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IBC Water AST1041TC-CL Installation & Operating Instructions Manual

With time clock control
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WITH TIME CLOCK CONTROL
INSTALLATION & OPERATING
Model :
Serial No :
Manufacturer and Supplier of
Telephone: (07) 3219 2233
Email: sales@ibcwater.com.au
AS1041TC-CL
WATER SOFTENER
INSTRUCTIONS
AST1041TC-CL
.............................
FILTRATION & WATER TREATMENT PRODUCTS
for commercial, industrial and residential application
Facsimile: (07) 3219 2266
Website: www.ibcwater.com.au
1
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Summary of Contents for IBC Water AST1041TC-CL

  • Page 1 WATER SOFTENER WITH TIME CLOCK CONTROL INSTALLATION & OPERATING INSTRUCTIONS Model : AST1041TC-CL Serial No : ……………………….. Manufacturer and Supplier of FILTRATION & WATER TREATMENT PRODUCTS for commercial, industrial and residential application Telephone: (07) 3219 2233 Facsimile: (07) 3219 2266 Email: sales@ibcwater.com.au...
  • Page 2 (kg) Inlet Minimum Maximum Drain W x D x H Outlet Flow gram/kg gram/kg Litres Per Kg metres AST1041TC-CL 1435/3.0 2870/10.0 25BSP ”F” 1.58 CABINET/ BRINE CHAMBER: POLY MOULDED System Operating Pressure: 330 - 690 kPa Temperature: x 43 Electrical: 240V—16VAC 50Hz 3 watts maximum...
  • Page 3 AS1041TC-CL Page...
  • Page 4 STEP 9 Load Two bags of 25kg high purity water softener salt into brine tank and replace lid. IBC Water recommends that only high purity salt be used in the softener . STEP 10 Refer to Instruction booklet for start up procedure (placing conditioner into Service") and it is recommended to read fully the instruction manual before commencing the installation and placing the system into operation.
  • Page 5 The final colour is usually blue but with some water a greyish coloured end point is obtained. Using 100ml sample - Hardness ppm = (number tablets x 2) – 1 Contact IBC Water if further details are required. AS1041TC-CL Page...
  • Page 6 1000 x C D x H NOTE: Select nearest lower whole number If necessary consult your dealer or IBC Water for advice on setting up the softener. EXAMPLE Household use for 5 people on 220 mg/l hard water using Model AST1041 at 2030 grams capacity.
  • Page 7 Note: Maximum number of days that can be selected is 99 AS1041TC-CL Page...
  • Page 8 CUSTOMER/ INSTALLER PROGRAMING INSTRUCTIONS The WS1-TC has been factory programmed with the majority of the commands and parameters installed. It is necessary on commissioning of the softener to program in the “DAYS between regenerations as calculated on page 5 and if desired another time of day when regeneration is to proceed or accept the factory default of 2am and to set up the clock to register the current time of day.
  • Page 9 Power outage When electric power is interrupted the microprocessor will hold all relevant information in memory except for the current time of day. Current time of day When power is restored the display will Flash and go to the Time-Hour Setting. Press SET HOUR and input the current Time OF Day.
  • Page 10 MODEL AST1041 WATER SOFTENER WITH CONTROL VALVE SERIES MODEL WS1-TC WS1-TC VALVE The Softener is shipped unassembled and it is necessary to Assemble the Strainer into the Valve( by Matching Up the Locating Lugs and Twisting To Lock) prior to the loading of the resin and screwing on the valve to the tank.

  • Page 11: Specifications

    GENERAL” WS1 TC” CONTROL VALVE SPECIFICATONS Inlet/Outlet Fittings 25mm BSPF PVC elbows Cycles Valve Material Noryl (1) or equivalent Regeneration Down flow FLOW RATES Service @15psi/1 bar drop (includes bypass & meter) 102 lpm Backwash @25psi/1.7 bar drop (includes bypass) 102 lpm OPERATING PRESSURE Minimum/Maximum...

  • Page 12: Table Of Contents

    Table of Contents Specifications …………………………………………………………… 9 Introduction ……………………………………………………………… 11 Special Features General Conditioner Information …………………………………….. 11 How Your Conditioner Works Model TC Control Front Panel Installation – important installation details….…………………….. 12-13 Bypass Valve …………………………………………………………… 13-14 Water Conditioner Regeneration ………………………………….…. 15 Automatic Regeneration Manual Regeneration Care of Your Water Conditioner ………………………………………...

  • Page 13: Introduction

    Introduction General Conditioner Information Model Control provides sophisticated Electronic Time Clock-based water conditioning. The control is factory default programmed for the majority How the Water Softener Works of the required settings and only requires simple minimal on site programming for the remaining In general, your water softener works in the follow-ing settings to suit the specific installation.

  • Page 14: Installation - Important Installation Details

    • Bypass untreated water is automatically available during regeneration unless a prevention solenoid valve fitted. Installation Drain Line Connection – to sewer All plumbing and electrical connections must conform to local codes. Inspect the unit carefully for carrier The ideal location for the unit is above and not more shortage or shipping damage.

  • Page 15: Bypass Valve

    For full understanding of the water softener we Important Installation Details recommend that the instruction manual be fully read before installation and commissioning of the softener The control valve, fittings and/or bypass are designed by undertaken. to accommodate minor plumbing misalignments but are not designed to support the weight of the system IMPORTANT: NUMBER...
  • Page 16 water is supplied to the plumbing system. (Figure 3. Diagnostic Position: The inlet handle points in the direction of flow and the outlet handle points to the centre of bypass valve, system water pressure is allowed to the control valve and the plumbing system while not allowing water to exit from the control valve to the plumbing.(Figure 3) 4.

  • Page 17: Water Conditioner Regeneration

    conditioning. Some locations may require more Water Conditioner Regeneration frequent injector and screen servicing. Your water conditioner regenerates for one of two Complete the following steps to clean the injector and reasons: the injector screen: • The control determines that the conditioner has reached the Days to Regen.

  • Page 18: Brine Line And Brine Tank Overflow Connection

    Brine Line Connection The brine line comprises a pick up air check assembly installed in the brine wall in the cabinet and connected by tubing to the brine elbow on top of the valve. Note: Make sure that all fittings and connections are tight so that premature checking does not take place.

  • Page 19: Placing Softener Into Operation

    Press the “▲▼” buttons in once simultaneously Placing Softener into Operation and release and again press but hold for 3 seconds until regeneration starts. Initial Start-Up 13. Allow to progress through to the draw mode”C2”. When the valve is in this mode check to see that 1.

  • Page 20: Valve Manual

    WS1-TC Manual Manual Initiated Regeneration The user can initiate manual regeneration. The user Control Valve Function and Cycles has the option to request the manual regeneration at of Operation the delayed regeneration set time or to have the regeneration occur immediately: 1.
  • Page 21 Injector Cap, Screen, Injector Plug and Injector The PC board powers the motor. The PC board’s two- prong jack connects wires to the direct current (DC) The screen, injector and/or injector plug(s) are motor. The motor is held in place on the drive bracket installed under the injector cap in an easy to access by a spring-loaded clip and a small bulge in the location on top of the valve.
  • Page 22 The refill flow control assembly is installed in an easy Installation Fitting Assemblies to access refill elbow located on top of the control valve.. The refill flow control assembly is attached to The installation fittings are used to connect the the control valve with a locking clip.

  • Page 23: Replacement Parts

    SPARE PARTS SERVICING INSTRUCTIONS AS1041TC-CL Page...
  • Page 24 WS1-TC Front Cover and Drive Assembly Drawing No. Order No. Description Quantity V3175TC-01 WS1TC Front Cover Assembly V3107-01 WS1 Motor V3106-01 WS1 Drive Bracket & Spring Clip V3108TC WS1 PC Board V3110 WS1 Drive Gear 12x36 V3109 WS1 Drive Gear Cover V3002TC WS1TC Drive ASY Not Shown...
  • Page 25 WS1TC Drive Cap Assembly, Downflow Piston, Regenerant Piston and Spacer Stack Assembly Drawing No. Order No. Description Quantity V3005 WS1Spacer Stack Assembly V3004 Drive Cap ASY V3178 WS1 Drive Back Plate V3011 WS1 Piston Downflow ASY V3174 WS1 Regenerant Piston V3135 O-ring 228 V3180...
  • Page 26 Injector Cap, Injector Screen, Injector, Plug and O-Ring Drawing No. Order No. Description Quantity V3176 Injector Cap V3152 O-ring 135 V3177 Injector Screen V3010-1A WS1 INJECTOR ASSY - BLACK V3010-1B WS1 INJECTOR ASSY - BROWN V3010-1C WS1 INJECTOR ASSY - VIOLET V3010-1D WS1 INJECTOR ASSY - RED V3010-1E...
  • Page 27 Refill Flow Control Assembly Drawing No. Order No. Description Quantity H4615 Elbow Locking Clip JCP-P-6 Polytube insert 3/8” JCPG-6PBLK Nut 3/8” H4613 Elbow Cap 3/8” V3163 O-ring 019 V3165-01* WS1 RFC Retainer ASY V3182 WSC RFC Not Shown H4650 Elbow ½” with nut and insert Option * Assembly includes V3182 WS1 RFC.
  • Page 28 Drain Line – ¾” Drawing No. Order No. Description Quantity H4615 Elbow Locking Clip PKP10TS8- BULK Polytube insert 5/8 Option V3192 WS1 Nut ¾ Drain Elbow Option V3158-01 WS1 Drain Elbow ¾ Male V3163 O-ring 019 V3159-01 WS1 DLFC Retainer ASy V3162-007 WS1 DLFC 0.7 gpm for ¾...
  • Page 29 Installation Fitting Assembly Order No: V3007-01 Description: WS1 Fitting ¾” & 1” PVC Solvent 90۫ ASY Drawing No. Order No. Description Quantity V3151 WS1 Nut 1” Quick Connect V3150 WS1 Split Ring V3105 O-Ring 215 V3189 WS1 Fitting ¾ & 1 PVC Solvent 90 AS1041TC-CL Page...
  • Page 30 Bypass Valve Drawing No. Order No. Description Quantity V3151 WS1 Nut 1” Quick Connect V3150 WS1 Split Ring V3105 O-ring 215 V3145 WS1 Bypass 1” Rotor V3146 WS1 Bypass Cap V3147 WS1 Bypass Handle V3148 WS1 Bypass Rotor Seal Retainer V3152 O-ring 135 V3155...
  • Page 31 V3156 O-ring 214 Flow Diagrams – Service and Backwash flow diagram…service AS1041TC-CL Page...
  • Page 32 flow diagram…backwash Flow Diagram – Down flow Brine AS1041TC-CL Page...
  • Page 33 flow diagram…downflow brine Flow Diagrams – Rinse and Fill AS1041TC-CL Page...
  • Page 34 flow diagram…rinse flow diagram…fill WS1 Wrench (Order No. V3193-01) AS1041TC-CL Page...

  • Page 35: Service Instructions

    Although no tools are necessary to assemble or disassemble the valve, the WS1 wrench (shown in various positions on the valve) may be purchased to aid in assembly or disassembly. Service Instructions AS1041TC-CL Page...
  • Page 36 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 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.
  • Page 37 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 SET HOUR and DOWN ▼buttons for 3 seconds or unplug power source jack (black wire) at the circuit board and plug back in.
  • Page 38 Reattach the main piston to the drive cap assembly. Reattach the regenerant piston to the main piston. Do not lubricate the piston rod, main piston or regenerant piston. Lubricant will adversely affect the clear lip seals. Reinsert the drive cap assembly and piston into the spacer stack assembly and hand tighten the drive cap assembly.
  • Page 39 Application Injector and/or Main Regenerant Stack Body Plug(s) Piston Piston WS1TC Downflow Softener or Injector in “DN” hole. V3011 V3174 V3005 V3001 Regenerating Filter Refill Flow Control Assembly or Refill Port Plug To clean or replace the refill flow control, pull out the elbow-locking clip and then pull straight up on the elbow. Replace the elbow locking clip in the slot so that it is not misplaced.
  • Page 40 Order No.: V3009 Description: WS1 Auxiliary Micro Switch Assembly iliary Micro Switch Assembly Order No.: V3009 Description: WS1 Auxiliary Microswitch Assembly Drawing No. Order No. Description Quantity V3301 WS1 MICROSWITCH V3302 WS1 MOLEX CONNECTOR Not Shown V3303 WS1 MOLEX TERMINAL V3304 WS1 SCREWS 4/40 X 5/8 V3305...
  • Page 41 AS1041TC-CL Page...

  • Page 42: Troubleshooting

    Troubleshooting AS1041TC-CL Page...

  • Page 43: Alarms

    Your water conditioning system is designed and manufactured for efficient, low maintenance service. However, if problems do occur, this section provides a list of possible causes and solutions. Alarms The control continuously monitors itself and sends an error to the display if it detects something wrong. When the error is sensed, the display shows the letters Err with a number from 1 to 3.
  • Page 44 Table 3 – Troubleshooting Procedures - cont… 6. Control does not draw a. Low water pressure a. Increase water pressure (330kpa) brine. b. Restricted drain line. b. Remove restriction. c. Injector or injector screen plugged. ! c. Clean injector and screen, Refer to the Cleaning the Injector/Injector Screen section in this manual.
  • Page 45 Microprocessor Troubleshooting Procedures Problem Possible Cause Solution a. AC Adapter unplugged a. Connect power 1. Timer does not display time b. No electric power at outlet b. Repair outlet or use working outlet of day. c. Defective AC adapter c. Replace AC adapter d.

  • Page 46: Glossary Of Terms

    Glossary of Terms Alarms Hardness Display errors alert you to operating conditions A common quality of water containing dissolved requiring attention. The display shows the type of calcium, magnesium and other elements. Water error. Refer to the Alarms section in this manual hardness is usually expressed milligrams per litre for additional information.

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