GE 400 User Manual

Autotrol® Brand 255 Valve / 400 Series Controls

Water Conditioning Control System

Home Owner Installation, Operation, and

Maintenance Manual

For sales or service questions please contact your local dealer:

Your Local Dealer Is:

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Valve Illustration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Disinfection of Water Conditioners . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Placing Conditioner into Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Common . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

255/440i Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

255/460i Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Valve Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Safety Information

This water conditioner’s control valve conforms to NSF/ANSI 44 for materials and structural integrity only. Generic systems were tested and certified by WQA as verified by the performance data sheet.

• Please review this entire Installation and Operation manual before installing unit.

• As with all plumbing projects, we recommend that this Water Conditioning Unit be installed by a trained professional water treatment dealer. Please follow all local codes for plumbing this unit.

• Follow local electrical codes. Install a correctly sized electrical bonding jumper between the inlet and outlet pipes when these devices are installed in metallic plumbing systems.

• Inspect this unit carefully for carrier shortage or shipping damage before beginning installation of unit.

• This system is not intended to be used for treating water that is microbiologically unsafe or of unknown quality without adequate disinfection before or after the system.

• This system is to be used only for potable water.

• Use only lead-free solder and flux, as required by federal and state codes, when installing soldered copper plumbing.

• Use caution when sweat joining metal pipes near this water conditioning system. Heat can adversely affect the plastic used in this system and bypass valve.

• Use only silicone grease for lubrication of this unit.

• Use only the power transformers supplied with this conditioning systems control valve unit.

• Do not allow this water conditioning unit to freeze. Damage from freezing will void this water conditioning unit’s warranty.

• Do not store flammable or volatile chemicals near this water conditioning unit.

• For the purpose of plumbing system sizing, only the rated service (i.e. "Normal") flow and corresponding pressure loss may be used. The rated service flow rates are the flow rates at which the performance capabilities of these devices were evaluated.

Contact your local Professional Water Dealer for system service, and to obtain Autotrol brand replacement parts for this control valve unit.

Valve Illustration

Autotrol 255 Valve Control Module

400 Series Control

Standard L-Lid Cover

Var iabl e Brine Control

Injector Access Plug

Tank Adapter Module

Brine Line Fitting Connection 1/4-inch NPT

Air Check

Figure 1

Probe Connection Slot

Optional

Optional i-lid Cover

i-lid Cover

Optional Bypass

Inlet Connection 3/4-inch or 1-inch NPT or BSPT

Drain Connection 3/8-inch or 1/2-inch NPT or BSPT

Tank Thread 2-1/2-inch - 8 male

Outlet connection 3/4-inch or 1-inch NPT or BSPT

Figure 2

Introduction

The 255 series control incorporates five cycles during operation, Figure 3 and is responsible for directing the flow of water during all phases of regeneration. The water conditioner consists of a control valve, mineral tank, resin and a salt storage tank. During the service cycle, hardness contaminants are removed from the water by the resin bed. The regeneration process consists of backwash, brine and slow rinse, fast rinse and brine refill cycles. During the regeneration process the hardness contaminants are removed from the resin bed and flushed to the drain, while the resin bed is regenerated with brine. A description of each cycle and its function is listed below:

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 salt 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. 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.

5. Brine Refill (Downflow):

Brine refill occurs during a portion of the fast rinse cycle. Water is directed to the salt tank at a controlled rate, to create brine for the next regeneration.

From Brine

Tank

To Brine

Tan k

SERVICE BACKWASH BRINE/SLOW RINSE FAST RINSE

BRINE REFILL

Figure 3

Installation

All plumbing must conform to local codes.

Inspect unit carefully for carrier shortage or shipping damage.

Location Selection

1. The distance between the unit and a drain should be as short as possible.

2. If it is likely that supplementary water treating equipment will be required, make certain adequate additional space is available.

3. Since salt must be added periodically to the brine tank, the location should be easily accessible.

4. Do not install any unit closer to a water heater than a total run of 10 feet (3 m) of piping between the outlet of the conditioner and the inlet to the heater. Water heaters can sometimes overheat to the extent they will transmit heat back down the cold pipe into the unit control valve.

Hot water can severely damage the conditioner. A 10-foot (3-m) total pipe run, including bends, elbows, etc., is a reasonable distance to help prevent this possibility. A positive way to prevent hot water from flowing from heat source to the conditioner, in the event of a negative pressure situation, is to install a check valve in the soft water piping from the conditioner. If a check valve is

installed, make certain the water heating unit is equipped with a properly

rated temperature and pressure safety relief valve. Also, be certain that local codes are not violated.

5. Do not locate unit where it or it’s connections (including the drain and overflow lines) will ever be subjected to room temperatures under 34

120

F (49oC).

F (1oC) or over

6. Do not install unit near acid or acid fumes.

7. The use of resin cleaners in an unvented enclosure is not recommended.

Water Line Connection

The installation of a bypass valve system is recommended to provide for occasions when the water conditioner must be bypassed for hard water or for servicing.

The most common bypass systems are the Autotrol (Figure 4) and plumbed-in globe valves (Figure 5). Though both are similar in function, the 256 Autotrol bypass offers simplicity and ease of operation.

Not in Bypass In Bypass

Series 256 bypass valve

Figure 4 Autotrol Series 256 Bypass Valve

Not in Bypass

Water

Conditioner

In Bypass

Water

Conditioner

Figure 5 Typical Globe Valve Bypass System

Drain Line Connection

1. Ideally located, the unit will be above and not more than 20 feet (6.1 m) from the drain. For such installations, use an appropriate adapter fitting (not supplied), to connect 1/2-inch (1.3-cm) plastic tubing to the drain line connection of the control valve.

2. If the unit is located more than 20 feet (6.1 m) from drain, use 3/4-inch (1.9-cm) tubing for runs up to 40 feet (12.2 m). Also, purchase appropriate fitting to connect the 3/4-inch tubing to the 1/2-inch NPT drain connection.

3. If the unit is located where the drain line must be elevated, you may elevate the line up to 6 feet (1.8 m) providing the run does not exceed 15 feet (4.6 m) and water pressure at conditioner is not less than 40 psi (2.76 bar). You may elevate an additional 2 feet (61 cm) for each additional 10 psi (0.69 bar).

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.

5. Where the drain empties into an overhead sewer line, a sink-type trap must be used.

IMPORTANT: Never insert drain line into a drain, sewer line or trap. Always

allow an air gap between the drain line and the wastewater to prevent the possibility of sewage being back-siphoned into conditioner.

Correct Way

Drain Line Tube

Right Wa y

Drain

Figure 6

Note: Standard commercial practices have been expressed here. Local codes

may require changes to these suggestions.

Brine Line Connection

It will be necessary to install the brine tube and line to a fitting installed on the air check. Teflon

Be sure all fittings and connections are tight so that premature checking does not take place. Premature checking is when the ball in the air check falls to the bottom before all brine is drawn out of the brine tank. See Placing Conditioner into Operation section.

*Teflon is a registered trademark of E.I. DuPont de Nemours and Company, Inc.

tape all threaded connections.

Overflow Line Connection

In the absence of a safety overflow and in the event of a malfunction, the BRINE TANK OVERFLOW will direct “overflow” to the drain instead of spilling on the floor where it could cause considerable damage. This fitting should be on the side of the cabinet or brine tank.

To connect overflow, locate hole on side of brine tank. Insert overflow fitting (not supplied) into tank and tighten with plastic thumb nut and gasket as shown (Figure 7). Attach length of 1/2-inch (1.3-cm) I.D. tubing (not supplied) to fitting and run to drain. Do not elevate overflow line higher than 3 inches (7.6 cm) below bottom of overflow fitting. Do not tie into drain line of control unit. Overflow line must be a direct, separate line from overflow fitting to drain, sewer or tub. Allow an air gap as per drain line instructions (Figure 6).

Overflow Fitting

Brine Tank

Installed

Connect 1/2-inch (1.3-cm) Tubing or Hose and Run

to Drain

Figure 7

Low Voltage Transformer

Use only the included transformer for powering the 400 series timers. Connect the plug of the transformer secondary cable to the mating socket on the control (see Figure 8).

Be certain that the transformer is plugged into a correct voltage source that is not controlled by a wall switch.

Increasing the Length of the Transformer Cord

If it is necessary to extend the length of the transformer cord, an optional 15-foot (4.6-m) extension is available (see Figure 9).

Figure 8

Figure 9

Disinfection of Water Conditioners

The materials of construction of the modern water conditioner will not support bacterial growth, nor will these materials contaminate a water supply. In addition, during normal use, a conditioner may become fouled with organic matter, or in some cases with bacteria from the water supply. This may result in an off-taste or odor in the water.

Thus, your conditioner may need to be disinfected after installation. Some conditioners will require periodic disinfection during their normal life. Consult your installing dealer for more information on disinfecting your conditioner.

Depending upon the conditions of use, the style of conditioner, the type of ion exchanger, and the disinfectant available, a choice can be made among the following methods.

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