3” BACKWASH VALVE WITH SUPERSTAR ACTUATOR BASIC SERVICE MANUAL

1. 3” BACKWASH VALVE WITH SUPERSTAR ACTUATOR BASIC SERVICE MANUAL • Does not apply to PLC-MP version SUPERSTARS

2. 3” BACKWASH VALVE EQUIPED WITH A SUPERSTAR ACTUATOR

3. TAKE NOTICE OF THE ALIGNMENT NOTCHES LOCATED ON THE VALVE BODY AND VALVE PLATE TO ENSURE PROPER POSITIONING WHEN SERVICING VALVE. NOTCHES

4. REMOVE THE CLEAR ACTUATOR COVER. ACTUATOR VALVE MULTI FUNCTION KEY PAD SWITCH VALVE INLET FROM FILTER PORTS TO FILTER PORTS RETURN TO POOL PORT

5. DISCONNECT ALL WIRING FROM CIRCUIT BOARD.

6. UNSCREW 4 CIRCUIT BOARD MOUNTING SCREWS AND CAREFULLY LIFT CIRCUIT BOARD WITHOUT DAMAGING MICROSWITCHES IN THE CENTER.

7. DISCONNECT RIBBON WIRE CONNECTORS FROM PLUG IN SOCKETS OF CIRCUIT BOARD AND MARK UNUSED PIN FOR REINSTALLATION PURPOSES.

8. UNSCREW MOTOR MOUNTING SCEWS (4 PER MOTOR) AND REMOVE MOTORS.

9. VERIFY THAT SMALL GEAR ATTACHED TO MOTOR IS NOT DAMAGED AND SPRING PIN IS NOT BROKEN.

10. UNSCREW 3 MOUNTING SCREWS OF LIFTING CAM CYLINDER WITH ROLLER BEARINGS AND PULL IT OFF THE ASSEMBLY.

11. VERIFY THAT ALL 3 ROLLER BEARINGS ARE FASTENED SECURELY AND NO VISUAL DAMAGES ARE SHOWN ON THE MOULDED LIFTING CAM ASSEMBLY. NOTE – POSITIONING PIN HAS TO LINE UP WITH MATCHING HOLE OF MATING PART WHEN REASSEMBLING. POSITIONING PIN

12. MOULDED ARROWS IN BLACK VALVE HOUSING AND IVORY MAIN GEAR HAVE TO LINE UP (TIIMING) WHEN ACTUATOR IS POSITIONED IN FILTER POSITION.

13. CAREFULLY TAKE MAIN GEAR OFF ACTUATOR BOTTOM (PREFERABLY IN VIRTICAL POSITION) – VERIFY THAT STEEL BEARINGS DID NOT LEAVE SIGNIFICANT ROLLER MARKS IN PLASTIC GEAR AND THAT NO GEARS ARE BROKEN OFF.

14. CHECK ACTUATOR SHAFT COUPLER – BRASS INSERTS MUST BE IN PLACE. CHECK PUMP LIMIT SWITCH FOR PROPER FUNCTIONING (NORMALLY CLOSED WITH GEAR REMOVED OR IN POSITION) SHAFT COUPLER

15. CHECK FOR DEBRIS IN LIFTING CAM POSITIONING SLOTS.

16. ONE SHOULD BE ABLE TO ROTATE THE MAIN GEAR (MOTORS REMOVED AND NO PRESSURE IN VAVLE) CLOCKWISE WITH MODERATE FORCE AND THE VAVLE ROTOR SHOULD BE LIFTING UP AND ROTATING. ONCE THE POSITIONING RIBS ARE LINED UP WITH THE POSITIONING SLOTS – ROTATE COUNTER CLOCKWISE AND THE LIFTING CAM BODY SHOULD SEAT ITSELF. ONCE SEATED THE BALL BEARINGS SHOULD BE SPINING FREELY. CAUTION: MAKE SURE TO POSITION THE GEAR WITH THE TIMING ARROWS ALIGNED AS SHOWN IN PREVIOUS SLIDE.

17. VAVLE ROTOR WITH SHAFT SEAL, SPRING AND ACTUATOR SHAFT COUPLER ATTACHED. VERIFY THAT OPEN PIE SEGNMENT OF VALVE ROTOR IS ALIGNED WITH SHAFT COUPLER POSITIONING HOLE. NON FRICTION WASHER O-RINGS SPRING OPEN PIE SEGNMENT

18. INSPECT BLACK EPDM SPOKE GASKET FOR DAMAGES AND PROPER PLACEMENT. Older models have the gasket in the valve housing

19. VERIFY PROPER PUMP INTERLOCK (TERMINAL 13 & 14) WIRING. PUMP MOTOR CONTACTOR 24 V AC TRANSFORMER

20. THERE WILL BE NO LED’S LIT UP ON TOUCH PAD SWITCHES IF THE RIBBON CONNECTORS ARE CONNECTED INCORRECTLY.Also check fuse on circuit board LED for SWITCH

21. IF A LIMIT SWITCH IS BROKEN THEN THE ACTUATOR WILL NOT STOP AT ITS DESIGNATED POSITION WHEN GOING THROUGH ITS CYCLE. CIRCUIT BOARD MUST BE REPLACED. WHEN SERVICING VALVE VERIFY THAT THE 3 MOUNTING SCREWS ARE TIGHT.

22. WHEN SERVICING SYSTEM VERIFY THAT PRESSURE SWITCH WIRES ARE CONNECTED AS SHOWN BELOW. IF CONNECTED INCORRECTLY, THE AUTOMATIC BACKWASH VALVE WILL GO INTO BACKWASH CYCLES AND NOT STAY IN THE FILTER POSITION AFTER THE INITIAL BACKWASH CYCLE. Polarity of wires does not matter Pressure switch adjustment wheel

23. IF PUMP CONTROL RELAY FAILS ( PUMP DOES NOT COME ON WHEN SUPERSATR IN POSITION) CHECK TERMINAL 13 &14 FOR CONTINUITY. • If no continuity—tap relay with handle of screwdriver – • Also, check if pump limit switch reads continuity—switch must be closed in order for relay to switch Relay Terminal 13&14