As many of you know, the Erie 541 series water softener control base platform used to be of the most common systems in the USA. There are a large number of installed mechanical and electronic versions of this controller in Utah, Idaho, Wyoming, the intermountain west, and in Europe.
The most common legacy version of this control is the 5-button 541 metered digital controller. The 5-button controller was first fielded in 1983 and went through three generational changes until it was discontinued in 1998.
The 1st and 2nd generation controllers have a red display (v1 had 6 buttons instead of 5), while the 3rd generation controller has a gray non-backlit display. Replacement circuit boards are no longer available, but they can sometimes be upgraded using a kit that works with 3-cycle, 5-cycle, and 7-cycle versions of this water softener control.
While the 110VAC digital metered control is extremely reliable, there are times when a circuit board needs to be replaced or removed and I am frequently asked how to wire the boards.
For your convenience, here is the standard wiring chart for 110/120VAC Erie control boards for the 541-170/542-172 series diaphragm soft water controls. The 3-cycle version omits the backwash solenoid, but wires identically on the other components.
Programming guide
1. Find the serial number on the back of the control.
2. Follow the steps to program the system.
3 cycle – Serial #: 541-190xx (No Solenoids on the back of system)
– Press button 2 and set Time of Day using button 3 (hours) and button 4 (minutes).
– Press button 2 and set Cleaning Time using button 3 (hours) and button 4 (minutes) (default is 2:00am).
– Press button 2 and set Capacity using button 3 (up) and button 4 (down) – 1200 gallons.
– Press button 2 and set Reserve using button 3 (up) and button 4 (down) – 350 gallons.
– Press button 2 and set Cycle 1 using button 3 (up) and button 4 (down) – 90 minutes.
– Press button 5 to confirm settings.
5 cycle – Serial #: 541-172xx (One Solenoid on the back of system)
– Press button 2 and set Time of Day using button 3 (hours) and button 4 (minutes).
– Press button 2 and set Cleaning Time using button 3 (hours) and button 4 (minutes) (default is 2:00am).
– Press button 2 and set Capacity using button 3 (up) and button 4 (down) – 1200 gallons.
– Press button 2 and set Reserve using button 3 (up) and button 4 (down) – 350 gallons.
– Press button 2 and set Cycle 1 using button 3 (up) and button 4 (down) – 5 minutes.
– Press button 2 and set Cycle 2 using button 3 (up) and button 4 (down) – 65 minutes.
– Press button 2 and set Cycle 3 using button 3 (up) and button 4 (down) – 5 minutes.
– Press button 5 to confirm settings.
7 cycle – Serial #: 541-170xx (Two Solenoids on the back of system)
– Press button 2 and set Time of Day using button 3 (hours) and button 4 (minutes).
– Press button 2 and set Cleaning Time using button 3 (hours) and button 4 (minutes) (default is 2:00am).
– Press button 2 and set Capacity using button 3 (up) and button 4 (down) – 1200 gallons.
– Press button 2 and set Reserve using button 3 (up) and button 4 (down) – 350 gallons.
– Press button 2 and set Cycle 1 using button 3 (up) and button 4 (down) – 5 minutes.
– Press button 2 and set Cycle 2 using button 3 (up) and button 4 (down) – 65 minutes.
– Press button 2 and set Cycle 3 using button 3 (up) and button 4 (down) – 5 minutes.
– Press button 2 and set Cycle 4 using button 3 (up) and button 4 (down) – 10 minutes.
– Press button 5 to confirm settings.
*T o manually cycle system, press button 1 (an arrow in the lower left corner will display. After 60 seconds the system will start the cleaning process)
**To change display options, press button 5 to switch between ‘time of day’, ‘capacity remaining’, and the flow meter.
Can you tell me what I need to do about my water softner (where I put the salt,) going dry and only leaving the salt no water?
What to trouble shoot? It is dated 9/87 so I am sure I need to replace something.
Thanks,
Dawn
Hi Dawn, all water systems will degrade and deteriorate over time, so things will break and wear out eventually requiring replacement. The system you have is designed to be easily repaired, so I’m sure that we can figure this one out.
Try the following steps and let me know how it goes:
Programming
Press button 2 on the controller – this will enter programming mode
Pressing button 2 again will advance to the next programming step
Pressing buttons 3 and 4 will allow you to make programming changes
Program your system with the following settings:
Time of day = Current time of day
Time of Regen = 2:00 am
Capacity = 1000 (Very low, just to get things started)
Reserve = 600 (600 gallons, rather high, but again just to kick things off)
Cycle 1 = 10 (Backwash)
Cycle 2 = 60 (Brine/Rinse)
Cycle 3 =10 (Rapid Rinse)
Cycle 4 = 16 (Timed Brine Tank Refill)
Press button 5 to exit programming mode
Salt Bridge Remediation
A salt bridge is a phenomenon where the salt dries into a hard crust and is suspended above the water level in the brine tank, precluding it from coming into contact with the water.
Add 5 gallons of water to the brine tank and then start a manual cleaning cycle (Press button 1 and wait 60 seconds for it to start). The 5 gallons of water will raise the water level by a minimum of 5 inches in the brine tank and help to dissolve any bridging.
After 70 minutes, the softener should have sucked all the water out of the brine tank. – If not, you have a mechanical problem that needs to be addressed.
After an additional 26 minutes, the system will be done cleaning and you should have soft water, unless the system has suffered major resin attrition.
Your system will also have added 8 gallons of water to the tank, which is about 8 inches of vertical height in an 18″ diameter tank.
Good luck !
Greg
i have problems with my water softner, i found the serial no. 191054-004.0000021c00. i don’t know what made it is and i don;t have a manual. with the manual control it works perfect, but it wont do it by its self. any advise will be appreciated.
Hi Oscar, it sounds like you might have an issue with your flow-meter. Can you post a picture of your system controller?
Greg, So awesome that you have this site! I finally found someone who knows their stuff! I have the same Erie valve softener but have no idea how to program it or how many cycles it needs to do per day. I live in Utah so the water is really hard. Do you have a manual for this machine?
Hi Clif, that is a good softener. If seen many keep running for decades.go to http://www.softenerhelp.com – you can find most softener manuals there.
The closest to your model’s software is this one: http://softenerhelp.com/manuals/isw/Spectrum_7360_User_Guide.pdf
Check back in here if you need more help.
Greg … I just found this post! I downloaded the manual, did what it said. It’s been several years since this thing has ran. How long do you think it will take to clean out and start working?
Hi Cliff, you should notice an immediate improvement on the cold softened water after a successful cleaning/regeneration cycle. Hot water can sometimes take up to a week to dilute out, depending on heater size and household water consumption. Let me know how it goes.
Greg, I have the Erie 5 button digital control timer on a 8×44 tank. It is like the 541-190xx you describe above. When I use button #2 to set the regeneration cycle, it only displays cycle 1, it does not show cycle 2,3,4 as described for the 541-170xxs. I have .75 cu/ft of resin in the tank and would like to set this up for 4000 grains per lb of salt, which would give me 3 lbs of salt and 12000 grains of capacity on my .75 cu/ft tank. Or I may also want to set it to 6lbs of salt per cu//ft, and that would be 4.5 lbs of salt and 18000 grains of capacity.
How do I figure out what the single regeneration cycle time setting should be set to? Since one gallon of water dissolves three pounds of salt, then I would want the timer set up so that it only uses one gallon of brine on the regeneration. Maybe I can put the float in a 1 gallon bucket of water and time how long it takes? But I’m not sure if the regeneration time setting is just for the brine flush, or does it include the backwash and brine fill also?
Hi Kent,
Your model is called a “3-cycle system”, wherein it does three things:
1. Service
2. Brine/Rinse
3. Tank Fill
Your computer can only control the brine/rinse cycle, which should be set for 75 minutes to be sure that it will clean properly.
Your brine refill is float controlled (Constantly pressurized while in service), so the computer has no control over it at all. It is reliant an the actual brine level in the tank. An 18″ diameter brine tank will yield 1 gallon of brine per vertical inch (without dry salt displacement) and it is most likely that you have a deck in the tank as well. Simply measure the height you want above the air-check on the float (be ure that it is also above the deck) and set it accordingly.
Greg, The water softener seems to kick on but I am not feeling any difference. Since it’s been a while, should I dump some water in the salt tank? If so, how much?
Hi Cliff, add 6 vertical inches to the tank and then start a cycle. Watch and see that it sucks all of that water out within the first 30 minutes of the brine/rinse cycle. If it doesn’t, check your injector for obstructions.
I’ve got a the cycle that won’t quit running. Over tried unplugging and reprogramming it. Any ideas why it would be doing that and what I can I do to trouble shoot it?
Hi Marc,
The most common reason for those Erie 541-xx digital diaphragm models to run down the drain is when the “flapper valve” (also known as the drain paddle assembly) gets scaled stuck in the open position; and only a mechanical repair will remedy the problem.
Your local soft water dealer should be able to help you out at a reasonable price. If you’d like to try a DIY repair, these guys carry the parts:
http://www.softenerparts.com/Drain_Paddle_Stem_Assembly_467_351_p/pe467351.htm
http://www.softenerparts.com/Drain_Seat_Erie_541E_409_192_71698_p/pe409197.htm
I hope you still check this site. I have a water softener with the numbers 541-190C3FAA serial number 94233. I have no idea what brand it is. It came with my house and there are no instructions. Help please!
Hi Breanna, those were once very good systems. Here’s the generic manual for it http://www.scribd.com/doc/73160918/Erie-Electronic-Installation-Manual
Is it running properly right now?
Hello. I have a 541 softener and what I suspect is another 541 electronic right after it then goes to house. Can program manual one but don’t understand the purpose of the electronic one. Very hard water where I live, oh they are both erie units Do not have operators manual for either, please help.
Greg – hoping you can help. I have an Erie 541-190C3FAA. I can’t figure out what to put for Capacity and reserve. Please help!
Hi, it will depend on the system size and water hardness.
Typically, the tank size will be listed on the dataplate on the side of the tank. If not, use your tape measure.
8×44 Tank = 32,000 Grain
10×47 Tank = 48,000 Grain
10×54 Tank = 54,000 Grain
10×60 Tank = 60,000 Grain
The capacity of the system is then divided by your water hardness to get you into a reasonable range for the system capacity.
For example, if you have an 8×44 tank (32,000 Grain Capacity) and 20 grains of water hardness your capacity will be 1600 Gallons.
If you don’t know your water hardness, a quick call to your water provider will be helpful.
Let me know if you need more help.
Hi, this should help: https://www.scribd.com/document/353428278/Erie-541-Programming-Guide
So I am a few years late with this, but the manual you gave me is just for installation and it’s already installed. I just need to know how to use it 🙂 I had the question from 2015 about the old Eerie Water Softener
Hey, Greg
I have read through your site here and it is very informative. Great information. I have just bought an older home that has an Erie 5-182C4FAB, Model #87137. No manual was available. I looked through your information and couldn’t find instructions or programing. Do you know where I might get some instructions or some help?
Thanks,
Steve Nielson
Hi Steve,
The programming sequence for the model 541-172 listed here will work perfectly for that model: http://gregknowswater.com/older-erie-541-softener-circuit-boards/
Hi Breanna, the programming instructions for the 541-190 listed here will work for you – http://gregknowswater.com/older-erie-541-softener-circuit-boards/
Let us know if you need more help or advice on operating it.
What state are you in?
Hello Greg,
I have a Erie 541-182C4FAB and I believe my drain hose valve is leaking. (clear hose that goes to my drain) Is there a valve or a seal that can be replaces to fix that from constantly draining a small amount of water when not in the middle of a cycle?
Hi Adam,
That’s typically the drain seal and paddle assembly; especially if it is more than 5 years old.
Post a picture of the top and front of your system control valve, and I can tell you which parts you need.
All the best,
Greg
Not quite sure how to post a picture
Hi Greg,
I have a 541-186C4FAB and I cannot find any links to it on the internet. On the door to the control panel it simply says Superior.
The difficulty that I am having is that about once a week when we turn on the water in the master bathroom sinks or shower in the morning between 5 and 7 AM there is allot of salinity in the water. If we let it run for 3 to 4 minutes it return to normal. Is this a normal feature of water softeners? Is there most likely something set incorrectly with the controls or an issue with the clock? We moved from Colorado to Northern Utah. We have never had a water softener before and I’m told that our spring water has a 12 to 14 grain hardness level.
Thanks
Bryan
This will likely be a relatively simple programming fix. Add 30 minutes to the brine/rinse time.
Hi Greg, I have a Erie 541-N482C4AB0DN water softener in the home I purchased recently. It does not give many options. It is set to re-generate every day at 2.am. I’m not sure it is necessary, What do you feel?
Secondly, I believe it consumes a lot of salt. It has been hardly three weeks and I had to re-fill another 3 bags again. Is this normal?
The date on the control panel shows 04/26/2004 and the letters INJ : 4. What does that mean?
Any comments would be appreciated.
Thanks
Andy