541D18

SERIES
Technical Manual

 A Division of AWTP, LLC

 Table of Contents

Introduction .....................................................................Page 1
Technical Specifications .................................................Page 2
Flow Diagrams ................................................................Page 3
Injector & Flow Control Selection
Injector................................................................Page 4
Drain flow control (optional) ...............................Page 4
Installation
Assembly............................................................Page 5
Installation ..........................................................Page 5
Installation check-out .........................................Page 6
Mixing valve (optional) .......................................Page 6
Drain flow adjuster..............................................Page 7
The Electro-mechanical Timer
Programming ......................................................Page 8
Extra features .....................................................Page 9
Fast program check............................................Page 9
Parts Replacement
Timer motor ........................................................Page 10
Solenoid .............................................................Page 10
Solenoid diaphragm ...........................................Page 10
Timer head assembly .........................................Page 11
Injector................................................................Page 11
Brine draw restrictor ...........................................Page 11
Incorporated drain flow control (option.) ............Page 11
Drain plunger......................................................Page 12
Main diaphragm..................................................Page 12
Body stem assembly ..........................................Page 12
Check disc..........................................................Page 13
Riser insert .........................................................Page 13
Aligning timer knob and clock gear ....................Page 13
Troubleshooting ..............................................................Page 14
Annual Maintenance .......................................................Page 16
Exploded Views & Part Numbers
Electro-mechanical timer....................................Page 18
Valve body .........................................................Page 20
Order Specifications .......................................................Page 22

Art. Nr.: Tech_Man-ENG-541D18-2007.12

 541D18 SERIES

Introduction
The 541D18 is an electro-mechanical 4-cycle control valve for softening of drinking and feed water supplies.
When the drain plunger is opened, the valve is automatically transferred to the regeneration position; together with
the additional solenoid valve, this simple and reliable system guarantees years of trouble-free service. The
mechanical 7 or 12 days timer offers fixed backwash and fast rinse cycle times and an adjustable brine/slow rinse
cycle time, for exact matching of water conditions and water usage. The valve is designed for hard water bypass
during regeneration. A built in adjustable blending device for mixing hard and soft water to suit the particular
needs of each installation is an optional feature. The valve requires a conventional float-controlled brine valve with
aircheck to control the brine refill. The following sequence is followed:

1. SERVICE:
Untreated water flows down through the resin bed and up through the riser tube; the water is conditioned when
passing through the resin. The throughput is dependent on the maximum permissible pressure drop for the
complete water softener and the maximum permissible specific load of the resin (generally taken as 40 litres
soft water per hour per litre resin).

2. BACKWASH:
Water flows down through the riser tube and up through the resin bed to drain; the resin bed is fully expanded
and all foreign materials are thoroughly washed from the resin, allowing a good brine cycle to occur.

3. BRINE:
Salt brine, drawn from the brine tank by the injector, flows down through the riser tube and slowly up through
the resin bed to drain; the resin is being regenerated when the salt brine passes through. The brine cycle is
terminated when the air check is shut.

4. SLOW RINSE:
Slow rinse continues for the remainder of the brine cycle; the injectors motive water flows down through the
riser tube and slowly up through the resin bed to drain, slowly washing the brine from the resin tank.

5. FAST RINSE:
Water flows to the brine tank and at the same time down through the riser tube and up through the resin bed to
drain, ensuring that all traces of brine are washed out. The resin bed is now ready for the next service cycle.

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Technical Specifications

 Valve body material Glass filled Noryl®

 Connections
- inlet/outlet Brass adapters BSP, 3/4” male/female, 1” male
- drain line 1/2” NPT with hose barb 13 mm
- brine line Compression fitting 3/8” polytube
- tank 2 1/2” - 8 NPSM
- riser tube 1,050” / 26,7 mm
 Mixing valve Optional
 Flow rates (valve with riser)
- service Kv = 4,1 / Cv = 4,8
- backwash Kv = 0,7 / Cv = 0,8
- fast rinse Kv = 0,7 / Cv = 0,8
 Application Softener 6” - 12”
 Operating pressure 1,4 - 8,3 bar / 20 - 120 psi
 Operating temperature 2 - 48 °C / 35 - 120 °F
 Electrical rating 24V - 50 Hz, max. 680 mA
 Regeneration 4 cycles, counter-current brining
 Controller Electro-mechanical
- regeneration initiation Time clock, 7 or 12 days timer
- regeneration type Delayed
- time of regeneration Adjustable
- backwash Fixed: ±12 min
- brine draw/slow rinse Adjustable: 50 - 95 min
- fast rinse Fixed: ±4,5 min
- refill Float valve controlled

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Flow Diagrams

SERVICE BACKWASH

BRINE / SLOW RINSE FAST RINSE

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Injector & Flow Control Selection

Injector
The injector determines the brine concentration (ratio between brine suction and rinse water) and the brine flow
through the resin bed, thus the contact time between brine and resin. Injector performances vary significantly with
operating pressure.

Inlet Inj. 9 Inj. 8 Inj. 5 Inj. 4 Inj. 3 Inj. 2 Inj. 1

press Brin Rins Brin Rins Brin Rins Brin Rins Brin Rins Brin Rins Brin Rins
. e e e e e e e e e e e e e e
bar l/min l/min l/min l/min l/min l/min l/min l/min l/min l/min l/min l/min l/min l/min
1,38 0,15 0,68 0,23 0,68 0,38 0,68 1,14 1,14 1,14 1,51 1,14 2,27 1,14 2,65
2,76 0,26 0,95 0,42 0,95 0,76 0,95 1,51 1,51 1,89 1,89 1,89 3,03 1,89 3,79
4,14 0,30 1,10 0,45 1,10 1,14 1,10 1,89 1,51 2,27 2,27 2,27 3,03 2,27 4,92
5,52 0,30 1,25 0,45 1,25 1,32 1,25 2,08 2,46 2,27 2,84 2,46 3,97 2,46 5,49
6,90 0,30 1,40 0,45 1,40 1,51 1,40 2,08 2,65 2,27 3,03 2,65 4,16 2,65 6,06

!!! The following table is only an indication and is valid for an inlet pressure of 3 bar, a bed height of 30” and
a salt consumption of 120-150 gr/l resin.

Resin volume Injector

Liter Nr.
<8 9
8 – 15 8
15 – 20 5
20 – 30 4
30 – 40 3
40 – 50 2
> 50 1

Drain flow control (optional)

The drain flow control determines the resin bed expansion during backwash, independent of the inlet pressure. The
optimal bed expansion is generally obtained at a backwash flow of 1,8 L/min per dm2 of resin bed surface. In case
of the 541 valve, it also helps to keep the piston in the regeneration position when the operating pressure is
extremely low (< 1,5 bar).

 Tank Drain F.C.

inch mm Nr. Gal/min (L/min)
6 152 U 1,2 (4,5)
7 178 U 1,2 (4,5)
8 203 E 1,6 (6,1)
9 229 G 2,0 (7,6)
10 254 J 2,6 (9,8)
12 305 K 3,5 (13,2)

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Installation

Assembly
For proper assembly of valve and resin tank, proceed as follows:

1. Rinse the resin tank well before use.

2. Attach the lower distributor to the riser tube using PVC-glue or a stainless steel pin.
3. Lower the riser tube into the resin tank so that it touches the bottom.
4. Cut the riser tube 13 mm (= 1/2”) below the top of the tank threads and chamfer the tube to prepare for
insertion into the control valve.
5. Temporary plug the top of the riser tube to prevent resin from entering the tube and fill the tank with resin for
max. 3/4.
6. Make sure the O-ring in the riser insert of the control valve is in the correct position; screw the upper
distributor onto the control valve.
7. Lubricate the threads, the top of the riser tube and the tank O-ring of the control valve.
8. Lower the control valve straight down onto the riser tube and screw it onto the tank.

Installation

!!! ATTENTION

 For proper functioning of the unit, incoming water pressure should be between a minimum of 1,4 bar during
regeneration and a maximum of 8,3 bar in service; if necessary, a pressure reducer must be installed ahead of
the system.
 Installation must only be undertaken by a person competent in plumbing.
 All plumbing and electrical connections must be done in accordance with local codes.
 Do not install the unit too close to a water heater (min. 3 m of piping between outlet of unit and inlet of heater);
water heaters can sometimes transmit heat back down the cold pipe into the control valve; always install a
check valve at the outlet of the unit.
 If the control valve is not equipped with a bypass, a three valve bypass system must be installed to enable
bypassing during servicing.

For proper installation of the unit, proceed as follows:

1. Inlet/outlet: connect the inlet and outlet to the control valve; when facing the front of the valve, the inlet is at
the right and the outlet at the left side.
2. Drain line: connect a hose to the drain line fitting on the valve and secure it; insert the drain hose into a
standpipe, with siphon if required; make sure the drain hose is:
 as short as possible,
 not elevated too much,
 free of kinks,
as this will all create undesired counter-pressure.
3. Brine line: a conventional float-controlled brine valve system with aircheck is required for proper brining
during regeneration; 3/8” polytube must be used to connect the brine system to the valve; do not overtighten the
nut.
4. Transformer: make sure the power source carries the same rating as the transformer; plug transformers output
lead (with plug ø 2,5 mm x 5,5 mm) into socket at the timers power lead and plug transformer into socket; the
connection can be secured by means of the wire clip.

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Installation check-out
When installation has been completed, the unit is ready to be placed into service. Proceed as follows, while
checking the unit for any leakages:

1. Place unit in bypass and turn on main water supply; open a cold water tap nearby and allow water to run for a
few minutes until all foreign material that may have resulted from the installation is washed out; close the tap.
2. Slowly shift the bypass valve to the service position and secure it; allow water to completely fill the resin tank.
3. Carefully open a cold water tap and allow water to run for at least 2 minutes to set the resin bed and purge air
from the system; close the tap.
4. Loosen the timer cover screw and pull away the front cover.
5. Program the control valve according to the specific installation (refer to “Programming” on pg. 8).
6. Slowly turn the timer knob counter clockwise until the backwash section on the regeneration cam pushes down
the actuator to open the drain plunger; depending on the pushed-in skipper tabs, this might take several
revolutions; the backwash/fast rinse solenoid is activated and the valve is now transferred to the backwash
position.
7. Allow water to run to drain until all of the air is purged from the system.
8. Fill the brine tank with water, higher then the air-check level.
9. Slowly turn the timer knob further counter clockwise, until the brine/slow rinse section on the regeneration cam
pushes down the actuator completely to keep the drain plunger open; the backwash/fast rinse solenoid is de-
activated and the valve is now transferred to the brine/slow rinse position.
10. Allow the valve to draw water from the brine tank until the aircheck closes.
11. Place unit in bypass.
12. Add the appropriate amount of water to the brine tank.
13. Add salt to the brine tank.
14. Set float of brine valve to the level of the water in the brine tank.
15. Shift bypass valve back to the service position.
16. Slowly turn the timer knob further counter clockwise, until the fast rinse section on the regeneration cam
pushes down the actuator to keep the drain plunger open; the backwash/fast rinse solenoid is re-activated and
the valve is now transferred to the fast rinse position.
17. Allow water to run to drain and brine tank.
18. Slowly turn the timer knob further counter clockwise, until the actuator is released and the drain plunger is
closed; the backwash/fast rinse solenoid is de-activated and the valve is now transferred back to the service
position.
19. Reset time of day.
20. Install the front cover.

Mixing valve (optional)

To adjust the residual hardness, the incorporated mixing valve must be regulated in function of the hardness of the
incoming water and the desired residual hardness; the scale on the mixing valve has no absolute indication, but
serves only as a reference point:
 To increase the residual hardness: turn screw counter clockwise.
 To decrease the residual hardness: turn screw clockwise.

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Drain flow adjuster

!!! ATTENTION

When the valve is equipped with an incorporated drain

flow control (optional), the drain flow adjuster is
assembled and locked in the wide open position! By
releasing the locking screw of the locking plate, the drain
flow adjuster can still be used, but note that the
maximum flow to drain is limited by the incorporated
drain flow control (optional).

With the drain flow adjuster it is possible to adjust the

water flow to drain during regeneration. This way the water consumption during backwash and fast rinse can be
tuned for the system’s size. The optimal bed expansion during backwash, is generally obtained at a backwash flow
of 1,8 L/min per dm2 of resin bed surface (depending on the type of resin). To adjust:
1. Place the unit in backwash position.
2. Check the flow to drain.
3. Adjust the flow to drain by turning the drain flow adjuster either to the right or to the left, until the
desired drain flow is obtained.
Also, the so created counter pressure helps to keep the piston of the valve in the regeneration position when the
operating pressure is extremely low (< 1,5 bar). To adjust:
1. Place the unit in brine/slow rinse position.
2. Turn the drain flow adjuster either to the right or to the left until the piston remains stable in the
regeneration position.
Do note that closing the drain flow adjuster too much, will result in bad suction of the injector.

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The Electro-
mechanical Timer

Programming
The electro-mechanical timer uses a 12 or 7 days skipper
wheel to set the day(s) of regeneration. Only the
brine/slow rinse cycle time can be set, while backwash
and fast rinse cycle times are fixed.

N: time of day window

A: clock plate

B: time of regeneration window M: timer knob

L: backwash section
C: day indicator

D: 12/7 days skipper wheel K: brine/slow rinse cycle

time indicator
E: skipper tabs J: brine/slow rinse section
I: fast rinse section

F: actuator G: drain plunger H: locking screw

 time of regeneration:
Turn the clock plate (A) until the desired time of regeneration appears in the time of regeneration window
(B).

 time of day:
Turn the timer knob (M) counter clockwise until the correct time of day on the clock gear appears in the
time of day window (N).

 day(s) of regeneration:
With all skipper tabs (E) pulled out, rotate the skipper wheel (D) until day “1” is aligned with the day
indicator (C); push in skipper tabs (E) which correspond with the desired days of regeneration.

 regeneration cycles:
 The length of the backwash cycle is determined by the length of the backwash section (L) on the
regeneration cam; this is fixed at ±12 min, and can not be adjusted.
 The length of the brine/slow rinse cycle is determined by the length of the brine/slow rinse section (J)
on the regeneration cams; this can be adjusted between 50 and 95 min:
 Turn the timer knob (M) counter clockwise until the regeneration cams are accessible.
 Loosen the locking screw (H).
 Twist the upper cam until the desired brine/slow rinse cycle time is aligned with the cycle
time indicator (K).
 Secure the locking screw (H).
 The length of the fast rinse cycle is determined by the length of the fast rinse section (I) on the
regeneration cam; this is fixed at ±4,5 min and can not be adjusted.

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Extra features
immediate regeneration: an immediate regeneration can manually be initiated by pushing in skipper tab (E) that
is aligned with the day indicator (C) and turning the timer knob (M) counter clockwise, until the time of day in
the time of day window (N) equals the time of regeneration (see time of regeneration window (B)); the time of day
and the skipper tab (E) must be reset, when the regeneration is terminated.

Fast program check

When You want to check if the system is operating correctly, proceed as follows:

1. Plug unit into power supply.

2. Open water supply to valve.
3. Loosen the timer cover screw and pull away the front cover.
4. Slowly turn timer knob (M) counter clockwise until the backwash section (L) on the regeneration cam pushes
down the actuator (F) to open the drain plunger (G); depending on the pushed-in skipper tabs, this might take
several revolutions; the backwash/fast rinse solenoid is activated and the valve is now transferred to the
backwash position.
5. Check the drain line for clear flow.
6. Slowly turn timer knob (M) counter clockwise until the brine/slow rinse section (J) on the regeneration cam
pushes down the actuator (F) completely to keep the drain plunger (G) open; the backwash/fast rinse solenoid is
de-activated and the valve is now transferred to the brine/slow rinse position.
7. Check brine draw by listening or feeling for suction.
8. Slowly turn timer knob (M) counter clockwise until the fast rinse section (I) on the regeneration cam pushes
down the actuator (F) to keep the drain plunger (G) open; the backwash/fast rinse solenoid is re-activated and
the valve is now transferred to the fast rinse position.
9. Check the drain line and brine line for flow.
10. Slowly turn timer knob (M) counter clockwise until the actuator (F) is released and the drain plunger (G) is
closed; the backwash/fast rinse solenoid is de-activated and the valve is now transferred back to the service
position.
11. Reset time of day.
12. Install the front cover.

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Parts Replacement
!!! BEFORE SERVICING:
 MAKE SURE THE CONTROL VALVE IS IN SERVICE POSITION
 DISCONNECT ALL ELECTRICAL POWER TO THE UNIT
 BYPASS OR DISCONNECT THE WATER SUPPLY
 RELIEF THE WATER PRESSURE

Timer motor
1. Remove the timer cover screw and lift off the timer and front cover.
2. Disconnect the wire nuts from the timer motor leads.
3. Remove the 2 screws holding the timer motor in place and lift away the motor.
4. Reverse the procedure for reassembly.

Solenoid
1. Remove the solenoid cable from the solenoid.
2. Remove the screw holding the solenoid in place and lift away the solenoid.
3. Reverse the procedure for reassembly.

Solenoid diaphragm
1. Remove the solenoid cable from the solenoid.
2. Remove the screw holding the solenoid in place and lift away the solenoid.
3. Remove the 2 remaining screws holding down the retainer.
4. Place a hand under the retainer and remove the retainer; the guide, the solenoid
plunger and the plunger spring will fall into Your hand.
5. Verify that the solenoid plunger moves smoothly against the plunger spring inside of
the guide; clean or replace if necessary.
6. Separate the solenoid diaphragm from the valve body.
7. Clean out the diaphragm cavity in the valve body.
8. Check the diaphragm for rips or tears; the diaphragm should have 1 hole in the
centre and 2 smaller holes off centre.
9. Reverse the procedure for reassembly.

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Timer head assembly

1. Remove the timer cover screw and lift off the timer and front cover.
2. Remove the drain hose from the drain line fitting.
3. Remove the solenoid cable from the solenoid.
4. Remove the 4 timer head screws and pull away the timer head assembly.
5. Reverse the procedure for reassembly; make sure the drain port O-ring is securely installed in the valve body
groove.

Injector
1. Remove the 3 screws holding the injector cover plate in place.
2. Lift off the injector cover plate.
3. Remove the injector and injector gasket.
4. Remove the injector filter and check for dirt or clogging.
5. Install the injector filter.
6. Install a new injector gasket; mind the alignment over the alignment post.
7. Install the injector; mind the alignment over the alignment post.
8. Install the injector cover plate.
9. Install the 3 injector cover plate screws and tighten them evenly.

Brine draw restrictor

For injectors 8 and 9, an additional 'restrictor' is used that is located in the brine elbow. The restrictor is tightly
pressed in, to ensure a leakage free seal. Do NOT remove the restrictor to prevent damage of restrictor and/or seal.

To access the restrictor for cleaning purposes:

1. Remove the brine line from the brine elbow.
2. Remove the clip that secures the brine elbow.
3. Check restrictor for dirt or clogging; clean if necessary by blowing air through restrictor.
4. Install the brine elbow and secure it with the clip.
5. Install the brine line to the brine elbow.

Incorporated drain flow control (optional)

1. Remove the timer cover screw and lift off the timer and front cover.
2. Remove the drain hose from the drain line fitting.
3. Remove the 4 timer head screws and pull away the timer head assembly.
4. Locate the drain flow control in the drain channel of the timer head.
5. Pull out the drain flow control.
6. Reverse the procedure for reassembly; make sure the drain port O-ring is
securely installed in the valve body groove.

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Drain plunger
1. Loosen the timer cover screw and pull away the front cover.
2. Loosen the retainer screw located below the timer gears on the front.
3. Pull the retainer down and away from the timer.
4. Place a hand under the plunger cap and press down on the drain plunger; the plunger cap,
O-ring and spring will fall into Your hand.
5. Clean out the plunger orifice in the timer head; lubricate lightly.
6. Check the O-rings on the drain plunger; clean or replace if necessary; lubricate lightly.
7. Check the O-ring of the plunger cup; clean or replace if necessary; lubricate lightly.
8. Install drain plunger in the plunger orifice of the timer head.
9. Install the O-ring in the plunger cap groove and the spring in the centre whole of the
plunger cap.
10. Install the plunger cap; press it in firmly.
11. Install the retainer.
12. Install the retainer screw.
13. Install the front cover.

Main diaphragm
1. Remove the timer cover screw and lift off the timer and front cover.
2. Remove the drain hose from the drain line fitting.
3. Remove the 4 timer head screws and pull away the timer head assembly.
4. Remove the screw and washer from the centre of the main diaphragm.
5. Remove the main diaphragm from the body stem assembly.
6. Reverse the procedure for reassembly; make sure the drain port O-ring is securely installed in the valve body
groove.

Body stem assembly

1. Remove the timer cover screw and lift off the timer and front cover.
2. Remove the drain hose from the drain line fitting.
3. Remove the 4 timer head screws and pull away the timer head assembly.
4. Pull forward the main diaphragm; put 2 fingers behind the membrane and pull out
the body stem assembly.
5. Inspect the centre check disc rubber seal for wear; clean or replace if necessary.
6. Lubricate the O-rings of the seat insert.
7. Install the body stem assembly.
8. Install the seat insert with 1of the 2 flats facing towards the top of the valve body.
9. Reverse the procedure for reassembly; make sure the drain port O-ring is securely
installed in the valve body groove.

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Check disc
1. Remove the solenoid cable from the solenoid.
2. Remove the 4 screws from the back cap.
3. Place a hand under the back cap and remove the back cap; the check disk spring might
fall into Your hand.
4. Remove the check disc from the body stem assembly.
5. Inspect the check disc rubber seal for wear; clean or replace if necessary.
6. Install the check disc on the body stem assembly and the check disc spring onto the
centre post of the check disc.
7. Make sure the back cap gasket is securely installed in the back cap grooves.
8. Align the mark on top of the back cap with the mark on the valve body and install the
back cap with the open end of the check disk spring onto the centre post of the back cap.
9. Install the 4 screws and tighten them.
10. Install the solenoid cable.

Riser insert
1. Remove the inlet and outlet from the control valve.
2. Remove the drain hose from the drain line fitting and the brine line from the brine elbow.
3. Remove the control valve from the resin tank.
4. Unscrew the upper distributor from the control valve.
5. Remove the 2 screws holding the adapter ring and riser insert in place.
6. Lift away the adapter ring.
7. Pull the riser insert out of the valve body.
8. Check the O-ring on the riser insert; clean or replace if necessary; lubricate lightly.
9. Install the riser insert; press it in firmly.
10. Install the adapter ring and tighten the 2 screws.
11. Make sure the O-ring in the riser insert of the control valve is in the correct position;
screw the upper distributor onto the control valve.
12. Lubricate the threads, the top of the riser tube and the tank O-ring of the control valve.
13. Lower the control valve straight down onto the riser tube and screw it onto the tank.
14. Install the drain hose to the drain line fitting and the brine line to the brine line fitting.
15. Install the inlet and outlet to the control valve.

Aligning timer knob and clock gear

1. Loosen the timer cover screw and pull away the front cover.
2. Place a hand under the timer and remove the clock gear screw; the
clock plate and spring washer will fall into Your hand.
3. Remove the locating dial.
4. Turn the timer knob until the pointer on the timer knob is pointing to
the centre of the clock gear.
5. Install the clock gear so that the black mark (a line) on the clock gear
is pointing to the centre of the timer knob (= aligned with the pointer
on the timer knob).
6. Reverse the procedure for reassembly.

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Troubleshooting

Hard (untreated) water to service

Cause Solution
1. Open or defective bypass 1. Close or verify bypass
2. Excessive water usage 2. Verify regeneration frequency
3. Valve in regeneration 3. /
4. Loss of resin 4. Refer to problem “Loss of resin”
5. Mixing valve open 5. Reduce mixing valve opening
6. Change in raw water hardness 6. Adjust regeneration frequency accordingly
7. Unit fails to regenerate 7. Refer to problem “Unit fails to regenerate”
8. Valve fails to draw brine 8. Refer to problem “Valve fails to draw brine”
9. Decreasing exchange capacity of resin 9. Clean or replace resin bed
10. No salt in brine tank 10. Add salt
11. Leak at riser tube 11. Verify that riser tube is seated correctly and is not cracked

Unit fails to regenerate

Cause Solution
1. Faulty electrical supply 1. Verify electrical service (fuse, transfo,...)
2. Defective timer motor 2. Replace timer motor
3. Regeneration frequency not 3. Verify days of regeneration on skipper wheel
programmed
4. Timer knob out of alignment with 4. Refer to Parts Replacement “Aligning timer knob and clock
clock gear gear”
5. Body stem assembly switches 5. Check minimum operating pressure; refer to Installation “Drain
continuously flow adjuster”

Valve fails to draw brine

Cause Solution
1. Low operating pressure 1. Verify operating pressure; must exceed 1,4 bar
2. Drain flow adjuster too much closed 2. Open drain flow adjuster slowly until unit draws brine
3. Plugged injector 3. Clean injector
4. Plugged injector filter 4. Clean injector filter
5. Solenoid plunger stuck in open 5. Clean or replace plunger and solenoid diaphragm.
position
6. Restricted drain line 6. Verify drain line for kinks or restrictions
7. Restricted brine line 7. Verify brine line for kinks or restrictions
8. Leak in brine line 8. Verify brine line and connections for air leakage
9. Not enough water in brine tank 9. Verify functioning and float setting of brine valve

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Excessive water in brine tank

Cause Solution
1. Improper setting of float 1. Verify float setting of brine valve
2. Defective brine valve 2. Verify or replace brine valve

Unit uses too much salt

Cause Solution
1. Excessive water in brine tank 1. Refer to problem “Excessive water in brine tank”
2. Unit regenerates too frequently 2. Verify days of regeneration on skipper wheel

Salt water to service

Cause Solution
1. Excessive water in brine tank 1. Refer to problem “Excessive water in brine tank”
2. Injector undersized 2. Verify injector selection
3. Improper brine/slow rinse time setting 3. Verify that brine/slow rinse time corresponds to the proper salt
level and amount of resin

Loss of resin

Cause Solution
1. Lower and/or upper distributor 1. Replace distributor(s)
damaged
2. Leak between riser tube and upper 2. Verify that riser tube is seated correctly and is not cracked
distributor

Loss of water pressure

Cause Solution
1. Mineral or iron build-up in resin tank 1. Clean resin bed and control valve; increase regeneration
frequency
2. Plugged lower and/or upper distributor 2. Verify that distributors are free of debris
3. Crushed lower and/or upper distributor 3. Replace distributor(s)

Drain flows continuously

Cause Solution
1. Drain plunger stuck in open position 1. Clean or replace drain plunger
2. Defective timer motor 2. Replace timer motor

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Annual Maintenance
To assure the correct functioning of the control valve, the following items must be checked annually:

1. Clean out injector and injector filter.

2. Clean out solenoid diaphragm.
3. Verify programming of timer; re-program timer if necessary.
4. Verify correct execution of program (refer to “Fast program check” on pg. 9).
5. Measure the residual hardness; adjust mixing valve if necessary.
6. Verify min. and max. water pressure; install pressure reducer if necessary.

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Exploded Views & Part Numbers

Electro-mechanical timer

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 541D18 SERIES

ITEM PART NUMBER DESCRIPTION

1 15/76 Screw, clock gear
2 529/309/2 Clock plate
3 525/303 Spring washer, clock plate
4 529/308/3 Locating dial
5 529/232/9 24 hr clock gear (12-days)
529/232/4 AM/PM clock gear (7-days)
6 19/23 Clip, actuator
7 529/218 Actuator
8 529/212 Spindle, actuator
9 541/802 Spring, actuator
10 529/202/2 Housing, timer head
11 185/115/1 O-ring, drain elbow
12 H1026/1 Drain elbow
13 72373 Front cover
14 72431 Timer cover (black)
15 15/207/12 Screw, timer cover
16 28/297/11 Transfo 230/24V - 50 Hz, 12VA, EuroT plug
28/297/18 Transfo 230/24V - 50 Hz, 12VA, UK plug
17 28/17/16BK/1 Solenoid cable black
18 28/8/2 Strain relief, solenoid cable
19 28/300/3 Power lead with plug
20 72263 Wire clip
21 28/8/28 Strain relief, power lead
22 29/70/8 Jumper cable
23 28/126/3 Micro switch
24 15/185/10 Screw, micro switch (2x)
25 28/26 Wire nut (2x)
26 15/76 Screw, timer motor (2x)
27 30/77/J Timer motor
28 541/300/* Drain flow control (optional)
29 15/185/10 Screw, ratchet
30 525/260 Ratchet
31 525/254/2 Gear, ratchet
32 529/280 Retainer, drain plunger
33 529/286 Plunger cap
34 185/022/1 O-ring, plunger cap
35 401/7 Spring, drain plunger
36 529/219/3/15 Drain plunger
37 15/92/24 Screw, retainer
38 529/239/1 Timer knob/cams
39 15/87 Screw, timer head (4x)
40 525/205 Spring washer, skipper wheel
41 525/241/12 Skipper wheel (12-days)
525/241/07 Skipper wheel (7-days)
42 525/274/1 Washer, day indicator (12-days)
525/274/2 Washer, day indicator (7-days)
43 15/185/10 Screw, skipper wheel

* Size: refer to “Sizing Table”

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 541D18 SERIES

Valve body

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ITEM PART NUMBER DESCRIPTION

1 15/91 Screw, solenoid (3x)
2 413/134/24 Solenoid
3 413/60 Retainer, solenoid
4 413/58 Guide, solenoid
5 413/62 Spring, solenoid plunger
6 413/61 Plunger, solenoid
7 413/59 Diaphragm, solenoid
8 15/222 Screw, back cap (4x)
9 541/208/2 Back cap
10 541/206 Gasket, back cap
11 541/239 Spring, check disc
12 541/246 Check disc
13 185/005/1 O-ring, mixing valve (2x)
14 541/940/6/1 Mixing valve (optional)
15 541/325 Gasket, injector
16 428/* Injector
17 541/221 Cover plate, injector
18 15/89 Screw, cover plate (3x)
19 72604 Filter, injector
20 72609 Locking plate, drain flow adjuster
21 15/76 Screw, locking plate
22 541/254 Spring clip
23 74015 Brine draw restrictor 0,8mm (with injector 9 only)
74022 Brine draw restrictor 1,0mm (with injector 8 only)
24 186/118 O-ring, brine elbow
25 568/336/0 Brine elbow
26 21/90 Nut, brine elbow
27 19/19 Clip, drain flow adjuster
28 186/134 O-ring, drain flow adjuster (2x)
29 541/238 Drain flow adjuster
30 529/244 O-ring, drain port
31 467/216 Seal, body stem
32 72605 Body stem
33 185/024/1 O-ring, seat insert (small)
34 541/204 Seat insert
35 185/029/1 O-ring, seat insert (large)
36 72602 Main diaphragm
37 72507 Retainer, main diaphragm
38 72245 Washer, main diaphragm
39 72552 Screw, main diaphragm
40 516/221 Spring, main diaphragm
41 15/90 Screw, adapter ring (2x)
42 185/67/4 O-ring, tank
43 541/232 Adapter ring
44 185/214/1 O-ring, riser tube
45 541/218 Riser insert 1,050”
46 185/029/1 O-ring, riser insert
47 541/257/1 Valve body (incl. 467/216)
541/257/1/R Valve body (incl. 467/216) for mixing valve
A RK/413 Repair kit solenoid membrane
B RK/541/244 Repair kit body stem and seat
C 72611 Repair kit body stem

* Size: refer to “Sizing Table”

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Order Specifications

541D18/TVID(/R)

T = Timer: A = 12-days
B = 7-days

V = Voltage: L = transfo 230/24VAC, 12VA, EuroT plug

R = transfo 230/24VAC, 12VA, UK plug
J = no transfo

I = Injector: 9, 8, 5, 4, 3, 2, 1

D = Incorporated drain flow control:

0 = no flow control, only drain flow adjuster

Nr. Gal/min (L/min)

U 1,2 (4,5)
E 1,6 (6,1)
F 1,8 (6,8)
G 2,0 (7,6)
H 2,2 (8,3)
J 2,6 (9,8)
T 3,0 (11,4)
K 3,5 (13,2)

/R = Incorporated mixing valve

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