Watts Radiant Wm100sm User Manual

OPERATING MANUAL

WATER QUALITY & CONDITIONING PRODUCTS

WATER CONDITIONER

with WM100SM valve

INTRODUCTION

and establishes the service piston positions. The display

General Warnings

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.

should flash all wording, then flash the software version (e.g.

154) and then reset the valve to the service position.

All plumbing should be done in accordance with local plumb-

ing codes. The pipe size for the drain line should be a mini-

mum of 1/2". Backwash flow rates in excess of 7 gpm or

length in excess of 20' require 3/4" drain line.

Do not use Vaseline, oils, other hydrocarbon lubricants or

spray silicone anywhere. A silicon lubricant may be used on

black o-rings but is not necessary. Avoid any type of lubri-

cants, including silicone, on red or clear lip seals.

Solder joints near the drain must be done prior to connect-

ing 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.

The nuts and caps are designed to be unscrewed or tight-

ened 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

screwdriver in slots on caps and/or tap with a hammer.

When assembling the installation fittings 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 get-

ting primer and solvent cement on any part of the o-rings,

split rings, bypass valve or control valve.

Do not use pipe dope or other sealants on threads, Teflon

tape must be used on the threads of the 1" NPT elbow or the

1/4" NPT connection and on the threads for the drain line

connection. Teflon tape is not necessary on the nut connec-

tion or caps because of o-ring seals.

After completing any valve maintenance involving the drive

assembly or the drive cap assembly and pistons, press the

NEXT and REGEN buttons for 3 seconds or unplug power

source jack from the printed circuit board (black wire) and

plug back in. This resets the electronics

Plug into an electrical outlet. Note: All electrical connections

must be connected according to local codes. (Be certain the

outlet is uninterrupted.)

Install grounding strap on metal pipes.

Principles of Softening and Ion-Exchange

Softening of water by the exchange process involves the

exchange or substitution of the hardness minerals, chiefly calci-

um and magnesium, for sodium minerals. The exchange is made

possible because the minerals are ionic in nature (often called

ionized impurities) which means they have an electrical charge.

The ion exchange process is based on the fact that like charges

repel one another, and unlike charges attract.

As the calcium and magnesium contact the resin beads in their

travel through the resin tank, they displace the sodium ions from

the exchange sites. During the ion exchange process, relatively

small amounts of other strongly charged cations such as iron

and manganese are also removed along with the calcium and

magnesium.

Ion exchange is possible for two reasons: (1) All cations do not

have the same strength of positive charge and (2) the resin

prefers the stronger charged cations calcium and magnesium

than it does the weaker sodium cations.

Calcium and magnesium ions in water are actually dissolved

rock. They have been dissolved by water, the “universal solvent”,

as it trickles down through strata of rock and soil it dissolves cal-

cium and magnesium deposits. This dissolved rock eventually

finds its way into an underground aquifer and when water from

the aquifer is pumped to the surface, it contains the dissolve

hardness minerals of calcium and magnesium and is said to be

hard water.

The exchanged sodium cations pass downward through the

resin “bed” and out the softener outlet, thus, the softener delivers

“soft”water.

Eventually, all of the resin exchange sites are occupied by calci-

um and magnesium and no further exchange can take place.The

resin is said to be exhausted and must be regenerated.

An ion exchange softener exchanges the hardness minerals, cal-

cium, and magnesium, for sodium, from the softener resin.

Sodium is less objectionable because it does not build up on sur-

faces as scale deposits.

The softener resin is regenerated with a dilute brine solution of

sodium chloride (common salt) and water. During regeneration

the flow of service water from the softener is first stopped. Brine

is drawn from the brine tank mixing with a separate stream of

water. The brine solution flows through the resin, contacting the

resin beads loaded with calcium and magnesium ions. Even

though the calcium and magnesium are more strongly charged

than the sodium, the concentrated brine solution contains

literally billions of weaker charged sodium ions which have the

power to displace the smaller number of calcium and magnesium

ions. When the calcium and magnesium ions are displaced, the

positive sodium ions are attracted to the negative exchange sites

is said to be regenerated and ready for the next softening cycle.

All three minerals are positively charged ions called cations. The

exchange takes place by passing water containing hardness

minerals over a man-made ion exchange resin contained in a

suitable tank. The resin, polystyrene divinyl benzene in most-

modern softeners, consist of millions of tiny plastic beads, all of

which contain many negatively charged exchange sites to attract

the positive cations. When the resin is in the regenerated state

these negatively charged exchange sites hold positively charged

sodium cations.

INTRODUCTION

Specifications TABLE I

Minimum/Maximum Operating Pressures

Minimum/Maximum Operating Temperatures

Current Draw & Voltage

20 psi (138 kPa) -125 psi (862 kPa)

40°F (4°C) -110°F (38°C)

0.5 Amperes 110 Volts Other options available

Table 2 contains a summary of specifications for the control valve and bypass valve.

Quick Reference Specifications TABLE 2

Service flowrate (includes bypass)

Backwash flowrate (includes bypass)

Minimum/Maximum Operating Pressures

Minimum/Maximum Operating Temperatures

Current Draw & Voltage

27 gpm (102.2 lpm) @ 15 psig (103 kPa) drop

27 gpm (102.2 lpm) @ 25 psig (172 kPa) drop

20 psi (138 kPa) -125 psi (862 kPa)

40°F (4°C) - 100°F (38°C)

0.5 Amperes110 Volts Other options available

0.5 gpm (1.9 lpm)

Regenerant Refill Rate

Injectors

See Injector Graphs

Drain Line Flow Controls

See Table 11

Inlet/Outlet Fitting Options

(a) 1" NPT elbow which has a unique drill out feature to

allow a 1/4" NPT connection to the inlet and/or outlet

(b) 3/4" & 1" PVC solvent weld fitting

(d) 3/4" straight brass sweat fitting

Distributor Tube Opening

Tank Thread

1.05" Diameter (3/4" U.S. PVC Pipe Size)

2-1/2" - 8 NPSM

Control Valve Weight

PC Board Memory

4.5 lbs 2.0 kg

Nonvolatile EEPROM

(Electrically erasable programmable read only memory)

Compatible with regenerants/chemicals

Sodium chloride, potassium chloride, potassium

permanganate, sodium bisulfite, sodium hydroxide,

hydrochloric acid, chlorine and chloramines

SOFTENING

CAPACITY

LBS. SALT

PER REGEN

FLOW RATE &

PRESSURE

MINERAL TANK

BRINE TANK

MODEL

PIPE

SIZE

TANK

SIZE

RESIN

CU. FT.

SIZE

SALT

FILL

SERV DROP

BKW

GPM

MAX

MIN

MAX MIN

GPM

PSI

M3011-W100SM

M3013-W100SM

M3015-W100SM

M3017-W100SM

M3019-W100SM

M3021-W100SM

9 X 48

10 X 54

12 X 52

13 X 65

16 X 65

21 X 62

1.5

18 X 36

24 X 41

300

600

30K

45K

60K

90K

120K

210K

20K

30K

40K

60K

80K

140K

2.0

2.7

3.2

5.3

7.5

1.25/1.5

105

11.0

CONTROL VALVE FUNCTIONS

Control Valve Function and Cycles of Operation

This glass filled Noryl fully automatic control valve is designed

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 remem-

bers 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.

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

andresin 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 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 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 screwdriv-

er, 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 softener will adjust the backwash and rinse cycles automat-

ically when the salt dosage is changed . 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:

EXCHANGE CAPACITY DATA

Brine fill – Brine tank is filled to dissolve salt for next

regeneration.

20,000 grain approx. per cu. Ft.

6 lbs. salt-sodium chloride

Backwash – Flow through the resin bed is reversed.

Water flows upward expanding and agitating the resin bed.

25,000 grain approx. per cu. Ft.

8 lbs. salt-sodium chloride

Brine in – Brine is educted from the brine tank and pass-

es through the resin bed in a downward flow, thus remov-

ing calcium and magnesium that has accumulated on the

resin beads and is flush to drain.

30,000 grain approx. per cu. Ft.

15 lbs. salt-sodium chloride

Note: To convert parts per million (PPM) or milligrams per

liter (mpl) to grains divide by 17.1

Backwash – A second backwash is performed

Example: Water hardness of 250 PPM

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.

(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.

Service – Softener goes back into service and ready to

soften water.

INSTALLATION

Installation Preview

Conduct a visual check of all equipment for any damage that

Note: Softener to be located at least 10 feet away from hot

may have occurred during shipment.

waterheater to protect against hot water back-up.

Note: 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 con-

cealed damage. The manufacturer is not liable for any dam-

age during transit.

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.

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.

Note: Units are shipped with media (resin & gravel), distribu-

tions tube, and control valve installed. Double-check the valve

installation on the tank. Tighten if necessary.

Note: All piping is to meet your local and state code. AVOID

CROSS CONNECTIONS!

Unit should be positioned with the valve control facing forward.

Position brine tank approximately 6" from the softener tank on

a smooth surface.

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.

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 tub-

ing. 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.

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.

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.

Be sure inlet/outlet isolating valves are closed and bypass

valve is open.

Installation

STEP 1: Select Location

STEP 2: Install a bypass

Locate main water supply for all faucets and appliances in

home (if possible outside faucets should be separate so not

to waste soft water).

Note: 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.

Select location that is easily accessible to 110vac power. A

15-foot power cord is provided.

After a location has been determine install bypass onto the

control valve. (Figures 1 and 3 show standard bypass on

valve.) (Figures 2 and 4 show 3-way by pass plumbing.)

You will also need a drain close by for disposal of regenerat-

ed wastewater.

Note: 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.

Leave enough room between walls so you can easily add salt

when needed.

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.

Note: If installing standard bypass, move to step 3.

Make sure water softener is in a level spot. You may be

required to put the softener on a platform, such as a piece of

3/4” plywood and shimmed to become level.

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 leak-

age. 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 misalign-

ments, but should never handle the weight of the plumbing

system.

Make sure softener is behind any other water conditioning

systems installed in series, except a system that is for taste

and odor or a Reverse Osmosis system.

Select a location were water damage will be least likely to

occur if a leak should develop.

If installing the softener in an outside location make sure

to protect from the elements, such as rain, sunlight, and

contamination.

INSTALLATION

Figure 2: Plumbing with 3-way b pass.

Figure 1: Plumbing with by pass (Standard).

Figure 4: 3-way bypass plumbing.

Figure 3: Bypass (standard).

When installing sweat copper follow state and

federal codes by using a lead free solder and

flux. Use a joint compound to seal threaded pipe.

Some homes use the cold water pipes for an elec-

trical ground (metal only). Whenfinished with

plumbing, a ground wire should bre connected

to the copper pipes to complete the ground cur-

cuit. Use two clamps and #4 copper wire for this.

Figure 5:

Figure 6:

INSTALLATION

STEP 3:

Note: 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.

Move softener

into place

Make sure floor is level.

Install shims if needed.

Measure, cut, and install

pipe and fittings to the

bypass valve (dry fit only

to make sure you have a

proper fit) inlet and out-

let side. Be sure hard

water is supplied to the

inlet side. Trace pipe to

be sure.

joints should be cool and solvent cements should be set

before installing the nut, split ring, and o-ring. Avoid get-

ting 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 accor-

dance with the manufacturer’s instructions.

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 mis-

alignment of the o-ring.

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 serv-

iceability. Do not use a pipe wrench to tighten nuts on

installation fittings. Hand tighten only.

Do not use pipe dope or other sealant on threads. Teflon

tapemust 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.

1” PVC MALE NPT ELBOW

3/4” x1” PVC SOLVENT ELBOW

STEP 4: Move brine

tank next to softener

and connect brine

draw line to value.

1” BRASS SWEAT

3/4” BRASS SWEAT

With brine tank next to the soft-

ener tank connect the brine

drawline to valve body.

Control valves that use a regen-

erant, come equipped with a

3/8" refill flow control assembly.

To complete the regenerant line connections orientate the

outlet in the desired direction and push the plastic insert into

the poly tube. Push the poly tube into the nut. Do not use

pipe dope or other sealant on threads. The threads for the

compression nut do not need Teflon tape. Tighten the nut

securely to create a pressure tight connection. A pliers or

crescent wrench may be used to tighten or unscrew the nut.

The nut, gripper and retainer sleeve is a 3-piece assembly

that can come apart if removed from the elbow body. Parts

must be reassembled exactly as shown in refill flow con-

trol assembly drawing to function properly. If the nut is

completely removed from the body, slip the nut, plastic

gripper and retainer sleeve on to the tube then tighten on

to the fitting. Complete the connection by installing the

loose end of the tubing to the brine valve in the salt tank.

Figure 8: Four types of installation fittings.

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 fit-

tings are designed to accommodate minor plumbing mis-

alignments 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

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 9: Brine Draw Connection.

Figure 11: Drain Line Connection

Figure 10: Also be sure drain line has an air gap.

STEP 5: Start-up

Place the bypass valve in the “bypass” position or mode

(see figures 12-14 below.)

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.

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.

Figure 12: Operating Mode

Figure 13: Bypass Mode

Figure 14: Bypass Mode

CONTROL PROGRAMMING

FILTER

SETTINGS*

TIME

CLOCK

DIR

RESERVE CAPACITY

SOFTENER

BACKWASH

ONLY

DAY

GALLON

REGENERANT

OVERRIDE

CAPACITY

Yes

Automatically Calculated Yes Off Auto

Yes

Off

Auto

If desired enter a value less

than estimated capacity

Yes

Any Number

Yes

Automatically calculated

Yes

Any Number

Auto

If desired enter a value less

than estimated capacity

Yes

Any Number Any Number

Yes

None

Yes

Any Number

Off

* Day override AND Gallon Capacity cannot be set to "off" at the same time

DIR/TIME CLOCK

OPTIONS

FACTORY DEFAULT PROGRAMMING

To change press and hold NEXT & ▼

For DIR Softeners, there are two

options for setting the Gallons

Capacity. The Gallons Capacity

1. Configuration . . . . . . . . . . . . . . . . . . . . .Softener

2. Grain Capacity . . . . . . . . . . . . . . . . . . . . . . . . .*

3. Pounds of salt per regeneration . . . . . . . . . . . .*

4. Backwash Duration . . . . . . . . . . . . . . . . .Normal

5. Gallons Capacity . . . . . . . . . . . . . . . . . . . . .Auto

6. Brine Refill . . . . . . . . . . . . . . . . . . . . . . . . . .Pre

7. Regenerant Flow . . . . . . . . . . . . . . . . . . . . . .dn

8. Regeneration Initiation . . . . . . . . . . .Normal +0

is automatically calculated if set

to AUTO. Reserve Capacity, is

Figure 15: Key Pad

automatically estimated based on water usage if AUTO is used.

The other option is to set the Gallons Capacity to a specific

number. If a specific number is set, reserve capacity is zero,

unless the value is manually set (i.e. the manufacturer inten-

tionally sets the gallon capacity number below the calculated

capacity of the system).

Installer Setup: Press NEXT & ▲

This control valve is set up in the AUTO mode; it can also be set

to regenerate immediately or at the next regeneration time by

changing the Regeneration Time Option. There arc three choic-

es for settings:

1. Hardness . . . . . . . . . . . . . . . . . . . . . . . .“grains”

2. Calendar Override . . . . . . . . . . . . . . . . . . . . . . .

3. Time of Regeneratiuon (hour) . . . . . . . .2:00AM

4. Time of Regeneratiuon (minute) . . . . . .2:00AM

1. “NORMAL” means regeneration will occur at the pre

set regeneration time.

Diagnostics: Press ▼ & ▲

2. “On 0” means regeneration will occur when the gallons

1. Number of days since last regeneration

2. Number of gallons since last regeneration

3. Reserve capacity gallons used in last 7 days

4. Daily gallon usage for last 64 days

5. Current flow rate

capacity reaches zero.

3. “NORMAL” and “on 0” means the regeneration will occur at

the preset regeneration time unless the gallons capacity

reaches zero. If the gallon capacity reaches zero, the

regeneration will begin 10 minutes after no water usage.

6. Maximum flow rate in the last seven days

7. Total gallons since the last reset

8. Number of days since last reset

9. Number of regenerations since the last reset

The user can initiate manual regeneration.The user has the option

to request the manual regeneration at the delayed regeneration

time or to have the regeneration occur immediately:

1. Pressing and releasing the REGEN button. “Regen t o d a y ”

will flash on the display and the regeneration will occur at

the delayed regeneration time. The user can cancel the

request by pressing and releasing the REGEN button. This

method of manually initiating regeneration is not allowed

when the system is set to immediately regenerate when the

capacity reaches zero.

Valve History: Press ▼ & ▲ then ▼ & ▲

1. Software version

2. Maximum flow rate since start-up

3. Total number of gallons since start-up

4. Total number of days since start-up

5. Total Number of regenerations since start-up

6. Number of error occurences since start-up

2. Pressing and holding the REGEN button for approximately

3 seconds will immediately start the regeneration. The user

cannot cancel this request, except by resetting the control

by pressing NEXT and REGEN buttons simultaneously for

3 seconds.

* Refer to specification table 2 page 4.

CONTROL PROGRAMMING

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

return to previous step.

INSTALLER (I) Displays/Settings

STEP 1I – Press NEXT and arrow up simulta-

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.

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 5I – Next RegenerationTime (minutes):

Set the minutes of day regeneration using the

arrow buttons. This display will 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.

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 regenerations. If value set to

“off” regeneration initiation is based solely on

gallons used. If value is set as a number (allow-

able 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 to days between regeneration

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.

(1 to 28); or OFF.

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-

vide treated water when the regeneration has been completed.

General Operation

MANUAL

User (U) Displays/Settings

REGENERATION

Sometimes there is a

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 treat-

ed before the system goes through a regeneration cycle. The

user can scroll between the displays as desired.

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 regener-

ation 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 sys-

tem 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.

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.

Note: If brine tank does not contain salt, fill with salt

and wait at least two hours before regenerating.

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.

PROGRAMMING (NOTE)

SANITIZING THE SYSTEM

1. At completion of softener

SET TIME OF DAY

installation you should

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 indi-

cates the time of day should

be reset.

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.)

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.

3. Press and hold regenera

tion button to start the

regeneration process

immediately.

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 returnto previous step.

Each water softener is

handled in a manner to

keep clean and sanitary.The

materials used will not con-

taminate 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.

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.

Figure 16:

The Brine System

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.

SYSTEM COMPONENTS DESCRIBED

The drive bracket holds the PC board, the motor, the drive

gears and the drive gear cover in place.

Components:

The control valve consists of the following components

1. Drive Assembly

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 dis-

plays/settings.

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)

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 plas-

tic, 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 direc-

tion of rotation to change the direction of piston motion. The

motor is easily replaced if necessary.

DRIVE ASSEMBLY

The drive assembly consists of the following parts:

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 deter-

mines if a light pulse was returned. The PC board counts the

pulses and determines when to stop driving the motor.

•

Drive Bracket

Printed Circuit (PC) Board

Motor

Drive Gears

Drive Gear Cover

CONTENTS

TABLE 10: Injector Order Information

DRIVE CAP ASSEMBLY

Main Piston and Regenerant Piston

PART #

COLOR

TANK DIA.

KC11V3010-1D

KC11V3010-1E

KC11V3010-1F

KC11V3010-1G

KC11V3010-1J

KC11V3010-1K

RED

WHITE

BLUE

YELLOW

LT BLUE

LT GREEN

The drive gears turn the main gear of the drive cap assembly,

which moves the piston. The screw-driven, horizontally mov-

ing piston stops at specific positions to direct the flow of water

to backwash, regenerate, rinse or refill. The PC board deter-

mines 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 pis-

ton position allows for greater flexibility and requires no

switches or cams.

10"

12"

13"

16"

21"

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

lenghts. 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.

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 nonregenerating filter: or

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

is used as an up flow softener.

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.

If the control valve is used as a softener or a regenerating

filter, a regenerant 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 refill flow control assembly is installed in an easy to access

refill elbow located on top of the control valve. The refill flow con-

trol 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.

The spacer stack assembly provides the necessary flow pas-

sage for water during the different cycles.The all-plastic spac-

er 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

self-lubricating EPDM o-rings while the interior surface is

sealed against the piston using slippery self cleaning direc-

tional (oneway) 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.

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 num-

bers, which correspond to the flow rate in gallons per minute.

See Table 11.

INJECTOR

he 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.

The drain line flow control and fitting are located on top of the

control valve and replaceable without the use of special tools.

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.

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

PART #

Number on Backwash Flow Rate

Fitting

GPM

The plug (#KC113010-IZ) prevents water from traveling through

the pathway. The injector lets water pass through the pathway.

The self-priming injector increases the velocity of the water, cre-

ating 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

KC11V3162-022

KC11V3162-027

KC11V3162-03

KC11V3162-053

KC11V3162-075

2.2

2.7

3.2

5.3

7.5

KC11V3190-110

110

CONTENTS

The drain line flow control can be installed in the standard

used for a RO feed, test ports, pressure tap ports, etc.

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.

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.

Bypass Valve

The bypass valve is typically used to isolate the control valve

from the plumbing system’s water pressure in order to per-

form 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 posi-

tions including a diagnostic position that allows service per-

sonal 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.

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 treat-

ed 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 max-

imums) and has a very low pressure drop. Water used for

regeneration is not metered. If the control valve is set to pre-

fill 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.

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 nonuse. 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)

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 is unknown. As days pass values

are stored as “O” for no flow or the actual number of galons.

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 calcu-

lates 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.

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

* 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 orient-

ed with respect to the semiconductor will develop a voltage proportional to the magnet-

ic 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.

SYSTEM COMPONENTS DESCRIBED

Figure 17:

Figure 18:

Figure 19

Figure 20::

SYSTEM COMPONENTS DESCRIBED

Service Instructions

To reassemble seat the bottom of the drive bracket so the

notches are engaged at the bottom of the drive back plate.

Push the top of the drive bracket towards the two latches.The

drive bracket may have to be lifted slightly to let the threaded

piston rod pass through the hole in the drive bracket. Maintain

a slight engaging force on top of the drive bracket while

deflecting the bracket slightly to the left by pressing on the

side of the upper right corner. This helps the drive gears

mesh with the drive cap assembly. The drive bracket is

properly seated when it snaps under the latches on the drive

back plate. If resistance is felt before latching, then notches

are not fully engaged, the piston rod is not in hole, the wires

are jammed between the drive bracket and drive back plate,

or the gear is not engaging the drive cap assembly.

DRIVE ASSEMBLY

Remove the valve cover to access the drive assembly.

Disconnect the power source plug (black wire) from the PC

board prior to disconnecting the motor or water meter plugs

from the PC board. The motor plug connects to the two-pin

jack on the left-hand side of the PC board. The power source

plug connects to the four-pin jack. The four-pin jack is

between the two-pin and three-pin jacks. The water meter

plug (gray wire) connects to the three.

The PC board can be removed separately from the drive brack-

et but it is not recommended. Do not attempt to remove the dis-

play panel from the PC board. Handle the board by the edges.

To remove the PC board from the drive bracket, unplug the

power, water meter and motor plugs from the PC board. Lift the

middle latch along the top of the drive bracket while pulling out-

ward on the top of the PC board. The drive bracket has two

plastic pins that fit into the holes on the lower edge of the PC

board. Once the PC board is tilted about 45˚ from the drive

bracket it can be lifted off of these pins. To reinstall the PC

board, position the lower edge of the PC board so that the

holes in the PC board line up with the plastic pins. Push the top

of the PC board towards the valve until it snaps under the

middle latch, weave the power and water meter wires into the

holders and reconnect the motor water meter and power plugs.

To inspect drive gears, the drive gear cover needs to be

removed. The drive gear cover is held in place on the drive

bracket by three clips. The largest of the three clips is always

orientated to the bottom of the drive bracket. Before trying to

remove the drive gear cover, the drive bracket must be

removed from the drive back plate. The drive gear cover can

be removed from the drive bracket without removing the

motor or the PC board. Simultaneously, push in and down on

the large clip at the bottom and the clip on the left-hand side

of the drive bracket behind the PC board. Keep your other

fingers behind the drive gear cover so the drive gears do not

drop on the ground. Replace broken or damaged drive gears.

Do not lubricate any of the gears. Avoid getting any foreign

matter on the reflective coating because dirt or oils may inter-

fere with pulse counting.

The drive bracket must be removed to access the drive cap

assembly and pistons or the drive gear cover. It is not

necessary to remove the PC board from the drive bracket to

remove the drive bracket.To remove the drive bracket start by

removing the plugs for the power source and the water meter.

Unweave the wires from the side holders. Two tabs on the

top of the drive back plate hold the drive bracket in place.

Simultaneously lift the two tabs and gently ease the top of

the drive bracket towards your body. The lower edge of

the drive bracket has two notches that rest on the drive

back plate. Lift up and outward on the drive bracket to

disengage the notches.

The drive gear cover only fits on one way, with the large clip

orientated towards the bottom. If all three clips are outside of

the gear shroud on the drive bracket the drive gear cover slips

easily into place.

The drive bracket does not need to be removed from the drive

plate if the motor needs to be removed. To remove the motor,

disconnect the power and motor plugs from the jacks on the PC

SERVICE INSTRUCTIONS

board. Move the spring clip loop to the right and hold. Rotate the

vinegar or replace the main piston.

motor at least a 1/4 turn in either direction before gently pulling

on the wire connectors to remove the motor. Pulling directly on

the wires without rotating the motor may break the wires off the

motor.

Reattach the main piston to the drive cap assembly. Reattach

the regenerant piston (if needed) to the main piston. Do not

lubricate the piston rod, main piston or regenerant piston.

Lubricant will adversely affect the red or clear lip seals. Reinsert

the drive cap assembly and piston into the spacer stack

assembly and hand tighten the drive cap assembly. Continue to

tighten the drive cap assembly using a screwdriver as a ratchet

until the black oring on the spacer stack assembly is no longer

visible through the drain port. Excessive force can break the

notches molded into the drive back plate. Make certain that the

main drive gear still turns freely. The exact position of the piston

is not important as long as the main drive gear turns freely.

Replace the motor if necessary. Do not lubricate the motor or the

gears. When reinstalling the motor gently turn the motor while

inserting so that the gear on the motor meshes with the gears

under the drive gear cover and the small plastic bulge engages

one of the slots on the motor housing. Reconnect the motor plug

to the two-pronged jack on the lower left-hand side of the PC

board. If motor will not easily engage with drive gear when rein-

stalling, lift and slightly rotate motor before reinserting.

Replace the valve cover. After completing any valve mainte-

nance, press and hold NEXT and REGEN buttons for 3 seconds

or unplug power source jack (black wire) and plug back in. This

resets the electronics and establishes the service piston position.

The display should flash all wording, then flash the software ver-

Reattach the drive assembly to the control valve and connect all

plugs. After completing any valve maintenance, press and hold

NEXT and REGEN buttons for 3 seconds or unplug power

source jack (black wire) and plug back in. This resets the elec-

tronics and establishes the service piston position. The display

should flash all wording, then flash the software version (e.g.

154) and then reset the valve to the service position.

sion (e.g. 154) and then reset the valve to the service position

DRIVE CAP ASSEMBLY, MAIN PISTON

AND REGENERANT PISTON

SPACER STACK ASSEMBLY

To access the spacer stack assembly remove the drive

assembly, drive cap assembly and piston. The spacer stack

assembly can be removed easily without tools by using thumb

and forefinger. Inspect the black o-rings and red or clear lip seals

for wear or damage. Replace the entire stack if necessary. The

spacer stack assembly has been 100% tested at the factory to

insure proper orientation of one-way seals. Do not disassemble

the stack.

The drive assembly must be removed to access the drive cap

assembly. The drive cap assembly must be removed to access

the piston(s). The drive cap assembly is threaded into the con-

trol valve body and seals with an o-ring.To remove the drive cap

assembly, use the special plastic wrench or insert a 1/4" to 1" flat

bladed screwdriver into one of the slots around the top 2" of the

drive cap assembly so it engages the notches molded into the

drive back plate around the top 2" of the piston cavity. See

Figure 5. The notches are visible through the holes. Lever the

screwdriver so the drive cap assembly turns counter clockwise.

Once loosened unscrew the drive cap assembly by hand and

pull straight out.

The spacer stack assembly may be chemically cleaned (dilute

sodium bisulfite or vinegar) or wiped with a soft cloth.

The spacer stack assembly can be pushed in to the control valve

body bore by hand. Since the spacer stack assembly can be

compressed it is easier to use a blunt object (5/8" to 1-1/8" in

diameter) to push the center of the assembly into the control

valve body. The assembly is property seated when at least four

threads are exposed (approximately 5/8"). Do not force the

spacer stack assembly in. The control valve body bore interior

can be lubricated with silicone to allow for easy insertion of the

entire stack. Do not use silicone or any other type of lubricant on

the red or clear lip seals or the piston.

The drive cap assembly contains the drive cap, the main drive

Missing Photo

Figure 21: To

Reattach the drive cap assembly, and piston(s) and the drive

assembly.

remove drive cap

After completing any valve maintenance, press and hold NEXT

and REGEN buttons for 3 seconds or unplug power source jack

(black wire) and plug back in. This resets the electronics and

establishes the service piston position. The display should flash

all wording, then flash the software version (e.g. 154) and then

reset the valve to the service position.

gear, drive cap spline, piston rod and various other parts that

should not be dissembled in the field. The only replaceable part

on the drive cap assembly is the o-ring. Attached to the drive cap

assembly is the main piston (downflow or upflow) and if a regen-

erant is used, a regenerant piston.

The regenerant piston (the small diameter one behind the main

piston) is removed from the main piston by unsnapping it from

its latch. Chemically clean in dilute sodium bisulfite or vinegar or

replace the regenerant piston if needed. To remove the main-

downflow or upflow piston fully extend the piston rod and then

unsnap the main piston from its latch by pressing on the side

with the number. Chemically clean in dilute sodium bisulfite or

INJECTOR CAP, SCREEN, INJECTOR

PLUG AND INJECTOR

Unscrew the injector cap and lift off. Loosen cap with special

plastic wrench or pliers if necessary. Attached to the injector cap

is a screen. Remove the screen and clean if fouled.

CONTENTS

The plug and/or injector can be pried out with a small

water meter.

screwdriver. The plug can be wiped clean. If the plug leaks

replace the entire plug. The injector consists of a throat and a

nozzle. Chemically clean the injector with vinegar or sodium

bisulfite. The holes can be blown out with air. Both pieces have

small diameter holes that control the flow rates of water to insure

that the proper concentration of regenerant is used. Sharp

objects, which can score the plastic, should not be used to clean

the injector. Scoring the injector or increasing the diameter of the

hole could change the operating parameters of the injector.

Two holes are labeled DN and UP. Check for compliance with

one of the following:

The water meter wire does not need to be removed from the PC

board if the water meter is only being inspected and cleaned.

To remove the water meter assembly, unscrew the meter cap on

the left side of the control valve. Pliers may be used to unscrew

the nut if necessary.

With the nut removed, a slot at the top of the water meter is

visible. Twist a flat blade screwdriver in the slot between the

control valve body and the meter. When the meter is part way

out it is easy to remove the water meter from the housing.

Once the water meter is removed from the control valve body,

use your fingers to gently pull forward on the turbine to remove

it from the shaft.

a. For downflow systems, the appropriate size injector is

located in the “DN” hole, a plug is in the “UP” hole and

the piston is a combination of the downflow main piston and

the regenerant piston;

b. For upflow systems, the appropriate size injector is located

in the “UP” hole, a plug is in the “DN” hole and the piston

is a combination of the upflow main piston and the regenerant

piston; or

c. For backwash only systems, a plug is in the “DN” hole and

in the “UP” hole, and the piston only has a downflow

main piston (the regenerant piston must be removed) and a

plug is in the refill flow control position.

Do not use a wire brush to clean. Wipe with a clean cloth or

chemically clean in dilute sodium bisulfite or vinegar. The turbine

can be immersed in the chemical. Do not immerse electronics. If

the turbine is scored or damaged or the bearings on the turbine

are worn replace the turbine.

Do not lubricate the turbine shaft. The turbine shaft bearings are

pre-lubricated. Do not use Vaseline, oils or other unacceptable

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

black o-ring.

Snap the turbine on the shaft and reinsert the water meter into

the side slot. Hand tighten the nut. Do not use a pipe wrench to

tighten nut.

Push the plug(s) and/or injectors firmly in place, replace the

screen and hand tighten the injector cap.

BYPASS VALVE

REFILL FLOW CONTROL ASSEMBLY

OR REFILL PORT PLUG

The working parts of the bypass valve are the rotor assemblies

that are contained under the bypass valve caps. Before working

on the rotors, make sure the system is depressurized. Turn the

red arrow shaped handles towards the center of the bypass valve

and back to the arrow direction several times to ensure rotor is

turning freely.

To clean or replace the refill flow control, pull out the elbow-

locking clip and then pull straight up on the elbow. Replace the

elbow-locking clip in the slot so that it is not misplaced. Twist to

remove the white flow control retainer. The flow control can be

removed by prying upward through the side slots of the retainer

with a small blade flat screwdriver.

The nuts and caps are designed to be unscrewed or tightened

by hand. If necessary a pair of 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 screwdriver in slots on caps and/or tap with a

hammer. To access the rotor, unscrew the cap and lift the cap,

rotor and handle out as one unit. Twisting the unit as you pull it

out will help to remove it more easily.There are three o-rings: one

under the rotor cap, one on the rotor stem and the rotor seal.

Replace worn o-rings. Clean rotor. Reinstall rotor.

Chemically clean the flow control or the white flow control

retainer using dilute sodium bisulfite or vinegar. Do not use a

wire brush. If necessary, replace the flow control o-ring on

the flow control retainer, or the o-ring on the elbow.

Reseat the flow control so the rounded end is visible in the flow

control. Reseat the white flow control retainer by pushing the

retainer into the elbow until the o-ring seats. Remove locking clip,

push down on elbow to reseat and insert locking clip.

When reinstalling the red arrow handles be sure that:

1. O-rings on both rotors face to the right when being viewed

from the front of the control valve when the handle pointers

are lined up with the control valve body arrows; or

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

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

the white retainer.

2. Arrows point toward each other in the bypass position.

WATER METER OR METER PLUG

Since the handles can be pulled off, they could be accidentally

reinstalled 180° from their correct orientation. To install the red

arrow handles correctly, keep the handles pointed in the same

direction as the arrows engraved on the control valve body while

tightening the bypass valve caps.

The water meter assembly is connected to the PC board by a

wire. If the entire water meter assembly is to be replaced, remove

the control valve cover and remove the power source and water

meter plugs from the PC board. Unlatch the drive assembly and

lean it forward. Unthread the water meter wire from the side of the

drive assembly and through the drive back plate. To reinstall,

rethread the water meter wire through the drive back plate and

the side of the drive assembly. Reattach the drive assembly

and the water meter and power plugs.

After completing, any valve maintenance, press and hold NEXT

and REGEN buttons for 3 seconds or unplug power source jack

(black wire) and plug back in. This resets the electronics and

establishes the service piston position. The display should flash

all wording then flash the software version (e.g. 154) and then

reset the valve to the service position.

If no water meter wire is visible, then a plug is installed not a

DRAWING AND PART NUMBERS

BRINE TANK AND SOFTENER TANK

Figure 17

Figure 18

FRONT COVER AND DRIVE ASSEMBLY

Drawing No.

Order No.

Description

Qty.

KC11V317501 W100SM Front Cover ASY 1

KC12V3107-0

W100SM Motor

W100SM Drive Bracket

& Spring Clip

KC12F3106-01

KC12V3108

KC12V3110

KC12V3109

KC12V3002

KC11V3186

W100SM PC Board

W100SM Drive Gear 12x36

W100SM Drive Gear Cover

W100SM Drive ASY

Not Shown

W100SM Transformer 110V-12V

*Drawing number parts 2 through 6 may be purchased as a complete assembly,

part V3002.

CONTENTS

DRIVE CAP ASSEMBLY, DOWNFLOW PISTON, UPFLOW PISTON,

REGENERANT PISTON AND SPACER STACK ASSEMBLY

Drawing No.

Order No.

Description

Qty.

KC12V3005 W100SM Spacer Stack Assembly

KC12V3004 Drive Cap ASY

KC12V3135 O-ring 228

KC12V3011 W100SM Piston Downflow ASY

KC12V3174 W100SM Regenerant Piston

KC12V3180 O-ring 337

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

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

Drawing No.

Order No.

KC12V3176

KC12V3152

KC12V3177

KC12V3010-12

KC12V3010-10

KC12V3010-IE

KC12V3170

KC12V3171

Description

Injector Cap

O-ring 135

Injector Screen

W100SM Injector ASY Z Plug

W100SM Injector ASY D Red

W100SM Injector ASY E White

O-ring 011

Qty.

Not Shown

O-ring 013

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

and one 013 (upper) o-ring.

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

are located in both holes.

DRAWING AND PART NUMBERS

Drawing No.

Order No.

KC12V3195-01

KC12H4615

Description

Qty.

W100SM Refill Port Plug ASY

Elbow Locking Clip

Polytube insert 3/8

Nut 3/8

KC12JCP-P-6

KC12JCPG-6PBLK

KC12H4613

Elbow Cap 3/8

KC12V3163

O-ring 019

KC12V3165-01

KC12V3182

W100SM RFC Retainer ASY

W100SM RFC

*Assembly includes WS1 RFC.

**This part is required for backwash only systems.

DRAIN LINE - 3/4"

Drawing No.

Order No.

KC12H4615

Description

Elbow Locking Clip

Qty.

KC12PKP10T58 Polytube insert 5/8

KC12V3192

Option

W100SM Nut 3/4 Drain Elbow

Option

KC12V3158-01 W100SM Drain Elbow 3/4 Male ASY

KC12V3163

O-ring 019

KC12V3159-01 W100SM DLFC Retainer ASY

KC12V3162-022 W100SM DLFC 2.2 gpm for 3/4

KC12V3162-027 W100SM DLFC 2.7 gpm for

DRAWING AND PART NUMBERS

WATER METER AND METER PLUG

Drawing No.

Order No.

KC12V3151

KC12V3003

Description

W100SM Nut 1” QC

W100SM Meter ASY

Qty.

KC12V3118-01 W100SM Turbine ASY

KC12V3105 O-ring 215

KC12V3003-01 W100SM Meter Plug ASY

* Order number KC12V3003 includes KC12V3118-01 and KC12V3105.

INSTALLATION FITTING ASSEMBLIES

Drawing No. Order No.

Description

Qty.

Drawing No.

Order No.

Description

Qty.

KC12V3151 W100SM Nut 1” Quick Connect

KC12V3150 W100SM Split Ring

KC12V3151 W100SM Nut 1” Quick Connect

KC12V3150 W100SM Split Ring

KC12V3105 O-ring 215

KC12V3149 W100SM Fitting 1” PVC Male NPT Elbow

KC12V3189 W100SM Fitting 3/4” & 1” PVC Solvent 90

Drawing No. Order No.

Description

Qty.

Drawing No.

Order No.

Description

Qty.

KC12V3151 W100SM Nut 1” Quick Connect

KC12V3150 W100SM Split Ring

KC12V3151 W100SM Nut 1” Quick Connect

KC12V3150 W100SM Split Ring

KC12V3105 O-ring 215

KC12V3188 W100SM Fitting 1” Brass Sweat

KC12V3188-01 W100SM Fitting 3/4” Brass Sweat

DRAWING AND PART NUMBERS

BYPASS VALVE

Drawing No.

Order No.

Description

Qty.

KC12V3151 W100SM Nut 1” Quick Connect

KC12V3150 W100SM Split Ring

KC12V3105 O-ring 215

KC12V3145 W100SM Bypass 1” Rotor

KC12V3146 W100SM Bypass Cap

KC12V3147 W100SM Bypass Handle

KC12V3148 W100SM Bypass Rotor Seal Retainer

KC12V3152 O-ring 135

KC12V3155 O-ring 112

KC12V3156 O-ring 214

(Not Shown) Order No.KC12 V3191-01. Description: WS100sm Bypass Vertical Adapter Assembly.

Order No.

KC12V3151

KC12V3150

KC12V3105

KC11V3191-01

Description

Qty.

W100SM Nut 1” Quick Connect

W100SM Split Ring

O-ring 215

W100SM Bypass Vertical Adaper

Assembly

W100SM WRENCH

(Order No. KC12V3193)

Although no tools are necessary to assemble or

disassemble the valve, the WS100SM wrench

(shown in various positions on the valve) may be

purchased to aid in assemble or disassembly.

DRAWING AND PART NUMBERS

flow diagram...service

flow diagram...rinse

flow diagram...backwash

flow diagram...fill

flow diagram...downflow brine

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.

A. Assure permanent electrical service

(check fuse, plug, pull chain or switch.

B. Timer is defective.

C. Power failure.

B. Replace timer.

C. Reset time of day.

A. Close bypass valve.

3. Hard Water

A. Bypass valve is open.

B. No salt in brine tank.

B. Add salt to brine tank and maintain

salt level abovewater level.

C. Injector screen plugged.

C. Clean injector screen.

D. Insufficient water flowing

into brine tank.

D. Check brine tank fill time and clean

brine line flow control if plugged.

E. Hot water tank hardness,

F. Leak at distributor tube.

E. Repeated flushing of the hot water

tank is required.

F. Make sure distributor tube is not

cracked. Check “O” Ring and tube

pilot.

G. Internal valve leaking.

G. Replace seals and spacers and or

piston.

4. Unit used too much salt.

5. Loss of water pressure.

A. Improper salt setting.

A. Check salt usage and sat setting.

B. See Problem No. 8.

B. Excessive water in brine tank.

A. Iron buildup in line to

water conditioner.

A. Clean line to water conditioner.

B. Iron buildup in water

conditioner.

B. Clear control and add mineral cleaner and

increase regeneration frequency.

C. Inlet of control plugged due

to foreign material broken loose

from pipes by recent work done

on plumbing system.

C. Remove piston and clean control.

6. Loss of mineral through drain line.

7. Iron in conditioned water.

A. Air in water system.

A. Assure that well system has proper

air eliminator control.

Check for dry well condition.

A. Fouled mineral bed.

A. Check backwash, brine draw,

and brine tank fill. Increase

frequency of regeneration.

Increase backwash time.

TROUBLESHOOTING

System Troubleshooting (continued)

PROBLEM

CAUSE

CORRECTION

8. Excessive water in brine tank.

A. Plugged drain line flow control.

B. Plugged injector system.

C. Foreign material in brine valve.

D. Defectie controller.

A. Clean flow control.

B. Clean injector and screen.

C. Replace timer.

D. Replace controller.

E. Foreign material in brine

E. Clean brine line flow control.

line flow control.

9. Softener fails to draw brine.

A. Drain line flow control is plugged.

B. Injector is plugged.

A. Clean drain line flow control

B. Clean injector.

C. Injector screen plugged.

D. Line pressure is too low.

E. Internal control leak.

C. Clean screen.

D. Increase line pressure to 20 P.S.I.

E. Change seals, spacers, and

piston assembly.

10. Control cycles continuously.

11. Drain flows continuously.

A. Broken or shorted switch,

A. Determine if switch or timer

is faulty and replace it, or replace

complete power head.

A. Piston is not positioned

correctly when in service.

A. Check timer program and positioning

of control. Replace power head

assembly if not positioning properly.

B. Foreign material in control.

B. Remove power head assembly

and inspect bore. Remove foreign

material and check control in

various regeneration positions.

C. Internal control leak

A. Clogged drain.

C. Replace seals and piston assembly.

A. Replace drain line.

12. Brine tank fills during brine step.

B. Internal piston seal leaks.

B. Replace seals in piston assembly.

See

Troubleshooting

Programming

(next page)

TROUBLESHOOTING

Troubleshooting Programming

PROBLEM

POSSIBLE CAUSE

SOLUTION

1. Timer does not display time of day

a. Transformer unplugged

b. No electric power at outlet

c. Defective transformer

d. Defective PC board

a. Switched outlet

a. Connect power

b. Repair outlet or use working outlet.

c. Replace transformer

d. Replace PC board

a. Use uninterrupted outlet

b. Reset time of day

2. Timer does not display

correct time of day

b. Power outage

c. Defective PC board

c. Replace PC board

3. No softening display when

water is flowing

a. Bypass valve in bypass position

c. Restricted/stalled meter turbine

a. Put bypass valve in service position

c. Remove meter and check for

rotation or foreign material

d. Defective meter

d. Replace meter

e. Defective PC board

a. Power outages

e. Replace PC board

4. Control valve regenerates at

wrong time of day of day

a. Reset control valve to correct time

b. Reset to correct time of day

c. Reset regeneration time

b. Time of day not set correctly

c. Time of regeneration incorrect

d. Control valve set at “on 0”

(immediate regeneration)

d. Check control valve set-up

procedure regeneration time option

e. Control valve set at NORMAL on 0

e. Check control valve set-up

procedure regeneration time option

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

3 seconds or unplug power source

Jack (black wire) and plug back in

to reset control valve

5. ERROR followed by code number

b. Foreign matter is lodged in control

b. Check piston and spacer stack

valve.

assembly for foreign matter.

Error Code 1001 -Unable to recognize

start of regeneration

c. High drive forces on piston

c. Replace piston(s) and spacer

stack assembled.

Error Code 1002 - Unexpected stall

d. Control valve piston not in home

position

d. Press NEXT and REGEN for

3 seconds or unplug power source

jack (black wire) and plug back in

to reset control valve

Error Code 1003 - Motor ran to long,

timed out trying to reach next cycle

position

e. Motor not inserted fully to engage

pinion, motor wires broken or

disconnected, motor failure

e. Check motor and wiring.

Replace motor if necessary

Error Code 1004 - Motor ran to long,

timed out trying to reach home

position

f. Drive gear label dirty or damaged

missing or broken gear

f. Replace or clean drive gear

g. Reseat drive bracket properly

h. Replace PC board

If other Error Codes display contact

the factory.

g. Drive bracket incorrectly aligned

to back plate

h. PC board is damaged or defective

i. PC board incorrectly aligned to

drive bracket

i. Ensure PC board is correctly

snapped on to drive

CONTENTS

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

c. Defective transformer

d. Defective PC board

b. Repair outlet or use working outlet

c. Replace transformer

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. Replace main or regenerant piston

a. Connect transformer

g. Broken main or regenerant piston

a. Transformer unplugged

7. Control valve does not regenerate

when REGEN button is pressed.

b. No electric power at outlet

b. Repair outlet or use working outlet

c. Broken drive gear or drive cap

c. Replace drive gear or drive cap assembly

d. Defective PC board

d. Replace PC board

a. By-pass valve in bypass position

b. Meter connection disconnected

c. Restricted/stalled meter turbine

a. Put control valve in service position

b. Connect meter to PC board

8. Control valve does not regenerate

automatically but does when

REGEN button is depressed

c. Remove meter and check for

rotation or foreign matter

d. Defective meter

e. Defective PC board

f. Set-up error

d. Replace meter

e. Replace PC board

f. Check control valve set-up

procedure

9. Time of day flashes on and off

a. Power has been out more than

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.

a. Reset the time of day

DISTRIBUTED BY:

Manufactured by Watts Water Quality & Conditioning Products, 13700 Highway 90 W., San Antonio, TX, USA

FORM: 0500-200 P/N: XOSW100SM

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