Sterling Water Treatment PKLX Series Catalytic Filter System Instruction Manual

Sterling Water Treatment PKLX Series Catalytic Filter System

Product Information: PKLX Series Catalytic Filter System
The PKLX Series Catalytic Filter System is a water treatment system manufactured by Franklin Water Treatment, LLC. It is designed to provide optimum filter performance and satisfactory water quality. The system features a control valve and a catalytic filter that effectively removes impurities from the water supply.

Specifications

• Manufacturer: Franklin Water Treatment, LLC
• Model: PKLX Series
• Address: 12630 US Highway 33 N Churubusco, IN 46723
• Phone: 260-693-1972
• Fax: 260-693-0602

Component Parts

• Control Valve
• Catalytic Filter
• Installation Fittings

Ten-Year Limited Warranty
The PKLX Series Catalytic Filter System comes with a ten-year limited warranty. Please refer to the user manual for detailed warranty terms and conditions.

Product Usage Instructions
Pre-installation Instructions

1. Ensure that no water is being drawn in the house.
2. Open the spigot nearest the pressure tank.
3. When the well pump starts, close the spigot and measure the time (in seconds) it takes to refill the pressure tank. This is the Cycle Time.
4. Using a container of known volume, draw water from the pressure tank and measure how many gallons are needed until the pump turns back on. This is the drawdown.
5. Calculate the pumping rate by dividing the drawdown by the Cycle Time and multiplying by 60.

Location Considerations
To ensure optimal performance, consider the following factors When selecting the location for installation:

1. The PKLX must be installed after the pressure tank in a private well system.
2. The system should be installed close to an adequate floor or laundry drain capable of handling the backwash cycle volume and flow rate.
3. An air gap should be provided between the PKLX drain line and the plumbing drain.
4. Water pressure must be within the range of 25 – 100 psi.
5. The system must not be exposed to freezing temperatures.
6. The control valve requires 115/120 V, 60 Hz electricity from an outlet that is not wired to a switch.
7. Do not install a cartridge-type filter prior to the PKLX. Any cartridge or in-line filter may be installed after the PKLX system.
8. Appliances requiring extended periods of continuous or high-flow water use should bypass the filter.

General Installation
Refer to Figure 1 for a typical installation diagram.

Bypass Valve

1. Normal Operation Position: The inlet and outlet handles should point in the direction of flow indicated by the engraved arrows on the control valve. This position allows water to flow through the control valve for normal operation of the filter.
2. Bypass Position: The inlet and outlet handles should point to the center of the bypass. This position isolates the system from the water pressure in the plumbing system, supplying untreated water to the building.

For more detailed installation instructions, operation guidelines, maintenance tips, and troubleshooting information, please refer to the complete user manual provided by Franklin Water Treatment, LLC.

Pre-installatio n Instructions

Description of the iron filtration system
The PKLX catalytic filtration system includes a single filtration tank with a pocket of air and a backwashing control valve. Incoming water flows into the control valve and is directed into the filtration tank. Exposure to the air in this tank will start oxidizing the iron which is then trapped by the media. The iron/sulfur-free water then returns to the control valve where it is directed into the service lines. Periodically the control valve will go through a backwash cycle. This cycle will typically begin at 1:00 A.M. flushing the accumulated iron to the drain. Part of this backwashing process includes an air draw cycle which will replenish the pocket of air in the filter tank and prepare the unit for the next period of service.

Water Quality
While the PKLX filter will perform under a variety of water qualities there are a few things that need to be considered to ensure satisfactory performance. The water should be tested to determine the concentration or levels of the items listed below. pH – A measurement of the acidity of the water. pH is reported on a scale from 0 to 14. Neutral water has a pH of 7.0, lower values indicate acidic water. The PKLX catalytic filter performs best when the pH is 7.0, or higher. The catalytic media is typically able to elevate the pH of the water to the level needed for oxidation to occur. Iron – A naturally occurring metallic element. Iron concentrations in excess of 0.3 milligrams/liter (mg/l) combine with oxygen causing orange or red (rust) stains on plumbing fixtures. Iron naturally exists in some water sources in either clear water (ferrous) state, red water (ferric) state or bacterial form. The PKLX catalytic filter can reduce any of these forms of iron.

Manganese – A naturally occurring metallic element. Manganese concentrations as low as 0.05 milligrams/liter (mg/l) can combine with oxygen to cause dark brown or black staining on fixtures. Additionally, manganese can cause an odor in the water similar to a “rotten egg” smell. The PKLX catalytic filter reduces manganese as well as iron. Manganese oxidation requires the pH of the water to be elevated to 8.2 or higher. Tannin A naturally occurring humic acid. Tannin is an acid caused by water passing through decaying vegetation. Coffee and Tea are prime examples of tannin in water. As hot water passes over the coffee beans or tea leaves, the tannin is extracted causing color and flavor in the water. Tannin concentrations as low as 0.3 milligrams per liter can cause a yellow discoloration in the water and may interfere with the KLX2 filter’s long-term ability to function properly as the media becomes coated with the tannic acid.

Hydrogen Sulfide – A naturally occurring gas. Hydrogen sulfide, more commonly referred to as sulfur gas, causes a distinct odor similar to “rotten eggs.” Due to its gaseous nature, hydrogen sulfide must be tested at the well site within 1 minute of drawing the sample. If a water sample has been sitting for a while the sulfur gas will dissipate and cause the hydrogen sulfide test to be lower than the actual concentration. If sulfur is present, the filter should be set to backwash more frequently to prevent the gas from building up.

Pre-installation Instructions (cont.)

Water Supply
This filter will function properly when the water supply is furnished by a jet pump, submersible pump, variable speed (constant pressure) pump or community water supply. As with all other filter systems, however, it is imperative that the well pump provides enough flow rate for the filter to adequately backwash. To ensure sufficient backwash flow rate, the following pumping rate test should be performed prior to installing the PKLX. The backwash flow rate required may vary from the installed DLFC depending on the media used with the filter.

1. Make certain no water is being drawn in the house.
2. Open the spigot nearest the pressure tank.
3. When the well pump starts, close the spigot and measure the time (in seconds) to refill the pressure tank (the well pump turns back off). This is Cycle Time.
4. Using a container of known volume, draw water from the pressure tank and measure how many gallons until the pump turns back on again. This is a drawdown.
5.  Calculate the pumping rate by dividing the drawdown by cycle time and multiplying by 60.

Location Considerations
The proper location to install the PKLX will ensure optimum filter performance and satisfactory water quality. The following factors should be considered in selecting the location of this system.

1. The PKLX must be installed after the pressure tank (private well system only).
2. The system should be installed as close as possible (preferably within 15’) to an adequate floor or laundry drain capable of handling the backwash cycle volume and flow rate (refer to unit specifications). An air gap should be provided between the PKLX drain line and the plumbing drain.
3. All water conditioning equipment should be installed at least 10’ prior to the water heater. Water temperatures exceeding 100°F can damage the internal components of the control valve and filter tank. An expansion tank may need to be installed in the line to the water heater to allow for thermal expansion and comply with local plumbing codes.
4. Water pressure must not exceed the range of 25 – 100 psi.
5. The system must not be subject to freezing temperatures.
6. The control valve requires 115/120 V, 60 Hz electricity from an outlet that is not wired to a switch.
7. Never install a cartridge-type filter prior to the PKLX. Any cartridge or in-line filter (if desired) may be installed after the PKLX system. This will prevent restricting the water flow and pressure available for backwash.
8. Appliances requiring extended periods of continuous or high-flow water use (i.e. geothermal heat pumps, swimming pools, lawn irrigation, outside hose bibs, etc.) should bypass the filter.

General Installation

GENERAL INSTALLATION & SERVICE WARNINGS
The water conditioner is not designed to support the weight of plumbing. Do not use Vaseline, oils, other hydrocarbon lubricants, or spray silicone anywhere. A silicone lubricant may be used on black “O” Rings. This will allow ease of installation and decrease the chance of rolling from the bypass and tank connections. Avoid any type of lubricant, including silicone, on red or clear lip seals. Do not use pipe dope or other sealants on threads. Teflon® tape may be used as required. Teflon® tape is not used on any connection where “O” Ring seals are used The nuts and caps are designed to be unscrewed or tightened by hand or with the special plastic Service Wrench, (CV3193, not included). If necessary, pliers can be used to unscrew the nut or cap. Do not use a pipe wrench to tighten nuts or caps. Do not place screwdriver in slots on caps and/or tap with a hammer.

NOTE : If the plumbing system is used as the ground leg of the electric supply, continuity should be maintained by installing ground straps around any non-conductive plastic piping or bypass used in the installation. Make sure the filter is not installed backward. The filter will not function properly if installed backwards and filter media may be forced into the service lines. Arrows molded into the valve body and red handles of the bypass indicate the direction of flow. The PKLX has a check valve (OV32) installed in the inlet of the control valve. This check valve will prevent hot water expansion in the plumbing. An expansion tank must be used on the water heater supply line to allow for thermal expansion. All local plumbing codes must be followed

Bypass Valve

The bypass valve is used to isolate the control valve from the plumbing system’s water pressure in order to perform control valve repairs or maintenance. The 1″ full-flow bypass valve incorporates four positions including a diagnostic position that allows a service technician to have pressure to test a system while providing untreated bypass water to the building. Be sure to install a bypass valve onto the main control valve, before beginning plumbing
or make provisions in the plumbing system for a bypass. The bypass body and rotors are glass-filled Noryl® and the nuts and caps are glass-filled polypropylene. All seals are self-lubricating EPDM to help prevent valve seizing after long periods of non-use. Internal “O” Rings can easily be replaced if service is required. The bypass consists of two interchangeable plug valves that are operated independently by red arrow-shaped handles. The handles identify the direction of flow. The plug valves enable the bypass valve to operate in four positions.

1. Normal Operation Position: The inlet and outlet handles point in the direction of flow indicated by the engraved arrows on the control valve. Water flows through the control valve for normal operation of a water softener or filter. During the regeneration cycle this position provides regeneration water to the unit, while also providing untreated water to the distribution system (Fig. 2).

2. Bypass Position: The inlet and outlet handles point to the center of the bypass. The system is isolated from the water pressure in the plumbing system. Untreated water is supplied to the building (Fig. 3).

3. Diagnostic Position: The inlet handle points toward the control valve and the outlet handle points to the center of the bypass valve. Untreated supply water is allowed to flow to the system and to the building, while not allowing water to exit from the system to the building (Fig. 4) . This allows the service technician to draw brine and perform other tests without the test water going to the building.
   NOTE: The system must be run through a rinse cycle before returning the bypass valve to the normal position.

4. Shut-Off Position: The inlet handle points to the center of the bypass valve and the outlet handle points away from the control valve. The water is shut off to the building. The water treatment system will depressurize upon opening a tap in the building. Negative pressure in the building combined with the softener being in regeneration could cause a siphoning of brine into the building. If water is available on the outlet side of the softener it is an indication of water bypassing the system (Fig. 5)

Installation Instructions

STEP 1: Unpack the filter unit, making sure to remove the entire contents of the shipping container prior to disposal.
STEP 2: If the filter already has the Katalox media loaded, skip to STEP 6. Otherwise, with the filter unit in the upright position, remove the control valve from the mineral tank being careful to not pull the distributor out of the gravel at the bottom of the tank
STEP 3: Cover the top of the distributor tube with the included red cap. Using the included blue media funnel, pour filter media into the mineral tank on top of the gravel underbed. 14” of space MUST be left empty at the top of the mineral tank to allow for media bed expansion during backwash and to prevent filter media from being discharged through the drain line.
STEP 4: Use a garden hose or bucket to fill the media tank with water.
STEP 5: Clean mineral tank threads to remove any filter media. Remove the red cap from the distributor tube and reinstall the control valve by threading it securely onto the mineral tank. (O-ring seal: HAND TIGHTEN ONLY!)
STEP 6: Shut off all water at the main supply. On the private well system, turn off the power to pump and drain the pressure tank. Make certain pressure is relieved from the complete system by opening nearest faucet to drain system. SHUT OFF FUEL / ELECTRICAL SUPPLY TO THE WATER HEATER.

STEP 7: Plumb the water supply line to the unit’s bypass valve inlet, located at the right rear as you face the unit. There are a variety of installation fittings available. They are listed under Installation Fitting Assemblies, pages 23-25. When assembling the installation fitting package (inlet and outlet), connect the fitting to the plumbing system first and then attach the nut, split ring, and “O” Ring. Heat from soldering or solvent cements may damage the nut, split ring, or “O” Ring. Solder joints should be cool and solvent cements should be set before installing the nut, split ring, and “O” Ring. Avoid getting solder flux, primer, and solvent cement on any part of the “O” Rings, split rings, bypass valve, or control valve. If the building’s electrical system is grounded to the plumbing, install a copper grounding strap from the inlet to the outlet pipe. Plumbing must be done in accordance with all applicable local codes. MAKE CERTAIN WATER ENTERS THROUGH INLET AND DISCHARGES THROUGH OUTLET.

STEP 8: Apply thread tape to DLFC Assembly. Remove the drain line flow control (DLFC) retainer clip (Figure 6, Page 7) and remove the DLFC assembly from the valve body, (Figure 6, Page 7). Apply thread tape to threads. Slide the drain fitting compression nut onto the provided drain tubing and place the tube insert inside the end of the tubing. Insert the tubing end with insert into drain elbow and tighten the compression nut onto the thread-taped elbow. Reinsert the DLFC assembly into the valve body, making certain it is FULLY inserted before replacing the retaining clip.
STEP 9: Install drain line. Use the provided ½” I.D. polyethylene tubing (DO NOT USE FLEXIBLE VINYL TUBING!) to run drain line from control valve DLFC fitting (Figure 6, Page 7) to floor drain or sump pit capable of handling the backwash rate of the filter (refer to specifications and flow rate on page 17) or discard the compression fitting and use the ¾” NPT fitting to connect a rigid pipe drain line . If the backwash flow rate is greater than 7.5 gpm, use the existing NPT connector with a rigid drain line. There must be an air gap at the end of the drain line to prevent the siphoning of wastewater. The length of the drain line should be 15’ or less.

AVOID OVERHEAD DRAINS
STEP 10: With the bypass valve handles in the bypass position (Figure 3, Page 5), turn on water supply. Turn the inlet bypass valve handle to the diagnostic position (Figure 4, Page 5) and allow the filter to pressurize. NOTE: the INLET and OUTLET knobs turn clockwise to close the port to the filter and counter-clockwise to open the port to the filter. Check for leaks and correct as needed. Return the inlet bypass valve handle to the bypass position.
STEP 11: Program control valve. Plug the transformer of the control valve into an uninterrupted electrical outlet (not wired to a switch) and use the buttons on the front of the control valve to adjust the initial settings.

SET THE TIME OF DAY

• Press the “CLOCK” button

• The upper left of the display will show “TIME SET HOUR”

• The hour will flash

•  Press the “UP” or “DOWN” buttons (the triangle pointing up or down) until the correct combination of hour and “AM” or “PM” is reached to match the current time.

• Press the “NEXT” button

• The upper left of the display will show “TIME SET MINUTES”

• The minutes will flash Press the “UP” or “DOWN” buttons until the minutes match the current time.

• Press the “NEXT” button to return to the main display

• Enter Programming: Press the “NEXT” and “UP” (triangle pointing up) buttons simultaneously for 3 seconds.

• Days Between Regeneration:

• The upper left of the display will show “DAYS BETWEEN REGEN SET”

•  A number will flash (default 3)

•  Using the “UP” or “DOWN” (triangle pointing up or down) buttons, set the number of days (default 3) between regenerations.
  NOTE : More frequent regeneration may be required depending on the quality of the water.

•  Regeneration Time: Press the “NEXT” button

•  The upper left of the display will show “REGEN TIME HOUR SET”

•  The hour will flash

• Regeneration Hour: Using the “UP” or “DOWN” buttons, set the combination of hour of day and “AM” or “PM”. Make sure the filter is not regenerating at the same time as any other water treatment equipment.

• Press the “NEXT” button

• The upper left of the display will show “REGEN TIME MINUTES SET”

• The minutes will flash

• Regeneration Minutes: Using the “UP” or “DOWN” buttons, set the minutes portion of the time when regeneration should occur.

• Exit Programming: Press the “NEXT” button to return to the main display

STEP 12 : Initiate Manual Regeneration (Backwash Cycle): With the bypass valve in the bypass position, press and hold the “REGEN” button for 3 seconds or until the word “BACKWASH” appears in the upper left of the display. The drive motor will run briefly, and a countdown timer will appear in the lower right of the display. There will be an audible release of pressure to the drain.
STEP 13: Unplug the transformer from the electrical outlet to keep the PKLX in backwash for an extended time to purge any air and remove media “fines” (very small particles of media).
STEP 14: Slowly turn the INLET knob of the bypass, counterclockwise, to a point approximately 1/3 of the way between the “Bypass” and “Service” positions (Figure 2, Page 5) or until the remaining air is released from the tank.
STEP 15: Once the air is purged, gradually turn the INLET knob of the bypass valve counterclockwise until it is fully in the “Service” position (Figure 2, Page 5). Then turn the OUTLET knob of the bypass valve counterclockwise until it is fully in the “Service” position (Figure 2, Page 5). and leave the control valve in the “Backwash” position for at least 10 minutes or until water flowing from the drain line runs clear; whichever is longer
STEP 16: Regenerate Draw Cycle: Plug the transformer into the electrical outlet. Press the “REGEN” button to advance the control valve to the “REGENERANT DRAW DN” cycle. Another count-down timer will appear in the time- of-day position, and “REGENERANT DRAW DN” will be shown in the upper part the display.
STEP 17: Complete Manual Regeneration: Allow the regeneration to complete and the filter will return to service mode automatically.
STEP 18: TURN ON FUEL / ELECTRICAL SUPPLY TO WATER HEATER.

General Operation

USER DISPLAYS
When the system is operating, one of several displays may be shown. Pressing NEXT will alternate between the displays. One of the displays is the current time of day. The second display shows days to a regen/gallons remaining (depending on how it is programmed). Days To A Regen is the number of days left before the system goes through a regeneration cycle. Capacity remaining is the number of gallons that will be treated before the system goes through a regeneration cycle. The third display is the current flow in gal/min. The user can scroll between the displays as desired by pushing NEXT or the display will scroll automatically. When water is being treated (i.e. water is flowing through the system) the word “GPM” flashes on the left side of the display when other than the flow rate is displayed. User screens will continuously scroll, switching views every 3 seconds. If the screens are manually scrolled, this screen will remain constant for 5 minutes then continue to scroll. The conditional screens will take precedence over the scrolling and the conditional conditions will apply. To manually reduce capacity, press the down button while capacity remaining or days to a regen is displayed

MANUAL REGENERATION
Sometimes there is a need to regenerate the system sooner than when the system calls for it, usually referred to as manual regeneration. There may be a period of heavy water usage because of guests or a heavy laundry day. To initiate a manual regeneration at the preset delayed regeneration time, press and release “REGEN”. The words “REGEN TODAY” will flash in the left corner of the display as it scrolls through displays to indicate that the system will regenerate at the preset delayed regeneration time. If you press the “REGEN” button in error, pressing the button again will cancel the request. To initiate a manual regeneration immediately, press and hold the “REGEN” button for five seconds. The system will begin to regenerate immediately. The request cannot be canceled. You must cycle all the way through the cycles to make it stop. PLEASE NOTE: This will reset the meter. Note: If the salt tank does not contain salt, fill it with salt and wait at least two hours before regenerating. If two regenerations are desired within 24 24-hour periods, press /release the REGEN button. REGEN TODAY will flash on the screen. Press and hold the REGEN button until the valve initiates an immediate regeneration.

Maintenance

1. Katalox Light media should be replaced when sulfur or iron reappears in the treated water and backwashing does not improve the water quality or if excessive pressure loss is experienced.

2. Verify the unit draws air during the REGENERANT DRAW cycle at least every 12 months. Clean or replace the air check valve (OV15HT) and/or the injector (CV3010-1I) and/or injector screen (CV3177-01), if needed.
   TO REBEL MEDIA

3. Pressure must be relieved on the system by placing the Bypass Valve in the “Bypass” position (Figure 3, Page 5) and initiating a manual regeneration (section 3, page 10).

4. Unplug the Control Valve from the electrical outlet to prevent it from advancing automatically.

5. Disconnect the Control Valve from the Bypass Valve.

6. Disconnect the Drain Line from the Control Valve

7. Unscrew the Control Valve from the Mineral Tank. Remove the distributor.

8. Siphon water from Mineral Tank. Remove existing media and gravel.

9. Rinse the Mineral Tank and replace the distributor, making certain that the distributor basket sits in the center of the tank bottom.

10. Cover the top of the distributor tube to prevent media from entering the tube during filling. Using a funnel, pour filter media into the mineral tank. Begin loading the tank with the gravel under bed. Filling the Mineral Tank 1/3 with water before loading gravel will cushion the fall and ensure even distribution of the gravel and media. 14” of space MUST be left empty at the top of the mineral tank to allow for media bed expansion during backwash and to prevent filter media from being discharged through the drain line.

11. Use a garden hose or bucket to fill the media tank with water.

12. Clean mineral tank threads to remove any filter media. Uncover the distributor tube and reinstall the control valve by threading it securely onto the mineral tank. O-ring seal; HAND TIGHTEN ONLY!

13.  Attach bypass valve to control valve body.

14.  Reattach Drain Line to Control Valve (Figure 6, Page 7).

15.  Gradually turn the INLET side knob of the bypass valve counterclockwise not more than ½ way (45 degrees) to the “Service” position (Figure 2, Page 5) allowing the unit to pressurize slowly. Check for leaks and correct as needed. Any air trapped in the media bed should begin purging to the drain and water should begin flowing to the drain.

16.  Once the air is purged, gradually turn the INLET knob of the bypass valve counterclockwise until it is fully in the “Service” position (Figure 2, Page 5). Then turn the OUTLET knob of the bypass valve counter-clockwise until it is fully in the “Service” position (Figure 2, Page 5). and leave the control valve in the “Backwash” position for at least 10 minutes or until water flowing from the drain line runs clear; whichever is longer.

17. Plug the transformer into the electrical outlet. Allow the air draw and rinse cycles to complete and the filter will return to service mode automatically

Troubleshooting

Excessive pressure drop through filter

|

A)               Filter not

backwashing

B)               Filter not

backwashing frequently enough for water condition

C)              Filter bed loaded with sand

D)              “Cementing” or “Channeling”

E)               Drain Line restricted

F)               Control Valve plugged with debris

| 1)                Check if display is blank, see “Blank Display” section of Page 14.

2)                Check if display has an error message, see “Error Code” section of Page 16.

3)                Verify drive motor is connected to circuit board connector J1 (labeled “MOTOR”) and is not faulty

4)                Ensure uninterrupted power supply

5)                Increase Backwash frequency

6)                Verify sediment being removed is less dense than the filter media and install a “Spin-Down” type sediment filter ahead of the PKXL to remove well sand

7)                Verify adequate pumping rate for backwash

8)                Probe media bed to check for “Cementing”

9)                Check drain line for restriction: frozen, plugged, kinked, exceeds 15’, overhead installation, flexible drain line, drain line diameter too small

10)        Disassemble and clean control valve

Contaminant not being properly removed

| A)               Leaking bypass valve

B)               Internal valve leak

C)              Distributor tube not seated properly in control valve

D)              Water usage flow rate exceeds filter specifications

| 1)                Verify bypass valve is in service position

2)                Replace piston and seal assemblies

3)                Verify distributor tube seated securely in control valve body

4)                Verify actual water usage flow rates against system specifications

5)                Increase length of backwash and rinse cycles

Media raises pH too high

| A)               Filter is brand new or newly re-bedded

B)               Wrong media used

| 1)                Give the unit time for the pH to stabilize

2)                Re-bed the unit with a less aggressive media

Media fails to raise pH sufficiently

|

A)               Water usage flow rate is too high to provide adequate contact time

B)               Media bed is “Cemented” or “Channeled”

| 1)                Verify actual water usage flow rates against system specifications

2)                Verify adequate pumping rate for backwash

3)                Check drain line for restriction: frozen, plugged, kinked, exceeds 15’, overhead installation, flexible drain line, drain line diameter too small

4)                Re-bed with a more aggressive media

Filter fails to remove iron

|

A)               pH too low (< 7)

B)               Insufficient air head

C)              Iron level or demand flow too high

| 1)                Add MpH Adder to filter tank or install soda ash injection system before iron filter

2)                Install/replace inlet check valve, replace air check valve and/or injector, replace seals & spacers

3)                Plumb a second unit in parallel

Troubleshooting (cont.)|
---|---
 |
PROBLEM| CAUSES| SOLUTIONS|

Loss of media to drain

| A)                   Air in system

B)               Insufficient soak time before first backwash after installing media

| 1)                Ensure well system has proper air elimination control

2)                Check media level and adjust if necessary

|

Media in service lines

| A)               Unit is installed backwards

B)               Distributor basket is broken

C)              Insufficient gravel under bed

| 1)                Re-plumb the water lines so that the supply side of the line is connected to the inlet of the bypass and the service side is connected to the outlet.

2)                Replace distributor.

3)                Add gravel to tank, manually backwash

|
Howling or whistling noise during regeneration| A) Inadequate drain

line diameter or drain line restricted

|

1. Reconfigure or replace drain line

|

Continuous flow of water to drain

| A)               Loss of electrical power during regeneration

B)               Debris in control valve

C)              Internal leak in control valve

|

1)                Ensure electrical outlet is functioning

2)                Disassemble and clean control valve

3)                Replace seals and/or piston

|

Filter backwashes at wrong time of day

| A)               Clock is not set properly

B)               Power outage

C)              Incorrect control valve programming

|

1)                Reset the clock (page 7)

2)                Verify control valve programming (page 8)

|

Display is blank

|

A)               Control valve circuit board needs reset

B)               Transformer is unpowered, unplugged or defective

C)              Defective circuit board

| 1)                Hold “NEXT” and “REGEN” buttons for 3 seconds

2)                Remove battery, unplug power for 5 seconds, plug back in, replace dead battery.

3)                Verify transformer is plugged into an electrical outlet that has power and transformer cable (black, 4 pins) is plugged into control valve connector J4 (labeled “POWER”)

4)                With transformer plugged into electrical outlet, use a volt meter to test the 2 outer pins (furthest left and furthest right) of connector J4 on the control valve circuit board. Should be approximately 15 volts DC. Replace transformer if defective.

5)                Replace circuit board if needed

|
ERROR CODE:| CAUSES| SOLUTIONS
---|---|---

1001 – unable to sense motor movement

| A)               Drive motor not inserted fully to engage pinion or is defective

B)               Circuit board not properly snapped into drive bracket

C)              Center reduction gear reflector dirty

| 1)                Re-insert motor, check for broken wires, verify motor plugged into connector J1 (labeled “MOTOR”) on control valve circuit board and reset control valve (hold “NEXT” and “REGEN” buttons for 3 seconds)

2)                Re-seat circuit board into drive bracket and reset control valve

3)                Clean reduction gear reflectors (page 20)

1002 – unexpected motor stall

|

A)               Obstruction in control valve

B)               Main drive gear too tight

C)              Improper voltage delivered to circuit board

| 1)                Remove piston and seal assemblies for inspection and repair or replacement and reset control valve (hold “NEXT” and “REGEN” buttons for 3 seconds)

2)                Loosen main drive gear and reset control valve

3)                Verify proper voltage is being supplied to circuit board (see Solution 4 under “Display is Blank” section, page 14)

1003 – motor ran too long, cannot find next cycle position

|

A)               Motor failure during regeneration

B)               Obstruction in control valve

C)              Drive bracket not snapped in place properly

| 1)                Re-insert motor, check for broken wires, verify motor plugged into connector J1 (labeled “MOTOR”) on control valve circuit board and reset control valve (hold “NEXT” and “REGEN” buttons for 3 seconds)

2)                Remove piston and seal assemblies for inspection and repair or replacement and reset control valve

3)                Re-seat drive bracket assembly and reset control valve

1004 – motor ran too long, timed out trying to reach home position

| A)               Drive bracket not snapped in place properly

B)               Center reduction gear reflector dirty

|

1)                Re-seat drive bracket assembly and reset control valve (hold “NEXT” and “REGEN” buttons for 3 seconds)

2)                Clean reduction gear reflectors (page 20)

1006 – MAV/SEPS/ NHBP/AUX MAV

motor ran too long,looking for park position

| A)               Control valve not programmed for ALT oFF

B)               Obstruction in control valve

| 1)                Enter cycle programming level and verify second parameter is set to ALT oFF

2)                Remove piston and seal assemblies for inspection and repair or replacement and reset control valve (hold “NEXT” and

“REGEN” buttons for 3 seconds)

1007 – MAV/SEPS/ NHBP/AUX MAV

motor ran too short looking for park position

| A)               Control valve not programmed for ALT oFF

B)               Obstruction in control valve

| 1)                Enter cycle programming level and verify second parameter is set to ALT oFF

2)                Remove piston and seal assemblies for inspection and repair or replacement and

reset control valve (hold “NEXT” and “REGEN” buttons for 3 seconds)

SPECIFICATIONS

Description| PKLX- 1054| PKLX- 1248| PKLX- 1354| PKLX- 1665
---|---|---|---|---
Filter Media Volume, cu. ft.| 1.0| 1.5| 2.0| 3.0
Gravel Underbed, lbs.| 20| 25| 30| 50
Operating Flow Rate, gpm|  |  |  |
Continuous

@ 5 gpm/ft2 of media surface area

| 3| 4| 5| 7
Service

@ 10 gpm/ft2 of media surface area

| 5| 8| 9| 14
Peak

@ 18 gpm/ft2 of media surface area

| 10| 14| 17| 25
Backwash

@ 15 gpm/ft2 of media surface area

| 9| 11| 13| 20
Water Usage|  |  |  |
Gallons

(Gallons at higher BW flow)

| 158| 190| 222| 334
Service Pipe Size, in.|  |  |  |
Standard| 1| 1| 1| 1
Tank Diameter x Height, in.| 10 x 54| 12 x 48| 13 x 54| 16 x 65
Minimum Space Required, in.|  |  |  |
Width| 11| 13| 14| 17
Depth| 16| 16| 17| 18
Height| 66| 60| 66| 77
Approximate Ship Wt., lbs.| 134| 167| 205| 303
(Media Not Included)|  |  |  |

Factory default settings: Filtering type, 8-minute backwash, 14-minute regenerate draw, 8-minute rinse, 3 days between regenerations. All models include: CV3007 – 1” MNPT elbow adapters and QFNCR4-2 – ¾” compression fittings for PEX, CPVC and copper

Component Parts Breakdown

Component Parts List

A

| PKLX-1054-VLV-L-BP| Control valve, cover, 9.0 GPM DLFC, less bypass for model PKLX-1054
PKLX-1248-VLV-L-BP| Control valve, cover, 11.0 GPM DLFC, less bypass for model PKLX-1248
PKLX-1354-VLV-L-BP| Control valve, cover, 13.0 GPM DLFC, less bypass for model PKLX-1354
PKLX-1665-VLV-L-BP| Control valve, cover, 20.0 GPM DLFC, less bypass for model PKLX-1665

B

| D100S- 48| Distributor tube, 1″ x 48″ for models PKLX-1248
D100S- 54| Distributor tube, 1″ x 54″ for models PKLX-1054, PKLX-1354
D100S- 65| Distributor tube, 1″ x 65″ for model PKLX-1665

C

| MTP1054N| 10 x 54 mineral tank, natural, base, 2.5″ top opening for model PKLX-1054
MTP1248N| 12 x 48 mineral tank, natural, base, 2.5″ top opening for model PKLX-1248
MTP1354N| 13 x 54 mineral tank, natural, base, 2.5″ top opening for model PKLX-1354
MTP1665N| 16 x 65 mineral tank, natural, base, 4.0″ top opening for model PKLX-1665 (Requires C5148212 tank bushing adapter for 2.5” valve thread)
D| K05P| KataloxLight, 0.50 cu. ft. pail

E

| QC20| 1/4″ x 1/8″ Gravel, 20 lb pail for model PKLX-1054
qty 1.25 – QC20| 1/4″ x 1/8″ Gravel, 20 lb Pail for model PKLX-1248
qty 1.5 – QC20| 1/4″ x 1/8″ Gravel, 20 lb Pail for model PKLX-1354
qty 1 – QC50| 1/4″ x 1/8″ Gravel, 50 lb Bag for model PKLX-1665
F| CV3006| Bypass valve, less fittings

Control Valve Breakdown

Control Valve Parts List

PKP10TS8BULK

| Compr. nut, ¾” FNPT, for drain elbow (not used with CV3008-05)

Insert, for 5/8” OD poly tube (not used with CV3008-05)

22

Not Shown

| CV3158-02 CV3008-05| Elbow, Drain, ¾” Male

1” NPT Straight Drain Fitting less DLFC for 11+ gpm BW flow rate

23| CV3159-01| Retainer, Drain Line Flow Control

24

| CV3162-090

*CV3190-110

*CV3190-130

*CV3190-200

| Flow Control Washer, 9.0 GPM (PKLX-1054)

*Flow Control Washer, 11.0 GPM (PKLX-1248)

*Flow Control Washer, 13.0 GPM (PKLX-1354)

*Flow Control Washer, 20.0 GPM (PKLX-1665)

• requires 1” drain housing CV3008-05

25| 6SA6| Stem Adapter
26| 98755K12| Air Screen
Not Shown| OV32| Cartridge Check Valve, Control Valve Inlet

Installation Fitting

CV3007

| 1″ PVC male NPT elbow assy|

2

|  | CV3007-01| 3/4″ & 1″ PVC solvent elbow assy| 2
1| CV3151| Nut, 1″ quick connect| 2| 1| CV3151| Nut, 1″ quick connect| 2
2| CV3150| Split ring| 2| 2| CV3150| Split ring| 2
3| CV3105| O-ring 215| 2| 3| CV3105| O-ring 215| 2
4| CV3149| Fitting| 2| 4| CV3189| Fitting| 2

CV3007-03

| 3/4″ brass sweat assembly|

2

1| CV3151| Nut, 1″ quick connect| 2| 1| CV3151| Nut, 1″ quick connect| 2
2| CV3150| Split ring| 2| 2| CV3150| Split ring| 2
3| CV3105| O-ring 215| 2| 3| CV3105| O-ring 215| 2
4| CV3188| Fitting| 2| 4| CV3188-01| Fitting| 2

CV3007-12

| 3/4″ brass shark bite assembly|

2

|  | CV3007-13| 1″ brass shark bite assembly| 2
1| CV3151| Nut, 1″ quick connect| 2| 1| CV3151| Nut, 1″ quick connect| 2
2| CV3150| Split ring| 2| 2| CV3150| Split ring| 2
3| CV3105| O-ring 215| 2| 3| CV3105| O-ring 215| 2
4| CV3628| Fitting| 2| 4| CV3629| Fitting| 2

1-1/4″ PLASTIC MALE NPT

Ref| Part #| Description| Qty
 | CV3007-04| 1-1/4″ plastic male NPT assembly| 2
1| CV3151| Nut, 1″ quick connect| 2
2| CV3150| Split ring| 2
3| CV3105| O-ring 215| 2
4| CV3317| Fitting| 2

Installation Fitting Assemblies

3/4″ QUICK CONNECT

Ref| Part #| Description| Qty
K| QFNCR4| 3/4″ QUICK CONNECT| 1*

SERVICE WRENCH – CV3193
Although no tools are necessary to assemble or disassemble the valve, the Service Wrench, (shown in various positions on the valve) is available to aid in assembly or disassembly.

TEN-YEAR LIMITED WARRANTY

WARRANTY – Franklin Water Treatment, LLC warrants this water conditioner against any defects that are due to faulty material or workmanship during the warranty period. This warranty does not include damage to the product resulting from accident, neglect, misuse, misapplication, alteration, installation, or operation contrary to printed instructions, or damage caused by freezing, fire, flood, or Acts of God. From the original date of consumer purchase, we will repair or replace, at our discretion, any part found to be defective within the warranty period described below. The purchaser is responsible for any shipping costs to our facility and any local labor charges.

• One year on the entire water conditioner
• Five years on the control valve (except the seal & spacer kit – 1 year)
• Ten years on the mineral tank

GENERAL CONDITIONS – Should a defect or malfunction occur, contact the dealer that you purchased the product from. If you are unable to contact the dealer, contact Franklin Water Treatment, LLC @ (260)693-1972. We will require a full description of the problem, model number, date of purchase, and selling dealer’s business name and address. We assume no warranty liability in connection with this water conditioner other than specified herein. This warranty is in lieu of all other warranties, expressed or implied, including warranties of fitness for a particular purpose. We do not authorize any person or representative to assume for us any other obligations on the sale of this water conditioner.

FILL IN AND KEEP FOR YOUR RECORDS
Original Purchaser Date of Purchase Model
Address of Original Installation City State
Dealer Purchased From Dealer Address City State
Franklin Water Treatment, LLC
12630 U.S. 33 North, Churubusco, IN 46723
Phone: (260)693-1972 Fax: (260)693-0602

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