Watts PWSTA 90-120K User Manual
Installation, Operation
Model 9000/9100/9500
Service Manual
and Maintenance Manual
Series PWSTA
Water Softener Systems
IOM-WQ-PWSTA
PURE WATER
Table of Contents
Job Specifications Sheet .................................2
General and Commercial Installation Checklist .................3
General and Commercial Installation Checklist.................. 5
Regeneration Cycle Program Setting Procedure ................8
Time Brine Refill and Meter Setting Procedure ..................9
9100 Electro Mechanical Timer Assembly .................... 11
9100 Power Head ......................................13
9100 Control Valve Assembly .............................15
9000/9100/9500 Second Tank Assembly .................... 17
9100 Meter Assembly ...................................18
9100 Bypass Valve .....................................20
2310 Safety Brine Valve..................................21
Water Conditioner Flow Diagrams ..........................22
Troubleshooting .......................................26
Mechanical Timer Valve Wiring.............................28
9100 Control Dimensions ................................ 29
Meter Flow Data .......................................30
Injector Flow Data ......................................31
Note: Do not use with water that is microbiologically unsafe or
of unknown quality without adequate disinfection before or after
the system.
Job Specifications Sheet
Job Number ________________________________________________
Model Number ______________________________________________
Water Test ___________________________________________ ______
Capacity Of Unit ________________________ Max. _____________ Per Regeneration
Brine Tank Size _____________________________________________
Salt Setting Per Regeneration _________________________________
Control Valve Specifications
1. Type of Timer
A. 82 minute available regeneration time, 1/15 RPM
B. 164 minute available regeneration time, 1/30 RPM
2. Type of Meter
Mechanical Valves (gallon settings)
Meter Standard Range
3/4" 125–2,125
1" 310–5,270
3. Timer Gallon Setting _________________________________ gal.
4. Regeneration Program Setting
A. Backwash ______________________________________ min.
B. Brine and Slow Rinse _____________________________ min.
C. Rapid Rinse ____________________________________ min.
D. Brine Tank Refill _________________________________ min.
5. Drain Line Flow Control _____________________________ gpm
6. Brine Refill Rate ____________________________________ gpm
7. Injector Size ____________________________________________
2
Model 9000/9100/9500
General and Commercial Installation Checklist
Water Pressure
A minimum of 25 lbs of 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.
Caution:
• Donotexceedwaterpressureof125psi.
!
• Donotexceed110°Fwatertemperature.
• Donotsubjectunittofreezingconditions.
!
Caution:
• Donotusewithwaterthatismicrobiologically
unsafeorofunknownquality.
• Testthewaterperiodicallytoverifythatthe
systemisperformingsatisfactorily.
3
Equipment Configuration
9100
tank two adapter
adapter clips
tank two
yokes
main control valve
Figure 1:9100
tank one
water meter
outlet
inlet
bypass valve
4
General and Commercial
Installation Checklist
1. Place the softener tanks where you want to install the unit.
NOTE:Besurethetanksarelevelandonarmbase.
2. During cold weather it is recommended that the installer warm
the valve to room temperature before operating.
3. Perform all plumbing according to local plumbing codes.
— Use a 1/2" minimum pipe size for the drain.
— Use a 3/4" drain line for backwash flow rates that exceed 7
gpm or length that exceeds 20' (6 m).
4. Both tanks must be the same height and diameter and filled with
equal amounts of media.*
5. The distributor tube must be flush with the top of each tank. Cut
if necessary. Use only non-aerosol silicone lubricant.*
6. Lubricate the distributor O-ring seal and tank O-ring seal. Place
the main control valve on one tank and the tank adapter on the
second tank.*
NOTE:Ifrequired,soldercoppertubingfortankintercon-
nection before assembling on the main control valve and
tankadapter.Maintainaminimumof1"distancebetween
tanksonnalassembly.
7. Solder joints near the drain must be done before connecting
the Drain Line Flow Control fitting (DLFC). Leave at least 6" (152
mm) between the DLFC and solder joints when soldering pipes
that are connected on the DLFC. Failure to do this could cause
interior damage to DLFC.
®
8. Use only Teflon
9. Be sure the floor under the salt storage tank is clean, level, and
strong enough to support the system..
10. Place approximately 1" (25 mm) of water above the grid plate. If
a grid is not utilized, fill to the top of the air check in the salt tank.
Do not add salt to the brine tank at this time.
11. Place the system in Bypass.
— 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.
12. Place the bypass In Service position and let water flow into the
mineral tank.
Electrical
13. Make all electrical connections according to codes. Plug the
valve into an approved power source. Do not insert meter cable
into the meter yet.
14. Tank one has control valve and tank two has adapter. See Figure
1, page 4.
15. Look on the right side of the control valve, it has indicators
showing which position the control valve is in during Regeneration and which tank is In Service.
— Figure 3, page 6 shows the valve In Service position with tank
one supplying conditioned water and tank two on standby.
NOTE: Make sure the meter cable is not inserted in the me-
terdome.Swingthetimerouttoexposetheprogramwheel.
Toswingtimerout,grabontothelowerrightcorneroftimer
faceandpulloutward.SeeFigure5,page7.
*Tanks12"indiameterandsmallerarefactoryloadedwithme-
dia.Checkingmediaamounts,distributortubelength,lubricatingthedistributorpilotO-rings,andlubricatingthetankseal
O-ringsonthesesizedsystemsisnotnecessary.
tape on the drain fitting.
Teflon® is a registered trademark of E.I. Dupont de Nemours & Company.
5
Model 9000/9100/9500
rapid rinse
brine rinse
backwash
tank one
Figure 3
brine fill
stand-by
tank two
: Control Valve Position Indicators
Figure 4
16. Cycle timer into backwash position. Turn manual knob so that
the micro switch rides on the first set of pins.
— In this position the tank's switch (lower piston) and the control
valve moves to the backwash position (upper piston).
— Wait until the positioning of upper and lower pistons stops
before advancing the timer further. If advanced too fast the
control will not home into the In Service position (it will not
advance to any other position). To correct this, rotate the
manual knob back to In Service and start again into backwash.
NOTE:Oncevalvepositionsitselfintothebackwashcycle,
thehomingcircuitlocksin.Thenunplugthesystem.Allow
thesystemtoremaininthebackwashpositionuntilairno
longerowsfromthedrainline.
17. Plug the unit back in with all the air backwashed, slowly cycle
the timer to the brine position; rapid rinse; and brine tank refill.
Wait for the control drive motor to position itself in each cycle
and stop, before advancing on to the next position.
: Timer
18. Once back in the In Service position, cycle the control valve
again into the backwash position. The tanks switch again, and
air head backwashes out of the other tank. Once the system
reaches the backwash position unplug it again. Allow the system
to remain in the backwash position until all air is purged from the
system. When all air is gone no air will come out of the drain line.
Then plug the unit back in.
Proceed to regeneration cycle program setting procedure. Cycle
the control back to the In Service position. Leave the timer in
theopenposition.DONOTinsertmetercableyet.
6
Model 9000/9100/9500
pin
storage
NOTE:
Two motors are available:
1/15 RPM has 82 minute Regeneration Time.
1/30 RPM has 164 minute Regeneration Time. See
Figure 5
: Program Wheel
Figure 5
.
7
Model 9000/9100/9500
Regeneration Cycle Program Setting Procedure
Setting the Regeneration Cycle Program
The Regeneration cycle program on the water conditioner is preset at the factory. However, portions of the cycle or
program time may be lengthened or shortened for local conditions or system design.
1. Expose cycle program wheel by grasping timer in lower right hand corner and pulling. This releases snap
retainer and swings timer to the left
NOTE:
2. Remove the program wheel by grasping program wheel and squeezing protruding lugs towards center. Lift
program wheel off timer.
— Switch arms may require movement to facilitate removal.
3. Return timer to closed position by engaging snap retainer in back plate.
— Make certain all electrical wires locate above snap retainer post.
Meter cable
must
be removed from meter dome before opening timer.
Changing Length of the Backwash Time
The program wheel in
group of pins starting at zero determines the length of time the unit backwashes.
Example:
— The number of pins multiplied by two equals minutes of backwash.
If there are six pins in this section, the time of backwash is 12 minutes (2 minutes per pin). To
change the length of backwash time, add or remove pins as required.
Figure 5
is In Service position. Looking at the numbered side of the program wheel, the
Changing Length of Brine and Rinse Time
The group of holes between the last pin in the backwash section and the second group of pins determines the
length of time that a unit will brine and rinse (2 minutes per hole).
To change the length of brine and rinse time, add or remove pins in the rapid rinse group of pins to increase or
decrease the number of holes in the brine and rinse section.
— The number of holes multiplied by two equals minutes of brine and rinse.
Changing Length Of Rapid Rinse
The second group of pins on the program wheel determines the length of time the water conditioner rapid rinses (2
minutes per pin). To change the length of rapid rinse time, add or remove pins at the higher numbered end of this
section as required.
— The number of pins multiplied by two equals minutes of rapid rinse.
NOTE:
Program wheels with 0–82 minute cycle times, use one minute per pin or hole to set Regeneration
times. The layout of pins and holes on the program wheel follow the same procedure as on this page.
Changing Length of Brine Tank Refill Time
The second group of holes on the program wheel determines the length of time the water conditioner refills the
brine tank (2 minutes per hole).
To change the length of refill time, move the two pins at the end of the second group of holes as required.
The Regeneration cycle is complete when the two pin set at end of the brine tank refill section trips the outer
micro-switch. The program wheel, however, continues to rotate until the inner micro-switch drops into the notch on
the program wheel.
8
Model 9000/9100/9500
Time Brine Refill and Meter Setting Procedure
Programming
1. The control valve is set at the factory for backwash; brine and slow rinse; rapid rinse and brine tank fill times.
Change any of these times by repositioning the pins and holes or adding more pins.
NOTE:
2. The control valve has a separate brine tank fill cycle.
— Calculate the desired salt setting using the brine line flow control rate of refill (in gpm) multiplied by the
Example:
NOTE:
3. Setting the gallon wheel.
Knowing the amount of resin in each tank and the salt setting per Regeneration, calculate the gallons
available, using the following capacities as a guide:
Two speed timer motors are available
1/15 RPM has 82 minute Regeneration Time and each pin or hole equals one minute.
1/30 RPM has 164 minute Regeneration Time and each pin or hole equals two minutes.
timer setting. Then, using one gallon of fresh water dissolving approximately 3 lbs salt, calculate the refill
time.
A desired 30 lbs salt setting:
The unit has a 1.0 gpm refill rate so a 10 gallon fill is required.
Set the timer refill section at 10 minutes.
There must always be two pins at the end of a refill time to stop the fill cycle.
With the Regeneration times set, place timer back to its original position, making sure the lower right
hand corner snaps back into the backplate and the meter cable slides through the backplate and does
not bind.
10 gallons x 3 lbs/gals = 30 lbs salt
10 minutes x 1.0 gpm = 10 gallon fill
(capacity per ft
compensated hardness of H
NOTE:
Example:
DO NOT SET THIS FIGURE - GO TO STEP 4
— Because the control valve regenerates with soft water from the other tank, subtract the water used for
Based on tank size:
More resin increases capacity, less resin decreases capacity.
More salt increases capacity, less salt decreases capacity.
tank diameter = 16"
compensated hardness = 35 grains per gal (tested sample)
3
resin (based on flow rate)
ft
lbs of salt = 8
capacity per ft
(24,000 x 4 ft
Regeneration. Take each Regeneration cycle and calculate the water used.
3
3
of resin per tank)
35 grains
3
x ft3 of resin per tank)
O
2
=4
= 24,000
= 2740 gallons available before regeneration
= gallons available
9
Model 9000/9100/9500
Example:
Unit is set for a 16" diameter tank with 4 ft3 of resin and salted at 8 lbs. per ft3, 7 gpm backwash,
#3 injector, 1.0 gpm brine refill, and 60 psi and timer set for
rinse, 10 min. rapid rinse, 10 min. brine tank fill.
10 min. backwash, 60 min. brine and
Backwash
Brine and Rinse
Rapid Rinse
Brine Tank Fill
With the 2740 gallons available calculated in Step 3, subtract the Regeneration water used from the
total water available.
2740 gallons available - 210 gallons used = 2530 gallons
4. Set meter wheel at approximately 2530 gallons. Lift the inner dial of the meter program wheel so that you can
rotate it freely. Position the white dot opposite the 2530 gallon setting.
NOTE:
5. Insert meter cable into meter.
6. Check bypass.
There is a slight delay between the time the meter zeros out and the cycle starts. Units using the:
1/15 RPM motor, 82 minute Regeneration Time has a 9
1/30 RPM motor, 180 minute Regeneration Time has an 18
This delay period is not critical on residential equipment. However, take this factor into consideration
for commercial applications by subtracting continuous flows for 9 minutes or 18 minutes from water
available.
10 minutes x 7.0 gpm = 70.0 gallons
60 minutes x 1.0 gpm = 60.0 gallons
10 minutes x 7.0 gpm = 70.0 gallons
10 minutes x 1.0 gpm = 10.0 gallons
Total Regeneration Water = 210.0 gallons
(in Regeneration, Step 4)
minute delay
minute delay
.
7. Plug in unit.
10
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