Fleck 5600 overview and programming instructions

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I wrote my own documentation because I had to figure out what was going on after my water softener people botched things up a few times. I hope it's right and will be helpful to some.
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OPERATION AND SETTINGS ON FLECK 5600 WATER SOFTENER

City water flows into the water softener’s cylindrical tank where unwanted calcium, magnesium, and iron sticks to resin beads. The cleaned water then flows into the household plumbing. After a preset number of gallons (set on the main control dial) pass through to the household plumbing, a “regen” process is triggered (only at 2AM) that flushes out the unwanted minerals collected on the resin beads. When the “regen” occurs, (usually every 3-15 days), it temporarily disconnects the water softener from the household plumbing for 75 minutes.

The “regen” process uses the 3-7 inches of concentrated saltwater on the bottom of the salt barrel as “cleaning fluid” to flush out the resin beads. The actual level of this water (set on the back of the control panel in “lbs of salt”) determines how clean the beads will get, which in turn determines how soft the water will be. After the “regen” uses this salt water (sucking it from the bottom of the barrel that the salt is soaking in) it will be replenished so saltwater will be available again for the next “regen” in a few days.

The resin beads in a water softener tank can clean a certain number of gallons of city water. The higher the hardness PPM number (Parts Per Million) of the city water the fewer gallons it can clean until the beads are cleaned again by the regeneration process. You can calculate the number of gallons a freshly regenerated tank of beads can clean. Then you can calculate how many days on average it will take to use that amount of water. This calculation factors in 75 gallons extra for each person in the house.

The original Fleck 5600 was introduced in 1982 and there are several different versions of it. They have slightly different dials or a programming display so each operates slightly different. All however have a setting on the back of the unit for lbs of salt to use for a regen. The original version and Econominder model require lining up the arrow, white dot, number of gallons its is calculated that it will use, and number of people in the house (if it has this dial). The Soft Minder version substitutes lining up the water hardness with the number of people in the house (instead of the number of gallons calculated) aligning them with the white dot and triangular arrow at 11 o'clock.

[1] Setting the lbs of salt to use for the “regen”. As previously described, the water softness is indirectly determined by how many lbs of salt are used for the “regen". Recommended lbs of salt to clean resin 100%, for popular sizes of main tanks:

24,000 grains (tank is 8x44") requires 9 lbs of salt.
32,000 grains (tank is 9x48”) requires 12 lbs of salt.
58,000 grains (tank is 10x54”) requires 18 lbs of salt.

The factory may recommend operating at 100% capacity to produce very soft water but many people believe it’s more practical to configure at 75% which uses about half as much salt and also water may not be as “slippery". 75% of the amounts above are 6.75, 9, and 13.5 lbs respectively. This is set on the back of the main controls and is fixed with a screw.

Example: For a 24,000 grains tank, set screw on back of main control panel to 6.75 lbs so the level of saltwater on bottom of the salt barrel will be appropriate to flush (or regenerate) the resin beads to 75% of their operating capacity.

[2] Setting the number of gallons to run through the resin tank before it triggers a “regen". A “regen” should occur when the resin beads in the cylindrical tank are saturated with unwanted minerals and need to be flushed. This is a ballpark estimate of the number of gallons the system can soften before needing the resin flushed. It is a calculation based on the hardness of the local city water, and it's made slightly more frequent by subtracting for each additional person living in the house. (Additional people increase odds that a lot more water could randomly be used one day before the “regen” has a chance to run at 2 AM).

Formula to estimate number of gallons that can be processed before triggering a “regen”:
Note: local city water hardness may be listed in PPM is converted to grains by dividing by 17.1.
(Capacity of resin tank in grains X .75 / city water hardness in grains) – 75 gallons per person

Example: 24,000 grain resin tank, city water hardness 356 PPM, 2 people living in house.
((24,000 X 0.75) / 356/17.1) – (75 X 2) = 715 gallons
Pull the main dial out aligning the white dot (top left of the wheel) with the triangular arrow, at a little more than 7.

If your unit has a hardness dial, you only need to line up the white dot, triangular arrow, and number of people in the house dial. This will use the dials themselves to calculate the number of gallons that the system can process before having to regenerate.

If your water seems too soft after a few days, increase this number so it won’t trigger a “regen until more water has been run through the resin tank. NOTE: The two most common problems over time are for the slats in the bottom of the cylinder inside salt bucket to clog or the tiny cylindrical filter (inside/right) of main control panel to plug up.

 

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Simple Summary (copied from a YouTube user)​

A Fleck 5600 Water Softener goes through a Regeneration Cycle every 3-15 days (in CT).

There are 6 steps in the cycle:
The Service Position - This is NOT part of the Regeneration Cycle

Step 1: Preliminary Slow Rinse (5 minutes)
Step 2: Backwash (10 minutes)
Step 3: Brine/Slow Rinse (50 minutes)
Step 4: Rapid Rinse (10 minutes)
Step 5: Settling Rinse (5 minutes)
Step 6: Brine Tank Refill (Usually 6 -16 minutes)
Note: The language on the actual valve may differ, but the steps are the same.

Fleck 5600 Metered Softener Cycle Details​

A Fleck 5600 Metered Softener keeps track of the gallons that it treats and when it reaches a preset number (programmed by the technician), it will automatically put itself through a Regeneration Cycle at 2 am.

When NOT in a cleaning cycle, the system is in a Service Position. This does not mean that it needs service, rather, it means that it is providing you with soft, treated water.

In the Service Position:
Untreated (raw) water enters the valve and flows DOWN through the resin.
The water is treated as it comes into contact with the resin.
The treated water at the bottom enters the riser pipe and flows up through the center tube, around the piston, and into the household plumbing.
When the resin beads get full, the Cleaning Cycle will automatically begin at 2 am.
The actual Cleaning Cycle, called a Regeneration, lasts about 75 minutes and consists of:

Step 1: Preliminary Slow Rinse (5 minutes)
Note: The flow rate is based on the drain line flow control button. Usually 2.2 - 3 GPM for homes.
Raw water flows down through the resin, up the riser pipe and out to drain.
FACT: During a cleaning cycle or "Regeneration", the house can use water BUT the water will be untreated (technically, all the way through the Rapid Rinse Stage)

Step 2: Backwash (Usually 10 minutes)
Note: The flow rate is based on the drain line flow control button. Usually 2.2 - 3 GPM for homes
Raw water flows DOWN the riser pipe and UP through the resin and out to drain. This lifts the resin and helps to flush and clean any trapped minerals, particles, gunk out of the tank. It also helps to fluff up the resin and break up any channeling of the media when it was in the Service position.

Although the backwash helps to clean the resin and tank, it's the brine rinse that really scrubs the beads clean.

Step 3: Brine/Slow Rinse (Usually 50 minutes)
Note: Flow Rate is based on the injector size. For example, a #1 White injector set flows at .476 GPM at 60 psi.
Raw water enters the valve, and passes through the nozzle and throat to help create suction.
Brine is then sucked from the brine tank, mixes with some raw water and flows DOWN through the resin, UP the riser pipe and OUT to drain.
During this brine rinse, the strong brine solution forces the hardness (calcium and magnesium) and iron (ferrous iron) off the resin beads.
The beads are now clean and coated with sodium ions
FACT: The brine usually enters the tank at .25 or .50 GPM. Slow and steady. SLOWER IS BETTER

Step 4: Rapid Rinse (Usually 10 minutes)
Note: The flow rate is based on the drain line flow control button. Usually 2.2 - 3 GPM for homes
Raw water enters the valve, flows DOWN the riser pipe, UP through the resin and OUT to drain.
This rinses the beads and gets rid of any extra sodium.
TIP: If you feel the water is salty, the rinse might not be long enough.

Step 5: Settling Rinse (Usually 5 minutes)
Note: The flow rate is based on the drain line flow control button. Usually 2.2 - 3 GPM for homes
Water flows DOWN through the resin, UP through the riser pipe and OUT to drain.
This puts the resin back to its normal resting place.

Step 6: Brine Tank Refill (This will vary depending on your salt setting)
Note: Every gallon will dissolve 3 lbs of salt -really it is 2.46. So if you need 12 pounds of salt to be dissolved, you need 4 gallons of water. Your valve will then allow water to flow typically at .50 GPM for (in this case) 8 minutes. Eight minutes will put 4 gallons of water into your brine tank and dissolve 12 pounds of salt.
FACT: The Brine Tank Refill step is NOT added to the total gallons used for a regeneration.
Raw water is diverted into the brine tank
The water will dissolve the salt (or potassium chloride) to get ready for the next cycle
FACT: This is called a WET brine tank because you make brine days BEFORE you actually need it.
FACT: A DRY brine tank makes brine 90 minutes before you need it (most digital valves do Dry)
FACT: Every gallon of water can dissolve 2.48 pound