IBC Water SAST1029 Manual

SAST1029 Page 1
WATER SOFTENER
SEMI AUTOMATIC
TWINTANK
INSTALLATION&OPERATING
INSTRUCTIONS
Model : SAST1029
Serial No: ………………………..
Telephone:[phone] Facsimile:[phone]
Email: [e-mail] Website: www.ibcwater.com.au
FILTRATION &WATERTREATMENTPRODUCTS
forcommercial, industrial andresidential application
Manufacturerand Supplierof

SAST1029 Page 2
1.Watertobe tested shouldbe taken fromatap afterthe watersoftener
2.Measure10mlof waterintoplasticbottlesupplied (approximately1/3full)
3.Add one Yes/Notablettosamplewater,replacecap and shakeuntil tablet
hascompletelydissolved.
(NOTE:do nothandleYes/Notabletwithfingers)
4.The finalcolourtobe obtained forsoft waterisgreen.(Note:The shade of
green mayvary.)If the colourturnsred,the waterisabove20 mg/lhardness,
thereforeanotherregeneration isrecommended.
5.Rinseplasticbottleaftereachtest hasbeen completed.
6.When used asabove,the tabletschange the colourfromgreen tored ata
hardness of approximately20ppmbased on asamplevolumeof 10mls.
Otherhardness testkitsareavailableformoreaccuratetestingeg.
Hardness Tablets
Directions: Takea50mlsampleofwaterinascrewcapped bottle.Add one (1)
tablettosample,shakeorcrushtodisintegrate.Repeatuntil lasttrace
ofreddishtinge disappears.The finalcolourisusuallyblue butwith
somewateragreyishcoloured end point isobtained.
Using 50mlsample-
Hardness ppm=(numberof tabletsx40)-20
LR(BW)Tablets
Directions: Takea100mlsampleofwaterinascrewcapped bottle.Add one (1)
tablettosample,shakeorcrushtodisintegrate.Repeatuntil lasttrace
ofreddishtinge disappears.The finalcolourisusuallyblue butwith
somewateragreyishcoloured end point isobtained.
Using 100mlsample-
Hardness ppm=(numbertabletsx2)–1
Contact IBCWaterif furtherdetailsarerequired.
HARDNESS TEST

SAST1029 Page 3
Toascertain DAYS between regeneration periodsthe following dataorestimationsare
required.
(Let Nbe the numberof days tobe calculated)
.1. ðWaterHardness inmg/l call ðH
.2. ðWaterSoftenerHardness RemovalCapacity
fromTable1ingrams call ðC
.3. ðDailyWaterUsage inlitres
call ðD
Forhouseholdsituationsallow250 litresperperson perday.
CALCULATION
N = 1000 xC
DxH
Select nearest lowerwholenumber
If necessaryconsult yourdealerorIBCWaterTreatment foradviceon setting up the
softener.
EXAMPLE
Householdusefor4peopleon 220 mg/lhardwaterusing
ModelSAST1029 at 1050 gramscapacity.
N = 1000 x2030
1000 x220
= 9.22 days
=9days
WATERSOFTENERCALCULATIONS
MODELSAST1029

SAST1029 Page 4
LOCATION&INSTALLATION
1. The softenerrequiresan inletwaterpressurebetween 140kPa(20psi)and 690kPa
(100psi).
2.The softenershouldserviceall waterlinesinthe houseexcept the toilet and outside taps.
The softenershouldbe positioned on alevelflatsurfaceclosetoadrainoranyother
properlytrapped wasteoutlet.
The brass adaptorssupplied aresuitablefor20mm (3/4")femalefittingsand the softener
shouldbe connected tothe supplywithrawwatertothe inletconnectorand softened
waterlinestothe outlet asindicated on the valve.
3.When facing the front of the controlthe inlet istothe right and the outlet istothe left.
4.The systempressuremust be between 140 kPaand 690 kPapsi.
5.If the systempressureisgreaterthan 690kPapsia pressurereducingvalve mustbe
installed.
6.The unit must be installed inaccordancewithlocalcodes.
7.Donot overtighten connections.
8.Drainline IDmust be at least 12mm.
9.Teflon tape shouldbe used when installing he drainfitting intothe controlvalve.
10.The drainline must be free of kinks.
11.Asafetyfloat withan aircheck isinstalled.
12.Insureall connectionsaretight.
13.Toinitiateregeneration, turnthe twist the timerknob clockwisetothe 2hourposition.
Note:DO NOTuse teflontapewhenconnectingthefittingkitstothecontrol valve.
14. Therearetwodrainlines,one fromthe brine tankand one fromthe softenervalve,these
linesmusthavean airgap ofatleast40mm ortwicethe pipe diameteratthe drain
entrance.The drainline fromthe brine tankisgravityfed and hencethe drainisrequired
tobe belowthe outlet elbowon the tank.
The drainline fromthe softenervalveisunderpressureduring regeneration butfor
correct operation amaximumof 2.4mof 15NBpipe withno risescan be connected.
Amanual Bypass shouldbeinstalled.

SAST1029 Page 5
TYPICAL INSTALLATIONDIAGRAM
ENSURETHEINSTALLATIONCONFORMSWITHALL LOCALPLUMBING CODES
Awaterconditionershouldbe installed on alevelfloororsurfaceascloseaspossibletoafloor
drain, laundrytub, orproperlytrapped plumbing outlet. Typicalinstallationsof conditionersand
filtersareshowninFigureBbelow:
FigureB: TYPICALWATERSOFTENERand FILTERINSTALLATION
WHENDISCHARGEDAT END OF DRAIN, LINEIS
AT: DRAINLINERECOMMENDATIONS
1. FloorLevel a.Useanylengthof1/2”pipe orlarger.
2. ControlLevel a.For30’ orless ofdrainline, use1/2”pipe or
larger.
b.For30’ ormoreofdrainline, use3/4”pipe or
larger.
Neverconnect the drainline intoadrain, sewerline ordraintray
without an airgap. Airgap shouldbe located indrainline, above
liquidlevelinbrine tank.
BRINETANK DRAIN
It isrecommended that the brine tankhavean overflowdrainline. Inthe absenceof asafety
brine valveorinthe event of anymalfunction of system, the brine tankwill be prevented from
overfilling. Useaminimumof a1/2”IDtubing.
DONOTCONNECTTHISDRAINLINETOTHECONDITIONERCONTROLDRAINLINE.
CAUTION:

SAST1029 Page 6
PLACINGTHESOFTENERINSERVICE
1. Turnthe timerknob full clockwisefrom “off” to “off” ie.Atimeof2hoursand open the
inletvalveslightly.Slowlyfill the resintank.Airand waterwill be expelled outthe drain
line.
2. Open the inletvalvefully,the brine tankshouldfill tothe properpresetleveland then the
float will closeoff.
3. Againturnthe knob back clockwisetooff (ie.2-hours.position).Watershouldbe drawn
fromthe brine tankand pass outthe drain.Allowtoflowatthe drainuntil anycolour,
objectionabletasteand odoursareabsentand then returntoanti-clockwisetooff
position.
4. The unitisnowoperational.Open the outletvalveand ensurethe bypass valveis
closed.Run the nearestcoldwatertap foraleast15 minutestoensurethe resinbed is
flushed.
BRINETANK
1. Placeatleast25kgofacoarserefined grade ofsalt(WaterSoftenerSalt)inthe brine
tankand alwaysmaintain drysalt abovethe waterlevel.
The tankcan holdup to50kgof coarsesalt.
2. Periodicallyitwill be necessarytoallowthe saltto"run-out"and clean outthe brine tank
of accumulated silt and insolublematerial.
REGENERATION
Always regeneratethe unitbeforethe softeneriscompletelyexhausted.Shouldcomplete
exhaustion occur,twoorpossiblythree regenerations,eachspaced four(4)hoursapart, will be
needed torestorethe resin.Toregeneratethe softener,turnthe timerknob clockwiseafull turn
ie.off tooff (do notexertundue pressure)and release.The unitwill then automatically
regenerateand returntoservice.

SAST1029 Page 7
During regeneration raw(hard)waterisbypassed toservicesoitisadvisabletoregeneratethe
unit when waterisnot needed.

SAST1029 Page 8
Water Conditioning ControlSystem
Installation, Operating and MaintenanceManual
541-030 VALVE

SAST1029 Page 9
The servicecycleposition directsuntreated waterto
flowdownthrough the resinbed inthe mineraltank
and up through the risertube. The wateris
conditioned when passing through the resin.
The slowrinsecycleposition directsaslowflowof
waterdownthrough the risertube and up through the
resinbed todrain. Thisslowflowofwaterpushesthe
brine solution through the resinbed.
Inbrine draw, concentrated salt brine isdrawnfrom
the brine tankand directed toflowdownthrough the
risertube and up through the resinbed tothe drain.
Brine isdrawnuntil the aircheck inthe brine tank
closes.
NOTE: THISCONTROL VALVE FUNCTIONSWITH
APRESSURISEDBRINELINE. THEUSE OF A
SAFETYFLOATINCONJUNCTIONWITHTHE
AIRCHECK ISREQUIRED
CycleFlow Diagrams

SAST1029 Page 10
Parts List
Item P/N Description Qty
1. 15-88 Screw, Backcap 4
2. 541-207 Backcap, 3Cycle 1
3. 541-206 Seal, Backcap 1
4. 541-239 ReturnSpring, Check Disc 1
5. 541-246 Check Disc 1
6. 541-325 Gasket, Injector 1
7. 428- Injector(SpecifySize) 1
8. 541-221 CoverPlate, Injector 1
9. 15-89 Screw, InjectorMount 3
10. 413-13 FilterScreen, Injector 1
11. 541-254 Spring Clip 1
12. 186-111-N O-ring, Brine Fitting 1
13. 541-250-1 Brine Fitting 1
14. 19-19 C-Clip, BackwashFlowAdjuster 1
15. 541-243 RinseFlowAdjusterw/o-rings 1
16.529-244 Gasket, Cross OverPort 1
17.541-244 BodyStemAssembly 1
18. 185-024-1 O-ring (Small), Seat Insert 1
19 541-204 SealInsert 1
20. 185-028-12 O-ring (Large), Seat Insert 1
21. 541-256 MainDiaphragm 1
22. 19-3 C-Clip, MainDiaphragm 1
23. 516-221 ReturnSpring, MainDiaphragm 1
24. 541-291-11 1 Hr. TimerAssembly 1
25. 15-87 Screw, TimerMount 4
26. 19-90 Screw, AdapterRing 2
27A. 185-231-1 O-ring, StructuralTank 1
27B. 186-105 O-ring, Park Tank 1
28. 541-232 AdapterRing 1
29A. 185-211-1 O-ring, 13/16"RiserAdapter 1
29B. 185-214-1 O-ring, 1.050"RiserAdapter 1
30A. 541-205 13/16"RiserAdapter 1
30B. 541-218 1.050"RiserAdapter 1
31. 185-029-1 O-ring (Outside), RiserAdapter 1
32. 541-257-1 ValveBody&Seal 1

SAST1029 Page 11

SAST1029 Page 12
Troubleshooting Guide
Problem Cause Solution
1.Unit failstoregenerate. a.Lowinlet pressure.
b.Drainline restricted.
c.The brine injectorisplugged.
d.Maindiaphragmistorn.
e.Regeneration lengthtoo short
a.Verifythat the serviceinlet pressureis
aminimumof20 psi.
b.Insurethe drainline isfree ofkinks.
c.Clean orreplaceinjector.
d.Replacediaphragm.
e.Insurethat the lengthofregeneration
exceeds20 minutes.
2.Hardwatertoservice. a.The bypass valveisopen orfaulty.
b.No salt instorage tank.
c.Not enough waterinthe storage tank.
d.Unit failstodrawbrine.
e.Excessivewaterusage.
f.Unit not regenerating.
g.Loss ofresin.
h.Change inrawwaterhardness.
i.Leakat the distributortube.
a.Closebypass valve.
b.Add salt.
c.Verifythat the safetyfloat isproperly
set.
d.See symptom/cause#6.
e.Check regeneration frequency.
f.See symptom/cause#1.
g.See symptom/cause#4.
h.Test waterhardness.
i.Verifythat the distributortube isseated
correctlyand isnot cracked.
3.Excessivesalt usage. a.Excessivewaterinstorage tank.
b.Regeneration istaking placetoo
frequently.
c.Faultysafetyfloat.
a.Verifythat the safetyfloat isproperly
set.
b.Verifywaterusage matchessystem
sizeand salt dosage.
c.Replacesafetyfloat.
4.Loss ofresin. a.Faultyaircheck instorage tank.
b.Leakat the distributortube. a.Clean orreplaceaircheck. b.Verifythat the distributortube isseated
correctlyand isnot cracked.
5.Salt watertoservice. a.Brine/slowrinsecycletimeset too
short.
b.Excessivewaterinthe storage tank.
c.Brine injectorundersized.
a.Verifycycletime.
b.Verifythat the safetyfloat isadjusted
correctlyand properly.
c.Verifyproperinjectorselection.
6.Controlfailstodraw
brine. a.Brine injectorplugged.
b.Filterscreen plugged
c.Looseline isrestricted.
d.Drainline isrestricted
e.Lowinlet pressure.
f.Maindiaphragmistorn.
a.Clean and replaceinjector. Followthe
proceduredetailed inthe parts
replacement section ofthismanual.
b.Clean and replacescreen.
c.Verifythat all the brine line connections
aretight.
d.Insurethat the drainline isnot kinked
orplugged.
e.Verifythat the serviceinlet pressureis
aminimumof20 psi.
f.Replacediaphragm.
7.Continuousflowto
drain. a.Defectiveclock assembly a.Replaceclock assembly.
8.Loss ofwaterpressure. a.Iron buildup inmineraltank.
b.Lowerdistributorbasket crushed. a.Increasesalt dosage orregenerate morefrequently.
b.Replacebasket and verifythat the
distributoriscut 1/2inchbelowthe top
ofthe tankthreads.

SAST1029 Page 13
Parts Replacement
General Information
Familiariseyourselfwiththe partsreplacement
proceduresand component partsthoroughlybefore
attempting anyrepair.
Insurethat the unit isinthe bypass position and
relievethe systempressurebeforeattempting any
repairprocedure.
RequiredTools
The following toolsarerequired toperformroutine
maintenanceon thisvalve:
PhillipsScrewdriver
NeedleNosePliers
AdjustableWrench
Small StandardScrewdriver
TimerAssemblyReplacement
1.Placethe bypass valveinto"bypass"position.
2.Relievethe systempressure.
3.Removethe four(4)head mounting screws.
4.Lift the timerassemblyawayfromthe valve
body.
5.Followthesestepsinreversetoreinstall the
timerassembly.
Note:Priorto re-instalmentinsure thatthe
main return spring iscentred over themain
diaphragm.
MainDiaphragmReplacement
1.Placethe bypass valveintothe "bypass"
position.
2.Relievethe systempressure. Removethe four
(4)head mounting screws.
3.Lift the timerassemblyawayfromthe valve
body.
4.Removethe c-clipfromthe centreofthe
diaphragm.
5.Lift the diaphragmawayfromthe bodystem
assembly.
6.Followthesestepsinreversetoreinstall the
timerassembly.
Note:Priorto re-instalmentinsure thatthe
main return spring iscentred over themain
diaphragmand thattheoutsideedges ofthe
main diaphragmare tucked into thevalve
body.
Rinse AdjustmentValveReplacement
1.Placethe bypass valveinto"bypass"
position.
2.Relievethe systempressure. Removethe
four(4)head mounting screws.
3.Lift the timerassemblyawayfromthe valve
body.
4.Removethe c-clipfromthe centreofthe
diaphragm.
5.Lift the diaphragmawayfromthe bodystem
assembly.
6.Removethe seat assembly.
7.Disconnect the large c-cliplocated on top of
the rinseadjustment valve.
8.Press the rinseadjustment valvedownand
out through the valvebodyassembly.
9.Inspect the o-ringson the valveforwear.
Clan orreplacethe valveassemblyif
necessary.
10.Lightlylubricatethe o-ringswithaDow111
Silicone based lubricant.
11.Followthesestepsinreversetore-install the
rinseadjustment valve.
DrainSeatReplacement
1.Placethe bypass valveintothe "bypass"
position.
2.Relievethe systempressure.
3.Disconnect the drainfitting fromthe control
valvedrainoutlet.
4.Usealarge standardscrewdrivertoremove
the drainseat. Turnout counterclockwise.
5.Priortoinstalling the drainseat, lubricatethe
o-ring(s)withdishsoap.
6.Turninthe drainseat, until the fitting
becomesbottomsout.
7.Toproperlyalign the drainseat withthe drain
paddleback out seat four(4)full turns.
8.Pressurisethe systemand check drainfor
leaks.
Note:After backing outthedrain seatthe
seatmay still require minoradjustmentto
eliminateleaks. Turn theseatin orout
until theleak to drain stops.

SAST1029 Page 14
InjectorandFilterScreenReplacement
1.Placethe bypass valveintothe "bypass"
position.
2.Relievethe systempressure.
3.Removethe three (3)screwsfromthe triangular
coverplate.
4.Lift awaythe coverplate.
5.Removethe injectorfromthe valvebodyand
separatethe gasket fromthe injector.
6.Inspect the injectorcavitiesforblockage.
7.Removethe filterscreen fromthe valvebody
and inspect the screen fordirt. Replaceif
necessary.
8.Followthe stepsinreversetore-install the
injectorand filterscreen.
Note:Priorto re-installing theinjectorgasket,
insure thatthesidemarked "OUT"isfacing
theinjector.
RiserReplacement
1.Placethe bypass valveintothe "bypass"
position.
2.Relievethe systempressure.
3.Disconnect the unit fromthe bypass connections.
4.Removethe unit fromthe resintank.
5.Turnout the upperdistributorbasket fromthe
unit adapterring.
6.Removethe two(2)adapterholddownscrews,
and lift awaythe adapterring.
7.Separateriserassemblyfromvalvebody.
8.Clean the risero-ringsand wipe out the valve
bodycavity.
9.Usethe Dow111 Silicone based lubricant to
lightlylubricatethe risero-ringsand the valve
bodycavity.
10.Followthesestepsinreversetore-install the
riserassembly.
Check Disc Replacement
1.Placethe bypass valveintothe "bypass"
position.
2.Relievesystempressure.
3.Removethe four(4)screwsfromthe backcap.
4.Placeahand underthe backcap and removethe
backcap. The check discreturnspring will fall
intoyourhand.
5.Removethe check discfromthe back ofthe
bodystemassembly.
6.Inspect the rubbersealon the check discfor
wear. Clean orreplaceifnecessary.
7.Re-install the check discon bodystemassembly.
8.Placeasmall amount ofDow111 silicone based
lubricant on the back cap centrepost.
9.Insurethat the back cap gasket isproperly
seated inBackcap.
10.Install check discreturnspring intocentrepost.
11.Align the mark on top ofthe back cap withthe
mark on the valvebodyand carefullydirect open
end ofreturnspring intocentrepost ofthe check
disc.
12.Install the four(4)back cap screws.
13.Pressurisesystemand check forleaks.
BodyStemAssemblyReplacement
1.Placethe bypass valveintothe "bypass"
position.
2.Relievethe systempressure.
3.Removethe four(4)head mounting screws.
4.Lift the timerassemblyawayfromthe valve
body.
5.Removethe c-clipfromthe centreofthe
diaphragm.
6.Lift the diaphragmawayfromthe bodystem
assembly.
7.Removethe seat assembly.
8.Lift out the bodystemassembly.
9.Inspect the centrecheck discrubbersealfor
wear. Clean orreplaceifnecessary.
10.Re-install the bodystemassembly.
11.Lightlylubricatethe seat assemblyo-ringswitha
Dow111 Silicone based lubricant.
12.Re-install the seat assembly, insurethat one of
the two(2)flatsisfacing towardsthe top ofthe
valvebody.
13.Re-install the maindiaphragmand the timer
assembly.
14.It isnownecessary toreseat the rearcheck disc.
Refertothe Check DiscReplacement procedure.

SAST1029 Page 15
BRINEVALVE ASSEMBLY
WindsorCabinet
Model FloatDistance (X)
SAS0715 100mm
SAS0922 200mm
SAS1029 260mm
AdjustmentofSoftenerBrineValve
1.Lift float rod tofull up position.
2.Set float todistanceshown. Measurefrom
the top of the crownnut tothe bottomof
the float.