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waterpurification.pentair.com FLECK 2900S SERVICE MANUAL
2 • FLECK 2900S Service Manual TABLE OF CONTENTS JOB SPECIFICATION SHEET 2 INSTALLATION 3 START-UP INSTRUCTIONS 3
3200 TIMER SETTING PROCEDURE 4
3210 & 3220 TIMER SETTING PROCEDURE 4 3200, 3210, 3220, 3230 REGENERATION CYCLE SETTING PROCEDURE 5
3200 TIME CLOCK TIMER ASSEMBLY 6
3210 METER DELAYED TIMER ASSEMBLY 8
3220 METER IMMEDIATE TIMER ASSEMBLY 10
3230 REMOTE START TIMER ASSEMBLY 12
UPPER ENVIRONMENTAL POWERHEAD ASSEMBLY 14 LOWER ENVIRONMENTAL POWERHEAD ASSEMBLY 16 CONTROL VALVE ASSEMBLY 18 CONTROL VALVE SIDE MOUNT ADAPTER 21
1600 SERIES BRINE SYSTEM 22
1650 BRINE SYSTEM ASSEMBLY 24
1700 BRINE SYSTEM ASSEMBLY 26
1710 BRINE SYSTEM ASSEMBLY 28
2” BRASS METER ASSEMBLY 29 2” PLASTIC METER ASSEMBLY 30
1600 SERVICE VALVE OPERATOR (NEW STYLE) 31
2300 SAFETY BRINE VALVE 32
2310 SAFETY BRINE VALVE 33
2350 SAFETY BRINE VALVE 34
GENERAL SERVICE HINTS FOR METER CONTROL 35 TROUBLESHOOTING 36 WATER CONDITIONER FLOW DIAGRAMS - DOWNFLOW 37 WATER CONDITIONER FLOW DIAGRAMS - UPFLOW 38 FLOW DATA & INJECTOR DRAW RATES - DOWNFLOW 39 ENVIRONMENTAL BACKPLATE DIMENSIONS 40 SYSTEM #4 41 SYSTEM #5 INTERLOCK 41 SYSTEM #6 & #7 42 SYSTEM #4 WIRING 43 SYSTEM #5 WIRING 45 SYSTEM #6 WIRING 46 SYSTEM #7 WIRING 47 1600/1700 SYSTEM NOZZLE & THROAT CHART 49 SERVICE ASSEMBLIES 50 JOB SPECIFICATION SHEET 1. Type of Timer: A. 7 Day or 12 Day B. Meter Initiated 2. Downflow: Upflow Upflow Variable 3. Meter Size: A. 3/4-inch Std Range (125 - 2,100 gallon setting) B. 3/4-inch Ext Range (625 - 10,625 gallon setting) C. 1-inch Std Range (310 - 5,270 gallon setting) D. 1-inch Ext Range (1,150 - 26,350 gallon setting) E. 1-1/2 inch Std Range (625 - 10,625 gallon setting) F. 1-1/2 inch Ext Range (3,125 - 53,125 gallon setting) G. 2-inch Std Range (1,250 - 21,250 gallon setting) H. 2-inch Ext Range (6,250 - 106,250 gallon setting) I. 3-inch Std Range (3,750 - 63,750 gallon setting) J. 3-inch Ext Range (18,750 - 318,750 gallon setting) 4. System Type: A. System #4: 1 Tank, 1 Meter, Immediate, or Delayed Regenera- tion B. System #4: Time Clock C. System #4: Twin Tank D. System #5: 2-5 Tanks, Interlock Mechanical 2-4 Tanks, Interlock Electronic Meter per unit for Mechanical and Electronic E. System #6: 2-5 Tanks, 1 Meter, Series Regeneration, Mechanical 2-4 Tanks, 1 Meter, Series Regeneration, Electronic F. System #7: 2-5 Tanks, 1 Meter, Alternating Regeneration,Mechanical
2 Tanks only, 1 Meter, Alternating
Regeneration, Electronic G. System #9: Electronic Only, 2-4 Tanks, Meter per Valve, Alternating H. System #14: Electronic Only, 2-4 Tanks, Meter per Valve. Brings units on and offline based on flow. 5. Timer Program Settings: 6. Drain Line Flow Control: gpm 7. Brine Line Flow Controller: gpm 8. Injector Size#: 9. Piston Type: A. Hard Water Bypass B. No Hard Water Bypass CALIFORNIA PROPOSITION 65 WARNING WARNING: This product contains chemicals known to the State of California to cause cancer or birth defects or other reproductive harm.
FLECK 2900S Service Manual • 3 INSTALLATION Water Pressure A minimum of 20 pounds (1.4 bar) of water pressure is required for regeneration valve to operate effectively. Electrical Facilities An uninterrupted alternating current (A/C) supply is required. NOTE: Other voltages are available. Please make sure your voltage supply is compatible with your unit before installation. Existing Plumbing Condition of existing plumbing should be free from lime and iron buildup. Piping that is built up heavily with lime and/ or iron should be replaced. If piping is clogged with iron, a separate iron filter unit should be installed ahead of the water softener. Location Of Softener And Drain The softener should be located close to a drain to prevent air breaks and back flow. Bypass Valves Always provide for the installation of a bypass valve if unit is not equipped with one. CAUTION Water pressure is not to exceed 125 psi (8.6 bar), water temperature is not to exceed 110°F (43°C), and the unit cannot be subjected to freezing conditions. Installation Instructions 1. Place the softener tank where you want to install the unit making sure the unit is level and on a firm base. 2. During cold weather, the installer should warm the valve to room temperature before operating. 3. All plumbing should be done in accordance with local plumbing codes. The pipe size for residential drain line should be a minimum of 1/2-inch (13 mm). Backwash flow rates in excess of 7 gpm (26.5 Lpm) or length in excess of 20 feet (6 m) require 3/4-inch (19 mm) drain line. Commercial drain lines should be the same size as the drain line flow control. 4. Refer to the dimensional drawing for cutting height of the distributor tube. If there is no dimensional drawing, cut the distributor tube flush with the top of the tank. 5. Lubricate the distributor o-ring seal and tank o-ring seal. Place the main control valve on tank. NOTE: Only use silicone lubricant. IMPORTANT: For valves equipped with electromechanical timers and stainless steel meters, refer to the Meter Dome and Union Orientation section. 7. Solder joints near the drain must be done prior to connecting the Drain Line Flow Control fitting (DLFC). Leave at least 6 inches (15 cm) between the DLFC and solder joints when soldering pipes that are connected on the DLFC. Failure to do this could cause interior damage to the DLFC. 8. Plumber tape is the only sealant to be used on the drain fitting. The drain from twin tank units may be run through a common line. 9. Make sure that the floor is clean beneath the salt storage tank and that it is level. 10. Place approximately 1 inch (25 mm) of water above the grid plate. If a grid is not utilized, fill to the top of the air check (Figure 1) in the salt tank. Do not add salt to the brine tank at this time. 11. On units with a by-pass, place in by-pass position. Turn on the main water supply. Open a cold soft water tap nearby and let run a few minutes or until the system is free from foreign material (usually solder) that may have resulted from the installation. Once clean, close the water tap. 12. Slowly place the by-pass in service position and let water flow into the mineral tank. When water flow stops, slowly open a cold water tap nearby and let run until the air is purged from the unit. 13. Plug unit into an electrical outlet. NOTE: All electrical connections must be connected according to local codes. Be certain the outlet is uninterrupted.
60002 Rev E
Figure 1 Residential Air Check Valve
4 • FLECK 2900S Service Manual START-UP INSTRUCTIONS The water softener should be installed with the inlet, outlet, and drain connections made in accordance with the manufacturer’s recommendations, and to meet applicable plumbing codes. 1. Turn the manual regeneraton knob slowly in a clockwise direction until the program micro switch lifts on top of the first set of pins. Allow the drive motor to move the piston to the first regeneration step and stop. Each time the program switch position changes, the valve will advance to the next regeneration step. Always allow the motor to stop before moving to the next set of pins or spaces. NOTE: For electronic valves, please refer to the manual regeneration part of the timer operation section. If the valve came with a separate electronic timer service manual, refer to the timer operation section of the electronic timer service manual. 2. Position the valve to backwash. Ensure the drain line flow remains steady for 10 minutes or until the water runs clear (see above). 3. Position the valve to the brine / slow rinse position. Ensure the unit is drawing water from the brine tank (this step may need to be repeated). 4. Position the valve to the rapid rinse position. Check the drain line flow, and run for 5 minutes or until the water runs clear. 5. Position the valve to the start of the brine tank fill cycle. Ensure water goes into the brine tank at the desired rate. The brine valve drive cam will hold the valve in this position to fill the brine tank for the first regeneration. 6. Replace control box cover. 7. Put salt in the brine tank. NOTE: Do not use granulated or rock salt. Meter Dome and Union Orientation Control valves outfitted with an electromechanical timer and stainless steel water meter include a special male x female threaded stainless steel union to insure proper installation and operation of the water meter. The location of this union in relation to the control valve and water meter is critical for proper operation. DO NOT omit or substitute this special union; it positions the meter dome at the correct distance from the control valve and allows re-positioning the water meter dome for proper operation. 1. Apply a suitable thread sealant to the male threads of the union and meter body. 2. Thread the union into the OUTLET port of the control valve, then thread the meter into the union. See illustrations below. 3. Rotate the water meter body so the meter dome is at the 12 o’clock position. Loosen the nut on the union to facilitate this if required. Once in position, tighten the union nut. 4. Connect the meter cable to the open port in the center of the meter dome. 5. Continue with the installation of the control valve. Position Meter Dome at 12 o’clock orientation Meter Union Valve Body Powerhead Assembly INSTALLATION CONTINUED
FLECK 2900S Service Manual • 5
3200 TIMER SETTING PROCEDURE
How To Set Days On Which Water Conditioner Is To Regenerate (Figure 2) Rotate the skipper wheel until the number “1” is at the red pointer. Set the days that regeneration is to occur by sliding tabs on the skipper wheel outward to expose trip fingers. Each tab is one day. Finger at red pointer is tonight. Moving clockwise from the red pointer, extend or retract fingers to obtain the desired regeneration schedule. How To Set The Time Of Day 1. Press and hold the red button in to disengage the drive gear. 2. Turn the large gear until the actual time of day is at the time of day pointer. 3. Release the red button to again engage the drive gear. How To Manually Regenerate Your Water Conditioner At Any Time 1. Turn the manual regeneration knob clockwise. 2. This slight movement of the manual regeneration knob engages the program wheel and starts the regeneration program. 3. The black center knob will make one revolution in the following approximately three hours and stop in the position shown in the drawing. 4. Even though it takes three hours for this center knob to complete one revolution, the regeneration cycle of your unit might be set for only one half of this time. 5. In any event, conditioned water may be drawn after rinse water stops flowing from the water conditioner drain line. How to Adjust Regeneration Time 1. Disconnect the power source. 2. Locate the three screws behind the manual regeneration knob by pushing the red button in and rotating the 24 hour dial until each screw appears in the cut out portion of the manual regeneration knob. 3. Loosen each screw slightly to release the pressure on the time plate from the 24-hour gear. 4. Locate the regeneration time pointer on the inside of the 24 hour dial in the cut out. 5. Turn the time plate so the desired regeneration time aligns next to the raised arrow. 6. Push the red button in and rotate the 24 hour dial. Tighten each of the three screws. 7. Push the red button and locate the pointer one more time to ensure the desired regeneration time is correct. 8. Reset the time of day and restore power to the unit. 61502-3200 Rev A Figure 2 3210 & 3220 TIMER SETTING PROCEDURE Typical Programming Procedure Calculate the gallon capacity of the system, subtract the necessary reserve requirement and set the gallons available opposite the small white dot on the program wheel gear (Figure 3). NOTE: Drawing shows 8,750 gallon setting. The capacity (gallons) arrow (15) shows zero gallons remaining. The unit will regenerate tonight at the set regeneration time. How To Set The Time Of Day 1. Press and hold the red button in to disengage the drive gear. 2. Turn the large gear until the actual time of day is opposite the time of day pointer. 3. Release the red button to again engage the drive gear. How To Manually Regenerate Your Water Conditioner At Any Time 1. Turn the manual regeneration knob clockwise. 2. This slight movement of the manual regeneration knob engages the program wheel and starts the regeneration program.
6 • FLECK 2900S Service Manual 3. The black center knob will make one revolution in the following approximately three hours and stop in the position shown in the drawing. 4. Even though it takes three hours for this center knob to complete one revolution, the regeneration cycle of your unit might be set for only one half of this time. 5. In any event, conditioned water may be drawn after rinse water stops flowing from the water conditioner drain line. Immediate Regeneration Timers These timers do not have a 24 hour gear. Setting the gallons on the program wheel and manual regeneration procedure are the same as previous instructions. The timer will regenerate as soon as the capacity gallons reaches zero. NOTE: The program wheel to the left may be different than the program wheel on the product. NOTE: To set meter capacity rotate manual knob one - 360° revolution to set gallonage. 61502-3200 Rev A Figure 3 3200, 3210, 3220, 3230 REGENERATION CYCLE SETTING PROCEDURE How To Set The Regeneration Cycle Program The regeneration cycle program on your water conditioner has been factory preset, however, portions of the cycle or program may be lengthened or shortened in time to suit local conditions.
3200 Series Timers (Figure 4)
- To expose cycle program wheel, grasp timer in upper left-hand corner and pull, releasing snap retainer and swinging timer to the right. 2. To change the regeneration cycle program, the program wheel must be removed. Grasp program wheel and squeeze protruding lugs toward center, lift program wheel off timer. Switch arms may require movement to facilitate removal. 3. Return timer to closed position engaging snap retainer in back plate. Make certain all electrical wires locate above snap retainer post. Timer Setting Procedure How To Change The Length Of The Backwash Time The program wheel as shown in the drawing is in the service position. As you look at the numbered side of the program wheel, the group of pins starting at zero determines the length of time your unit will backwash. For example, if there are six pins in this section, the time of backwash will be 12 min. (2 min. per pin). To change the length of backwash time, add or remove pins as required. The number of pins times two equals the backwash time in minutes. How To Change The Length Of Brine And Rinse Time 1. The group of holes between the last pin in the backwash section and the second group of pins determines the length of time that your unit will brine and rinse (2 min. per hole). 2. To change the length of brine and rinse time, move the rapid rinse group of pins to give more or fewer holes in the brine and rinse section. Number of holes times two equals brine and rinse time in minutes. How To Change The Length Of Rapid Rinse 1. The second group of pins on the program wheel determines the length of time that your water conditioner will rapid rinse (2 min. per pin). 2. To change the length of rapid rinse time, add or remove pins at the higher numbered end of this section as required. The number of pins times two equals the rapid rinse time in minutes. How To Change The Length Of Brine Tank Refill Time 1. The second group of holes in the program wheel determines the length of time that your water conditioner will refill the brine tank (2 min. per hole). 2. To change the length of refill time, move the two pins at the end of the second group of holes as required. 3. The regeneration cycle is complete when the outer microswitch is tripped by the two pin set at end of the brine tank refill section. 4. The program wheel, however, will continue to rotate until the inner micro switch drops into the notch on the program wheel. 61502-3210 Rev A Figure 4 3210 & 3220 TIMER SETTING PROCEDURE CONTINUED
FLECK 2900S Service Manual • 7 [ THIS PAGE LEFT INTENTIONALLY BLANK ]
8 • FLECK 2900S Service Manual
615023200 Rev A
3200 TIME CLOCK TIMER ASSEMBLY
FLECK 2900S Service Manual • 9 Item No. QTY Part No. Description 4-40 x 1-1/8 1/30 RPM 1/30 RPM 1/30 RPM 1/30 RPM 6-32 x .156 Timer Black Timer Assembly Auxiliary, Optional Filter 2 Min Per Pin Softener, 2 Min Per Pin *Call your distributor for Part Number Item No. QTY Part No. Description
10 • FLECK 2900S Service Manual
3210 METER DELAYED TIMER ASSEMBLY
FLECK 2900S Service Manual • 11 Item No. QTY Part No. Description Black 6-20 x 1/2 RPM 1/30 RPM 1/30 RPM 1/30 RPM 6-32 x .156 Drive 4-40 x 1 1/8 inches Timer Delayed Timer Assembly Label 0-21,000 gal Label 0-100,000 gal Range 375 m3 Auxiliary, Optional Filter 2 Min Per Pin Softener, 2 Min Per Pin *Call your distributor for Part Number Item No. QTY Part No. Description
12 • FLECK 2900S Service Manual
3220 METER IMMEDIATE TIMER
FLECK 2900S Service Manual • 13 Item No. QTY Part No. Description System #5 1/30 RPM 1/30 RPM 1/30 RPM 1/30 RPM 4-40 x 1-1/8 Item No. QTY Part No. Description inches Stainless Steel, Timer Immediate Timer Assy Label 0-21,000 gal Label 0-100,000 gal Range 375 m3 Auxiliary, Optional Softener Immediate 2 Min Per Pin Filter Immediate 2 Min Per Pin *Call your distributor for Part Number
14 • FLECK 2900S Service Manual
3230 REMOTE START TIMER ASSEMBLY
FLECK 2900S Service Manual • 15 Item No. QTY Part No. Description 4-40 x 1-1/8 6-20 x 1/2 1/30 RPM 1/30 RPM 1/30 RPM 1/30 RPM 1/30 RPM 1/30 RPM 3200 Stainless Steel, Timer inches Auxiliary, Optional Softener Immediate 2 Min Per Pin Filter Immediate 2 Min Per Pin *Call your distributor for Part Number Item No. QTY Part No. Description
16 • FLECK 2900S Service Manual UPPER ENVIRONMENTAL POWERHEAD ASSEMBLY 61501-2900 Rev G
FLECK 2900S Service Manual • 17 Item No. QTY Part No. Description Assembly Hz 50/60 Hz Hz Blue, 2900 Upflow Upflow, Variable #2073 X 1 MS Steel Zinc TYPE 1 Steel Zinc RR Stack, After Brine Fill Black 0307 0304 X 3/8 Type “B” RC 44-47 inch 3200ET #2733 Environmental, Black w/ Clear Window Yellow Commercial, 809- Gray Gray 1/2 Type 25 Steel Zinc Environmental Valves Heyco #30-1 Cord Black US, Round, 120V,Sys 5,6,7&2900/3150/3900 Round, 240V 50/60 Hz, Downflow Less Lower Drive Brine Cam Switch, Item 9 & 10 50/60 Hz, Downflow Less Lower Drive Brine Cam Switch, Item 9 & 10 120V, Downflow 120V, System 7, Downflow Not Shown: 15.25 inch long, 2 inch Brass Meter 17.5 inch long 2 inch Stainless Steel Meter *Upflow Only **Call your distributor for Part Number Item No. QTY Part No. Description UPPER ENVIRONMENTAL POWERHEAD ASSEMBLY CONTINUED
18 • FLECK 2900S Service Manual LOWER ENVIRONMENTAL POWERHEAD ASSEMBLY 61501-2900 Rev G 19 9 14 108
FLECK 2900S Service Manual • 19 Item No. QTY Part No. Description 18-8-SS (only used for shipping) SP FAM 50-60 Hz, Fam 2 50/60 Hz, SP Lower 8-32 x 5/16 Black Rod SYS4, ENV
4 Remote Start
Sys 5 & 6, Duplex, Enviromental
5 Multiple, Enviromental
Syst 6 Multiple, Lead, Enviromental 6, Multiple, Middle/Lag, Enviromental Syst #7, Duplex, Lead, Enviromental Duplex, Lag, Enviromental #7, Multiple, Enviromental ID Enviromental, 2900 Lower Drive 24/60, System #4 System #4 System #4 System #5 and #6, Lead/Lag System #7, Lead System #7, Lag Assembly Not Shown: Adding Second Switch Adding Third Switch *Call your distributor for Part Number Item No. QTY Part No. Description LOWER ENVIRONMENTAL POWERHEAD ASSEMBLY CONTINUED
20 • FLECK 2900S Service Manual 1819 1311 12 234 Upflow Downflow 3536 CONTROL VALVE ASSEMBLY Item No. QTY Part No. Description NPT U.S. Tap Machined, w/Soft Water Adapter NPT, NP, U.S. Tap, Top Coll MACHD, NPT, U.S. Tap, Aux Tap, Top Coll NPT, NP, U.S. Tap, Aux Tap, Top Coll U.S. Tap, SVO, Top Coll MACHD, NPT, U.S. Tap, Aux Tap, SVO, Top Coll MACHD, NPT, U.S. Tap, Soft ADAPT, Top Coll NPT, NP, U.S. Tap, Soft ADAPT, Top Coll Tap, Aux Tap, SFT ADPT, Top Coll NPT, U.S. Tap, SVO, Soft ADAPT, Top Coll NPT, U.S. Tap, SVO, SFT ADPT, AX TP Top BSP, Metric Tap, Top Coll BSP, NP, Metric Tap, Top Coll Item No. QTY Part No. Description 61500-2900 Rev F
FLECK 2900S Service Manual • 21 Brass 2900/2930, NHWBP Brass, HW White Black Rod 2900S Steel 10 - 24 x 3/8 Downflow, Upper Downflow, Upper, Hot Water Upflow, Upper Upflow, Upper, Hot Water Upper Upper, Hot Water Upper, VITON, Chemical Resistent Lower Lower, Hot Water Lower, Silicone Lower Lower, Hot Water NHWBP, Lower NHWBP, Lower, Hot Water Not Shown: F, NPT, No Button F, NPT, 0.6 gpm F, NPT, 0.8 gpm F, NPT, 1.0 gpm F, NPT, 1.2 gpm F, NPT, 1.3 gpm F, NPT, 1.5 gpm F, NPT, 1.7 gpm F, NPT, 2.0 gpm F, NPT, 2.4 gpm F, NPT, 3.0 gpm F, NPT, 3.5 gpm F, NPT, 4.0 gpm Item No. QTY Part No. Description CONTROL VALVE ASSEMBLY CONTINUED Item No. QTY Part No. Description
22 • FLECK 2900S Service Manual CONTROL VALVE ASSEMBLY CONTINUED F, NPT, 4.5 gpm F, NPT, 5.0 gpm F, NPT, 6.0 gpm F, NPT, 7.0 gpm F, NPT, No Button F, NPT, 8.0 gpm F, NPT, 9.0 gpm F, NPT, 10.0 gpm F, NPT, 12.0 gpm F, NPT, 15.0 gpm F, NPT, 20.0 gpm F, NPT, 25.0 gpm NPT, No Button NPT, 0.06 gpm NPT, 0.08 gpm NPT, 1.0 gpm NPT, 1.2 gpm NPT, 1.3 gpm NPT, 1.5 gpm NPTF, No Button NPTF, 1.7 gpm NPTF, 2.0 gpm NPTF, 2.4 gpm NPTF, 3.0 gpm NPTF, 3.5 gpm NPTF, 4.0 gpm NPTF, 4.5 gpm NPTF, 5.0 gpm NPTF, 6.0 gpm NPTF, 7.0 gpm F, NPT, Brass, No Button F, NPT, 8.0 gpm F, NPT, 9.0 gpm F, NPT, 10 gpm F, NPT, 12 gpm F, NPT, 15 gpm F, NPT, 20 gpm F, NPT, 25 gpm 30 gpm 35 gpm *Upflow Only Item No. QTY Part No. Description
FLECK 2900S Service Manual • 23 CONTROL VALVE SIDE MOUNT ADAPTER Item No. QTY Part No. Description Flange Rotating N-SERS Cap 18-8 2850/2900/2930 2850/2900/2930 BSP/MTC 2850/2900/2930 BSP/NP 2850/2900/2930
61415 Rev B
24 • FLECK 2900S Service Manual
1600 SERIES BRINE SYSTEM
Item No. QTY Part No. Description x 3/8 Tube 2850/2900s w/Quad Ring Seat 18-8 Stainless Steel
60029 Rev C
Item No. QTY Part No. Description
FLECK 2900S Service Manual • 25 Brown Grey Grey Grey Grey Grey Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel
1600 SERIES BRINE SYSTEM CONTINUED
Upflow, #0, w/Reg Cap, 20 psi Upflow, #1, w/Reg Cap, 20 psi Upflow, #2, w/Reg Cap, 20 psi Upflow, #3, w/Reg Cap, 20 psi Upflow, #4, w/Reg Cap, 20 psi *Upflow Only Item No. QTY Part No. Description
26 • FLECK 2900S Service Manual
1650 BRINE SYSTEM ASSEMBLY
60011 Rev D
Item No. QTY Part No. Description Brass 1/4 NPT x 3/8T 1650 Plastic (Includes items 25 and 26) Plastic 18-8 Stainless Steel Grey Grey Grey Item No. QTY Part No. Description
FLECK 2900S Service Manual • 27 Grey Grey Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel Brown Grey Grey Grey Grey Grey Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel .50 GPM .25 GPM
1.0 GPM
Upflow, #0, w/Reg Cap, 20 psi Upflow, #1, w/Reg Cap, 20 psi Upflow, #2, w/Reg Cap, 20 psi Upflow, #3, w/Reg Cap, 20 psi Upflow, #4, w/Reg Cap, 20 psi *Upflow Only
1650 BRINE SYSTEM ASSEMBLY CONTINUED
Item No. QTY Part No. Description Item No. QTY Part No. Description
28 • FLECK 2900S Service Manual
1700 BRINE SYSTEM ASSEMBLY
60034 Rev D
FLECK 2900S Service Manual • 29 Item No. QTY Part No. Description 1/2T x 3/8 NPT Item No. QTY Part No. Description x 2-3/4-inch 18-8 Stainless Steel Complete Complete Complete Complete Not Shown: 3/4 x 3/4 Slip *Upflow Only NOTE: Item number 26 (11893) is used on injector sizes 2 through 5C. Part number 10228 is used on injector sizes 6C.
1700 BRINE SYSTEM ASSEMBLY CONTINUED
30 • FLECK 2900S Service Manual
60604 Rev F
Item No. QTY Part No. Description Top 2900 Bottom 8-32 X 5/16 Plastic Tube 1/2T X 3/8NPT
1710 BRINE SYSTEM ASSEMBLY
1.0 gpm 1.2 gpm 1.5 gpm 2.0 gpm 2.4 gpm 3.0 gpm 4.0 gpm 5.0 gpm Not Shown Item No. QTY Part No. Description
FLECK 2900S Service Manual • 31 2-INCH BRASS METER ASSEMBLY Item No. QTY Part No. Description Metric Meter Meter Plastic 3/4-inch to 2-inch, Ext Plastic, Pdl 10-24 x 1/2 18-8 Stainless Steel SS, Metric Brass Inline, NPT, STD, Brass, Paddlewheel Inline, BSP, STD, Brass, Paddlewheel NPT, EXT, Brass Paddlewheel Inline, BSP, EXT, Brass, Paddlewheel Not Shown inch Item No. QTY Part No. Description
32 • FLECK 2900S Service Manual 2-INCH STAINLESS STEEL METER ASSEMBLY Item No. QTY Part No. Description Standard Range Extended Range Stainless Steel, NPT Standard Range Stainless Steel, NPT Extended Range Stainless Steel, BSP Standard Range Stainless Steel, BSP Extended Range (Optional on models with electronic controls) Optional on models with electronic controls) Not Shown (optional) 2 inch to 1-1/2 inch (optional) Item No. QTY Part No. Description IMPORTANT: For valves equipped with electromechanical timers and stainless steel meters, refer to the Meter Dome and Union Orientation section.
FLECK 2900S Service Manual • 33 7B8 60621_REVB 2-INCH PLASTIC METER ASSEMBLY Item No. QTY Part No. Description w/Impeller Shaft Seat Steel Meter Meter 5/8 18-8 Stainless Steel Meter Plastic, NPT, Machined, Flow Straightener Plastic, BSP, Machined, Flow Straightener Plastic, NPT Plastic, BSP
60621 Rev D
NPT, STD, Plastic, w/Plastic Nipples, Paddlewheel NPT, STD, Plastic, w/Brass Nipples, Paddlewheel BSP, STD, Plastic, Plastic Nipples, Paddlewheel BSP, STD, Plastic, Brass Nipples, Paddlewheel NPT, EXT, Plastic, w/Plastic Nipples, Paddlewheel NPT, EXT, Plastic, w/Brass Nipples, Paddlewheel BSP, EXT, Plastic, Plastic Nipples, Paddlewheel BSP, EXT, Plastic, Brass Nipples, Paddlewheel Item No. QTY Part No. Description
34 • FLECK 2900S Service Manual
1600 SERVICE VALVE OPERATOR (NEW
STYLE)
60150 Rev A
Item No. QTY Part No. Description Celcon 1/4 NPT x 3/8 Tube After RR Stack After Brine Fill Coated Assembly, 1600, New Style, Item No’s 1-11 Item No. QTY Part No. Description
FLECK 2900S Service Manual • 35 Item No. QTY Part No. Description Less Elbow NPT x 3/8 Tube Hydro Long Long Long Long Long
60027 Rev D
2300 SAFETY BRINE VALVE
Item No. QTY Part No. Description
36 • FLECK 2900S Service Manual
2310 SAFETY BRINE VALVE
Item No. QTY Part No. Description 2310 .75 Rod Rod Rod Rod Rod Hydro Long Long Long Long Long Long Long Long Long Item No. QTY Part No. Description
FLECK 2900S Service Manual • 37
2350 SAFETY BRINE VALVE
Item No. QTY Part No. Description Water Less Fittings Commercial, Hot Water Less Fittings Not Shown 2350
38 • FLECK 2900S Service Manual GENERAL SERVICE HINTS FOR METER CONTROL Problem: Softener delivers hard water Reason: Reserve capacity has been exceeded. Correction: Check salt dosage requirements and reset program wheel to provide additional reserve. Reason: Program wheel is not rotating with meter output. Correction: Pull cable out of meter cover and rotate manually. Program wheel must move without binding and clutch must give positive clicks when program wheel strikes regeneration stop. If it does not, replace timer. Reason: Meter is not measuring flow. Correction: Check meter with meter checker.
FLECK 2900S Service Manual • 39 Problem Cause Correction Water conditioner fails to regenerate. Electrical service to unit has been interrupted Assure permanent electrical service (check fuse, plug, pull chain, or switch) Timer is defective. Replace timer. Power failure. Reset time of day. Hard water. By-pass valve is open. Close by-pass valve. No salt is in brine tank. Add salt to brine tank and maintain salt level above water level. Injector screen plugged. Clean injector screen. Insufficient water flowing into brine tank. Check brine tank fill time and clean brine line flow control if plugged. Hot water tank hardness. Repeated flushings of the hot water tank is required. Leak at distributor tube. Make sure distributor tube is not cracked. Check o-ring and tube pilot. Internal valve leak. Replace seals and spacers and/or piston. Unit used too much salt. Improper salt setting. Check salt usage and salt setting. Excessive water in brine tank. See "Excessive water in brine tank". Loss of water pressure. Iron buildup in line to water conditioner. Clean line to water conditioner. Iron buildup in water conditioner. Clean control and add mineral cleaner to mineral bed. Increase frequency of regeneration. Inlet of control plugged due to foreign material broken loose from pipes by recent work done on plumbing system. Remove piston and clean control. Loss of mineral through drain line. Air in water system. Assure that well system has proper air eliminator control. Check for dry well condition. Improperly sized drain line flow control. Check for proper drain rate. Iron in conditioned water. Fouled mineral bed. Check backwash, brine draw, and brine tank fill. Increase frequency of regeneration. Increase backwash time. Excessive water in brine tank. Plugged drain line flow control. Clean flow control. Plugged injector system. Clean injector and screen. Timer not cycling. Replace timer. Foreign material in brine valve. Replace brine valve seat and clean valve. Foreign material in brine line flow control. Clean brine line flow control. Softener fails to draw brine. Drain line flow control is plugged. Clean drain line flow control. Injector is plugged. Clean injector Injector screen plugged. Clean screen. Line pressure is too low. Increase line pressure to 20 psi Internal control leak Change seals, spacers, and piston assembly. Service adapter did not cycle. Check drive motor and switches. Control cycles continuously. Misadjusted, broken, or shorted switch. Determine if switch or timer is faulty and replace it, or replace complete power head. Drain flows continuously. Valve is not programming correctly. Check timer program and positioning of control. Replace power head assembly if not positioning properly. Foreign material in control. Remove power head assembly and inspect bore. Remove foreign material and check control in various regeneration positions. Internal control leak. Replace seals and piston assembly. TROUBLESHOOTING
40 • FLECK 2900S Service Manual WATER CONDITIONER FLOW DIAGRAMS - DOWNFLOW
1 Service Position
2 Backwash Position
3 Brine Position
4 Slow Rinse Position
5 Rapid Rinse
6 Brine Tank Refill Position
FLECK 2900S Service Manual • 41 WATER CONDITIONER FLOW DIAGRAMS - UPFLOW
2 Brine Position
3 Slow Rinse Position
4 Back Wash Position
6 Brine Tank Fill Position
42 • FLECK 2900S Service Manual FLOW DATA & INJECTOR DRAW RATES - DOWNFLOW TR22089-2900s Valve 1600 Series Injector Draw Rates 0.40 0.60 0.80 1.00 1.20 1.40 1.60 1.80 2.00 2.20 2.40 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 Inlet Pressure - psi m p g - e t a R w o l F # 2 # 3 # 4 1600 series injectors Slow Rinse Rates - gpm pressure 20 0.68 0.78 1.08 30 0.77 0.97 1.28 40 0.86 1.09 1.50 60 1.00 1.27 1.63 90 1.19 1.52 1.93 125 1.38 1.76 2.20 all injectors used the steel cap and an air disperser TR22089-2900s Valve 1600 Series Injector Slow Rinse Rates 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0 3.2 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 Inlet Pressure - psi m p g - e t a R w o l F # 2 # 3 # 4 TR22089-2900s Valve 1600 Series Injector Total Flow to Drain in Draw 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5 9.0 9.5 10.0 10.5 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 Inlet Pressure - psi m p g - e t a R w o l F # 3C # 4C # 5C # 6C 1700 series injectors Slow Rinse - gpm pressure # 3C # 4C # 5C # 6C 20 0.93 1.84 2.34 3.13 30 1.06 2.19 2.82 3.70 40 1.18 2.40 3.14 4.12 60 1.42 2.80 3.68 4.82 90 1.64 3.34 4.35 5.70 125 1.90 3.88 5.00 6.58 # 3C - steel cap, no o-ring, air disperser # 4C & 5C - steel cap, o-ring, air disperser # 6C & 7C - brass cap, o -ring, no air disperser TR22089-2900s Valve 1700 Series Injector Slow Rinse Rates TR 22089 - 2900s valve 1700 Series Injector Draw Rates 0.5 0.7 0.9 1.1 1.3 1.5 1.7 1.9 2.1 2.3 2.5 2.7 2.9 3.1 3.3 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 Inlet Pressure - psi Flow Rate - gpm # 3C # 4C # 5C # 6C 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 Inlet Pressure - psi m p g - e t a R w o l F # 3C # 4C # 5C # 6C TR22089-2900s Valve 1700 Series Injector Total Flow to Drain in Draw TR22089 Rev A
FLECK 2900S Service Manual • 43 ENVIRONMENTAL BACKPLATE DIMENSIONS 61500-2900LNE Rev B
44 • FLECK 2900S Service Manual SYSTEM #4 Typical Single Tank Installation with Optional Meter SYSTEM #5 INTERLOCK Typical Twin Tank Installation with Optional Meter Interlock and No Hard Water Bypass
FLECK 2900S Service Manual • 45 SYSTEM #6 & #7 Twin Series Regeneration Installation with a Remote Meter Twin Alternator Installation NOTE: On System 7, the power cord is on Unit 2. NOTE: System 7 can run with either one or two brine tanks. Two brine tanks should be used if regeneration is less than 4 hours.
46 • FLECK 2900S Service Manual SYSTEM #4 WIRING Single Valve Regeneration Immediate and Delayed Valve Wiring
18684 Rev E
FLECK 2900S Service Manual • 47 SYSTEM #4 WIRING CONTINUED With Remote Starter Valve Wiring
15405 Rev G
48 • FLECK 2900S Service Manual SYSTEM #5 WIRING Interlocked Regeneration Valve Wiring 18685-01 Rev D 18685-02 Rev D
FLECK 2900S Service Manual • 49 SYSTEM #6 WIRING Series Regeneration Valve Wiring 18686-01 Rev E 18686-02 Rev E
50 • FLECK 2900S Service Manual SYSTEM #7 WIRING Alternating Regeneration Valve Wiring 18687-01 Rev E 18687-02 Rev E
FLECK 2900S Service Manual • 51 SYSTEM #7 WIRING CONTINUED
16172 Rev G
52 • FLECK 2900S Service Manual 1600/1700 SYSTEM NOZZLE & THROAT CHART
1600 Brine System
1700 Brine System
FLECK 2900S Service Manual • 53 SERVICE ASSEMBLIES Adapters:
61525 Softwater Adapter Kit, 2900s
61415 Adapter Assy, Sidemount
61415NP Adapter Assy, Sidemount, NP 2850/2900/2930 61415-20 Adapter Assy, Sidemount, BSP/MTC 2850/2900/2930 61415-20NP Adapter Assy, Sidemount, BSP/NP 2850/2900/2930 Air Checks: 60002-34 Air Check, #500, 34 inches Long 60003-34 Air Check, #500, HW, 34 inches Tube 60009-01 Air Check, #900, Commercial, HW Less Fittings Auxiliary Micro Switch: 60320-02 Switch Kit, 3200/9000 Timer Auxiliary 60320-11 Switch Assy, 2900, Lower Drive (For Adding 2nd Switch) 60320-08 Switch Assy, 2900, Lower Drive Aux (For Adding Third Switch) Brine Line Flow Controls (BLFC): 60020-25 BLFC, 25 GPM, 1600 60020-50 BLFC, 50 GPM, 1600 60020-100 BLFC, 10 GPM, 1600 60011-090 Brine Valve, 1650, Short Stem 60010-25 BLFC, 1650, 25 GPM, Plastic 60010-50 BLFC, 1650, 50 GPM, Plastic 60010-100 BLFC, 1650, 10 GPM, Plastic Brine Valves:
60011 Brine Valve, 1650, Less BLFC
60029 Brine Valve, 1600, Short Stem Brass,
60029HW Brine Valve, 1600, Short Stem Hot Water 60034-XX Model 1700 brine valve assy (specify flow control 10 - 50 ) 60604-XX Model 1710 brine valve assy (specify flow control 10 - 50 ) Covers: 60217-02 Environmental Lower Cover, Black 60219-02 Environmental, Cover, Black 60232-XX Designer 2 Piece 60232-110 Cover, Designer, 1 Piece Black 14800-02 Cover, Dust, Lower, 2900, Black Drain Line Flow Controls (DLFC): 60366-XX 1-inch FNPT x 3/4-inch FNPT (specify flow control 6 - 70) 60701-XX 1-inch FNPT x 1-inch FNPT (specify flow control 80 - 250) 60702-XX 1-inch FNPT x 1-inch MNPT (specify flow control 80 - 250) 60708-XX 1-inch FNPT x ¾-inch FNPT (specify flow control 80 - 250) 60721-XX 1-inch FNPT x 1-inch FNPT (specify flow control 6 - 70) Cam Assemblies: 60160-00 Drive Cam Assy, RR, White 60160-20 Drive Cam Assy, Std 60160-22 Drive Cam Assy, Link, Environmental
2900 Lower Drive
60160-30* Drive Cam Assy, Upflow 60160-31* Drive Cam Assy, Upflow, Variable 24-Hour Gear Assemblies:
19205 Gear Assy, 24 Hour, Silver, 5600, 12 AM
60519-02 Gear Assy, 3200 24 Hour 2 Times/Day, w/ Silver Label 60519-03 Gear Assy, 3200, 24 Hour 3 Times/Day, w/Silver Label 60519-04 Gear Assy, 3200, 24 Hour 4 Times/Day, w/Silver Label 60519-06 Gear Assy, 3200, 24 Hour (12:00) 6 Times/Day, w/Silver Label Injector Assemblies (Complete): 60480-XX 1600/1650 - 3/8-inch brine (specify size of injector) Meters:
60393 Meter Assy, 2900, 2-inch Std
60394 Meter Assy, 2900, 2-inch Ext
60616 Meter Assy, Elec 2-inch
60620 Meter Assy, 2-inch Plastic, Std
60621 Meter Assy, 2-inch Plastic, Ext
60625 Meter Assy, 2-inch Plastic Electronic
61439 Meter Sleeve w/O-ring, Machd
Piston Assemblies:
60103 Piston Assy, 2900/2930, HWBP Lower
60103-01 Piston Assy, 2900/2930, HWBP, HW, Lower
60104 Piston Assy, 2900/2930, NHWBP Lwr,
2900s, Soft Wtr Rgn 60104-01 Piston Assy, 2900/2930, NHWBP, HW Lwr, 2900s Soft Wtr Rgn
61540 Piston Assy, 2900s, Downflow Upper
61540-01 Piston Assy, 2900s Downflow Upper, HW 61545* Piston Assy, 2900s, Upflow Upper 61545-01* Piston Assy, 2900s, Upflow Upper, HW
61550 Piston Assy, 2900s, HWBP Lower
61550-03 Piston Assy, 2900s, HWBP Lower, HW
61555 Piston Assy, 2900s, NHWBP Lower
61555-03 Piston Assy, 2900s, NHWBP Lower, HW Program Wheel Assemblies: 60405-20 Program Wheel, w/3/4-inch Ext Label 1-1/2 inch Std Set @ 100 60405-50 Program Wheel, w/2-inch Std Label Set @ 21 60405-60 Program Wheel, w/2-inch Ext Label 60405-70 Program Wheel, w/1-1/2 inch Ext Label
54 • FLECK 2900S Service Manual SERVICE ASSEMBLIES CONTINUED Safety Brine Valves:
60014 Safety Brine Valve Assy, 2310
60038 Safety Brine Valve , 2350
60027-FFA Safety Brine Valve Body, 2300 Fitting Facing Arm 60027-FFS Safety Brine Valve Body Fitting Facing Stud 60026-30SAN Float Assy, 400A/2350, 30-inch HW 60028-30 Float Assy, 2300, 30-inch White 60028-30 Float Assy, 2300, 30-inch, Blue/White 60068-30 Float Assy, 2310, w/30-inch Rod Sales & Service Aids:
40738 Literature, 2900 Spec Sheet
41689 Literature, 2900s S/Manual
40717 Literature, Catalog Assy, PWT
Seal & Spacer Kits:
61530 Seal & Spacer Kit, 2900s Upper
61530-01 Seal & Spacet Kit, 2900s, HW Upper
60128 Seal & Spacer Kit, 2900/2930 Lower
60128-01 Seal & Spacer Kit, 2900/2930, HW Lower Service Equipment:
11098 Stuffer Tool Assy, Complete
12682 Puller Tool Assy, 2900/3150
12683 Stuffer Tool Assy, 2900/3150
13061 Puller Assy, Port Ring
16174 Silicone, 2 oz Tube
60460 Meter Checker Kit, Std
60461 Meter Checker Kit, Ext
16586-8 Silicone, Dow #7 8 Lb Service Valve Operator Assemblies:
60150 SVO Assy, 1600 O/S
60150-01 SVO Assy, 1600 N/S Skipper Wheel Assemblies:
14860 Skipper Wheel Assy, 7 Day
14381 Skipper Wheel Assy, 12 Day
*Upflow Only
FLECK 2900S Service Manual • 55
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