......... 10

DIAGNOSTIC PROGRAMMING MODE ................................11

POWER HEAD ASSEMBLY ..................................................12

CONTROL VALVE ASSEMBLY ............................................. 13

BYPASS ASSEMBLY............................................................15

2310 SAFETY BRINE VALVE ............................................... 16

TROUBLESHOOTING .......................................................... 17

GENERAL SERVICE HINTS FOR METER CONTROL ..........19

WATER CONDITIONER FLOW DIAGRAMS .........................20

REMOVING THE GEAR BOX ASSEMBLY .............................21

INSERTING THE CIRCUIT BOARD .....................................21

CONNECTING THE CIRCUIT BOARD .................................21

DIMENSIONAL DRAWINGS ................................................ 22

METER FLOW DATA ............................................................ 22

INJECTOR FLOW DATA .......................................................23

IMPORTANT PLEASE READ:

• The information, specifications 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.

• It is established that when daytime water pressure is
above 80 psi (5.5 bar), the maximum pressure rating of
125 psi (8.6 bar) can be exceeded. A pressure regulator
must be installed on this system or warranty is voided.

• 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 prefilter 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.

CALIFORNIA PROPOSITION 65 WARNING

This product contains chemicals known to

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

2 • FLECK 7000XTR Service Manual

JOB SPECIFICATION SHEET

NOTE: Some options may not be available depending on

valve model or other options chosen.

Circle and/or fill in the appropriate data for future reference.

1. System Type:
A. Meter Immediate
B. Time Clock Delayed
C. Volume Override Delayed
D. Volume Override Immediate
E. Meter Delayed Weekly Reserve
F. Meter Delayed Variable Reserve
G. Meter Delayed Fixed Reserve

2. Valve Type:
A. 7000XTR

C. Regenerant Flow:

A. Downflow
B. Filter
C. Downflow Fill First

4. Display Format:
A. U.S.
B. Metric (French Degrees, German Degrees, or PPM)

5. Unit Capacity:

__________Grains/French Degrees/German Degrees/PPM

6. Water Hardness:

__________Grains/French Degrees/German Degrees/PPM

7. Capacity Safety Factor:
A. Zero
B. __________%

8. Volume Override:__________(Gallons or M3)

9. Regeneration Day Override:
A. Off
B. Every__________Days

10. Regeneration Time:
A. Delayed__________AM/PM
B. __________Immediate

11. Regeneration Cycle:
A. Step #1 _ _ : _ _ : _ _
B. Step #2 _ _ : _ _ : _ _
C. Step #3 _ _ : _ _ : _ _
D. Step #4 _ _ : _ _ : _ _
E. Step #5 _ _ : _ _ : _ _
F. Step #6 _ _ : _ _ : _ _

12. Auxiliary Relay:
A. Enabled

a. Auxiliary Relay Start 1 _ _ : _ _ : _ _
b. Auxiliary Relay End 1 _ _ : _ _ : _ _
c. Auxiliary Relay Start 2 _ _ : _ _ : _ _
d. Auxiliary Relay End 2 _ _ : _ _ : _ _

B. Disabled

13. Chemical Pump:
A. Enabled
B. Disabled

14. CPO Aux Relay Volume:__________(Gallons or M3)

15. CPO Aux Relay: _ _ : _ _ : _ _

16. Flow Meter Size: 1.25-inch Turbine

17. Generic Flow Meter for Maximum Flow Rate:
Add__________Gallons every__________Pulses

FLECK 7000XTR Service Manual • 3

WATER SOFTENER CONTROL VALVE

CAUTION

WARNING:

VALVE INSTALLATION AND START-UP

Water Pressure

A minimum of 20 psi (1.3 bar) inlet water pressure is required
for regeneration valve to operate effectively.

Electrical Facilities

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

• Voltage supply is compatible with unit before installation.

• 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. Replace piping that has heavy lime and/or iron
build-up. If piping is clogged with iron, install a separate iron
filter unit ahead of the water softener.

Location of Softener and Drain

Locate the softener close to a clean working drain and connect
according to local plumbing codes.

Bypass Valves

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

• Minimum Water pressure 20 psi.

• Maximum water pressure 125 psi.

• Minimum water temperature 34°F.

• Maximum water temperature 110°F.

• Ambient temperature 34° to 122° F(1° to 50°C).

• Disconnect all power sources before servicing.

• Always operate with cover in place.

NOTE: This product should be installed by qualified personnel.
NOTE: Comply with all plumbing codes when installing

this product. Comply with all electrical codes when
installing this product.

The system MUST be depressurized before

removing any connections for servicing.

PROCEDURES

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, clean base.

2. Perform all plumbing according to local plumbing codes.

3. Cut the 1.05 inch (2.6 cm) distributor tube flush with the
top of the tank (A). Deburr the outside of the tube (B) after
cutting. Lubricate the o-ring (C) with non-petroleum
based grease.

41119 REV A

Figure 1

4. Lubricate the distributor o-ring seal and tank o-ring seal.
Use only non-aerosol silicone lubricant.

5. Load media and place the control valve on the tank.

6. All soldering MUST be done on any connections requiring
soldering prior to connecting the main control valve. The
main control valve will by damaged if it is connected at the
time of soldering.

7. Apply plumber tape to all threaded fittings.

8. 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.

9. Make plumbing connections to valve.

10. Plug the valve into an approved power source.

NOTE: Make all electrical connections according to codes.

11. Place the bypass In Service position. Cycle the valve to the
Backwash position, and let the water flow slowly into the
mineral tank until the air is purged from the unit.

12. Add water to the brine tank until the top of the air check
is covered. Manually step the valve to the Brine Draw
Position, and allow the valve to draw water from the brine
tank until it stops.

NOTE: The air check will check at approximately the

midpoint of the screened intake area.

13. Manually step the valve to the Brine Refill Position, and
allow the valve to return to In Service automatically.

14. With the valve In Service, check that there is at least 1 inch
(2.5 cm) of water above the grid in the brine tank, if used.

15. Fill the brine tank with salt.

16. Allow the control to run automatically. Setup is
now complete.

4 • FLECK 7000XTR Service Manual

TIMER OPERATION

Figure 2

Valve State

INI (Initializing)

INI will display on the screen for 30 to 45 seconds when
initializing after a power failure reset or programming.

Regeneration

• A time initiated control valve regenerates when the
number of programmed days has been reached

• A flow initiated control valve regenerates when the
volume count is zero or is below reserve capacity

System Type Regeneration Trigger

Time Clock Delayed A) Day override parameter is reached and

Meter Immediate Regenerates as soon as the volume

Meter Delayed Fixed

Reserve

Meter Delayed

Variable Reserve

Meter Delayed

Weekly Reserve

Volume Override

Immediate

Volume Override

Delayed

B) the time of day matches the regeneration
day override time

remaining has been depleted

A) Volume remaining has been depleted
to the fixed reserve volume and B) the
regeneration time has been reached

A) Volume remaining has been depleted
to the variable reserve volume and B) the
regeneration time has been reached

A) Volume remaining has been depleted to
the weekly variable reserve volume and B)
the regeneration time has been reached

As soon as the programmed volume
remaining has been depleted from the tank

As soon as soon as the programmed volume
remaining has been depleted from the tank
and the regeneration time has been reached

RGQ (Regeneration Queued)

RGQ indicates that the reserve has been entered in a delayed
system and regeneration has been queued. When in the main
screen, press the Shift button to toggle service (SRV) with RGQ.

Service (SRV)

SRV will display when the unit is in service.

LED Status Lights

Blue LED

Illuminates while the unit is in service and no errors exist. The
unit will always be in service unless a regeneration trigger has
occurred (green LED light will be displayed).

Green LED

Illuminates when the unit is in Regeneration mode, unless an
error condition exists.

Red LED

Illuminates when there is an error.

Flow Indicator

A rotating line (appearing as a rotating star shape) will display
on the screen when flow is going through the the meter.

Setting the Time of Day

1. Press and hold the Up or Down button for 2 seconds.

2. Press the Shift button to select the digit you want to modify.

3. Press the Up or Down buttons to adjust the value.

4. Press the Extra Cycle button to return to the normal
display screen, or after a 5 second timeout.

NOTE: The “D” button (Diagnostic) can be pressed to exit

without saving.

Manually Initiating a Regeneration

1. When timer is in service, press the Extra Cycle button for 5
seconds on the main screen.

2. The timer advances to Regeneration Cycle Step #1, and
begins programmed time count down.

3. Press the Extra Cycle button once to advance valve to
Regeneration Cycle Step #2 (if active).

4. Press the Extra Cycle button once to advance valve to
Regeneration Cycle Step #3 (if active).

5. Press the Extra Cycle button once to advance valve to
Regeneration Cycle Step #4 (if active).

6. Press the Extra Cycle button once to advance valve to
Regeneration Cycle Step #5 (if active).

7. Press the Extra Cycle button once to advance valve to
Regeneration Cycle Step #6 (if active).

8. Press the Extra Cycle button once more to advance the
valve back to in service.

NOTE: A queued regeneration can be initiated by

pressing the Extra Cycle button. To clear a queued
regeneration, press the Extra Cycle button again
to cancel. If regeneration occurs for any reason
prior to the delayed regeneration time, the manual
regeneration request shall be cleared.

FLECK 7000XTR Service Manual • 5

WARNING:

TIMER OPERATION CONTINUED MASTER PROGRAMMING MODE FLOW

CAUTION

Queued Regeneration (RGQ)

From the display screen, while the unit is in service, hold down
the Extra Cycle button until “RGQ” displays. The valve will
regenerate when the set regeneration time has been reached.

Timer Operation During Regeneration

In the main display screen, the timer shows the current
regeneration cycle and the time for that step. The green
LED light will display when the unit is in regeneration. Once
all regeneration steps are complete, the timer returns to in
service, and displays a blue LED light.

Timer Operation During Programming

The timer enters program mode (unit must be in service).
While in the program mode the timer continues to operate
normally, monitoring water usage. Timer programming is
stored in memory permanently upon a normal exit from
programming mode.

Timer Operation During A Power Failure

All program settings are stored in permanent memory.
Current valve position, cycle step time elapsed, and time of day
are stored during a power failure, and will be restored upon
power re-application. Time is kept during a power failure, and
time of day is adjusted upon power up (as long as power is
restored within 12 hours).

NOTE: The time of day on the main display screen will flash

for 5 minutes when there has been a power outage.
The flashing of the time of day can be stopped by
pressing any button on the display.

CHART

Before entering Master Programming, please

contact your local professional water dealer.

NOTE: Depending on current option settings, some displays

cannot be viewed or set.

Entering Master Programming Mode

1. Press and hold the Shift and Up buttons for 5 seconds.

2. Set the Time of Day display to 12:01 P.M. or 12:01HR. Then
go to the main display screen, press the Up and Down
buttons at the same time for 5 seconds.

To Set Time Of Day:

1. Press and hold the Up or Down buttons for 2 seconds.

2. Press the Shift button to select the digit you want to modify.

Regeneration Day Override Feature

If the Day Override option is turned on and the valve reaches
the set Regeneration Day Override value, the Regeneration
Cycle starts at the programmed regeneration time.

Flow Meter Equipped Timer

As treated water is used, the Volume Remaining display counts
down from the calculated system capacity, less the reserve
volume. Once capacity reaches the reserve volume, the system
will regenerate based on the set regeneration time. If set for
an Immediate system, the unit will regenerate immediately
once it reaches zero capacity. If it is a Fixed, Variable, or
Weekly reserve, the unit will queue a regeneration (RGQ) and
count down Reserve Volume until the set regeneration time.

NOTE: Reserve Volume is only available in a RGQ system.

Volume Remaining

(Less Reserve)

Transformer must be grounded and ground wire

must be terminated to the back plate where
grounding label is located before installation.

Reserve Volume

6 • FLECK 7000XTR Service Manual

MASTER PROGRAMMING MODE FLOW
CHART CONTINUED

FLECK 7000XTR Service Manual • 7

MASTER PROGRAMMING MODE

CAUTION

When the Master Programming Mode is entered, parameters
can be set to make the timer function as needed.

Before entering Master Programming, please

contact your local professional water dealer.

NOTE: Depending on current option settings, some displays

cannot be viewed or set.

Entering Master Programming Mode:

1. Press and hold the Shift and Up buttons for 5 seconds.
OR

2. Set the time of day display to 12:01 PM or 12:01HR (See
the User Programming section to learn how to set Time of
Day). Then go to the main display screen, press the Up and
Down buttons at the same time for 5 seconds.

Exiting Master Programming Mode:

1. Press the Extra Cycle button once per display until all
are viewed. Master Programming Mode is exited and the
normal display screen appears.

2. To exit the Master Programming Mode without saving,
press the Diagnostic button.

NOTE: If no keypad activity is made for 5 minutes while in

the Master Programming Mode, or if there is a power
failure, no changes will be made, and the unit will go
back to the main display screen.

Resets:

Soft Reset: Press and hold the Up and Down buttons for 25
seconds until 12:00PM (or 12:00HR) appears. This resets all
parameters except for the flow meter totalizer volume.

Master Reset: Hold the Extra Cycle button while powering up
the unit. This resets all of the parameters in the unit. Check
and verify the choices selected in Master Programming Mode.

4. Display Format

This program step selects the display format.

• Press the Up or Down buttons to adjust this value.

• Press the Extra Cycle button.

5. Unit Capacity

This program step selects the timer’s total capacity of
hardness that can be removed.

• Press the Shift button to select the digit you want to modify.

• Press the Up or Down buttons to adjust this value.

• Press the Extra Cycle button.

6. Feed Water (Hardness)

This program step is used to set the feed water hardness. The
system will automatically calculate volume remaining based
on the unit capacity, capacity safety factor, and feed water
hardness entered.

• Press the Shift button to select the digit you want to modify.

• Press the Up or Down buttons to adjust this value.

• Press the Extra Cycle button.

NOTE: Feed Water Hardness will not be shown in Volume

Override or Time Clock system types.

1. System Type

This program step selects the system type.

• Press the Up or Down buttons to adjust this value.

• Press the Extra Cycle button.

2. Valve Type

This program step selects the valve type.

• Press the Up or Down buttons to adjust this value.

• Press the Extra Cycle button.

3. Regenerant Flow

This program step selects how the regenerant flows through
the tank (must match cam). The selections available will vary
depending on the previously chosen valve model.

• Press the Up or Down buttons to adjust this value.

• Press the Extra Cycle button.

7. Capacity Safety Factor

This program step is used to set the reserve capacity of the unit.
This is a percentage by which the unit’s capacity is reduced.

• Press the Shift button to select the digit you want to modify.

• Press the Up or Down buttons to adjust this value.

• Press the Extra Cycle button.

8. Volume Override

This program step is used to set the volume override of the unit.

• Press the Shift button to select the digit you want to modify.

• Press the Up or Down buttons to adjust this value.

• Press the Extra Cycle button.

8 • FLECK 7000XTR Service Manual

MASTER PROGRAMMING MODE

CONTINUED

9. Regeneration Day Override

This program step sets the maximum amount of time (in days)
the unit can be in service without a regeneration.

• Press the Shift button to select the digit you want to modify.

• Press the Up or Down buttons to adjust this value.

• Press the Extra Cycle button.

10. Regeneration Time

This program step sets the time of day for the regeneration to
occur in delayed systems.

• Press the Shift button to select the digit you want to modify.

• Press the Up or Down buttons to adjust this value.

• Press the Extra Cycle button.

13. Timed Auxiliary Relay Output Window (Start & End
Time Setting)

This option setting consists of two displays. The first display
sets the turn-on time of the output, referenced to the start
of the first regeneration cycle. The second display sets the
output turn-off time, referenced again to the start of the first
regeneration cycle. An OFF setting cancels this setting. All
settings are in minutes and output timing is synchronized with
regeneration cycle timing.

Start Time: Any time during regeneration.
End Time: At start time, and anytime during the

regeneration cycle.

14. Chemical Pump Auxiliary Relay Output Window

This option setting consists of two displays. The first display
sets the volume of water flow at which the output turns on.
The second display sets the on time (in seconds) of the output.

• Activate output after volume set is reached.

• Press the Shift button to select the digit you want to modify.

• Press the Up or Down buttons to adjust this value.

• Press the Extra Cycle button.

11. Regeneration Cycle Step Programming

This program step programs the Regeneration Cycle step
times 1 through 6. Please refer to the chart below for
regenerant flow default cycle steps and times.

Cycle Time

1 Back Wash 10 Minutes

2 Brine & Slow Rinse 1 Hour

3 Rapid Rinse 10 Minutes

4 Brine Tank Fill 12 Minutes

5 N/A N/A

12. Auxiliary Relay Output

The next two displays are part of a series of settings used to
program the optional relay output. The first setting turns the
output on/off during regeneration only. The second turns the
output on during service only, every time a set volume of water
used has accumulated.

NOTE: When auxiliary outputs are in the OFF (default)

setting, press the Up or Down buttons to set the first
setting. Then press the Extra Cycle button to advance
to the second setting.

15. Flow Meter Size

This program step sets the size of the flow meter.

• Press the Up or Down buttons to adjust this value.

• Press the Extra Cycle button.

16. Maximum Flow Rate

This program step sets maximum flow rate of the generic
flow meter.

• Press the Shift button to select the digit you want to modify.

• Press the Up or Down buttons to adjust this value.

• Press the Extra Cycle button.

17. Pulses per Gallon/Liter

This program step sets the pulses per gallon/liter for generic
flow meters.

• Press the Shift button to select the digit you want to modify.

• Press the Up or Down buttons to adjust this value.

• Press the Extra Cycle button.

18. End of Master Programming Mode

FLECK 7000XTR Service Manual • 9

USER PROGRAMMING MODE FLOW

DIAGNOSTIC PROGRAMMING MODE FLOW

CHART

NOTE: Depending on current option settings, some displays

cannot be viewed or set.

Entering User Mode

1. Press and hold the Up and Down buttons for 5 seconds.

CHART

NOTE: Depending on current option settings, some displays

cannot be viewed or set.

Entering Diagnostic Mode

1. Press and release the “D” button.

2. Press the Extra Cycle button once per display until all
displays are viewed and the normal display screen appears.

3. Press and release the “D” button during this mode to exit
the Diagnostic Mode.

4. Depending on current option settings, some displays
cannot be viewed.

USER PROGRAMMING MODE

NOTE: Depending on current option settings, some displays

cannot be viewed or set.

1. Enter User Mode

• Press and hold the Up and Down buttons for 5 seconds.

2. Set Feed Water Hardness

• Press the Shift, Up, and Down buttons to move the cursor
and change the value of the numbers.

• Press the Extra Cycle button to proceed to the next step.

NOTE: Feed Water Hardness will not be shown in Volume

Override or Time Clock system types.

3. Set Regeneration Day Override

• To turn on and set the days, press the Down button.

• Press the Shift, Up, and Down buttons to move the cursor
and change the value of the numbers.

• Press the Extra Cycle button to proceed to the next step.

4. Regeneration Time

• Press the Shift, Up, and Down buttons to move the cursor
and change the value of the numbers.

• Press the Extra Cycle button

5. End of User Programming Mode

10 • FLECK 7000XTR Service Manual

DIAGNOSTIC PROGRAMMING MODE

NOTE: Depending on current option settings, some displays

cannot be viewed.

Overview Diagnostic Mode

The current Diagnostic Programming Mode screen will display
until either the Extra Cycle button is pressed through for each
screen, or the Diagnostic button is pressed. In the event of
regeneration occurring while in the Diagnostic Programming
Mode, the regeneration step and time remaining will be
displayed. When regeneration completes, the display will
return to the normal time of day display screen.

Entering and Exiting Diagnostic Mode

Press and release the “D” button to enter the Diagnostic
Programming Mode. Pressing the Extra Cycle button will move to
the next diagnostic screen. Press the Extra Cycle button once per
display until all are viewed. Pressing the Diagnostic button while
in Diagnostic Mode will cause the unit to leave the Diagnostic
Mode and return to the normal time of day display screen.

1. Current Flow Rate

This program step displays the calculated flow rate for the
timer. The below flow rates are the maximum flow rate the
timer will read for each meter.

1.25 inch Turbine: 90 gpm (0.34 m3/m)

• Press the Extra Cycle button.

9. Software Version

This program step displays the timer’s software program
version number.

• Press the Extra Cycle button to exit.

NOTE: Diagnostic Programming Mode will stop if the system

goes into a regeneration.

2. Peak Flow Rate

This program step displays the peak flow rate (1 minute
average) since the last regeneration.

• Press the Extra Cycle button.

3. Totalizer

This program step displays the total volume of treated water
that passes through the meter.

• Reset to zero by holding the Up and Down buttons for five
seconds while in the totalizer screen.

• Press the Extra Cycle button.

4. Hours Between Last Two Regenerations

This program step displays the time between the last two
regenerations saved.

• Press the Extra Cycle button.

5. Hours Since Last Regeneration

This program step displays the hours since the last regeneration.

• Press the Extra Cycle button.

6. Volume Remaining

This program step displays the volume remaining. The timer
will regenerate if the volume remaining is set to zero. The
maximum ranges are the same as the maximum volume
calculated on the main screen.

• Press the Extra Cycle button.

7. Reserve Capacity

This program step displays the reserve capacity, ensuring soft
water is available at all times.

• Press the Extra Cycle button.

8. Previous Day’s Water Usage

This program step displays the previous day’s water usage.

• Press the Extra Cycle button.

FLECK 7000XTR Service Manual • 11

POWER HEAD ASSEMBLY

Item No. QTY Part No. Description

1 ..............1 ...... 42349 ..............Motor, 24V, 2 RPM, 7000

2 ..............1 ...... 10218 ..............Switch, Micro

3 ..............1 ...... 40978 ..............Plate, Upper Support

4 ..............1 ...... 42356 ..............Circuit Board Assy, XTR7000

5 ..............1 ...... 40702 ..............Shaft, Encoder, 7000

6 ..............1 ...... 40703 ..............Gear, Main

7 ..............1 ...... 40704 ..............Cam, Brine, Downflow

8 ..............1 ...... 40979 ..............Plate, Lower Support

9 ..............1 ...... 61635-01 .........Cover Assy, 7000-II, Black

1 ...... 61634-01 .........Cover Assy, 7000-II, Gray

10 ............1 ...... 40980 ..............Backplate, 7000

11 ............4 ...... 13602 ..............Screw, Phil Rd Hd, 6-32 x

5/16

12 • FLECK 7000XTR Service Manual

61501-7000XT REV A

Item No. QTY Part No. Description

12 ............1 ...... 12473 ..............Screw, Hex Wsh, 10-24 x 5/8

13 ............2 ...... 11805 ..............Scerw, Rd Hd, 4-40 x 5/8

Type 1

14 ............1 ...... 40981 ..............Transformer, US 24V, 9.6VA,

7000

15 ............1 ...... 19791-01 .........Meter Cable Assy, Turbine/

SE

16 ............1 ...... 41122 ..............O-ring, -007

17 ............1 ...... 40960-03 .........Label, UL Nameplate, 7000,

US/24

CONTROL VALVE ASSEMBLY

61500-7000EXP REV C

FLECK 7000XTR Service Manual • 13

CONTROL VALVE ASSEMBLY CONTINUED

Item No. Qty. Part No. Description

1 ..............1 ...... 61050 ..............Valve Body Assy, 7000,

32 mm Dist

2 ..............1 ...... 61542-10 .........Piston Assy, 7000, Softener,

D/F 35 gpm

....... 61453-10 .........Piston Assy, 7000, Softener,

D/F 28 gpm

....... 61452-20 .........Piston Assy, 7000, Filter

35 gpm

3 ..............3 ...... 40576 ..............Clip, H, Plastic, 7000

4 ..............1 ...... 61438 ..............Seal & Spacer Kit, 7000, D/F

5 ..............1 ...... 60016-01 .........Brine Valve Assy, 7000,

560CD

6 ..............1 ...... 40577 ..............Turbine Meter Assy, 7000

7 ..............1 ...... 61XXX ..............Injector Assy, 7000

Injector Number

....... 61454-000 .......#000

....... 61454-00 .........#00

....... 61454-0 ..........#0

....... 61454-1 ..........#1

....... 61454-2 ..........#2

....... 61454-3 ..........#3

....... 61454-4 ..........#4

....... 61454-5 ..........#5

8 ..............1 ...... 40556 ..............Cap, Injector

9 ..............1 ...... 61XXX ..............BLFC Assemblies

BLFC Size/GPM

....... 61450-00 .........3/8-inch/Blank

....... 61450-12 .........3/8-inch/0.125

....... 61450-25 .........3/8-inch/0.25

....... 61450-50 .........3/8-inch/0.50

....... 61450-100 .......3/8-inch/1.0

....... 61451-00 .........1/2-inch/Blank

....... 61451-12 .........1/2-inch/0.125

....... 61451-25 .........1/2-inch/0.25

....... 61451-50 .........1/2-inch/0.50

....... 61451-100 .......1/2-inch/1.0

Item No. QTY Part No. Description

10 ................1 ...... 61XXX ..............DLFC Assemblies

DLFC Size/GPM

....... 61455-00 .........3/4-inch/Blank

....... 61455-17 .........3/4-inch/1.7

....... 61455-20 .........3/4-inch/2.0

....... 61455-24 .........3/4-inch/2.4

....... 61455-30 .........3/4-inch/3.0

....... 61455-35 .........3/4-inch/3.5

....... 61455-40 .........3/4-inch/4.0

....... 61455-45 .........3/4-inch/4.5

....... 61455-50 .........3/4-inch/5.0

....... 61455-60 .........3/4-inch/6.0

....... 61455-70 .........3/4-inch/7.0

11 ............1 ...... 43776 ..............O-ring, -021, 7000,

CSTM

12 ............2 ...... 13302-01 .........O-ring, -014, 560CD

13 ............1 ...... 40946 ..............Clip, Brine Retaining

14 ............1 ...... 40945 ..............Clip, Drain Retaining

15 ............1 ...... 40950 ..............Screen, Injector, 7000

16 ............1 ...... 40951 ..............O-ring, -220

17 ............1 ...... 18280 ..............Collector, Top, 1-inch x .011,

Gray

18 ............1 ...... 61419 ..............Kit, 1.05-inch Distributor,

Adapter

19 ............1 ...... 19054 ..............O-ring, -124

20 ............1 ...... 18303-01 .........O-ring, -336, 560CD

23 ............1 ...... 61XXX ..............DLFC Kits

DLFC Size/GPM

....... 61456-00 .........1-inch/Blank

....... 61456-8.0 ........1-inch/8.0

....... 61456-9.0 ........1-inch/9.0

....... 61456-10 .........1-inch/10.0

....... 61456-12 .........1-inch/12.0

....... 61456-15 .........1-inch/15.0

....... 61456-20 .........1-inch/20.0

....... 61456-25 .........1-inch/25.0

....... 61456-30 .........1-inch/0.0

Not Shown:

....... 40677 ..............Tube, Distributor, 32MM

....... 40924 ..............Distributor, 32MM

....... 40697-02 .........Collector, 32MM Bayonet

....... 12763-10 .........Stuffer Tool Assy, 7000

Filter Valves

....... 40947-01 .........Plug, Brine Valve, w/O-ring

....... 40990-01 .........Plug, Injector, w/O-ring

14 • FLECK 7000XTR Service Manual

BYPASS ASSEMBLY

41118 REV A 41147 REV A

Important: To bypass the valve, turn bypass knob on both
sides of the valve to bypass position. When returning to
service, put the inlet into service before the outlet.

Item No. QTY Part No. Description

1 ..............1 ...... 40569-01 .........Bypass Assembly, 7000, with

Clip

2 ..............2 ...... 40563-01 .........Connector Assy, 1-inch NPT,

w/O-ring

....... 40563-11 .........Connector Assy, 1-inch BSP,

w/O-ring

....... 40565-01 .........Connector Assy, 1-1/4 inch

NPT w/O-ring

....... 40565-11 .........Connector Assy, 1-1/4 inch

BSP w/O-ring

3 ..............2 ...... 41242-01 .........Connector Assy, 1-inch &

1/4-inch Sweat, w/O-ring

....... 41243-01 .........Connector Assy, 1-1/4 inch &

1-1/2 inch Sweat, w/O-ring

4 ..............2 ...... 40576 ..............Clip, H, Plastic, 7000

5 ..............1 ...... 40951 ..............O-ring, -220

Not Shown

1 ...... 61462 ..............By-Pass Service Kit, 7000

(Includes all internal parts

for 7000 bypass assembly -

bypass body not included)

FLECK 7000XTR Service Manual • 15

2310 SAFETY BRINE VALVE

Item No. QTY Part No. Description

1 ..............1 ...... 60014 ..............Safety Brine Valve Assy, 2310

2 ..............1 ...... 60068-30 .........Float Assy, 2310, w/30-inch

Rod

3 ..............1 ...... 60002-34 .........Air Check, #500

42112 REV A

16 • FLECK 7000XTR Service Manual

TROUBLESHOOTING

Timer

If an error is detected, an error screen will alternate with the
main display screen every few seconds, and the LED light will
be red.

During an error condition, the unit continues to monitor
the flow meter and update the remaining capacity. Once an
error condition is corrected, the unit returns to the operating
status it was in prior to the error, and regeneration resumes
according to normal programming. If an error is cleared by
reprogramming the unit in the Master Programming Mode,
the volume remaining may be reset to the full unit capacity
(as though it had just regenerated). If an error is present,
a regeneration can only occur manually by pressing and
holding the Extra Cycle button for 5 seconds. If the unit was
in regeneration when the error occurred, it will complete the
regeneration cycle and go into service.

When the problem is corrected, and the error no longer displays
(it may take several seconds for the unit to stop displaying the
error message), the unit will return to normal operation. The
LED light will no longer be red, and will turn Green if the unit is
regenerating, or Blue if the unit is in service.

Problem Correction

Flashing/blinking

display

Unit not responding

after going into

regeneration

Unit displays “ERROR

CODE: REPLACE UNIT”

(corrupted UAP)

Power outage has occurred. Either wait 5
minutes for blinking to stop, or press any
key on the keypad.

Verify the unit is configured correctly (ex:
wiring valve type). Perform a Master Reset
by holding the Shift button and cycling
power. Check and verify the choices
selected in Master Programming Mode.

Contact your local water treatment
professional.

Error Display Screen Examples:

Error

Code

01 ERROR CODE:

02 ERROR CODE:

03 ERROR CODE:

04 ERROR CODE:

05 ERROR CODE:

Display

Message

PROGRAM UNIT

PROGRAM UNIT

SERVICE UNIT

SERVICE UNIT

SERVICE UNIT

Correction

Go through all screens in Master

Programming Mode.

Go through all screens in Master

Programming Mode.

Perform a Master Reset by holding
the Shift button and cycling power.

Go through all screens in Master

Programming Mode. Manually initiate a

regeneration cycle by pressing the Extra

Cycle button for 5 seconds.

Perform a Master Reset by holding
the Shift button and cycling power.

Go through all screens in Master

Programming Mode. Manually initiate a

regeneration cycle by pressing the Extra

Cycle button for 5 seconds.

Call your local water treatment

professional as soon as possible. Leave

the unit running (do not unplug).

NOTE: If the above corrections do not work, please contact

your local water treatment professional.

FLECK 7000XTR Service Manual • 17

WARNING:

TROUBLESHOOTING CONTINUED

Control Valve

The controller MUST be depressurized before

removing any quick connection clips for
servicing. The connector should be pushed
toward the control while removing clips.

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

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

Excessive water in brine tank. Plugged drain line flow control. Clean flow control.

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 it, or

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

Electrical service to unit has been interrupted Assure permanent electrical service (check fuse, plug,

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

Injector screen plugged. Clean injector screen.

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

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

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

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

Inlet of control plugged due to foreign

material broken loose from pipes by recent

work done on plumbing system.

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

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 (1.3 bar)

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

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

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

Internal control leak. Replace seals and piston assembly.

pull chain, or switch)

water level.

control if plugged.

and tube pilot.

Increase frequency of regeneration.

Remove piston and clean control.

control. Check for dry well condition.

Increase frequency of regeneration. Increase
backwash time.

replace complete power head.

power head assembly if not positioning properly.

Remove foreign material and check control in various
regeneration positions.

18 • FLECK 7000XTR Service Manual

GENERAL SERVICE HINTS FOR METER
CONTROL

Problem Cause Correction

Softener delivers hard water Reserve capacity has been exceeded. Check salt dosage requirements and reset reserve

Meter is not measuring flow. On Mechanical Meter: Check with meter checker kit.

capacity to provide additional reserve.

If volume is not registering, check the meter cap and
impeller for debris, and ensure they can move freely.

On Electronic Meter: Check for a short in the meter
cable. Ensure that it is programmed as a meter, and
that the turbine and impeller can move freely.

FLECK 7000XTR Service Manual • 19

WATER CONDITIONER FLOW DIAGRAMS

In Service Position

Second Backwash Position

40988 REV A 41121 REV A

Backwash Position

40988 REV A 41121 REV A

Brine Position

40988 REV A 41121 REV A

Rapid Rinse Position

40988 REV A 41121 REV A

Brine Tank Refill Position

40988 REV A 41121 REV A

Slow Rinse Position

40988 REV A 41121 REV A

20 • FLECK 7000XTR Service Manual

40988 REV A

41121 REV A

REMOVING THE GEAR BOX ASSEMBLY

42554 REV A

42554 REV A

40988 REV A

1. Unplug the power source.

2. With a 3/8 inch nut driver, turn the cycle cam counter-

clockwise to the position shown in the illustration above.

3. Slightly pull the two tabs outward and push the gearbox

slightly upward to remove.

4. When returning the valve to service after powerhead

disassembly, manually step valve through regeneration
using the extra cycle button until the valve is in service.

INSERTING THE CIRCUIT BOARD

2. When all the way down, snap the circuit board into place
under the notches on the right.

CONNECTING THE CIRCUIT BOARD

42554 REV A

After the circuit board is installed:

1. Connect the motor wires to the motor connector on the
circuit board.

2. Connect the transformer cable to the transformer
connector on the circuit board.

3. Connect the meter cable to the meter cable connector on
the circuit board.

4. Connect the meter cable sensor end to the opening on the
valve body.

5. Thread the meter cable and power cable along the path
shown in the above illustration.

6. Insert screw to secure circuit board.

1. To insert circuit board, align notches on left side of board
with flexible finger on power head. Apply pressure to left
while rotating the board back.

42554 REV A

FLECK 7000XTR Service Manual • 21

DIMENSIONAL DRAWINGS

61500-7000XTR-LNE REV A

METER FLOW DATA

22 • FLECK 7000XTR Service Manual

TR18753 Softener
TR18688 Filter
41140-02 REV A

INJECTOR FLOW DATA

TR18755 REV B

FLECK 7000XTR Service Manual • 23

For Fleck® Product Warranties visit:

Fleck® para las garantías de los productos visite:

Pour Fleck® garanties produit visitez le site :

www.pentairaqua.com/pro

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