Tech Manual Powerline Filter (PF) Series

Tech Manual Powerline Filter (PF) Series Models: PF 2162 PF 2465 PF 3072 PF 3672 PF 4272 PF 4872

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TABLE OF CONTENTS 1.0 General Information About this Manual...3 Filtration Technology...5 The Powerline Product Line...6 2.0 Equipment Specifications System Configuration...7 Component Functionality...7 3.0 Installation Getting Started...10 Pre-installation Review...10 Powerline Installation...11 Unpacking...11 Tank Placement...11 Distributor Assembly...11 Media Loading...12 Control Valve...13 Interconnecting Plumbing...13 Backwash Flow Control...14 Drain Line...14 Electrical Service...14 4.0 Operation and Maintenance Normal Operating Procedures Pre Start-up Check List...15 Start-up Procedures - Simplex...15 System Flow Paths...18 Troubleshooting...18 5.0 Parts 2850 Control Valve...21 3150 Control Valve...22 3150 Drive Assembly...23 3900 Control Valve Assembly...24 Timer Assemblies...25 Misc. Parts...27 6.0 Drawings Control Valves...28 Page - 2

GENERAL INFORMATION About this Manual This manual will cover information needed for the proper installation and operation of your Kinetico Powerline Filter System. We have also included information regarding the frequently asked questions about filtration systems. This information may be more technical in nature, but provides further insight to the continued operation of this equipment to its highest standards. This manual will use various icons to help highlight issues that are relevant to the safe operation of this equipment. The following icons will be used as described: General information regarding the application of this product will be highlighted by this icon. This will include technical specifications and expected operational results. Lock out electrical power Use appropriate lockout procedures when servicing. Maintain safe pressure This sign indicates the safe operating pressure range. Consult maintenance section Refer to the maintenance section for specific instructions. Consult equipment specifications section Refer to the equipment specifications section for specific instructions. Consult MSDS sheets A caution icon will be used to present any information that may hold a potential hazard or concern during the installation, use or maintenance of this product. Should this information not be followed, it may result in damage of this equipment and its surroundings. Electrical shock or electrocution hazard Pinch point or crushing hazard Chemical hazard Page - 3

The warning icon will be used to present any information that may result in a severe hazard or concern during the installation, use or maintenance of this product. Should this information not be followed, it may result in severe physical harm. Stay clear Do not touch No access Only properly trained and authorized persons can enter area or open panel. Any tools or materials required during the installation, use or maintenance of this equipment will be preceded by this icon. Using these specific tools will minimize time and effort. Not using the proper tool may result in damage to this equipment, its surroundings or even physical harm. If there are any additional questions pertaining to this equipment, please contact your local Kinetico Dealer for further assistance. Page - 4

Filtration Technology Many water supplies contain suspended solids. This material can cause excessive wear on equipment such as water heaters, boilers, steamers and humidifiers. Removing the solids from water elongates the life of many appliances. Water may also contain disinfectant chemicals such as chlorine. In many commercial processes, the chlorine must be removed before the water can be used. With the Kinetico product line, three types of filters are used: Carbon, Macrolite TM and Calcite. Each media offers a different type of filtration property, and selection of the proper filter will depend upon site conditions. Calcite A crushed and screened white marble material (calcium carbonate) is used to neutralize acidic or low ph waters. Calcite, on contact with acidic waters, slowly dissolves the calcium carbonate media to raise the ph. This effectively neutralizes the potential corrosion of copper and other metals found in plumbing systems. Periodic backwashing is necessary to maintain high service flow rates and prevent packing the filter bed. Calcite dissolves and must be replaced. The frequency depends on the ph and water demands. As calcite neutralizes the water, it will increase hardness, and a softener may need to be added after the filter. Disc selection is partially dependent upon the amount of water being used on a daily basis. Activated Carbon Used for the removal of taste, odor and color, granular activated carbon used in Kinetico equipment is an excellent filtration medium with efficient adsorption characteristics. The most common application is the removal of chlorine from the water supply. Activated carbon requires only periodic backwashing to eliminate accumulated suspended matter and re-grade the filter bed. When the filter bed loses the capacity for chlorine, the bed must be replaced. If the unit is used in conjunction with a chlorine feed system for the removal of oxidized iron, the unit should be set to backwash 1-2 times per week of operation. Macrolite TM A processed mineral oxide manufactured exclusively by Kinetico, is used as a highly efficient filter media for the removal of oxidized iron and suspended matter. 40-60 mesh Macrolite ceramic media has a tremendous loading capacity and an extremely fast cleanup time when backwashing at 6-7 gpm/ft 2. This ceramic media is chemically inert and is not affected by acids and bases. Tests have shown that its attrition rate is nearly zero. This media typically removes suspended solids down to the 5 micron range. Page - 5

The Powerline Filter Product Line Kinetico s Powerline Filters have a capacity to accommodate flow requirements from 15 gpm to 125 gpm. Calcite Carbon Macrolite PF 2161 S T1 15 gpm 20 gpm 25 gpm PF 2465 S T1 20 gpm 25 gpm 30 gpm PF 3072 S T2 30 gpm 40 gpm 50 gpm PF 3672 S T2 50 gpm 60 gpm 70 gpm PF 4272 S T2 XX XX 90 gpm PF 4272 S T3 XX 75 gpm XX PF 4872 S T3 XX XX 125 gpm Powerline - Simplex Filters No Media Flow Part # Model # Description @ 15psi loss 70858 PF 2161 S T1 Simplex Powerline Filter, 21 x 61 Media Tank, No Media N/A 70859 PF 2465 S T1 Simplex Powerline Filter, 24 x 65 Media Tank, No Media N/A 70860 PF 3072 S T2 Simplex Powerline Filter, 30 x 72 Media Tank, No Media N/A 70861 PF 3672 S T2 Simplex Powerline Filter, 36 x 72 Media Tank, No Media N/A 70862 PF 4272 S T2 Simplex Powerline Filter, 42 x 72 Media Tank, No Media N/A 70863 PF 4272 S T3 Simplex Powerline Filter, 42 x 72 Media Tank, No Media N/A 70864 PF 4872 S T3 Simplex Powerline Filter, 48 x 72 Media Tank, No Media N/A Calcite Filters 70879 PN 2161 S4 T1 Simplex Powerline Calcite Filter, 21" x 61" Media Tank 15 gpm 70880 PN 2465 S6 T1 Simplex Powerline Calcite Filter, 24" x 65" Media Tank 20 gpm 70881 PN 3072 S8 T2 Simplex Powerline Calcite Filter, 30" x 72" Media Tank 30 gpm 70882 PN 3672 S14 T2 Simplex Powerline Calcite Filter, 36" x 72" Media Tank 50 gpm Carbon Filters 70891 PC 2161 S4 T1 Simplex Powerline Carbon Filter, 21" x 61" Media Tank 20 gpm 70892 PC 2465 S6 T1 Simplex Powerline Carbon Filter, 24" x 65" Media Tank 25 gpm 70893 PC 3072 S8 T2 Simplex Powerline Carbon Filter, 30" x 72" Media Tank 40 gpm 70894 PC 3672 S14 T2 Simplex Powerline Carbon Filter, 36" x 72" Media Tank 60 gpm 70895 PC 4272 S26 T3 Simplex Powerline Carbon Filter, 42" x 72" Media Tank 75 gpm Macrolite Filters 70118 PM 2161 S3.5 T1 Simplex Powerline Macrolite Filter, 21" x 61" Media Tank 25 gpm 70119 PM 2465 S5 T1 Simplex Powerline Macrolite Filter, 24" x 65" Media Tank 30 gpm 70120 PM 3072 S8 T2 Simplex Powerline Macrolite Filter, 30" x 72" Media Tank 50 gpm 70121 PM 3672 S12 T2 Simplex Powerline Macrolite Filter, 36" x 72" Media Tank 70 gpm 70122 PM 4272 S16 T2 Simplex Powerline Macrolite Filter, 42" x 72" Media Tank 90 gpm 70123 PM 4872 S21 T3 Simplex Powerline Macrolite Filter, 48" x 72" Media Tank 125 gpm Page - 6

EQUIPMENT SPECIFICATIONS System Configuration Simplex System With a single tank unit (Simplex), a continuous flow of filtered water is not possible. During the backwash process, untreated water is by-passed through the system. For this reason, simplex systems are usually specified in non-critical applications, or if backwashes can be performed during distinct shut-down periods. Simplex systems are designed to backwash based on time. Component Functionality The Powerline is comprised of various components. A brief description has been provided for each of these major components. An illustration has been provided to help the operator become familiarized with the parts of the Powerline. Tank Tank sizes vary from 21 x 61 to 48 x 72. These sizes only represent the size of the tank; they do not include the base or valve in the height. Upper Diffuser The diffuser prevents channeling of the inlet stream into the top of the media bed. Two styles of diffusers are used; plastic models that attach to the top of the control valve are used in 1 ½ and 2 systems. 3 valve systems use a stainless steel diffuser that sits on the flange adapter inside of the tank. Lower Distributors The lower distributors are a hub and lateral design. The high surface area of the laterals minimizes pressure loss through the system. On some laterals there may be slots that are blocked off (not opened fully). This design assures proper flow and even distribution of the water through the media bed. The polypropylene construction of the distributor assembly gives it excellent durability. 42 and 48 tanks use a two tiered distributor system. Riser Tube A riser tube is used to connect the lower distributor to the control valve. The 2850 valve uses a 1 ½ riser, the 3150 a 2 riser and the 3900 a 3 riser. Prior to installation, the riser tube must be trimmed to proper length. Page - 7

Gravel A two-part gravel under-bed is used to provide support to the lower distributor assembly. The under-bed also improves flow distribution and reduces system pressure drop. Note: The Macrolite filter uses only one layer of garnet. Media A variety of filtration media can be used in the Powerline filters. Media include: Carbon Calcite Macrolite 2850 3150 3900 Control Valve Three different control valves are used with the Powerline filter systems: 2850, 3150 and 3900 valves. All valves are used in a top-mounting configuration. The 2850 has 1 ½ " FNPT inlet/outlet connections and attachs to the media tank by a 4 threaded adapter included on the valve. The 3150 valve also attaches using a 4 thread, but the inlet/outlet connections are 2 FNPT. The 3900 has 3" FNPT inlet/outlet connections and attaches to the media tank by a 6 flange. All valves are constructed from leadfree brass and offer an adjustable backwash cycle. Service Piston The service piston found on the 3900 valve allows water to be by-passed during backwash. White pistons designate an un-filtered water bypass, while black pistons represent a filtered water by-pass. Backwash Flow Control The backwash and fast rinse flow rates are regulated by a flow control attached to the outlet of the drain port. (Arrow shows regulated flow direction.) Page - 8

Powerhead In single tank systems (Simplex), an electromechanical timer is used to provide backwash control. The timer specifies the number of days between regeneration, with regenerations occurring at 12:00 am of the specified day. Times for each stage of the backwash sequence are specified by the number of pins inserted into the regeneration program wheel (located on the back of the timer). Page - 9

INSTALLATION Getting Started The following procedures have been developed to assist during the installation of your Powerline Filter. The installation of this Powerline System should be performed by a qualified service person with an understanding of local and regional codes that may affect the installation requirements. Pre-installation Review Before beginning the installation of the Powerline System, confirm system configuration to be installed and components that have been ordered. Please review Powerline specification sheet that includes required components. Review of the customer s facility is also recommended, especially critical operating data that could affect the operation of the system: Water pressure to the Powerline will affect the performance during regeneration. The Powerline system will not operate properly if the inlet pressure fluctuates below a dynamic pressure of 25 psi. This minimum pressure must be maintained to the system at all times. Should the pressure fluctuate below this level, a booster pump may be required. Pressures should not exceed 125 psi. If supply water fluctuates above this level, a pressure regulating device will be required. Ambient temperature must be maintained above 32 F (0 C). Freezing temperatures will cause breakage of equipment and void all warranties. Inlet water temperature must be maintained between 35 F and 100 F to prevent damage to the system. System Location The Powerline Filter is designed for indoor or outdoor installation (when under a protective structure). When reviewing the installation site, please take into account the following factors: Level Dry Access to drain Access to electrical hookup Access to adequate water supply The equipment is not recommended for outdoor installations with direct exposure to the elements. Outdoor installations should be under an awning or some other protective structure. Page - 10

Electrical Service Electrical service must be continuous and should be checked for proper voltage. All electrical connections must be connected according to all local and national codes. Use electrical conduit if applicable. Powerline Systems are available in a variety of voltages: 120 VAC, 60HZ 220 VAC, 50HZ Powerline Installation Tools and Installation Materials 18 Pipe Wrench Flathead Screwdriver (medium & small) Torch (Acetylene) Pipe Cutter (PVC and Copper) Flux Solder PVC Cement and Cleaner Pipe Clamps Level Chalk Line Fitting Brush Sand Cloth Needle Nose Pliers Teflon Tape and Paste 2-5/16 Open End Wrench Unpack Place all equipment in location including media tanks, brine tanks and remote meters. Unpack media pallet containing gravel, media, control valve and distributor head. Riser tube will be found packaged in each media tank box. Confirm all equipment has been received. Media Tank(s) Brine Tank(s) Gravel Media Control Valve(s) Backwash Flow Restrictor Brine Refill Flow Restrictor Riser Tube(s) Lower Distributor(s) Tank Placement Place media tanks into tentative positions. Without media or distributors loaded into the tanks, thread the control valve onto the top of the tank. After tightening, rotate the tank so that the valve is facing the right direction. This will help to minimize moving the media tank after it has been loaded. Distributor Assembly After placing the media tanks, prepare the internal distributor assembly. The riser tube and hub are preglued, but not cut to length. Insert the riser tube assembly into the tank and center the hub in the bottom of the tank. Mark where to cut riser tube and remove from tank. Cut the riser tube based on the tank and valve type. Be sure that the edge that was just cut is chamfered to prevent rolling or cutting of the O-ring. Page - 11

Model 2850 - Cut tube 3/8" below the top of tank. Model 3150 - Cut tube 3/8" below the top of tank. Model 3900 - Cut tube flush with top of flange on tank. Assemble the laterals to the hub inside the top opening of the tank. Insert the laterals into the hub and turn them 1/4 turn to lock them in place. After all laterals are locked into place, gently lower the assembly to the bottom of the tank, keeping the hub centered. Media Loading Fill the media tank with water, approximately six inches above the laterals. This will prevent damage to the distributor system when adding the gravel and media. Load the gravel into the tank through the top opening. Use a funnel, and be sure to cap or tape off the opening of the riser tube to prevent material from being loaded into the riser tube. The coarse gravel (part number 1226A) is loaded first, followed by the finer gravel (part number 57580). Calcite & Carbon Systems Tanks Size Coarse Gravel Fine Gravel part # 1226A part # 57580 1/4 x 1/8 gravel 20# gravel 21 x 61 Tanks 1.0 ft 3 24 x 65 Tanks 1.0 ft 3 1.0 ft 3 30 x 72 Tanks 1.0 ft 3 2.0 ft 3 36 x 72 Tanks 2.0 ft 3 2.0 ft 3 42 x 72 Tanks 3.0 ft 3 3.0 ft 3 48 x 72 Tanks 3.0 ft 3 3.0 ft 3 Macrolite Systems Tanks Size Gravel Garnet 21 x 61 Tanks 1.0 ft 3 (3 bags) 24 x 65 Tanks 2.0 ft 3 (5 bags) 30 x 72 Tanks 3.0 ft 3 (8 bags) 36 x 72 Tanks 4.0 ft 3 (10 bags) 42 x 72 Tanks 6.0 ft 3 (16 bags) 48 x 72 Tanks 6.0 ft 3 (16 bags) After the gravel is loaded, load media into each vessel. In multiple tank systems, be sure to load identical volumes of media into each tank. The following tank size / media fills apply for the Powerline series: Media Tank Size Carbon Calcite Macrolite 21 x 61 Tanks 4.0 ft 3 4.0 ft 3 3.5 ft 3 24 x 65 Tanks 6.0 ft 3 6.0 ft 3 5.0 ft 3 30 x 72 Tanks 8.0 ft 3 8.0 ft 3 8.0 ft 3 36 x 72 Tanks 12.0 ft 3 12.0 ft 3 12.0 ft 3 42 x 72 Tanks 26.0 ft 3 N/A 16.0 ft 3 48 x 72 Tanks 32.0 ft 3 N/A 21.0 ft 3 After all media has been loaded, bring the water level in the tank to about three inches from the top of the vessel. Remove the cap from the top of the riser tube to prepare for the control valve installation. Page - 12

Install Control Valve 2850 The 2850 valve mounts to the top of the tank through a 4 thread. Before mounting the valve, clean the tank top and valve bottom. Next, lubricate the distributor O-ring and the valve body O-ring with silicone grease. Position the valve body on the top of the tank. To help prevent cross threading, first turn the valve body counterclockwise until threads have seated properly. Once the valve is seated properly, tighten the valve by turning it clockwise until it is tight. 3150 The 3150 valve mounts to the top of the tank through a 4 thread. Before mounting the valve, clean the tank top and valve bottom. Next, lubricate the distributor O-ring and the valve body O-ring with silicone grease. Position the valve body on the top of the tank. To help prevent cross threading, first turn the valve body counterclockwise until threads have seated properly. Once the valve is seated properly, tighten the valve by turning it clockwise until it is tight. 3900 The 3900 valve mounts to the top of the tank through a flange connection. Before mounting the valve, clean off the top of the tank and bottom of the valve. Next, lubricate the distributor O-ring and the valve body O-ring with silicone grease. The valve can be placed onto the riser tube now, and the split flange can be placed around the bottom of the valve. The 12 bolts can be inserted through the split flange ring, the flange ring and the tank flange. Thread corresponding nuts onto the bolts, and tighten in an alternating fashion. Interconnecting Plumbing The tank manufacturer recommends that vacuum breakers be installed on the inlet side of the plumbing before the by-pass tee for all equipment. Flex connections may also be required to allow for tank expansion. For systems using multiple tanks, a balanced header is necessary to distribute flow equally to all equipment. It is also strongly recommended each tank have inlet/outlet isolation valves as well as a system by-pass. The use of unions on the inlet, outlet and drain line connections are recommended. This will allow for easy access to the valve should maintenance be required. A system by-pass is also recommended. This will allow greater flexibility when servicing the equipment. Page - 13

Backwash Flow Control For all control valves, one backwash flow control is required on the drain line of the unit. The drain line for the 3150 and 3900 valves is located at the top of the valve, while the 2850 s drain is on the right side. For single tank systems, the backwash flow control can be threaded directly into this port (arrow shows flow control direction). Following the flow control, a union should be used. This will allow easy access to the flow control should cleaning or modification to it be required. For multiple tank systems, the backwash flow control should be mounted in the common drain header. Also, in this configuration, unions should be used around the flow control to simplify future service. Drain Line Gap Air The drain line should be the same size as the drain line flow control connection. It is recommended that a piece of clear PVC be installed into the drain line. This can assist in system Start-up and future maintenance of the system. The clear PVC gives a view of the backwash water, and shows the volume, if any, of media loss during backwash. A 1 1/2 air gap should be maintained at the discharge point. If this is hard-plumbed, a union is required close to the valve for serviceability issues. Electrical Service A standard electrical plug is provided with the control valve. Should a long connection be desired, a new plug can be made using 3 conductor #14 SO/SJO cords. Page - 14

OPERATION AND MAINTENANCE Normal Operating Procedures Pre-Start-up Check List After the installation of the Powerline and all accessory equipment is complete, the system can be commissioned into service. During this first operational run, a few additional steps are required. These procedures both confirm that the installation has been done correctly and adjusts the Powerline to operate in the specific site conditions at the customer s facility. Before starting the system up, review the following items to make sure the system is ready for Start-up: Have all installation fittings been properly cured? Have all unions and ball valves been tightened? Confirm voltage of incoming power supply to system wiring. Are all isolation valves closed? After reviewing these conditions, begin the commissioning by energizing power to the Powerline System. Start-up Procedures-Simplex To start up the equipment, plug in the power cord, remove the valve cover and open the timer assembly housing door. Actuate the unit into a backwash cycle by turning the timer knob clockwise to the first set of pins. The backwash cycle starts when the pins engage the micro-switch. The inlet valve should be partially opened, and the outlet valve should be closed. Microswitch Back of Timer Timer Pins If the tank was filled with water earlier, then the flow to the drain should begin almost immediately. Flush the tank at a low flow for at least 10 to 15 minutes. During this time, the drain flow should be monitored for loss of media. If this happens, immediately stop the flow by closing the inlet valve and repeat the above process by flushing the tank at a low flow. After approximately 15 minutes, open the inlet valve fully and continue to monitor the drain flow for media loss. If no media loss has occurred, unplug the unit and let it continue to backwash for another 15 minutes. Once this time has elapsed, plug the unit back into the power source and advance the timer knob to a point just before the home position notch. Repeat this process for additional units if needed. Position Program Wheel Timer Motor After the flushing procedure has been completed and the program wheel is returned to the home position, check all cycles for proper responses: Filter cycles 1. Backwash (upflow) Advance knob to the first set of pins. You ll see a high flow to drain. 2. Settle Time (downflow) Advance knob to just beyond the last backwash pin. 3. Fast rinse (downflow) Advance knob to the second set of pins. The flow rate to drain will increase. 4. Settle time (downflow) Advance knob to just beyond the fast rinse pins. 5. Program End The last two (2) pins of the program wheel stop the brine refill. If the time of any cycle needs to be changed, the program wheel can be removed, and the roller pins can be added or removed as needed. Page - 15

The installation should now be complete. The by-pass valve can be closed, and the inlet and the outlet valves opened. Setting the Regeneration Cycle The regeneration cycle program on the valve has been preset; however, portions of the program may be lengthened or shortened in time to suit local conditions. To expose the cycle program wheel, grasp the timer in upper left-hand corner and pull, releasing the snap retainer and swinging the timer to the right. To change the regeneration cycle program, the program wheel must be removed. Grasp the program wheel and squeeze the protruding lugs toward the center, and lift the program wheel off the timer. (Switch arms may require movement to facilitate removal.) The program wheel contains holes for the program pins. As the wheel turns, the micro-switch is activated and deactivated by these pins. Each pin represents two minutes. The time for each stage can be adjusted by the number of pins or spaces associated with that stage. The stages are directly controlled by the pin and space placement. They are: Backwash Settle time Fast rinse Settle time A final set of two pins is also used to signal the completion of the cycle. Modification of the regeneration cycle should start with the first stage and then move through each subsequent stage. Pins should always be added at the end of the cycle being adjusted. This will affect the length of the next cycle, and that cycle may also need to be adjusted. Backwash Time The first set of pins represents the backwash time. Standard backwash for all systems is 10 minutes, or five pins. To increase this time, simply add consecutive pins to this stage, to match the desired time. Each pin represents two minutes. A minimum of two pins is required to make sure the cycle begins. Backwash Settle Time The empty two spaces following the backwash pins represent the settle time. Adding spaces increases the time of this stage. Each empty hole represents two minutes of the stage. A minimum of two spaces is required to make sure the cycle is initiated. Brine Slow and Rinse Fast Rinse Following the settle time and slow rinse stage is a group of pins which represent the fast rinse stage. The cycle time is changed based on the number of pins used. Each pin is two minutes. A minimum of two pins is required to assure that this stage has been activated. Fast Rins Page - 16

Settle Time The spaces following the fast rinse represent the settle time. Each space is two minutes. Adding consecutive spaces will lengthen the stage, while removing spaces will shorten the cycle. A minimum of two spaces is required to assure the stage is activated. Refil l Cycle End Two final pins are required to signal the end of the regeneration cycle. End Recommended Pins / Spaces BW Settle Time Fast Rinse Settle Time End Model PINS SPACES PINS SPACES PINS Carbon 2161 10 2 5 2 2 2465 10 2 5 2 2 3072 10 2 5 2 2 3672 10 2 5 2 2 4272 10 2 5 2 2 Calcite 2161 10 2 5 2 2 2465 10 2 5 2 2 3072 10 2 5 2 2 3672 10 2 5 2 2 Macrolite 2161 10 2 5 2 2 2465 10 2 5 2 2 3072 10 2 5 2 2 3672 10 2 5 2 2 4272 10 2 5 2 2 4872 10 2 5 2 2 Page - 17

Setting the Time of Day Press and hold the red button to disengage the 24-hour gear. Turn the 24-hour gear until the actual time of day is at the pointer. Release the red button to again engage the 24-hour gear. Setting the Backwash Day Rotate the skipper wheel until the number 1 is at the red pointer. Set the days that backwash is to occur by sliding tabs on the skipper wheel outward to expose trip fingers. Each tab is one day. The finger at the red pointer is tonight. Moving clockwise from the red pointer, extend or retract fingers to obtain the desired backwash schedule. Starting a Manual Backwash Rotate the manual backwash knob clockwise one click. This will begin the backwash process. System Flow Paths Service Unfiltered water enters the center tube through the bottom distributor, then flows up through the center tube, around the piston and out the side outlet of the valve. Backwash Unfiltered water enters the unit at the valve inlet, flows through the backwash valve piston, down the center tube, through the bottom distributor, up through the resin, around the piston and out the drain line. If optional no hard water by-pass is used, water flow to the outlet is prevented by an extended section of the service piston which closes the outlet port from by-pass water until the end of rapid rinse. Fast Rinse Unfiltered water flows through the backwash valve, directly down through the filter media into the bottom distributor and up through the center tube, around the piston and out the drain line. Troubleshooting Equipment will not backwash Power has been disrupted In-line meter not operational Program wheel may be set incorrectly Timer motor Unfiltered water at outlet Water statistics have changed Unit not backwashing Pin and Spacer setting incorrect Backwash valve assembly Check the following: fuses, breakers, micro-switches, wiring connections at terminal block and connection at remote meter Check cable connection at meter or clutch, check impeller assembly Reset gallons wheel Inoperative, replace Retest water, adjust program wheel See section Equipment will not regenerate Check and reset as needed Clean backwash flow restrictor or replace O-ring seal at distributor O-ring pinched or missing Page - 18

Riser tube cut incorrectly Internal water by-pass leaking Unfiltered water by-pass piston being used Simplex system Backwash piston leaking Low flow not being metered Low media Uses too much water Incorrect times set on program wheel Brine line flow control Loss of water pressure Inlet flow restricted Low incoming water pressure May occur during high water usage at facility Remove valve, check height, replace riser or cut and couple Check and replace seals, spacers and piston Check end cap assembly. Should be white for water passage during backwash and black for no water passage during backwash Will deliver unfiltered water during backwash unless using no hard-water piston assembly on lower piston assembly Check and replace seals, spacers and piston Make sure units are receiving adequate flow rates. Minimum flow required for 2 meters - 3.0 gpm., for 3 meters - 7.0 gpm. Top off, find reason for media loss and correct Check draw and refill rates and reset for better efficiency Clean Check inlet of plumbing and piston chamber of valve Well pump defective, well not providing sufficient water, city water supply insufficient Test pressure at various points down stream of equipment, also while equipment is in backwash Inlet or outlet valves defective or partially closed Check valves Laterals or hub cracked or crushed Media bed loaded with foreign material Loss of mineral to drain Air in water Pressure regulator defective Iron in filtered water Check drain line for blockage Check drain flow control for blockage Inlet pressure too low for proper backwash System losing capacity Well or city water stats have changed Check product water for media or possibly gravel Check bed and replace if necessary Well system (pump) drawing air. Check for crack in the well line, defective check valve and O-ring seal for pitless adapter If possible, test pressure after regulator, replace if necessary Clean or replace Clean or replace Test and advise customer Retest water, check for low flows and increase frequency of backwash. If brine draw and refill times are incorrect, reset Retest raw water, adjust program Page - 19

Unit cycles continuously Loose micro-switch Broken piston Timer motor may be burned out Drain flows continuously Broken piston Adjust by tightening, or replace Replace seals, spacers and piston Replace Replace seals, spacers and piston Spacing incorrect between back plate and valve Shimming between backplate and valve body may be body which will cause piston to be out of required synchronization Internal leak Foreign material in valve Replace seals, spacers and piston Check piston chamber and clean, replace seals, spacers and piston if necessary Page - 20

PARTS 2850 Control Valve ITEM QTY Part Number Description 1 1 FL16250 Valve Body 2 6 FL16101 Seal 3 5 FL16638-01 Spacer 4 1 FL16092 Piston 5 1 FL16436 Piston Rod 6 1 FL16395 End Plug Assembly 7 1 F14805 Injector Body Gasket 8 1 FL14802-03C Injector Throat, 3C Yellow 1 FL14802-04C Injector Throat, 4C Green 1 FL14802-05C Injector Throat, 5C White 1 FL14802-06C Injector Throat, 6C Red 9 1 FL17777 Injector Body 10 1 FL14801-03C Injector Nozzle, 3C Yellow 1 FL14801-04C Injector Nozzle, 4C Green 1 FL14801-05C Injector Nozzle, 5C White 1 FL14801-06C Injector Nozzle, 6C Red 11 1 FL14803 Injector Screen 12 1 FL10229 Injector Cover Gasket 13 1 FL11893 Injector Cover 14 2 FL14804 Screw - Injector Body 16 1 FL16455 O-ring - Top of Tank 16 1 FL13577 O-ring 17 1 FL16221 Air Dispenser 18 1 FL17776 Injector Body 19 1 FL10914-1 Injector Throat - No. 1 1 FL10914-2 Injector Throat - No. 2 1 FL10914-3 Injector Throat - No. 3 20 1 FL10227 Injector Screen 21 1 FL10913-1 Injector Nozzle - No. 1 1 FL10913-2 Injector Nozzle - No. 2 1 FL10913-3 Injector Nozzle - No. 3 22 2 FL1 0692 Screw - Injector Body 23 1 FL60366-12 Brass, DLFC 1, 1.2 gpm 1 FL60366-15 Brass, DLFC 1, 1.5 gpm 1 FL60366-20 Brass, DLFC 1, 2.0 gpm 1 FL60366-24 Brass, DLFC 1, 2.4 gpm 1 FL60366-30 Brass, DLFC 1, 3.0 gpm 1 FL60366-35 Brass, DLFC 1, 3.5 gpm 1 FL60366-40 Brass, DLFC 1, 4.0 gpm 1 FL60366-50 Brass, DLFC 1, 5.0 gpm 1 FL60366-60 Brass, DLFC 1, 6.0 gpm 1 FL60366-70 Brass, DLFC 1, 7.0 gpm Page - 21

3150 Control Valve Item N o Qty. Part N o De scrip tion 1 1 70359 Valve Body, 3150 2 8 70491 Seal 3 5 70548 Spacer - Port 5 70277 Spacer - Port Hot Water 4 2 70550 Spacer 2 70549 Spacer - Hot Water 5 1 70279 Piston 6 1 70371 Clip - Piston Rod 7 1 70355 Piston Rod 8 1 70366 "O" Ring- End Plug - 035 9 1 70263 End Plug Assembly, 3150 White 10 1 70360 Seal 11 1 70236 Adapter - 3150 - Side Mount 12 2 70312 Screw - Hx Head 13 1 70358 Adapter 3150, - Top Mount 4" x 8 Thd 14 1 70335 O Ring - 229 Dist. 15 1 70436 O Ring - 240 Tank 1 70340 "O" Ring - Top of "Park" Tank Page - 22

3150 Control Drive Assembly Item N o Qty. Part N o De scrip tion 1 1 70208 Back Plate 2 1 70356 Bracket - Motor Mounting 3 2 70267 Nut 5/16-18 4 1 70310 Drive Motor - 115V, 60Hz 70249 Drive Motor - 220V, 50Hz 70248 Drive Motor - 24 VAC, 60 Hz 5 1 70231 Bracket - Switch Mounting 6 4 70554 Insulator 7 3 70562 Microswitch 8 1 70230 Pin, Hinge 9 4 70522 Nut 1/4-20 10 2 70439 Lockwasher 11 2 70460 Screw - Pan Hd 12 2 70457 Nut 5-40 13 1 70302 Bracket, Brine Side 14 2 70556 Screw, Round Head 15 1 Terminal Block 16 2 70303 Bushing 17 1 70298 Washer 18 1 70304 Retaining Ring, Bowed "E" 19 2 70555 Screw - Hex Head Thread Cutting 20 1 70207 Light Bracket 21 4 70559 Drive Mount Screw 22 2 70234 Screw - Hex Hd 23 2 70466 Washer, Lock, #8 Internal 24 1 70253 Cam Assembly - Service after RR 1 70254 Cam Assembly - Service after Brine Refill 25 4 70523 Screw - Hex Head 26 1 70206 Lamp Window 27 1 70218 Screw Cover 28 1 70210 Cover, Black 28 1 70209 Cover, Lamp Window 29 1 70225 Seal, Window 30 1 70217 W indow, 2900 31 1 70220 Seal, Cover 32 4 70215 Screw 33 1 70308 Drive Gear 34 1 70305 Retaining Ring 35 1 70489 Retaining Ring - E 36 1 70307 Drive Link 37 1 70493 Pin - Drive Link 38 1 70306 Bearing - Drive Link 39 1 70481 Clip 40 1 70309 Drive Pinion 41 1 70512 Roll Rin 42 1 70527 Screw - Flat Head 43 3 70534 Screw - Hex Head 44 1 Tim er 45 1 70467 Power Cord, 7 ft. 46 1 70228 Strain Relied 47 1 70259 Harness 48 1 70204 Hole Plug 3/4 DIA 49 1 70205 Hole Plug 7/8 DIA 50 1 70260 Motor Lead W ire 51 1 70266 Wire Harness 52 1 70364 Strain Relief, Harness 53 1 70322 Meter Cable Assembly-2750 54 2 70334 Label, Terminal Strip 55 1 70219 Cable Guide Page - 23

3900 Control Valve Assembly Item N o Qty. Part N o De scrip tion 1 1 70359 Valve Body, 3150 2 8 70491 Seal 3 5 70548 Spacer - Port 4 2 70550 Spacer 5 1 70279 Piston 6 2 70371 Clip - Piston Rod 7 1 70355 Piston Rod 8 1 70366 "O" Ring- End Plug - 035 9 1 70263 End Plug Assembly, 3150 White 10 2 70312 Screw - Hx Head 11 1 70287 "O" Ring- 149 12 1 70291 Coupling 13 1 70288 "O" Ring- 140 14 1 70360 Seal 15 1 70297 3" Adapter Body - 3900 16 1 70296 Seal 17 2 70295 Spacer- Narrow 18 1 70294 Spacer - Wide 19 1 70293 Piston 1 70286 Piston - No Hard W ater By-pass 20 1 70292 Piston Rod 21 1 70289 "O" Ring - 238 22 1 70262 End Plug Assembly- White, Hard W ater By-pass 1 70261 End Plug Assembly-Black, No Hard W ater By-pass 23 1 70240 "O" Ring - 238 24 2 70268 "O" Ring - 362 25 1 70274 Tank Adapter 3900-6" -8 26 2 70273 Flange Segment 27 12 70521 Screw - Hex Head 28 1 70283 Pipe Plug - 2" NPT 1 70272 Flow Disperser 29 2 70258 Flange Segment 30 1 70257 Flange Ring 31 1 70256 "O" Ring - 442 32 12 70245 Screw 33 12 70224 Washer 34 12 70267 Nut 5/16-18 36A 1 70237 Adapter, 3900 - Side Mount, 90 Degree 36B 1 70226 Adapter, 3900- Side Mount 70199 3900 Piston, Upper 70198 3900 Piston, Lower Hard W ater By-pass 70197 3900 Piston, Lower No Hard W ater By-pass 70194 3150 & 3900 Seal Kit, Upper 70193 3900 Seal Kit, Lower 70101 3900 Meter Module, 3" 70100 3900 Meter Module, 3" Ext. Rng Page - 24

Model 3000 Time r Assembly Part N o De scrip tion 70511 Self Tapping Screw 70526 Motor Plate 70515 Idler Shaft Spring 70499 Idler Start Assembly 70533 Bearing (Idler Shaft Front) 70510 Timer Panel - Painted 70507 Skipper Wheel Support 70516 Skipper Wheel Detent Spring 70517 3/16" Diameter Ball 70536 Skipper Wheel - 12 Day 70477 Skipper Wheel - 7 Day 70497 Skipper W heel Screw 70463 Round Head Machine Screw 70503 Day of Regeneration Screw 70508 Time of Day Pointer 70513 Knob 70535 Program Wheel Shaft Lever 70519 Retaining Ring 70448 Time of Day Washer 70518 Spring Washer 70501 24 Hour Gear Dial 70500 24 Hour Gear 70498 Main Bearing 70509 Microswitch Mounting Block 70416 Insulator 70532 Microswitch 70332 Microswitch 70504 Screw - Round Head 70506 Pal-Nut 70505 Shaft and Clutch Assembly 70531 Program W heel 70514 Wing Nut 70323 Roll Rin 70478 Screw-Switch Mtg. Block 70537 Timer Motor 70496 24 Hour Gear Stud 70439 Lockwasher 70465 Timer Hinge Assembly 70494 Wire Harness 70241 Wire Harness - 3000 - Immediate Regeneration 70455 Screw-Timer Bracket 70192 3000 Skipper Wheel, 12 Day 70168 3000 12-Day Timer, STF, 120/60 Model 3000 Time r Assembly Part N o De scrip tion 70426 Timer Housing 70454 Cycle Actuator Arm 70214 24 Hour Gear Assembly, Silver 70213 24 Hour Gear Assembly, Tan 70423 Knob 70446 Screw-Timer Knob & Meter Mounting Plate 70479 Button Decal 70410 Skipper Wheel Assembly 12 Day 70368 Skipper W heel Assembly 7 Day 70453 Regeneration Pointer 70412 Spring Clip 70442 Spring - Skipper Wheel Detent 70444 Ball - 1.4" Diameter Gear Detent 70326 Spring - Main Gear Detent 70420 Main Drive Gear 70212 Program W heel 70323 Roll Rin 70451 Idler Shaft 70441 Spring - Idler 70452 Idler Gear 70450 Drive Gear 70422 Motor Mounting Plate 70419 Motor - 120VAC, 60 Hz 70415 Motor - 24VAC, 60 Hz 70447 Screw - Motor Mounting 70511 Self Tapping Screw 70424 Hinge Bracket 70416 Insulator 70532 Microswitch 70332 Microswitch 70504 Screw - Round Head 70418 Decal - Time of Day 70417 Decal - Instructions 70428 Skipper W heel Ring 70421 Harness 70458 Wire Connector (Not Shown) 70361 Ball 1/4" Diameter Main Gear 70331 Ground W ire 70132 3200 12 Day Timer, STF, 120/60 Page - 25

3210 Time r Assembly Part N o De scrip tion 70425 Timer Housing 70432 Cycle Actuator Arm 70214 24 Hour Gear Assembly, Silver 70213 24 Hour Gear Assembly, Tan 70427 Knob 70446 Screw-Timer Knob & Meter Mounting Plate 70479 Button Decal 70102 Program Wheel Assembly 70431 Program Wheel Retainer 70433 Screw, Program Wheel Mfg. 70412 Spring Clip 70326 Spring - Main Gear Detent 70361 Ball 1/4" Diameter Main Gear 70420 Main Drive Gear 70212 Program W heel 70323 Roll Rin 70451 Idler Shaft 70441 Spring - Idler 70452 Idler Gear 70450 Drive Gear 70445 Curved Washer 70422 Motor Mounting Plate 70419 Motor - 120VAC, 60 Hz 70414 Motor - 24VAC, 60 Hz 70447 Screw - Motor Mounting 70430 Drive Pinion, Program W heel 70429 Clutch, Drive Pinion 70411 Spring 70413 Spring Retainer 70511 Self Tapping Screw 70424 Hinge Bracket 70416 Insulator 70532 Microswitch 70332 Microswitch 70504 Screw - Round Head 70418 Decal - Time of Day 70417 Decal - Instructions 70421 Harness 70458 Wire Connector (Not Shown) 70331 Ground W ire Page - 26

Miscellaneous Parts Media Part # Quantity Description 1226A cu/ft Course Gravel 57580 cu/ft Fine Gravel 1222 cu/ft Calcite 6784 cu/ft Macrolite 57728 cu/ft Carbon 64143 cu/ft Garnet, Gravel Flow Controls Part # Quantity Description 68167 ea. 10 gpm, 2900 ¾ FNPT x ¾ FNPT 68169 ea. 15 gpm 2900 ¾ FNPT x ¾ FNPT 68171 ea. 25 gpm 2900 ¾ FNPT x ¾ FNPT 70136 ea. 25 gpm 2850 1 FNPT x 1 FNPT 68178 ea. 40 gpm 3150/3900 2 MNPT x 2 MNPT 68181 ea. 55 gpm 3150/3900 2 MNPT x 2 MNPT 68185 ea. 75 gpm 3150/3900 2 MNPT x 2 MNPT 70140 ea. 85 gpm 3150/3900 2 MNPT x 2 MNPT Powerline Piston and Seal Parts Part # Quantity Description 73312 ea. Piston, 2850, HWBP 73313 ea. Kit, Seal & Spacer, 2850 73314 ea. Piston, 2850, NHWBP 73318 ea. Piston, 3150/3900, Upper 73319 ea. Piston, 3150, NHWBP, Upper 73320 ea. Kit, Seal&Spacer, 3150/3900 Upper 73321 ea. Kit, Seal&Spacer, 3900, Lower 72592 ea. Piston, 3 HWBP 72591 ea. Piston, 3 NHWBP Powerline Motor Asy Part # Quantity Description 73833 ea. Motor, Regen Asy 2900/2850 73835 ea. Motor, Regen Asy 3900/3150 72836 ea. Motor, Lower Asy, 3900 Page - 27

DRAWINGS 2850 Control Valve Page - 28

3150 Control Valve Page - 29

3900 Control Valve Page - 30

TECH MANUAL POWERLINE FILTER SERIES 2009, Kinetico Incorporated Page - 31