Hellenbrand ProMate Series Owner's Manual page 32

DRIVE ASSEMBLY
Remove the valve cover to access the drive assembly.
Disconnect the power source (black wire) from the PC board prior
to disconnecting the motor or water meter plugs from the PC
board. The power source plug connects 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.
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 the PC board, position the
lower edge of the PC board so that the holes in the PC board line
up with the plastic pins. 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.
The drive bracket must be removed to access the drive cap
assembly and pistons or the drive gear cover. It is not neces-
sary to remove the PC board from the drive bracket to remove
the drive bracket. To remove the drive bracket start by removing
the plugs from the power source and the water meter. Unweave
the wires from the side holders. 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 drive the gars 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 if felt be-
fore latching, then notches are not fully engaged, the piston rod
is not in hole, the wires are jammed between the drive bracket
and drive back plate, or the gear is not engaging the drive cap
assembly.
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.
32
ServiCe inSTruCTiOnS
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.
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 wire are
vertical (up & down) before gently pulling on the wire connectors
to remove the motor. Pulling directly on the wired without rotat-
ing 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 engag-
es 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 competing any valve maintenance
involving the drive assembly or the drive cap assembly and
pistons unplug power source jack from the printed circuit board
(black wire) and plug back in or press and hold NEXT and REGEN
buttons for 3 seconds. This resets the electronics and estab-
lishes 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
assembly. 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. The
notches are visible through the holes. Lever the screwdriver so
the drive cap assembly turns counter clockwise. Once loosened
unscrew the drive cap assembly by hand and pull straight out.