GE 268, 263 User Manual

Operations Manual

Models: 268 Co-Current Conditioner

263 Three-Cycle Filter

How To Use This Manual 3

General Warnings And Safety Information 4

System Operation Cycle Functions 6

Equipment Installation 8

Valve Layout 8

Control Layout 9

Location Selection 10

Water Line Connection 12

Drain Line 14

Regenerant Line Connection 15

Overflow Line Connection 16

Electrical Connection 18

Valve Camshaft 19

Disinfection Of Water Conditioners 20

Ultramax Controller 22

Display Icons 23

Keypad — Buttons 24

Things You Might Need to Know 25

Programming Overview 26

Level I Programming 26

Level II Programming 28

Level III Programming 33

Placing Conditioner Into Operation 34

Performa Exploded View 37

Performa Parts List 38

Troubleshooting 39

2 Table of Contents Rev A

How To Use This Manual

This installation manual is designed to guide the installer through the process of installing and starting conditioners featuring the Ultramax series controllers.

This manual is a reference and will not include every system installation situation. The person installing this equipment should have:

• Knowledge of water conditioning and how to determine proper

Left Side Right Side

Icons That Appear In This Manual

control settings

• Basic plumbing skills

• The directional instructions "left" and “right" are determined by looking at the front of the unit.

Introduction

WARNING: Failure to follow this instruction can result in personal

injury or damage to the equipment.

NOTE: This will make the process easier if followed.

Inspect the unit for damage or missing parts. Contact your supplier if any discrepancies exist.

How To Use This Manual 3

Rev A

General Warnings And Safety Information

Electrical

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.

Mechanical

• Do not use petroleum based lubricants such as vaseline, oils, or hydrocarbon based lubricants. Use only 100% silicone lubricants.

• All plastic connections should be hand tightened. Teflon 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 the drain line should be done before connecting the drain line 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 1/2-inch diameter. Use 3/4-inch 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 Teflon* tape on the threads of the 1-inch NPT elbow, the drain line connections, and other NPT threads.

*Teflon is a trademark of E.I. duPont de Nemours.

4 General Warnings And Safety Information Rev A

General

• Observe all warnings that appear in this manual.

• Keep the media tank in the upright position. Do not turn 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 34°F (1°F) and 100°F (38°C).

• Working water pressure range is 20 to 120 psi (1.38 to 8.27 bar). In

Canada the acceptable working water pressure range is 20 to 100 psi (1.38 to 6.89 bar).

• Use only regenerant 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

microbiologically 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 water connection (bypass or manifold) 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.

General Warnings And Safety Information 5

Rev A

System Operation Cycle Functions

1. Service (Downflow)

Untreated water is directed down through the resin bed and up through the riser tube. The hardness ions attach themselves to the resin and are removed from the water. The water is conditioned as it passes through the resin bed.

2. Backwash (Upflow)

The flow of water is reversed by the control valve and directed down the riser tube and up through the resin bed. During the backwash cycle, the bed is expanded and debris is flushed to the drain.

3. Brine/Slow Rinse (Downflow)

The control directs water through the brine injector and brine is drawn from the regenerant tank. The brine is then directed down through the resin bed and up through the riser tube to the drain. The hardness ions are displaced by sodium ions and are sent to the drain. The resin is regenerated during the brine cycle. Brine draw is completed when the air check closes.

4. Repressurized Cycle (Hard Water Bypass Flapper Open)

This cycle allows the air and water to hydraulically balance in the valve before continuing the regeneration.

5. Fast Rinse (Downflow)

The control directs water down through the resin bed and up through the riser tube to the drain. Any remaining brine residual is rinsed from the resin bed.

6. Brine Refill

Water is directed down through the resin bed to the regenerant tank at a controlled rate, to create brine for the next regeneration.

6 System Operation Cycle Functions Rev A

Cycle Water Flows

From Regenerant

SERVICE BACKWASH BRINE/SLOW RINSE

To Regenerant

Tank

REPRESSURIZE

FAST RINSE

BRINE REFILL

System Operation Cycle Functions 7

Rev A

Equipment Installation

Valve Layout

Control Module

One Piece Valve

Disc Spring

Valve Discs

Mount

Outlet

Drain

Refill Controller

Motor

Injector and cap

Regenerant Tube Connection

Optical Sensor

Camshaft

Inlet

Backwash

Drain Control

Injector Screen

Filter

8 Equipment Installation Rev A

Control Layout

Ultramax Controller

LCD Display

PM MIN LBS

x100

Lockout Connection

Secondary Valve Motor Control

(not used)

Down Button

Set Button

Refill Sensor Probe Outlet

Turbine Input or Dry Contact Signal Input

Manual Regen Button

Up Button

AC Adapter (low voltage) Input

Main Motor & Optical Sensor Connection

Control Layout 9

Rev A

Location Selection

Location of a water treatment system is important. The following conditions are required:

• Level platform or floor

• Room to access equipment for maintenance and adding regenerant (salt) to tank.

• Ambient temperatures over 34°F (1°C) and below 120°F (49°C).

• Water pressure below 120 psi (8.27 bar) and above 20 psi (1.4 bar).

• In Canada the water pressure must be below 100 psi (6.89 bar).

• Constant electrical supply to operate the controller.

• Total minimum pipe run to water heater of ten feet (three meters) to prevent backup of hot water into system.

• Local drain for discharge as close as possible.

• Water line connections with shutoff or bypass valves.

• Must meet any local and state codes for site of installation.

• Valve is designed for minor plumbing misalignments. Do not support weight of system on the plumbing.

Outdoor Locations

• Be sure all soldered pipes are fully cooled before attaching plastic valve to the plumbing.

When the water conditioning system is installed outdoors, several items must be considered.

• Moisture — The valve and 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. If it is necessary to locate the conditioner in direct sunlight, a protective outdoor cover (PN 1242287) over the valve and controller is necessary. A valve skirt (PN 1242286) that provides further protection is available.

• Temperature — Extreme hot or cold temperatures will 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

10 Location Selection Rev A

return to normal. A protective cover should assist with high temperature applications.

• Insects — The controller and valve have been designed to keep all but

the smallest insects out of the critical areas. Any holes in the top plate can be covered with a metal foil ductwork tape. The top cover should be installed securely in place.

• Wind — The Ultramax cover is designed to withstand a 30 mph

(48 Kph) wind when properly installed on the valve.

Location Selection 11

Rev A

Water Line Connection

Figure 1 Autotrol Series 1265 bypass for use with Performa

A bypass valve system should be installed on all water conditioning systems. Bypass valves isolate the conditioner 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 illustrations below show the two common bypass methods.

Figure 2 Typical Globe Valve Bypass System

Normal Operation

Out

Water

Conditioner

Normal Operation In Bypass

In Bypass

Water

Conditioner

Out

Water

Conditioner

Water

Conditioner

Water

WARNING: The inlet water must be connected to the inlet port of the

valve. When replacing non-Autotrol valves, the inlet and outlet may be reversed. It is also possible for the plumbing to be installed in an opposite order. Do not solder pipes with lead-based solder.

12 Water Line Connection Rev A

WARNING: Do not use tools to tighten plastic fittings. Over time,

stress may break the connections. When the 1265 bypass valve is used, only hand tighten the nuts.

WARNING: Do not use petroleum grease on gaskets when connecting

bypass plumbing. Use only 100% silicone grease products when installing any Autotrol brand valve. Non-silicone grease may cause plastic components to fail over time.

WARNING: Several tube adapters are available to connect the valve

to the water plumbing. See Parts List.

Water Line Connection 13

Rev A

Drain Line

Drain Line Connection

NOTE: Standard commercial practices are expressed here. Local

codes may require changes to the following suggestions. Check with local authorities before installing a system.

1. The unit should be above and not more than 20 feet (6.1 m) from the drain. Use an appropriate adapter fitting to connect 1/2-inch (1.3 cm) plastic tubing to the drain line connection of the control valve.

2. If the backwash flow rate exceeds 5 gpm (22.7 Lpm) or if the unit is located 20-40 feet (6.1-12.2 m) from drain, use 3/4-inch (1.9 cm) tubing. Use appropriate fittings to connect the 3/4-inch tubing to the 3/4-inch NPT drain connection on valve.

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

4. Where the drain line is elevated but empties into a drain below the level of the control valve, form a 7-inch (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.

Figure 3 Drain Line Connection

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.

Right Wa y

Air Gap

Drain

WARNING: Never insert drain line directly into a drain, sewer line or

trap (Figure 3). Always allow an air gap between the drain line and the wastewater to prevent the possibility of sewage being back-siphoned into the conditioner.

14 Drain Line Rev A

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