ARFQ 0608 DCR2500000046 - Addendum No. 3.pdf

ARFQ 0608 DCR2500000046

REQUEST FOR QUOTATION

CHILLER REPLACEMENT PROJECT

MOUNT OLIVE CORRECTIONAL COMPLEX AND JAIL

CHILLER REPLACEMENT 1 ADDENDUM NO. 3

PROJECT

ADDENDUM NO. 3

Questions:

Q1: Can you list a final and revised scope of work?

A1: Please note that anything that is listed in the specifications and previous addendums that is stated that it must be replaced with new and is not listed below, the contractor must replace with new. Below is a general summary of the scope of work:

A1a: Chillers:

1) Replace existing two (2) chillers and chiller controls with new. New chillers must be type air-cooled screw liquid chillers. New chillers must operate off of R-513A.

2) Replace existing four (4) butterfly valves located by the existing chillers.

3) Replace all existing outdoor pipe insulation and metal lagged with new.

4) Replace all existing pressure gauges and shut-off valves with new.

5) Replace the existing heat trace with new.

6) The existing electrical disconnect can be reused.

7) The contractor is responsible for expanding the concrete chiller pads if required for new chillers.

8) Because the refrigerant is different from the existing, the contractor is responsible for flushing out the existing piping if required for the new chiller units.

A1b: Pumps:

1) Replace existing primary cold water pumps no. 1 and 2 with new.

2) Replace existing secondary pumps no.1 and 2 with new.

3) Replace the existing primary and secondary pump controls with new.

4) Replace all existing motor starters with new.

CHILLER REPLACEMENT 2 ADDENDUM NO. 3

5) Replace all existing two (2) speed drives with new.

6) Replace all existing control actuators and valves for main loop with new.

7) Replace existing chemical feeder with new.

8) Replace existing expansion tank, isolation valves, and drains with new.

9) Replace existing water softener and values with new. The existing is

Fulton FB 900 Series automatic water condition system.

10) Replace all existing triple duty valves with new.

11) Replace all existing suction diffusers with new.

12) Replace all existing connectors with flex connectors for supply and return piping with new.

13) Replace all existing pressure gauges, thermostats, and shut-off valves with new.

14) Replace existing DynaQuip Controls, drainmaster with new.

15) Replace all existing series 1510 base mounted centrifugal pump kits with

16) Replace all existing 4AC series 1510 centrifugal pump – base mounted with new.

17) Replace all existing 3E series 1510 centrifugal pump – base mounted with

18) All new pipes, etc. must have the same size and type of insulation that the existing that is being replaced does.

19) Replace all existing centrifugal-action separators with new.

20) The existing electrical VFD fuse box and disconnect switch can be reused.

A1c: Building automation control system:

1) The existing Metasys must be disconnected from the old equipment and reconnected to the new equipment. The Metasys is manufactured by

CHILLER REPLACEMENT 3 ADDENDUM NO. 3

Johnson Controls, Inc. Any modifications that the contractor must do to make the existing system work, the contractor is responsible for.

A1d: Startup and training:

1) The contractor is responsible for having the equipment startup and providing training to the facility staff.

Q2: Can you provide size and info on the (2) control valves that you want replaced?

A2: VSI electric actuator, series 1000

Q3: Can you provide size and info on the expansion tank that you want replaced?

A3: The contractor must install the correct size expansion tank for what size equipment that will be installed.

Q4: Is it intended for all the insulation from the ground penetrations to the new chillers be replaced?

A4: Yes

Clarifications:

C1: Please see the attached equipment information for the operation and maintenance manuals for the existing equipment. Please note that the O & M manuals for the existing chiller units are not included in the attached.

C2: The bid time and date has changed: 10:30 AM E.S.T. on April 18, 2025

Bell & Gossett Submittal: B .. SJOF Page 1 of 1

TRIPLE DUTY®VALVE-STRAIGHT PATTERN

PERFORMANCE DATA

B-830F

CVRATCNO Cv RATING AT 100% OF STEM RISE tm%1) REFERENCE 3DS•28 3D6•2•1/28 3DS•3S 3D8-4S 30S•&S 3D8•0S 3DS•88 3DS-t0S 3DS-12S 3DS•14S

A 83 119 204 365 602 748 1,085 1.851 2,448 S.000 (18.91 (27.0\ (43.6) l82.9l (114.0) 1169.4) (246.4) 1420.4) 1666.6) (881,3\

B 77 117 191 -320 497 701 1,079 • 1,826 2t430 3.226 117.6\ (26.8) (43.41 112.7) {112.9) (169.2) (245.0) (414.7} (551.9) 1732.4}

A. FLOWMETER Cv FOR BALANCING. MINIMUM READING OF 3 FEET (.9 m) OF PRESSURE DROP REQUIRED FOR

ACCURATE FLOW DETERMINATION.

B. Cv FOR CALCULATING PRESSURE DROP ACCROSS THE VALVE.

NOTE: MAXIMUM RECOMMENDED PRESSURE DROP SHOULD NOT EXCEED 25 FEET (7.6 m).

• CONTACT YOUR LOCAL BELL & GOSSETT REPRESENTATIVE FOR COMPLETE PERFORMANCE CURVE DATA

DISTANCE REQUIRED

TO D19A.881!MBLE A

(VALVI! CLOSED) #- '

DIMENSIONS IN INCHES mml APPROX.

A

SHPG.

MODEL FLANGE wr.LB8.

NUMBER size• OPEN CLOSED B C D E IKal

3DS·2S 2 10·31'8 • 8-3/4 8-318 3 8-314 3-1/2 24

160.8} {264) 1248} 1213) 176.2\ (222) l89) {11\

A 308-2·112S 2-1/2 11 10-1/4 8•7/8 3-112 8-3/4 3•1/2 28

(83.6l 1279) (260) 1226\ f89\ 1222) 189} {13)

3DS-3S 3 12-3/8 1W/16 10 3.314 9-314 3-16/16 39

(76.2) 1314\ 1291\ (264\ (88\ (248\ (100\ (18\

-3DS-4S

4 18•7/8 16-7/8 14-1/2 4-1/2 14-1/16 6-1/4 94

1101.81 (429) {403) (388) (114) 1367) (1691 (43\

3OS-6S 6 18-1/2 17-1/4 16 6 16-3/16 6-7/8 114

11271 (470) (438) 1406\ '127) 1388\ (176) (62)

3DS•6S ·8 20-3/4 19-1/4 18 6-1/2 17 8·1/4 188

·'162A\ (6271 ·1489\ (467} (1401 ('132\ {210l (85)

308-88 8 24-3/4 23•1/4 21-112 6·3/4 20-7/16 10-3/8 316 1203.2) (629) l691l 1646\ (172) 1619) 1284) (144)

3DS-10S 10 28•7/8 28-112 25-112 8 23-1/4 12-1/4 468

1254) 1733) 1673) (6481 1203) (690) (311\ (208}

3DS•12S 12 33·112 31-1/8 30 8-1/2 26-9/16 14•1/2 662

l304.8\ 1851\ (781\ (762) (241\ (676\ (368) {301\

30S-14S 14 37 35-1/2 33.314. 10-1/2 29-6/8 16-1/2 780 (355.6} fA40) 19021 1857) 1267) 1753) (419} (355\

·sTANOARO 126 PSIG (862 kPa) ANSI FLANGES.

Dimensions aro aubJect ro chango, Not to be used for construcUon pu,poaes unless certified. PROPER IN8TAllATION

SHOWING STEM UPRIGHT

TYPICAL SPECIFICATIONS

Furnish and Install as shown on plans. a straight pattern valve designed to perfom1 the funcUons of a nonslam check valve. throttling valve, shutoff valve end calibralfon balancfng valve.

The valve shall be a heavy-duly cast iron conslruclion with standard 125 pslg (862 kPa) ANSJ flanged connections, and rated ror a maximum workfng pressure of 175 pslg (1207 kPa) at 250°F (121°C). The valve shall be filled with a bronze seat, replaceabre brass disc with EPDM seat Insert, stalnless steel stem, and challer•preventlng spring and calibrated nameplate. The valve deslgn shall permit repacking under full system pressure.

ITT

8200 N. AusUn Avenue Morton Grove, IL 600&3 Phone (847)988-3700 Facslmlle (847)966-9052 www.betrgossell.com

The valve shall be equipped with brass readout valve (with Integral check valve) for taking differential pressure readlngs across the orifice for accu,ate system balance.

Valve Cv rating at Cull open position not to be fess than ___ ..

(Refer to the 100% stem rise varue shown In row 11B" for required valve.)

All valves shall be ITT Bell & Gossett Model No. aos. __ s Triple Duty Valve.

file://N:\Rep08\Hooker08\Proiects\TCI MT OLIVE2 EQUIPMENT\Submittals Jan-18-2... 1/18/2012 l

:J;\:r -- ,'..- _1 Bell & Gossett Submittal: B-225.SE i I , Lt n i !

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~ITT

JOB: JCI MT OLIVE2 EQUIPMENT

UNIT TAG: PRIMARY P-1·2

ENGINEER:

CONTRACTOR: JOHNSON CONTROLS

4AC

REPRESENTATIVE: Slelfens•Shullz, lno. •

ORDER NO.

SUBMITTED BY: CHARLES HOOKER

APPROVED BY:

Series 1510

I SUBMITTAL I

B-225.SF

DATE: 1/1812012

DATE:

DATE:

Centrifugal Pumps - Base Mounted

SPECIFICATIONS

FLOW 400 (GPM) HEAD __ 2_4_(_FT_)_

HP 6 RPM _ __ 1s_o_o __

VOLTS _____ 2_o_s-_23_0l_4_60 ___ _

CYCLE __ a_o __ PHASE ___ 3 __

ENCLOSURE ODP N_oma Premium Elllclonl

APPROX. WEIGHT 313

SPECIALS

Noto: Equlppod with NEOPRENE coupling

HEAO(l'ee()

MATERIALS OF CONSTRUCTION

18J BRONZE FITTED O ALL IRON

FEATURES

18J 1-ALERT"' Corn!ilion Monllor 18J ANSUOSHA Coupllno Guard 18} Conler o,op Out Spacer Coupllf)Q 18} Fabncaled Heavy Duty Baseplate

MAXIMUM WORKING PRESSURE

18} 176 psi (12 bar)W,P.

w/125II ANSI flange drilUng 0 250 psi (17 bar) W.P.

W/260/IANSI nango dr!IITng (requires 1510-S) tlO, r111 11Ji-llll-l'§~~

0• o~~,.....,....,..,,,..,.,..,'i,.,iio4',;,.., -+---~""-4~"0,;;o""'· .~ ... !!': .. -!!' .. +-. ;.",, -~- ...,.;.,..,..,-::60~ .. o ....... ~. ·""·""· ........ ......... .._a'"""iio Capacity (OPM)

ESP-REP \/20t1 .04 © COPYRIGHT 2009 ITT Corporallon

TYPE OF SEAL

18l 1610 Slondard Seal

(Buns-Carbon/Ceramic} 01610 •F Standard Seol w/ Flush Line

(Buns-Carbon/Ceramic) D 1610-S Stuffing Box conslrucllon w/ Flushed

Mechanlcal Slnglo Seal (EPR-Tungslon Carbide/Carbon)

0 1610 -D Stuffing Box construction w/ Flushed Double Mechanical Seal (EPR-Carbon/Coromlc) Requires exlemal water gource

01610-PF Slu!Ong Box COnslrucUon WI Packing (Graphlle Impregnated Tenon)

Design Capacl!y =400.0 GPM Oeston Head s:24,0 l'eel suction Size c 5" suet, Velocity " 6.4 lps Discharge Size " 4" Olso. Velocity c 10.Hps

Min. Imp. Ola, = 5" Mox. Imp. Ole,= 7" Cul Ola. c 6.75"

Mox. l'IOW = 694 GPM B.l:.P. l'low :: 380 OPM

Eff,@ OUty•Polnt" 77.64 'I', Motor Size ::5 HP

B.H.P.@ DUly•Polnl c 3.14 BHP Max. B,tl,P, ror Imp. Cul= 3,38 BHP

Bell & Gossett file://N:\R.ep08\Hooker08\Prqjects\JCI MT OLIVE2 EQUIPMENT\S1.1bmitt11ls J an-18-2... 1/18/2012

. t . t • . • • • • • • • . . • . • • • . . • • • • • • ~ • • ' :. . • • • . . •••••.• \ •••• •• • . • • • • • • • • • • • • • • • •

Bell & Gossett Submittal: B-225.SE

Serles 151 O 4AC Centrifugal Pump Submittal

DIMENSIONS• m

MOTO B HOMAX HD

F

145T 1 32·1/8 10-3/4 787 816 273

182T 31 34.314 10-3/4 787 883 273 m>1e4 31 35-1/2 10·3/4 787 902 273

213T -5/8 :38-1/8 10.3/4 870 968 273 E

215T 8 44 10-3/4 1118 273

254T 1 47 .. 314 12 121S 305

256T 1 49-1/2 13 1257 330

284TS 1 48-3/4 13

1238 330

288TS 1 60-1/4 13

8 1276 330

324TS 1 62•1/4 12

8 1327 305

326TS 1 64 12

1372 305

STUF

MOTOR HB HCMAX HD

FRAME e

145T ·5/8 35·5/8 879 805

1821 •5/8 38·3/8 879 976

184T -5/8 39-1/8 879 984

213T 9-3/8 41-5/8 100 1057 I!

215T 8-1l 46-3/8 12 1181 1178 305

254T 1•3/ 60•1/8 12 31 1273 305

258T 1·3/. 61-7/8 13 1314 1317 330

284TS 1·3/. 51-1/8 13

314 1298 330

288TS 1•3/ 62-5/8 13

314 1337 330

3241S 1·3/ 64-5/8 12 31" 1387 305

326TS 1·3/ 68-318 12

314 1432 305

FLANGE DIMENSIONS IN INCHES (MM)

SIZE THICKNESS o.o.

DJscharge 4•(102) M/4 (32) 9•1/2(273)

Suctfon &· (127) 1·3/&·(35) 10.

3/4.(273)

FLANGES ARE 126# ANSI• STANDARD

260# ANSI -AVAILABLE

HMMAX

25 4-5/16 14--1/2 635 110 388 26 4.S/16 18 635 110 406 26 4-S/10 16 635 110 406

28-5/8 4-5/18 10-5/8 727 110 422

33-3/8 4-5/18 16-5/8 18-1/4 848 110 422 484

36-1/2 6-7/16 18•7/8 18-1/2 927 138 479 495

3tJ.1/2 5-7/16 21 19-1/2 927 138 533 495

38-1/2 6-7/16 21 20·1/2 927 138 633 621

3fJ.1/2 6-7/16 21 20-1/2 927 138 533 621

38·1/2 6-7/16 21 19·1/2 827 138 533 49

38-1/2 6a7/16 21 19·1/2 927 138 533 495

G BOX1510•P •S, 1610•D

HL HMMAX HO

4•5/16 14·1/2 18-1/4 109 368 464

4"5/18 16 18•1l4 109 406 464

4~16 16 18-114 109 406 484

~5/16 18•5/8 18-1/4 109 422 484

6-7/18 1M/8 19•1/2 138 454 495

6-7/16 18·7/8 18•1/2 138 479 495

6•7/16 21 18•1/2 138 533 495

6•7/16 21 20·1/2 138 533 621

6-7/16 21 20·1/2 138 533 521

6-7/18 21 19-1/2 138 633 495

5-7/16 21 18·1/2 138 633 495

Dlmonslons aro eu oct to c ange. Not to be used or cons uc on purposes un ess certified, B-225.5F z z file://N:\Rep08\Hooker08\J>r<dects\JCI MT OLIVE2 EQUIPMENT\Submittals Jan-18-2... 1/18/2012

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Bell & Gossett Submittal: B-226. lF

~ITT

JOB: JCI MT OLIVE2 EQUIPMENT

UNIT TAO: SECONDARY P-3-4

ENGINEER:

CONTRACTOR: JOHNSON CONTROLS

3E

REPRESENTATIVE: Sleffens,Shullz, fno.

ORDER NO,

SUBMITTED BY: CHARLES HOOKER

APPROVED BY:

Series 1510

I SUBMITTAL I

B-226.1G

DATE: 1/18/2012

DATE:

DATE:

Centrifugal Pumps - Base Mounted

SPEGIFICA TIONS

FLOW 400 (GPM) HEAD __ 100_(_FT_)_

HP _ __ 2_0 __ RPM 1800

VOLTS ______ 2_00 _____ _

CYCLE __ 6_0__ PHASE 3

ENCLOSURE ODP Nema Premium Efficfenl

APPROX, WEIGHT 660

SPECIALS

Nolo: Equip pod wllh NEOPRENE coupling

MATERIALS OF CONSTRUCTION

18JBRONZE FITTED □ALL IRON

FEATURES

181 1-ALERT'u Condition Monllor ® ANSVOSHA Coupling Guard

18) Center Drop Out Spacer Coupnng 181 Fabrfe(llod Honvy Duly Basoplalo

MAXIMUM WORKING PRESSURE

181 176 psi (12 bar) W.P.

w/12611 ANSI flange drilllng 0 260psI(17bar)W.P.

w/26011 ANSI flange drilling (requires 11510-S)

" 2011P

TYPE OF SEAL

1811610 Slandard Seal

(Bunn-Carbon/Coromlc) 01610 •F Standard Seal w/ Flush Line

(Buna,Carbon/Ceramlo) 01610 -S SlufOng Box (:()OSlrucUon w/ Flushed

Mechanical Single Seal (EPR-TungGlon Carbide/Carbon)

D 1610 •O Stuffing Box constAAUon w/ Flushed Double Mechanical Seal (EPR-Carbon/Ceramlc) Requires external waler sou<ce

D 1610-PF Sluffing Box Construction w/ Packing (Graphite lmpregnaled Tenon)

Daslon capaolly =400.0 GPM Design Hend =100.0 Feel

8Ucllon $IZe = 4" suet. Velocl!y = 10.1 fps Discharge Size" 3" Disc. Velocity a 17.4 fps

Min. Imp, Ola.:: O " Max. Imp, Din. r: 11" Cul Ola,:: 10,625"

150•

- -··-··I

, nHp+---+--.1 Mox. Plow D 616 OPIII 8,E.P, Flow "434 GPM

·- ·-+---11---¼--+---l--¼--+---l- --+--+10HP'_ ·-_ .,_ __ _

25• _1--......;.---+--l----+---+---l--+--+--l---+---+--l---+----!--I

• - -- -- - -!-- +---lr---¼-- +---t---+--+--t----+---1--1

Elf.@ Duty,Pollll :: 76,84 % Motor Size r:20 HP

8.H.P.@ Duty,Polnt;; 13,22 BHP Mox, 8,11,P, for o- ' aoo•·~· . w • • • • 4s0 -~. •• 600 76() Imp. cut111G.63 BHP

Cnpaclly (CPM)

ESP·REP v2011.04 © COPYRIGHT 2009 ITT Corporetlon Bell & Gossett file://N:\Rep08\Hooker08\Projccts\JCI_MT _ OLIVE2 _EQUIPMENT\Submittals_Jan-18-2... 1/18/2012

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Bell & Gossett Submittal: B-226.lF

Serles 1510 3E Centrifugal Pump Submittal

DIMENSIONS• Inches mm)

MOTOR HA HB HD

FRAME .

184T

213T

215T

264T

"l.•FRAMI!

-266T 8-11 14 122 3

324TS 61 14

28 3

328TS 2·1 14

33 3

364TS 4·3' ·1

381 1

3651S 65 •1 397 1

404TS 7-11 1

464 19

MOTOR HA HD

FRAME .

184T

213T

216T

254T

"L•FRAME

268T

324TS

326TS

384TS

385TS

404TS 151 1

Dimensions are su ec o c ange. ol to be use

FLANGES ARE 126# ANSI -STANDARD

260# ANSI •AVAlLABLE

STANDARD SEAL 1510 1610•f

HF1 HF2 HL HMMAX

19-1/4

18-7/8

19-7/8

20-7/8

-5/1 20-7/8 11 630

1 23-1/8 11 687

/1 23-1/8 110 687 15/ 26-314 125 879 16/16 26·3/4

125) 879 5/16 26-3/8

126) 721

STUFFING BOX 1610•PF 1510-S, 1510-D

HF1 HF2 HL HMMAX

19-1/4 '189

19-7/8

19-7/8

20-7/8

•5/1 20-7/8 1 530 -5/1 23-1/8 10 687 •5/1 23-1/8 1 687 16/ 28-3/4 12 679 15/ 28-314 12 679 16/ 28·3/8 12 721 or cons rue on purposes un ess ce lfle , B•226.1G

HO

3.

3.

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CORRUGATED HOSE

& BRAID, STAINLESS STEEL

QTY, PIPE SIZE A PRESSURE-

NPS (IN)

2i. 9"

2·1/211 9"

3" 9" 4u g•

8 511 11° (r 11" 8" 12n

10" 13" 1211 14"

14" 14"

1611 1411

• FOR SAFE WORKING PRESSURE

ABOVE 70°F, MULTIPLY PRESSURE

SHOWN AT 70°F TIMES CORRECTION

FACTOR OF REQUIRED TEMP,

TEMP°F FACTOR

70 1.0 200 .92

300 .86

400 .82

600 ,77

600 .73

CUSTOMER:JOHNSON CONTROLS

PROJECT: MT.OLIVE2

(PSI)

ENGINEER::.,__ __________ _

CARBON STEEL FLANGE

150# DRILLING FLAT.FACE

NOTES

P-1·2·3·4

MAX INTERMITTENT OFFSET FROM t 1/811

MAX. PERMANENT OFF~ET FROM t 3/8"

Rat. D

H2a W. HUBBARD ST.

CHtCA.00, IL eos12 1£1.131t-na-aaoo FAXt512•7"8•04tS WWW,UtflWltX,COM

METRA• MINI

STAINLESSSTEELPUMPCONNECTOR

DRAWNBY: AD DATE: 03/24/2011

APPROVED: MR DATE: 03/24/2011

sc,ue: DRAWING NUMBER:

NONE 150 SF• MM

Pump Serles:

Flow Rate: (GPM) Pump Speed (RPM) Weight: (lbs) SuoUon Size: (fn) Discharge Size: (fn) Impeller Diameter: (In) Max Imp. Dia. : (GPM) Max. Flow: (GPM) Flow@ BEP: (GPM) Motor Power, HP:

Pump Power (BHP):

Max Power (BHP):

FrameStze:

Cost Per KWH Days I Year In operation Estimated Full year costs

System Fluld:

Pump Details

10.625 13.22 16.63 256T

0.10 $9186.96

Water

Pump Size:

Total Head: (Feet) NPSH req: (Feet) Cost Index:

Suction Veloolly: (fps) Discharge Veloclty: (fps) Efficiency:

Duty Flow/Max Flow(%) Min. Reo. Flow: (GPM) Selected Motor Size (kw) Duly-P(Jlnt Horsepower (kw) Maximum Power (kw) Aprox. FLA (230/460v):

EspPlus v 3.8.1 ~

3E

7.86 10.1 17.4 76.84 14.91 9.86 12.4 48.0/24.0 r·· i )

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Pump Series:

Flow Rale: (GPM) Pump Speed (RPM) Weight: (lbs) Suction Size: (in) Discharge Size: (In) Impeller Diameter: (In) Max Imp. Dia. ; (GPM) Max. Flow: (GPM) Flow@ SEP: (GPM) Motor Power, HP:

Pump Power (BHP):

Max Power (BHP):

Frame Size:

Cost Per KWH Days / Year In operation Estimated Full year costs

System Fluld:

EspPlus v 3.8.1

Pump Details

1510 Pump Size: 4AC 400 Total Head: {Feet) ·.24 1750 NPSH req: (Feel) 7.24 295 Cost Index: 113

6 Suction Velocity: (fps) 6.4 4 Discharge Velocity: (fps) 10.1

6.76 Efficiency: 77.54

7 Duty Flow/Max Flow(%) 67 694 Min. Rec. Row: (GPM) 77.8 389 Selected Motor SJze (kw) 3.73 6 Duty-Point Horsepower (kw) 2.34

3.14 Maximum Power (kw) 2.62

3.38 Aprox. FLA (230/460v): 13.0/6.5

184T

0.10

. $2268.97

Water

3().0 - L/-S l

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BIELl & GOSSETT I INSTRUCTION SHEET I P81555

Series 1510 Based Mounted Centrifugal Pump Kits Assembly Instructions

IMPORTANT

AEVISIONC

The Series 1510 pump kits are to assembled by quafiffed per sonnel only. Any questions regarding the assembly procedure should be referred to the ITT Bell & Gossett Service Manager.

Impeller cap screws and washers are furnished with the kit. All 8. Mount motor to saddle using 4 cap screws, 4 lock washers, other fasteners and shims must be furnished by assembler. 8 flat washers and 4 nuts.

(Refer to Fastener Chart for proper sizing of cap screws, nuts

9. Apply pump coupler half to pump shaft and motor coupler and washers.)

half to motor shaft. 1lghten one coupler half In Its final posl-

1. Mount volute to base, adding a minimum of .025' In shims tlon and add coupler sleeve. If using a two piece sleeve, hang between volute and base. Use 4 cap screws, 4 lock the wire ring loosely In the groove next to the teeth. Sllde washers, 4 flat washers and risers when applicable. the loose flange tightly up against the sleeve and back off

2. Assemble volute cover plate to small bearing assembly 1/a" for axial clearance. Tighten the loose flange to the shaft.

(1" shaft) with 4 cap screws. On large bearing assembly Check vertical and horizontal mlsalfgnment by using a (1 ¼• shaft), use 8 cap screws. straight edge scale or piece of bar stock with the center

3. Press seal Insert In volute cover plate. Push pump shaft notched to provide clearance for the raised portion of the forward from rear of bearing assembly to take up end play. coupler sleeve. For 3500 rpm operation, It will be necessary

Moisten the Inner diameter of seal assembly with soapy to check the angular misalignment by using a dlal Indicator water, maintaining forward pressure on the shaft , and press or micrometer calipers. Measure the gap at Intervals around seal firmly In place. Carbon seal face must be tight against the periphery of the coupling to determine minimum and ceramic Insert. Apply small end of tapered spring on seal. maximum gap. The difference between these two values should be as close to zero as possible.

4. Make certain that Impeller has been properly cul to size for If the angular alignment was adjusted, it wlll be necessary to required GPM and feet of head and balanced. Slide Impeller onto bearing assembly shaft until It bottoms against the recheck the vertical and horizontal misalignment again.

shaft shoulder. Fasten impeller using one cap screw, one If using a two piece sleeve, force the wire ring Into Its Internal lock washer and one large Impeller washer. Make groove In the center of the sleeve. The use of a blunt screw certain that cap screw Is tightened to 18-20 foot pounds on driver may be necessary.

small bearing assembly (1 " shaft) and 40-44 foot pounds on

10. Apply coupler guard using 4 cap screws, 4 lock washers the large bearing assembly (1 ¼" shaft).

and 4 nuts.

5. Mount bearing assembly, Impeller, volute gasket and cover plate to volute. 11. Recheck all exposed nuts and cap screws for tightness.

6. Add foot support to base and bearing frame using 4 cap 12. Complete all name plate data and affix to base.

screws, 4 lock washers, 4 flat washers and 4 nuts. In some 13. Complete and return Pump l<lt Data Card to the Customer Instances, the nuts wlll be welded direct to the base cross Service Dept., ITT Bell & Gossett, 8200 N. Austin Ave., member. Morton Grove, IL 60053.

7. Mount saddle to base with 4 cap screws, 4 lock washers, 14. Affix Installation and service Instructions (P81673).

8 flat washers and 4 nuts.

15. Make certain complete unit Is properly lubricated.

Bell & Gossett IIT Industries

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EXPLODED VIEW

lyplcalView

BfAIUHG FRAME MOUNTING

NOTE: 1 1/◄" and 11/a• VOLUTES REQUIRE 4-¼• HEX HD. PIPE PLUGS.

ALL OTHERS REQUIRE 4-1/4• HEX HD. PIPE PLUGS.

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BEARING FRAME~MlilY !MPfU.El r.AP SCREW

FASTENER CHART

VOLUTE TO BASE

PUMP SIZE FASTENERS •

11 /◄AC thru 3AC Fr 1#143T thru 215T 4AO thru 4BO.

FR #143Tthru 256T

11/4AC thru SAC Fr #254T thru 266T

3E lhru SE and 68Cthru4GB All Frames

5G,6Gand6E Alf Frames

4•7'1ax 1¾ Oap Screw 4-7 /ta Washer 4-7/10 Lock Washer

4-7 /ts x 3 Cap Screw 4-7/te Washer 4-7'1s Lock Washer 4-1/2 x 2 Cap Screw 4-1/2Nut 4-½Washer 4-½ Lock Washer 4.JS/e x 2¼ Cap Screw 4-6/sNut 4-6/sWasher 4-5/a Lock Washer

COVER PLATE TO VOLUTE

A Size Pumps 8-3/e x 7/a } B Size Pumps 12-7/1s x 1 Cap Screws G and ESize Pumps 16-1/ax 1¼

BEARING FRAME TO COVER PLATE

Small Frame 4..3/s x 1 } Large Frame 8-8/a x 1 1/◄ Cap Screws

SUPPORT FOOT

AIi Sizes 4-7 '1e x 1 Cap Screw

SADDLE TO BASE

1 ¼AB thru 480 Fr#143T-256T

3E lhru 5E and 6BOlhru4GB All Frames

5G,6Gsnd6E All Frames m Industries

4-3/a x 1 Cap Screw 4-3/aNut 5.3/a Washer 4-3/s Lock Washer 4-½x 1½CapScrew 4-½Nut 8-½Washer 4-¼ Lock Washer 4-6/e x 1 ½ Cap Screw 4-5/a Nut 8-5/s Washer 4-5/e Lock Washer

MOTOR TO SADDLE

FRAME SIZE • FASTENERS

143T, 145T

1821, 184T

213T,215T

2541;256T 284T,286T.

324T,326T 364T,365T

404TS

4-5/te x 11/4 Oap Screw 4-5/teNut 8-6/te Washer 4-6/te lock Washer 4-3/e X 11/z Qap Screw 4-3/s Nut 8-3/awasher 4..3/a Lock Washer 4-3/a x 2 Cap Screw 4-3/a Nut 9.S/a Washer 4-3/a Lock Washer 4-7 /tax 2 Cap Screw 4-7/teNut 8-7 '1s Washer 4-7 '1a Lock Washer 4•½ x 2¼ Cap Screw 4·'12 Nut 8-½Wastter 4-½ Lock Washer 4-6/a x 23/t Cap Screw 4-6/aNut 8-6/sWasher 4-6/a Lock Washer i Bell & Gossett

USA

Bell & Gossett 8200 N. Austin Avenue Morton Grove, IL 60053 Phone: (847) 966-3700 Facsimile: (84n 966-9052 http!l/fhs.Jttlnd.com

INTL.

Bell & Gossett I Export Dept.

8200 N. AusUn Avenue Morton Grove, IL 60053 Phone: (847) 966·3700 Facslmfle: (84n 966-8366 Cable: BELGOSSITT

CANADA

Ffuid Products 55 Royal Road Guelph, Ontario, 0 COP't'Mlf{f 1978, 1998 avm lllDIStRfS.YiC.

PRINTEO IN U.S.A. 8-88

N1H 1T1, Canada Phone: (619) 821-1900

FB 900 Series .3/4''---1 ''

AUTOMATIC WATER

CONDITIONERS

INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL

FILL IN FOR FUTURE REFERENCE

MODEL NO:. _________ _ _

SERIAL NO: ___ _______ _

DATE INSTALLED: ----------

0 EAL ER: ___ _ _______ _

FB900 314'•1• Updaled 10/0612009

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TABLE OF CONTENTS

900 SERIES 3/4"- 1" MANUAL

Product Warranty ____ __________________ 1

General Arrangement Drawing 2

Dimension Table 3

Specification Table 4

Installation Instructions 6

Softener Tank Loading 7

Mounting Control Valve Assembly 8

Installation of Connection Piping 9

Start-Up Procedure 1 O

Calculation of Soft_eners Capacity 12

Setting the Water Meter Gallonage 13

Performing Manual Regeneration 13

Setting the Regeneration Program Timer 14

Water Softener General Operation 15

Flow Diagram 16

Wiring Diagram 20

Timer Assembly 21

----- ----- 23

---------- 25

---------- 27

---------- 28

- --------- 30

----- - - --- 31

------- --- 32

---------- 34

_FiJftbn 900 SERIES 3/4"-1" ·MANUAL

WATER TREATMENT PRODUCT WARRANTY

Fulton Boiler Works warrants all water treatment products manufactured and/or distributed by it to be free from defects in materials and workmanship for a period of one (1) year from the date of shipment. The fiberglass mineral tank(s) alone have a warranty for a period of five (5) year from the date of shipment. If within that period any products shall be proven to Fulton Boiler Works' satisfaction to be defective, those products will be replaced, or their price refunded at Fulton Boiler Works' option.

Fulton Boiler Works' obligations or nonperformance, defective, or any damage caused by its products or their use, and buyer's exclusive remedy therefore, shall be limited to product replacement or refund and shall be conditioned upon Fulton Boiler Works' receiving written notice together with a demand for such replacement or refund:

The foregoing warranty is exclusive and in lieu of all other expressed implied warranty (except of title) including but not limited to implied warranty of merchantability and fitness for particular purpose.

Fulton Boiler Works will not be subject to and disclaims the following:

1. Any other obligations or liabilities arising out of breach of contract or out of warranty.

2. Any obligations whatsoever arising from tort claims (including negligence and strict liability) or arising under other theories of law with respect to products sold or services rendered by Fulton Boiler Works or any undertakings, acts, or omissions relating thereto.

3. All consequential, incidental, and contingent damages.

Labor charges, changebacks or handling charges are excluded from Fulton Boiler Works' warranty provisions.

WATER SOFTENER GUARANTEE

Under normal operating conditions:

1. The softener effluent shall be zero soft as determined by a soap test.

2. The loss of softening resin through attrition during the first three (3) years shall not exceed 3% per year. •

3. The softening resin shall not be washed out of the system during backwash.

4 . The color and turbidity of the softener effluent shall not be greater than the incoming water.

Any mechanical equipment proving defective in workmanship or material within one year after installation or (18) months after shipment, whichever comes first, shall be r eplaced FOB factory.

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FULTON 900/950 SERIES • INSTALLATION DIMENSIONS AND SPECIFICATIONS

HElGHT WtDn-t LENGTHS BRINE DRAIN MANlFOLD SHIPPING

TUBE PIPE SIZE WEIGHT

SIZE SIZE

FB

MODEL Inches Inches Inches • lnthes • Inches • Inches Pounds

NO.

FB 150-900 52 18 38{3) 318 1/2 3/4 110

FB 300-900 48 18 42(3) 318 1/2 3/4 175

FB450•900 62 18 45(3) 3JB 1/2 3/4 235

FB 600-900 (950) 62 18 52 (3) 3/8 (1/2) 1/2 (1) 1 (1-1/2) 310

FB 900-900 (950) 75 18 56(3) 3/8 (1fl} 1/2 (1) 1 (1-1/2} 580

FB 1200-900 f950) 75 24 68(4) 3/8 (112) 1/2 (1) 1 (1-1/2) 750

FB 1500-900 f950l 75 24 72(4) 3/8 (112) 1/2 (1) 1 (1-112} 1000

FB 1800-900 (9501 72 24 78(4) 318 (1/2) • 1/2 (1) 1 (1•1/2} 1100

FB 2100-900 (950) 72 24 78 (4) 318 (1/2} 1/2 (1) 1 (1-1/2) 1250

F82400-950 82 24. 84{5) 112 1 1-1/2 1510

· F8 2700-950 82 24 84 (5) 1/2 1 1-1/2 1620

FB3000.950 82 24 84(5) 1/2 1 M/2 1730

FB4500-950 82 30 102(5) 112 1 1-1/2 2650

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• NOTE: Numbers fn ( ) ara for the 950 Senes s--f

Height iJ O.> co (Tl

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BRINE TUBJN1

BRINE TANK·

_@LLD!_

11.JTLIT

BY·PASS VALVE

{(NORMALLY Q.OSEO)

RAW WATER INLET-:: =;·;:-c:;·,' :-SOFr WATER Oun.ET

INLET ISOLATION A.I ~ Ovn.ET ISOLATION

VALVE./ II II '-VALVE

REVISIONS

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.VALVE

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~Fulton

FB 900 SERIES SOFTENER

WITH 9000 VALVE

NOTE:

All PIPING, flTT1NGS, ETC. SHOWN IN

BP.OKEN LINES ARE SUPPLIED BY OTHERS.

FB 900 SERIES SOFTENER

GENERAL ARRANGEMENT

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MODEL FB-900 150

Valve Size Inches 3/4

Capacity Maximum 15

(Kllogralns) Minimum 10

Continuous 11 ~ Service

a. Peak 15 ~ w Backwash &

~ Fast Flush 1.2 s: Brine Draw 0.31

0 & Rinse rt Brine Tank

0.25 Renn

Pins 5 Backwash

Minutes 10 en Pins 30 (9 Brine Draw z i= w &Rinse

Minutes 60 U)

..J Pins 5 w w . Fast Flush J: Minutes 10 s: z ii: Pins 5 0:: Brine Tank w Renll ~ Minutes 10 F

Return to Pins 2

Service Minutes 4

Size Dia x Height

7x44 0:

ln rfu,c w Gravel Pounds 0 z~ Subfill t~ Resin Cubic Feel 1/2 0 U)

Freeboard Inches 17

Tank Size Dia x Height 18x33 lnrh"c

Code 0 Injector

Color RED

Maximum Sall Pounds 290 :a Slorane U) Maximum 7.5 >- Sall Dosage en w Minimum 3 z Cr'.

[!) Maximum 10

Refill Time Minimum 4

Regeneration Maximum 40 per Sall Refill Minimum 100

Regeneration Gallons 40

Waste Volume

900 SERIE.S 3/4"-1" MANUAL.

SPECIFICATION TABLE

300 450 600 900 1200 1500 1600 2100

3/4 3/4 3/4 1 1 1 1 1

30 45 60 90 120 150 180 210

20 30 40 45 80 100 120 140

13 13 16 17 18 19 18 18

18 1B 21 22 23 24 23 23

2.0 3.0 3.5 5.0 6.0 8.0 12.0 12.0

0.45 1.0 1.0 1.0 1.2 1.2 1.5 1.5

0.50 1.0 1.0 1.0 1.0 2.0 2.0 2.0

5 5 5 5 5 5 5 5

10 10 10 10 10 10 10 10

30 30 30 30 30 30 30 30

60 60 60 60 60 60 60 60

5 5 5 5 5 5 5 6

10 10 10 10 10 10 10 10

5 4 5 8 10 7 8 9

10 8 10 16 20 14 16 18

2 2 2 2 2 2 2 2

4 4 4 4 4 4 4

9x40 10x54 12x52 14x65 16x65 18x65 21x62 21x62

0 0 0 30 35 40 80 80

1 1 1/2 2 3 4 5 6 7

8 17 16 21 21 24 23 18

18x33 18x40 18x40 18x40 24x40 24x40 24x50 24x50

1 3 3 3 4 3c 4c 4c

WHT YEL YEL YEL GRN YEL GRN GRN

290 320 320 270 550 500 650 600

15 22.5 30 45 60 75 90 105

(j 9 12 18 24 30 36 42

10 8 10 16 20 14 16 18

4 4 4 6 8 6 6 8

20 15 10 6 9 7 6 6

50 38 26 15 23 17 17 17

64 116 126 156 188 228 272 366

·15++&?51 ~ .u:~n ·@#¥\MAArumw

SPECIFICATION NOTES

900 SERIES 3/4"-1" MANUAL

Maximum salting is 15 pounds of salt per cubic foot of resin. This setting gives the longest time between regenerations and the highest capacity. It has an efficiency of 2,000 grains of hardness removed per pound of salt. The regeneration timer is setup for maximum salting at the factory.

Minimum salting is 6 pounds of salt per cubic foot of resin. It has an efficiency of 3,300 grains of hardness removed per pound of salt.

On continuous flow rates pressure loss does not exceed 15 psig.

On peak flow rates pressure loss does not exceed 25 psig.

Minimum operating pressure is 25 psi.

Maximum operating pressure is 120 psi.

Standard units are designed to soften unheated water within the range of 35-100°F.

Power requirements are 120 Volt, 60 Hertz, Single Phase, 2 amps non-interrupted.

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Freeboard is the distance between the surface of the resin and the top of the tank. 1 , Salt specifications are palletized or solar salt, 99% pure, containing less than 1 % insolubles. \ \ l ;

The Pinwheel Setting time intervals are factory set and user adjustable.

The 1" water meter has a capacity range of 1,550 - 26,350 gallons and a flow range of

0.7 - 40 GPM with accuracy± 5%.

The ¾" water meter has a capacity range of 625 - 10,625 gallons and a flow range of

0.25 - 15 GPM with accuracy ± 5%.

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...... Fulfon 900 SERIES 3/4"-1 '' MANUAL ••

I ! INSTALLATION INSTRUCTIONS

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GENERAL INFORMATION

1. Minimum operating pressure is 25 psi.

If pressure less than 25 psi is encountered, a pump must be installed.

Note: The control valve will not operate correctly if feeding into an atmospheric tank. A pressure control device must be added to the outlet to maintain the minimum pressure.

2. Maximum operating pressure is 120 psi.

If pressure greater then 120 psi is encountered, a pressure regulator must be installed.

3. Power requirements are shown on a voltage sticker on the motor inside cover of the control valve. You can also tell by wire color on the motor: Black wires are 115 volt. Yellow wires are 220 volt. Blue wires are 24 volt

4. Standard units are designed to soften unheated water not to exceed 100° F.

Special valve assemblies are available to handle heated water supplies exceeding 100°F.

Consult factory if applicable.

5. Each softener tank is shipped with distributor manifold and control valve preassembled.

Take care when uncrating and erecting so that no items are damaged.

6. The distributor assembly has been shipped inside the fiberglass mineral tank.

Check to make sure that there is no damage to the riser pipe, baskets, laterals, or hub prior to loading media.

LOCATE SOFTENER

1. Select a location that is accessible and near a floor drain that has adequate carrying capacity to handle the softener regeneration flow. See specification table for the flow rate.

2. Erect each the softener tanks on a concrete or other firm foundation and level.

Note: If the system is skid mounted, it will be prepiped and preloaded at the facto_ry. Skip the following instructions and go to the section "Installation of Connection Piping".

3. Position the brine tank according to the illustration and supplementary brine tank information.

Keep the brine tank as close as possible to the softener tanks.

Note: The distance between the softener and brine tanks will affect the brine injector performance, as the distance increases the injector performance decreases. This may cause an inadequate regeneration. Maximum recommended distance is 5 ft.

4. A grounded electric receptacle is required for the control valve.

••• ••• •• ••·••• :.:.::.:.'.:.::._ : .~ •.:.: :. • • • • • ~: I••• •,: •': •. •. :. • : • • • ••

==Fullon 900 SERIES .3/4"~1 '.' MANUAL ·. ·.,· ..

LOAD SOFTENER TANK

Note: If the system is skid mounted, it will be prepiped and preloaded at the factory. Skip the following instructions and go to the section of "Installation of connection piping".

1. On Models FB 150, 300, 450, and 600 the softening media has been pre-loaded at the factory.

Skip this section and go to "Mounting Control Valve Assembly".

2. Fill a tank approximately 1 /3 full of water using a hose, bucket, etc. Plug the PVC distributor manifold pipe using a plastic cap, cork, rag, etc. No gravel or resin should go into this distributor manifold pipe.

3. Verify the distributor manifold is center in the tank with the distributor resting on the bottom of the tank. Verify the riser pipe is still plugged.

Note: Reference the specification table in the front of this manual for the correct quantities of gravel and resin. These quantities are for each tank. Make sure you have the required amounts on site before you begin.

4. With care not to damage any lateral, pour in the gravel provided for each tank through the top opening in the tank and level out evenly. This will cover the distributor assembly.

Note: Wetting the gravel in the bags before loading will eliminate the normal amount of dust.

5. When gravel is loaded and leveling is completed, proceed as follows:

6. With the distributor riser pipe still plugged, add the proper amount of resin supplied for each tank through the top opening in the tank.

Caution: The softener resin is very slippery. Take care when stepping on any spilled resin.

Remove spilled resin 'from ·standing surface immediately.

7. When loading is complete, remove plastic cap, cork, or rag that was used to plug the distributor riser pipe. Be careful not to let any foreign debris fall into the pipe. The result could be damage to system.

8. Repeat instruction steps 1-7 for the second softener tank.

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900 SERIES 3/4~'-1" MANUAL

l ..

~ ·, MOUNTING CONTROL VALVE ASSEMBLY

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1. On the right side tank, verify that the distributor riser pipe is not plugged.

2. Lubricate the distributor o-ring on the bottom of the control valve with silicone.

3. Screw the control valve into top opening of tank making sure the distributor riser pipe slides easily through the distributor a-ring. Care must be taken not to 11nlck11 this a-ring as hard water leakage could result.

4. Tighten down the control valve to ensure positive o-ring seal at top of tank.

5. On the left side tank, verify that the distributor riser pipe Is not plugged on the second softener tank.

• 6. Lubricate the distributor o-ring on the bottom of the second tank adapter assembly with silicone.

7. Screw the second tank adapter assembly Into top opening of tank making sure the distributor riser pipe slides easlly through the distributor o-ring. Care must be taken not to 11nlck" this o-ring as hard water leakage could result.

8. Attach the second tank adapter assembly to the control valve.

MOUNTING WATER METER ASSEMBLY

1. Locate the electromechanical meter. The water meter· has a flow arrow stamped on it. The flow arrow on the meter should be pointing away from the control valve.

2. Attach the meter to the control valve's outlet water connection.

3. Interconnect meter cable between the control valve timer and water meter dome.

Page8

-====. C mll;On fwaJt r-\JI IJ

INSTALLATION OF CONNECTION PIPING

Note:

900 SERIES 3/4''- 1" MANUAL

0 Use thread sealing tape on all threaded piping connections.

o Install the piping conforming to federal, provincial, and local codes.

0 Unions or flanges are recommended at the control valve's inlet and outlet connections o To enhance the monitoring of the system's performance sample valves and pressure gauges can be installed at the inlet and outlet piping of the softening unit (not provided).

o If distance of drain line is over 10 ft. vertical or 25 ft. horizontal run, increase drain line one pipe size over that provided on the control valve.

0 Do not make a direct connection to the drain. Provide an air gap of at least four times the diameter of the pipe to conform to sanitation codes and to permit observation of the flow.

o It is not recommended that an overhead or a long horizontal drain run be used. The increase of backpressure will cause problems when drawing brine.

Caution: All piping must be properly supported. The tank and valve assemblies are not meant to support the connecting piping.

1. Install piping as shown on installation diagram. It is recommended that unions be installed before the inlet and outlet valves to facilitate service of unit. Be sure piping is free of thread chips and other foreign matter. The connecting piping should be the same size or larger then the service inlet and outlet of the control valve.

2. Verify that the flow arrow stamped on the drain flow controller is pointing away from the control valve. See installation diagram or valve manual for the location. Install a drain line from backwash control assembly to an appropriate drain using a minimum of elbows. Install a union near the backwash control to facilitate cleaning. Do not install a valve on the drain line. •

3. Interconnect the brine line tubing between the control valve and the brine tank. Verify that the brine line tubing is not kinked or restricted

4. Run flexible tubing (not provided) from the brine tank's over flow fitting to an appropriate, non elevated, open drain.

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. Fulfon WiM¥I 900 SERIES 3/4"-1" MANUAL j START"UP ( .i j i

1. Again, make sure all plumbing is complete and tight including drain line and brine line.

Make sure all electrical connections are complete per wiring diagrams provided.

2. Using a bucket or hose, fill brine tank with water to 2" above salt platform. Do not add salt at this time.

3. Make sure inlet and outlet isolation valves are closed. Align the Service Position Indicator with the Time of Day pointer Turn on power to the system.

Note: Start up only one (1) tank at a time.

0 0

MANUAL

REGENERATION

KNOB

4. Remove the black plastic cover from the control valve. Pull out the meter cable from the meter dome. The regeneration timer is secured to the backplate of the control valve.

The timer is hinged on the right side. Grab the upper left corner of the timer and pull towards you. The timer will swing out to the right. The backside of the timer has a program wheel with holes and pins in it. Each hole or pin represents two (2) minutes. The holes and pins control the regeneration cycle times as follows

To rrunually,wt ,yde, turn t nob doc\wb,.

~YS RE~OVE CABLE

FROM ~lrnR BEfORE

S\\1/IG~IG TIIIER OPEii.

o Step 1 (Backwash) First group of pins e Step 2 ( Brine Dr'aw/ Slow Rinse) First group of holes o Step 3 (Fast Rinse) o Step 4 (Brine Tank Refill) o Return to Service

Second group of pins

Second group of holes

Third group of pins

BRINEJHINSE

Note: Brine Draw/ Slow Rinse step is actually two events. The brine is suctioned from the brine tank until the level falls to the bottom of the brine valve. An air check in the valve will close once the brine is to low. This is the end for the Brine Draw step and should last about twenty (20) minutes. The rest of the time in Step 2 is Slow Rinse.

5. Locate the manual regeneration knob on the front side of the timer. Slightly turn the knob clockwise. The softener control valve will advance to Bacl<wash position. Be patient this will take several minutes.

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--=RJlton 900 SERIES 3/4"-1"-MANUAL

STARTRUP continued

6. Remove electrical power from unit, and then slowly open inlet water valve approximately half open. Water will begin to fill through bottom distributor into tank. When tank is full, water will begin to flow out of drain line. Slowly open inlet valve until full open. Allow water to flow from drain line for approximately 15 minutes.

Warning: Monitor this drain water flow carefully. There is a problem if you see softener resin in the drain water. Turn off inlet water immediately and then consult factory.

7. Restore electrical power to unit. Advance the control valve to Brine Draw I Slow Rinse position, using the same method as step 5. Make sure unit draws water from brine tank.

There should also be reduced flow at the drain line.

8. Advance the control valve to the Fast Rinse position. Remove electrical power to the unit.

Let water run to drain position for approximately 5 minutes or until water runs clear.

9. Restore electrical power to unit. Advance the control valve to Brine Refill position. Water should begln to refill brine tank. Allow the brine tank to refill until water in salt tank is again 2" above the salt platform. There should be no flow to drain in this valve position.

10. Advance control valve to Service position. Brine tank refill should stop. Open outlet valve and run water at the nearest cold water faucet to the water softener system for approximately 5 minutes.

11. Repeat instruction steps 1-10 for each softener tank.

brine rinse backwash lank one

12. Determine the gallons of soft water your softener can produce reference page 11.

13. Set the gallonage determined in step 12, reference page 12.

14. Consult the specification table, and then add salt to the brine tank. Use pelletized or solid sail, 99.0 - 99.8% pure salt containing less than 0.5% insoluble.

15. Use the test kit provided to check water for softness. Check the water hardness daily the first week in order to establish how often the softener should be regenerated.

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=-Fuffon 900 SERIES 3/4"-1-''=,--MANUAL

HOW TO CALCULATE SOFTENERS CAPACITY

"Batch size" is the term used for the amount of water passing through and being softened by the water softener between regenerations. This is a simple calculation provided two pieces of information are known:

• Size of the water softener in grains (gr,) (i.e. FB-600-900 has 60,000 grains capacity per tank).

• Hardness of the raw water being treated by the water softener.

BATCH SIZE EQUATION

i .I t J Grain capacity of softener divided by the grains of hardness equals batch size.

i ' i .I SAMPLE CALCULATION

' j !

i ! Assume: unit is a FB-600-900 i' •;

j ·, Assume: the hardness of the water was measured to be 20 grains

Using our equation take 60,000 / 20 = 3,000 gallons.

10% reserve capacity= 300 gallons.

3,000 gallons - 300 gallons= 2,700 gallons (batch size)

For immediate regeneration type meter control the meter setting would be at 3,000 gallons.

Commonly this value is adjusted to 90 percent of the actual value (in this example 2,700 gallons) to assure not over-running the softener.

For time delay type meters the amount of gallons is determined as in our example except an additional amount of gallons must be deducted from the actual gallons to allow soft water to be available until the softener regenerates at the selected delay time of day or night. This compensation is necessary since the meter will indicate regeneration required time prior to the set delay time.

=..Fulton 900 SERIES 3/4"-.1?'.---MANUAL

HOW TO SET THE WATER METER GALLONAGE;

Set the gallons required by lifting the gallon dial and rotating it so that the number of gallons required is aligned with the white dot on the program wheel gear. Release the gallon dial and check for firm engagement with the gear.

Note: To set meter capacity at the initial start-up, either:

" Rotate the manual regeneration knob one full revolution.

o Rotate the program wheel manually clockwise and align the white dot with the capacity arrow.

HOW TO MANUALLY REGENERATE YOUR WATER CONDITIONER AT ANY TIME

Turn the manual regeneration knob clockwise.

This slight movement of the manual regeneration knob engages the program wheel and starts the regeneration program. The manual regeneration knob will make one revolution in approximately three hours and stop in the position shown in the drawing. Even though it takes three hours for this center knob to complete one revolution, the regeneration cycle of your unit might be set only half of this time. In any event, conditioned water may be drawn after rinse water stops flowing from the water conditioner drain line.

GALLON LABEL

PROGRAM WHEEL

WHITE DOT

CAPACITY ARROW

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GALLON D IAL

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SET BUTTON

TIME OF DAY

POINTER

SERVICE

POSITIOI~

INDICATOR

MANUAL

REGENERA T IOf.J

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MA A I C .: a~o"' n u;ww lUII! 900 SERIES 3/4"-1 " MANUAL

HOW TO SET THE REGENERATION PROGRAM TIMER

The regeneration program on your water softener has been factory set. However, portions of the program may be lengthened or shortened in time to suit local conditions.

Remove the black plastic cover from the control valve. Pull out the meter cable from the meter dome. The regeneration timer is secured to the backplate of the control valve. The timer is hinged on the right side. Grab the upper left corner of the timer and pull towards you. The timer will swing out to the right. The backside of the timer has a program wheel with holes and pins in it. BRINETI\Nl<REFILL

FAST FLUS

., Step 1 (Backwash) First group of pins

0 Step 2 ( Brine Draw/ Slow Rinse) First group of holes

0 Step 3 (Fast Rinse) Second group of pins l3RINF./RINSE e Step 4 (Brine Tank Refill) Second group of holes

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BACKWASH

0 Return to Service Third group of pins

To change the regeneration program it is easer to remove the program wheel by pushing the two black tabs located in the center of the program wheel while pushing up on the program wheel.

As you look at the number side of the program wheel, starting at zero the number of the group of pins determines the length of time that your unit will b~ in Backwash. If there are six pins in this section, the time of backwash will be 12 minutes (2 minutes per pin). You must add or remove pins to change the length of this time. All the following groups of holes or pins must be adjusted to maintain their original time.

Important: Changing the time duration in any step will require a readjustment of all pins and holes for all the following steps.

The number of the group of spaces determines the length of time that your unit will be in Brine Draw I Slow Rinse. You must add or remove to the number of holes to change the length of this time. All the following groups of pins or holes must be adjusted to maintain their original time.

Use this method to adjust the time of the regeneration steps for your water softener.

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WATER SOFTENER GENERAL OPERATION

e Backwash: The cycle duration is factory set at 10 minutes for clean feed water applications. Increase time duration to 15 minutes when turbidity is present in the feed water.

e Brine Draw/Rinse: The cycle duration is factory is set at 60 minutes to assure the required amount of brine is introduced and rinsed from the resin. Increase time duration when the injector feed pressure is below 40 psi.

e Fast Flush: The cycle duration is factory set at 10 minutes to rinse chlorides from the resin prior to the softener is placed onfine. Increase time duration to 15 minutes if traces of chlorides ·are present in the service outlet water.

0 Brine Tank Refill: The cycle duration is factory set at the maximum salt to achi~ve maximum softener capacity. The published minimum salt can be programmed to reduce salt consumption by 50% and reduced softening capacity by 30%.

e Cycle End: The cycle duration is factory set at 4 minutes. Its purpose is to identify the end of regeneration and advance the softener control valve to the Standby position.

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====c ·flj0 L @&:ru on 900 SERIES 3/4"-1" MANUAL

FB 900 SERIES .,. Flow Diagram

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1 • SERVICE POSITION

Hard water enters the unit at the valve inlet, flows around the lower piston, and down through the mineral in the first tank. Conditioned water enters the center tube through the bottom distributor, flows up through the center tube, around the lower piston, through the meter, and out the valve outlet. The second mineral tank is regenerated and on standby.

2 - TANKS SWITCHING

(the meter has initiated a regeneration)

Hard water enters the unit at the valve inlet, flows around the lower piston, through the pipe leading to the second mineral tank, and down through the mineral in the second tank. Conditioned water enters the center tube of the second tank through the bottom distributor, flows up through the center tube, through the pipe leading back to the main valve, around the lower piston, through the meter, and out the valve outlet. The depleted first mineral tank is out of the flow path, and ready for regeneration .

;;::.-:..., F.ulfon 900 SERIES 3/4"~1" MANUAL

FB 900 SERIES .. Flow Diagram cont'd t.llNEMt li\1/K r. I

3 - BACKWASH

Conditioned water from the second mineral tank flows around the lower piston, around the…