Watts PWSR145, PWSR160, PWSR190, PWSR130 Installation, Operation And Maintenance Manual

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PWSR Series Softeners

Installation, Operation and Maintenance Manual

WARNING

Read this Manual BEFORE using this equipment. Failure to read and follow all safety and use information can

result in death, serious personal injury, property damage, or damage to the equipment.

Keep this Manual for future reference.

WARNING

You are required to consult the local building and plumbing codes prior to installation. If the information in this manual is not consistent with local building or plumbing codes, the local codes should be followed. Inquire with governing authorities for additional local requirements.

IOM-WQ-PWSR

WARNING

Need for Periodic Inspection/Maintenance: This product must be tested periodically in compliance with local codes, but at least once per year or more as service conditions warrant. All products must be retested once maintenance has been performed. Corrosive water conditions, and/or unauthorized adjustments or repair could render the product ineffective for the service intended. Regular checking and cleaning of the product’s internal components helps assure maximum life and proper product function.

WARNING

Do not use with water that is microbiologically unsafe or of unknown quality adequate disinfection before and after the system.

NOTICE

Hydrocarbons such as Kerosene, Benzene, Gasoline, etc., may damage products that contain O-rings or plastic components. Exposure to such hydrocarbons may cause the products to leak. Do not use the product(s) contained in this document on water supplies that contain Hydrocarbons such as Kerosene, Benzene, Gasoline, etc.

PWSR Series Softeners

Table of Contents

System Speciﬁcations ....................................2

Control Valve Functions ..................................3

General Installation Instructions ............................4

Safety Information & General Warnings ..................... 4-5

Pre-Installation Considerations ........................... 5-6

Installation Preview ......................................6

System Components Described ............................ 7

Bypass Valve Installation .................................. 8

Installation Instructions ................................ 6-10

PWSR Quick Programming Guide .................... 11-12

Control Programming ................................ 13-14

System Components Described ........................ 14-16

Drawings and Part Numbers ........................... 17-22

System Troubleshooting .............................. 23-26

Notes ...............................................27

Page 2

System Speciﬁcation Table

A. Models Chart

MINERAL TANK BRINE TANK FLOW RATE & PRESSURE

TANK

SIZE

RESIN

GRAVEL

(LBS.)

TANK

SIZE

SALT

FILL

SERVICE

(GPM)

DROP

(PSI)

BKW

(GPM)

SHIP WT.

(LBS.)

MODEL NO.

CAPACITY

(MAX.)

PIPE SIZE

(IN.)

PWSR130 30,000 1" 9 " x 48" 1 15 18" x 36" 350 9 - 12 15 - 25 2.2 110 PWSR145 45,000 1" 10" x 54" 1.5 20 18" x 36" 350 12 - 16 15 - 25 2.7 130 PWSR160 60,000 1" 12" x 52" 2 30 18" x 36" 350 15 - 20 15 - 25 3.5 190 PWSR190 90,000 1" 14" x 65" 3 60 18" x 40" 400 18 - 23 15 - 25 4.2 265

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Control Valve Functions

Control Valve Function and Cycles of Operation

This glass ﬁlled Noryl fully automatic control valve is designed as the primary control center to direct and regulate all cycles of a water softener. The control valve can be set to regenerate on demand (consumption of a predetermined amount of water) and/or as a time clock (passage of a particular number of days).

The control valve is compatible with a variety of regenerants and resin cleaners. The control valve is capable of routing the ﬂow, of water in the necessary paths to regenerate or backwash water treatment systems. The injector regulates the ﬂow of brine or other regenerants. The control valve regulates the ﬂow rates for backwashing rinsing and the replenishing of treated water into a regenerant tank.

The control valve is designed to deliver high service (27 gpm @ 15 psig) and backwash (27 gpm @ 25 psig) ﬂow rates when the bypass has straight ﬁttings. The control valve uses no traditional fasteners (e.g. screws), instead clips, threaded caps and nuts and snap type latches are used. Caps and nuts only need to be ﬁrmly hand tightened because radial seals are used. Tools required to service the valve include one small blade screwdriver, one large blade screwdriver, pliers and a pair of hands. A plastic wrench is available which eliminates the need for screw-drivers and pliers. Disassembly for servicing takes much less time than comparable products currently on the market.

The transformer power pack comes with a 15-foot power cord and is designed for use with the control valve. The transformer power pack is for dry location use only. The control valve remembers all settings for two hours if the power goes out. After two hours the only item that needs to be reset is the time of day, all other values are permanently stored in the nonvolatile memory. The control valve does not need batteries.

When the control valve is used as a down ﬂow softener, two backwashes always occur. The softener will start regenerant preﬁll before regeneration, the preﬁll starts two hours before the regeneration time set. During the 2-hour period in which the brine is being made, treated (softened) water is still available. For example: regeneration time = 2:00 am, preﬁll option selected, downﬂow softener. Fill occurs at 12:00 a.m., start of backwash cycle occurs at 2:00 a.m.

The softener will adjust the backwash and rinse cycles automatically increase with increasing, salt dosage. Backwashes can be set to be NORMAL or LONGER. The option selected will apply to all backwashes. Tables 4 and 5 show the length of the cycles when the valve is set up as a softener.

Regeneration Steps and Purpose:

Brine ﬁll – Brine tank is ﬁlled to dissolve salt for next regeneration. Backwash – Flow through the resin bed is reversed. Water ﬂows

upward expanding and agitating the resin bed. Brine in – Brine is educted from the brine tank and pass-es through

the resin bed in a downward ﬂow, thus removing calcium and magnesium that has accumulated on the resin beads and is ﬂush to drain.

Backwash – A second backwash is performed Rinse – The resin is now ﬂushed downward at a set ﬂow rate. This

resettles the bed and rinses out any remaining brine left in the resin bed.

Service – Softener goes back into service and ready to soften water.

Exchange Capacity Data

20,000 grain approx. per cu. Ft. 6 lbs. salt-sodium chloride 25,000 grain approx. per cu. Ft. 8 lbs. salt-sodium chloride 30,000 grain approx. per cu. Ft. 15 lbs. salt-sodium chloride

NOTICE

To convert parts per million (PPM) or milligrams per liter (mpl) to grains divide by 17.1

Example: Water hardness of 250 PPM (250 PPM divided by 17.1 PPM/gr.) equals 14.6 gr. It is recommended that a good grade of solar or pellet salt be used. One-gallon water will dissolve approximately 3.0 lbs. of salt One gallon of saturated brine weighs 10.74 lbs.

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WARNING

General Installation Guidelines

This water conditioner’s control valve conforms to UL/ CE Standards. Generic valves were tested and certiﬁed for compliance as veriﬁed by the agency listing. This water conditioning system is to be used only for potable water. Inspect the water conditioning system for carrier shortage or shipping damage before beginning installation.

Operating Perameters:

• Operating ambient temperature: 40° to 110°F (5° to 43°C).

• Operating water temperature: 40° to 110°F (5° to 43°C).

• Operating water pressure range : 25 to 120 psi (1.7 to

8.27bar).

Installation Perameters: All plumbing should be done in

accordance with local plumbing codes.

• Do not use pipe dope or other sealants on threads. Use Teﬂon tape on the threaded inlet, outlet and drain ﬁttings. Teﬂon tape is not necessary on the nut connection or caps because of o-ring seals.

• All plastic connections should be hand tightened. Teﬂon® tape may be used on connections that do not use an O-ring seal. Do not use pipe dope type sealants on the valve body. Do not

use pliers or pipe wrenches.

• Observe drain line requirements.

• Keep the media tank in the upright position. Do not turn upside down or drop. Turning the tank upside down or laying the tank on its side can cause media to enter the valve.

• The pipe size for the drain line should be a minimum of ½”. Backwash ﬂow rates in excess of 7 gpm (26.5 lpm) or length in excess of 20’ (6.1m) require ¾” drain line.

• Do not support the weight of the system on the control valve ﬁttings, plumbing, or the bypass.

Environmental:

• Use only regenerants designed for water conditioning. Do not use ice melting salt, block salt or rock salt. During cold weather it is recommended that the installer warm the valve to room temperature before operating.

is a trademark of E.I. duPont de Nemours.

Teﬂon

• Do not use petroleum-based lubricants such as Vaseline, oils or hydrocarbon-based lubricants. Use only 100% silicone lubricants.

• Do not allow this water conditioning system to freeze. Damage from freezing will void this water conditioning system’s warranty.

• HYDROCARBONS SUCH AS KEROSENE, BENZENE, GASOLINE, ETC., MAY DAMAGE PRODUCTS THAT CONTAIN O-RINGS OR PLASTIC COMPONENTS. EXPOSURE TO SUCH HYDROCARBONS MAY CAUSE THE PRODUCTS TO LEAK. DO NOT USE THE PRODUCT(S) CONTAINED IN THIS DOCUMENT ON WATER SUPPLIES THAT CONTAIN HYDROCARBONS SUCH AS KEROSENE, BENZENE, GASOLINE, ETC.

• THIS WATER METER SHOULD NOT BE USED AS THE PRIMARY MONITORING DEVICE FOR CRITICAL OR HEALTH EFFECT APPLICATIONS.

• Do not use Vaseline, oils, other hydrocarbon lubricants or spray silicone anywhere. A silicone lubricant may be used on black o-rings but is not necessary.

Electrical:

• Use only the power transformer supplied with this water conditioning system.

• All electrical connections must be completed according to local codes.

• The power outlet must be grounded.

• All electrical connections must be connected according to local codes. (Be certain the outlet is uninterrupted.)

• Install grounding strap on metal pipes.

• The power adapter comes with a 15 foot power cord and is designed for use with the control valve. The power adapter is for dry location use only. The control valve remembers all settings until the battery power is depleted if the power goes out.

• After the battery power is depleted, the only item that needs to be reset is the time of day; other values are permanently stored in the nonvolatile memory. The control valve battery is not rechargeable but is replaceable.

• No user serviceable parts are on the PC board, the motor or the power adapter. The means of disconnection from the main power supply is by unplugging the power adapter from the wall.

• Install an appropriate grounding strap across the inlet and outlet piping of the water conditioning system to ensure that a proper ground is maintained.

• To disconnect power, unplug the AC adapter from its power source.

Soldering:

• Use only lead-free solder and ﬂux, as required by federal and state codes, when installing soldered copper plumbing.

• Use caution when installing soldered metal piping near the water conditioning system. Heat can adversely affect the plastic control valve and bypass valve.

• Solder joints near the drain must be done prior to connecting the drain line ﬂow control ﬁtting. Leave at least 6” between the drain line control ﬁtting and solder joints when soldering pipes that are connected on the drain line control ﬁtting. Failure to do this could cause interior damage to the drain line ﬂow control ﬁtting.

• When assembling the installation ﬁtting package (inlet and outlet), connect the ﬁtting to the plumbing system ﬁrst and then attach the nut, split ring and o-ring. Heat from soldering or solvent cements may damage the nut, split ring or o-ring. Solder joints should be cool and solvent cements should be set before installing the nut, split ring and o-ring. Avoid getting primer and solvent cement on any part of the o-rings, split rings, bypass valve or control valve.

Control Valve:

• This glass ﬁlled Noryl1 (or equivalent) fully automatic control valve is designed as the primary control center to direct and regulate all cycles of a water softener or ﬁlter.

• The control valve, ﬁttings and/or bypass are designed to accommodate minor plumbing misalignments but are not designed to support the weight of a system or the plumbing.

• The nuts and caps are designed to be unscrewed or tightened by hand or with the special plastic wrench. If necessary a pliers can be used to unscrew the nut or cap. Do not use a pipe wrench to tighten or loosen nuts or caps. Do not place a screwdriver in the slots on caps and/or tap with a hammer.

• After completing any valve maintenance involving the drive assembly or the drive cap assembly and pistons unplug power source jack from the printed circuit board (black wire) and plug back in or press and hold NEXT and REGEN buttons for 3

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General Warnings (continued)

WARNING

Installation Guidelines:

seconds. This resets the electronics and establishes the service piston position. The display should ﬂash all wording, then ﬂash the software version and then reset the valve to the service position.

• The control valve is compatible with a variety of regenerants and resin cleaners. The control valve is capable of routing the ﬂow of water in the necessary paths to regenerate or backwash water treatment systems. The injector regulates the ﬂow of brine or other regenerants. The control valve regulates the ﬂow rates for backwashing, rinsing, and the replenishing of treated water into a regenerant tank, when applicable.

• Control valve installation is made easy because the distributor tube can be cut ½” above to ½” below the top of tank thread. The distributor tube is held in place by an o-ring seal and the control valve also has a bayonet lock feature for upper distributor baskets.

Pre-Installation Considerations

A. Water Pressure

A minimum of 25 pounds of water pressure is required for regeneration valve to operate effectively. Do not exceed maximum water pressure of 125 pounds of water pressure.

B. Electrical Facilities

A continuous 120 volt, 60 Hertz current supply is required. Make certain the current supply is always hot and cannot be turned off with another switch.

C. 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.

D. Where to Install the Softener

Consider the following points when determining where to install the water softener:

• Place the system as close as possible to a sewer drain.

• Do not install the softener where it would block access to the waterheater, or access to the main water shutoff, water meter, or electrical panels.

• Keep outside faucets on hard water to save soft water and salt.

• Install the softener in a place where water damage is least likely to occur if a leak develops.

• A 120VAC electrical outlet is needed to plug in the transformer. If the outlet is remote (up to 100 feet), use 18 gauge wire to connect.

• Always connect the system to the main water supply pipe before the water heater.

• Install the system where it will not be subject to temperatures outside of the limits stated in the Speciﬁcation section or to direct sunlight.

Noryl is a trademark of Sabic.

PWSR Series Softeners 5

E. Bypass Valves

Always provide for the installation of a bypass valve.

F. Valve to Tank Installation Instructions

1. Spin the valve onto the tank, ensuring the threads are not cross-

threaded.

NOTICE

The control valve have right-hand threads, or clockwise, to install

2. Rotate the valve freely without using force until it comes to a stop

(this position is considered zero).

3. Rotate the valve clockwise from zero, between ¼ turn and ½

turn to fully tighten. No tools are needed. Hand tight is enough. Overtightening may cause valve or tank damage.

NOTICE

If lubricant is required, a silicone compound is strongly recommended. Dow Corning Watts), is recommended for best possible results. Dow Corning Release Compound is used in the manufacture of this control valve. The use of other types of lubricants may attack the control’s plastic or rubber components. Petroleum-based lubricants can cause swelling in rubber parts, including O-rings and seals.

Silicone Compound (available from

Page 6

Pre-Installation Considerations (continued)

G. Pre Installation and Loading of Media

Systems that are 13” in diameter and larger are not loaded with media. These systems must be loaded with media before placing into service. To load a system follow the below steps.

1. Cap the top open end of the distributor tube with tape and plastic sheeting to keep foreign debris from entering the distributor tube. This cap must be secure and not come off during media loading.

2. Place the distributor tube, screen end down, into the mineral tank and center it in the bottom. The top of the distributor tube should be ﬂush with the top of the tank.

3. Make sure the plastic and tape cap is secure to the top of the distributor tube, place a funnel on the top of the tank and load ﬁrst the gravel (if different sizes of gravel are used load the largest gravel ﬁrst, then the smaller gravel) then the resin media into the tank. The cap must not come off of the distributor tube during the loading of the media.

4. Remove the plastic cap from the distributor tube. DO NOT PULL UP ON THE DISTRIBUTOR TUBE when removing the cap. The distributor tube top must remain ﬂush with the top of the tank.

5. Clean any media from the threads and top of the mineral tank.

6. Lubricate the O-rings on the bottom of the control valve (distributor pilot O-ring and top of tank O-ring). Use nonpetroleum based silicone lubricant only.

7. Place the control valve on top of the tank. When doing this step, seat the top of the distributor tube inside the centered O-ring sealed port on the bottom of the valve ﬁrst then press the valve down until the tank threads come in contact with the valve threads. This ensures that the distributor tube is properly seated into the bottom of the control valve. Thread the valve on to the tank clockwise. Be careful not to cross thread the valve or over tighten it. A hand tight snug ﬁt is appropriate for the control valve torque. A wrench is not necessary. Do not use thread sealant or PTFE tape on the valve base threads.

8. The system is now ready for installation. Follow the Installation Section in the Installation, Operation and Maintenance Manual.

Installation Preview (continued)

Connect raw water supply line to the inlet valve connection. Connect treated water outlet to service line. It is suggested that the pipe size be equal or one size larger than the valve connection.

NOTICE

Softener to be located at least 10 feet away from hot water heater to protect against hot water back-up.

WARNING

When piping with copper, solder all piping as sub-assemblies before installing. Internal damage can result from the high heat of the torch.

It is recommended that manual isolating valves be installed on the inlet and outlet piping along with a system bypass valve. This will isolate the unit when service is required. Run drain line to a sump, drain trench, or other open drain. Open drains are required for taking samples and allowing a visual check. Avoid overhead pipe runs to drain facility, as undue backpressure will affect the operation of injectors.

NOTICE

All piping is to meet your local and state code. AVOID CROSS CONNECTIONS!

Position brine tank approximately 6” from the softener tank on a smooth surface.

Connect the brine air check assembly in the salt/brine tank to the brine suction (eductor) connection. If brine tank is located more than 6 feet from softener tank, use one size larger tubing. Tubing 5/8” should be installed from the brine tank over-ﬂow to drain. This is a gravity drain designed to divert brine to the drain in the event of a malfunction, which would cause overﬂow of the brine tank.

Be sure inlet/outlet isolating valves are closed and bypass valve is open.

WARNING

Do not exceed water pressure of 120 psi (8.2 bar). Do not exceed 110°F (43.3°C). Do not subject unit to freezing conditions.

Installation Preview

Conduct a visual check of all equipment for any damage that may have occurred during shipment.

NOTICE

If there is obvious damage to any equipment, it should be noted on the carrier’s Bill Of Lading. Open and inspect the contents of all closed crates, cartons, etc. and inspect for concealed damage. The manufacturer is not liable for any dam-age during transit.

Position the equipment in its proper location, setting on a ﬂat surface. Level equipment as required. Equipment out of plumb can exhibit poor ﬂow characteristics, which will affect the performance of the system.

NOTICE

Units are shipped with media (resin & gravel), distributions tube, and control valve installed. Double-check the valve installation on the tank. Tighten if necessary.

Unit should be positioned with the valve control facing forward.

Check the main line water pressure. The softener is designed for a minimum of 20 psi and a maximum of 125 psi working pressure. If the line pressure exceeds this limit, a pressure-reducing valve should be installed.

Maximum allowable water temperature is 40°F (4°C) – 110°F (38°C). A 120vac 60 cycle electrical source must be available for operation of the controller.

Installation Instructions.

1. Turn off water heater(s).

2. Turn off the main water supply to the home and open an inside faucet (cold and hot) to relieve any pressure within the plumbing system.

Select Location

1. Place the system in the desired installation location. Make sure that the location is level and sturdy enough to support the weight of the system once it is in operation.

2. You will need to locate the water softener at least 10 feet away from the hot water heater so that hot water does not backup and damage the softener.

3. You will need a drain close by for disposal of regenerated wastewater.

4. If installing the softener in an outside locations, make sure to protect softener from the elements, such as freezing temperatures, rain, sunlight and contamination

Install a By-Pass

NOTICE

Always install a bypass, either a 3-way valve system or the standard bypass for the valve you have. This will allow you to shut off the water supply to the softener, but still have water in the house if the softener is in need of repair.

6 PWSR Series Softeners

Page 7

Installation Instructions (continued)

SYSTEM COMPONENTS DESCRIBED

Install a By-Pass (continued)

After a location has been determine install bypass onto the control valve. (On page 8, Figures 1 and 3 show standard bypass on valve.) (Figures 2 and 4 show 3-way by pass plumbing.)

NOTICE

If installing a 3-way bypass valve, do so now.

Close main water supply valve, at the well or at the water meter.

Shut off electrical or fuel supply to the water heater.

Open all faucets to drain pipes.

NOTICE

The bypass (provided) easily connects to the valve body using nuts that only require hand tightening. The split ring retainer design holds the nut on and allows load to be spread over the entire nut surface area reducing the chance for leakage.

Make certain the nut is placed on ﬁrst, then the split retainer ring, followed by the o-ring to make the seal. A silicon lubricant may be used on the black o-ring seals. This design allows for an approximate 2-degree misalignment of the plumbing. This design will allow for minor plumbing misalignments, but should never handle the weight of the plumbing system.

System Components Described

PWSR Series Softeners 7

Page 8

Bypass Valve Installation

INSTALLATION

Figure 1: Plumbing with by pass (Standard).

Figure 3: Bypass (standard).

When installing sweat copper follow state and fed-

When installing sweat copper follow state and

eral codes by using a lead free solder and flux. Use

federal codes by using a lead free solder and ﬂux. Use a joint compound to seal threaded pipe. Some

a joint compound to seal threaded pipe. Some

homes use the cold water pipes for an electrical

ground (metal only). When ﬁnished with plumbing,

ground (metal only). When finished with plumbing,

a ground wire should be connected to the copper

pipes to complete the ground circuit. Use two

clamps and #4 copper for this.

Figure 5:

Figure 6:

clamps and #4 copper for this.

Figure 2: Plumbing with 3-way b pass.

Figure 4: 3-way bypass plumbing.

Figure 6:

Figure 5:

8 PWSR Series Softeners

Page 9

Installation Instructions (continued)

Move Water Softener Into Place

1. Connect the cold water supply to the inlet of the water conditioning system. While constructing the supply line, install a master supply valve (user supplied) in the supply line and close it.

2. Connect the feed water line to the home to the outlet of the system.

3. Make sure ﬂoor is level.

Measure, cut, and install pipe and ﬁttings to the bypass valve (dry ﬁt only to make sure you have a proper ﬁt) inlet and outlet side. Be sure hard water is supplied to the inlet side. Trace pipe to be sure.

The installation ﬁttings connect to the control valve or the bypass valve using nuts that only require hand tightening. Hand tighten nut connections between control valve and installation ﬁttings,control valve and bypass valve, and bypass valve and installation ﬁttings allow for easy serviceability. Do not use a pipe wrench to tighten nuts on installation ﬁttings. Hand tighten only.

NOTICE

When assembling the installation ﬁtting package, connect the ﬁtting to the plumbing system ﬁrst and then attach the nut, split ring and o-ring. Heat from soldering or solvent cements may damage the nut, split ring, and o-ring. Make sure solder joints are cool before assemble is started.

Slip the nut onto the ﬁtting ﬁrst, then the split ring second and the o-ring last. Hand tighten the nut. If the ﬁtting is leaking tightening the nut will not stop the leak. Remove the nut, remove the ﬁtting, and check for damage or misalignment of the o-ring.

Do not use pipe dope or other sealant on threads. Teﬂon tape must be used on the threads of the 1" NPT elbow and the 1/4" NPT connection and on the threads for the drain line connection. Teﬂon tape is not necessary on the nut connection or caps because of o-ring seals.

Move Brine Tank Next to Softener and Connect Brine Draw Line to Valve

1. Connect the brine tank to the water softener control valve brine inlet port using the factory supplied ﬁttings and tubing. Add enough water to the brine tank so that water covers the top of the air check. DO NOT ADD SALT AT THIS TIME.

2. With brine tank next to the softener tank connect the brine draw line to valve body. Connect to valve body 3/8" Quick Connect ﬁtting.

Control valves that use a regenerant, come equipped with a 3/8"

reﬁll ﬂow control assembly.

Complete the connection by installing the loose end of the tub-

ing to the brine valve in the salt tank.

3/8" Quick Connect

Fitting

Connect the Drain Line

1. Plumb the drain line to an appropriate drain abiding by all local, city, and state codes. Use a 3/4” drain line for backwash ﬂow rates of 7 gpm or for drain lines of 7 gpm and less that exceed 20’ in length. Use a 1” drain line for backwash ﬂow rates of 10 gpm and 12 gpm.

2. If the drain line is a 5/8" ﬂexible poly tube, slide the nut onto the poly tube, then place the poly tube insert into the end of the poly tube and tighten the nut on to the 3/4" drain line ﬁtting. The nut is only designed for use with ﬂexible poly tube. Use other nuts if attaching different materials. Run line to a drain. Making sure you have a 1 1/2" airgap. You may use a ﬂoor drain, standpipe or any open type drain (see Fig. 7 on page 10).

Do not use Vaseline, oils, or other unacceptable lubricants on

o-rings. A silicon lubricant may be used on the black o-ring.

Use a pliers or crescent wrench to tighten or unscrew the nut. Do not use a pipe wrench to tighten or loosen nut. Do not use pipe dope or other sealant on threads. Use Teﬂon tape on the threads of the drain line control ﬁtting when installing 3/4" NPT or 1" straight ﬁtting.

Split ring retainer design holds the nut on and allows load to be spread over the entire nut surface area reducing the chance for leakage. The split ring design, incorporated into the installation ﬁttings allows approximately 2 degrees off axis alignment to the plumbing system. The installation ﬁttings are designed to accommodate minor plumbing misalignments but are not designed to support the weight of a system or the plumbing.

When assembling the installation-ﬁtting package, connect the ﬁtting to the plumbing system ﬁrst and then attach the nut, split ring and o-ring. Heat from soldering or solvent cements may damage the nut, split ring, or o-ring. Solder joints should be cool and solvent cements should be set before installing the nut, split ring, and o-ring. Avoid getting primer and solvent cement on any part of the o-rings, split rings, and bypass valve or control valve. Solvent cements and primers should be used in accordance with the manufacturer’s instructions.

PWSR Series Softeners 9

Page 10

Installation

INSTALLATION

STEP 5: Connect the Drain Line

If the drain line is a 5/8" flexible poly tube, slide the nut onto the poly tube, then place the poly tube insert into the end of the poly tube and tighten the nut on to the 3/4" drain line fit- ting. The nut is only designed for use with flexible poly tube. Use other nuts if attaching different materials. Run line to a drain. Making sure you have a 1 1/2" airgap. You may use a floor drain, standpipe or any open type drain (see Fig 10).

Do not use Vaseline, oils, or other unacceptable lubricants on o-rings. A silicon lubricant may be used on the black o-ring. Use a pliers or crescent wrench to tighten or unscrew the nut. Do not use a pipe wrench to tighten or loosen nut. Do not use pipe dope or other sealant on threads. Use Teflon tape on the threads of the drain line control fitting when installing 3/4" NPT or 1" straight fitting.

Figure 10: Also be sure drain line has an air gap.Figure 11: Drain Line Connection

Figure 9: Brine Draw Connection.

STEP 5: Start-up

Place the bypass valve in the “bypass” position or mode (see figures 12-14 below.)

Open the main water supply valve.

Open a couple of cold water faucets that are to be conditioned and let run until air is expelled and pipes are full.

Open the outlet valve of the bypass.

Close the bypass valve.

Press and hold the regen button on the keypad for 3 seconds.

This will put the valve in manual mode. Now press the Regen button twice.This will put the system in backwash. Slowly open the inlet valve. (Open the valve a little at a time, pausing several times to allow the unit to fill slowly and expel air.) When the tank has filled and a steady flow to the drain is achieved, let the system run until clear water can be seen coming from the drain line. When water is clear press the regen button 4 times. This will take the valve back to service position. Open several cold water and hot water faucets and let run until hot water heater is full and cold water faucets have expelled trapped air. Turn electrical power back on or re-light the hot water heater. Now continue with control valve setup.

Figure 7: Also be sure drain line has an air gap. Figure 8: Drain Line Connection

Start Up

1. Conﬁrm that the bypass valve is in the bypass position (see images 9, 10 & 11 below)

2. Place the bypass valve in the “bypass” position or mode (see ﬁgures 9-11 below.)

3. Open the user supplied feed water valve. Check for leaks and repair as needed.

4. Open the outlet valve of the bypass.

5. Open a couple inside hot and cold faucets until all air has been purged from the plumbing system. then close the faucets.

6. Initiate an Immediate Manual Regeneration by pressing and holding the “REGEN” button for 3 seconds. This will place the system into “Backwash” mode, unplug the system from its electrical outlet once it has cycled into the backwash position. This will stall the unit in the “Backwash” mode so all air can be purged from the tank.

7. Close the bypass valve.

8. Adjust the user supplied feed water valve to 1/4 open and place the bypass valve into the “Service/Operating Mode” position.

9. Air will come out of the drain line until the backwashing tank is completely purged of air. Then water will ﬂow to drain. Allow water to ﬂow to drain for 15 minutes or until the water to drain is clear of resin color throw.

10. Plug the system back into the electrical outlet and manually cycle the control valve through the remaining regeneration steps by pressing the “Next” button until it arrives in the Service position.

11. Check for system for leaks and repair as needed.

12. Installation is now complete and the system is ready for programming and one cycle of brine tank reﬁll so that the correct amount of water is in the brine tank for the ﬁrst regeneration cycle. The brine tank reﬁll must be done after programming the system. Add Salt to brine tank, ﬁll the brine tank about 1/2 full,

DO NOT FILL BRINE TANK COMPLETE FULL

Figure 9: Operating Mode Figure 10: Bypass Mode Figure 11: Bypass Mode

10 PWSR Series Softeners

Page 11

PWSR System Programming

PWSR Quick Programming Guide

A quick programming guide has been listed below for convenience speciﬁcally for the PWSR series water softening systems. For other programming requirements not listed in the Quick Programming Guide, please see the detailed programming section of this manual.

NOTICE

The electronics in the PWSR control valve are used across a wide variety of control valves and applications, including backwashing ﬁlters. All programming for the electronics has been included in this manual for reference however the valve must be programmed for Twin Alternating Softening Applications when called for during valve programming.

PWSR Series Softeners 11

Page 12

NOTICE

The Water Hardness level of the feed water needs to be known prior to programming system as well as the Water Softener Capacity of the system being installed, to insure proper programming and efﬁciency of system

Chart 1: Setting Time of Day

Press the Set Clock button Adjust hours using the Up and Down arrow buttons

Press the Next button to advance to the minutes.

Press the Next button to set time To Exit

Adjust minutes with the Up and Down arrow buttons.

NOTICE

Once in the programming settings, simply use the UP and DOWN arrow buttons to change values

Chart 2: Master Programming

To enter the Master Programming mode, press and hold the NEXT and DOWN arrow buttons simultaneously for 3 – 5 seconds

Press NEXT Button

Press NEXT Button Brine Tank Refill Mode - This setting should be set to POST

Press NEXT Button Regenerate Flow Mode - This flow setting should be set to Down Flow – dn.

Press NEXT Button Regeneration Time - This setting should be set to NORMAL

Press NEXT Button This will complete Master Programming Steps

The display will change to SET SOFTENING with the word SOFTENING will be blinking. This indicates you are now in the Master Programming Mode

System Type – For a WATER SOFTENER, leave this setting alone. If for some reason the display reads SET FILTER, press the UP arrow button and change to SET SOFTENER

Capacity – Enter the CAPACITY of the water softener that you have ie. 30K, 45K, 60K or

90K.

Salt Setting – Enter the desired pounds of salt per regeneration ie. 6 lbs. per cu.ft. of resin for most efficiency, 15 lbs. per cu.ft. for maximum capacity – default setting should be 9 pounds for a 45K water softener – you must confirm

A 30K water softener has 1 cu.ft., 45K has 1.5 cu.ft., 60K has 2 cu.ft. and 90K cu.ft. has 3 cu.ft. Example - 45K water softener would be set to a minimum salt setting of 9 pounds for most efficiency (recommended)

Backwashing Mode - Setting to Normal or Longer. NORMAL is the standard setting. Longer may be needed for well water with heavier sediment issues. Contact Pure Water Technical Support at 1.800.224.1299, then press #2 for details.

Gallon Capacity Mode - Set to AUTO for most efficient setting. Owner’s manual has additional settings, contact Pure Water Technical Support for Details. Note: You may see a gallon capacity on this screen, hit the UP arrow button several times until you see AUTO on the screen.

NOTICE

Next you will need to set up Installer Programming, this MUST be done in addition to the Master Programming

To enter Installation Display Setting Programming mode, press and hold the NEXT and UP arrow buttons simultaneously for 3 - 5 seconds

Press Next Button

Press Next Button Press the UP and DOWN arrow button to adjust the minutes.

Press Next Button

Hardness Setting - Set the level of hardness in grains per gallon (GPG) present in the raw water. Example: 18 grains per gallon (GPG). Adjust grains per gallon with the Up and Down arrow buttons.

Day Override. Default should be set to 14 Days. Watts Pure Water water softeners regenerate based on water usage, but this day override setting will come into play if the softener sits idle or has not regenerated and will automatic initiate regeneration on the 14th day.

Regeneration Time. Default setting is 2:00 AM. If time change is needed, press the UP and

DOWN arrow buttons to adjust the hour time.

Programming completed, Valve will return to normal mode and will be in service.

If you have additional questions regarding your water softener programming, please contact Pure Water Technical Support at 1.800.224.1299, then press #2

Chart 3: Installer Programming

12 PWSR Series Softeners

Page 13

Control Programming

Press NEXT to go to step 4I. Press REGEN to return to previous step.

STEP 4I –

Next Regeneration Time (hour): Set the hour of day for regeneration using down or up arrow buttons. AM/PM toggles after 12. The default time is 2:00 am. This display shows “REGEN on 0 GAL” if “on 0” is selected in Step 9S or Step 7F. Press NEXT to go to step 5I. Press REGEN to return to previous step.

STEP 5I –

Next Regeneration Time (minutes): Set the minutes of day regeneration using down or up arrow buttons. This display not be shown if “on 0” is selected in Step 9S or Step 7F. Press NEXT to exit Installer Displays/ Settings. Press REGEN to return to previous step.

To initiate a manual regeneration immediately, press and hold the “REGEN” button for three seconds. The system will beam to regenerate immediately. The control valve may be stepped through the various regeneration cycles by pressing the “REGEN” button.

REGENERATION MODE

Typically a system is set to regener- ate at a time of low water usage. An example of a time with low water usage is when a household is asleep. If there is a demand for water when the system is regenerating, untreated water will be used.

When the system begins to regenerate, the display will change to include information about the step of the regeneration process and the time remaining for that step to be completed.The system runs through the steps automatically and will reset itself to pro-

CONTROL PROGRAMMING

INSTALLER (I) Displays/Settings

STEP 1I –

Press NEXT and arrow up simulta-

neously for 3 seconds.

STEP 2I –

Hardness: Set the amount of hard- ness in grains of hardness as calcium carbonate per gallon using, arrow down or arrow up but- tons. The default is 20 with value ranges from 1 to 150 in 1 grain increments. Note the grains per gallon can be increased if soluble iron needs to be reduced. Press NEXT to go to step 3I. Press REGEN to exit Installer Displays/Settings.

STEP 3I –

Day Override: When gallon capacity is set to off, sets the number of days between regeneration’s. When gallon capacity is set to AUTO or to a number sets the maximum number of days between regeneration. If value set to “off” regeneration initiation is based solely on gallons used. If value is set as a number (allowable range from 1 to 28) a regeneration initiation will be called for on that day even if sufficient number of gallons were not used to call for a regeneration. Set Day Override using arrow buttons: number to days between regeneration (1 to 28); or OFF.

Press NEXT to go to step 4I. Press REGEN to return to previous step.

STEP 4I –

STEP 5I –

Next Regeneration Time (hour): Set

Next Regeneration Time (minutes):

Installer (I) Displays/Settings

STEP 1I – Press NEXT and arrow up simultaneously for 3 seconds.

STEP 2I – Hardness: Set the amount of hardness in grains of hardness as calcium carbonate per gallon using, arrow down or arrow up but-tons. The default is 20 with value ranges from 1 to 150 in 1 grain increments. Note the grains per gallon can be increased if soluble iron needs to be reduced. Press NEXT to go to step 3I. Press REGEN to exit Installer Displays/Settings.

STEP 3I – Day Override: When gallon capacity is set to off, sets the number of days between regeneration’s. When gallon capacity is set to AUTO or to a number sets the maximum number of days between regeneration. If value set to “off” regeneration initiation is based solely on gallons used. If value is set as a number (allowable range from 1 to 28) a regeneration initiation will be called for on that day even if sufﬁcient number of gallons were not used to call for a regeneration. Set Day Override using arrow buttons: number to days between regeneration (1 to

28); or OFF.

General Operation

User (U) Displays/Settings

When the system is operating one of two displays will be shown. Pressing NEXT will alternate between the displays. One of the displays is always the current time of day. The second display is one of the following: days remaining or gallons remaining. Days remaining are the number of days left before the system goes through a regeneration cycle. Capacity remaining is the number of gallons that will be treated before the system goes through a regeneration cycle. The user can scroll between the displays as desired.

If the system has called for a regeneration that will occur at the preset time of regeneration, the words REGEN TODAY will appear on the display.

When water is being treated (i.e. water is ﬂowing through the system) the word “Softening” ﬂashes on the display.

NOTICE

If brine tank does not contain salt, ﬁll with salt and wait at least two hours before regenerating.

PWSR Series Softeners 13

Press NEXT to go to step 4I. Press REGEN to return to previous step.

STEP 4I – Next Regeneration Time (hour): Set the hour of day for regeneration using down or up arrow buttons. AM/PM toggles after 12. The default time is 2:00 am. This display shows “REGEN on 0 GAL” if “on 0” is selected in Step 9S or Step 7F. Press NEXT to go to step 5I. Press REGEN to return to previous step.

STEP 5I – Next Regeneration Time (minutes): Set the minutes of day regeneration using down or up arrow buttons. This display not be shown if “on 0” is selected in Step 9S or Step 7F. Press NEXT to exit Installer Displays/ Settings. Press REGEN to return to previous step.

Regeneration Mode

Typically a system is set to regenerate at a time of low water usage. An example of a time with low water usage is when a household is asleep.

If there is a demand for water when the system is regenerating, untreated water will be used.

When the system begins to regenerate, the display will change to include information about the step of the regeneration process and the time remaining for that step to be completed. The system runs through the steps automatically and will reset itself to pro-vide treated water when the regeneration has been completed.

Manual Regeneration

Sometimes there is a need to regenerate the system, sooner than when the system calls for it, usually referred to as manual regeneration. There may be a period of heavy water usage because of guests or a heavy laundry day.

To initiate a manual regeneration at the preset delayed regeneration time, when the regeneration time option is set to “NORMAL” or “NORMAL + on 0”, press and release “REGEN”. The words “REGEN TODAY” will ﬂash on the display to indicate that the system will regenerate at the preset delayed regeneration time. If you pressed the “REGEN” button in error, pressing the button again will cancel the request. Note: If the regeneration time option is set to “on 0” there is no set delayed regeneration time so “REGEN TODAY” will not activate if “REGEN” button is pressed.

To initiate a manual regeneration immediately, press and hold the “REGEN” button for three seconds. The system will begin to regenerate immediately. The request cannot be cancelled.

Page 14

Programming (Note) Sanitizing the System

1. At completion of softener installation you should sanitize the system.

2. Take the lid off of the salt tank and then take the cap off of the brine well. Pour about 3/4 to 1 1/2 ounce of 5.25% common household bleach into the brine well. Replace cap and lid. (This can be

Figure 16:

The Brine System

Set Time of Day

The user can also set the time of day. Time of day should only need to be set after extended power outages or when day-light savings time begins or ends. If an extended power outage occurs, the time of day will ﬂash on and off which indicates the time of day should be reset.

STEP 1U – Press SET CLOCK. STEP 2U – Current Time (hour): Set the

hour of the day using down or up arrow buttons. AM/PM toggles after 12. Press NEXT to go to step 3U.

STEP 3U – Current Time (minutes):Set the minutes of the day using down or up arrow buttons. Press NEXT to exit Set Clock. Press REGEN to return to previous step.

POWER LOSS If the power goes out for less than two hours, the system will automatically reset itself. If an extended power outage occurs, the time of day will ﬂash on and off which indicates the time of day should be reset. The system will remember the rest.

ERROR MESSAGE If the word “ERROR” and a number are alternately ﬂashing on the display contact the OEM for help. This indicates that the valve was not able to function properly.

1. At completion of softener installation you should sanitize the system.

2. Take the lid off of the salt tank and then take the cap off of the brine well. Pour about 3/4 to 1 1/2 ounce of

5.25% common household bleach into the brine well. Replace cap and lid. (This can be done with or without salt in tank.)

3. Press and hold regeneration button to start the regeneration process immediately.

Each water softener is handled in a manner to keep clean and sanitary. The materials used will not contaminate your water supply or cause bacteria to grow. However, during shipping, storage, installation, and operation, bacteria growth could develop. Some water supplies may require periodic disinfecting.

System Components Described

Components:

The control valve consists of the following components

1. Drive Assembly

2. Drive Cap Assembly, Main Piston and Regenerant Piston

3. Spacer Stack Assembly

4. Injector Cap, Screen, Injector Plug and Injector

5. Reﬁll Flow Control Assembly or Reﬁll Port Plug

6. Drain Line Flow Control and Fitting Assembly

7. Water Meter or Meter Plug

8. Installation Fitting Assemblies

9. Bypass Valve (optional)

Drive Assembly

The drive assembly consists of the following parts:

• Drive Bracket

• Printed Circuit (PC) Board

• Motor

• Drive Gears

• Drive Gear Cover

The drive bracket holds the PC board, the motor, the drive gears and the drive gear cover in place.

The PC board receives and retains information, displays the information,determines when to regenerate and initiates regeneration. The display shows different types of information in the initial system set up (for softeners or ﬁlters), installer displays/settings, diagnostics, and valve history or user displays/settings.

The PC board’s two-prong jack connects wires to the direct current (DC) motor. The motor is held in place on the drive bracket by a spring-loaded clip and a small bulge in the plastic, which ﬁts in one of the slots on the motor housing. The motor turns drive gears that drive the piston to cycle positions for backwashing, regeneration, rinsing, reﬁll or service. The motor is fully reversible (turns both ways) and changes direction of rotation to change the direction of piston motion. The motor is easily replaced if necessary.

There are three drive gears held in place by the drive gear cover. All three drive gears are the same size. A reﬂective coating is applied to the gears. As the center drive gear turns a light shines on the coating and a light sensing diode determines if a light pulse was returned. The PC board counts the pulses and determines when to stop driving the motor.

14 PWSR Series Softeners

Page 15

System Components Described

Drive Cap Assembly

Main Piston and Regenerant Piston

The drive gears turn the main gear of the drive cap assembly, which moves the piston. The screw-driven, horizontally moving piston stops at speciﬁc positions to direct the ﬂow of water to backwash, regenerate, rinse or reﬁll. The PC board determines the position of the piston by counting pulses produced when the piston is moved. An optical sensor looking at one of the reduction drive gears generates these pulses. Each cycle position is deﬁned by a number of pulses. The counter is zeroed each time the valve goes to the service position. The PC board ﬁnds the service position by noting the increase in current delivered to the motor when the mechanical stop at the service position is reached. This method of controlling piston position allows for greater ﬂexibility and requires no switches or cams.

One of two main pistons is always used:

1. The down ﬂow piston which is used when the control valve is used as a down ﬂow softener, regenerating ﬁlter or non regenerating ﬁlter: or

2. The up ﬂow piston, which is used when the control valve is used as an up ﬂow softener.

If the control valve is used as a softener or a regenerating ﬁlter, are generant piston must be attached to the main piston. If the control valve is to be used on system that does not require a regenerant to be added the regenerant piston must be removed.

Spacer Stack Assembly

The spacer stack assembly provides the necessary ﬂow passage for water during the different cycles. The all-plastic spacer stack assembly (patent pending) is a one-piece design, which allows the stack to be removed using your ﬁngers.

The exterior of the stack is sealed against the body bore with selflubricating EPDM o-rings while the interior surface is sealed against the piston using slippery self cleaning directional (one way) silicone lip seals. The lip seals are red or clear in color and have a special slippery coating so that the piston does not need to be coated or lubricated.

Table 10: Injector Order Information

Part # Color Tank Dia. KC11V3010-1D Red 9" KC11V3010-1E White 10" KC11V3010-1F Blue 12" KC11V3010-1G Yellow 13"

KC11V3010-1I Orange 16"

KC11V3010-1K Lt Green 21"

Reﬁll Flow Control Assembly

The reﬁll ﬂow control assembly consists of a reﬁll ﬂow elbow, reﬁll ﬂow control retainer assembly, reﬁll ﬂow control, poly tube insert and nut assembly. The reﬁll ﬂow control retainer ﬁts in the reﬁll elbow. The reﬁll ﬂow control retainer houses the reﬁll ﬂow control, which controls the ﬂow rate when the regenerant tank is being reﬁlled. The reﬁll ﬂow control is a ﬂexible washer-like part with a small oriﬁce and a precision molded contour that delivers a steady 0.5 gpm regenerant tank reﬁll rate at varying inlet pressures. Reﬁll is accomplished with treated water.

The reﬁll ﬂow control assembly is installed in an easy to access reﬁll elbow located on top of the control valve. The reﬁll ﬂow control assembly is attached to the control valve with a locking clip. The locking clip allows the elbow to rotate 270 degrees so the outlet can be orientated towards the regenerant tank.

Drain Line Flow Control/Fitting

The drain line ﬂow control assembly includes a drain line ﬂow control and a ﬁtting. The drain line ﬂow control allows proper media bed expansion by regulating the ﬂow rate to the drain.

The drain line ﬂow control is a ﬂexible washer-like part with an oriﬁce and a precision molded contour. The ﬂow rates are within +- 10% over the pressure range of 1-0 psi to 125 psi. The ﬂexible washer-like parts are identiﬁed with three numbers, which correspond to the ﬂow rate in gallons per minute. See Table 11.

The drain line ﬂow control and ﬁtting are located on top of the control valve and replaceable without the use of special tools.

Injector

The screen, injector and/or injector plug(s) are installed under the injector cap in an easy to access location on top of the valve. The injector cap contains four slots so no water accumulates in the cap. The injector cap is designed to be hand tightened.

Under the injector cap there is an easy to clean removable screen to prevent fouling of the injector. There are two holes under the injector cap labeled “DN” and “UP”. The holes will be ﬁlled with a plug or an injector.

The plug (#KC113010-IZ) prevents water from traveling a certain pathway. The injector lets water pass through the pathway. The selfpriming injector increases the velocity of the water, creating a zone of negative pressure that draws in the concentrated liquid regenerant, such as sodium chloride (brine), potassium permanganate, sodium hydroxide, hydrochloric acid, etc. The regenerant blends with the stream of water, which passes through the media to regenerate the bed.

The injector provides a consistent regenerant/water mixture ratio over the entire operating pressure range of the control valve. The injector provides good performance in a variety of applications, which may involve elevated drain lines and long regenerant draw lengths. Injectors are chosen by knowing the type, amount, and regenerant ﬂow rate for a particular type of media. The color coded injectors give different regenerant draw, slow rinse and total ﬂow rates over the pressure range. See Table 10 for color codes.

PWSR Series Softeners 15

Table 11: Drain Line Flow Control (3/4" Fitting)

Part #

Number on Backwash Flow Rate

Fitting GPM KC11V3162-022 22 2.2 KC11V3162-027 27 2.7 KC11V3162-042 42 4.2 KC11V3162-053 53 5.3 KC11V3162-075 75 7.5 KC11V3190-110 110 11

Page 16

System Components Described

The drain line ﬂow control can be installed in the standard 1/4" drain line elbow, which accommodates 5/8" poly tube or 3/4" NPT drain line connections. The optional nut and poly tube insert for the 3/4" drain line elbow is designed for use with ﬂexible poly tube only. The 3/4" drain line elbow can be rotated 180 degrees so the outlet can be orientated to the nearest drain. The same retainer is used for all drain line ﬂow controls for the 3/4" ﬁtting.

Water Meter or Meter Plug

The water meter is installed on the outlet side of the control valve. The water meter uses a turbine to total gallons of treated water. The turbine rotates with the ﬂow of water and reports its rate of rotation through Hall-effect 8 circuitry to the printed circuit (PC) board. This rotation permits the PC board to record the total volume of treated water and the ﬂow rate. The small centrally located magnet is shielded from water, which reduces substantially iron-fouling problems with the turbine. The turbine is accurate to within ± 5% over a wide operating ﬂow rate range (0.25 gpm up to control valve maximums) and has a very low pressure drop. Water used for regeneration is not metered. If the control valve is set to preﬁll the regenerant, water used between the preﬁll cycle up to the start of the regeneration cycle is metered. If the control valve is in regeneration mode (e.g. a backwash cycle) and there is a water demand that water usage is not metered.

When facing the front of the control valve, the water meter is positioned on the left-hand side of the control valve. Allow sufﬁcient clearance to clean and repair the water meter with out disconnecting the plumbing or disassembling any other parts of the control valve.

A unique feature of this control valve is the ability to display actual water usage for the last 63 days. The values are initially stored as "_" because it is unknown. As days pass values are stored as “O” for no ﬂow or the actual number of -gallons. The counting of the gallons starts at the regeneration time. If no regeneration time can be set (i.e. when the valve is set for immediate regeneration) the counting, of gallons starts at 12 a.m. Day 1 is yesterday, day 2 the day before yesterday, etc. As new values are added the oldest history disappears.

Another unique feature is that the valve automatically calculates a reserve capacity when set up as a softener with “Gallons Capacity” set to “AUTO”. The reserve capacity for a given day of the week is the middle value stored for the last three non-trivial water usages (i.e. less than 20 gallons day) in seven-day intervals which is then adjusted either upward or downward depending upon the difference between today’s water usage and the estimated reserve capacity.

Bypass Valve

The bypass valve is typically used to isolate the control valve from the plumbing system’s water pressure in order to perform control valve repairs or maintenance. The W100SM bypass valve is particularly unique in the water treatment industry due to its versatility and state of the art design features. The 1" full ﬂow bypass valve incorporates four positions including a diagnostic position that allows service personal to work on a pressurized system while still providing untreated bypass water to the facility or residence. Its completely non-metallic, all plastic design allows for easy access and serviceability without the need for tools.

The bypass body and rotors are glass ﬁlled Noryl and the nuts and caps are glass ﬁlled polypropylene. All seals are self-lubricating EPDM to help prevent valve seizing after long periods of non-use. Internal o-rings can easily be replaced if service is required.

The bypass consists of two interchangeable plug valves that are operated independently by red arrow shaped handles. The handles identify the ﬂow direction of the water. The plug valves enable the bypass valve to operate in four positions.

1. Normal Operation Position: The inlet and outlet handles point

in the direction of ﬂow indicated by the engraved arrows on the control valve. Water ﬂows through the control valve during normal operation and this position also allows the control valve to isolate the media bed during the regeneration cycle. (See Figure 17)

2. Bypass Position: The inlet and outlet handles point to the

center of the bypass, the control valve is isolated from the water pressure contained in the plumbing system. Untreated water is supplied to the plumbing system. (See Figure 18)

3. Diagnostic Position: The inlet handle points in the direction of

ﬂow and the outlet handle points to the center of bypass valve, system water pressure is allowed to the control valve and the plumbing system while not allowing water to exit from the control valve to the plumbing. (See Figure 19)

4. Shut Off Position: The inlet handle points to the center of the

bypass valve and the outlet handle points in the direction of ﬂow, the water is shut off to the plumbing systems. If water is available on the outlet side of the softener it is an indication of water bypass around the system (i.e. a plumbing connection somewhere in the building bypasses the system). (See Figure 20)

Installation Fitting Assemblies

The installation ﬁttings are used to connect the optional bypass or the control to the plumbing system. There are four installation-ﬁtting assemblies available:

1. 1" NPT elbow

2. 3/4" & 1" PVC solvent weld elbow ﬁtting

3. 1" straight brass sweat ﬁtting **

4. 3/4" straight brass sweat Fitting **

Both elbow ﬁttings have a unique drill out feature to allow a 1/4" NPT connection to the inlet and/or outlet which can be used for a RO feed, test ports, pressure tap ports, etc.

The installation ﬁtting assemblies are sold in pairs and consist of two ﬁttings, two nuts, two split rings and two o-rings. The installation ﬁtting assemblies and the bypass valve are sold separately from the control valve.

* Some semiconductor materials exhibit a phenomenon in the presence of a magnetic field that is adaptable to sensing devices. When a current is passed through one pair of wires attached to a semiconductor, another pair of wires properly attached and oriented with respect to the semiconductor will develop a voltage proportional to the magnetic field present and the current in the other pair of wires. Holding the exiting current constant and moving a permanent magnet near the semiconductor produces a voltage output proportional to the movement of the magnet. Hall-effect devices provide a high-speed response, excellent temperature stability and no physical contact.

** Has not been tested for compliance with California Proposition 65 so this fitting should not be installed in California.

16 PWSR Series Softeners

Page 17

DRAWINGS AND PART NUMBERS

BRINE TANK AND SOFTENER TANK

Drawings and Part Numbers

Brine Tank and Softener Tank

7300224

30K = 7300135 45K = 7300137 60K = 7300139 90K = 7300141

7300167

7300165

Figure 17 Figure 18

Front Cover and Drive Assembly

FRONT COVER AND DRIVE ASSEMBLY

DRAWING NO. ORDER NO. DESCRIPTION QTY.

Drawing No. Order No. Description Qty.

1 7300839 W100SM Front Cover ASY 1

2 7300833 W100SM Motor 1

3 KC12F3106-01 W100SM Drive Bracket 1

4 7300834 W100SM PC Board 1

5 KC12V3110 W100SM Drive Gear 12x36 3

6 KC12V3109 W100SM Drive Gear Cover 1

Not Shown

Not Shown 7300838 W100SM Transformer 110V-12V 1

7300839 7300833

7300834

KC12V3002 W100SM Drive ASY *

7300838

W100SM Front Cover ASY 1

W100SM Motor 1

& Spring Clip

W100SM PC Board 1

W100SM Transformer 110V-12V

PWSR Series Softeners 17

Page 18

DRAWINGS AND PART NUMBERS

DRIVE CAP ASSEMBLY, DOWNFLOW PISTON, UPFLOW PISTON,

REGENERANT PISTON AND SPACER STACK ASSEMBLY

Drawings and Part Numbers

Drive Cap Assembly, Downﬂow Piston, Upﬂow Piston, Regenerant Piston and Spacer Stack Assembly

DRAWING NO. ORDER NO. DESCRIPTION QTY.

Drawing No. Order No. Description Qty.

1 7300826 W100SM Spacer Stack Assembly 1

2 KC12V3004 Drive Cap ASY 1

3 KC12V3135 O-ring 228 1

4 7300832 W100SM Piston Downflow ASY 1

5 7300836 W100SM Regenerant Piston 3

6 KC12V3180 O-ring 337 1

Note: The regenerant piston is not used in backwash only applications

Note: The regenerant piston is not used in backwash only applications.

7300826 W100SM Spacer Stack Assembly 1

7300832 W100SM Piston Downflow ASY 7300836 W100SM Regenerant Piston

1 3

Injector Cap, Injector Screen, Injector, Plug and O-ring

INJECTOR CAP, INJECTOR SCREEN, INJECTOR, PLUG AND O-RING

Drawing No. Order No. Description Qty.

1 KC12V3176 Injector Cap 1

2 KC12V3152 O-ring 135 1

3 KC12V3177 Injector Screen 1

4 KC12V3010-12 W100SM Injector ASY Z Plug 1

5 KC12V3010-10 W100SM Injector ASY D Red 1

KC12V3010-IE W100SM Injector ASY E White

Not Shown KC12V3170 O-ring 011 *

Not Shown KC12V3170 O-ring 011 * Not Shown KC12V3171 O-ring 013 *

Not Shown KC12V3171 O-ring 013 *

*The injector plug and the injector each contain one 011 (lower)

*The Injector plug and the injector each contain one 011 (lower)

and 013 (upper) o-ring.

Note: For upflow position, injector is located in the up hole and injector

Note: For upﬂow position, injector is located in the up hole and injector

plug in the down hole. For a filter that only backwashes injector plugs

plug in the down hole. For a ﬁlter that only backwashes injector plugs

are located in both holes.

18 PWSR Series Softeners

Page 19

DRAWINGS AND PART NUMBERS

Drawing No. Order No. Description Qty.

1 KC12V3195-01 W100SM Refill Port Plug ASY ** 2 KC12H4615 Elbow Locking Clip 1 3 KC12JCP-P-6 Polytube insert 3/8 1 4 KC12JCPG-6PBLK Nut 3/8 1 5 KC12H4613 Elbow Cap 3/8 1 6 KC12V3163 O-ring 019 1 7 KC12V3165-01 W100SM RFC Retainer ASY 1 8 KC12V3182 W100SM RFC 1

*Assembly includes WS1 RFC. **This part is required for backwash only systems.

Drawings and Part Numbers

Brine Line Connection

ORDER NO. DESCRIPTION

V4144-01 3/8” Quick Connect Fitting

3/8" Quick Connect

Fitting

Drain Line - 3/4"

DRAWING NO. ORDER NO. DESCRIPTION QTY.

Drawing No. Order No. Description Qty.

1 KC12H4615 Elbow Locking Clip 1

1 KC12H4615 Elbow Locking Clip 1 2 KC12PKP10T58 Polytube insert 5/8 Option

2 KC12PKP10T58 Polytube insert 5/8 Option

3 KC12V3192 W100SM Nut 3/4 Drain Elbow Option

4 KC12V3158-01 W100SM Drain Elbow 3/4 Male ASY 1

4 KC12V3158-01

5 KC12V3163 O-ring 019 1

6 KC12V3159-01 W100SM DLFC Retainer ASY 1

7 KC12V3162-022 W100SM DLFC 2.2 gpm for 3/4 *

KC12V3162-027 W100SM DLFC 2.7 gpm for 1" *

KC12V3162-027 W100SM DLFC 2.7 gpm for

W100SM Drain Elbow 3/4 Male ASY

DRAIN LINE - 3/4"

PWSR Series Softeners 19

Page 20

DRAWINGS AND PART NUMBERS

WATER METER AND METER PLUG

INSTALLATION FITTING ASSEMBLIES

Drawing No. Order No. Description Qty.

1 KC12V3151 W100SM Nut 1” QC 1 2 KC12V3003* W100SM Meter ASY 1 3 KC12V3118-01 W100SM Turbine ASY 1 4 KC12V3105 O-ring 215 1 5 KC12V3003-01 W100SM Meter Plug ASY 1

* Order number KC12V3003 includes KC12V3118-01 and KC12V3105.

Drawings and Part Numbers

Water Meter and Meter Plug

ORDER NO. DESCRIPTION

7300827 Water Meter Plug Assembly

Installation Fitting Assemblies

ORDER NO. DESCRIPTION

0002169 1" PVC Male NPT Elbow (pair)

ORDER NO. DESCRIPTION

0002170 1" Brass Sweat

ORDER NO. DESCRIPTION

KC11V3007-01 3/4" & 1" PVC Socket 90 Elbow (pair)

ORDER NO. DESCRIPTION

0002171 3/4" Brass Sweat (pair)

20 PWSR Series Softeners

Page 21

Drawings and Part Numbers

Bypass Valve Assembly

ORDER NO. DESCRIPTION

0002167 Bypass Valve Assembly

PWSR Wrench

(Order No. 7300839)

Although no tools are necessary to assemble or disassemble the valve, the PWSR Wrench (shown in various positions on the valve) may be purchased to aid in assemble or disassembly.

PWSR Series Softeners 21

Page 22

DRAWINGS AND PART NUMBERS

flow diagram...service flow diagram...rinse

Drawings and Part Numbers

Flow Diagram...Service Flow Diagram...Rinse

flow diagram...backwash flow diagram...fill

Flow Diagram...FillFlow Diagram...Backwash

Flow Diagram...Downﬂow Brine

flow diagram...downflow brine

22 PWSR Series Softeners

Page 23

Troubleshooting

System Troubleshooting

Problem Cause Correction

1. Loss of Resin A. Broken distribution tube A. Replace distribution tube.

B. Inlet/Outlet connection reversed. B. Reconnect inlet/outlet connection properly.

2. Softener fails to regenerate. A. Electrical service to unit has been interrupted.

B. Timer is defective. B. Replace timer.

C. Power failure. C. Reset time of day.

3. Hard Water A. Bypass valve is open. A. Close bypass valve.

B. No salt in brine tank. B. Add salt to brine tank and maintain

C. Injector screen plugged. C. Clean injector screen.

D. Insufficient water flowing

into brine tank.

E. Hot water tank hardness E. Repeated flushing of the hot water

F. Leak at distributor tube. F. Make sure distributor tube is not

G. Internal valve leaking. G. Replace seals and spacers and or

4. Unit used too much salt. A. Improper salt setting. A. Check salt usage and sat setting.

A. Assure permanent electrical service

(check fuse, plug, pull chain, or switch).

salt level above water level.

D. Check brine tank fill time and clean

brine line flow control if plugged

tank is required.

cracked. Check “O” Ring and tube pilot.

piston.

5. Loss of water pressure. A. Iron buildup in line to

6. Loss of mineral through drain line. A. Air in water system. A. Assure that well system has proper

7. Iron in conditioned water. A. Fouled mineral bed. A. Check backwash, brine draw,

PWSR Series Softeners 23

B. Excessive water in brine tank. B. See Problem No. 8.

water conditioner.

B. Iron buildup in water

conditioner.

C. Inlet of control plugged due

to foreign material broken loose from pipes by recent work done on plumbing system.

A. Clean line to water conditioner.

B. Clear control and add mineral cleaner

and Increase frequency regeneration.

C. Remove piston and clean control.

air eliminator control. Check for dry well condition.

and brine tank fill. Increase frequency of regeneration. Increase backwash time.

Page 24

Troubleshooting

System Troubleshooting (continued)

Problem Cause Correction

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

B. Plugged injector system. B. Clean injector and screen.

C. Foreign material in brine valve. C. Replace timer.

D. Defective controller. D. Replace controller.

E. Foreign material in brine

line flow control.

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

B. Injector is plugged. B. Clean injector.

C. Injector screen plugged. C. Clean screen.

D. Line pressure is too low. D. Increase line pressure to 20 P.S.I.

E. Internal control leak. E. Change seals, spacers, and

10. Control cycles continuously. A. Broken or shorted switch A. Determine if switch or timer

11. Drain flows continuously. A. Piston is not positioned correctly when in service.

B. Foreign material in control. B. Remove power head assembly

E. Clean brine line flow control.

piston assembly.

is faulty and replace it, or replace complete power head.

A. Check timer program and positioning

of control. Replace power head assembly if not positioning properly.

and inspect bore. Remove foreign material and check control in various regeneration positions.

C. Internal control leak C. Replace seals and piston assembly.

12. Brine tank fills during brine step. A. Clogged drain. A. Replace drain line.

B. Internal piston seal leaks. B. Replace seals in piston assembly.

See Troubleshooting Programming (next page)

24 PWSR Series Softeners

Page 25

Troubleshooting

Troubleshooting Programming

Problem Possible Cause Solution

1. Timer does not display time of day a. Transformer unplugged a. Connect power

b. No electric power at outlet b. Repair outlet or use working outlet

c. Defective transformer c. Replace transformer

d. Defective PC board d. Replace PC board

2. Timer does not display correct time of day

3. No softening display when a. Bypass valve in bypass position a. Put bypass valve in service position

4. Control valve regenerates at wrong time of day of day

5. ERROR followed by code number

Error Code 1001 -Unable to recognize start of regeneration

Error Code 1002 - Unexpected stall

Error Code 1003 - Motor ran to long,

timed out trying to reach next cycle position

Error Code 1004 - Motor ran to long,

timed out trying to reach home position

If other Error Codes display contact

the factory.

a. Switched outlet a. Use uninterrupted outlet

b. Power outage b. Reset time of day

c. Defective PC board c. Replace PC board

b. Restricted/stalled meter turbine b. Remove meter and check for

c. Defective meter c. Replace meter

d. Defective PC board d. Replace PC board

a. Power outages a. Reset control valve to correct time

b. Time of day not set correctly b. Reset to correct time of day

c. Time of regeneration incorrect c. Reset regeneration time

d. Control valve set at “on 0”

(immediate regeneration)

e. Control valve set at NORMAL on 0 e. Check control valve set-up

a. Control valve has just been serviced a. Press NEXT and REGEN for 3 seconds or

b. Foreign matter is lodged in control valve b. Check piston and spacer stack

c. High drive forces on piston c. Replace piston(s) and spacer stack

d. Control valve piston not in home position d. Press NEXT and REGEN for 3 seconds or

e. Motor not inserted fully to engage

pinion, motor wires broken or disconnected, motor failure

rotation or foreign material

d. Check control valve set-up

procedure regeneration time option

unplug power source Jack (black wire) and plug back in to reset control valve

assembly for foreign matter

assembled.

unplug power source jack (black wire) and plug back into reset control valve

e. Check motor and wiring.

Replace motor if necessary

PWSR Series Softeners 25

f. Drive gear label dirty or damaged

missing or broken gear

g. Drive bracket incorrectly aligned to back plate g. Reset drive bracket properly

h. PC board is damaged or defective h. Replace PC board

i. PC board incorrectly aligned to drive bracket i. Ensure PC board is correctly snapped on to drive

f. Replace or clean drive gear

Page 26

Troubleshooting

Troubleshooting Programming (continued)

Problem Possible Cause Solution

6. Control valve stalled in regeneration a. Motor not operating a. Replace motor

b. No electric power at outlet b. Repair outlet or use working outlet

c. Defective transformer c. Replace transformer

d. Defective PC board d. Replace PC board

e. Broken drive gear or drive cap assembly e. Replace drive gear or drive cap assembly

f. Broken piston retainer f. Replace drive cap assembly

g. Broken main or regenerant piston g. Replace main or regenerant piston

7. Control valve does not regenerate automatically when REGEN button is depressed and held

8. Control valve does not regenerate automatically but does when REGEN button is depressed

9. Time of day flashes on and off a. Power has been out more than

a. Transformer unplugged a. Connect transformer

b. No electric power at outlet b. Repair outlet or use working outlet

c. Broken drive gear or drive cap assembly c. Replace drive gear or drive cap assembly

d. Defective PC board d. Replace PC board

a. Bypass valve in bypass position a. Put control valve in service position

b. Meter connection disconnected b. Connect meter to PC board

c. Restricted/stalled meter turbine c. Remove meter and check for

d. Defective meter d. Replace meter

e. Defective PC board e. Replace PC board

f. Set-up error f. Check control valve set-up procedure

two hours, the transformer was unplugged and then plugged back into the wall outlet, the transformer plug was unplugged and then plugged back into the board or the NEXT and REGEN buttons were pressed to reset the valve.

rotation or foreign matter

a. Reset the time of day

26 PWSR Series Softeners

Page 27

NOTES

Page 28

LIMITED WARRANTY: Certain Watts products come with a limited warranty from Watts Regulator Co. Other products may have no warranty or are covered by the original manufacturer’s warranty only. For speciﬁc product warranty information, please visit www.watts.com or the published literature that comes with your product. Any remedies stated in such warranties are exclusive and are the only remedies for breach of warranty. EXCEPT FOR THE APPLICABLE PRODUCT WARRANTY, IF ANY, WATTS MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED. TO THE FULLEST EXTENT

PERMITTED BY APPLICABLE LAW, WATTS HEREBY SPECIFICALLY DISCLAIMS ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, AND IN NO EVENT SHALL WATTS BE LIABLE, IN CONTRACT, TORT, STRICT LIABILITY OR UNDER ANY OTHER LEGAL THEORY, FOR INCIDENTAL, INDIRECT, SPECIAL OR CONSEQUENTIAL DAMAGES, INCLUDING, WITHOUT LIMITATION, LOST PROFITS OR PROPERTY DAMAGE, REGARDLESS OF WHETHER IT WAS INFORMED ABOUT THE POSSIBILITY OF SUCH DAMAGES.

WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

For more information: www.watts.com/prop65

USA: Tel: (800) 224-1299 • Fax: (978) 794-1848 • Watts.com/PureWater

Canada: Tel: (905) 332-4090 • Fax: (905) 332-7068 • Watts.ca/PureWater

Latin America: Tel: (52) 81-1001-8600 • Watts.com/PureWater

Watts PWSR145, PWSR160, PWSR190, PWSR130 Installation, Operation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual