Service Instructions - Hellenbrand H-150 Series Owner's Manual

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 con-
nects 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 holders.
Two tabs on the top of the drive back plate hold the drive
bracket in place. Simultaneously lift the two tabs and gen-
tly 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.
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serviCe insTruCTions

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 remov-
ing 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 ei-
ther 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 mo-
tor 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 eas-
ily 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 main-
tenance, 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.