Service Instructions - Hellenbrand ProMate Series Owner's Manual

CONTROL VALVES
The twin alternating control valve consist of the following
components:
1. Drive Assembly
2. Drive Cap Assembly, Main Piston and Regenerant Piston
3. Spacer Stack Assembly
4. Injector Cap, Screen, Injector Plug and Injector
5. Refill Flow Control Assembly or Refill Port Plug
6. Drain Line Flow Control and Fitting Assembly
7. Water Meter
8. Twin Transfer Valve.
DRIVE ASSEMBLY
The drive assembly consists of the following parts:
• Drive Bracket
• Printed Circuit (PC) Board
• Motor
• Drive Gears
• Drive Gear Cover
The drive bracket hold the PC board, the motor, the drive gears
and drive gear cover in place.
The PC board receives and retains information, displays the infor-
mation, determines when to regenerate and initiates regenera-
tion. The display shows different types of information in the initial
setup (for softeners or filters), installer display settings, diagnos-
tics, valve history or user display settings.
The PC board powers the motor. The PC board's two-prong
jack connects wires to the direct current (DC) motor. The motor
is held in place on the drive bracket by a spring-loaded clip and
a small bulge in the plastic, which fits in one of the slots on the
motor housing. The motor turns drive gears that drive the piston
to cycle positions for backwashing, regeneration, rinsing, refill
or service. The motor is fully reversible (turns both ways) and
changes direction of rotation to change the direction of piston
motion. The motor is easily replaced if necessary.
There are three drive gears held in place by the drive gear cover.
All three drive gear are the same size. A reflective coating is
applied to the gears. As the center drive gear turns a light shines
on the coating and a light sensing diode determines if a light
pulse was returned. The PC board counts the pulses and deter-
mines when to stop driving the motor.
DRIVE CAP ASSEMBLY, MAIN PISTON AND
REGENERANT PISTON
The drive gears turn the main gear of the drive cap assembly,
which moves the piston. The screw-driven, horizontally moving
piston stops at specific positions to direct the flow of water to
backwash, regenerate, rinse or refill. The PC board determines
the position of the piston by counting pulses produced when the
piston is moved. An optical sensor looking at one of the reduc-
tion drive gears generates these pulses. Each cycle position
is defined by a number of pulses. The counter is zeroed each
time the valve goes to the service position. The PC board finds
the service position by noting the increase in current delivered
to the motor when the mechanical stop at the service position
is reached. This method of controlling piston position allows for
greater flexibility and requires no switches or cams (US Patent
6444127).
One of two main pistons is always used:
1. A 1.25" diameter downflow piston is used when the control
31

ServiCe inSTruCTiOnS

valve is used as a downflow softener, regenerating filter or non-
regenerating filter.
2. A 1.25" diameter upflow piston is used when the control valve
is used as an upflow softener.
If the control valve is used as a softener or a regenerating filter,
a regenerant piston must be attached to the main piston. If the
control valve is to be used on a system that does not require a
regenerant to be added, the regenerant piston must be removed.
SPACER STACK ASSEMBLY
The spacer stack assembly provides the necessary flow passage
for water during the different cycles. The all-plastic spacer stack
assembly is a one-piece design which allows the stack to be
removed using your fingers.
The exterior of the stack is sealed against the body bore with
self lubricating EPDM o-rings, while the interior surface is sealed
against the piston using slippery self cleaning directional (one-
way) silicone lip seals. The lip seals are clear in color and have
a special slippery coating so that the piston does not need to be
lubricated.
INJECTOR CAP, SCREEN, INJECTOR PLUG
AND INJECTOR
The screen, injector and/or injector plug(s) are installed under
the injector cap in an easy to access location on top of the valve.
The injector cap contains four slots so no water accumulates in
the cap. The injector cap is designed to be hand tightened.
Under the injector cap there is an easy to clean removable screen
to prevent fouling of the injector. There are two holes under the
injector cap labeled "DN" and "UP". The holes will be filled with
a plug or an injector.
The plug (pn 102319) prevents water from traveling a certain
pathway. The injector lets water pass through the pathway. The
self-priming injector increases the velocity of the water, creating
a zone of negative pressure that draws in the concentrated liquid
regenerant, such as sodium chloride (brine), potassium perman-
ganate, etc. The regenerant blends with the stream of water,
which passe through the media to regenerate the bed.
The injector provides a consistent regenerant/water mixture ratio
over the entire operating pressure range of the control valve. The
injector provides good performance in a variety of applications,
which may involve elevated drain lines and long regenerant draw
lengths. Injectors are chosen by knowing the type, amount, and
regenerant flow rate for a particular type of media. Guidelines
can be found in the media manufacturer's literature. The color
coded injectors give different regenerant draw, slow rinse and
total flow rates over the pressure range. See injector graphs
(pages 38-39) for total, slow rinse and draw rates.
The control valve has been manufactured to be one of the follow-
ing:
• regeneration downflow (for softeners or regenerating filters
install injector in DN location, plug in UP location)
• regeneration upflow (upflow option is for softeners only. Install
injector in UP location, plug in other hole location)
• no regenerant (both the DN and UP holes have injector plugs
installed) and plug installed for the refill elbow.
NOTE: It is okay to field covert valves from upflow to downflow
and vise versa with the twin alternating valve as long as software
supports upflow brine.