Intro4u2u

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 plug from the PC board. The
motor plug connects to the two-pin jack on the left-hand side of the PC board. The power source plug connects to the four-pin jack.
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 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 one plastic pin that fits into the hole on the lower edge of the PC board. Once the PC board is tilted
about 45° from the drive bracket it can be lifted off of the pin. To reinstall the PC board, position the lower edge of the PC board so
that the hole in the PC board lines up with the plastic pin. Push the top of the PC board towards the valve. Align the upper hole on
lefthand side of PC board with the pin and push in until the PC board snaps under the middle latch, weave the power wire into the
holders and reconnect the motor 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 necessary to
remove the PC board from the drive bracket to remove the drive bracket. To remove the drive bracket start by removing the plug for
the power source. Unweave the wire 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 towards your body. 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 towards 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 hole, the power wire is jammed between the drive bracket and drive back plate, or the gear is
not engaging the drive cap assembly.
To inspect drive gears, the drive gear cover needs to be removed. 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. Before trying to remove the drive gear
cover, the drive bracket must be removed from the drive back plate. The drive gear cover can be removed from the drive bracket
without removing the motor or the PC board. Simultaneously, push in and down on the large clip at the bottom and the clip on the
left-hand side of the drive bracket behind the PC board. Keep your other fingers behind the drive gear cover so the drive gears do not
drop on the ground.
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 ¼ turn in either direction 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.
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Replace the motor if necessary. Do not lubricate the motor or the gears. When reinstalling the motor gently turn the motor while
inserting so that the gear on the motor meshes with the gears under the drive gear cover and the small plastic bulge engages one of
the slots on the motor housing. Reconnect the motor plug to the two pronged jack on the lower left hand side of the PC board. If
motor will not easily engage with drive gear when reinstalling, lift and slightly rotate motor before reinserting.
Replace the valve cover. After completing any valve maintenance, press and hold SET HOUR and DOWN buttons for 3 seconds or
unplug power source jack (black wire) from the circuit board and plug back in. This resets the electronics and establishes the service
piston 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 ¼” to ½” flat bladed 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. See Figure 5. 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.
The drive cap assembly contains the drive cap, the main drive gear, drive cap spline, piston rod and various other parts that should
not be dissembled in the field. The only replaceable part on the drive cap assembly is the o-ring. Attached to the drive cap assembly
is the main piston and, if a regenerant is used, a regenerant piston.
Figure 5
WS1TC Manual Page 37
The regenerant piston (the small diameter one behind the main piston) is removed from the main piston by unsnapping it from its
latch. Chemically clean in dilute sodium bisulfite or vinegar or replace the regenerant piston if needed. To remove the main piston
fully extend the piston rod and then unsnap the main piston from its latch by pressing on the side with the number. Chemically clean
in dilute sodium bisulfite or vinegar or replace the main piston.
Reattach the main piston to the drive cap assembly. Reattach the regenerant piston (if needed) to the main piston. Do not lubricate
the piston rod, main piston or regenerant piston. Lubricant will adversely affect the red or clear lip seals. Reinsert the drive cap
assembly and piston into the spacer stack assembly and hand tighten the drive cap assembly. Continue to tighten the drive cap
assembly using the special wrench or a screwdriver as a ratchet until the black o-ring on the spacer stack assembly is no longer
visible through the drain port. Excessive force can break the notches molded into the drive back plate. Make certain that the main
drive gear still turns freely. The exact position of the piston is not important as long as the main drive gear turns freely.
Reattach the drive assembly to the control valve and connect all plugs. After completing any valve maintenance, press and hold SET
HOUR and DOWN buttons for 3 seconds or unplug power source jack (black wire) from the circuit board and plug back in. This
resets the electronics and establishes the service piston position.
Spacer Stack Assembly
To access the spacer stack assembly remove the drive assembly, drive cap assembly and piston. The spacer stack assembly can be
removed easily without tools by using thumb and forefinger. Inspect the black o-rings and red or clear lip seals for wear or damage.
Replace the entire stack if necessary. The spacer stack assembly has been 100% tested at the factory to insure proper orientation of
one way seals. Do not disassemble the stack.
The spacer stack assembly may be chemically cleaned (dilute sodium bisulfite or vinegar) or wiped with a soft cloth.
The spacer stack assembly can be pushed in to the control valve body bore by hand. Since the spacer stack assembly can be compressed
it is easier to use a blunt object (5/8” to 1-1/8” in diameter) to push the center of the assembly into the control valve body.
The assembly is properly seated when at least four threads are exposed (approximately 5/8”). Do not force the spacer stack assembly
in. The control valve body bore interior can be lubricated with silicone to allow for easy insertion of the entire stack. Do not use
silicone or any other type of lubricant on the red or clear lip seals or the piston.
Reattach the drive cap assembly and piston(s) and the drive assembly.
After completing any valve maintenance, press and hold SET HOUR and DOWN buttons for 3 seconds or unplug power source jack
(black wire) from the circuit board and plug back in. This resets the electronics and establishes the service piston position.
Injector Cap, Screen, Injector Plug and Injector
Unscrew the injector cap and lift off. Loosen cap with special plastic wrench or pliers if necessary. Attached to the injector cap is a
screen. Remove the screen and clean if fouled.
The plug and/or injector can be pried out with a small screwdriver. The plug can be wiped clean. If the plug leaks replace the entire
plug. The injector consists of a throat and a nozzle. Chemically clean the injector with vinegar or sodium bisulfite. The holes can
be blown out with air. Both pieces have small diameter holes that control the flow rates of water to insure that the proper concentration
of regenerant is used. Sharp objects, which can score the plastic, should not be used to clean the injector. Scoring the injector
or increasing the diameter of the hole could change the operating parameters of the injector.
Two holes are labeled DN and UP. Check for compliance with one of the following:
a. for down flow systems, the appropriate size injector is located in the “DN” hole, a plug is in the “UP” hole and that the piston is
a combination of the down flow main piston and the regenerant piston; or
b. for backwash only systems, a plug is in the “DN” hole and in the “UP” hole, and that the piston only has a down flow main
piston (the regenerant piston must be removed) and a plug is in the refill flow control position.
Push the plug(s) and/or injectors firmly in place, replace the screen and hand tighten the injector cap.
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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. Twist to remove the white flow control retainer. The flow control can be removed
by prying upward through the side slots of the retainer with a small blade flat screwdriver.
Chemically clean the flow control or the white flow control retainer using dilute sodium bisulfite or vinegar. Do not use a wire brush.
If necessary, replace the flow control, o-ring on the flow control retainer, or the o-ring on the elbow.
Reseat the flow control so the rounded end is visible in the flow control. Reseat the white flow control retainer by pushing the
retainer into the elbow until the o-ring seats. Remove locking clip, push down on elbow to reseat and insert locking clip.
Do not use Vaseline, oils, or other unacceptable lubricants on o-rings. A silicon lubricant may be used on the o-ring on the elbow or
the white retainer.
Meter Plug
This control valve does not come equipped with a meter, instead a plug is installed. The plug should not need to be serviced.
To remove the meter plug assembly, unscrew the meter cap on the left side of the control valve. Pliers may be used to unscrew the
nut if necessary.
With the nut removed, a slot at the top of the meter plug is visible. Twist a flat blade screwdriver in the slot between the control valve
body and the meter plug. When the meter plug is part way out it is easy to remove the meter plug from the housing.
Do not use a wire brush to clean. Wipe with a clean cloth or chemically clean in dilute sodium bisulfite or vinegar.
Do not use Vaseline, oils, or other unacceptable lubricants on the o-ring. A silicon lubricant may be used on the black o-ring.
Reinsert the meter plug into the side slot. Hand tighten the nut. Do not use a pipe wrench to tighten nut.
Bypass Valve
The working parts of the bypass valve are the rotor assemblies that are contained under the bypass valve caps. Before working on
the rotors, make sure the system is depressurized. Turn the red arrow shaped handles towards the center of the bypass valve and
back to the arrow direction several times to ensure rotor is turning freely.
The nuts and caps are designed to be unscrewed or tightened by hand. If necessary a pliers can be used to unscrew the nut or cap.
Do not use a pipe wrench to tighten or loosen nuts or caps. Do not place screwdriver in slots on caps and/or tap with a hammer.
To access the rotor, unscrew the cap and lift the cap, rotor and handle out as one unit. Twisting the unit as you pull it out will help to
remove it more easily. There are three o-rings: one under the rotor cap, one on the rotor stem and the rotor seal. Replace worn orings.
Clean rotor. Reinstall rotor.
When reinstalling the red arrow handles be sure that:
1. O-rings on both rotors face to the right when being viewed from the front of the control valve when the handle pointers are
lined up with the control valve body arrows; or
2. Arrows point toward each other in the bypass position.
Since the handles can be pulled off, they could be accidentally reinstalled 180°° from their correct orientation. To install the red arrow
handles correctly, keep the handles pointed in the same direction as the arrows engraved on the control valve body while tightening
the bypass valve caps.
After completing any valve maintenance, press and hold SET HOUR and DOWN buttons for 3 seconds or unplug power source jack
(black wire) from the circuit board and plug back in. This resets the electronics and establishes the service piston position.