Installation Instructions and Owner s Manual. NES & INT2 Series. Water Softener System

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1 Installation Instructions and Owner s Manual NES & INT2 Series Water Softener System First Sales, LLC US Highway 33 N Churubusco, IN Phone (260) Fax (260) NES Instruction Manual docx

2 Table of Contents Pre-installation Instructions Page 3 Installation Page 5 Bypass Valve & Brine Tank Page 6 Control Valve Display Panel Page 7 Control Valve Programming Page Unit Specifications: NES, NECS Page 9 Unit Specifications: NES-HE, NECS-HE, INT2 Page 10 Component Parts Breakdown & List Page 11 Control Valve Breakdown Page 12 Control Valve Parts List Page 13 Troubleshooting Page Electrical Connections Page 16 Ten Year Limited Warranty Page 17 2

3 Preinstallation Instructions Description of the water softener system This water softener system includes a brine (salt) tank and a resin (media) tank with a backwashing control valve. Incoming water flows into the control valve and is directed down through the ion exchange softening resin. This resin exchanges the hardness ions for softer ions. The softened water then returns to the control valve where it is directed into the service lines. Periodically the control valve will go through a regeneration cycle. The frequency of this regeneration process will depend on the size of water softener, incoming water quality and amount of water used. This cycle is factory preset to begin at 2:00 A.M. At this time the control valve will draw the brine solution out of the salt tank and flush both the accumulated hardness and excess salt to the drain. The control valve will then put fresh water back into the salt tank to make brine for the next regeneration cycle. Water Quality The water should be tested to determine the concentration, or levels of the items listed below: Hardness - Hardness in drinking water is defined as those minerals that dissolve in water having a positive electrical charge (cat ions). The primary components of hardness are calcium (Ca++) and magnesium (Mg++) ions. But dissolved iron (Fe++) and manganese (Mn++) also contribute to total adjusted hardness. Hardness produces scale, soap scum and white mineral deposits which shorten the life of water using appliances, plumbing and fixtures. Water that has less than 1 grain of hardness is considered to be soft water. ph - A measurement of the acidity of the water. ph is reported on a scale from 0 to. Neutral water has a ph of 7.0, lower values indicate acidic water. If your ph is below 6. you may consider installing an acid neutralizer before the water softener to elevate the ph. Iron - A naturally occurring metallic element. Iron levels in excess of 0.3 milligrams/liter (mg/l) combine with oxygen causing orange or red (rust) stains on plumbing fixtures. Iron exists in some water sources in clear water (ferrous) state, red water (ferric) state or bacterial form. Iron levels that exceed 2.0 mg/l require special ion exchange resin for reduction, or if bacterial or ferric (red water) iron is present or iron level exceeds 4.0 mg/l, an iron filter should be installed ahead of this water softener. Manganese - A naturally occurring metallic element. Manganese levels as low as 0.05 milligrams/liter (mg/l) can combine with oxygen to cause dark brown or black staining on fixtures. Additionally, manganese can cause an odor in the water similar to a rotten egg smell. This water softener may reduce manganese as well as iron; however, an iron filter may be required in some cases. Tannin - A naturally occurring humic acid. Tannin is caused by water passing through decaying vegetation. Coffee and Tea are prime examples of tannin in water. Tannin levels as low as 0.5 milligrams per liter can cause a yellow discoloration in water. Consult your dealer for a system designed to remove both tannin and hardness. Hydrogen Sulfide - A naturally occurring gas. Hydrogen sulfide, more commonly referred to as sulfur gas, causes a distinct odor similar to rotten eggs. Due to its gaseous nature, hydrogen sulfide must be tested at the well site within 1 minute of drawing the sample. If sulfur is present additional equipment will be required. An air injection type iron filter can typically treat up to 2 milligrams per liter of sulfur gas. 3

4 Location Considerations The proper location to install the water softener system will ensure optimum performance and satisfactory water quality. The following factors should be considered in selecting the location of the equipment. 1. The water softener should be installed after the pressure tank (private well system only). Operating pressure of the softener must be limited to within psi range. 2. The water softener should be installed as close as possible (preferably within 15 ) to an adequate floor or laundry drain capable of handling the backwash cycle volume and flow rate. 3. All water conditioning equipment should be installed prior to the water heater. Water temperatures exceeding 100 F can damage the internal components of the control valve and filter tank. Install with at least 10 of pipe before the water heater to prevent thermal damage to the equipment. An expansion tank may need to be installed in the line to the water heater in order to allow for thermal expansion and comply with local plumbing codes. 4. The water softener should not be subject to freezing temperatures. 5. Ensure that any cartridge or in-line type filter installed prior to the water softener does not restrict the water flow and pressure available for backwash and interfere with normal operation 6. Appliances requiring extended periods of continuous or high flow water use (i.e. geothermal heat pumps, swimming pools, lawn irrigation, outside hose bibs, etc.) should bypass the water softener. (see installation diagram Fig. 1). Grounding Strap Softened Cold Water 10 Minimum Distance Iron Free Water Check Valve Untreated Water Softened Hot Water Inlet from water supply Water Heater NES Softener Iron Filter (if required) Pressure Tank (well system only) FIGURE 1: Typical Installation 4

5 Installation 1. Place the softener tank where you want to install the unit. Be sure it is within 15 feet of a drain that is lower than the control valve and near a non-switched electrical outlet. Be sure the tank is on a level and firm base. Install the unit with at least 10 feet of piping before the water heater to prevent hot water from backing into the softener. Turn off the main water supply and drain the system. 2. During cold weather it is recommended that the entire unit is warmed to room temperature before operating. 3. Perform all plumbing according to local plumbing codes. 4. The drain line is the most important part of the installation. a. NEVER USE VINYL TUBING NEVER. Vinyl tubing is generally clear; kinks easily; and collapses when warm. b. The ideal drain line is made of ridged or semi-ridged pipe with very few elbows and no kinks. c. Drain line should never exceed the height of the unit. OVER HEAD DRAINS SHOULD BE AVOIDED. d. Drain line should not be longer than 15 feet. e. The larger the drain line diameter the better never less than ½ inch ID. OUTLET SOFT WATER INLET HARD WATER RETAINER CLIPS BYPASS IN SERVICE POSITION METER MODULE DRAIN ELBOW ELBOW LOCKING CLIP FIGURE 2: Top View of Control Valve with Bypass 5. Heat from a solder torch should never transfer heat to the bypass valve, elbow connectors, or drain fitting. 6. Connect the inlet to the water supply and the outlet to the piping going toward the water heater. Use only Teflon tape or paste (other types of pipe dope may destroy the plastic elbows). DO NOT INSTALL THE INLET AND OUTLET BACKWARDS DOUBLE CHECK. 5

6 7. Sweep the floor carefully where the salt tank will set. Debris may puncture the bottom of the tank.. Connect the 3/ brine line to the safety float in the brine tank and to the control valve. Brine Line To Control Valve Brine Refill Elbow Safety Brine Valve Brine Tank Overflow Elbow Safety Float Salt Platform Brine Overflow Drain Line (Not included) To Floor Drain Brine Well Air Check FIGURE 3: Brine Tank Components 9. Add enough water to the salt tank so it covers the salt shelf by two inches. DO NOT add water softener salt to the brine tank yet. 10. Set the time of day and the water hardness see User Mode Programming section (page 7-). 11. With the bypass valve in the bypass position (Figure 4B) open the supply valve. Check for leaks at the connectors. Fig. 4A: Service Position Fig. 4B: Bypass Position FIGURE 4: Bypass 12. Put the unit into backwash by holding down the Right Button (Figure 5, page 7) for five seconds. When the valve stops in the backwash position, unplug the transformer and turn the bypass valve partially toward the service position to allow the unit to fill slowly and purge the air mineral tank. When the tank is full and only water discharges to drain the bypass valve can be fully opened. 13. Plug in the transformer and press the Right Button (Figure 5, page 7) to advance the control valve to the Brine Draw (BD) position. Verify that the water in the brine tank drops below the salt grid within minutes. If so, fill the brine tank with salt and allow the unit to complete regeneration automatically. If not, see Section 7 of Troubleshooting on page. 6

7 Display Operation FIGURE 5: Display Panel SET BUTTON 1. Press and hold Set Button for 5 seconds to enter Programming Mode. 2. When valve is in Programming Mode, press Set Button to confirm setting and advance to next menu option. RIGHT BUTTON 1. Press and hold Right Button for 5 seconds to initiate an immediate regeneration cycle. 2. Press and release Right Button during a regeneration cycle to immediately advance the valve to the next step in the regeneration process. 3. When the valve is in Programming Mode, press the Right Button to move the cursor. UP BUTTON 1. When the valve is in the Programming Mode, press Up Button to adjust setting. 7

8 Programming Enter Programming Mode: Press and Hold the SET Button for 5 seconds. Use Up Button to set current hour Use Up Button to set current minute Use Up Button to set AM/PM Use Up Button to set ADJUSTED Hardness Exit Programming Mode

9 SPECIFICATIONS Description Model Numbers NES-0.75-S NES-1-S NES-1.5-S NES-2-S NECS-0.75-S NECS-1-S NESCC-1-S Volume, cu. ft. (liters) 0.75 (21) (2) 1.5 (42) 2.0 (57) 0.75 (21) (2) (2) Resin Capacity, grains (grams), 3 minute brine fill *21,000 (1,361) *24,000 (1,551) 27,000 (1,750) 33,000 (2,13) *21,000 (1,361) *24,000 (1,551) *24,000 4 minute brine fill 22,500 (1,45) 2,000 5 minute brine fill -NA- 30,000 (1,944) *33,000 (2,13) 37,500 6 minute brine fill -NA- -NA- 42,000 minute brine fill -NA- -NA- 45,000 (2,916) 36,000 (2,333) 44,000 (2,51) *4,000 (3,110) 56, minute brine fill -NA- -NA- -NA- 60,000 (3,) Operating Flow Rate, gpm (lpm) Continuous (3 gpm/ft 3 ) 2 () Service ( gpm/ft 3, <=15psi drop) 6 (23) Peak (Max. 20 psi drop) 12 (45) Pressure Loss psi Continuous Flow Rate 2 Service Flow Rate 7 Peak Flow Rate 19 (131) Regen. Flow Rates, gpm (lpm) Backwash & Rapid Rinse 2.0 (7.6) Brine Draw / Slow Rinse 0.3 / 0.45 Brine Fill (3.) Service Pipe Size, in. (cm) For 1 replace S with -1S in model # 3 (11) (30) 13 (49) 3 (21) 10 (69) 20 (13) 2.4 (9.1) 0.3 / 0.45 (3.) 5 (19) 10 (3) 13 (49) 5 (34) 13 (90) 20 (13) 3.0 (11.4) 0.3 / 0.45 (3.) 6 (23) 12 (45) (53) 5 (34) 15 (103) 19 (131) 4.0 (15.1) 0.56 / 0.4 (2.12 / 3.1) (3.) 22,500 (1,45) 2,000 (1,) -NA- 30,000 (1,944) 2,000 (1,) 30,000 (1,944) -NA- -NA- -NA- -NA- -NA- -NA- -NA- -NA- -NA- 2 () 6 (23) (53) 1 (7) 5 (34) 20 (13) 2.4 (9.1) 0.3 / 0.45 (3.) 3 (11) (30) (53) 2 () (55) 19 (131) 3.0 (11.4) 0.3 / 0.45 (3.) 3 (11) (30) (53) 2 () (55) 19 (131) 3.0 (11.4) 0.3 / 0.45 Factory Regeneration Settings Default size setting SMALL SMALL MEDIUM LARGE SMALL SMALL SMALL Regenerate after capacity (grains) 12,000 12,000 24,000 2,000 12,000 12,000 12,000 Backwash (minutes) Brine Draw (minutes) Fast Rinse (minutes) Brine Refill (minutes) (3.) Total Water Used, gallons (liters) 4 (12) Dimensions in. (cm) Mineral Tank, diameter x height x44 (20x112) 52 (197) 9x4 (23x122) 67 (254) 10x54 (25x137) 112 (424) 12x4 (30x122) 52 (197) 10x35 (25x9) 5 (220) 10x35 (25x9) 5 (220) 10x35 (25x9) Brine Tank, depth x width x height 15x15x35 (3x3x9) 15x15x35 (3x3x9) 15x15x35 (3x3x9) 15x15x35 (3x3x9) 13x13x35 (33x33x9) 13x13x35 (33x33x9) x23x35 (36x5x9) Overall, depth x width x height 15x23x52 (3x5x132) 15x24x56 (3x61x2) 15x25x62 (3x64x157) 15x27x56 (3x69x2) 13x23x43 (33x5x109) 13x23x43 (33x5x109) x25x43 (36x64x109) Approximate Ship Wt., lbs. (kg) (32) (39) (50) (64) (32) (39) (39) 9

10 Description Model Numbers NES-1-S-HE NES-1.5-S-HE NES-2-S-HE NECS-1-S-HE INT2-S Volume, cu. ft. (cu. mtr.) (0.03) 1.5 (0.04) 2.0 (0.06) (0.03) (0.03) Resin Capacity, grains (grams), 2 minute brine fill *27,000 3 minute brine fill 30,000 4 minute brine fill 34,000 6 minute brine fill 36,000 (2,333) 27,000 (1,750) *40,500 (2,624) 42,500 (2,754) 45,000 minute brine fill -NA- 54,000 9 minute brine fill -NA- -NA- -NA- *27,000 (1,750) 40,500 (2,624) *54,000 (3,499) 60,000 (3,) 6,000 (4,406) 70, minute brine fill -NA- -NA- 72,000 (4,666) Operating Flow Rate, gpm (lpm) Continuous (3 gpm/ft 3 ) (11) (19) (23) Service ( gpm/ft 3, <=15psi drop) (30) Peak (Max. 20 psi drop) (53) Pressure Loss psi Continuous Flow Rate 2 Service Flow Rate 7 Peak Flow Rate 1 (124) Regen. Flow Rates, gpm (lpm) Backwash & Rapid Rinse 2.4 (9.0) Brine Draw / Rinse 0.3 / 0.45 Brine Fill (3.79) SPECIFICATIONS Continued 12 (45) (53) 3 (21) (97) 1 (124) 3.0 (11.40) 0.3 / 0.45 (3.79) 13 (49) 15 (57) 4 (2) (97) 1 (124) 4.0 (15.1) 0.56 / 0.4 (2.12 / 3.1) (3.79) 30,000 (1,944) 34,000 (2,203) 36,000 (2,333) -NA- -NA- -NA- 3 (11) (30) 15 (57) 1 (7) 6 (41) 1 (124) 3.0 (11.40) 0.3 / 0.45 (3.79) 1,000 (1,166) *24,000 (1,551) 2,000 (1,) 30,000 (1,944) -NA- -NA- -NA- 3 (11) (30) (53) 2 () (55) 19 (131) 2.0 (11.40) 0.3 / 0.45 (3.79) Service Pipe Size, in. (cm) For 1 replace S with -1S in model # Factory Regeneration Settings Default size setting -NA- -NA- -NA- -NA- -NA- Regenerate after capacity (grains) 1,000 27,000 36,000 1,000 16,000 Backwash (minutes) Brine Draw (minutes) Fast Rinse (minutes) Brine Refill (minutes) Total Water Used, gallons (liters) 46 (174) Dimensions in. (cm) Mineral Tank, diameter x height 9x4 (23x122) 62 (235) 10x54 (25x137) 110 (416) 12x4 (30x122) 52 (197) 10x35 (25x9) 43 (163) 10x35 (25x9) Brine Tank, depth x width x height 15x15x35 (3x3x9) 15x15x35 (3x3x9) 15x15x35 (3x3x9) 13x13x35 (33x33x9) 13x13x35 (33x33x9) Overall, length x width x height 15x24x56 (3x61x2) 15x25x62 (3x64x157) 15x27x56 (3x69x2) 13x23x43 (33x5x109) 13x2x44 (33x71x112) Approximate Ship Wt., lbs. (kg) (39) (50) (64) (39) (41) 10

11 Component Parts Breakdown & List REF DESCRIPTION MODEL NUMBER NES-075-S NES-1-S NES-1.5-S NES-2-S NECS-075-S NECS-1-S NESCC-1-S A Control Valve NE-0.75VlvAssyL/BP NE-1VlvAssyL/BP NE-1.5VlvAssyL/BP NE-2VlvAssyL/BP NEC-0.75VlvAssyL/BP NEC-1VlvAssyL/BP NEC-1VlvAssyL/BP B Mineral Tank MTP044GR MTP094GR MTP1054GR MTP124GR MTP0935GR MTP1035GR MTP1035GR C Distributor D100S-4 D100S-4 D100S-54 D100S-4 D100S-4 D100S-4 D100S-4 D Resin 1 ½ H05P 2 H05P 3 - H05P 4 H05P 1 ½ - H05P 2 H05P 2 H05P E 1/4/ x 1/ gravel QC20 QC20 QC20 QC25 QC20 QC20 QC20 F Brine Tank Assy. BT34ASSY BT34ASSY BT34ASSY- 2"GRIDEXT BT34ASSY- 4"GRIDEXT BT1234ASSY BT1234ASSY BTCABASSY G Overflow Elbow BT-OVERFLO BT-OVERFLO BT-OVERFLO BT-OVERFLO BT-OVERFLO BT-OVERFLO BT-OVERFLO H Safety Brine Valve SBVASSY SBVASSY SBVASSY SBVASSY SBVASSY SBVASSY SBV33ASSY I Salt Platform BTSG BTSG BTSG BTSG BTSG12 BTSG12 CH J Stainless Steel Bypass Valve 60040SS 60040SS 60040SS 60040SS 60040SS 60040SS 60040SS K Elbow Locking Clip FC103 FC103 FC103 FC103 FC103 FC103 FC103 REF DESCRIPTION MODEL NUMBER NES-1-S-HE NES-1.5-S-HE NES-2-S-HE NECS-1-S-HE INT2-S A Control Valve NE-1-HEVlvAssyL/BP NE-1.5-HEVlvAssyL/BP NE-2-HEVlvAssyL/BP NEC-1-HEVlvAssyL/BP INT2VlvAssyL/BP B Mineral Tank MTP094GR MTP1054GR MTP124GR MTP1035GR MTP1035GR C Distributor D100S-4 D100S-54 D100S-4 D100S-4 D100S-4 D Resin 2 UHE05P 3 - UHE05P 4 UHE05P 2 UHE05P 2 H05P E 1/4/ x 1/ gravel QC20 QC20 QC25 QC20 QC20 F Brine Tank Assy. BT34ASSY BT34ASSY-2"GRIDEXT BT34ASSY-4"GRIDEXT BT1234ASSY BT1234ASSY G Overflow Elbow BT-OVERFLO BT-OVERFLO BT-OVERFLO BT-OVERFLO BT-OVERFLO H Safety Brine Valve SBVASSY SBVASSY SBVASSY SBVASSY SBVASSY I Salt Platform BTSG BTSG BTSG BTSG12 BTSG12 J Stainless Steel Bypass Valve 60040SS 60040SS 60040SS 60040SS 60040SS K Elbow Locking Clip FC103 FC103 FC103 FC103 FC103 11

12 Control Valve Parts Breakdown 12

13 Control Valve Parts List REF # Part Number Description A NE-PH Powerhead, Metered B NE-FC Front Panel and Circuit Board Assembly C Piston Assembly D Seal and Spacer Kit E NES Injector and Drain Housing Assy, 2.4 gpm DLFC, #1 Injector, 1 GPM BLFC F Brine Stem Assembly G EM-1 Meter Module (includes cable) H 60040SS Stainless Steel Bypass Valve Motor, 24v/60hz, 2 RPM 2 NE-TRANS Transformer, 110v Input--24v Output O-Ring, Distributor, O-Ring, Tank, Injector Throat, #1, White (for NE-1, NEC-1 and NE-1.5) Injector Throat, #2, Blue (for NE-2) Injector Screen Injector Nozzle, #1, White (for NE-1, NEC-1 and NE-1.5) Injector Nozzle, #2, Blue (for NE-2) O-Ring, Flow Control Washer, 2.4 GPM (for model NE-1) Flow Control Washer, 3.0 GPM (for model NEC-1 and NE-1.5) Flow Control Washer, 3.5 GPM (for models NE-2 Only) 10 NE-DRAIN ELB Drain Elbow, Quick Connect x ½ barbed 11 NE-DRAIN CLIP Quick Release Clip, Drain Elbow 12 NE-CON ORG Connector O-Ring Bypass Valve Seal, Single Lever 13

14 Troubleshooting PROBLEM CAUSE SOLUTION 1. Softener fails to regenerate 2. Softener delivers hard water 3. Unit uses too much salt 4. Loss of water pressure 5. Loss of resin through drain line 6. Iron in softened water 7. Excessive water level in brine tank A. Electrical service to unit has been interrupted A. Ensure permanent electrical service to unit (switch, circuit breaker, plug, etc.) B. Faulty control board B. Replace control board C. Defective valve drive motor C. Replace drive motor D. Improper unit programming D. Check programming and correct as needed A. Bypass valve is open A. Close bypass valve B. No salt in brine tank B. Add salt to brine tank and maintain salt level above water level C. Injectors or screen plugged C. Clean or replace injectors and screen D. Insufficient water flowing into brine D. Check brine tank fill time and clean tank brine line flow control E Leak at distributor tube E. Check length of distributor tube and pilot tube o-ring F. Internal valve leak F. Replace piston and seals/spacer kit G. Flow meter obstructed G. Clean flow meter H. Flow meter cable disconnected from either meter or circuit board H. Connect meter cable I. Reprogram the circuit board to the I. Improper programming proper adjusted hardness and softener capacity A. Reprogram the circuit board to the A. Improper programming proper adjusted hardness, salt setting and softener capacity B. Excessive water in brine tank B. See Problem # 7 A. Softener too small for application A. Check application requirements and resize water softener as required B. Clean or replace plumbing, as B. Foreign material buildup in plumbing necessary, additional treatment system or water softener equipment may be required A1. Check for low water table A. Air in water system conditions in well A2. Check for positive seal on brine line connections B. Drain line flow control is too large B. Ensure proper drain line flow control is installed A. Iron exceeds recommended parameters or iron bacteria is present B. Iron fouled resin A. Test incoming water supply and install an iron filter prior to softener, as needed B. Check and lengthen backwash, brine draw and brine fill times. Increase frequency of regeneration. Use resin cleaner in brine tank. A. Restricted drain flow control A. Clean drain line flow control B. Drain line too long or installed overhead or restricted B. Verify drain line is not restricted or improperly installed C. Replace drain line with rigid or semirigid C. Vinyl drain line was used material with no kinks and as few elbows as possible D. Brine valve sticking (soft water) D. Replace brine valve assembly E. Injector/screen plugged (hard water) E. Clean or replace injectors and screen F. Improper programming F. Reprogram the circuit board as required G. Either end of the brine line is loose G. Tighten loose brine line connections

15 Troubleshooting (continued) PROBLEM CAUSE SOLUTION. Salty water after regeneration 9. Water leaks to drain continuously A. Injectors or screen plugged A. Clean or replace injectors and screen B. Restricted drain flow control B. Clean drain line flow control C. Brine valve sticking C. Replace brine valve assembly D. Brine tank is overfilled D. See Problem # 7 E. Rinse cycle too short E. Lengthen rinse cycle A. Foreign material in control valve A. Remove and inspect piston and seal kit. Replace as necessary B. Drive motor stopped during regeneration cycle B. Check for obstruction in piston and seals. Replace drive motor. Inspect condition of power head gears C. Control valve continuously cycling C. See Problem #10 D. Internal valve seal leak D. Replace seals and/or piston 10. Control valve continuously cycling A. Faulty control board A. Replace control board 15

16 Electrical Connections 16

17 17

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