If you have the code Err 1 this would normally indicate the program settings have been corrupted. Press any key. If Err 1 does not clear you will want to replace the controller.

If you have the code Err 3 this would indicate one of three different things all regarding the Camshaft. See below troubleshooting steps to resolve this issue.

If you have a loose salt line connection it can cause the salt tank to overflow. Verify all salt line connections are tight. Re-tighten if necessary.

A drain line which is restricted by debris can be an issue. Ensure the drain line is not restricted. If so, remove any debris.

You could have debris preventing the #4 valve disc from closing. You will want to verify there is no debris in the #4 valve disc. If so, remove the debris for normal function. The below diagram will assist you in locating the #4 valve disc.

If you have a worn valve disc it is not able to function properly, causing flowing or dripping water at the drain or salt line after a recharge. Inspect the #4 disc valve for any extensive wear. If it is damaged or worn out you will need to replace the valve disc. The below diagram will assist you in locating the #4 valve disc.

If there was leaking from an external bypass valve before or during your recharge, you would have hard water leakage after the recharge. You will need to replace the bypass valve.

The o-ring around the rise pipe may be damaged. Inspect the o-ring and if there are any kinks, wear, or damage you will need to replace the o-ring. If the o-ring is not positioned properly, re-position the o-ring and verify you have a tight seal.

If you have improperly programmed the salt settings, it will cause hard water to leak after a recharge. To resolve this issue, you will need to reset your salt settings.

If for some reason you have a restricted drain line, this will cause your AF-40K valve not to drain. You will want to find and remove any restrictions.

You may also have an injector plugged. If that is the case, you will need to clean out the injector as well as the screen in order to clear the obstruction.

Your valve discs must be free from debris. If debris is preventing the valve discs from closing, you will need to remove any foreign matter from the valve discs.

If your control will not automatically recharge you may have a defective motor. Contact tech support at 800-752-5582 and they will assist you in verifying this problem and replacing your motor if necessary.

If you have a meter which is clogged with debris this will cause your control to not recharge automatically. Remove and clean the meter.

If your control is blank and/or unresponsive you do not have power to the motor/control. Check the AC adapter and power supply to ensure the connection is tight.

The time of day is set incorrectly. Reset the time of day using the below diagram.

Low water pressure can cause intermittent salt draw. Check your water pressure and make sure you maintain a minimum of 20 psi (1.3 bar) feed.

Your AF-40K softener requires salt to condition your water. If you do not have salt in the salt tank your water will not be conditioned. Add the appropriate level of salt and then manually run the recharge cycle again.

You may have a plugged injector. Clean the injector and screen. Once this has been completed, manually recharge the softener in order to condition your water.

It is possible that you have no drain line flow control. If not, install a drain line flow control.

If you have anything obstructing the drain line, your flow can be obstructed. Remove any obstruction.

This could be an indication that your settings are not set up correctly. Verify your hardness level, and water usage in order to determine which mode best fits your family mode setting (HE, STD or HC). Contact tech support at 1-800-752-5582 if you need additional assistance figuring this out.

If you run out of salt your water will not be conditioned. If this is the case, did you check the salt levels and refill the salt after the last recharge? If not, refill the salt tank. If so, refill the salt tank and check your settings. Verify your hardness level, and water usage in order to determine which mode best fits your family's mode setting (HE, STD or HC). Contact tech support at 1-800-752-5582 if you need additional assistance figuring this out.

There is a bypass valve. If the bypass valve has been switched to the bypass position, it will bypass the service flow. Switch the bypass valve off.

If the meter cable gets dislodged from the valve your control will not display service flow. Fully insert the meter cable into the valve.

If you have a meter which is clogged with debris this will cause your control to not display service flow. Remove and clean the meter.

Safety - There are no user-serviceable parts in the AC adapter, motor, or controller. In the event of a failure, these should be replaced. All electrical connections must be completed according to local codes. Use only the power AC adapter that is supplied. The power outlet must be grounded. To disconnect power, unplug the AC adapter from its power source. Do not use petroleum based lubricants, Vaseline®, oils, or hydrocarbon based lubricants. Use only 100% silicone lubricants.

Mechanical - All plastic connections should be hand tightened. Plumber's tape may be used on connections that do not use an o-ring seal. Do not use pliers or pipe wrenches. All plumbing must be completed according to local codes. Soldering near any plastic fittings should be done before connecting fittings to the valve. Excessive heat will cause interior damage to the valve. Observe drain line requirements. Do not use lead-based solder for sweat solder connections. The drain line must be a minimum of ½" diameter. Use ¾" pipe if the backwash flow rate is greater than 7 gpm (26.5 Lpm) or the pipe length is greater than 20 feet (6 m). Do not support the weight of the system on the control valve fittings, plumbing, or the bypass. It is not recommended to use sealants on the threads. Use plumber's tape on all threaded connections.

General - Observe all warnings that appear in these instructions. Keep the unit in the upright position. Do not turn on its side, upside down, or drop. Turning the tank upside down will cause media to enter the valve. Operating ambient temperature is between 34°F (1°C) and 120°F (49°C). Operating water temperature is between 35°F (1°C) and 100°F (38°C). Working water pressure range is 20 to 125 psi (1.38 to 8.6 bar). In Canada, the acceptable working water pressure range is 20 to 100 psi (1.38 to 6.89 bar). Use only salts designed for water softening. Do not use ice melting, block, or rock salts. Follow state and local codes for water testing. Do not use water that is micro-biologically unsafe or of unknown quality. When filling media tank, do not open water valve completely. Fill tank slowly to prevent media from exiting the tank. When installing the bypass water connection, connect to the plumbing system first. Allow heated parts to cool and cemented parts to set before installing any plastic parts. Do not get primer or solvent on o-rings, nuts, or the valve.

The location of your water treatment system is important. You need to have a level platform or floor as well as room to access equipment for maintenance and adding salt to your tank. The ambient temperatures need to be over 34°F (1°C) and below 120°F (49°C). Your water pressure must be below 125 psi (8.6 bar) and above 20 psi (1.4 bar). In Canada, the water pressure must be below 100 psi (6.89 bar). You need to have a constant electrical supply to operate the controller. The total minimum pipe run to the water heater of can be no more than ten feet (three meters) to prevent backup of the hot water into the water treatment system. Your local drain for the discharge must be as close as possible. You must have water line connections with a shut-off or bypass valves. Must meet any local, state and international codes for the installation site. Valve is designed for minor plumbing misalignments. Do not support weight of system on the plumbing. Be sure all soldered pipes are fully cooled before attaching plastic valve to the plumbing.

It is recommended that the system be installed indoors. When the water conditioning system must be installed outdoors, several additional items must be considered.

Moisture — The valve and premier controller are rated for NEMA 3 locations. Falling water should not affect performance. The system is not designed to withstand extreme humidity or water spray from below. Examples are: constant heavy mist, near corrosive environment, upwards spray from sprinkler.

Direct Sunlight — The materials used will fade or discolor over time in direct sunlight. The integrity of the materials will not degrade to cause system failures.

Temperature — Extreme hot or cold temperatures may cause damage to the valve or controller. Freezing temperatures will freeze the water in the valve. This will cause physical damage to the internal parts as well as the plumbing. High temperatures will affect the controller. The display may become unreadable but the controller should continue to function. When the temperature drops down into normal operating limits the display will return to normal.

Insects — The controller and valve have been designed to keep all but the smallest insects out of the critical areas. The top cover should be installed securely in place.

A bypass valve system is included and will be installed on all water conditioning systems. Bypass valves isolate the softener from the water system and allow unconditioned water to be used. Service or routine maintenance procedures may also require that the system is bypassed.

The bypass valve is shipped to you in the bypass position. When the valve is in bypass, water will not enter the softening tank. The water in the building will not be treated. Series 360 bypass operation (shown in diagram above) shows the handles in the service position.

Once you have selected your location, check the direction of the water flow in the main pipe. The softened water flow diagram can be used to plan the new plumbing assembly. Inspect the main water pipe. Write down the type of pipe (copper, plastic, galvanized etc.). Record the size of the pipe. Plastic style pipes usually have the size printed on the outside. Other pipes can be measured for the outside diameter and converted into the pipe size at the store. Do not use pipe that is smaller than the main water pipe.

The bypass requires two connector fittings that connect to the plumbing. Size is to be determined for specific installation requirements. If the main plumbing is galvanized piping and you are installing copper pipe, then you must use dielectric insulating connectors between the two styles of pipe. Place the tank in the desired position. The design of the tank does not allow for bad alignment of the connections. You may ask your supply store about flexible connections.

Take measurements and create a drawing of your installation. Include pipe lengths and elbows that are needed. If the water flow is from right to left you will need to cross the plumbing to the softener. Take the drawing to your plumbing supply store. Consult with their expert for installation ideas and suggestions. Assemble the plumbing.

If pipes will be sweat soldered, do not connect adapters to the bypass until the pipes have cooled. The inlet water must be connected to the inlet port of the valve. When replacing an existing system, it is possible that the inlet and outlet plumbing is installed in a reverse position. Be certain the inlet connection on the valve is connected to the incoming water fitting from the water supply. Do not use petroleum grease on gaskets when connecting bypass plumbing. Use only 100% silicone grease products when installing any plastic valve. Non-silicone grease may cause plastic components to fail over time.

The bypass assembly connects to the water system by means of a connector assembly. The connector is secured to the plumbing and then inserted into the bypass. A clip is used to hold it in place. Before inserting the connector, check that all o-rings are in place and not damaged; lubricate the o-rings and sliding surfaces with 100% silicone. Firmly insert the connector into the bypass and press the locking clip into position. Make certain the clip is fully engaged.

If you need to remove a clip, turn off the water supply and release the water pressure at the valve. Push the water line connectors into the bypass and valve. This will help release the o-rings that may have seated in place. Remove the clip by inserting a flat blade under the top center of the clip and lifting (prying) up.

Do not use pliers to remove a clip. It is likely the clip will break.

Note - Before turning on the water to the valve, rotate the two handles on the bypass valve 2-3 times. This will help seat the o-rings and prevent leaking.

The drain line flow control (DLFC) ½” NPT requires assembly. Locate parts and a roll of plumber tape (not included). Wrap the tape over threads of the flow control. Screw the flow control and a proper size drain fitting together, hand tighten. Place the ball into the flow control and insert the assembly into the drain line opening. Push the assembly in and secure with the drain line clip.

Note - Standard commercial practices are expressed here. Local codes may require changes to the following suggestions. Check with local authorities before installing a system.

Step #1 - The unit should be above and not more than 20’ (6.1 m) from the drain. Use an appropriate adapter fitting with a hose clamp to connect ½” (1.3 cm) plastic tubing to the drain line connection of the control valve.

Step #2 - If the backwash flow rate exceeds 5 GPM (18.9 LPM) or if the unit is located 20-40’ (6.1-12.2 m) from drain, use ¾” (1.9 cm) tubing. Use appropriate fittings to connect the 3/4-inch tubing to the ¾” NPT drain connection on valve.

Step #3 - The drain line may be elevated up to 6’ (1.8 m), provided the run does not exceed 15’ (4.6 m) and water pressure at the softener is not less than 40 psi (2.76 bar). Elevation can increase by 2’ (61 cm) for each additional 10 psi (.69 bar) of water pressure at the drain connector.

Step #4 - Where the drain line is elevated but empties into a drain below the level of the control valve, form a 7” (18 cm) loop at the far end of the line so that the bottom of the loop is level with the drain line connection. This will provide an adequate siphon trap.

If you need to remove a clip, turn off the water supply and release the water pressure at the valve. Push the water line connectors into the bypass and valve. This will help release the o-rings that may have seated in place. Remove the clip by inserting a flat blade under the top center of the clip and lifting (prying) up.

Where the drain empties into an overhead sewer line, a sink type trap must be used. Secure the end of the drain line to prevent it from moving.

Waste connections or drain outlets shall be designed and constructed to provide for connection to the sanitary waste system through an air gap of 2 pipe diameters or 1” (22 mm), whichever is larger. Never insert the drain line directly into a drain, sewer line, or trap (see above diagram). Always allow for an air gap between the drain line and the wastewater to prevent the possibility of sewage being back-siphoned into the softener.

In the event of a malfunction, the salt tank overflow will direct “overflow” to the drain instead of spilling on the floor. This fitting should be on the side of the cabinet. Attach the length of ½” (1.3 cm) I.D. Tubing (not supplied) to the fitting and run to the drain. Do not elevate the overflow line higher than the overflow fitting (see diagram below). Do not tie into the drain line of the control unit. The overflow line must be a direct, separate line from the overflow fitting to drain, sewer, or tub. Allow an air gap as per the drain line instructions.

The salt line from the brine tube connects to the valve. Make certain all fitting connections are hand tightened. Be sure that the salt line is secure and free from air leaks. Even a small leak may cause the salt line to drain out, and the softener will not draw salt from the tank. This may also introduce air into the valve, causing problems with valve operation.

This valve and control are for dry location use only, unless used with a listed class 2 power supply suitable for outdoor use.

All Premier series controllers operate on a 12-volt alternating current power supply. This requires use of the proper supplied AC adapter included with your system.

Note - Make sure the power source matches the rating printed on the AC adapter. The power source should be constant. Be certain the AC adapter is not on a switched outlet. Power interruptions longer than 8 hours may cause the controller to lose the time setting. When power is restored, the time setting must then be re-entered.

The water supply valve should be off, or the valve is in bypass. At initial power-up, the camshaft may need to rotate to the home (in service) position. The camshaft may take 1 to 2 minutes to return to the home position. Err 3 will be displayed until the camshaft returns to the home position. If more than 2 minutes elapses, verify that the motor is turning the camshaft. If it is not turning, check the “troubleshooting” section.

When the camshaft has reached the home (service) position the display will show “- -:- -”. If the time of day alternating with capacity remaining is displayed, then the controller has used short term memory to load settings. Short term memory will hold settings for approximately eight hours. These settings include water used today, water used since last recharge, current time of day, and recharge state. Un-programmed controls will have the following default settings; hardness - 25 grains per gallon, salt setting - HE (high efficiency). The system will recharge every 15 days (calendar override) even if no water is used. Unplug system for long periods of no water usage. Calendar override is not programmable. In addition, water used is set to 0. The internal system clock is set to 8:00 am. The display continues to show “- -:- -” until the time is manually set, which updates the internal clock. A recharge will be initiated when the internal system clock reaches 12:00 am. The recharge icon will flash.

Set the time of day - Press the time of day button. Press it again within 5 seconds and the time will increment. Press and hold for 2 seconds to rapidly increment the setting. Release the button and the time will be saved after 5 seconds.

Pick the salt setting - The controller starts (defaults) with the HE (high efficiency) setting. If you want to check or change the setting, press the salt amount button to display the current setting. To change it, press the salt amount button again within 5 seconds. The new setting will be saved after 5 seconds.

Setting HC - This setting maximizes the system capacity between recharges and will also use the most salt. This setting can be used if you have high water hardness or high water usage. Example: 3 or more people and/or hardness above 25 GPG.

Setting SD - This setting will provide a mid-range capacity. Less salt is used than the HC (high capacity), setting. More water between recharges is provided than when the HE (high efficiency) setting is used. Use this setting if the conditioner is running out of capacity when set to HE. This setting is also used if the HC setting is providing too much capacity. Use this setting if your usage or water hardness fall between the HC and HE examples.

Setting HE - This setting minimizes salt used for a recharge (uses the least amount of salt) and provides the least amount of water between recharges. This setting can be used if you have low water hardness or low water usage. Example: 2 or less people and/or hardness below 20 GPG.

Enter the hardness of the water - The controller starts (defaults) at a hardness of 25 GPG. Check your water for the actual hardness. Press the water hardness button to display the current settings. To change the setting, press the button again within 5 seconds. To rapidly increase the setting, push and hold the water hardness button. Release the button and the setting will be saved after 5 seconds. A hardness setting too high, will cause the system to recharge more often and use more salt and water than what is needed to soften your water. A hardness setting too low, will cause the system to recharge less often. The system may pass hard water shortly before it recharges.

After you have performed the previous initial power-up steps, you will need to place the softener into operation. Follow these steps carefully.

If the inlet water valve is opened too rapidly or too far, media may be lost out of the tank into the valve or the plumbing. In the 1/4 open position, you should hear air slowly escaping from the valve drain line.

Note - We recommend that you do not put salt into the tank until after the control valve has been put into operation. With no salt in the tank, it is much easier to view water flow and motion in the tank. As you advance through each cycle, there will be a slight delay before you can advance to the next cycle. The hourglass icon will light while the camshaft is indexing.

Press and hold the recharge key to start a recharge.

In order to advance the recharge cycles, you will simultaneously press time of day and recharge to advance to the next cycle. An hourglass will display while the cam is advancing. When the cam reaches the next cycle, the time remaining will be displayed. Repeat pressing the time of day and recharge to advance through each cycle. To determine which cycle the controller is in during a recharge, use the below table. The time remaining is displayed on the controller. Find the time remaining below your salt setting. The cycle column will have the cycle number. Press and hold time of day and recharge for 3 seconds to advance through all remaining recharge cycles. Hourglass will flash. Camshaft will advance to service - may take 1 to 2 minutes. For cycle times see table 1. Before turning on the water supply, you will need to check the following items. Make sure all plumbing is installed and secured. The valve drain line is in place and the end is held securely at the drain. There is no salt in the tank. The controller is on and has been programmed following the three steps. The display should be showing the time of day with the colon flashing. The inlet water is off and the bypass is not in bypass.

Note - The camshaft does not move between cycles 4 and 5. Cycle 5 begins when the brine in the salt tank runs out and the check valve closes.

If any of the above are not true, please correct the item before proceeding further.

The following steps will describe how to perform a quick recharge to verify the system is working correctly. Turn the incoming water on at a low flow position. Listen to the water flow as it is entering the media tank. Do not open the valve completely because media may enter the valve. Now, start a recharge.

Open a service faucet. The salt tank will begin to fill with water. Air will come out of the faucet. After all of the air has left the media tank the water will run without air spurts. When the salt tank has 3 to 4 inches (7.6 or 10.1 cm) of water, turn off the faucet and advance to the next cycle. Turn the inlet water on full.

The brine prep cycle allows the water in the salt tank to dissolve the salt. During this cycle inspect for leaks. If any leaks are present, they should be repaired before proceeding. If there are no leaks, advance to the next cycle. Backwash forces water through the media to the drain. Inspect the water for air bubbles and small particles. When the water is running clear, advance to the next cycle.

Brine draw and slow rinse run at the same time. The discharge to drain will slow down. The water in the salt tank will lower. If the water is leaving the salt tank, advance to the next cycle. The re-pressurize cycle is short and allows internal system pressures to stabilize. After 1-2 minutes advance to the next cycle. Fast rinse is a full pressure rinse of the media in the tank. The discharge to drain should be high. Advance to the next cycle.

Backwash 2 is a second back-washing of the media tank. Discharge to the drain will be slow. Advance to the next cycle. Fast rinse 2 is the last cycle in the recharge process. Flow to drain will be high. This cycle is 1 min long. Allow this cycle to complete and advance to service. The controller will start the first time with a recharge scheduled to start at the normal time of recharge. The media in the tank will function properly until that first recharge. Fill the salt tank with softener salt. The display should be showing the current time of day and the colon will be flashing.

Some softeners may need to be disinfected after installation and some softeners will require periodic disinfection during their normal life. Depending upon the conditions of use, the style of softener, the type of ion exchanger, and the disinfectant available, you have the choice of 5.25% sodium hypochlorite or calcium hypochlorite. These materials are satisfactory for use with polystyrene resins, synthetic gel zeolite, greensand, and bentonites.

5.25% sodium hypochlorite - These solutions are available under trade names such as Clorox® (Clorox® is a registered trademark of Clorox® company). If stronger solutions are used, such as those sold for commercial laundries, adjust the dosage accordingly.

Dosage - Polystyrene resin; 1.2 fluid ounce per cubic foot (35.5 ml per 0.03 cubic meter). Non-resinous exchangers; 0.8 fluid ounce per cubic foot (23.7 ml per 0.03 cubic meter).

Salt tank softeners - Backwash the softener and add the required amount of hypochlorite solution to the well of the salt tank. The salt tank should have water in it to permit the solution to be carried into the softener. Proceed with the normal recharge. Clorox® (Clorox® is a registered trademark of Clorox® company).

Calcium hypochlorite - (70% available chlorine), is available in several forms including tablets and granules. These solid materials may be used directly without dissolving before use.

Dosage - 129.5 mg, approximately 0.1 ounce per cubic foot (3 ml per 0.03 cubic meter).

Salt tank softeners - Backwash the softener and add the required amount of hypochlorite to the well of the salt tank. The salt tank should have water in it to permit the chlorine solution to be carried into the softener. Proceed with the normal recharge.