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:
Table of Contents
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
2
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.
3
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
Air Check
Figure 1
Probe Connection Slot
Optional
Optional i-lid Cover
i-lid Cover
Optional Bypass
S
S
A
P
Y
B
S
S
A
P
Y
B
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
4
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.
5
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
6
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
o
120
F (49oC).
o
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
B
Y
P
A
S
S
B
Y
P
A
S
S
®
Series 256 bypass valve
A
P
A
P
S
Y
S
B
S
Y
S
B
Figure 4 Autotrol Series 256 Bypass Valve
Not in Bypass
Water
Conditioner
In Bypass
Water
Conditioner
Figure 5 Typical Globe Valve Bypass System
7
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.
8
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.
9
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.
10
Sodium or Calcium Hypochlorite
Application
These materials are satisfactory for use with polystyrene resins, synthetic gel
zeolite, greensand and bentonites.
5.25% Sodium Hypochlorite
These solutions are available under trade names such as Clorox*. If stronger
solutions are used, such as those sold for commercial laundries, adjust the
dosage accordingly.
1. Dosage
a. Polystyrene resin; 1.2 fluid ounce per cubic foot.
b. Non-resinous exchangers; 0.8 fluid ounce per cubic foot.
2. Brine tank conditioners
a. Backwash the conditioner and add the required amount of hypochlorite
solution to the brine well of the brine tank. The brine tank should have water
in it to permit the solution to be carried into the conditioner.
b. Proceed with the normal regeneration.
Calcium Hypochlorite
Calcium hypochlorite, 70% available chlorine, is available in several forms
including tablets and granules. These solid materials may be used directly without
dissolving before use.
1. Dosage
a. Two grains (approximately 0.1 ounce) per cubic foot.
2. Brine tank conditioners
a. Backwash the conditioner and add the required amount of hypochlorite to
the brine well of the brine tank. The brine tank should have water in it to
permit the chlorine solution to be carried into the conditioner.
b. Proceed with the normal regeneration.
Placing Conditioner into Operation
Initial Start-Up
After the water conditioning system is installed, the conditioner should be
disinfected before it is used to treat potable water. Refer to the Disinfection of
Water Conditioners section in this manual. Complete the following steps to place
the conditioner into operation:
1. Remove control valve cover.
Note: The following steps will require turning the indicator knob (Figure 11)
to various positions. Insert a wide-blade screwdriver into arrow slot in
indicator knob and press in firmly. With knob held in, rotate
*Clorox is a trademark of the Clorox Company.
11
COUNTERCLOCKWISE only until arrow or knob points to desired position.
Rotation is made much easier if you grasp the camshaft with your free hand
and turn it at the same time. Then permit knob to spring back out.
2. Insert screwdriver into slot in indicator knob (Figure 11). Press in and rotate
knob COUNTERCLOCKWISE until arrow points directly to the word
BACKWASH.
3. Fill resin tank with water.
a. With water supply off, place the bypass valve(s) into the “NOT IN BYPASS”
position.
b. Open water supply valve very slowly to approximately the 1/4 open
position.
IMPORTANT: If opened too rapidly or too far, resin may be lost. In this position,
you should hear air escaping slowly from the drain line.
c. When all of the air has been purged from the tank (water begins to flow
steadily from the drain), open the water supply valve all the way.
d. Allow water to run to drain until clear.
e. Turn off water supply and let the unit stand for about five minutes. This will
allow all trapped air to escape from the tank.
4. Add water to brine tank (initial fill).
With a bucket or hose, add approximately 4 gallons (15 liters) of water to brine
tank. If the tank has a salt platform above the bottom of the tank, add water
until the level is approximately 1 inch (25 mm) above the platform.
12
Control Valve
Air Check
Check Ball
Female Elbow
Brine Line
Figure 10 - Control Valve
5. Put into operation.
a. Open water supply valve slowly to full open position.
b. Carefully advance indicator knob COUNTERCLOCKWISE to center of
FAST RINSE/REFILL position and hold there until air check (Figure 10) fills
with water and water starts to flow through brine line into brine tank. Do not
run for more than two minutes.
c. Advance indicator knob COUNTERCLOCKWISE until arrow points to the
center of the BRINE/SLOW RINSE position.
d. With the conditioner in this position, check to see if water is being drawn
from the brine tank. The water level in the brine tank will recede very slowly.
Observe for at least three minutes. If the water level does not recede or
goes up, or if air enters the transparent air check chamber and the ball falls
and seats, reference Troubleshooting section.
e. Advance indicator knob COUNTERCLOCKWISE to CONDITIONED
WATER.
f. Run water from a nearby faucet until the water is clear and soft.
13
400 Series Control Settings
440i Control
Day Arrow
Skipper Pins
Skipper Wheel
Indicator Knob
Timer
Locking Pin
Time Arrow
Timer Knob
Figure 11
Programming
1. Set days of regeneration on skipper wheel (Figure 11).
• Pull all skipper pins outward (away from control).
• Rotate skipper wheel until day arrow points to current day or number 1.
• Depress skipper pin(s) at day(s) for which regeneration is desired.
2. Set the time of day.
• Grasp timer knob and pull outward.
• Rotate in either direction until the timer arrow points to the actual time of
day.
• Release timer knob.
Note: With the time of day properly set, the conditioner will regenerate at about
2:30 a.m. If you prefer to have the unit regenerate at an earlier or later time, simply
set current time-of-day accordingly (e.g., to have the unit regenerate at 4:30 a.m.—
two hours later—set the clock two hours earlier than the actual time of day.)
Note: The Timer Locking Pin should always be horizontal (Figure 11) during
operation.
14
460i Control
Programming
Water Flow Indicator
PM Indicator
Indicator Knob
Timer
Locking Pin
Time Set Button
Figure 12
Hour Time Display
Transforme r P l u g
Receptacle
Access Door
Raised
Ta b
Jumper
Spare
Jumper
Plug the wall-mount transformer into a functioning electrical outlet that is not
controlled by a switch. Plug the transformer into the transformer plug receptacle
on the control.
Open the access door by pushing the raised tab on the door toward the left while
pulling the tab out (Figure 12).
Time of Day Setting
With the jumper on the set of pins next to the word TIME (Figure 13), set the time
of day to the closest hour by pressing the black TIME SET button. PM hours are
indicated by a light next to the letters PM on the display window.
Note: The use of a small needle-nose pliers will aid in moving the jumper.
Note: The unit is factory set to regenerate at 2:00 a.m. If you prefer to have the
unit regenerate at an earlier or later time, simply set the current time of day
accordingly (e.g., to have the unit regenerate at 4:00 a.m.—two hours later—set
the clock two hours earlier than the actual time of day).
Note: The Timer Locking Pin should always be horizontal (Figure 12) during
operation.
15
Hardness Setting
Move the jumper to the set of pins next to the word HARDNESS (Figure 14).
Press the black TIME SET button until the hardness of the incoming water supply
is displayed. The hardness range is from 1 to 99 grains per gallon.
To change water hardness stated in parts per million (PPM) to grains per gallon
(GPG) use this formula:
Parts per Million
17.1
Capacity Setting
Move the jumper to the set of pins next to the word CAPACITY (Figure 15). Press
the black TIME SET button until the correct capacity value is displayed. The
capacity range is 1 to 99 kilograins. Refer to the Suggested Salt Dial Settings
table.
Return the jumper to the top set of pins next to the word TIME and replace the
access door. The jumper must NOT be left on any pins other than the top pair
next to the word TIME. Otherwise, the unit may show a blank display.
=
Grains per Gallon
Figure 13 Figure 14
Figure 15
Note: A spare jumper is located on the bottom set of pins.
In the event that the hardness or capacity setting must be changed, simply follow
the appropriate steps described above.
Calendar Override Setting
1. Disconnect power.
2. Place jumper on Pin A and reconnect power.
3. Move jumper to Pin B. A zero will appear, indicating zero days of calendar
override. All 460i controllers are preprogrammed in this manner at the
manufacturer.
16
4. Depress the black TIME SET button. The numbers will roll from “0” to “15.”
Release the switch at the desired number of days for the calendar override. For
example, releasing the switch at “10” would program a 10-day calendar
override.
5. Disconnect power.
6. Place jumper back on TIME and reconnect power.
7. The calendar override program is maintained during power outages by the
NOVRAM circuitry.
8. To remove the calendar override, follow the same steps above and program
back to “0.”
Common Features
When using the 255 valve with the 440i or 460i controls, there are several
features and procedures that are unique to the 400 series controls. They are as
follows:
Salt Dial Adjustment
These models may be adjusted to produce maximum to minimum conditioning
capacities by setting the salt dial, which controls the amount of salt used per
regeneration. When desired, the minimum setting may be used on installations if
the frequency of regeneration is increased to compensate for lower regenerated
conditioning capacity. The installing dealer will set the unit for proper salt usage.
Further adjustments are needed only if the hardness of the water supply changes
or if water use changes dramatically. Capacity will need to be adjusted
accordingly.
To adjust salt dosage, insert a small screwdriver into the white indicator knob and
move pointer to proper salt setting (Figure 13).
Note: To convert the salt settings from English to metric, divide by 2.2 (e.g., 12
pounds ÷ 2.2 = 5.5 kg of salt).
Figure 13
17
Table 1 – Suggested Salt Dial Settings (Pounds of Salt) For Various Size Softeners
Capacity
Setting
(Kilograins)
12 4.5——————
16 9.05.5—————
20 —8.56.0 ———
24 — 14.0 8.5 7.0 — — —
30 — — 15.0 11.0 9.0 — —
32 — — 18.5 12.5 10.0 9.0 —
35 — — — 16.0 12.0 10.0 9.0
40 — — — 11.5* 17.0 14.0 12.0
48 — — — — 14.0* 10.5* 17.0
60 ——————15.0*
0.5 Ft
3
0.75 Ft31.0 Ft31.25 Ft31.5 Ft31.75 Ft32.0 Ft
3
*This setting requires the use of “XS” (extra salt) cam and doubles the amount of
the setting.
The amount of salt placed in the brine tank has nothing to do with the amount of
salt used during the regeneration cycle. Water will dissolve and absorb salt only
until it becomes saturated. A given amount of brine (salt-saturated water) contains
a specific amount of salt. The salt dial controls the amount of brine used during
the regeneration cycle (e.g., when set at 15 pounds (6.8 kg) the amount of brine
the conditioner will use for each regeneration will contain 15 pounds (6.8 kg) of
salt, etc.)
Never let the amount of salt in the brine tank be lower than the normal liquid level.
Do not overload the brine tank with salt.
Guest Cycle (Manual Regeneration)
When abnormally high water usage exhausts your water conditioner’s capacity
ahead of schedule, an extra regeneration can be achieved. Depress the indicator
knob on the 440i (Figure 11) with a wide-blade screwdriver and turn
COUNTERCLOCKWISE to START to initiate a regeneration. For the 460i, simply
depress the indicator knob (Figure 12). It will take a few minutes for regeneration
to start. A normal regeneration will take approximately two hours.
18
Preventive Maintenance
Inspect and clean brine tank and screen filter on end of brine pickup tube once a
year or when sediment appears in the bottom of the brine tank.
Clean injector screen and injector once a year:
1. Unplug the wall-mount transformer.
2. Shut off water supply or put bypass valve(s) into bypass position.
3. Relieve system pressure by opening valve No. 5
(at rear) with a screwdriver.
4. Using a screwdriver, remove injector screen and injector cap (Figure 16).
5. Clean screen using a fine brush. Flush until clean.
6. Using a needle-nose pliers, pull injector straight out.
7. Flush water into the injector screen recess of the valve body to flush debris out
through the injector recess.
8. Clean and flush the injector.
9. Lubricate the O-rings on the injector, injector cap and injector screen with
silicone lubricant.
10. Reinstall the injector, injector cap and injector screen. See IMPORTANT note.
11. Plug the wall-mount transformer into outlet; reset time of day.
12. Slowly open water supply valve or return bypass valve(s) to the “not in bypass”
position.
IMPORTANT: Do not overtighten the plastic cap. Seat the cap lightly into
position. Overtightening may cause breakage of the plastic cap that may not be
immediately evident.
Figure 16
19
Replacement Parts for Autotrol Brand 255 Control
Valve Body
18
19
16
15
5
4
Tank Adapter
Module
6
2
21
20
3
7
17
1
9
8
10
22
t
21
23
21
7
22
22
t
e
l
n
i
n
i
a
r
d
e
l
t
u
o
11
13
12
23
14
22
20
255 Valve & Tank Adapter Module
Code Part No. Description Qty.
1 1000232 Valve Assembly, w/o Flow Controls 1
2 Camshaft: 1
1031950 Standard, One-Piece
1033024 Standard, Segmented
1033025 Extra Salt, Segmented
1033026 Long Rinse, Segmented
1032969 Water Saver, Segmented
3 1030501 Camshaft Bearing 1
4 1031391 Timer Locking Pin 1
5 1000226 Screen/Cap Assembly w/O-Ring 1
6 Drain Control Assembly w/O-Rings: 1
1000209 No. 7 (1.2 gpm; 4.5 Lpm)
1000210 No. 8 (1.6 gpm; 6.1 Lpm)
1000211 No. 9 (2.0 gpm; 7.6 Lpm)
1000212 No. 10 (2.5 gpm; 9.5 Lpm)
1000213 No. 12 (3.5 gpm; 13.2 Lpm)
1000214 No. 13 (4.1 gpm; 15.5 Lpm)**
1000215 No. 14 (4.8 gpm; 18.2 Lpm)**
7 1030502 Ball, Flow control 2
8 Brine Refill Control: 1
1034261 1 to 10 lbs Salt
1034263 3 to 19 lbs Salt
9 Injector Assembly with O-Rings: 1
1032970 “A” Injector - White
1032971 “B” Injector - Blue
1032972 “C” Injector - Red
10 1000269 Injector Cap with O-Ring 1
12 1032416 Air Check Kit 1
13 1010429 O-Ring BN 1
14 1010428 O-Ring EP 1
15 Locking Bar: 1
1031402 English Language
1031403 French Language
1031404 German Language
1031405 Italian Language
1031406 Japanese Language
1031407 Spanish Language
16 1006093 Screw, No. 8 x 9/16 inch 1
17 1001580 Spring, Valve Discs 9
18 1032565 Valve Cover, Standard, Black 1
19 1000062 i-Lid Cover 1
20 1000297 Extended Connector (For use with i-Lid Cover) 1
21
Kits:
21 1001404 O-Ring Group: Tank Adapter, 1010117 (1),
1010407 (1), 1010410 (4)
22 1040459 O-Ring Group: Piping Boss 1010431 (1),
1010411 (2)
23 1041010 13/16 Rubber Insert (Optional)
Valve Discs:
* 1000250 Standard
* Not Shown
**Flow control does not use Flow Control Ball (1030502).
22
Replacement Parts
440i
D
B
A
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Y
IN
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S
/
LO
W R
IN
S
E
F
A
S
T
R
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IN
F
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IL
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L
/
CO
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WA
IT
IO
T
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N
R
E
D
MA
NUAL REG
P
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S
CL
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K
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CKWIS
ENERA
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A
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CKWAS
I
G
H
T
S
T
H
A
R
T
U
N
T
T
O
E
R
L
S
E
-
E
T
A
T
IM
S
E
E
O
P
U
F
LL
D
A
K
A
N
Y
N
D
O
3A
R
B
O
M
T
A
T
E
6A
M
Meter Adapter
1
460i
1
3P
M
N
O
O
N
9A
M
2
2
3
256 Bypass Valve
Piping Boss
1
1
S
S
A
P
Y
B
S
S
A
P
Y
B
2
Note: Do not use pipe joint compound when
threading pipe into the Noryl piping boss. Use
only Teflon* pipe tape. Do not overtighten pipe
into Noryl piping boss.
2
23
255 Series Accessories
Part
Code
1 440i Assembly 1
2 460i Assembly 1
3 Transformer 1
* 1030234 Transformer Extension Cord 15 foot (4.5 m) 1
No. Description Qty.
1000810 Japanese
1000811 North American
1000812 Australian
1000813 British
1000814 European
Piping Boss
1 Piping Boss Kit (includes Hardware): 1
1040277 3/4-inch NPT, Brass 3/8-inch NPT Drain
1040278 1-inch NPT, Brass 1/2-inch NPT Drain
1040281 3/4-inch BSPT, Brass 3/8-inch BSPT Drain
1040282 1-inch BSPT, Brass 1/2-inch BSPT Drain
1040279 3/4-inch NPT, Noryl 1/2-inch NPT Drain
1040280 1-inch NPT, Noryl 1/2-inch NPT Drain
1040283 3/4-inch BSPT, Noryl 1/2-inch BSPT Drain
1040284 1-inch BSPT, Noryl 1/2-inch BSPT Drain
2 1040339 Piping Boss installation Kit 1
Meter Adapter
1 1032350 Kit, Meter Adapter 1
2 1032351 Meter Install Kit 1
Bypass Valve
1 1040769 Bypass Body Assembly with Install Kit 1
2 1040524 Bypass Installation Kit 1
24
Tube Adapter Kits
* 1001606 3/4-inch Copper Tube Adapter Kit 1
* 1001670 1-inch Copper Tube Adapter Kit 1
* 1041210 1-1/4-inch Copper Tube Adapter Kit 1
* 1040547 90 degree Elbow Adapter Kit 1
* 1001608 22-mm Copper Tube Adapter Kit 1
* 1001613 3/4-inch CPVC Tube Adapter Kit 1
* 1001614 1-inch CPVC Tube Adapter Kit 1
* 1001615 25-mm CPVC Tube Adapter Kit 1
* 1001769 3/4-inch NPT Plastic Pipe Adapter Kit 1
* 1001603 1-inch NPT Plastic Pipe Adapter Kit 1
* 1001604 3/4-inch BSPT Plastic Pipe Adapter Kit 1
* 1001605 1-inch BSPT Plastic Pipe Adapter Kit 1
* 1001611 3/4-inch BSPT Brass Pipe Adapter Kit 1
* 1001610 1-inch NPT Brass Pipe Adapter Kit 1
* 1001612 1-inch BSPT Brass Pipe Adapter Kit 1
25
Troubleshooting
The technology upon which the Series 255 control is based is well established
and proven in service over many years. However, should a problem or question
arise regarding the operation of the system, the control can be very easily
serviced. The control module can be quickly replaced or adjustments can be
made at the installation. We recommend that you contact your local professional
water treatment dealer for most concerns. For parts mentioned, refer to exploded
views in the Replacement Parts section of this manual.
IMPORTANT: Service procedures that require the water pressure to be
removed from the system are marked with a ! after the possible cause. Refer to
Preventative Maintenance section for instructions.
Common
Problem Possible Cause Solution
1. Brine tank
overflow.
2. Flowing or
dripping
water at
drain or brine
line after
regeneration
.
3. Hard water
leakage after
regeneration
.
a. Uncontrolled brine refill
flow rate.
b. Air leak in brine line to air
check.
c. Drain control clogged
with resin or other debris.
a. Valve stem return spring
weak.
a. Improper regeneration.
b. Leaking of external
bypass valve.
c. O-ring around riser pipe
damaged.
a. Remove brine control to clean ball
and seat.
b. Check all connections in brine line
for leaks. Refer to instructions.
c. Clean drain control.
a. Replace spring. (Contact dealer.)
a. Repeat regeneration after making
certain correct salt dosage was
set.
b. Replace bypass valve. (Contact
dealer.)
c. Replace O-ring. (Contact dealer.)
26
4. Control will
not draw
brine.
a. Low water pressure.
b. Restricted drain line.
c. Injector plugged !
d. Injector defective !
e. Valve disc 2 and/or 3 not
closed.
f. Air check valve
prematurely closed.
a. Make correct setting according to
instructions.
b. Remove restriction.
c. Clean injector and screen.
d. Replace injector and cap.
(Contact dealer.)
e. Remove foreign matter from disc
and check disc for closing by
pushing in on stem. Replace if
needed. (Contact dealer.)
f. Put control momentarily into brine
refill. Replace or repair air check if
needed. (Contact dealer.)
27
255/440i Troubleshooting
Problem Possible Cause Solution
1. Control will not
regenerate
automatically.
2. Control
regenerates at
wrong time of day.
3. Control will not
draw brine.
4. System using
more or less salt
than salt dial
setting.
5. Intermittent or
irregular brine
draw.
6. No conditioned
water after
regeneration.
a. Transformer or motor not
connected.
b. Defective timer motor.
c. Skipper pins not down on
timer skipper wheel.
d. Binding in gear train of
timer.
a. Timer set incorrectly. a. Correct time setting
a. Low water pressure.
b. Restricted drain line.
c. Injector plugged.
d. Injector defective.
e. Air check valve closes
prematurely.
f. Timer locking pin not
horizontal.
a. Foreign matter in
controller causing
incorrect flow rates.
b. Defective controller
a. Low water pressure.
b. Defective injector.
a. No salt in brine tank.
b. Injector plugged.
c. Air check valve closes
prematurely.
a. Connect power.
b. Replace motor. (Contact
c. Depress pins for days
d. Replace timer. (Contact
a. Set pump to maintain 20 psi
b. Change drain to remove
c. Clean injector and screen.
d. Replace injector. (Contact
e. Put control momentarily into
f. Turn to horizontal position.
a. Remove brine control and
b. Replace brine control.
a. Set pump to maintain 20 psi
b. Replace injector. (Contact
a. Add salt to brine tank.
b. Clean injector and screen.
c. Put control momentarily into
dealer.)
regeneration required.
dealer.)
according to instructions.
at softener.
restriction.
dealer.)
brine/slow rinse. Replace or
repair air check if needed.
(Contact dealer.)
(Contact dealer.)
flush out foreign matter.
Manually position control to
brine/slow rinse to clean
controller (after so doing
position control to "purge” to
remove brine from tank).
(Contact dealer.)
at softener.
dealer.)
brine/slow rinse. Replace or
repair air check if needed.
(Contact dealer.)
28
Problem Possible Cause Solution
7. Control
backwashes or
purges at
excessively low or
high rate.
a. Incorrect drain controller
used.
b. Foreign matter affecting
controller operation.
a. Replace with correct size
b. Remove drain controller and
255/460i Troubleshooting
Problem Possible Cause Solution
1. Clock does not
display time of
day.
2. Clock does not
display correct
time of day.
3. Time display
continues to
advance.
4. Time display
shows something
other than time of
day.
5. No water flow
display when
water is flowing.
a. Transformer cord
unplugged.
b. No electric power at
outlet.
c. Defective transformer.
d. Defective circuit board.
a. Outlet operated by
switch.
b. Incorrect voltage or
frequency (Hz).
c. Power outages.
a. Defective time set switch. a. Replace timer. (Contact
a. Electrical interference.
b. Defective circuit board.
a. Bypass valve in bypass.
b. Meter probe
disconnected or not fully
connected to meter
housing.
c. Restricted meter turbine
rotation due to foreign
material in meter !
d. Defective meter probe.
e. Defective circuit board.
a. Connect power.
b. Repair outlet or use working
c. Replace transformer.
d. Replace timer. (Contact
a. Use outlet not controlled by
b. Replace timer with one of
c. Reset clock.
a. Disconnect power to unit.
b. Replace timer. (Contact
a. Shift bypass valve to not-in-
b. Fully insert probe into meter
c. Remove meter housing, free
d. Replace timer. (Contact
e. Replace timer. (Contact
controller. (Contact dealer.)
clean ball and seat.
outlet.
(Contact dealer.)
dealer.)
switch.
correct voltage and
frequency (Hz). (Contact
dealer.)
dealer.)
Restore power and reset
time of day display.
dealer.)
bypass position.
housing.
up turbine and flush with
clean water. Turbine should
spin freely. If not, replace
meter. (Contact dealer.)
dealer.)
dealer.)
29
Problem Possible Cause Solution
6. Control
regenerates at
wrong time of day.
7. Timer stalled in
regeneration
cycle.
8. Continuous
regeneration.
Camshaft does
not stop at the end
of regeneration.
9. Control will not
regenerate
automatically or
when button is
pressed.
a. Power outages.
b. Clock set incorrectly.
a. Motor dead.
b. Motor runs backward.
c. No electric power at
outlet.
d. Broken gear.
e. Defective switch.
f. Air leak in brine
connections.
g. Binding of camshaft.
h. Water pressure greater
than 125 psi (8.6 bar)
during regeneration !
i. Defective circuit board.
a. Broken switch actuator
on gear.
b. Defective switch.
a. Electric cord or
transformer unplugged.
b. No electric power at
outlet.
c. Defective motor.
d. Broken gear.
e. Binding in gear train.
f. Defective switch.
a. Reset clock to correct time of
day.
b. Reset clock to correct time of
day.
a. Replace timer. (Contact
dealer.)
b. Replace timer. (Contact
dealer.)
c. Repair outlet or use working
outlet.
d. Replace timer. (Contact
dealer.)
e. Replace timer. (Contact
dealer.)
f. Check all junction points and
make appropriate
corrections.
g. Remove foreign object
obstruction from valve discs
or camshaft.
h. Install pressure regulator.
i. Replace timer. (Contact
dealer.)
a. Replace timer. (Contact
dealer.)
b. Replace timer. (Contact
dealer.)
a. Connect power.
b. Repair outlet or use working
outlet.
c. Replace timer. (Contact
dealer.)
d. Replace timer. (Contact
dealer.)
e. Replace timer. (Contact
dealer.)
f. Replace timer. (Contact
dealer.)
30
Problem Possible Cause Solution
10. Control will not
regenerate
automatically but
will regenerate
when button is
pressed.
11. Run out of soft
water between
regenerations.
12. Brine tank
overflow.
a. If water flow display is not
operative, refer to Item 5.
b. Defective circuit board.
c. Incorrect hardness and
capacity settings.
a. Improper regeneration.
b. Incorrect salt setting.
c. Incorrect hardness or
capacity settings.
d. Water hardness has
increased.
e. Restricted meter turbine
rotation due to foreign
material in meter !
a. Brine valve disc 1 being
held open by foreign
matter.
b. Uncontrolled brine refill
flow rate.
c. Valve disc 2 not closed
during brine draw causing
brine refill.
d. Air leak in brine line to air
check.
e. Improper drain control for
injector.
f. Drain control clogged
with resin or other debris.
a. Same as Item 5.
b. Replace timer. (Contact
c. Set to correct values. See
a. Repeat regeneration,
b. Set salt control to proper
c. Set to correct values. See
d. Set hardness to new value.
e. Remove meter housing, free
a. Manually operate valve stem
b. Remove variable salt
c. Flush out foreign matter
d. Check all connections in
e. Too small of a drain control
f. Clean drain control.
dealer.)
Programming section.
making certain that correct
salt dosage is used.
level. See salt setting chart.
Programming section.
See Programming section.
up turbine and flush with
clean water. Turbine should
spin freely; if not, replace
meter. (Contact dealer.)
to flush away obstruction.
controller to clean it and the
ball.
holding disc open by
manually operating valve
stem.
brine line for leaks. Refer to
instructions.
with a “B” or “C” injector will
reduce draw rates.
Reference Pressure
Graphs.
31
Problem Possible Cause Solution
13. System using
more or less salt
than salt control is
set for.
14. Intermittent or
irregular brine
draw.
15. No conditioned
water after
regeneration.
a. Inaccurate setting.
b. Foreign matter in
controller causing
incorrect flow rates.
c. Defective controller.
a. Low water pressure.
b. Defective injector !
a. Unit did not regenerate.
b. No salt in brine tank.
c. Plugged injector !
d. Air check valve closed
prematurely.
a. Make correct setting.
b. Remove variable salt
c. Replace defective part.
a. Set pump to maintain at
b. Replace both injector and
a. Check for power.
b. Add salt to brine tank.
c. Remove injector and flush it
d. Put control momentarily into
controller and flush out
foreign matter. Manually
position control to brine draw
to clean controller (after so
doing, position control to
“purge” to remove brine from
tank).
(Contact dealer.)
least 20 psi (1.38 bar) at
softener.
injector cap. (Contact
dealer.)
and injector screen.
refill to free air check.
Replace or repair air check if
needed. (Contact dealer.)
Valve Specifications
Working Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120 psi (1.38 - 8.27 bar)
Standard 12 Volt Transformer Input Electrical Rating . . . . . . . . . . . . . . . . . . . . . 115V 60 Hz
Optional 12 Volt Transformer Input Electrical Rating . . . . . . . . . . 115V 50 Hz, 230V 50 Hz,
230V 60 Hz, 100V 60 Hz, 100V 50 Hz
Operating Ambient Temperature. . . . . . . . . . . . . . . . . . . . . 34 ° F to 120 ° F (1 ° C to 49 ° C)
Operating Water Temperature. . . . . . . . . . . . . . . . . . . . . . . 34 ° F to 100 ° F (1 ° C to 38 ° C)
For service or parts, please contact your local professional
water treatment dealer.
© Copyright 2004 GE Water Technologies
Printed in the USA P/N 1018075 Rev. I
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