Service 101

1. Service 101 Water King

2. Service is important • Service after the sale defines your customer commitment. • The service technician is the point of personal contact with the customer. • Sales personnel need to participate in service and start up to connect themselves with the equipment they sell. Water King

3. Types of service calls • Service calls for parts plus labor. • Warranty determinations. • Warranty repairs. • Start ups. • Equipment surveys leading to quotations. Water King

4. Required service skills • Troubleshooting • Valve calibration • Valve rebuilding Calibration Trouble shooting Rebuilding Water King

5. Before you leave the shop • Review reference material for O&M. • Call customer and make arrangements. • Determine softener model numbers. • Troubleshoot the problem over the phone. • Take parts. • Establish billing rates procedures. Water King

6. At the jobsite • Establish contact with company representative. • Gain access to the location. • Meet and greet as necessary. Water King

7. Ask the operator. Don’t touch anything until you, Water King

8. Ask the operator: • What was the reason for the call out? • What in particular is different than previously noted? • What does he believe the problem to be? • When was the last time he added salt? • How often does he normally add salt? • How much does he normally add? • What has been done to try to remedy the problem? Water King

9. Ask the operator: • When was the last hardness test? • Does the problem seem to be common with both columns? (If twin) • Ask for the log sheets. • Ask operator to review the piping arrangement. • Ask if it is possible to bypass the system and not disrupt facility operations. Water King

10. Make as many observations as possible. Don’t touch anything until you, Water King

11. Observations • Does the unit have power to it? • Is the service light on? • Does the unit have salt in brine tank? • Level of water in brine tank? • What is inlet and outlet water pressure? • Is piston is service position? Water King

12. Observations • Any flows to drain? • Is time of day set correctly? • Take a water sample – in and out. • Conduct TEST. • Does it match the operator log sheet? • Which unit is on line? Water King

13. Observations • General condition of equipment. • Condition of wiring. Is it corroded or damaged? • Metered system – When was last regeneration? • Does meter work? Is it registering flow? • Is supply valve to softener open? • Is bypass valve open? Water King

14. Make certain it is OK to start cycling softener.Re-Check with operator. Don’t touch it yet!!! Water King

15. Now you can touch unit.Start repairs. Water King

16. Take unit out of service • Prove your problem. • Go SLOW. • Open bypass valve and close outlet valve(s). • Inlet valve to remain open. • This will prevent unwanted water or salt in effluent supply. Water King

17. What will happen? The five cycles • Service. Raw water passes “down flow” through the resin bed. • Backwash. The resin bed is fluidized loosening the resin particles and removing suspended matter captured during the service cycle. • Brine Draw. A brine solution is applied “down flow” to the resin bed removing the hardness ions from the resin matrix. • Slow Rinse. The brine is rinsed from the resin bed at a low flow rate to reduce water use. • Fast Rinse. The resin is rinsed at a higher rate to remove all brine from the bed. After the fast rinse cycle, the softener is on Standby until returned to Service. Water King

18. Problem:Hard Water, not using salt. • Determine model number and find out regeneration flow rates. Water King

19. UBLE SHOOTING TROUBLE SHOOTING Water King

20. Initiate Regeneration Water King

21. Initiate regeneration • Initiate regeneration from timer. This will put unit in backwash position. Water King

22. Backwash • Observe piston position. • Observe flow to drain. • Measure flow if possible with bucket and stop watch (Ref required flow from catalog or O&M.) Water King

23. Backwash • Flow rate low: • Low water pressure. • Plugged backwash flow control. • Other restriction in backwash lines. • Flow rate normal: • Move on. • Recheck brine level measurement. Water King

24. Advance cycle to next position Water King

25. Brine draw • Observe flow rate to drain. During this cycle all water that is going to drain is passing through injector. • Flow rate to drain will be much lower than backwash rate. Water King

26. Brine draw • Flow rate to drain low… • Low water pressure. • Plugged injector. • Clean or replace. Water King

27. Brine draw • Flow rate to drain high... • Water is bypassing injector. • Injector not properly seated. • Piston broken or leaky seals. • Unit out of calibration. Water King

28. Brine draw • Flow Rate to drain normal... • Move on  Water King

29. Brine draw • Recheck brine level measurement. • Brine should be drawing a minimum of one-inch per minute. Water King

30. Brine level not moving • Disconnect line between softener and brine tank. Put finger over tube. • Poor Vacuum: • No vacuum or pressure from control valve. • Problem is in the control valve. • Injector, piston, or BW flow control problem. Water King

31. Brine level not moving • Good vacuum • Good vacuum will be obvious. Seems to get stronger and stronger with time. • Problem is in the brine tank. Water King

32. Brine level not moving • Brine tank problems – brine valve • Cracked • Dirty • Plugged • Clean or replace brine valve Water King

33. Advance cycle to next position Water King

34. Fast rinse • Full service flow passes to drain through backwash rate of flow controller. • Observe flow to drain. • Use white paper or styrofoam cup to check for resin to drain. Water King

35. Advance cycle to next position Water King

36. Service • Observe valve position • Service light should illuminate on valve • Shut off kit should open • Open bypass valves • Unit is returned to service Water King

37. Other problems Water King

38. Salt in service line • Problem is from poor brine draw. • Too long to get in so it is never rinsed out. Water King

39. Salt in service line • Plugged injector. • Low water pressure. • BW flow control restriction. • Fast rinse not long enough. • Pressure drop in front of unit. Water King

40. Salt in service line • Variations in inlet water pressure can cause problems. Need good constant pressure. • Problems may occur under 40 psi. Water King

41. Mineral to service • Unit installed backwards (up-flow). • Broken distributor. • Mineral in BW pit. BW flow control failure (BW rate too high) or broken distributor. • Repair or replace. Water King

42. Insufficient service flow rate • High pressure drop • Bad Resin • Draw sample and inspect • Shut off kit not fully opening • Clogged distributors Water King

43. Troubleshooting SOK • Aquamatic valve vent restricted • Ruptured diaphragm • Asco valve not operating properly Water King

44. Aquamatic valve drawing Water King

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48. Twin units: One hard, one soft • Check brine director valve. • Check brine director. • Remove one side at a time to verify correct operation of director. • Clean or replace. Water King

49. Brine tank overflowing • Foreign material lodged in BV seat. • Remove and clean. • Float binding on brine well. • Realign. • Faulty BV seal. • Replace BV seal. • Fittings defective. • Tighten or replace. Water King

50. The End Water King