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Service instructions – Hellenbrand H-125 Series User Manual

Page 35

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35

serviCe insTruCTiOns

Drive Assembly

Remove the valve cover to access the drive assembly.

Disconnect the power source plug (black wire) from the PC

board prior to disconnecting the motor or water meter plugs

from the PC board. The power source plug connects to the

four-pin jack. The motor plug connects to the two-pin jack

on the left-hand side of the PC board. The water meter plug

(gray wire) connects to the three-pin jack on the far right-hand

side of the PC board.

PC Board Replacement

The PC board can be removed separately from the drive

bracket but it is not recommended. Do not attempt to remove

the display panel from the PC board. Handle the board by

the edges. To remove the PC board from the drive bracket,

unplug the power, water meter and motor plugs from the PC

board. Lift the middle latch along the top of the drive bracket

while pulling outward on the top of the PC board. The drive

bracket has two plastic pins that fit into the holes on the lower

edge of the PC board. Once the PC board is tilted about 45º

from the drive bracket it can be lifted off of these pins. To

reinstall a board, push the top of the PC board towards the

valve until it snaps under the middle latch, weave the power

and water meter wires into the holders and reconnect the mo-

tor, water meter and power plugs.

Drive Bracket Replacement

The drive bracket must be removed to access the drive

cap assembly and pistons or the drive gear cover. It is not

necessary to remove the PC board from the drive bracket to

remove the drive bracket. To remove the drive bracket start

by removing the plugs for the power source and the water me-

ter. Unweave the wires from the side holders. Two tabs on

the top of the drive back plate hold the drive bracket in place.

Simultaneously lift the two tabs and gently ease the top of the

drive bracket forward. The lower edge of the drive bracket

has two notches that rest on the drive back plate. Lift up and

outward on the drive bracket to disengage the notches.

To reassemble, seat the bottom of the drive bracket so the

notches are engaged at the bottom of the drive back plate.

Push the top of the drive bracket toward the two latches. The

drive bracket may have to be lifted slightly to let the threaded

piston rod pass through the hole in the drive bracket. Main-

tain a slight engaging force on top of the drive bracket while

deflecting the bracket slightly to the left by pressing on the

side of the upper right corner. This helps the drive gears

mesh with the drive cap assembly. The drive bracket is

properly seated when it snaps under the latches on the drive

back plate. If resistance is felt before latching, then notches

are not fully engaged, the piston rod is not in hold, the wires

are jammed between the drive bracket and drive back plate,

or the gear is not engaging the drive cap assembly.

Drive Gear Replacement

To inspect the drive gears, the drive gear cover needs to be

removed. Before trying to remove the gear cover, the drive

bracket must be removed from the drive back plate. (Refer to

the instructions above regarding removing the drive bracket

from the drive back plate. The drive gear cover can be

removed from the drive bracket without removing the motor

or the PC board.) The drive gear cover is held in place on the

drive bracket by three clips. The largest of the three clips is

always orientated to the bottom of the drive bracket. With the

PC board facing up, push in and down on the large clip on the

drive gear cover. Handle the cover and the gears carefully so

that the gears do not fall off the pegs in the cover.

Replace broken or damaged drive gears. Do not lubricate

any of the gears. Avoid getting any foreign matter on the

reflective coating because dirt or oils may interfere with pulse

counting.

The drive gear cover only fits on one way, with the large clip

orientated towards the bottom. If all three clips are outside of

the gear shroud on the drive bracket the drive gear cover slips

easily into place.

Drive Motor Replacement

The drive bracket does not need to be removed from the drive

plate if the motor needs to be removed. To remove the motor,

disconnect the power and motor plugs from the jacks on the

PC board. Move the spring clip loop to the right and hold. Ro-

tate the motor at least a 1/4 turn in either direction so the wires

are vertical (up & down) before gently pulling on the wire

connectors to remove the motor. Pulling directly on the wires

without rotating the motor may break the wires off the motor.

Replace the motor if necessary. Do not lubricate the motor

or the gears. To reinstall the motor, move the spring clip loop

to the right and hold. Gently turn the motor while inserting so

that the gear on the motor meshes with the gears under the

drive gear cover. Release the spring clip loop and continue

to rotate the motor until the wires are horizontal and the mo-

tor housing engages the small plastic bulge inside the drive

bracket motor retainer. Reconnect the motor plug to the

two-pronged jack on the lower left side of the PC board. If

the motor will not easily engage with the drive gears when

reinstalling, lift and slightly rotate the motor before reinserting.

Reconnect the power plug.

Replace the valve cover. After completing any valve main-

tenance, press and hold NEXT and REGEN buttons for 3

seconds or unplug power source jack (black wire) and plug

back in. This resets the electronics and establishes the

service piston position. The display should flash all wording,

then flash the software version and then reset the valve to the

service position.

Drive Cap Assembly, Main Piston and Regenerant Piston

The drive assembly must be removed to access the drive

cap assembly. The drive cap assembly must be removed to

access the piston(s). The drive cap assembly is threaded into

the control valve body and seals with an o-ring. To remove

the drive cap assembly use the special plastic wrench or

insert a 1/4" to 1/2" flat blade screwdriver into one of the slots

around the top 2" of the drive cap assembly so it engages the

notches molded into the drive back plate around the top 2"

of the piston cavity. See Figure 29. The notches are visible

through the holes. Lever the screwdriver so the drive cap as-

sembly turns counter clockwise. Once loosened, unscrew the

drive cap assembly by hand and pull straight out.

The drive cap assembly contains the drive cap, the main drive

gear, drive cap, piston rod and various other parts that should

not be dissembled in the field. The only replaceable part on

the drive cap assembly is the o-ring. Attached to the drive

cap assembly is the main piston and if a regenerant is used, a

regenerant piston.