34
SERVICE INSTRUCTIONS
Drive Assembly
Remove the valve cover to access the drive assembly.
Disconnect the power source plug (black wire) from the PC board
prior to disconnecting the motor or water meter plugs from the PC
board. The power source plug connects to the four-pin jack. The
motor plug connects to the two-pin jack on the left-hand side of the
PC board. The water meter plug (gray wire) connects to the three-pin
jack on the far right-hand side of the PC board.
PC Board Replacement
The PC board can be removed separately from the drive bracket but
it is not recommended. Do not attempt to remove the display panel
from the PC board. Handle the board by the edges. To remove the
PC board from the drive bracket, unplug the power, water meter and
motor plugs from the PC board. Lift the middle latch along the top of
the drive bracket while pulling outward on the top of the PC board.
The drive bracket has two plastic pins that fit into the holes on the
lower edge of the PC board. Once the PC board is tilted about 45º
from the drive bracket it can be lifted off of these pins. To reinstall a
board, push the top of the PC board towards the valve until it snaps
under the middle latch, weave the power and water meter wires into
the holders and reconnect the motor, water meter and power plugs.
Drive Bracket Replacement
The drive bracket must be removed to access the drive cap assembly
and pistons or the drive gear cover. It is not necessary to remove
the PC board from the drive bracket to remove the drive bracket. To
remove the drive bracket start by removing the plugs for the power
source and the water meter. Unweave the wires from the side hold-
ers. Two tabs on the top of the drive back plate hold the drive bracket
in place. Simultaneously lift the two tabs and gently ease the top of
the drive bracket forward. The lower edge of the drive bracket has
two notches that rest on the drive back plate. Lift up and outward
on the drive bracket to disengage the notches.
To reassemble, seat the bottom of the drive bracket so the notches
are engaged at the bottom of the drive back plate. Push the top of
the drive bracket toward the two latches. The drive bracket may
have to be lifted slightly to let the threaded piston rod pass through
the hole in the drive bracket. Maintain a slight engaging force on
top of the drive bracket while deflecting the bracket slightly to the
left by pressing on the side of the upper right corner. This helps the
drive gears mesh with the drive cap assembly. The drive bracket is
properly seated when it snaps under the latches on the drive back
plate. If resistance is felt before latching, then notches are not fully
engaged, the piston rod is not in hold, the wires are jammed between
the drive bracket and drive back plate, or the gear is not engaging
the drive cap assembly.
Drive Gear Replacement
To inspect the drive gears, the drive gear cover needs to be removed.
Before trying to remove the gear cover, the drive bracket must be
removed from the drive back plate. (Refer to the instructions above
regarding removing the drive bracket from the drive back plate. The
drive gear cover can be removed from the drive bracket without
removing the motor or the PC board.) The drive gear cover is held
in place on the drive bracket by three clips. The largest of the three
clips is always orientated to the bottom of the drive bracket. With
the PC board facing up, push in and down on the large clip on the
drive gear cover. Handle the cover and the gears carefully so that
the gears do not fall off the pegs in the cover.
Replace broken or damaged drive gears. Do not lubricate any of
the gears. Avoid getting any foreign matter on the reflective coating
because dirt or oils may interfere with pulse counting.
The drive gear cover only fits on one way, with the large clip orientated
towards the bottom. If all three clips are outside of the gear shroud
on the drive bracket the drive gear cover slips easily into place.
Drive Motor Replacement
The drive bracket does not need to be removed from the drive plate
if the motor needs to be removed. To remove the motor, disconnect
the power and motor plugs from the jacks on the PC board. Move
the spring clip loop to the right and hold. Rotate the motor at least
a 1/4 turn in either direction so the wires are vertical (up & down)
before gently pulling on the wire connectors to remove the motor.
Pulling directly on the wires without rotating the motor may break
the wires off the motor.
Replace the motor if necessary. Do not lubricate the motor or the
gears. To reinstall the motor, move the spring clip loop to the right
and hold. Gently turn the motor while inserting so that the gear on
the motor meshes with the gears under the drive gear cover. Release
the spring clip loop and continue to rotate the motor until the wires
are horizontal and the motor housing engages the small plastic bulge
inside the drive bracket motor retainer. Reconnect the motor plug to
the two-pronged jack on the lower left side of the PC board. If the
motor will not easily engage with the drive gears when reinstalling,
lift and slightly rotate the motor before reinserting. Reconnect the
power plug.
Replace the valve cover. After completing any valve maintenance,
press and hold NEXT and REGEN buttons for 3 seconds or unplug
power source jack (black wire) and plug back in. This resets the
electronics and establishes the service piston position. The display
should flash all wording, then flash the software version and then
reset the valve to the service position.
Drive Cap Assembly, Main Piston and Regenerant Piston
The drive assembly must be removed to access the drive cap as-
sembly. The drive cap assembly must be removed to access the
piston(s). The drive cap assembly is threaded into the control valve
body and seals with an o-ring. To remove the drive cap assembly use
the special plastic wrench or insert a 1/4” to 1/2” flat blade screwdriver
into one of the slots around the top 2” of the drive cap assembly so
it engages the notches molded into the drive back plate around the
top 2” of the piston cavity. See Figure 29. The notches are visible
through the holes. Lever the screwdriver so the drive cap assembly
turns counter clockwise. Once loosened, unscrew the drive cap as-
sembly by hand and pull straight out.
The drive cap assembly contains the drive cap, the main drive gear,
drive cap, piston rod and various other parts that should not be dis-
sembled in the field. The only replaceable part on the drive cap as-
sembly is the o-ring. Attached to the drive cap assembly is the main
piston and if a regenerant is used, a regenerant piston.
The regenerant piston (the small diameter one behind the main piston)
is removed from the main piston by pressing sideways and unsnap-
ping it from its latch. Chemically clean this in dilute sodium bisulfite
or vinegar, or replace the regenerant piston if needed. To remove
the main downflow or upflow piston fully extend the piston rod and
then unsnap the main piston, from its latch by pressing on the side
with the number. Chemically clean this in dilute sodium bisulfite or
vinegar, or replace the main piston.
