Transcript Document

Service 101
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Service is important
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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.
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Types of service calls
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Service calls for parts plus labor.
Warranty determinations.
Warranty repairs.
Start ups.
Equipment surveys leading to
quotations.
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Required service skills
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Troubleshooting
Valve calibration
Valve rebuilding
Trouble
shooting
Calibration
Rebuilding
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Before you leave the shop
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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.
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At the jobsite
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Establish contact with company
representative.
Gain access to the location.
Meet and greet as necessary.
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Don’t touch anything until
you,
Ask the
operator.
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Ask the operator:
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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?
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Ask the operator:
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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.
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Don’t touch anything until
you,
Make as many
observations
as possible.
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Observations
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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?
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Observations
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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?
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Observations
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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?
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Don’t touch it yet!!!
•Make certain it is OK to start cycling
softener.
Re-Check with operator.
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Now you can
touch unit.
Start repairs.
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Take unit out of service
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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.
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What will happen?
The five cycles
1.
2.
3.
4.
5.
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.
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Problem:
Hard Water, not using salt.
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Determine model number and find out
regeneration flow rates.
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Possible Cause
a.
b.
c.
HARD
WATER
TO
SERVICE
d.
e.
f.
g.
h.
i.
j.
k.
l.
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No salt.
Salt bridging.
Low or no brine draw
Bypass valve
Float setting
Brine shut-off valve
Electrical power
Timer erratic (Does
not regenerate at the
proper time.)
Build up on grid
plate.
Improper salt
dosage, low salting
units.
Leaking bypass in
plumbing.
Twin units, one is
hard, one unit soft.
Solution
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
Make sure salt is in the brine tank
Carefully break up salt with a stick.
See No. 1
Fully close valve and outlet valves.
If water runs to service,
disassemble and repair if
necessary.
Adjust float
Make sure the brine shut-off valve
is fully opened.
Check power supply.
Replace the timer
Clean grid plate
Increase salt dosage, remove a
plug.
Shut off the inlet, outlet and bypass
of the conditioner, check for the
flow of water at a soft water faucet.
Remove and clean brine director.
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Initiate
Regeneration
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Initiate regeneration
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Initiate regeneration from timer. This will
put unit in backwash position.
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Backwash
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Observe piston position.
Observe flow to drain.
Measure flow if possible with bucket
and stop watch (Ref required flow from
catalog or O&M.)
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Backwash
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Flow rate low:
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Flow rate normal:
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Low water pressure.
Plugged backwash flow control.
Other restriction in backwash lines.
Move on.
Recheck brine level measurement.
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Advance
cycle to next
position
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Brine draw
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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.
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Brine draw
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Flow rate to drain low…
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Low water pressure.
Plugged injector.
Clean or replace.
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Brine draw
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Flow rate to drain high...
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Water is bypassing injector.
Injector not properly seated.
Piston broken or leaky seals.
Unit out of calibration.
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Brine draw
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Flow Rate to drain normal...
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Move on
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Brine draw
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Recheck brine level measurement.
Brine should be drawing a minimum of
one-inch per minute.
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Brine level not moving
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Disconnect line between softener and
brine tank. Put finger over tube.
Poor Vacuum:
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No vacuum or pressure from control valve.
Problem is in the control valve.
Injector, piston, or BW flow control
problem.
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Brine level not moving
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Good vacuum
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Good vacuum will be obvious. Seems to
get stronger and stronger with time.
Problem is in the brine tank.
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Brine level not moving
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Brine tank problems – brine valve
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Cracked
Dirty
Plugged
Clean or replace brine valve
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Advance
cycle to next
position
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Fast rinse
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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.
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Advance
cycle to next
position
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Service
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Observe valve position
Service light should illuminate on valve
Shut off kit should open
Open bypass valves
Unit is returned to service
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Other
problems
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Salt in service line
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Problem is from poor brine draw.
Too long to get in so it is never rinsed
out.
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Salt in service line
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Plugged injector.
Low water pressure.
BW flow control restriction.
Fast rinse not long enough.
Pressure drop in front of unit.
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Salt in service line
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Variations in inlet water pressure can
cause problems. Need good constant
pressure.
Problems may occur under 40 psi.
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Mineral to service
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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.
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Insufficient service flow rate
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High pressure drop
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Bad Resin
Draw sample and inspect
Shut off kit not fully opening
Clogged distributors
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Troubleshooting SOK
Aquamatic valve vent restricted
 Ruptured diaphragm
 Asco valve not operating properly
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Aquamatic valve drawing
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Twin units:
One hard, one soft
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Check brine director valve.
Check brine director.
Remove one side at a time to verify
correct operation of director.
Clean or replace.
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Brine tank overflowing
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Foreign material lodged in BV seat.
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Float binding on brine well.
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Realign.
Faulty BV seal.
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Remove and clean.
Replace BV seal.
Fittings defective.
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Tighten or replace.
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The End
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WATER KING, INC.
102 Charbonnet Road
Duson, LA 70529
Phone: (337) 988-2360
Fax: (337) 981-7922
E-mail: [email protected]
Web site: www.waterking.com
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