CLEAVER-BROOKS. SAB/Q Heavy Duty Co-Current Commercial and Industrial Water Softeners

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1 $25.00 CLEAVER-BROOKS SAB/Q Heavy Duty Co-Current Commercial and Industrial Water Softeners SAB/Q Series thru Water Softeners: Single, Twin and Triple Configurations Contents: Operating Instructions Installation Instructions Calibration Instructions Manual No /97 Performance Proven Worldwide

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3 Section A-1 Table of Contents EQUIPMENT SPECIFICATIONS A-1 Table of Contents...1 A-2 Installer Alert...2 A-3 Identification of the SAB/Q Softener System...3 A-4 Performance Specifications...4 THEORY AND OPERATION B-1 SAB/Q Series Water Softener: Theory of Operation B-2 SAB/Q Multi-Port Control Center... Flow Diagrams & Operation B-3 Operation of Capacitrol Brinemaker...11 B-4 Operation of CB/RC Controller B-5 Operation of Remote Mounted Solenoid Valve for Multi-Tank Operation B-6 Brine Line Operation for Multi-Tank Operation INSTALLATION, CALIBRATION AND SERVICE C-1 SAB/Q System Installation and Start-up C-2 Service and Installation of the Capacitrol Brinemaker C-3 Wiring Procedures C-4 CB/RC Operating Programs C-5 Start Up Check List C-6 Troubleshooting Guide C-7 Before You Start & Preventative Maintenance C-8 Service of the Multi-Port Valve & Flow Control Assembly C-9 Service of the CB/RC Controller C-10 Parts List C-11 Sample of Log...88 Table of Contents 1

4 INSTALLER ALERT Section A-2 CAUTION: Failure to observe the following precautions prior to installation could result in permanent damage to the CB/RC Electronic Programmable Controller(s) which is NOT covered under warranty. PRECAUTIONS Each of the following precautions will refer the installer to the appropriate installation instruction portion of this manual. Should you have any questions concerning any item in this manual, consult the factory or your local Cleaver-Brooks authorized representative. Optional Flow Sensor Package - (reference Section C-1) 1. When ordered with the flow sensor option package, a flow sensor is provided for each multi-port valve. 2. The installation location of the flow sensor is critical for proper operation. 3. The flow sensor installation fitting provided must be used unmodified for proper operation. Remote Solenoid Kit - (reference Sections B-5 and C-3) 1. Multiple tank systems will include a factory installed remote solenoid for each CB/RC Electronic Programmable Controller. Field wiring is required. 2. Single tank systems will NOT include a remote solenoid kit. Electrical - (reference Section C-3) 1. Polarity between multiple CB/RC controllers and the 24 volt transformer supplied must be maintained. 2. The interconnecting cables supplied must be used for installation. 3. DO NOT install the 9 volt battery(s) provided for each CB/RC Electronic Programmable Controller until all wiring has been completed. 4. The CB/RC Controller should be installed on a dedicated electrical circuit. ELECTRICAL INTERFERENCE FCC Guidelines: The CB/RC Electronic Programmable Controller generates and uses radio frequency energy and if not installed and used properly, in strict accordance with the manufacturer's instructions, may cause interference to radio and television reception. It has been type tested and found to comply with the limits for a Class A computing device in accordance with the specifications in Subpart J of Part 15 of FCC rules, which are designed to provide reasonable protection against such interference in a residential installation. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures: Adjust the receiving antenna Relocate the electronic water treatment equipment controller with respect to the receiver Plug the electronic water treatment controller into a different outlet so that the electronic water treatment controller and receiver are on different branch circuits. If necessary, the user should consult the dealer or an experienced radio/television technician for additional suggestions. The user may find the following booklet prepared by the Federal Communications Commission helpful: "How to Identify and Resolve Radio-TV Interference Problems." This booklet is available from the U.S. Government Printing Office, Washington, D.C , Stock No Section A-2

5 Section A-3 Identification of the SAB/Q Water Softener Cleaver-Brooks s SAB/Q line of Commercial/Industrial softeners is designed to remove hardness from water. Hard water passes through the multi-port valve into the top of the softener tank. It flows down through a bed of cation resin where hardness is removed through a process called ion exchange. Softened water leaves the bottom of the tank, passes through the multi-port valve and into the service lines. Eventually, the bed of resin becomes exhausted or saturated with water hardness and must be regenerated. The capacity or exhaustion point of a water softener will depend on the resin quantity in the softener tank, the amount of solution used to regenerate the resin, the raw water hardness level and flow rate. The resin exchange capacity is measured in grains per gallon (GPG) where 1 grain of water hardness is equal to 17.1 parts per million of total water hardness. Total water hardness is defined as the concentration of calcium, magnesium and iron (either dissolved or undissolved) in the water. Resin regeneration is a process consisting of four distinct steps: backwash, brine, slow rinse, and flush. The resin is regenerated with a brine or sodium chloride (NaCl) solution that is created in the brine maker with pelletized salt and water. A regeneration cycle normally requires 72 minutes to complete. For more information on the ion exchange process, refer to section B-1, SAB/Q System Theory of Operation. Upon completion of the regeneration cycle, the softener returns to the service cycle and begins to soften water again. The SAB/Q softener system consists of resin, multi-port valve package, CB/RC Electronic Programmable Controller, brine maker and, in some cases, flow sensors or external service valves. 1. The required operating pressure is psi. If water pressure is higher, a pressure regulating valve should be installed ahead of the system. If the water pressure is lower, additional equipment may be required to maintain a 30 psi minimum operating pressure. 2. The specified operating temperature is F or C. 3. The softener is shipped with the multi-port valve and electrical controls fully assembled. Take care when uncrating and erecting the system to not damage the valve or CB/RC controller. NOTE: The CB/RC controller may be ordered as remote mounted in which case the CB/RC controller will not be mounted on the multi-port valve but shipped separately. 4. If the resin tanks are to be installed and not put into use for some time, the resin should not be loaded into the tank. In addition, provisions should be made to protect the resin. The resin should be kept sealed in the bags or drums it was shipped in, with care taken to prevent exposure to repeated freeze/thaw conditions which can deteriorate the resin beads. The resin should be stored in a cool dry place out of direct sunlight. Prior to system start up for operation, load the resin as described in Section C-1. Section A-3 3

6 Section A-4 PERFORMANCE SPECIFICATIONS Depending on the SAB/Q softener model selected, there is a wide range of operational flow rates, installation pipes sizes and exchange capacities. This manual covers Cleaver-Brooks SAB/Q series standard softener models 150 thru When selecting and sizing a SAB/Q softener for a specific application, special attention should be paid to the amount of time that the softener is required to operate, the raw water peak flow rate, continuous flow rate, and the dimensions of the installation location. A softener that does not have enough softening capacity is considered to be undersized. A softener that is oversized for a specific flow rate may experience water channeling where the raw water entering the softener seeks that path of least resistance through the resin bed. Essentially, the raw water passing through the resin bed is traveling at such a low flow rate that it passes only through a few selected spots on the surface area of the bed. In this case the softener decreases in efficiency and eventually allows hard water leakage. SAB/Q units will vary in exchange capacity depending on the sodium chloride (NaCl) or salt used in the regeneration. Cleaver-Brooks SAB/Q model 150 to 1050 softener specifications are as follows: NOTE: The Cleaver-Brooks SAB/Q water treatment system is designed to be used on clear (non turbid) water supplies. SPECIFICATIONS TABLE FOR SAB/Q COMMERCIAL/INDUSTRIAL WATER SOFTENERS * Allow a minimum of 24" clearance above the overall system height for access into top of tank/s. 4 Section A-4

7 Section B-1 OPERATION OF THE CB/RC-MULTI-PORT CONTROL CENTER The CB/RC-multi-port control center is designed for use with automatic, semi-automatic or manually operated water softeners. Normal range of application is 30 p.s.i. to 100 p.s.i. water pressure, with water temperatures up to 120 O F. The multi-port valve operation is smooth and entirely free of water hammer noises. The multi-port valve is well designed and constructed from the finest material. As with any mechanical device, periodic maintenance or repair is required. The multi-port valve is a unique and complete piece of equipment. Appendix A describes the multi-port valve operation, disassembly and repair. In addition, the various accessory items furnished with the valve, such as the pilot strainer, by-pass valve, etc. will be explained along with assembly and service instructions. The multi-port valve consists of five individual diaphragm valves and one by-pass valve, housed in a compact casting. These valves operate by pressure and are actuated by an external pilot valve (either automatically, semi-automatically or manually) in the proper sequence for the regeneration cycle. Additionally, a backwash flow controller is used on the drain outlet to control the backwash flow rate and fast flush flow rate, see page 63. A brine injector, which draws in brine to regenerate the softening mineral is mounted on the rear of the valve. (Refer to Appendix A.) Information on the multi-port valve sequence of operation and its relationship to the softener system is found on pages 6-9 of this manual. Section B-1 5

8 Section B-1 THE SAB/Q SERIES WATER SOFTENER: THEORY OF OPERATION WHAT IS HARD WATER? Water is said to be hard when it carries too high a concentration of calcium and magnesium. Acceptable water hardness levels will vary depending on the application. WHY SHOULD HARDNESS BE REMOVED? Hard water causes scaling and etching which greatly impairs the life and efficiency of industrial boilers, air-conditioning systems, cooling towers, water heaters, refrigeration plants and other equipment using water. WHAT CAN WE DO ABOUT IT? Hard water can be controlled very efficiently with the use of a ion exchange water softener. HOW DOES IT WORK? The components of dissolved minerals are called ions. They carry either a positive or negative charge. It happens that hardness ions of minerals dissolved in water carry a positive charge. These positively charged ions (cations) are attracted to a synthetic softening material called ion exchange resin. The heart of the softening system, therefore, is a deep bed of resin which draws calcium and magnesium ions, as well as ferrous iron, from the water as it passes through the resin bed. CAN THE RESIN DRAW OUT HARDNESS IONS INDEFINITELY? No. During normal operation, the resin becomes saturated with positive ions and functions less efficiently. When hardness leakage occurs, the resin should be regenerated to restore its efficiency. 6 Section B-1

9 HOW DO YOU REGENERATE RESIN? Section B-1 You regenerate a resin bed by removing the mineral ions through a process called "ion-exchange". This regeneration process takes approximately 72 minutes. It takes four steps to complete this process. Each of the following steps are graphically depicted in section B-2, Flow Diagrams of the SAB/Q: 1. BACKWASH During the backwash cycle, raw water flows rapidly upward (in reverse direction) through the resin bed to expand the bed and flush out accumulated dirt, sediment and other sources of turbidity. 2. BRINE Salt brine is drawn from a brine storage container and allowed to flow slowly down through the resin bed. The brine solution removes the calcium and magnesium ions from the resin. 3. SLOW RINSE Brine is then followed by a raw water rinse. This rinse cycle will remove most of the remaining brine, exchanged calcium and magnesium ions from the resin. 4. FLUSH Slow rinse is followed by Flush, a very rapid down flow of raw water which removes the last traces of brine, and settles the resin bed. HOW OFTEN MUST YOU REGENERATE? Frequency must be determined for each installation based on the amount of water usage, its degree of hardness and the amount of resin through which it flows. In some cases it is necessary to utilize a resin cleaner where the untreated water contains iron. Contact your localcleaver-brooks authorized representative for more information. HOW DO YOU CONTROL THE REGENERATION PROCESS? In some cases the regeneration is controlled manually, whereby the softener operator conducts a series of water tests to determine the exhaustion point of the resin bed. The regeneration process is then manually performed as needed. However, the regeneration process for your SAB/Q Commercial/Industrial Softener can also be controlled automatically either on a predetermined time, volume, or external signal basis through the use of the CB/RC controller with optional flow sensor. See sections B-4 and C-4, for further information. Section B-1 7

10 Section B-2 FLOW DIAGRAM - SERVICE CYCLE 1. These diagrams illustrate the simplicity of the multi-port valve and positive control of flow direction. 2. Note that only diaphragm valves 1 & 4 are open and flow is directed to top of resin tank, through resin bed, out bottom of tank into service line. 3. Pressure is directed to Pilot Valve which distributes pressure to other valves. 4. Pressure is also directed through the brine injector ports to brining assembly in Brine Maker, where proper liquid level is maintained. FLOW DIAGRAM - BACKWASH CYCLE 1. Expands and cleans resin bed. 2. Pilot Valve changes ports to direct water into bottom of resin bed and out the top of tank. Diaphragm Valves 2, 5 and 17* are open. 3. Flow is to drain and is controlled by automatic backwash control: a. Flow control assembly b. Accurate control from 30 to 100 psi c. Insures against resin loss d. Allows open backwash outlet in resin tank * Single tank systems only 8 Section B-2

11 Section B-2 FLOW DIAGRAM - BRINING CYCLE 1. Bypass opens.* 5. Note brining assembly detail showing valve in open position. 2. Valve #6 to drain opens venting resin tank. 6. Brine is blended with water by brine injector. 3. Pressure directed through pilot valve holds other valves closed. 7. Brine passes into resin tank. 4. Flow through brine injector draws brine into top of resin tank. 8. Note only two valves are open in this cycle (No. 6 and No. 17*) * Single tank systems only FLOW DIAGRAM- SLOW RINSE CYCLE 1. A continuation of brining cycle. 5. Brine injector is controlling rinse rate at 1.2 GPM/sq. ft. of bed area. 2. Pilot Valve Position Dial does not move. 6. Brine is slowly rinsed through resin bed to insure good contact with resin. 3. Measured amount of brine introduced to resin tank. 7. Spent brine is directed to drain. 4. Air shut-off valve closed (see brining assembly detail). 8. Bypass remains open. * All other diaphragm valves remain in same position. * Single tank systems only Section B-2 9

12 Section B-2 FLOW DIAGRAM - FLUSH CYCLE 1. Increased flow is directed to top of resin tank, down through bed, and out to drain. 2. Settles and packs resin bed. 3. Purges resin tank of hard water. 4. Insures that all brine has been rinsed out. 5. Brine tank refills to one inch above salt platform. 6. Diaphragm valves 1, 6 and 17* are open. 7. Unit returns to service position and bypass closes. * * NOTE: Bypass is always closed on twin or triple units. 10 Section B-2

13 Section B-3 OPERATION OF BRINE MAKER The Capacitrol brinemaker consists of an open tank with a perforated platform dividing it into two sections (see figure B-3, #1). The area above the platform is used for salt storage and the area below the platform is used to create the brine solution. A tubular brine well containing an automatic brining assembly runs through a hole in the platform. The brining assembly is used to control brine withdrawal and fresh water refill into the brine tank. Liquid flows in and out of the brine well through holes in its side. After each regeneration water flows from the brine injector through the brine line, to the brining assembly. This water then begins to refill the brine well. The water level will continue to rise in the brine well until it reaches the small holes in the side of the well. At that point, water passes though the holes and starts to fill the base of the brine tank. Water will continue to rise in the brine tank until it reaches a level of approximately 1 to 1 1/4 above the salt platform, where it makes contact with the salt. The brining assembly will shut off the refill once the water level in the brine tank reaches an acceptable level. Salt on the platform dissolves slowly to form a concentrated brine. It is normal for the brine level to rise considerably above the salt platform even though the brining assembly is closed. In fact, even the brine float, which controls the flow of water into the brine well through the brining assembly, can be fully submerged as salt dissolves in water and raises the water level in the brine tank. However, a leaky brining assembly may cause a continuous overflow of the brine tank. Repair or replace the leaky brining assembly in this instance. See Section C-2, Service and Installation of the Capacitrol Brinemaker, for further service instructions. During the brine cycle of a regeneration, the brine injector, which is mounted on the back of the multiport valve, creates a vacuum on the brine line. This vacuum opens the brining assembly and allows liquid or brine to be drawn from the brinemaker. When the desired brine volume is withdrawn, the lower float assembly seats, causing an air check, and prevents air from entering the system. The amount of brine drawn during the regeneration cycle depends on the placement of the salt adjustment plug in the brine well. Only the brine above the open hole is drawn. Fig. B-3, #1 Section B-3 11

14 Section B-4 OPERATION OF THE CB/RC ELECTRONIC PROGRAMMABLE CONTROLLER The CB/RC electronic programmable controller is a sophisticated, state of the art system designed to monitor and control the operation of the SAB/Q water softener service and regeneration cycles. Water pressure sources from the multi-port valve allow the CB/RC controller's six position pilot valve to actuate the diaphragm valves in the multi-port valve. This water pressure passes from the pilot strainer, located on the top right corner of the multi-port valve, up to the pilot valve mounted on the rear of the CB/RC controller (or optionally housed in a remote pilot valve box mounted on the upper left corner of the multi-port valve when the CB/RC program module is to be remote mounted). Depending upon the position of the pilot valve (i.e. what cycle the pilot valve is in), water will flow to certain diaphragms to pressure them closed. At the same time, the pilot valve will vent off pressure (to drain), allowing the other diaphragms to open as the operation cycles change. Additionally, the CB/RC controller with 6 position pilot valve allows the system to be used with the brine reclaim option. This option can save the user up to 50% in operating expenses. Contact your local Cleaver-Brooks authorized representative for more information about the SaltAway system. OPERATING SEQUENCES OF THE 6 POSITION PILOT VALVE The standard sequence of operation for the CB/RC 6 position pilot valve is as follows: CYCLES SERVICE: Indicates that the softener is in the service mode. When multiple tanks are used, the location of the position dial in the SERVICE mode may also indicate the unit has been regenerated and is available for service. (The CB/RC module will also display STANDBY). The position dial should be aligned so that the SERVICE setting is aligned with the position indicator on the outer edge of the pilot valve body. See Fig. B-4, #1 #1 - BACKWASH: The first step of the regeneration process. The CB/RC controller activates the pilot valve drive motor circuit causing the pilot valve spool to rotate clockwise slowly from the service position to position #1 or the backwash position. #1 on the position dial is now aligned with the position indicator. Fig. B-4, #1 #2, 3, 4 - BRINE CYCLE: The second step of the regeneration process. The pilot valve drive motor rotates the pilot valve spool into the #2 - BRINE DRAW cycle followed by the #3 - INITIAL BRINE RINSE cycle and the #4 - FINAL BRINE RINSE cycle. As each cycle is completed (or timed out) the pilot valve drive motor continues to rotate the pilot valve spool to the proper position for each cycle. As the pilot valve spool is rotated through each cycle, the position indicator on the pilot valve aligns with the proper cycle number on the position dial. #5 - FLUSH: After cycle #4 has been completed, the pilot valve spool rotates to the #5 or FLUSH position. #5 on the position dial is now aligned with the position indicator. Upon completion of the Flush cycle, the pilot valve spool will rotate the position dial back to Service. #6 - NOT USED: While there is no #6 position indicated on the pilot valve assembly, a 6th cycle is provided within the CB/RC programming module. This is an optional program feature and is not used in this application. 12 Section B-4

15 Section B-4 The softener has now completed a regeneration cycle and is either returned to an on line or standby status. CB/RC CONTROLLER FEATURES AND OPERATION Note: The Position dial should only be rotated in a clockwise direction. Attempting to rotate counter clockwise will strip the position dial, requiring replacement. DO NOT ATTEMPT TO ROTATE POSITION DIAL COUNTER CLOCKWISE. HOMING DEVICE: The CB/RC controller is equipped with a micro switch that senses the position of the pilot cam wheel. The switch is open when the valve is in the SERVICE position and is closed for any of the regeneration cycles. Should the CB/RC controller receive a signal indicating the switch is closed when it should be in the open, SERVICE position, the CB/RC display screen will indicate a PHASE condition. The CB/RC controller will not act upon the condition for 15 minutes. In the sixteenth minute the CB/RC controller will attempt to self-correct. Should it not correct by the 30th minute, the audible alarm may sound requiring user attention to correct the condition. MULTIPLE CONTROLLER INTERFACE: When used in a multiple tank configuration, an CB/RC controller is provided for each multi-port valve. Up to three CB/RC controllers may be interconnected simply through the installation of a 24 volt shielded cable that is provided with the CB/RC controllers. The multiple tank interface allows the individual CB/RC controller to communicate information such as flow rates, regeneration schedules, and on-line/standby status to the other CB/RC controllers in the system. Refer to Section C-3 for wiring diagram information and installation instructions. MULTIPLE TANK INTERLOCK: The multiple tank interlock works in conjunction with the multiple controller interface to inhibit simultaneous regenerations from multiple tank configurations. The Multiple Tank Interlock and Multiple Controller Interface also eliminate the need for a separate alternating sequencer typically used in multiple tank systems. Section B-4 13

16 Section B-5 OPERATION OF REMOTE MOUNTED SOLENOID VALVE FOR MULTI-TANK OPERATION NOTE: Proceed to Section B-6 if your system is a single tank configuration. The remote solenoid is only required for multiple tank systems. The purpose of the remote mounted solenoid valve is to assist the CB/RC controller in providing automatic alternating or progressive flow operation for multiple tank systems. These remote solenoids are piped from port #1 of the solenoid to port #4 of each multi-port valve in the system. Tubing is provided from port #2 of the solenoid to the "IN" port of the pilot valve as well as from port #3 of the solenoid to port #4 of the pilot valve. See Fig.B-5, #1. MULTI-PORT VALVE (Rear View) Fig. B-5, #1 14 Section B-5

17 Section B-5 SEQUENCE OF OPERATION Whenever a regeneration or a standby mode is required in a multiple tank system, the CB/RC controller sends a signal to the output C terminal of the main CB/RC circuit board, activating the remote solenoid valve. When the remote solenoid valve is electrically activated, ports #2 and #1 of the remote solenoid become common. This solenoid action will direct pressure from the constant IN pressure supply to multi-port valve #4, closing diaphragm valve #4 which prohibits the flow of water through the outlet of the multi-port valve. Once the CB/RC controller signals the unit to return to an "Online" status, the signal from output C is removed and the remote solenoid valve is deactivated. When the remote solenoid valve is electrically deactivated, ports #1 and #3 of the remote solenoid become common. This solenoid action will allow pressure, or lack of pressure, from pilot port #4 to control multi-port valve port #4. With the pilot valve in the Service position, pilot valve port #4, and therefore multi-port valve port #4, are vented to drain, thereby opening the multi-port valve #4 and allowing soft water to flow through the outlet of the multi-port valve. Fig. B-5, #2 Refer to section C-3 for wiring instructions for the CB/RC solenoid. Remote Solenoid Fig. B-5, #3 Section B-5 15

18 Section B-6 BRINE LINE OPERATION In addition to the CB/RC remote solenoid valve, multiple tank SAB/Q systems must also have a brine line diaphragm valve(s) and check valve(s) installed in the brine lines, Fig.B-6, #1 & #2. These items prevent the dilution of the saturated brine when it is drawn from the brine tank during a regeneration. Both the brine line diaphragm valve and check valve work to control the flow of water to and from the brine maker. The function of both of these valves and their sequence of operation in two tank and three tank systems is detailed below. Refer to section C-10 for more information on the service and parts breakdown of the brine line diaphragm valve. Without water pressure in the control tube, the brine line diaphragm valve is kept closed by spring action. Pressurizing the control tubes via pilot valve port #6 from the multi-port valve pilot on the appropriate tank, Fig.B-6 #3, causes the brine line diaphragm to open. Check Valve Part # Fig. B-6, #1 The brine maker is always refilled through the brine line diaphragm valve with water from the right unit on twin systems and the center unit on triple systems. Automatic operation is as follows: TWIN SYSTEMS 1.The LEFT unit is in SERVICE and the RIGHT unit is REGENER- ATING. Pressure from pilot valve port #6 of the LEFT unit pilot valve keeps the brine line diaphragm valve open so that brine may be drawn into the RIGHT unit. The brine line check valve prevents any backflow from the LEFT unit into the brine line. When the RIGHT unit finishes regenerating, raw water flows to the brine maker through the open brine line diaphragm valve until the brining assembly closes. 2.The RIGHT unit is in SERVICE and the LEFT unit is REGENER- ATING. Pressure is relieved from pilot valve port #6 of the LEFT unit pilot valve. The brine line diaphragm valve closes, preventing backflow of water form the RIGHT unit into the brine line. Diaphragm Valve Part # Fig. B-6, #2 The LEFT unit draws brine through the brine line check valve. When the LEFT unit completes the FLUSH (#5) cycle and returns to the SERVICE position, the brine line diaphragm valve opens allowing the brine maker to refill until the brining assembly closes. The brine line check valve prevents any backflow from the LEFT unit into the brine line. 16 Section B-6

19 Section B-6 TRIPLE SYSTEMS 1.The LEFT unit and CENTER unit are in SERVICE and the RIGHT unit is REGENERATING. Pressure is relieved form port #6 of the RIGHT unit pilot valve. The brine line diaphragm valve tubed to RIGHT unit closes, preventing backflow of water from the CENTER unit into the RIGHT unit. The brine line check valve installed on the LEFT unit prevents any backflow from the LEFT unit into the brine line. When the RIGHT unit completes the FLUSH (#5) cycle and returns to the SERVICE position, the CENTER unit brine line diaphragm valve repressurizes, opening and allowing the brine maker to refill from the CENTER unit. 2.The CENTER unit and RIGHT unit are in SERVICE and the LEFT unit is REGENERATING. Pressure is relieved from port #6 of the LEFT unit pilot valve. The brine line diaphragm valve tubed to the LEFT unit closes, preventing the backflow of water from the CENTER and RIGHT units into the LEFT unit. When the LEFT unit completes the FLUSH (#5) cycle and returns to the SERVICE position, the brine line diaphragm tubed to the LEFT unit repressurizes, opening and allowing the brine maker to refill from the CENTER unit. 3.The RIGHT unit and LEFT unit are in SERVICE and the CENTER unit is REGENERATING. The brine line check valves located on the brine line to the LEFT unit and the brine line to the RIGHT unit prevent the backflow of water into the CENTER unit during REGENERATION. When the CENTER unit completes the FLUSH (#5) cycle and returns to the SERVICE position, make-up-water flows from the CENTER unit into the brine tank, refilling the brine tank. Fig. B-6, #3 Section B-6 17

20 Section C-1 Drawing Not To Scale Fig. C-1 #1 Drawing Not To Scale Fig. C-1 #2 18 Section C-1 Drawing Not To Scale Fig. C-1 #3

21 SAB/Q SYSTEM INSTALLATION AND STARTUP There are a number of steps required to properly install and start up a softener. Make certain to follow each step carefully to insure that the softener runs trouble free. Also, be sure all plumbing practices conform to local plumbing codes. Section C-1 LOCATE SOFTENER 1. Select a position near a floor drain that has adequate carrying capacity to handle the softener backwash flow rate. Refer to section A-3, Performance Specifications for specific backwash flow rate. 2. Before standing the unit upright, check inside the tank to make sure that all of the plastic distributors and laterals are tight (see Fig. C-1, #5). DO NOT PROCEED IF ANY DISTRIBUTORS OR LATERALS ARE BROKEN. CONSULT YOUR LOCAL CLEAVER-BROOKS AUTHORIZED REPRESENTA- TIVE OR THE FACTORY FOR ASSISTANCE. If any are loose, hand tighten only. DO NOT USE A WRENCH. 3. Erect the resin tank on a level firm foundation, preferably concrete. The valve and piping normally face the front for easy access. 4. Level the system. INSTALL PIPING 1. Depending on the type of softener system (i.e. single, twin,etc) and installation parameters, required pipe lengths and piping accessories will vary. Sample layout drawings (Figs.C-1# 1, 2 & 3) are provided to aid in installing a Cleaver- Brooks SAB/Q unit. If the layout drawings are not sufficient for your application, consult the factory or your local Cleaver-Brooks authorized representative for specific installation guidelines. The use of unions on the inlet and outlet isolation valves is recommended to facilitate service of the softener unit. It is recommended that a full flow by-pass line be provided. NOTE: All pipe fittings and assemblies should follow good plumbing practices for installation. They are: a. Checking the threads and making certain that they are clean and free of foreign matter. b. Fittings must be free of cracks or chips. c. Prepare threads with either a pipe dope sealant or Teflon tape. (see Fig C-1, #4) d. Make certain that the fittings are not cross threaded during the assembly process. e. Do not over-tighten fitting or threaded pipe being inserted into a cast or forged part. 2. Pipe a drain line from the backwash flow control assembly (left side of the multiport valve) to the drain. Use a minimum of elbows and increase or decrease the pipe size in order to make a connection to the backwash flow control assembly. (see Fig C-1, #5) DO NOT Install a valve in this line or use pipe smaller than listed in the table below: TANK DIAMETER SOFTENER DRAIN PIPE SIZE MODEL NO , 450, / / & Install a union near the backwash flow control assembly to facilitate service when required. DO NOT make a direct connection to the drain. Provide an air gap of at least four times the diameter of the drain pipe to conform to sanitation codes and to permit the observation of the drain flow. Fig C-1, #4 Fig C-1, #5 Section C-1 19

22 Section C-1 TWIN SOFTENER BRINE LINE VALVE INSTALLATION For twin softener configurations, a brine line diaphragm valve and check valve (see Fig.C-1, #7 & #8) are required to prevent dilution of the brine prior to the brine solution entering the brine injector during the regeneration process. The LEFT unit pilot valve is furnished with a coil of plastic tubing for connection to the brine line diaphragm valve. Refer to Fig.C-1, #6 for location of the brine line check valve and diaphragm. 1. Assemble the brine line diaphragm valve to the RIGHT unit brine connection and the check valve to the LEFT unit brine connection. Make sure that the flow arrows point towards the softeners. 2. Connect the extra GREEN plastic tubing from port #6 of the LEFT unit pilot valve to the brine line diaphragm valve. 3. Although unions are not provided, it is recommended that unions be installed in the brine line as shown on Fig.C-1, #6 for ease of service and access to the brining assembly in the brine maker. 4. Do not complete the Brinemaker installation at this time. Complete Section C-1 before proceeding to Section C-2, Service and Installation of the Capacitrol Brinemaker. TRIPLE SOFTENER BRINE LINE VALVE INSTALLATION Triple softener configurations require two (2) brine line diaphragm valves and check valves (Fig.C-1, #7 & #8) to prevent dilution of the brine prior to the brine solution entering the brine injector during the regeneration process. The LEFT unit pilot valve and RIGHT unit pilot valve are furnished with a coil of plastic tubing for connection to the brine line diaphragm valves. Refer to Fig.C-1, #6 for location of brine line diaphragm and check valves. 1. Attach one brine line check valve to the LEFT unit brine connection and one to the RIGHT unit brine connection. Make sure that the flow arrows on the check valve point towards the softeners. 2. Although unions are not provided, prior to installing the brine line diaphragm valves, it is recommended that unions be installed in the brine line as shown on Fig.C-1, #6. 3. Install one brine line diaphragm valve to the CENTER unit brine connection. Connect the extra GREEN tubing provided from port #6 of the RIGHT unit pilot valve to the diaphragm valve. 4. Install the second brine line diaphragm valve in the brine line between the LEFT unit and the CENTER unit (See Fig.C-1, #6). Connect the extra GREEN tubing provided from port #6 of the LEFT unit pilot valve to the diaphragm valve. 20 Section C-1

23 Section C-1 5. Repeat the above procedure with the pilot valve from the LEFT unit and the brine line diaphragm valve located between the LEFT and CENTER units. 6. Do not complete the Brinemaker installation at this time. Complete Section C-1 before proceeding to Section C-2, Service and Installation of the Capacitrol Brinemaker. Fig. C-1, #6 Check Valve Diaphragm Valve Part # Part # Fig. C-1, #7 Fig. C-1, #8 Section C-1 21

24 Section C-1 Installation of Flow Sensor - Optional NOTE: Time-based regeneration programs do not require the optional flow sensor. If your system is to be time-based and flow sensors were not included, please proceed to LOAD RESIN TANK instructions on page 29. The CB/RC controller has the capability to initiate a regeneration sequence based upon the volume of water treated. When using the volume based programs, a vital part of the operation of the SAB/Q system is the installation of a flow sensor assembly. Not only is it important to have the proper flow sensor for the installation application, but it is equally important to make certain that the flow sensor is located in the proper location for accurate registration of the flow. For example: a twin water softener unit will include (2) CB/RC Controllers and (2) flow sensors. Each of these flow sensors must be connected to the output piping of each individual water treatment column. This means the plumbing coming from the unit is where the flow sensor must be attached, not the common plumbing that all of the water treatment columns Fig. C-1, #9 These packages have been preselected based on the output port size of the Multi-Port Control Center and the type of pipe being used at the site. If you have a special application or need a different flow sensor package other than the one that is sent with the kit consult the factory for help. The seven flow sensor packages are as follows. 1. Copper sweat tee 2. Threaded galvanized tee 3. Copper brazolet 4. Iron Saddle 5. Schedule 80 PVC tee 6. Carbon steel weldolet 7. Stainless steel weldolet 22 Section C-1

25 Section C-1 Location of the Flow Sensor Package The accuracy of the flow sensor package depends on the proper use of the fitting that mounts the package to the piping and also the location of the flow sensor package in the piping system. As stated earlier, the flow sensor is to be mounted on the output plumbing of the water treatment column. The piping that the flow sensor is being connected to should be the same diameter as the mounting fitting. The flow sensor must also be located in a free-flowing straight run of pipe. This straight flow includes the upstream piping of the flow sensor and also the downstream piping of the flow sensor. In some instances the installation may have a series of reducing fittings, elbows and valves. The formula for the proper length of upstream and downstream straight piping is a minimum of 10 pipe diameters of free-flowing straight pipe upstream of the flow sensor and 5 pipe diameters of free flowing straight pipe downstream. EXAMPLE: A flow sensor that is installed on a length of 2" diameter straight pipe. See Fig.C-1, #10. Example: D=2" 10 x D=20" 5 x D =10" Fig. C-1, #10 Major obstructions will require considerably longer straight runs of upstream piping. EXAMPLE: A flow sensor that is installed on a length of 2" diameter straight pipe that has a 90 o elbow upstream from the desired location. See Fig.C-1, #11. IT MAY ALSO BE NECESSARY, DUE TO PIPING RESTRICTIONS, TO UTILIZE AN IN LINE FLOW STRAIGHTENER. Contact your local Cleaver-Brooks authorized representative for further information. 20 x D 5 x D Fig. C-1, #11 Section C-1 23

26 Section C-1 The examples below are intended as guide lines for the proper length of straight pipe required both upstream and downstream of the flow sensor installation point. These recommendations are minimum requirements. See Fig.C-1, # X D 5 X D 25 X D 5 X D Straight Pipe Two Elbows in Same Plane 15 X D 5 X D 40 X D 5 X D Reducer Prior to Flow Sensor Two Elbows, Different Planes 20 X D 5 X D Single Elbow Prior to Flow Sensor Fig. C-1, #12 50 X D 5 X D Valve Prior to Flow Sensor Position of the Flow Sensor Package The flow sensor position is also important to the accuracy of the output signal When installing the flow sensor in a horizontal pipe, the optimum position of the flow sensor in the pipe is at 0 or 180 degrees, assuming the pipe is always full of liquid and contains no suspended solids. Air pockets or sediment in the pipe will disturb the rotation of the flow sensor, causing inaccuracy in the output signal. Because of certain installation requirements due to space restrictions, it maybe necessary to tilt the flow sensor slightly, (max. 45 o angle). Excessive angles will cause bearing drag on the flow sensor rotor at lower flow rates. See Fig.C-1, #13. Fig. C-1, #13 24 Section C-1 On a vertical pipe run, it is preferable to locate the flow sensor where the flow is upward. But, if downward flow is necessary, the system must be designed to prevent air/water vapor pockets from developing in the pipe which will affect the performance of the flow sensor. The maximum distance that the flow sensor can be located from the CB/RC controller is 500 ft.

27 Section C-1 INSTALLATION Note: Flow Sensors must be installed as indicated. Failure to follow these instructions may result in improper operation. Please refer to any supplemental instructions accompanying the flow sensor for additional information. 1. Once you have located the flow sensor package and determined if the size and material type of the package are correct for the equipment at the site, proceed with installing the flow sensor mounting package. Fig. C-1, #14 2. You should follow good plumbing practices for all the installations. They are: a. Check the threads and make certain that they are clean and free of foreign matter. b. Fittings must be free of cracks and chips. c. Prepare threads with either a pipe sealant or Teflon tape. d. Make certain that the fittings are not cross threaded during the assembly process. e. Do not over-tighten the fittings or the threaded pipe that is being threaded into a casting or forging. f. Follow proper soldering processes as outlined in the plumbing code. 3. For each of the different types of installations, certain requirements must be followed to assure a proper installation. a. Copper sweat tee - for use on copper tubing sizes. 1", 1-1/4", 1-1/2" and 2". The 1" copper sweat tee does not have a plastic insert for the flow sensor, but, all of the other sizes do. This insert should be removed as is necessary to properly solder the tee into the correct position. A tag is attached to the fitting to indicate the proper "H" dimension of the plastic insert when reassembling. This dimension is critical to the proper calibration of the flow sensor. Note the location of the notch to the pipe. See Fig.C-1, #14 & #16. b. Threaded galvanized tee - for use on galvanized/iron pipe sizes 1", 1-1/4", 1-1/2" and 2". All tees are threaded with NPT threads and have a plastic insert to attach flow sensor. This insert is factory installed and should not be removed as it is necessary in determining the proper location for the flow sensor wheel, when inserted into the fitting, as well as the flow orientation of the probe. Again this insert should not be removed from the tee assembly. See Fig.C-1, #16. Fig. C-1, #15 Fig. C-1, #16 Section C-1 25

28 Section C-1 Fig C-1, #17 c. Copper brazolet - for use on copper pipe sizes 2-1/2" and 3". The copper brazolet should be installed by a certified welder. A hole will need to be drilled in the pipe at the desired location as described in C-6, Location of the Sensor Package. The hole size should be 1-7/16" and must be completely deburred and free of any projections. Prior to welding the brazolet, the plastic insert must be removed. A special tool is provided with each brazolet assembly for the removal and the replacement of the plastic insert. When the plastic insert is replaced (after the welding is complete), Teflon tape should be used on the threads. Also there is a special card that is attached to the insert, this card indicates the proper "H" dimension for the insert depth when you reassemble the insert back into the brazolet. This dimension is critical to the proper calibration of the flow sensor. Note the location of the notch to the pipe. See Fig.C-1, #15 & #16. d. Iron saddle - for use on steel pipe 2-1/2" to 3". A 1-7/16" hole will need to be drilled in the pipe at the desired location as described in C-6, Location of the Sensor Package. The assembly comes complete with a plastic insert which is factory installed and should not be removed. The assembly also comes with a rubber washer which must be installed between the clamp and pipe. Coat the rubber washer with a silicon lubricant and place it on the inside of the saddle and form it around the raised groove. With the flat side of the rubber washer facing the pipe surface, insert the plastic insert and saddle to the drilled hole. Using the saddle clamps, tighten the saddle into place, Fig.C-1, #17. e. PVC socket weld tee - for use on 1", 1-1/4", 1-1/2", 2", 2-1/2", 3" and 4" schedule 80 PVC pipe. All tees are socket welded with a NPT threaded port containing a plastic insert to attach the flow sensor. This insert is factory installed and should not be removed as it is necessary in determining the proper location for the flow sensor wheel when inserted into the fitting, as well as the flow orientation of the probe. Again this insert should not be removed from the tee assembly. 26 Section C-1

29 Section C-1 CB/RC FLOW SENSOR DATA Section C-1 27

30 Section C-1 CB/RC FLOW SENSOR DATA 28 Section C-1

31 LOAD RESIN TANK INSTALL GRAVEL SUPPORT BED 1. Verify that the correct type and amount of gravel for the resin installation is on site. The proper amount of gravel for resin loading is indicated on the following table to insure that you have a sufficient quantity of gravel for the support bed. If the correct type and amount of gravel is not on site, DO NOT load the tank. Contact the factory or your local Cleaver- Brooks authorized representative for assistance. Section C-1 2. Make sure all manual valves are closed. Add approximately 2 feet of water to the resin tank (Fig. C-1, #19) prior to loading the gravel to prevent damage to the distribution system. It is not recommended that the tank be entered to receive and load the gravel. With water in the tank, carefully pour the gravel slowly into the tank, leveling as loading progresses. On tanks with only a handhole in the top, it is recommended that a funnel be used to load the gravel into the tank to help prevent spillage. When properly loaded, the gravel should cover the distributors and laterals. If it does not, contact your local Cleaver-Brooks authorized representative or the factory for assistance before proceeding to Step 3. CAUTION: Should it be necessary to enter the tank, it is recommended that a respirator be worn by any person entering the tank to load gravel. Wet the bags of gravel to reduce the amount of dust caused by the loading procedure. 3. LEVEL THE GRAVEL SUPPORT BED. An easy way to determine the levelness of the gravel support bed is to add water to the surface of the gravel. It may be necessary to add or remove water to insure that the water level is at or near the same height of the gravel level. Make certain that the brine line shutoff valve is installed and closed before proceeding. Rotate the position indicator (or dial) on the rear of the pilot to the BACKWASH (No. 1) position and slowly open the manual inlet isolation valve about 1/3 open. Allow the tank to slowly fill with water to the surface of the gravel. Close the manual inlet isolation valve and level the gravel. Make certain that no foreign materials are left in the tank. This includes the bags that the gravel is shipped in. Fig C-1, #18 Fig C-1, #19 Section C-1 29

32 Section C-1 Fig C-1, #20 INSTALLING RESIN 1. Before adding the resin, verify that the correct type and amount of resin for the softener you are installing is on site. Again, refer to table on previous page for the correct resin quantity. If the correct type and amount of resin is not on site, contact the factory or your local Cleaver-Brooks authorized representative. 2. With the position dial in the BACKWASH (No. 1) position slowly open the manual inlet isolation valve about 1 /3 open. Allow the tank to slowly fill about 1 /3 full of water. Close the manual inlet isolation valve. 3. Slowly pour in the correct amount of resin, see Fig. C-1, #20. It is recommended that a funnel be used on those SAB/Q units with handhole covers, when loading resin into the tank. Make certain that no foreign material is left in the tank. 4. Use a tape measure or measuring stick to verify the "M" or freeboard distance after the resin is installed. 5. Open the manual inlet isolation valve about 1 /3 open and allow the tank to fill with water to the manhole or handhole cover level. Then, close the manual inlet isolation valve. 6. Replace the handhole or manhole cover with the gasket in the top head and secure. 7. Rotate the position dial to the SERVICE position and slowly open the manual inlet isolation valve about 1 /3 open. Allow the tank to pressurize. 8. Check the resin tank and piping for leaks. If leaks occur, shut the softener system down and depressurize the unit, following the instructions in section C-7 for depressurization procedures. Once the softener has been depressurized and the resin tank has been drained, disconnect the softener piping at the source of the leak and apply either teflon tape or sealant paste on the piping threads. Reconnect the softener piping and re-pressurize the softener system, per steps 5 thru 7 above. 9. Open the manual inlet valve completely. MULTI-PORT VALVE AND CONTROLS At start-up, it is desirable to bleed air from the CB/RC controller pilot valve tubing by loosening the tubing nut at the multi-port valve diaphragm cap, while under pressure. When water squirts from the fitting, tighten the nut until the leaking stops. DO NOT tighten excessively. Bleed the valves in the following sequence: 1. Rotate the position dial clockwise to the SERVICE position. Bleed valves 2, 5, 6, and Rotate the position dial to the BACKWASH (No. 1) position. Bleed valves 1 and Rotate the position dial back to the SERVICE position. INITIAL BACKWASH 1. Rotate the position dial to the BACKWASH (No. 1) position. Backwash the resin for 10 minutes or until drain water is clear. 2. After the backwash is complete, rotate the position dial back to the SERVICE position. 30 Section C-1

33 SERVICE AND INSTALLATION OF THE BRINE MAKER CHECK BRINE INJECTOR Section C-2 Brine, or saltwater solution (NaCl) is drawn from the brinemaker by a brine injector, mounted on the rear of the multi-port valve. Check the operation of the brine injector as follows: 1. With the manual brine valve(s) still closed, rotate the position dial to the BRINE (No. 2) position. Allow the flow of water to the drain to slow and proceed to step Prior to piping the brine line to the brining assembly, open the manual brine valve and place a hand over the opening. There should be a positive suction. Lack of suction or ejection of water indicates a clogged brine injector or a restriction in the drain line. Check the brine injector first and then the drain line, if necessary. 3. Close the manual brine valve and rotate the position dial to the SERVICE position. 4. Repeat steps 1 thru 3 for each resin tank in the system. INSTALL BRINE MAKER The brinemaker is shipped partially assembled, with the brining assembly shipped in separate carton. The brine line piping, pre-cut for normal tank arrangement, is furnished, attached to the resin tank. There are four holes in the side of the brine well. The upper most hole is an equalization hole and must be left open at all times. The remaining bottom three holes are used for setting the salt dosage for the system (see Fig. C-2 #1). The tank has three salt settings, Maximum, Reduced and Minimum. Two plugs are supplied with the brinemaker. When shipped, the system is set up for maximum salting, which provides maximum softening capacity as shown in the Specification Table in Section A-3. Salt dosage adjustment is made by using the plugs and holes in the following manner: MAXIMUM SALTING 15 lbs/ft 3 Equalization Hole Open Top Hole Plugged Middle Hole Plugged Bottom Hole Open REDUCED SALTING 10 lbs/ft 3 Equalization Hole Open Top Hole Plugged Middle Hole Open Bottom Hole Plugged MINIMUM SALTING 6 lbs/ft 3 Equalization Hole Open Top Hole Open Middle Hole Plugged Bottom Hole Plugged Fig C-2 #1 Section C-2 31

34 Section C-2 Fig. C-2 # 2 Table C-2 # 1 "H" Setting * Measure from top of brining assembly body to bottom of large float with float rod in raised position. To change the factory salt setting proceed as follows: NOTE: Excessive amounts of pipe dope on piping may create operation difficulties. 1. Remove the brine tank cover and brine well cover. 2. Remove the brining assembly from the brine well (if installed). 3. Remove the overflow assembly from the side of the brine well. 4. Remove the brine well from the brine tank 5. Position the salt dosage plugs in the bottom three holes of the brine well as previously described on page Replace the brine well into the brine tank. Insert the overflow assembly through the side of the well and reconnect. Be sure that the brine well pad seal is in position (refer to the illustration on the previous page). The seal should fit snugly around the brine well. 7. Refer to table C-2 #1 and Fig. C-2 #2 to set brine valve "H" setting. 8. Replace the brining assembly (Fig. C-2 #2) into the brine well. 9. Connect the brine line. NOTE: It is recommended that a union be installed in the brine line prior to the manual brine valve to allow for easy removal of the brining assembly. Also allows for verification of suction through brine line. BRINING ASSEMBLY CHECK OUT Use a hose and add water to the brine tank until the level in the brine well reaches the equalization hole in the brine well, just below the salt platform. Open the manual brine valve and allow the brine tank to finish filling through the brining assembly to check out the valve operation. The water level in the brine tank should be about 1 to 1 1/4 above the salt platform when the float shuts off the flow of water. IMPORTANT: The water level must be between 1" and 1 1/4 above the salt platform to provide proper contact of water with salt. If the water level is not correct proceed as follows: LOW WATER LEVEL: Close the manual brine valve. Disconnect the brine line and remove the brining assembly from the brine well. Slide the rubber stop above the upper float on the float rod as required. Replace the brining assembly into the brine well and reconnect the brine line. Repeat initial steps from above and check the water level. Refer to table C-2 #1 and figure C-2 #2 for proper "H" dimension. HIGH WATER LEVEL: Turn the position dial to the rear of the pilot body to the BRINE (# 2) position and allow the unit to draw water from the brine maker. When the level is drawn down below the salt platform, close the manual brine valve. Disconnect the brine line and remove the brining assembly from the brine well. Slide the rubber stop above the upper float on the float rod as required. Replace the brining assembly into the brine well and reconnect the brine line. Rotate the position dial on the rear of the pilot back to the SERVICE position. Repeat initial steps from above and check the water level. Refer to table C-2 #1 and figure C-2 #2 for proper "H" dimension. 32 Section C-2

35 Section C-2 BRINE TANK OVERFLOWS 1. Check the brine valve float rod guide for proper alignment (Float rod should travel up and down without binding). Float must be vertical so that poppet rod assembly seats properly and shuts off the flow of water through the brining assembly. 2. If poppet rod assembly is lifted to the high level position, and continues to allow water to refill the brine tank, check brine poppet or poppet U-cup seal in brining assembly for wear or damage. Refer to section C-10 for parts list reference. BRINE TANK LOADING Replace the brine well cover and fill the brine tank with high purity, refined salt such as compressed pellet, solar pellets, briquette or salt blocks. DO NOT use livestock salt licks since these blocks contain additives. DO NOT use granulated salt since it will fall through the salt platform screen. Crude rock salts are not normally recommended since they contain sludge forming impurities that collect on the platform and prevent proper salt-water contact. IMPORTANT A gallon of fresh water makes about 1.2 gallons of saturated brine, therefore, it is normal for the brine level to rise considerably above the salt platform (After contact with the salt for a period of time). The float may even be completely submerged before the first regeneration. Do not be concerned unless continued brine tank overflow indicates a leaky brine valve, then remove and clean the brine valve. START UP COMPLETION The system is now ready for service. All system inlet and outlet valves should be opened. Close any external by-pass valves. Section C-2 33

36 Section C-3 ELECTRICAL INSTALLATION INSTALLER ALERT CAUTION: Failure to observe the following precautions prior to proceeding with the CB/RC Electrical Installation instructions may result in permanent damage of the CB/RC program module. This type of damage is not covered by warranty. BEFORE YOU BEGIN The CB/RC controller utilizes a microprocessor and should be treated with care. Be sure to carefully observe the following instructions. 1. DO NOT insert the 9 volt battery provided or plug in the 24 volt transformer until instructed. 2. For maximum protection of the CB/RC controller it is recommended that a dedicated 120 volt circuit is provided for the SAB/Q system. 3. If the CB/RC controller is to be remote mounted, remove the program module and store in a safe location prior to mounting the CB/RC enclosure. 4. The CB/RC controller may be remote mounted no more than 200 feet away from the SAB/Q system. 5. Maintain at least 10 feet between the CB/RC controller and any electrical distribution panels, raceways carrying 300 volts or more, and 1 horsepower or greater electrical motors. 6. DO NOT include the CB/RC wiring cables in any conduit or raceway containing other 120 volt or higher circuits. 7. Failure to use the wiring cable provided may result in poor CB/RC controller performance. Contact the factory or your local Cleaver-Brooks authorized representative for assistance. 34 Section C-3

37 Section C-3 CB/RC REMOTE MOUNTING INSTRUCTIONS (OPTIONAL) For some installations it may be desirable to have the CB/RC six position pilot valve assembly separate from the CB/RC controller. Please skip this section and proceed to WIRING PROCEDURES AND DIAGRAMS, page 36 if your SAB/Q system was provided with the CB/RC controller(s) mounted on the multi-port valves(s). The Remote Mounting package option consists of a wall mount type CB/RC Controller and a multi-port valve mounted pilot valve assembly. An electrical shielded, eight (8) conductor cable, TYPE B, is used to interconnect these devices, see Fig.C-3, #8. Note: DO NOT EXCEED 200 FEET BETWEEN THE REMOTE MOUNTED CB/RC CONTROLLER AND THE MULTI-PORT VALVE MOUNTED PILOT VALVE ASSEMBLY. CAUTION: Do not provide power to the CB/RC controller until instructed. Locate the CB/RC controller as follows: 1. Select a flat ridged surface at or near eye level and away from direct exposure to rain, condensation and/or direct sunlight and at least 10 feet away form any electrical panels or raceways carrying 300 volts or more and 1 horsepower or greater motors. 2. Allow sufficient room for the clear hinged cover to swing open, as well as ample clearance from the bottom of the controller to allow room for the electrical cables and strain relief fittings. 3. To mount the CB/RC Controller Enclosure, locate the two hasp locking pins on the right side of the enclosure. To unlock and open the clear cover, use a screw driver to turn the slot in the pins horizontally. Then press on both cover barbs at the same time and lift slightly up and away from the enclosure. Fig. C-3, #1 A. Access to the interior of the CB/RC is easily achieved by removing the controller keypad. (See Fig.C-3, #1) The keypad is kept in place with 4 pieces of velcro found on the rear of the key pad. Simply pull the keypad away from the enclosure and disconnect the circuit board assembly ribbon from the rear of the module. With the keypad module removed and safely set aside, remove the four screws securing the keypad mounting plate. B. Using the CB/RC Controller Enclosure as a template, locate the mounting hole in the upper center portion of the CB/RC Controller Enclosure. (See Fig.C-3, #2) DO NOT DRILL HOLES THROUGH ANY SURFACE OF THE ENCLOSURE AS THIS WILL DESTROY THE NEMA RATING. Using appropriate fasteners securely mount the CB/RC Controller Enclosure to the location desired. (Note: Fasteners not supplied) Repeat steps 1 thru 3 for each CB/RC Controller Enclosure. Fig. C-3, #2 Section C-3 35

38 Section C-3 WIRING PROCEDURES AND DIAGRAMS PREPARATION: 1. Remove the two screws securing the CB/RC circuit board access cover (See Fig.C-3, #3) on each CB/RC controller provided. 2. Using a small screwdriver, loosen all the terminal strip binding screws that do not contain wires by turning counterclockwise until the wire clamp has been fully opened. (See Fig.C-3, #4). CABLE ROUTING: All input and output connections to the CB/RC circuit board are 24 volt or less. Shielded type cable is provided for installation. Note it is imperative that this type cable is used to reduce the possibility of radiated electrical noise from entering the wiring. This precaution will ensure reliable operation of the CB/RC controller. Although the cables do not have to be run in conduit, it is necessary that long runs of cable be supported or protected by strapping them to the equipment piping. If conduit will be used to route the shielded cables, two factors must be considered: 1. DO NOT share the same conduit or raceway with 120 volt or higher circuits. 2. Keep cables at least 6 inches away from 120 volt or higher electrical circuits. 3. GROUND the conduit (if metallic) to a known "earth ground" location. Water-tight strain reliefs are provided in the bottom of the CB/RC controller enclosure for shielded cable interconnecting wiring. Remove the compression nut and rubber sleeve from each fitting. Prior to connection of the shielded cable wires to the circuit board, slide the compression nut and sleeve over the cable for the wiring connections. When wiring is completed, apply a small amount of silicone to the rubber sleeve and reassemble. This will assure all wiring is secure and assist in making the tightening of the fitting easier. Fig. C-3, #3 Fig. C-3, #4 36 Section C-3

39 Section C-3 Following the basic wiring schematic provided (See Fig.C-3, #5) begin installing the wiring to the CB/RC circuit board(s). Note that the schematic refers up to five CABLE TYPES identified as Cable A, Cable B, Cable C, Cable D and Cable E. The following chart further identifies these cables to help eliminate possible confusion. Additional wiring schematics are also shown to provide detailed information on how the installation of individual cable wires are related to the CB/RC circuit board as well as schematics describing other optional installations. Table C-3, #1 Section C-3 37

40 Section C-3 COMPOSITE SCHEMATIC OF BASIC SINGLE, TWIN OR TRIPLE SAB/Q INTERCONNECTIONS Refer to detailed schematics for individual wire connections. Notes: * CONNECT ALL SHIELD WIRES (BARE) EXCEPT FROM FLOW SEN- SORS TO EARTH GROUND. Flow sensor device is optional and not required for time or external signal application, Fig. C-3,#11, Page 42. Required on twin or triple configurations only. See the "Multiple CB/RC Controllers" schematic. Page 40. ** All connections must maintain polarity. See "Transformer" schematic. Page 39. Remote solenoid. Used only on multiple tank systems. See "Remote Solenoid" schematic. Page 41. Fig. C-3, #5 38 Section C-3

41 Section C-3 TRANSFORMER SCHEMATIC CAUTION! When connecting TWO or THREE CB/RC Controllers to a single transformer, maintain polarity. 1. Connect a RED wire from ONE of the transformer outermost terminals to EACH of the CB/RC Controller's 24 VOLT R terminals. 2. Connect a BLACK wire from the OTHER outermost transformer terminal to EACH of the CB/RC Controller's 24 VOLT B terminals. 3. Connect the GREEN wire form the CENTER terminal of the transformer to the EARTH GROUND terminal of the CB/RC Controller. Failure to observe polarity may result in permanent damage to the CB/RC Controller(s) which is NOT covered by warranty. Fig. C-3, #6 Fig. C-3, #7 Section C-3 39

42 Section C-3 INTERCONNECTING MULTIPLE CB/RC CONTROLLERS (OPTIONAL) When two (2) or three (3) CB/RC Controllers are networked together for coordinated operation of twin or triple configurations, their COM (communication) input terminals must be interconnected. Refer to Fig.C-3, #8 for details. It is also necessary to wire the remote solenoid, page 39, at this time. SKIP THIS PROCEDURE IF INSTALLING A SINGLE UNIT. CAUTION! Be certain to observe the polarity requirements ( + ; - ) between controllers. Failure to do so will cause improper operation identified by ALARM 4 status in the display when power is applied. Should this condition occur, check the wiring. Fig. C-3, #8 INTERNAL TERMINATION OF COMMUNICATION CABLE When multiple tank systems are installed, it is necessary to verify the proper internal termination of the communication cable. This is achieved by locating the J4 jumper strap on the lower right corner of the CB/RC circuit board. (See Fig.C-3, #9) Using Table C-3, #2, determine the correct location of the jumper strap. To remove the jumper strap, gently pull the strap away from the CB/RC circuit board exposing all three pins. Position the jumper strap over the two correct pins until firmly seated. NOTE: CARE SHOULD BE TAKEN TO NOT BEND OR BREAK THE PINS. Repeat this procedure as needed for each CB/RC controller. Table C-3, #2 CB/RC Circuit Board J4 No [ ] [ ] Yes [ ] Terminate 40 Section C-3 Fig. C-3, #9

43 Section C-3 REMOTE SOLENOID SCHEMATIC (Multiple tanks only) Multiple tank configurations, (twin and triples) require the addition of a remote solenoid valve, (See section B-5). Although each remote solenoid is shipped attached to the multi-port valve, it is necessary to complete the wiring at the time of the equipment installation. Refer to Fig.C-3, #5 and Fig.C-3, #10 for detailed information. Fig. C-3, #10 Note: The remote solenoid is not provided for single tank configurations. Section C-3 41

44 Section C-3 FLOW SENSOR SCHEMATIC (OPTIONAL) The CB/RC controller is capable of operating with a flow sensor device to provide flow rate information, totalization and volume based regeneration initiation (See Section C-1, pages 22 thru 26). Refer to Fig. C-3,#11 for wiring information of the MK-2535 flow sensor to the CB/RC controller. Fig. C-3, #11 42 Section C-3

45 Section C-3 COMPOSITE SCHEMATIC OF BASIC SINGLE, TWIN OR TRIPLE SAB/Q SYSTEMS WITH REMOTE MOUNTED CB/RC CONTROLLERS Refer to detailed schematics for individual wire connections. Notes: * CONNECT ALL SHIELD WIRES (BARE) EXCEPT FROM FLOW SENSORS TO EARTH GROUND. Flow sensor device is optional and not required for time or external signal application. Fig. C-3,#11, page 42. Required on twin or triple configurations only. See the "Multiple CB/RC Controllers" schematic. Page 40. ** All connections must maintain polarity. See "Transformer" schematic. Page 39. Remote valve operator. schematic. See page 44. Fig. C-3, #12 Section C-3 43

46 Section C-3 REMOTE PILOT VALVE SCHEMATIC - (OPTIONAL) Fig. C-3, #13 When the CB/RC controller is to be remote mounted from the SAB/Q system, CABLE B is used to provide an electrical (24 volt) connection between the CB/RC controller and the remote pilot valve operator (Fig.C-3, #13). Multiple tank configurations also require the addition of a remote, multi-port valve mounted solenoid. The remote solenoids CABLE E provides two wires, black and white. These wires should be secured to the 7 and 8 positions of the remote pilot valve operator terminal strip, Fig.C-3, #16 where they will terminate with the black and white wires from CABLE B of the CB/RC terminal strip. Refer to Fig.C-3, #15 & #16 for detailed wiring information. NOTE: The CB/RC controller may be mounted up to 200 feet from the Remote Pilot Valve Operator. Fig. C-3, #14 Fig. C-3, #16 44 Section C-3 Fig. C-3, #15

47 Section C-3 COMPOSITE SCHEMATIC OF ALL SINGLE, TWIN OR TRIPLE SAB/Q INTERCONNECTIONS Refer to detailed schematics for individual wire connections. Notes: Remote push button, differential pressure switch, hardness/turbidity monitor etc., with a reset type normally open dry contact intended to initiate a regeneration. See "Remote Signal Inputs" Schematic. Page 46. Flow sensor device is optional and not required for time or external signal application. Fig. C-3,#11, page 42. Required on twin or triple configurations only. See the "Multiple CB/RC Controllers" schematic. Page 40. * CONNECT ALL SHIELD WIRES (BARE) EXCEPT FROM FLOW SENSORS TO EARTH GROUND. Use dry contacts of relay to activate self powered alarm device See "Remote Signal Outputs" schematic. Page 47. Remote dry contact from pressure, level, temperature, conductivity sensor to activate alarm See "Remote Signal Inputs" Schematic. Page 46. Required only for remote pilot valve operator installations. See "Remote Pilot Valve Operator" schematics. Page 44. ** All connections must maintain polarity. See "Transformer" schematic. Page 39. Remote solenoid. Used only on multiple tank systems. See "Remote Solenoid" schematic. Page 41. Fig. C-3, #17 Section C-3 45

48 Section C-3 REMOTE SIGNAL DEVICES (OPTIONAL) Two (2) inputs are provided for optional signal devices. Consult with the owner/operator of this system to determine if one or both of the features described below is desired. 1. Start Input - The CB/RC Controller is capable of initiating regeneration sequences as required based on several program options available during the programming sequence. On occasion it may be desirable to override the programmed Regeneration Start sequence with an external device such as a remote push button, batch meter, differential pressure switch, hardness monitor, turbidimeter, etc. Select an UN-POWERED contact within the device that will close when a Regeneration Start is desired. The contact must automatically open following the start of a regeneration sequence. Connect the contact to the START terminals of the CB/RC Controller as shown. Use type "C" shielded cable. Refer to Fig. C-3, #18. IMPORTANT: Connect the Bare shield wire at the CB/RC Controller Earth GND terminal. Cut Off the Bare shield at the signal device end. DO NOT connect it. Fig. C-3, #18 2. In Alarm Input - The CB/RC Controller has a built in Alarm system comprised of an audible horn, a silence button and a visual status display. It is possible to utilize this feature for the purpose of alerting an operator when a monitored condition requires attention. A variety of sensors able to measure temperature, pressure, level, etc. can be connected either individually or in parallel networks. Select an UN-POWERED contact within the device that will close when an alarm condition occurs. Connect the contact to the IN ALARM terminals of the CB/RC Controller as shown. Use type "C" shielded cable. Refer to Fig. C-3,#19. IMPORTANT: Connect the Bare shield wire at the CB/RC Controller Earth GND terminal. Cut Off the Bare shield lead at the sensor device end. DO NOT connect it. 46 Section C-3 Fig. C-3, #19

49 REMOTE ALARM DEVICES (OPTIONAL) Section C-3 An output is provided to operate an optional audible alarm or a central alarming system when a fault is detected by the CB/RC Controller. Consult with the owner/operator of this system to determine if one or both of the features described below is desired. CAUTION: DO NOT exceed the electrical rating of the OUT ALARM output. 1. Audible Alarm - The CB/RC Controller is equipped with an integral self-powered alarm horn. Should a substantially louder audible alarm or a remote location for the audible alarm be required, the remote alarm feature must be implemented. IMPORTANT: All external alarm devices connected to the CB/RC Controller must be Self-Powered. A 6 VOLT DC solid state relay must be connected to the OUT ALARM terminals. The relay will energize when an alarm condition occurs. The relay will de-energize when the ALARM SILENCE key on the CB/RC Controller keypad is depressed. Use Type "C" shielded cable to connect the relay. Refer to Fig. C-3,#20 IMPORTANT: Connect the Bare shield wire at the CB/RC Controller Shield terminal. Cut Off the Bare shield lead at the relay end. DO NOT connect it. NOTE: OUT ALARM electrical rating - 6 VOLT 10 ma. Fig. C-3, #20 2. Central Alarm Systems - the AUDIBLE ALARM feature described above can be modified slightly utilizing the same relay to signal a central alarm system. Refer to Fig. C-3,#21. NOTE: OUT ALARM electrical rating - 6 VOLT 10 ma. Fig. C-3, #21 Section C-3 47

50 Section C-3 WIRING PROCEDURES (CONTINUED) COMPLETION: 1. Once all interconnecting wires and cables have been completely installed and checked, locate the 9 volt alkaline battery provided with each CB/RC controller. 2. Remove the CB/RC controller keypad by pulling the keypad away from the enclosure, releasing the Velcro adhesion. 3. Install the 9 volt battery in the battery holder provided inside the CB/RC enclosure (Fig.C-3, #22). Repeat for each CB/RC controller. 4. Reattach the CB/RC controller keypad to the enclosure and replace the main CB/RC circuit board access cover. 5. Plug in the 24 volt transformer. 6. Proceed to Section C-4 CB/RC Operating Programs. Fig. C-3, #22 48 Section C-3

51 Section C-4 CB/RC OPERATING PROGRAMS There are several operating programs available to control the operation of the SAB/Q water softener system. These programs are designed to be inputted in the field to allow the system to be customized to user requirements. Refer to the programming book for programming instructions. The following is a list of the standard programs used for water softening applications. Select the appropriate program for your system and refer to the programming manual for detailed programming instructions. Refer to Section C-5, System Start Up, to resume installation after programming has been completed. BATCH I -(BATCH IMMEDIATE) Single Tank - TYPE CODE 20 A single media tank regenerated as often as the preset volume has been treated. The only limiting factor to the number of daily regenerations is the speed at which the brine system can produce brine. The softener system should be sized for at least 6 hours of online time to allow for brine makeup. The regeneration sequence will be initiated immediately after the preset volume has been treated. After regeneration the resin tank will immediately be placed back on line. (Used in conjunction with the flow sensor option.) Two Tanks Alternating - TYPE CODE 21/22 Same as TYPE CODE 20 except that the system will operate with two resin tanks, one of which will be on line while the other tank is regenerated and standing by. Each tank can regenerate several times per day. The pair will alternate as the preset volume of each tank is treated. Simultaneous regenerations are not possible. (Used with the flow sensor option.) Two Tanks Progressive Parallel - TYPE CODES 23/25 Three Tanks Progressive Parallel - TYPE CODES 24/25/26 Same as TYPE CODE 20 except that the system will operate with two or three resin tanks. One tank is chosen by the programmer as the master or primary tank. The master is programmed with a flow trip level that shall determine the on line or off line status of the other tank(s) in the system. Should the flow of treated water through the master tank exceed the programmed trip level, slave one (or the secondary tank) is brought on line, splitting the treated water flow between the two tanks. If a third tank (or slave two) is present, any flow greater than two times the programmed trip level will cause the slave two tank to be brought on line. See the example, Fig.C-4, #1 on page 48. Section C-4 49

52 Section C-4 As each tank's preset volume is treated, it will be taken immediately off line, regenerated and returned to either an on line or stand by status, depending upon the treated water flow requirements. To reduce the possibility of one resin tank regenerating while another is soon to be exhausted, each CB/RC controller continually monitors the status of the other CB/RC controller(s) in the system. An internal calculation of the system is made by the CB/RC controller of the tank with the least amount of on line time remaining and a decision is made to initiate a premature regeneration if the remaining tank(s) on line time is not anticipated to be long enough to handle the system requirements. (Used with the flow sensor option.) To further inhibit the possibility of simultaneous regenerations, a regeneration delay can be programmed into each CB/RC controller delaying the time between regenerations by up to 16 hours to allow for brine make up. Raw 30gpm Fig.C-4, #1 PROGRESSIVE FLOW EXAMPLE Master 35 gpm Trip Level On-line Slave 1 Off-line/ Standby Slave 2 Off-line/ Standby Treated 30gpm Raw 40gpm Master 35 gpm Trip Level On-line Slave 1 On-line Slave 2 Off-line/ Standby Treated Raw 80gpm Master 35 gpm Trip Level On-line Slave 1 On-line Slave 2 On-line Treated 50 Section C-4

53 Section C-4 BATCH D (BATCH DELAYED) Single Tank TYPE CODE 30 A single resin tank regenerated a maximum of once per 24 hour period based on two conditions occurring in this order: 1. Preset volume of treated water is reached and, 2. Regeneration start time of day occurs. The regeneration sequence will occur at the programmed start time if the preset volume of treated water is reached. The tank is placed back on line immediately following a regeneration. (Used with the flow sensor option.) DAY/WK (DAY OF THE WEEK) Single Tank TYPE CODE 50 A single resin tank is regenerated on the basis of a day of the week schedule determined by the programmer (minimum 1 day per week; maximum every day per week). The regeneration sequence is initiated at a user set time. The unit goes back on line immediately following a regeneration. Two Tanks Alternating TYPE CODE 51/52 Same as TYPE CODE 50 except that the system will operate with two resin tanks, one of which will be on line while the other is regenerated and placed in standby. Up to two resin tanks can regenerate on a user specified day. The pair will alternate at the beginning of each regeneration sequence. A programmed regeneration day will be ignored if it happens to occur for a resin tank which is in standby. Simultaneous regenerations are not possible. PREDICT Single Tank TYPE CODE 00 A single resin tank is regenerated a maximum of once per 24 hour period, based on treated water used. The regeneration schedule is determined automatically by the CB/RC controller through a series of mathematical calculations internally performed. These calculations are affected by the amount of water treated on both a daily and weekly nature. Should the preset volume of water through the system not be obtained within a specified period of days, a calendar override feature will allow the user to force regenerations to occur on a specified day and time to prevent damage to the resin due to inactivity. The unit goes back on line immediately following a regeneration. Two Tanks Alternating TYPE CODE 01/02 Same as TYPE CODE 00 except that the system will operate with two resin tanks, one of which will be on line while the other is regenerated and placed in standby. Each tank could regenerate once within a 24 hour period as determined by the controller. The pair will alternate as each is calculated to be exhausted. Simultaneous regenerations are not possible. Section C-4 51

54 Section C-4 CB/RC PROGRAM FEATURES All of the above program options offer the following standard and optional features. Refer to the programming manual for more information. STANDARD CB/RC PROGRAM FEATURES 1. Regenerations may be initiated manually from a push button. 2. Regeneration initiation may be: A. Fully automatic - User initiation not required. B. Semi-automatic - Requires user attention to initiate regeneration as indicated by the CB/RC controller. CB/RC OPTIONAL PROGRAM FEATURES 1. Flow rate indication is available when a flow sensor is incorporated into the system 2. Cumulative Volume Totalization is available when a flow sensor is incorporated into the system. In addition each CB/RC programming module has a brief descriptive Program Identification Chart on the rear of the module. (Fig.C-4, #2) Electronic Programmable Water Treatment Equipment Controller Program Identification Type Options Configuration Options Type Description of Operation PREDICT Equipment Controller Code Single Single 00 Regeneration initiation is determined by the Controller, based Alternating Twin MONITOR Single - 10 MSTRALT 01 on water usage patterns and delayed to a user set time. SLVALT 02 Batch Monitor-Provides a visual and audible alarm along with electrical output signals based on two user set time intervals and two user set volumes. Single Single 20 Alternating MSTRALT 21 Regeneration initiation occurs Twin SLVALT 22 immediately after a user specified BATCH I Parallel MSTRTWN 23 volume has been treated. (IMMEDIATE) Twin SLV1 25 Parallel MSTRTPL 24 Progressive Flow Mode Triple SLV1 25 available in parallel twin and SLV2 26 triple configurations. BATCH D Single Single 30 Regeneration initiation occurs at (DELAYED) Alternating MSTRALT 31 a user set delayed time after a Twin SLVALT 32 user specified volume has been treated. SINGLE SINGLE 40 Regeneration initiation occurs INTERVAL Alternating MSTRALT 41 after user selected 24 hour time Twin SLVALT 42 intervals (1-99) have occurred at a user set delayed time. DAY/WK Single Single 50 Regeneration initiation occurs (DAY OF WEEK) Alternating MSTRALT 51 on a user set day of the week Twin SLVALT 52 or any combination of week days at a user specified time. Single Single 60 Regeneration initiation occurs MINUTE Alternating MSTRALT 61 immediately after user selected Twin SLVALT 62 1 minute time intervals (1-9,999) have occurred. Single Single 70 Regeneration initiation occurs SIGNAL Alternating MSTRALT 71 after a user set time interval Twin SLVALT 72 (1-999 minutes) activated by an external signaling device. Lift Here To Expose Discharge Switch. Use Wood Rod To Activate. WARNING: Power Must Be Disconnected Before Automatic Discharge. Specifications Power Requirements 24VAC,+2VAC; 15VA. Minimum Memory Backup Internal Capacitor 24 hours External Battery 48 hours Output Rating A,B & C24 VAC 50/60 20W. each Out Alarm 6 10 MA. (Max) FLO+; 9.5 4MA. Environment Temperature storage /160 0 F Operation 0 0 /140 0 F Humidity; 95% relative. Avoid moisture contact. Inputs Start & Cam External Dry Contact Closure; 100 Ω Max. Flow IN/GND External.Dry Contact or Hall 100 Ω Max. Important This controller to be used only with I/O Circuit Board P/N Complies as a Class A Computing Device pursuant to Subpart J of Part 15 of FCC rules. No user serviceable parts inside. Refer servicing to qualified personnel. U.S.PATENTS 5,060,167 5,351, Section C-4 Fig. C-4, #2

55 Section C-5 SYSTEM START UP Once you have completed the installation procedures described in Sections C-1 thru C-4, you are ready to put the system on line. Prior to beginning the final start up procedure it is recommended that you review the following check list to be sure the system is properly installed up to this point. CHECK LIST 1. The resin tank has been properly loaded with gravel and resin. (Refer to Section C-1) 2. The drain line has been properly installed. (Refer to Section C-1) 3. Air has been bled from the multi-port valve and the system has been properly pressurized. (Refer to Section C-1) 4. Each resin tank has been backwashed manually. (Refer to Section C-1) 5. The brine line has been properly installed. (Refer to Section C-1) 6. The salt dosage adjustment plugs are installed in the brine well for the desired salting level. (Refer to Section C-2) 7. The salt shelf, supports and platform are properly installed. (Refer to Section C-2) 8. The brining assembly is properly adjusted to allow 1" to 1 1/4" of water above the salt shelf. (Refer to Section C-2) 9. The CB/RC controller(s) have been correctly and completely wired. Including any and all optional items such as flow sensors and remote solenoids. (Refer to Section C-3) 10. All CB/RC controllers have been properly programmed and are active (power on).(refer to Section C-4) Section C-5 53

56 Section C-5 INITIATING AN AUTOMATIC REGENERATION SEQUENCE After all checklist items have been completed, it is necessary to step each CB/RC controller through a regeneration sequence to verify the proper operation of the CB/RC controller. All steps of the regeneration sequence process will be initiated by depressing the START/STEP key for three seconds when indicated. 1. Make sure the position arrow on the pilot valve body is aligned with the SERVICE position of the position dial. 2. Power should be on. 3. Close the manual brine line valve(s). 4. Depress the START/STEP key on the CB/RC keypad for three seconds. The position dial should rotate clockwise to the #1 BACKWASH cycle within 3 minutes. There will be a high flow of water to drain. Allow the system to operate in the BACKWASH cycle for about 3 minutes. 5. Depress the START/STEP key (for 3 seconds) allowing the position dial to rotate to the #2-INITIAL BRINE DRAW cycle. There will be a low flow of water to drain. Allow the system to operate in the INITIAL BRINE DRAW cycle for about 3 minutes. 6. Depress the START/STEP key (for 3 seconds) allowing the position dial to rotate to the #3-INITIAL BRINE RINSE cycle. There will be a low flow of water to drain. Allow the system to operate in the INITIAL BRINE RINSE cycle for about 3 minutes. 7. Depress the START/STEP key (for 3 seconds) allowing the position dial to rotate to the #4-FINAL BRINE RINSE cycle. There will be a low flow of water to drain. Allow the system to operate in the FINAL BRINE RINSE cycle for about 3 minutes. 8. Depress the START/STEP key (for 3 seconds) allowing the position dial to rotate to the #5-FLUSH cycle. There will be a high flow of water to drain. 9. Allow the CB/RC controller to complete the #5 cycle and automatically rotate through the #6 cycle and back into the SERVICE position. The flow to drain will stop. As the position dial rotates through the #6 cycle and back into SERVICE, PHASE may appear in the CB/RC program module display window. THIS IS NOR- MAL AND WILL CLEAR AUTOMATICALLY UPON THE RETURN OF THE PILOT TO SERVICE. 10. Repeat steps 1 thru 8 for each CB/RC controller before proceeding to step Open the manual brine line valve(s). 12. Close any open bypass valves. 13. Allow the raw water to enter the system for softening. 14. Test the conditioned water for softness. An indication of soft water means the unit is operating properly. A hard water indication over 1 grain per gallon may indicate a problem. Consult the Troubleshooting Guidelines in Section C Section C-5

57 Section C-6 TROUBLESHOOTING GUIDE We will now review the Troubleshooting Guide and Preventive Maintenance Table for the service functions of the Softener System. IMPORTANT: The SAB/Q softener is a mechanical device and is designed to respond to outside control sources to perform the service and regeneration functions. Many system complaints result from simple oversights such as poor electrical connections, lack of salt in the brine system, or the unit not regenerating at the proper time. It is important to review the following SAB/Q System Troubleshooting Guide first to determine the cause of a particular problem or complaint. It is advisable to have a water hardness or soap test kit available when trying to diagnose a service problem. These kits are very important for troubleshooting a water softener. A pressure gauge may be required for checking water and air pressure. A stopwatch and measuring bucket may be needed to check water flow rates. Failure of the softener to operate properly is often caused by a minor problem that can easily be corrected by the owner. To save time and expense, check the following list before referencing the troubleshooting guide. HARD WATER PROBLEM Test for soft water at sampling cock located on the lower right-hand corner of multi-port valve: 1. If water tests soft. a. By-pass valve may have been open and has since been closed. b. Softener may have been exhausted when hardness was discovered. Verify that the brinewell hole setting and the regeneration schedule are proper for this application. Refer to section C-2 service of the Capacitrol Brinemaker for more information. 2. If water tests hard: a. Electrical connection may be faulty or a fuse may be blown. b. Brinemaker may not contain salt. c. Manual brine line valve(s) may be closed. They should remain open. d. If rock salt is being used, sludge may be preventing the salt from dissolving. Clean the brinemaker and refer to section C-2 brine tank loading for recommended salts. e. Water level in the brinemaker may be low. The level must be above the platform. Move the float stop up on the brining assembly, if necessary. Refer to Section C-2, Service and Installation of the Capacitrol Brinemaker, for further instruction on setting the brining assembly. f. Brine injector may be plugged. Place the position dial in the initial brine draw position and observe if brine is drawn in. If not, relieve the tank pressure, remove the lower cap from the injector body and clean the brine injector. Refer to Appendix A. HOW TO USE THE TROUBLESHOOTING GUIDE 1. Locate the problem in the left hand column. 2. Follow the Check Procedure in the order shown until the cause of the trouble is found. 3. Review the Cause comments. These are only comments. You should refer to the sections listed in the manual to give you the proper instructions and information for service requirements. 4. The Information column gives the section location that explains the theory of operation, replacement procedure and the page for the replacement parts. You may find a multitude of sections listed, as well as pages. This is because a key piece of information may be referenced in one or more of these sections or pages. 5. Prior to removing or replacing a part read Before You Start, Section C-7 to make certain you review the safety precautions that are required before work begins. Section C-6 55

58 Section C-6 TROUBLESHOOTING GUIDELINES The chart below lists some possible problems or symptoms of mechanical failure and the suggested service procedure. 56 Section C-6

59 Section C-6 TROUBLESHOOTING GUIDE Section C-6 57

60 Section C-6 TROUBLESHOOTING GUIDE 58 Section C-6

61 Section C-7 SAB/Q PREVENTIVE MAINTENANCE Table C-7, #1 PREVENTATIVE MAINTENANCE - BEFORE YOU START There are two basic reasons for any service procedure: a) Preventive maintenance is being performed, or b) A system problem is being corrected. See Table C-7 #1 or Troubleshooting Guidelines section C-6. In either of these cases, before you start you should fully test the system and make certain that there is not a problem that might be missed. You should follow the system manual for the complete system test and check out procedure. You should write down your test results after you perform the service process and retest the system to make certain that you performed the service process correctly and corrected a system problem. You need to take some basic safety precautions before you start and during the service process. PRECAUTIONS INCLUDE: 1. Review the manual before you start the service process. 2. Disconnect all electrical equipment as it applies in the System Manual. Also, in some cases, you may be spilling water on the floor surface area. To protect yourself from electrical shock, disconnect all electrical power. 3. Follow the different procedures for depressurizing the water treatment system. In some cases, the incoming water needs to be shut off. In other cases, it may be required to shut off the hard water inlet valve, soft water outlet valve, and the manual brine valve to the brine injector. When draining the resin tank, be sure that an adequate drain facility is available for the water flow to prevent flooding or water damage. Section C-7 59

62 Section C-7 PROCEDURE FOR DEPRESSURIZING THE MULTI-PORT VALVE AND SYSTEM FOR SERVICE 1. Complete shut down procedure. a. Disconnect the electrical power to the CB/RC controller. b. Make certain that the lines you shut off are for the system you are doing service on. 1. Open by-pass valve if one is available. 2. Shut off the source water supply line (inlet). 3. Shut off the processed water supply line (outlet). 4. Shut off the manual brine valve. 5. Any external source of pressure to the pilot valve. c. Rotate the position dial on the pilot valve to the backwash (#1) position. d. Open the soft water sample cock. e. Make certain that there is no pressurized water coming out of the sample cock. If pressurized water is flowing from the sample cock, retrace your steps. f. Once the tank has been depressurized, open the resin tank cover and allow the tank to drain down so the water level is below the valve height. Be prepared to replace handhole O-ring or manhole cover gasket. g. Proceed with servicing the SAB/Q System. Throughout this manual we suggest the use of a mild cleaning solvent and a silicone lubricant. We suggest the following brands or their equivalents: Solvent: Simple Green water soluble for removing corrosion and dirt. Lubricant: Dow Corning #11 silicone grease. NORMAL ATTENTION BY OWNER Maintain an adequate supply of high purity Sodium Chloride salt (NaCl) in the brine maker. DO NOT USE granulated salt. Refer to the Install Brine Maker section in this manual for further instructions on the proper types of salt. Again, regularly test for soft water using a soft water test kit to determine if the hole setting and the regeneration schedule are satisfactory. Hole settings refer to brine dosage setting in brinemaker. See section C-2, Service and Installation of Brine Maker for more information. A daily check is recommended to avoid over exhaustion, or capacity depletion of the resin which will reduce its efficiency. Maintain a log of the softener operation to indicate if adjustment of either the hole setting or regeneration schedule is required, and to indicate when the salt supply in the brinemaker needs replenishing. 60 Section C-7

63 Section C-8 SERVICE & INSTALLATION OF THE MULTI- PORT VALVE The multi-port control center is designed for use with both automatic or manually operated water softeners. Normal range of application is 30 p.s.i. to 100 p.s.i. water pressure, with water temperatures up to 120 F. The multiport valve operation is smooth and entirely free of water hammer. The multi-port valve is well designed and constructed from the finest material. As with any mechanical device, periodic maintenance or repair is required. The multi-port valve is a unique and complex piece of equipment. Appendix A describes the multi-port valve operation, disassembly and repair of this control valve. The various accessory items furnished with the valve, such as pilot valve, by-pass valve, etc. will also be explained along with disassembly and service instructions. The multi-port valve consists of five individual diaphragm valves and one bypass valve, housed in a compact casting. These valves operate by pressure and are actuated by an external pilot valve (either automatically or manually) in the proper sequence for the regeneration cycle. Additionally, a backwash flow controller is used on the drain outlet to control the back-wash flow rate and fast flush flow rate, see page 63. A brine injector, which draws in brine to regenerate the softening mineral is mounted on the back of the multi-port valve. (Refer to Appendix A.) Section C-8 61

64 Section C-8 FLOW DIAGRAMS Flow patterns for the regeneration and service cycles are governed by the individual diaphragm valves. These valves close when under pressure and open when pressure is vented. Each is identified by a number cast on the front of the main valve body. Control tubing connects each numbered valve with the corresponding numbered port of the pilot valve. Sequence of the regeneration cycle depends on which Model Cycle Controller is used. Notes - #3 is not used on standard SAB/Q systems but available for timed brine draw applications. #17 is always closed on multiple tank systems. #8/10 is not used on standard SAB/Q systems. 62 Section C-8

65 Section C-8 BACKWASH FLOW CONTROLLERS - THEORY OF OPERATION AND SERVICE Located on the drain connection of the multi-port valve, the purpose of the backwash flow controller is to regulate the up flow backwash required to expand and agitate the resin in the resin tank. The controller will allow maximum expansion of the resin, while preventing any loss to the drain. The flow control principle is simple and trouble free. The specified rate of flow will be constant regardless of inlet pressure variations. This is accomplished by the automatic change in orifice size of the flow washer as inlet pressure varies. The flow washer pictured above is installed, either in a single or multiple configuration within a special nipple. The selection and the number of flow washers can achieve any desired backwash flow rate. Occasionally, the Backwash Flow Controller may become plugged with scale, rust, or other foreign material. If this occurs, cleaning is required. This can be done while the softener is in the SERVICE and under pressure. BACKWASH FLOW CONTROLLER DISASSEMBLY 1.) Remove clean-out plug and inspect the flow washer area. (see Fig. C-8, #1) 2.) Remove any foreign material lodged in or near the flow washer(s). (see Fig. C-8, #2) Section C-8 63

66 Section C-8! NOTE: AVOID USING A SHARP OBJECT WHICH MIGHT CUT OR DAMAGE THE RUBBER FLOW WASHER(S). SHOULD IT NOT BE POSSIBLE TO CLEAR THE CON- TROLLER THROUGH THE CLEAN OUT PLUG, REMOVAL OF THE FLOW CON- TROL NIPPLE WILL BE REQUIRED TO GAIN BETTER ACCESS OF THE FLOW WASHER AREA. Fig C-8, #1 If removal of the Backwash Flow Control nipple is necessary, disconnect the flexible tubing from the compression fitting. Carefully separate the nipple from both the drain line and the multi-port valve (see Fig C-8, #3). Inspect and clean flow washer(s) (see Fig C-8, #4, #5). Fig C-8, #2 BACKWASH FLOW CONTROLLER REASSEMBLY 1. When replacing the Backwash Flow Control nipple, make certain the compression fitting is downstream from the flow washer. 2. Connect the flexible tubing to the compression fitting located in the side of the Backwash Flow Control nipple. Fig C-8, #3 3. Insert and tighten clean-out plug. (see Fig C-8, #1) Fig C-8, #4 Fig C-8, #5 64 Section C-8

67 Section C-8 REPLACEMENT FLOW WASHER FOR BACKWASH FLOW CONTROLLERS To order replacement flow washer(s) for your backwash flow controller, refer to the system specifications in the installation section of this book. Locate the backwash rate for your system, Section A-4, page 4, then find the part number and quantity of flow washer(s) required from the tables below.! IMPORTANT- To prevent system problems, the flow washers must be installed with the identifying letter or number side up. (Adjacent to the retaining ring) For flow rates from 2.4 GPM to 11.5 GPM, only one flow washer required. Backwash Rate GPM = 10.0 Part No. Flow Washer = (1) SAB 150 Series For Flow Rates from 12 GPM to 30 GPM, the entire Flow controller must be ordered. Backwash Rate GPM = 13.5 Part No. Flow Washer = SAB 210 Series SAB 300 & 450 Series SAB 600 & 750 Series For flow rates from 35 GPM to 115 GPM, a number of small flow washers are used in common housing. EXAMPLE: If you wish to order Flow Washer for a backwash rate of 45 GPM SAB 900 & 1050 Series), you would order (4) Part No Backwash Rate GPM = 45.0 Flow Washer = 11.5 GPM Part Numbers - (4) For Flow Rates not listed or in excess of 115 GPM or for hot water use (140 O to 200 O ) consult factory. Reference the Part List section for proper Kit Part Number when ordering replacement parts. Section C-8 65

68 Section C-9 SERVICE OF THE CB/RC CONTROLLER THE CB/RC PROGRAM MODULE The CB/RC controller program module contains six different cycles and cycle settings (refer to Section B-4), responsible for the duration of the system regeneration sequence. Each cycle has a factory default time preprogrammed to assure enough time is allowed for the regeneration process. Should it be necessary to modify the time programmed for each cycle, refer to the chart below for information on time limits per cycle and the Programming manual for reprogramming instructions. *NOTE - Cycle #6 is not used for this application. 66 Section C-9

69 Section C-9 CB/RC PROGRAM MODULE AND BATTERY REPLACEMENT NOTE: A loss of programming may be experienced when replacing the battery. 1. Prior to beginning, make sure the current program has been recorded on the program log sheet provided in the Programming Manual. If not, refer to the appropriate Programming Manual for instructions about reviewing existing program information. 2. Unplug the transformer powering the CB/RC controller. 3. Open the clear hinged cover and gently pull the CB/RC program module away from the enclosure (Fig.C-9, #1). Disconnect the ribbon cable from the socket on the rear of the module. 4. To replace the 9 volt alkaline battery, remove the battery inside the CB/RC enclosure and replace with a new 9 volt alkaline battery. NOTE- It is recommended that the battery be replaced a minimum of every 12 months or after experiencing power outages greater than 20 minutes. 5. Reconnect the ribbon cable at the rear of the new CB/RC program module and reposition the module back on the Velcro adhesive strips. 6. Plug in the transformer powering the CB/RC controller. 7. Reprogram the CB/RC controller using the information recorded in step 1, if necessary. Fig. C-9, #1 CB/RC PILOT DRIVE MOTOR ASSEMBLY REPLACEMENT Fig. C-9, #2 1. Refer to steps 1 thru 3 under CB/RC Program Module and Battery Replacement. Remove the CB/RC program module mounting plate by loosening the 4 screws securing it in place (Fig.C-9, #2). 2. The pilot valve drive motor assembly is held in place with 3 panhead screws. Remove the screws and disconnect the motor leads. NOTE: At this point it is also advisable to visually inspect the cam gear and micro-switches for any wear indicating the need for replacement. Refer to Cam Gear And Micro-Switch Replacement for detailed instructions. 3. Install the replacement pilot valve drive motor assembly making certain that the gears and assembly are properly engaged. Securely tighten the 3 screws and reconnect the motor leads. (Refer to Fig.C-9, #3). Replace the mounting plate and four screws. 4. Reinstall the CB/RC program module following steps 5 thru 7 under CB/RC Program Module And Battery Replacement. Fig. C-9, #3 Section C-9 67

70 Section C-9 CAM GEAR AND PILOT VALVE CIRCUIT BOARD REPLACEMENT 1. Refer to steps 1 thru 3 under CB/RC Program Module and Battery Replacement. Remove the CB/RC program module mounting plate by loosening the 4 screws securing it in place (Fig.C-9, #1). 2. The pilot valve drive motor assembly is held in place with 3 panhead screws. Remove the screws and disconnect the motor leads. The pilot valve drive motor assembly can now be removed for access to the cam gear and\or pilot valve circuit board. 3.Remove the cam gear. Slide the 3 gray nylon spacers off of the screw posts and lift the pilot valve circuit board out of the CB/RC enclosure (Fig.C-9, #4). 4. Disconnect the six remaining wire leads (brown, yellow, orange, red, green and blue). Reconnect the wire leads to the appropriate color coded terminal on the new pilot valve circuit board 5. Position the pilot valve circuit board assembly back over the 3 screw posts and slide into place. 6. Reinstall the new cam gear. NOTE: The cam gear is designed to only be installed one way onto the pilot valve spool. The flat portion of the pilot valve spool must align with the flat side of the cam gears pilot valve spool receptacle. When properly positioned, the cam will snap into place on the pilot valve spool. (Fig.C-9, #1). 7. Replace the 3 gray nylon spacers followed by the pilot valve drive motor assembly making certain that the gears and assembly are properly engaged. Securely tighten the 3 screws and reconnect the motor leads. Replace the mounting plate and 4 screws. 8. Reinstall the CB/RC program module following steps 5 thru 7 under CB/RC Program Module And Battery Replacement. Fig. C-9, #4 Fig. C-9, #5 68 Section C-9

71 Section C-9 PILOT VALVE SPOOL REMOVAL & REPLACEMENT 1. Follow the instructions for depressurizing the system, Section C-7, page Manually rotate the position dial on the pilot valve clockwise to the #1 - BACKWASH position to relieve pressure (see Fig.C-9, #6). Allow the flow of water at drain to stop before proceeding. 3. Remove the panhead retaining screw located at the bottom rear portion of the pilot valve body. Grasp the position dial and pull the pilot valve spool assembly from the pilot valve body. (see Fig.C-9, #7). 4. A retaining clip on the rear of the position dial secures the pilot valve spool assembly to the position dial. Using a screw driver, gently pry the retaining clip off of the pilot valve spool. 5. LIGHTLY lubricate all seals on the replacement pilot valve spool with Dow Corning #11 silicon grease and reassemble the position dial back onto the valve spool assembly. NOTE: When inserting the pilot valve spool assembly into the position dial, the larger flat portion of the pilot valve spool assembly must align with the ALIGN TO FLAT indicating arrow. 6. Replace the new pilot valve spool assembly into the pilot valve body making sure that the #1 on the position dial aligns with the pilot valve body position indicator arrow. 7. Replace the small panhead retaining screw to secure the pilot valve spool assembly into the pilot valve body and slowly reopen the inlet service valve. 8. Slowly manually rotate the position dial clockwise, back to the #1 BACK- WASH position, allowing water to flow to the drain. Bleed the air from ports 1 and 4 of the multi-port valve. Allow Backwash to continue for 10 minutes. 9. Rotate the position dial slowly clockwise to the SERVICE position and bleed the air from ports 2, 5, 6, and 17 of the multi-port valve. 10. Once the system has been repressurized, open the treated water outlet valve and manual brine valve(s). Close the external by-pass valve and restore power to the CB/RC controller. Fig. C-9, #6 Fig. C-9, #7 Section C-9 69

72 Section C-9 Fig. C-9, #8 PILOT VALVE BODY ASSEMBLY REMOVAL 1. Refer to steps 1 thru 3 under CB/RC Program Module and Battery Replacement. Remove the CB/RC program module mounting plate by loosening the 4 screws securing it in place. 2. Follow the instructions for depressurizing the system, Section C-7, page Remove all pilot valve tube connections from the pilot valve body. (Fig.C-9, #8). 4. Remove the pilot valve drive motor assembly located inside the CB/RC controller enclosure by removing the 3 panhead screws securing it in place. Disconnect the two yellow motor leads. 5. Remove the cam gear by gently pulling it toward you. 6. Locate and remove the 3 gray nylon spacers from the screw posts and slide the pilot valve circuit board out of the CB/RC enclosure. 7. Disconnect the six remaining color coded wire leads (brown, yellow, orange, red, green, and blue) from the pilot valve circuit board. 8. Remove the 2 large panhead screws located inside the enclosure that secure the pilot valve body assembly. The pilot body assembly will now separate from the enclosure. 9. Refer to Pilot Valve Assembly Replacement for reinstallation instructions. PILOT VALVE ASSEMBLY REPLACEMENT 1. When installing the replacement pilot valve body to the rear of the CB/RC enclosure, make certain the word POSITION faces outward and right side up. Securely tighten the 2 panhead machine screws removed in step 8 of the Pilot Valve Body Assembly Removal procedure. 2. Reconnect the six color coded wire leads to the appropriate color coded terminal on the pilot valve circuit board and slide back into position over the 3 screw posts. 3. Replace the 3 gray nylon spacers and the cam gear. NOTE: The cam gear is designed to only be installed one way onto the pilot valve spool. The flat portion of the pilot valve spool must align with the flat side of the cam gears pilot valve spool receptacle. When properly positioned, the cam will snap into place on the pilot valve spool. (Fig.C-9, #5). 4. Replace the pilot valve drive motor assembly making certain that the gears and assembly are properly engaged. Securely tighten the 3 screws and reconnect the motor leads. Replace the mounting plate and 4 screws. 5. Reconnect the pilot valve tubing to the pilot valve body. NOTE: Numbers on the pilot valve body must correspond with the numbers on the multi-port valve when reconnecting the tubing. 6. Reinstall the CB/RC program module following steps 5 thru 7 under CB/RC Program Module And Battery Replacement. 7. Slowly reopen the inlet service valve. 8. Slowly rotate manually the position dial clockwise back to the #1 BACKWASH position allowing water to flow to the drain. Bleed the air from ports 1 and 4 of the multi-port valve. Allow Backwash to continue for 10 minutes. 9. Rotate the position dial slowly clockwise to the SERVICE position and bleed the air from ports 2, 5, 6, and 17 of the multi-port valve. 10. Once the system has been repressurized, open the treated water outlet valve and manual brine valve(s). Close the external by-pass valve and restore power to the CB/RC controller. 70 Section C-9

73 MAIN CIRCUIT BOARD REPLACEMENT Section C-9 1. Refer to steps 1 thru 3 under CB/RC Program Module and Battery Replacement. Remove the CB/RC program module mounting plate by loosening the 4 screws securing it in place. 2. Refer to steps 2 & 3 of the Cam Gear And Pilot Valve Circuit Board Replacement and remove the pilot valve drive motor, cam gear and pilot valve circuit board assemblies. 3. Disconnect all wiring to the terminal strip of the main circuit board. Disconnect all wire leads connected to the main circuit board assembly. Remove the two lower panel screws to further expose the main circuit board. 4. Remove the 9 volt alkaline battery. Locate and remove the single Phillips screw securing the battery holder. Remove the two large panhead screws from the lower portion of the main circuit board. 5. Gently lift and remove the main circuit board thru the top portion of the CB/RC controller enclosure. Install the new main circuit board. (Fig.C-9, #9). 6. Secure the two large panhead screws into the lower portion of the main circuit board as well as the small Phillips screw securing the battery holder. At this point it is recommended that a new 9 volt alkaline battery be inserted into the battery holder. 7 Verify the correct J4 termination setting. (Refer to Section C-3 page 40). 8. Reconnect all color coded wire leads to the top portion of the main circuit board assembly. 9. Replace the pilot valve drive motor, cam gear and pilot valve circuit board per steps 2, 3, & 4 of the Pilot Valve Assembly Replacement instructions. 10. Reconnect all wiring to the lower portion of the terminal strip. Refer to Section C-3 for wiring installation instructions. NOTE: IT IS VERY IMPORTANT TO MAINTAIN POLARITY BETWEEN MULTIPLE CONTROLLERS AND THE 24 VOLT TRANSFORMER. 11. Replace the lower panel cover plate and reinstall the CB/RC program module per steps 5 thru 7 under the CB/RC Program Module and Battery Replacement instructions. Fig. C-9, #9 Section C-9 71

74 Section C-9 CB/RC ALARM HORN REPLACEMENT 1. Refer to steps 1 thru 3 under CB/RC Program Module and Battery Replacement. Remove the CB/RC program module mounting plate by loosening the 4 screws securing it in place. 2. Disconnect the two wire leads to the CB/RC alarm horn (violet and gray). 3. Grasp the round retaining nut securing the CB/RC alarm horn on the right exterior side of the CB/RC enclosure and turn counter clockwise to remove, Fig.C-9, # Slide the CB/RC alarm horn out of the enclosure and replace. DO NOT reuse the old o-ring. A new o-ring is provided in the replacement kit. 5. To install the new CB/RC alarm horn, insert it thru the enclosure with the threads outward. Position the o-ring over the threads and securely hand tighten the nut to the assembly. Note that the retaining nut has 3 small groves on the side that faces outward. DO NOT use a wrench to secure the alarm horn. HAND TIGHTEN ONLY. 6. Reconnect the two wire leads. The violet wire should be attached to the positive post of the CB/RC alarm horn and the gray to the negative. 7. Reinstall the CB/RC program module following steps 5 thru 7 under CB/RC Program Module And Battery Replacement. Fig. C-9, #10 72 Section C-9

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