Flotrol F60 User manual

F60 Downflow Brining
Service Manual
IMPORTANT: Fill in pertinent information on page 3 for future reference.

Page 3
MODEL F60
Job No.
Job Specification Sheet
Model No.
Water Test
Capacity Per Unit
Mineral Tank Size . HeightDiaMeter
Brine Tank Size & Salt Setting per Regeneration:
Control Valve Specifications
1. Type of Timer (see pages 8-11)
2. Timer Program Settings
A) Backwash min.
B) Brine & Slow Rinse min.
C) Rapid Rinse min.
D) Brine Tank Refill min.
3 Drain Line Flow Controller gpm
4 Brine Line Flow Controller gpm
5 lnjector Size #
6 Service Valve Operation Units (SVO)
Size of Service Valve
A) 7 Day or 12 Day
B) 1,250 to 21,250 Gallon Meter or
6,250 to 106,250 Gallon Meter or
Other
C) Meter Wiring Package
1. System #4 - 1 Tank; 1 Meter; Immediate or Delayed Regeneration
2. System #5 - 2 Tanks; 2 Meters; Interlock
3. System #6 - 2 Tanks; 1 Meter; Series Regeneration
4. System #7 - 2 Tanks; 1 Meter; Alternator

Page 4
WATERPRESSURE: A minimum of 25 pounds of waterpressure is required for regeneration valve to
operate effectively.
ELECTRICAL FACILITIES: A continuous 115 volt, 60 Hertz current supply is required. (Other voltages
avaiIable.) Make certain the current supply is always hot and cannot be turned off with another switch.
EXISTING PLUMBING:Condition of existing plumbing should be free from Iime and iron buildup. Piping that
is built up.
heavily with lime and/or iron should be replaced. If piping is clogged with iron, a separate iron filter unit
should be installed ahead of the water softener.
LOCATION OF SOFTENER AND DRAIN: The softener should be Iocated close to a drain.
BY-PASS VALVES: Always provide for the installation of a by-pass valve.
CAUTION: Water pressure is not to exceed 120 p.s.i., water temperature is not to exceed 100˚F, and the
unit cannot be subjected to freezing conditions.
1. Place the softener tank where you want to install the unit making sure the unit is Ievel and on a firm
base.(Maximum 7 feet apart for twin units.)
2. All plumbing should be done in accordance with Iocal plumbing codes. The pipe size for the drain line
should be the same size as the drain line flow control connection. Water Meters are to be installed on soft
water outlets. Twin units with (1) one Meter shall be installed on common soft water outlet of units.
3. Make sure that the floor is clean beneath the salt storage tank and that it is Ievel.
4. Place approximately 13 of water above the grid plate (if used)in your salt tank Salt may be placed in the
unit at this time.
5. Place in by-passposition. Turn on the main water supply. Open a cold soft water tap nearby and Iet run a
few minutes or until the system is free from foreign material (usually solder) that may have resulted from
the installation.
6. Place the by-pass in service position.
7. Manually index the softener control into “service” position and Iet water flow into the mineral tank. When
water flow stops,close inlet valve, place control in “backwash” positionto relieve head of air, then gradually
open inlet valve to purge remaining air in tank. Return control to “service”position.
8. Electrical: AlI electrical connections must be connected according to codes. Use electrical conduit if
applicable. Plug into power supply.
INSTALLATION INSTRUCTlONS
MODEL F60
General Commercial Pre-Installation Check List

Page 5
Rotate the skipper wheel until the number “1” is at the red
pointer. Set the days that regeneration is to occur by sliding
tabs on the skipper wheel outward to expose trip fingers.
Each tab is one day. Finger at red pointer is tonight. Moving
clockwise from the red pointer, extend or retract fingers to
obtain the desired regeneration schedule.
Press and hold the red button in to disengage the drive gear.
Turn the Iarge gear until the actual time of day is at the time
of day pointer.
Release the red button to again engage the drive gear.
Turn the manual regeneration knob clockwise.
This slight movement of the manual regeneration knob
engages the program wheel and starts the regeneration
program.The black center knob will make one revoIution
in the following approximately
three hours and stop in the position shown in the drawing.
Even thought it takes three hours for this center knob to
complete one revolution, the regeneration cycle of your
unit might be set only one half of this time.ln any event,
conditioned water may be drawn after rinsewater stops
flowing from the water conditioner drain Iine.
1. Disconnect the power source.
2. Locate the three screws behind the manual regeneration
knob by pushing the red button in and rotating the 24 hour dial
until each screw appears in the cut out portion of the manual
regeneration knob.
3. Loosen each screw slightly to reIease the pressure on the
time plate from the 24 hour gear.
4. Locate the regeneration time pointer on the inside of the
24 hour dial in the cut out.
5. Turn the time plate so the desired regeneration time aligns
next to the raised arrow.
6. Push the red button in and rotate the 24 hour dial. Tighten
each of the three screws.
7. Push the red button and Iocate the pointer one more time
to ensure the desired regeneration time is correct.
8. Reset the time of day and restore power to the unit.
How To Set Days On Which Water Conditioner Is To
Regenerate:
How To Set The Time Of Day:
How To Manually Regenerate Your Water
Conditioner At Any Time:
How to Adjust Regeneration Time:
MODEL F60
Timer Setting Procedure
TIM E
OF DAY
Manual
Regeneration
Knob
24 HR. Gear
Service
Position
Indicator
Red Time
Set Button
TO MANUALLY
TO SET TIME OF DAY-
PRESS RED BUTTON AND
TURN LARGE DIAL UNTIL
TIME IS AT ARROW.
START CYCLE
TURN KNOB
CLOCKWISE.
Skipper Wheel,12 Day
(Shows Every Other
Day Regeneration)
Red Pointer

Page 6
PIN STORAGE
RAPID RINSE SETION
(2MIN. PER PIN)
BACKWASH SECTION
(2MIN. PER PIN)
BRINE & RINSE
(2MIN.PER HOLE)
BRINE TANK
PROGRAM WHEEL FOR
REGENERATION CYCLE
The regeneration cycle program on your water condi-
tioner has been factory preset, however, portions of the
cycle orprogram may be Iengthened or shortened in
time to suitlocal conditions.
Conditioner will rapid rinse (2 min. per pin).
To change the length of rapid rinse time, add or
remove pins at the higher numbered end of this section
as required. The number of pins times two equals the
rapid rinse time in minutes.
The second group of holes in the program wheel
determines the Iength of time that your water condi-
tioner will refill the brine tank (2 min. per hole).
To change the Iength of refill time, move the two pins at
the end of the second group of holes as required.
The regeneration cycle is complete when the outer
microswitch is tripped by the two pin set at end of the
brine tank refill section. The program wheel, however,
will continue to rotate until the inner microswitch drops
into the notch on the program wheel.
To expose cycle program wheel, grasp timer in upper
Ieft Hand corner and pull, releasing snap retainer and
swinging timer to the right.
To change the regeneration cycle program, the
program wheel must be removed. Grasp program
wheel and squeeze protruding Iugs toward center, Iift
program wheel off timer. (Switch arms may require
movement to facilitate removal.)
Return timer to closed position engaging snap retainer
in back plate. Make certain all electrical wires locate
above snap retainer post.
The program wheel as shown in the drawing is in the
service position. As you Iook at the numbered side of
the program wheel, the group of pins starting at zero
determines the Iength of time your unit will backwash.
FOR EXAMPLE: If there are six pins in this section, the
time of backwash will be 12 min. (2 min. per pin). To
change the Iength of backwash time, add or remove
pins as required. The number of pins times two equal
the backwash time in minutes.
The group of holes between the Iast pin in the back-
wash section and the second group of pins determines
the length of time that your unit will brine and rinse (2
min. per hole).
To change the Iength of brine and rinse time, move the
rapid rinse group of pins to give more or fewer holes in
the brine and rinse section. Number of holes times two
equals brine and rinse time in minutes.
The second group of pins on the program
wheel determines the Iength of time that your water
How To Change The Length Of Brine Tank Refill
Time:
3200 & 321 0 Series Timers (Figure to Right)
How To Set Regeneration Cycle Program:
Timer Setting Procedure for 3200 & 3210 Timer
How To Change The Length Of The Backwash
Time:
How To Change The Length Of Brine And Rinse
Time:
How To Change The Length Of Rapid Rinse:
MODEL F60
Regeneration Cycle Program Setting Procedure

Page 7
Calculate the gallon capacity of the system, subtract
the necessary reserve requirement and set the gallons
required by Iifting the gallon dial and rotating it so that
the number of gallons required is aligned with the
white dot on program wheel gear. Release and check
for firm engagement with gear.
5. In any event, conditioned water may be drawn
after rinse water stops flowing from the water condi-
tioner drain Iine.
These timers do not have a 24 hour gear. Setting the
gallons on the program wheel and manual regenera-
tion procedure are the same as previous instructions.
To set Meter capacity at initial start-up either
1. Rotate manual regeneration knob one full
revolution.
—or—
2. Rotate program wheel manually clockwise or
counter clockwise and align white dot with capacity
arrow.
This procedure must be followed any time the program
wheel setting is changed.
1. Press and hold the red button in to is engage the
24 hour gear.
2. Turn the 24 hour gear until the actual time of
day is at the time of day pointer
3. Release the red button to again engage the 24
hour gear.
1. Turn the manual regeneration knob clockwise
one “click.”
2. This slight movement of the manual regeneration
knob engages the program wheel and starts the
generation program.
3. The black center knob will make one revolution
in the following approximately three hours and stop in
the position shown in the drawing.
4. Even though it takes three hours for this center
knob to complete one revolution, the regeneration
cycle of your unit might be set for only one half of this
time.
Note, drawing shows 8,750 gallon setting. The capac-
ity (gallons) arrow denotes remaining gallons exclusive
of fixed reserve.
Typical Programming Procedure
Immediate Regeneration Timers:
Note:
How To Set The Time Of Day:
How To Manually Regenerate Your Water Condi-
tioner At Any Time:
MODEL F60
Commercial Demand Regeneration Control Timer Settings
TO MANUALLY
TO SET TIME OF DAY-
PRESS RED BUTTON AND
TURN LARGE AIAL UNTIL
TIME IS AT ARROW.
START CYCLE-
TURN KNOB
CLOCKWISE.
CAPACITE
CAPACITY
KAPAZITAT
CAPACITA
CAPACIDAD
M3
CAUTION
ALWAYS REMOVE CABLE
FROM METER BEFORE
SWINGING TIMER OPEN.
Program Wheel
Manual Regeneration Knob
Red Time
Set Button
White Dot
(M3Capacity)
M3Label
Service
Position
Indicator
Capacity
(M3Remaining)
24 HR. Gear

Page 8
MODEL F60
Timer Assembly (For Mechanical Clock)
11
16
15
13
12
17 18 19
20
21
6
22
23
24 25 26
27
28
29
30
31
1
3
4
5
67
2
8
9
10
32 6
14
24
27
27

Page 9
Timer Assembly (For Mechanical Clock)
MODEL F60
Item No. Quantity Part No. Description
1 1 051-00078-00 Timer Housing
2 1 069-00180-00 Decal- Instructions
3 1 051-00074-00 Cycle Actuator Arm
4 1 099-00177-00 24 Hour Gear Assembly
5 1 051-00089-00 Knob
6 4 066-00002-00 Screw,tchw,NO.6-20x1/2,b,black,Zn,1022
7 1 069-00179-00 Button Decal
8 1 099-00176-00 Skipper Wheel Assembly
9 2 078-00008-00 Ball
10 2 058-00003-00 Spring –Detent- Skipper Wheel
11 1 069-00181-00 Decal- Time of Day
12 1 052-00013-00 Spring Clip
13 1 058-00002-00 Spring- Denent- Main Gear
14 1 051-00081-00 Plastic Ball-0.25inch Dia.
15 1 057-00023-00 Main Drive Gear
16 1 099-00178-00 Program Wheel(ST) Assembly
17 1 057-00016-00 Idler Pinion
18 1 058-00001-00 Spring- Idler
19 1 057-00014-00 Idler Gear
20 1 057-00013-00 Driver Gear
21 1 052-00046-00 Motor Mounting Plate
22 1 053-00022-00 Motor2 Assembly ( 220V/50HZ )
23 3 066-00010-00 Screw,ccch,NO.6-32x1/8,Zn,1022
24 2 066-00011-00 Screw,ccch,NO.6-32UNCx1/4,Zn,1022
25 1 052-00041-00 Hinge Bracket
26 2 066-00012-00 Screw,tchw,NO.8-18x3/8,Zn,1022
27 3 052-00048-00 Insulator- Drive Assembly
28 1 043-00003-00 Switch3
29 1 043-00002-00 Switch2
30 2 066-00055-00 Screw, tcp, NO. M3-24x1.125,b,Zn,1022
31 1 051-00070-00 Skipper Wheel Ring
32 1 051-00071-00 Regeneration Pointer
Bold faced items are recommended spare parts.

Page 10
MODEL F60
Timer Assembly (For Mechanical Meter)
1
3
4
56
2
15
16
17
18
19 20 21
22
23
5
24
25
26
27
28
29
30 31 32
33
34
35
36
30
33
33
13 146
9
7
8
10 11 12

Page 11
Timer Assembly (For Mechanical Meter)
MODEL F60
Item No. Quantity Part No. Description
1 1 051-00078-00 Timer Housing
2 1 069-00188-00 Decal- Instructions2
3 1 057-00011-00 Cycle Actuator Gear- SM
4 1 051-00089-00 Knob
5 4 066-00002-00 Screw,tchw,NO.6-20x1/2,b,black,Zn,1022
6 2 069-00179-00 Button Decal
7 1 069-00186-00 Gallons Label
8 2 066-00008-00 Screw-PSWA
9 1 057-00012-00 Progran Skipper Wheel
10 1 051-00049-00 Dial
11
1 069-00043-00 Quantity Label-40ton
1 069-00184-00 Quantity Label-200ton
1 069-00185-00 Quantity Label-375ton
1 069-01125-00 Quantity Label-1200ton
12 1 051-00050-00 Retainer-PSWA
13 1 051-00068-00 Program Wheel Retainer
14 1 066-00026-00 Screw,tcc,NO.6-20x1/2,JIS SUS304
15 1 069-00181-00 Decal- Time of Day
16 1 052-00013-00 Spring Clip
17 1 057-00024-00 Main Drive Gear(SM)
18 1 099-00192-00 Program Wheel(SM) Assembly
19 1 057-00016-00 Idler Pinion
20 1 058-00007-00 Spring- Idler
21 1 057-00014-00 Idler Gear
22 1 057-00013-00 Driver Gear
23 1 052-00046-00 Motor Mounting Plate
24 1 053-00022-00 Motor2 Assembly（220V/50HZ（
25 3 066-00010-00 Screw,ccch,NO.6-32x1/8,Zn,1022
26 1 057-00021-00 Drive Pinion- Program Wheel
27 1 051-00085-00 Clutch Drive Pinion
28 1 058-00004-00 Spring
29 1 051-00069-00 Spring Retainer
30 2 066-00011-00 Screw,ccch,NO.6-32UNCx1/4,Zn,1022
31 1 052-00041-00 Hinge Bracket
32 2 066-00012-00 Screw,tchw,NO.8-18x3/8,Zn,1022
33 3 052-00048-00 Insulator- Drive Assembly
34 1 043-00004-00 Switch4
35 1 043-00002-00 Switch2
36 2 066-00055-00 Screw,tcp,NO.M3-24x1.125,b,Zn,1022
Bold faced items are recommended spare parts.

Page 12
MODEL F60
Assembly Drawings and Part Numbers
F60 Control Valve Assembly
1
2
3
4
5
6
LARG E BRINE SYSTEM ASSEMBLY
FILTER PARTS
16
18
19
17
78910 11 12
13
14 14
15
NRWB PISTON ASSEMBLY
RW B PISTON ASSEMBLY
14
15
14
13 13
7810 20 21
BLOCK-A
BLOCK-B 13
BLOCK-C
B LO C K -B

Page 13
Assembly Drawings and Part Numbers
F60 Control Valve Assembly Parts List
MODEL F60
Item No. Quantity Part No. Description
1 2 066-00028-00 Screw M12*35
21 052-00279-00 FT Valve Body (NPT)
1 052-00060-00 FT Valve Body (BSP)
3 1 060-00042-00 Valve-Tank Adapter Seal
41 060-00083-00 O-Ring-229 (US)
1 060-00043-00 O-Ring-230 (Metric)
5 1 052-00067-00 Adapter-Top Mount 4"-8 Th'd (Metric)
6 1 060-00033-00 Valve -Tank Adapter O-Ring -240
7 1 051-00171-00 Clip-Piston Rod
8 1 052-00061-00 Piston
9 1 052-00062-00 Piston Assembly (NRWB)
10 1 060-00021-00 O-Ring-035
11 1 051-00167-00 Black End Plug (NRWB)
12 1 052-00063-00 Piston Rod
13 8 060-00084-00 Seal
14 5 051-00165-00 Spacer
15 2 051-00166-00 Narrow Spacer
16 4 066-00029-00 Screw-Hex-HD
17 2 052-00068-00 Cover
18 2 060-00023-00 O-Ring -116
19 2 052-00074-00 Pipe Plug-1/2” ( NPT)
20 1 051-00415-00 White End Plug (RWB)
21 1 052-00097-00 FT Piston Rod
Bold faced items are recommended spare parts.

Page 14
MODEL F60
Control Drive Assembly (For 60 Mechanical)
34
12345
8910 11
14 15
17
18 19
27 26 25 24 23
22
21
20-1
39
38
37
35
10
28
32
16
29
30
33
36
40
FOR SM
20-2
31
67
13
12

099-00750-00

Page 16
MODEL F60
Assembly Drawings and Part Numbers
F60 Control Valve Assembly
1
2
6
7
10
16
12
12
8
9
10
11
12
15
13
14
24
25
17
4
3
5
18
19
20
21
22
23
10
9

Page 17
Assembly Drawings and Part Numbers
Large Brining System Assembly Parts List
MODEL F60
Item No. Quantity Part No. Description
1 1 052-00081-00 Stem Guide Assembly
2 1 068-00011-00 Retaining Ring
3 1 058-00006-00 Spring
4 2 066-00005-00 Screw
51 052-00280-00 Brine Valve Body (NPT)
1 052-00064-00 Brine Valve Body (BSP)
6 1 099-00717-00 Brine Valve Stem Assembly
7 1 060-00049-00 O-Ring -124
8 1 052-00298-00 Brine Tube Assembly
9 2 052-00296-00 Tube Fitting
10 6 066-00029-00 Screw-Hex, HD
11 1 052-00066-00 Injector Cap
12 3 060-00023-00 O-Rings -116
13 1 051-00176-00 10#Injector Nozzle
1 051-00174-00 8#Injector Nozzle
14 1 052-00065-00 Injector Body
15 1 051-00175-00 10#Injector Throat
1 051-00172-00 8#Injector Throat
16 1 052-00074-00 Pipe Plug-1/2" (NPT)
17 1 052-00068-00 Injector Plug
18 1 068-00008-00 Retaining Ring
19 1 051-00182-00 Spring Clip
20 1 060-00058-00 RFC Washer-10 gpm
21 1 051-00185-00 Filter Sheet
22 1 060-00046-00 O-Ring-AS020
23 1 052-00283-00 1" RFC Housing (NPT)
1 052-00076-00 1" RFC Housing (BSP)
24 1 051-00325-00 1"Female NPT*1"Slip
25 1 051-00119-00 1” Air Check
Bold faced items are recommended spare parts.

Page 18
1
2
3
4
5
6
7
8
9
10
11
14
13
12
MECHANICAL METER COVER ASS'Y ELECTRONIC METER COVER ASS'Y
MODEL F60
Assembly Drawings and Part Numbers
2" Flow Meter Assembly & Parts List
Item No. Quantity Part No. Description
1 1 052-00086-00 Impeller Shaft Retainer
2 1 051-00195-00 Impeller
3 1 052-00085-00 Impeller Shaft
4 1 060-00026-00 O-Ring
5 1 099-00734-00 Meter Cover Assembly (Mechanical)
6 4 066-00020-00 Screw-Hex Hd,M5*12
71 052-00320-00 2” Meter Body (NPT)
1 052-00070-00 2” Meter Body (BSP)
8 1 060-00030-00 O-Ring-227
91 052-00321-00 Nipple Quick Connect (NPT)
1 052-00071-00 Nipple Quick Connect (BSP)
10 1 051-00181-00 Flow Straightener
11 1 052-00072-00 Nut Quick Connect
12 1 061-00003-00 Meter Cable Assembly (17.5”)
13 1 047-00013-00 Meter Cable Assembly (99.5”)
1 047-00038-00 Meter Cable Assembly (300”)
14 1 099-01754-00 Meter Cover Assembly (Electronic)
Bold faced items are recommended spare parts.

Page 20
Correction: Check salt dosage requirements and reset program wheel to provide additional reserve.
Cause could be that . . . Program Wheel Is Not Rotating With Meter Output.
Correction:
Correction:
Pull cable out of meter cover and rotate manually. Program wheel must rnove without binding
and clutch must give positive “clicks” when program wheel strikes regeneration stop. lf it does not, repIace
timer.
Check meter with meter checker.
Cause could be that . . . Meter Is Not Measuring Flow.
Cause couId be that . . . Reserve Capacity Has Been Exceeded.
Problem: Softener Delivers Hard Water.
General Service Hints
Check flow control.
Clean injector and screen.
Replace timer.
D. Replace brine valve seat and clean valve.
E. Clean brine line flow control.
A. Clean drain line flow control.
B. Clean injector.
C. lncrease line pressure to 25 P.S.I. min.
D. Check drive motor and switches.
A. Determine if switch or timer is faulty and
replace it, or replace complete power head.
A. Check timer program and positioning of
control. Replace power head assembly if not
positioning properly.
B. Remove power head assembly and
inspect bore, remove foreign material and
check control in various regeneration
positions.
Replace seals and piston assembly.
Drain Iine fIow controI is pIugged.
Injector is plugged.
Line pressure is too low.
Internal Control Leak.
Plugged drain line flow control.
Plugged injector system.
Timer not cycling.
Foreign material in brine valve.
Foreign material in brine line flow
control.
A.
B.
C.
C.
8. Softener fails to draw brine.
7. Excessive water in brine tank
PROBLEM CAUSE CORRECTION
10. Drain flows continuously.
9. Control cycles continuously.
A.
B.
C.
D.
E.
A.
B.
C.
D.
A. Missadjusted, broken or shorted
switch.
A. Valve is not programming
correctly.
B. Foreign material in control.
C. lnternal control leak
MODEL F60
F60 Downow Service Instructions