Clack Valves WS1.5 Installation & Service Manual Download | Manualshive

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Water Specialist

1.5”, 2” and 2”QC Control Valve

Drawings and Service Manual

HYDROCARBONS SUCH AS KEROSENE, BENZENE, GASOLINE, ETC., MAY DAMAGE
PRODUCTS THAT CONTAIN O-RINGS OR PLASTIC COMPONENTS. EXPOSURE TO
SUCH HYDROCARBONS MAY CAUSE THE PRODUCTS TO LEAK. DO NOT USE THE
PRODUCT(S) CONTAINED IN THIS DOCUMENT ON WATER SUPPLIES THAT CONTAIN

HYDROCARBONS SUCH AS KEROSENE, BENZENE, GASOLINE, ETC.

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Summary of Contents for WS1.5

Page 1: ...H AS KEROSENE BENZENE GASOLINE ETC MAY DAMAGE PRODUCTS THAT CONTAIN O RINGS OR PLASTIC COMPONENTS EXPOSURE TO SUCH HYDROCARBONS MAY CAUSE THE PRODUCTS TO LEAK DO NOT USE THE PRODUCT S CONTAINED IN THIS DOCUMENT ON WATER SUPPLIES THAT CONTAIN HYDROCARBONS SUCH AS KEROSENE BENZENE GASOLINE ETC ...

Page 2: ...Page 2 WS1 5 2 and 2 QC Drawings and Service Manual ...

Page 3: ... Assemblies 30 Injector Graphs 35 39 Motorized Alternating Valve Applications 43 47 No Hard Water Bypass 48 49 Service Instructions Service Step Description Exploded Views Instructions 1 Front Cover and Drive Assembly 12 2 Drive Cap Assembly 26 29 13 3 Pistons 26 29 14 4 Spacer Stack Assembly 26 29 14 5 7 Injector Cap Screen Injector Plug and Injector 31 33 15 6 Refill Flow Control Assembly or Ref...

Page 4: ...___________ _________________________________________________________ Misc Service Flow Rates min _________ max ___________ Tank Size Diameter _________ Height ______________ Resin or Media Volume ___________________________ Resin or Media Type _____________________________ Capacity _______________________________________ Salt or Fill Setting per Regeneration _________________ Brine Tank Size ____...

Page 5: ...Valve standard base 29 7 2 Valve quick connect base 32 3 CV Backwash 1 5 Valve 10 1 5 Gen 2 Valve 10 4 2 Valve standard base 16 0 2 Valve quick connect base 17 0 Meter Accuracy Flow Range 5 1 5 0 5 75 gpm 1 9 283 lpm 2 1 5 150 gpm 5 7 568 lpm Regenerant Refill Rate 1 5 Valves 0 5 gpm 1 9 lpm 2 Valves Variable Shipped from Factory with 2 2 gpm 8 33 lpm Injectors 1 5 Valves See Injector Graphs V3010...

Page 6: ...Page 6 WS1 5 2 and 2 QC Drawings and Service Manual WS1 5 Gen 2 ...

Page 7: ...WS1 5 2 and 2 QC Drawings and Service Manual Page 7 WS2 ...

Page 8: ...Page 8 WS1 5 2 and 2 QC Drawings and Service Manual WS2 QC ...

Page 9: ...l an inlet shutoff valve and plumb to the unit s inlet Installation of a bypass valve is recommended If using plastic fittings ground the water conditioner per local electrical codes Do not install any water conditioner with less than 10 feet of piping between its outlet and the inlet of a water heater If a water meter is used install the water meter on the outlet side of the control valve The tur...

Page 10: ... a 1 threaded connection To ensure acceptable operation of the injectors use 1 pipe to connect to the brine tank An overflow drain line from the regenerant tank that discharges into an acceptable drain is recommended as a regenerant overflow could damage furnishings or the building structure Connect a line to the overflow fitting on the regenerant tank If an overflow fitting is not already install...

Page 11: ...llow water to run into the regenerant tank and prepare it for the next regeneration Allow the regenerant tank to fill automatically Systems with a salt grid should see a water level 1 2 above the grid 8 Add salt to the tank and allow ample time to dissolve salt for the brine solution 9 SANITIZE Add a sanitizer to the regenerant tank brine well following dosage recommendations specified by the medi...

Page 12: ...spect the motor for free spinning and remaining brush life visible through slots on the size of the motor Check the pinion gear for endplay If the pinion gear is pushed tight against the motor housing eliminating endplay slide it away from the housing so the end of the shaft is flush with the end of the gear The PC board can be removed separately from the drive bracket but it is not recommended Do...

Page 13: ...bly 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 V3193 02 Figure 1 or insert a to flat bladed screwdriver into one of the slots around the top 2 of the drive cap assembly so it engages the notches molded into the drive back plate a...

Page 14: ...ly to the control valve and connect all plugs After completing any valve maintenance press and hold NEXT and REGEN buttons for 3 seconds or unplug power source jack 4 pin black cable 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 4 Spacer S...

Page 15: ...t can be chemically cleaned with vinegar or dilute sodium bisulfate The holes can be blown out by air Sharp objects which can score the plastic should not be used to clean the injector Scoring the the injector or increasing the diameter of the injector hole could change the operating parameters of the injector If the WS1 5 Gen 2 valve does not use a regenerant the injector plug should not need to ...

Page 16: ...iver being careful not to mar the plastic seat The flow control and retainer may be chemically cleaned using dilute sodium bisulfite or vinegar do not clean with abrasive methods Reassembly Insert the flow washers back into their respective bores confirming correct flow control orientation see diagram in the exploded view section Place back into the housing and reassemble the housing fitting Do no...

Page 17: ...e regenerates at wrong time of day a Power outage a Reset time of day If PC Board has battery back up present the battery may be depleted See Front Cover and Drive Assembly drawing for instructions b Time of day not set correctly b Reset to correct time of day c Time of regeneration set incorrectly c Reset regeneration time d Control valve set at on 0 immediate regeneration d Check programming set...

Page 18: ...incoming water pressure water pressure must remain at minimum of 25 psi b Incorrect injector size b Replace injector with correct size for the application c Restricted drain line c Check drain line for restrictions or debris and clean 11 Excessive water in regenerant tank a Improper program settings a Check refill setting b Plugged injector b Remove injector and clean or replace c Drive cap assemb...

Page 19: ...too tight c Loosen main drive gear Press NEXT and REGEN buttons for 3 seconds to resynchronize software with piston position or disconnect power supply from PC Board for 5 seconds and then reconnect d Improper voltage being delivered to PC Board d Verify that proper voltage is being supplied Press NEXT and REGEN buttons for 3 seconds to resynchronize software with piston position or disconnect pow...

Page 20: ...ynchronize software with piston position or disconnect power supply from PC Board for 5 seconds and then reconnect d Foreign matter built up on piston and stack assemblies creating friction and drag enough to time out motor d Replace piston and stack assemblies Press NEXT and REGEN buttons for 3 seconds to resynchronize software with piston position or disconnect power supply from PC Board for 5 s...

Page 21: ... QC Drawings and Service Manual Page 21 WS1 5 Control Valve Cycle Positions SERVICE BACKWASH Raw water inlet Treated water supply Raw water inlet Raw hard water is bypassed during regeneraion Backwash water to drain ...

Page 22: ...l DRAW RINSE Raw water inlet Raw hard water is bypassed during regeneraion Regenerant water to drain Regenerant solution being drawn in Injector feed from raw water inlet Rinse water to drain Raw water inlet Raw hard water is bypassed during regeneraion ...

Page 23: ...d 2 QC Drawings and Service Manual Page 23 TREATED WATER REFILL Raw water inlet Treated water supply Treated water to regenerant tank WS2 Control Valve Cycle Positions SERVICE Raw water inlet Treated water supply ...

Page 24: ...ACKWASH Backwash water to drain Raw water inlet Raw hard water is bypassed during regeneraion DRAW Raw water inlet Raw hard water is bypassed during regeneraion Regenerant water to drain Regenerant solution being drawn in Injector feed from raw water inlet ...

Page 25: ...QC Drawings and Service Manual Page 25 RINSE Rinse water to drain Raw water inlet Rinse water is bypassed during rinse cycle TREATED WATER REFILL Raw water inlet Treated water supply Treated water to regenerant tank ...

Page 26: ...k Assembly 1 7 Back Plate Refer to Programming and Cover Drawing Manual 1 8 V3419 O ring 347 1 9 V3418 O ring 328 for valve bodies with NPT threads 1 V3441 O ring 226 for valve bodies with BSPT threads 1 10 V3400 01 WS 1 5 NPT Valve Body 1 V3400BSPT 01 WS 1 5 BSPT Valve Body 1 11 D1300 Top Baffle Diffuser 1 5 50MM 1 V3174 regenerant piston not used for backwash only valves V3010 15Z injector plug ...

Page 27: ...ds 1 V3441 O ring 226 for valve bodies with BSPT threads 1 10 V3950 01 WS 1 5 NPT Valve Body w V3468 1 V3950BSPT 01 WS 1 5 BSPT Valve Body w V3465 1 Not Shown V3468 Test Port Plug 1 4 NPT 2 V3465 Test Port Plug 1 4 BSPT 2 11 D1300 Top Baffle Diffuser 1 5 50MM 1 V3174 regenerant piston not used for backwash only valves V3010 15Z injector plug and V3195 01 refill port plug assembly must be used for ...

Page 28: ...k Plate Refer to Programming and Cover Drawing Manual 1 8 V3729 WS2 STACK ASSEMBLY 1 9 V3419 O RING 347 FOR WS15 1 10 V3641 O RING 225 for valve bodies with NPT threads 1 V3441 O RING 226 for valve bodies with BSPT threads 11 V3700 01 WS2 BODY NPT 1 V3700BSPT 01 WS2 BODY BSPT 12 V3468 WS2H PLUG 1 4 HEX NPT 2 V3465 WS2H PLUG 1 4 HEX BSPT 13 D1300 TOP BAFFLE DFSR CLACK 1 5 50MM 1 V3726 WS2 Brine Pis...

Page 29: ...01 WS2 BODY QC NPT 1 V3737BSPT 01 WS2 BODY QC BSPT 12 V3054 WS2H 4IN BASE CLAMP ASSEMBLY 1 13 V3276 WS2H BOLT HEX 5 16 18 X 1 3 4 1 14 V3269 WS2H NUT 5 16 18 SS HEX 1 15 V3468 WS2H PLUG 1 4 HEX NPT 2 V3465 WS2H PLUG 1 4 HEX BSPT Not Shown D1300 01 TOP BAFFLE DFSR CLACK 2 63MM 1 V3054 WS2H 4IN BASE CLAMP ASY includes a V3276 WS2H BOLT HEX 5 16 18 X 1 3 4 and V3269 WS2H NUT 5 16 18 SS HEX V3726 WS2 ...

Page 30: ...n of distributor pilot o ring 1 2 Drawing No Order No Description Quantity 1 V3202 01 WS2H BASE 1 2 V3419 O RING 347 1 Drawing No Order No Description Quantity 1 V3444 WS2H SCREW HEXCAP 5 16 18X2 SS 12 2 V3293 WS2H WASHER SS 5 16 FLAT 24 3 V3445 WS2H WASHER SPLIT LOCK 5 16 SS 12 4 V3447 WS2H NUT HEX 5 16 8 FULL SS 12 5 COR60FL O RING 6 FLANGE ADAPTER 1 6 V3261 01 WS2H FLANGE BASE 1 V3260 02 WS2H 2...

Page 31: ...WS1 5 Injector Feed Tube 1 4 V3177 01 WS1 Injector Screen 1 5 V3969 WS1 5 Injector Draw Tube 1 6 V3176 WS1 Injector Cap 1 7 V3152 O ring 135 1 8 See page 33 WS 1 5 Injector 1 9 V3498 Refill Flow Control 1 2 1 10 V3428 WS 1 5 Refill Retainer Assembly 0 5 GPM 1 11 V3163 O ring 019 1 12 H4612 Regenerant Elbow w Flow Control 1 13 JCPG 8PBLK Nut Compression 1 2 Black 1 14 JCP P 8 Insert Polytube 1 2 1 ...

Page 32: ... Any V3162 XXX flow control may be used WS2 valves are shipped with a V3162 022 2 2 gpm flow control Flow control sizes range from 0 7 up to 10 gpm WS2 valves can only be set for minutes of fill because various sizes of flow controls can be used To calculate for pounds or kilograms of salt take minutes of fill times the flow rate of the flow control being used to arrive at the number of gallons of...

Page 33: ...vary depending on the design and application of the system The injectors are sized for a typical downflow softener using standard mesh synthetic cation exchange media regenerating with sodium chloride See the injector graphs on the following pages to meet specific applications Variances in drain and draw line restrictions will effect injector performance RORUHG ODFN For WS1 and WS1 25 valves Do no...

Page 34: ...163 O ring 019 1 6 H4612 Elbow Cap 1 7 JCPG 8PBLK Nut Compression Black 1 8 JCP P 8 Insert Polytube 1 9 V3182 WS1 RFC 1 10 V3498 WS1 5 Brine Elbow Asy w RFC Option Not Shown V3434 01 WS1 5 Refill Asy 5 8 x 3 4 includes fitting refill retainer assembly o ring nut and polytube insert for 5 8 brine line connection Option V3428 contains a V3182 WS1 0 5 gpm RFC Water Flow Proper RFC orientation directs...

Page 35: ...te gpm Draw Total Slow Rinse 1 2 3 4 5 6 100 200 300 400 500 600 700 800 900 Pressure kPa Flow Rate lpm Slow Rinse Total Draw 0 2 0 4 0 6 0 8 1 1 2 1 4 1 6 20 40 60 80 100 120 Pressure psi Flow Rate gpm Slow Rinse Total Draw VIOLET ORDER NO V3010 15B or V3010 2R 15B Metric Units VIOLET ORDER NO V3010 15B or V3010 2R 15B US Units RED ORDER NO V3010 15C or V3010 2S 15C Metric Units RED ORDER NO V301...

Page 36: ... 3 20 40 60 80 100 120 Pressure psi Flow Rate gpm Draw Slow Rinse Total WHITE ORDER NO V3010 15D or V3010 2T 15D Metric Units WHITE ORDER NO V3010 15D or V3010 2T 15D US Units BLUE ORDER NO V3010 15E or V3010 2U 15E Metric Units BLUE ORDER NO V3010 15E or V3010 2U 15E US Units 2 4 6 8 10 12 14 16 100 200 300 400 500 600 700 800 900 Pressure kPa Flow Rate lpm Draw Slow Rinse Total 1 1 5 2 2 5 3 3 5...

Page 37: ...400 500 600 700 800 900 Pressure kPa Flow Rate lpm Draw Slow Rinse Total 1 2 3 4 5 6 7 20 40 60 80 100 120 Pressure psi Flow Rate gpm Draw Slow Rinse Total ORANGE ORDER NO V3010 15H Metric Units ORANGE ORDER NO V3010 15H US Units ORDER NO V3010 15I Metric Units ORDER NO V3010 15I US Units 5 9 13 17 21 25 29 33 37 100 200 300 400 500 600 700 800 900 Draw Slow Rinse Total 1 2 3 4 5 6 7 8 9 10 20 40 ...

Page 38: ...6 8 10 12 14 16 18 20 40 60 80 100 120 Pressure psi Flow Rate gpm Order No V3010 2A US Units Total Slow Rinse Draw 0 1 2 3 4 20 40 60 80 100 120 Pressure psi Flow Rate gpm Order No V3010 2C US Units Total Slow Rinse Draw 0 1 2 3 4 5 6 7 20 40 60 80 100 120 Pressure psi Flow Rate gpm Order No V3010 2E US Units Total Slow Rinse Draw 0 2 4 6 8 10 12 14 16 20 40 60 80 100 120 Pressure psi Flow Rate gp...

Page 39: ...300 400 500 600 700 800 900 Pressure kPa Flow Rate lpm Order No V3010 2E Metric Units Total Slow Rinse Draw 0 10 20 30 40 50 60 100 200 300 400 500 600 700 800 900 Pressure kPa Flow Rate lpm Order No V3010 2A Metric Units Total Slow Rinse Draw 0 2 4 6 8 10 12 14 16 100 200 300 400 500 600 700 800 900 Pressure kPa Flow Rate lpm Order No V3010 2C Metric Units Total Slow Rinse Draw 0 3 6 9 12 15 18 2...

Page 40: ... 4 5 1 Direction of Flow 2 5 4 6 1 3 9 8 7 Direction of Flow All drain line flow control housings are shipped without flow control washers See drain line flow control washer section for available flow selections Drain Line Flow Controls 1 3 4 DLFC not supplied At least one V3190 XXX must be installed in center hole Plugs may be knocked out or drilled to use up to six V3162 XXX Direction of Flow 2 ...

Page 41: ...trol V3162 027 2 7 GPMDrain line flow control V3162 032 3 2 GPMDrain line flow control V3162 042 4 2 GPMDrain line flow control V3162 053 5 3 GPMDrain line flow control V3162 065 6 5 GPMDrain line flow control V3162 075 7 5 GPMDrain line flow control V3162 090 9 0 GPMDrain line flow control V3162 100 10 0 GPMDrain line flow control V3190 090 9 0 GPMDrain line flow control V3190 100 10 0 GPMDrain l...

Page 42: ...lip Installation of the WS2 Meter NPT Assembly can be accomplished with 2 NPT pipe For WS2 Meter BSPT Assembly use 63mm pipe WHEN INSTALLING THE METER MAKE SURE THE ARROW ON THE METER BODY IS GOING THE SAME DIRECTION AS THE WATER FLOW THIS WATER METER SHOULD NOT BE USED AS THE PRIMARY MONITORING DEVICE FOR CRITICAL OR HEALTH EFFECT APPLICATIONS OPERATING PRESSURES 20 PSI MINIMUM 125 PSI MAXIMUM OP...

Page 43: ...ols with individual meters with some International or Custom PC Boards When using the Motorized Alternating Valve with two meters it is necessary to disconnect or cut the left wire on the interconnect cable This is the wire closest to the center cut out on the PC Board The 8 alternator valve motor cable must be threaded through the back plate and connected to the two pin connector labeled DRIVE on...

Page 44: ...A port until the error is corrected and reset A PORT CONTROL VALVE ALTb CONTROL VALVE ALTA VALVE INLET VALVE OUTLET VALVE INLET VALVE OUTLET UNTREATED WATER INLET TREATED WATER OUTLET C PORT B PORT METER Follow meter instruction sheet REGENERATION WITH HARD WATER REGENERATION WITH SOFT WATER A PORT CONTROL VALVE ALTb UNTREATED WATER INLET TREATED WATER OUTLET METER VALVE INLET VALVE OUTLET METER F...

Page 45: ...EN WRENCH REQUIRED 4 4 8 V3072 MAV NOHWBY 1 125 15 DRIVE ASY 1 1 9 V3506 01 MAV NOHRD 1 125 15 PISTON 1 1 10 V3074 MAV NOHWBY 1 125 15 STACK ASY 1 1 11 V3525 01 MAV BODY 1 5 NPT 1 N A 12 V3525BSPT 01 MAV BODY 1 5 BSPT N A 1 Not Shown V3474 WS ALT CONNECT CORD 8FT BLK 1 1 Order No V3071 Description MOTOR ALT VLV 1 5 NPT REV2 or Order No V3071BSPT Description MOTOR ALT VLV 1 5 BSPT REV2 1 2 3 4 5 6 ...

Page 46: ...SS 5 32 HEX ALLEN WRENCH REQUIRED 4 4 8 V3078 MAV NOHWBY 2 DRIVE ASY 1 1 9 V3634 01 MAV NOHWBY 2 PISTON 1 1 10 V3077 MAV NOHWBY 2 STACK ASY 1 1 11 V3633 01 WS2 MAV BODY NPT 1 N A V3633 01BSPT WS2 MAV BODY BSPT N A 1 Not Shown V3474 WS ALT CONNECT CORD 8FT BLK 1 1 Order No V3076 Description MOTOR ALT VLV 2 NPT REV2 or Order No V3076BSPT Description MOTOR ALT VLV 2 BSPT REV2 1 2 3 4 5 6 7 8 10 11 9 ...

Page 47: ... for WS1 5 WS2L or WS2 valves using V3071 or V3076 piston style MAV s and regenerating with hard water Note These drawings are for reference Installer needs to install inlet outlet isolation ball valves for each control valve and a three valve bypass for the system It is recommended to have some unions in the plumbing Meter should be mounted horizontally or in a downflow vertical position to reduc...

Page 48: ... 4 BHSCS SS 5 32 HEX ALLEN WRENCH REQUIRED 4 4 8 V3072 MAV NOHWBY 1 125 15 DRIVE ASY 1 1 9 V3506 01 MAV NOHRD 1 125 15 PISTON 1 1 10 V3886 WS15 NHWBY STACK ASY 1 1 11 V3832 01 WS15 NHWBY BODY M X F NPT 1 N A V3832BSPT 01 WS15 NHWBY BODY M X F BSPT N A 1 Not Shown V3805 STRAIN RELIEF COVER KIT 1 1 Order No V3097 Description NO HARDWATERBYPASS 15INMXF NPT or Order No V3097BSPT Description NOHARDWATE...

Page 49: ...4 20 X 1 1 4 BHSCS SS 5 32 HEX ALLEN WRENCH REQUIRED 4 4 8 V3078 MAV NOHWBY 2 DRIVE ASY 1 1 9 V3634 01 MAV NOHWBY 2 PISTON 1 1 10 V3887 WS2 NHWBY STACK ASY 1 1 11 V3828 01 WS2 NHWBY BODY M X F NPT 1 N A V3828BSPT 01 WS2 NHWBY BODY M X F BSPT N A 1 Not Shown V3805 STRAIN RELIEF COVER KIT 1 1 Order No V3098 Description NO HARDWATERBYPASS 2INMXF NPT or Order No V3098BSPT Description NO HARDWATERBYPAS...

Page 50: ...Page 50 WS1 5 2 and 2 QC Drawings and Service Manual ...

Page 51: ...n smaller tank sizes The V3010 2 15 adpter can be used with any V3010 15X injector The V3010 15X injector includes one V3416 O RING 012 lower and one V3171 O RING 013 upper PAGE 36 Removed V3010 2V 15F PAGE 37 Removed V3010 2W 15G and V3010 2X 15Hs 3 V3592 SCREW 8 1 PHPN T 25 SS 3 3 5 4 2012 PAGE 30 PAGE 31 5 See page 33 WS 1 5 Injector 1 8 See page 33 WS 1 5 Injector 1 7 3 2012 PAGE 32 Not Shown ...

Page 52: ...ranty shall be limited at its option to replacement or repair of any Softener and Filter Control valve covered by this Limited Warranty Prior to returning a Control Valve OEM must obtain a return goods authorization number from Clack and return the Control Valve freight prepaid If any Control Valve is covered under this Limited Warranty Clack shall return the Control Valve repaired or its replacem...

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