GE DX400 User Manual

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Autotrol Performa ProSoft

With 960 Series Control

5-Cycle Conditioner

5-Cycle FA Filter

Water Conditioning Control System

Installation, Operation and Maintenance Manual

Table of Contents

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Location Selection Water Line Connection Drain Line Connection Regenerant Line Overflow Line Connection

Placing Conditioner into Operation . . . . . . . . . . . . . .5

Electrical Connection

960 ProSoft Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Programming Level I Features Level II Features Manual Regeneration Automatic Regeneration

Performa 960 FA Control . . . . . . . . . . . . . . . . . . . . . . .12

Programming Level I Features Level II Features Manual Regeneration Automatic Regeneration

Removing the Valve Assembly for Servicing . . . . .18

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . .18

Injector Screen and Injector Water Meter

Removing the Control . . . . . . . . . . . . . . . . . . . . . . . . . .13

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Pressure Graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Identification of Control Valving . . . . . . . . . . . . . . . .23

Valve Disc Principle of Operation . . . . . . . . . . . . . . .23

Flow Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Disinfection of Water Conditioners. . . . . . . . . . . . . .31

Installation

All plumbing and electrical connections 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 treatment equipment will be required, make certain adequate additional space is available.

3. Since salt must be added periodically to the regenerant 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 along 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 flowing from heat source to the conditioner, in the event of a reverse flow 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 its connections (including the drain and overflow lines) will ever be subjected to room temperatures under 34 over 120

F (49oC).

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

7. The use of resin cleaners in an unvented area 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 Series 1265 bypass valve (Figure 1) and plumbed-in globe valves (Figure 2). Though both are similar in function, the Autotrol Series 1265 bypass offers simplicity and ease of operation.

F (1oC) or

Not in Bypass

Conditioner

Water

Out

In Bypass

Water

Conditioner

Out

Figure 1 - Autotrol Series 1265 Bypass Valve

Not in Bypass In Bypass

Water

Conditioner

Water

Conditioner

Water

Figure 2 - Typical Globe Valve Bypass System

Drain Line Connection

Note: Standard commercial practices are expressed here.

Local codes may require changes to the following suggestions.

1. Ideally located, the unit will be above and not more than 20 feet (6.1 m) from the drain. For such installations, using an appropriate adapter fitting, 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 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 3/4-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) water pressure.

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 the conditioner.

Regenerant Tank

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

Overflow Fitting Installed

Right Wa y

Figure 3

Note: Standard commercial practices have been expressed here. Local codes may require changes to these suggestions.

Regenerant Line Connection

It will be necessary to install the regenerant line to the regenerant fitting on the valve (3/8-inch NPT).

Be sure all fittings and connections are tight.

Overflow Line Connection

In the absence of a safety overflow and in the event of a malfunction, the REGENERANT 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 regenerant tank.

Figure 4

Battery Back-Up

The Performa ProSoft conditioner features a battery back-up feature that will allow the controller to continue to keep time and record water usage during a power outage. The control’s display will not light, but the controller will continue to measure water usage for up to five hours. When power is restored to the unit , it will continue to work as before. Connect a nine-volt alkaline battery to the connecting cable at the back of the conditioner’s control box, Figure 5.

To connect overflow, locate hole on side of regenerant tank. Insert overflow fitting (not supplied) into tank and tighten with plastic thumb nut and gasket as shown (Fi gure 4). Atta ch leng th of 1 /2-inc h (1. 3-cm) I. D. t ubin g (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 3).

Figure 5

Placing Conditioner into Operation

After all previous steps have been completed, the unit is ready to be placed into operation. Follow these steps carefully.

1. Remove control valve cover by f irst depressing the plastic clips on the side of the cover. Pull front of cover up.

Note: The following steps will require turning the cycle indicator (Figure 6) to various positions. Manually rotate the camshaft COUNTERCLOCKWISE only until cycle indicator points to desired position. (See manual regeneration sections for each control’s manual operation.)

2. Rotate cycle indicator COUNTERCLOCKWISE until it points directly to the word BACKWASH.

3. Fill media tank with water. A. With water supply off, place the bypass valve(s)

into the “service” position.

B. Open water supply valve very slowly to

approximately the 1/4 open position.

IMPORTANT: If opened too rapidly or too far, media may be lost. In the 1/4 open 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 main 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 regenerant tank (initial fill). With a bucket or hose, add approximately 4 gallons

(15 liters) of water to regenerant 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.

5. Place the conditioner into operation. A. With the water supply valve completely open,

carefully advance the cycle indicator COUNTERCLOCKWISE to the center of the REFILL position. Hold at this position until water starts to flow through the regenerant line into the regenerant tank. Do not run for more than one or two minutes.

B. Advance the cycle indicator

COUNTERCLOCKWISE until it points to the center of the REGENERANT/SLOW RINSE position.

C. With the conditioner in this position, check to see if

water is being drawn from the regenerant tank. The water level in the regenerant tank will recede very slowly. Observe water level for at least three minutes. If the water level does not recede, or if it goes up, reference the Troubleshooting section.

D. Advance the cycle indicator

COUNTERCLOCKWISE to the SERVICE position and run water from a nearby faucet until the water is clear and soft.

Electrical Connection

100 VAC, 115 VAC, and 230 VAC units: Remove twist tie

from the power cord and extend cord to its full length. Make sure power source matches the rating printed on the control. Be certain a wall switch does not control the outlet.

12 VAC: Connect the plug of the transformer (supplied) secondary cable to the mating socket at the rear or bottom of the timer housing. Be certain the transformer is secure and is plugged into a power source of correct voltage that is not controlled by a wall switch.

960 ProSoft Control

Conditioner Systems

Cycle Indicator

Regen Button

Figure 6

Programming

This section covers all aspects of programming the control. The control is shipped from the factory with default values for Hardness and Capacity. These default values will result in a system capacity of 100 gallons (1 cubic meter). While the control will operate with these values, they should be changed to meet the actual operating conditions.

Note that some parameters have a single unit of measure option such as the Rinse Time which is only entered in minutes. Other parameters have dual units such as Salt Amount which can be entered in pounds or kilograms. To select which units are active, look for a comment in the NOTES column of Table 1 and Table 3. It will reference another parameter that selects which units are active. For example, Parameter P12 (Table 3) selects U.S. units if it is set to “0” and metric if it is set to “1.”

Level I Parameters (Table 1)

Level I Parameters are identified as those that have an LED indicator on the front panel. The green indicator illuminates next to the name of the active control setting. The end user has access to all of these parameters. In general, pressing the down arrow (↓) button displays the Level I Parameters in the following order:

• Time of Day

• Time of Regeneration

• Hardness

• Salt Amount

• Capacity

If you continue to press the down arrow (↓) button, the parameters start over with Time of Day. Pressing the up arrow (↑) button displays the parameters in reverse order. Refer to Table 1 for a description of these parameters and the available ranges for each parameter.

Press the SET button and the far right number on the display starts flashing. If you want to change this number, press the up arrow (↑) button to increase the number or the down arrow (↓) button to decrease the number. To skip the number without changing, press the left arrow (←) button. When you reach the far left digit, pressing the left arrow (←) button will return you to the far right digit.

Note: If you press and hold either the up arrow (↑) button or the down arrow (↓) button for more than one second, the flashing number will increment or decrement at the rate of 10 counts per second.

When the number is correct, press the left arrow (←) button. The first number stops flashing and the next number starts flashing. You can only change the flashing number. Continue changing numbers until you reach the desired setting. Press the SET button. The numbers stop flashing and the control accepts the new setting. After approximately 30 seconds, the control starts alternating the display between Time of Day and Capacity.

Note: If a beep sounds, the new setting is not accepted because it was outside the allowable range. The old value will be displayed.

Time of Day

Press the SET button. The display will show the Time of Day with the minutes digit blinking. If you want to change this number, press the up arrow (↑) button to increase the number or the down arrow (↓) button to decrease the number. To skip the number without changing, press the left arrow (←) button. The first number stops flashing and the next number starts flashing. You can only change the flashing number. When you have reached the far left digit, pressing the left arrow (←) button returns you to the far right digit. Continue changing numbers until you reach the desired setting. Press the SET button to enter the value.

Time of Regeneration

The next value displayed is the Time of Regeneration. It has a default value of 2:00 a.m. If this is not acceptable, press the SET button and change the number. Press the SET button to enter the value. If 2:00 a.m. is acceptable, press the down arrow (↓) button.

Hardness

Hardness is the next value displayed. This value is the water hardness expressed in grains per gallon (milligrams per liter). The default value is 10 grains/gallon (100 mg/L). If this is not acceptable, press the SET button and enter a new value. Any value between 3 and 250 grains per gallon (30 and2500 milligrams per liter) is allowed. Press the SET button to enter the new value.

Salt Amount

Salt Amount is the next value displayed. The default value for Salt Amount is 6 pounds (2.7 kilograms) of salt; refer to Table 2 for suggested salt settings.

Note: This is the total amount of salt for a regeneration, not pounds per cubic foot. If 6 pounds is not acceptable, press the SET button and change the numbers. If 6 pounds is acceptable, press the down arrow (↓) button.

Capacity

amount. The default value is 1.0 kilograin (0.1 kilogram). If this is not acceptable, press the SET button and enter a new value. Any value between 0.1 and 140 kilograins (.01 and 14.00 kilograms) is allowed.

Note: If the calculation for the system capacity exceeds 9999 gallons (99.99 cubic meters) (P5, Capacity, divided by P3, Hardness,) the control will display 9999 (99.99) for capacity until the water usage has dropped the remaining capacity below that number. When water is flowing

through the system, the colon in the Time of Day display will blink.

At this time, all of the mandatory parameters are filled and the control is ready for operation. To further increase the efficiency of the system see P6 and P7 in the Level II Parameters Section. The display will alternate between the Time of Day and Capacity if no keys are pressed for 30 seconds. The Capacity value is the volume remaining in gallons (cubic meters for metric) before a regeneration is needed.

Verify proper power outage operation by briefly removing power to the control. The unit will beep and show the time of day when power is turned on.

If you wish to fine-tune the operation of this control, refer to Tables 1 and 3 for details concerning allowable values, defaults, and parameter descriptions. The programming procedure is the same for all of these parameters.

Capacity is the next value displayed and is expressed in kilograins (kilograms). Refer to Table 2 for the capacity setting that corresponds to the resin bed volume and salt

Table 1 - Level I Programming Parameters

Parameter

Name Description

P4 Salt amount

P5 Capacity of unit

Time of day

AM or PM

Time of day of

regeneration

Hardness of

water

Range of Values

1:00 to 12:59

00:00 to 23:59

1:00 to 12:59

AM or PM

00:00 to 23:59

3 to 250

30 to 2500

0.2 to 51

0.1 to 25.5

0.1 to 140.0

0.01 to 14.00

Minimum

Increments

1 None Hour:minute

1 2:00 AM Hour:minute

0.2

0.1

0.01

Default

100

2.5

1.0

0.1

Units of

Measure

Grains/gallon

mg/L

Pounds

Kilograms

Kilograins Kilograms

Notes

Range depends on value

selected for P13. Enter the

current time.

Range depends on value

selected for P13. Skip this

parameter to accept the default

or enter a new time.

Unit of measure depends on

value selected for P12. Test

water hardness and enter that

value.

Unit of measure and default

depends on value selected for

P12. Refer to Table 2.

Unit of measure depends on

value selected for P12. Enter the

unit capacity.

Table 2 - Suggested Salt Dial Settings (Pounds of Salt) For Various Size Softeners - P1 through P5

Capacity Setting

(Kilograins)

12 4.6 — —————— 16 9.0 5.6 —————— 20 — 8.6 6.0————— 24 — 14.0 8.6 7.0 — — — — 30 — — 15.0 11.0 9.0 — — — 32 — — 18.6 12.6 10.0 9.0 — — 35 — — — 16.0 12.0 10.0 9.0 — 40 — — — 23.0 17.0 14.0 12.0 — 48 — — — — 28.0 21.0 17.0 14.0 60 — — — — — — 30.0 21.0

0.5 Ft

0.75 Ft

1.0 Ft

Level II Parameters (Table 3)

The Level II Parameters are P6 through P19 in Table 3. The Home Owner Manual for this product does not mention these parameters, so the end user does not normally have access to these values. To access Level II Parameters, simultaneously press and hold the down arrow (↓) and up arrow (↑) buttons for three seconds.

If the control was alternating between Time of Day and Capacity when the above button sequence is entered, the display shows P1. If a different Level I Parameter was displayed, the display shows the “P” number for that parameter. Refer to Table 3 to find the “P” number associated with each parameter. Use the up arrow (↑) button or the down arrow (↓) button to move from one parameter to the next . The display cycles through the “P” numbers shown in Table 1 and Table 3. When you reach P19, the next P number will go back to P1.

1.25 Ft

1.5 Ft

1.75 Ft

2.0 Ft

2.5 Ft

Special Notes for Level II Parameters

The programming parameters in Level II can be used to increase the efficiency of this conditioner. Especially note the regenerant Draw Value parameter. This was set at the factory to meet the needs of a system with low water pressure. If an installation has higher water pressure or uses a large injector the efficiency of the system can be improved by changing P6 and P7.

Refill Control Value

The Refill control valve must be set to 33. The valve is molded into the end of the refill control as shown in Figure 7. Verify that the setting is 33 and move on to the next parameter.

When the parameter number you want to change is on the display, press the left arrow (←) button to display the data assigned to that parameter. Press the SET button and the far right number on the display starts flashing. If you want to change this number, press the up arrow (↑) button or the down arrow (↓) button. To skip the number without changing, press the left arrow (←) button. When the number is correct , press the SET button. The numbers stop flashing and the control accepts the new setting. If a beep sounds, the new setting was not accepted. Refer to Table 3 for allowable values for that parameter.

To change or view other parameters, press the left arrow (←) button to have the display show “P” numbers. Now use the up arrow (↑) button or the down arrow (↓) button to move to the parameter number you wish to change.

To exit the Level II programming mode, simultaneously press and hold the down arrow (↓) and up arrow (↑) buttons for three seconds, or wait 30 seconds without pressing a button. The control starts alternating the display between Time of Day and Capacity.

Figure 7 - Refill Control

Table 3 - Level II Programming Parameters

Parameter

Name Description Range of Values

P6 Refill controller 1 to 99 1 33

P8 Not used NA NA NA NA NA

P9 Backwash time 3 to 30 1 14 Minutes

P10 Slow rinse time 8 to 125 1 40 Minutes

P11 Fast rinse time 2 to 19 1 4 Minutes

P12 Units of Measure 0 to 1 1 0

P13 Clock mode 0 to 1 1 0

P14

P15 Reserve type 0 to 3 1 0

P16

P17 Operation type 0 to 2 1 2

P18

P19 Factory defaults 1 99

Regenerant

draw value

Calendar

override

Fixed reserve

capacity or initial

average value

Salt/capacity

change lockout

1 to 99 1 25

0 to 30 1 0 Days

0 to 70 1 30

0 to 1 1 0

Minimum

Increments

Default

Units of

Measure

Percent of

capacity

Enter the value molded into the

end of the refill controller.

Select number from Table 4 and

enter that number.

Skip this parameter to accept the

default or enter a value.

Skip this parameter to accept the

default or enter a value.

Skip this parameter to accept the

default or enter a value.

0 = U.S., 1 = metric. Skip this

parameter to accept U.S. or enter

1 for metric.

0 = 12-hour clock.

1 = 24-hour clock. Skip this

parameter for a 12-hour clock or

enter 1 for a 24-hour clock.

0 = no calendar override. Skip this

parameter for no calendar

override or enter a value.

0 = variable reserve, 1 = fixed

reserve, 2 = variable reserve with

immediate regen,

3 = fixed reserve with immediate

regen. Skip this parameter to

accept the default or enter a

different reserve type.

Description depends on the value

entered for P15. Skip this

parameter to accept the default or

enter a different value.

2 = 5-cycle

cocurrent conditioner.

0 = none, 1 = salt/capacity change

locked out. Skip this parameter to

accept the default or enter 1 to

lock out salt/capacity change.

Loads in a set of default values.

Refer to the Special Notes for

Level II Parameters section in this

manual. Do Not Change.

Notes

Regenerant Draw Value

Parameter P7 is used by the control to calculate the regenerant draw time. The default value of 25 was selected for a “B” injector with low water pressure or an “A” injector with moderate water pressure. If this does not match your installation, press the SET button and enter a new value. Refer to Table 4 for the correct value. Find the injector used in the Performa valve. The injector cap is labeled with the injector letter and the injector is color coded for easy identification. Next, determine the typical water pressure for this installation. The Regenerant Draw Va lue is an estim at e of t he flow rate of r egen erant t hroug h the injector. This rate varies with water pressure and injector type as shown in Table 4. The control calculates the regenerant draw time using this value and the salt amount. The regenerant draw time is added to the Rinse Time (P10) to determine the total Regenerant Draw/Slow Rinse Time.

Table 4 - Regenerant Draw Value

Regenerant

Injector Color

A White 19 26 31 BBlue24 30 37 C Red 29 37 40

D Green 32 48 60

Draw Value

30 psi

Regenerant Draw Value

50 psi

Regenerant Draw Value

at 70 psi

• This control does not use Parameter P8. No entry is

needed for this parameter.

• Parameter P12 selects the units of measure. Be sure

that this is set to the correct value before entering any data for Parameters P3, P4 or P5.

• Parameter P13 selects the clock display mode. If the

12-hour mode is selected, a PM indicator is used. If the 24-hour mode is selected, the PM indicator is not used.

• Parameter P15 has four allowable values. Values 0 or

1 will cause the control to wait for Parameter P2, time of day of regeneration, to begin the regeneration. Values 2 or 3 will cause the control to start the regeneration as soon as the capacity is exhausted.

• When Parameter P15 selects a variable reserve type,

0 or 2, Parameter P16 is used to calculate the initial seven average daily water usage values. The control multiplies the total capacity by the percentage entered for Parameter P16 and uses that value as the initial average daily usage for each day of the week until water usage establishes new averages.

• Parameter 17 has several allowable values, however,

many are reserved for future options and thus should not be used. Improper regenerations will occur if P17 is not set to 2.

• Parameter P18 allows the installer to lock the Salt

Amount and Capacity values so they cannot be changed. When Parameter 18 is set to 1, those two settings can only be viewed when the control is in the Level II mode. The settings will be skipped when the control is in the Level I mode. When Parameter 18 is set to zero, the Salt Amount and Capacity can be viewed and changed in either Level I or Level II.

• Parameter P19 is used at the factory to enter default

values. This parameter does not need to be changed. Changing this parameter will erase the values for all other parameters and replace them with default values.

Manual Regeneration

Electricity is used only to run the timer and to rotate the camshaft. All other functions are operated by water pressure. Therefore, in the event of a power outage, all regeneration positions may be dialed manually. Manual regeneration can be accomplished by removing the cover and turning the camshaft COUNTERCLOCKWISE to each regeneration cycle. Rotating the camshaft COUNTERCLOCKWISE by hand changes the cycles of operation. Each cycle position can be identif ied by viewing the cycle indicator on the front of the control. The following cycle times should be used for proper regeneration:

BACKWASH—14 minutes Regenerant/SLOW RINSE—52 minutes FAST RINSE/REFILL—10 minutes PURGE—6 minutes

Do not exceed 10 minutes for the FAST RINSE/REFILL cycle as this will cause excessive salt usage during the next regeneration and possibly a salt residue in the softened water.

Guest Cycle

To force the control to perform a regeneration, press the REGEN button (Figure 6). This button is located on the front of the control. When you press the REGEN button, the control performs a full regeneration of the conditioner.

If you press this button again more than one minute after regeneration begins, but before the regeneration is complete, a second regeneration will start when the first regeneration is finished. The display will freeze and

only show the Regen Time Remaining as an indication that the second regeneration will be performed. When the first regeneration is complete, the second one will begin and the display will alternate between Time of Day and Regen Time Remaining.

Automatic Regeneration

There are two ways to have the control automatically start a regeneration: calendar override or having the control monitor the water usage.

Calendar Override

This feature is set in Parameter P14. It can be set for one to 30 days. If it is set to zero, this feature is disabled. When this feature is active, the control keeps track of the number of days since the last regeneration and when that number equals the value set in P14, a regeneration is automatically started at the Time of Regeneration set in P2.

Control Monitors the Water Usage

The control compares the water usage to the calculated volume capacity of the system. The control uses the Capacity Parameter P5 divided by the Hardness Parameter P3 to calculate the volume capacity of the system. It also uses a reserve value to determine if a regeneration is necessary. If the water usage since the last regeneration is greater than the system capacity minus the reserve, a regeneration is needed.

Note: If the water usage exceeds 150% of the system capacity between regenerations, the control will automatically call for a second regeneration the next day even if no water is used. This feature is included to make sure that an exhausted resin bed is completely recharged.

Since a new installation has no history of water usage, the control multiplies the percent of capacity value set in Parameter P16 by the total system capacity to determine starting average for each day of the week. The factory set default value for P16 is 30 which means that 30% of the total system capacity is used for the starting average for each day.

Program Parameter P15 is also used to select whether the control waits until the Time of Regeneration set in Parameter P2 to start a regeneration, or if the control should begin a regeneration immediately when the capacity remaining is less than the reserve.

Reserve Options

There are two types of reserve options for this control: fixed reserve and historical water usage pattern. They are selected with Parameter P15.

Fixed Reserve

When the fixed reserve is selected, the control multiplies the maximum system capacity by the percent value set in Parameter P16 and uses the result as a reserve.

Water Usage Pattern

The other reserve option allows the control to adjust the reserve based upon the historical water usage pattern of the system. The control keeps track of the water usage for each day of the week and uses that day’s average usage multiplied by 1.2 as the reserve for that day. Every day at the Time of Regeneration, the control recalculates the day’s average water usage. If less than 10% of a day’s average water usage is used, the control will not change the day’s average. If more than twice the day’s average is used, the control uses the actual usage in the reserve calculation.

Performa 960 FA Control 5-Cycle Filter System

Performa

TIME OF DAY

TIME OF REGEN FACTOR A FACTOR B CAPACITY REGEN TIME

REMAINING

Performa 960 FA Level I Parameters (Table 5)

Level I Parameters are identif ied as those that have an LED indicator on the front panel. The green indicator illuminates next to the name of the active control setting. The end user has access to all of these parameters. In general, pressing the DOWN ARROW (↓) button displays the Level I Parameters in the following order:

• Time of Day

• Time of Regeneration

• Factor A

• Regenerant Dosage

• Capacity

Figure 8

This section covers all aspects of programming the Performa 960 FA control. The control is shipped from the factory with default values for most parameters. These default values will result in a system capacity of 100 gallons (1 cubic meter). While the control may operate with these values, the following parameters must be changed to meet the actual operating conditions, and achieve maximum system capacity and efficiency:

• Time of Day

• Time of Regeneration

• Factor A

• Regenerant Dosage

• Capacity of the Unit

• Refill Controller Value

• Regenerant Draw Rate

• Slow Rinse Time

Note that some parameters have a single unit of measure option such as the Slow Rinse Time which is only entered in minutes. Other parameters have dual units such as Regenerant Dosage which can be entered in gallons or liters. To select which units are active, look for a comment in the NOTES column of Table 5 and Table 7 on page 14. It will reference another parameter that selects which units are active. For example, parameter P12 (Table 8) selects U.S. units if it is set to “0” and metric if it is set to “1”.

If you continue to press the DOWN ARROW (↓) button, the parameters start over with Time of Day. Pressing the UP ARROW (↑) button displays the parameters in reverse order. Refer to Table 5 for a description of these parameters and the available ranges for each parameter.

Press the SET button and the far right digit of the display starts flashing. If you want to change this number, press the UP ARROW (↑) button to increase the number or the DOWN ARROW (↓) button to decrease the number. To skip the number without changing, press the LEFT ARROW (←) button. When you reach the far left digit, pressing the LEFT

ARROW (←) button will return you to the far right digit . Note: If you press and hold either the UP ARROW (↑)

button or the DOWN ARROW (↓) button for more than one second, the flashing number will increment or decrement at the rate of 10 counts per second.

When the number is correct, press the LEFT ARROW (←) button. The far right digit stops flashing and the next digit to the left starts flashing. You can only change the flashing number. Continue changing numbers until you reach the desired setting. Press the SET button. The numbers stop flashing and the control accepts the new setting. After approximately 30 seconds, the control starts alternating the display between Time of Day and Capacity.

Note: If the new setting is not accepted because it was outside the allowable range, the old value will be displayed.

Time of Day

Regenerant Dosage

Press the SET button. The display will show the Time of Day with the minutes digit blinking. If you want to change this number, press the UP ARROW (↑) button to increase the number or the DOWN ARROW (↓) button to decrease the number. To skip the number without changing, press the LEFT ARROW (←) button. The first number stops flashing and the next number starts flashing. You can only change the flashing number. When you have reached the far left digit, pressing the LEFT ARROW (←) button returns you to the far right digit. Continue changing numbers until you reach the desired setting. Press the SET button again to save the value.

Time of Regeneration

The next value displayed is the Time of Regeneration. It is similar to Time of Day programming. It has a default value of 2:00 a.m. If 2:00 a.m. is acceptable, press the DOWN ARROW (↓) button. If this is not acceptable, press the SET button and change the numbers. Press the SET button again to save the value.

Factor A

Factor A is the next value displayed. Factor A is the potassium permanganate demand of the water being treated. Determine the potassium permanganate demand of the water supply and enter that value for Factor A. The formula below can be used to calculate potassium permanganate demand from a water analysis.

Regenerant dosage is the next value displayed. Refer to Table 6 to find the correct regenerant dosage setting based on the volume of filter media and the average room temperature of the installation site. Enter the correct value from Table 6.

Capacity

Capacity is the next value displayed. Refer toTable 7 to find the correct system capacity setting based on filter media volume. Enter the capacity setting from Table 7.

Note: The Performa 960 FA control uses the Capacity and Factor A settings to calculate the system capacity in gallons (cubic meters). If the calculated system capacity exceeds 9999 gallons (99.99 cubic meters), the control will display 9999 (99.99 cubic meters), for capacity until the water usage has dropped the remaining capacity below that number. When water is flowing through the system, the colon in the Time of Day display will blink.

At this time, all of the Level I Parameters are programmed. The display will alternate between the Time of Day and Capacity if no keys are pressed for 30 seconds. The Capacity value displayed is the volume remaining in gallons (cubic meters for metric) before a regeneration is needed.

To complete the initial programming of the Performa 960 FA proceed to the Level II Parameters, page 15.

From water analysis:

Iron content (Fe

Manganese content (MN

S content x 4= ________ppm

Total Demand= ________ppm

Example:

4.0 ppm iron = 4.0 ppm

3.0 ppm Manganese x 2 = 6.0 ppm

2.5 ppm H Potassium Perm. Demand = 20.0 ppm

) = ________ppm

) x 2= ________ppm

S x 4 = 10.0 ppm

Table 5 -Performa 960 FA Level I Programming Parameters

Parameter

Name Description

Time of day

AM or PM

Time of day of

regeneration

P3 Factor A

Regenerant

Dosage

P5 Capacity of Unit

Table 6 - Regenerant Dosage Settings (gallons x 10) for Various Size Iron Filters

Range of Values

1:00 to 12:59

00:00 to 23:59

1:00 to 12:59

AM or PM

00:00 to 23:59

3 to 250

30 to 2500

0.5 to 99.5 01 to 25.5

0.1 to 140.0

0.01 to 14.00

Minimum

Increments

Default Units of Measure Notes

1 None Hour: minute

1 2:00 AM Hour: minute

0.5

0.1

0.01

100

2.5

1.0

0.1

Gallons x 10

PPM-gallons

PPM

PPM x 10

Liters x 10

PPM-liters

Range depends on value selected

for P13. Enter the current time.

Range depends on value selected

for P13. Skip this parameter to

accept the default or enter a new

time.

Unit of measure depends on value

selected for P12. Enter potassium

permanganate demand.

Unit of measure depends on value

selected for P12.

Select regenerant dosage from

Table 6 and enter that value.

Unit of measure depends on value

selected for P12.

Enter the system capacity setting

from Table 7.

Temperature

0.75 ft31.00 ft31.25 ft31.50 ft31.75 ft32.00 ft32.50 ft

3.00 ft

3.50 ft

50°F 4.0 5.0 6.0 8.0 9.0 10.0 13.0 15.0 18.0

60°F 3.0 4.0 5.0 6.0 7.0 9.0 9.0 11.0 13.0

70°F 3.0 3.0 3.0 4.0 4.0 5.0 6.0 8.0 9.0

Table 7 - Capacity Settings for Various Size Iron Filters

Filter Size/Cubic Feet of Manganese Greensand

Filter Size 0.75 ft31.00 ft31.25 ft31.50 ft31.75 ft32.00 ft32.50 ft

Capacity Setting7.51012.51517.520 25 30 35

3.00 ft

3.50 ft

Table 8 - Performa 960 FA Level II Programming Parameters

Parameter

Name Description

P6 Refill controller 1 to 99 1 33

P8 Not used NA NA NA NA NA

P9 Backwash time 3 to 30 1 14 Minutes

P10 Slow Rinse time 8 to 125 1 40 Minutes

P11 Fast Rinse time 2 to 19 1 4 Minutes

P12 Units of measure 0 to 1 1 0

P13 Clock mode 0 to 1 1 0

P14

P15 Reserve type 0 to 3 1 0

P16

P17 Operation type 0 to 2 1 2 2 = 5 cycle Cocurrent conditioner

P18

P19 Factory defaults 0 to 3 1 99

Regenerant draw

value

Calendar

override

Fixed reserve

capacity or initial

average value

Regen. Dosage/

Capacity change

lock out

Range of Values

1 to 99 1 25

0 to 30 1 0 Days

0 to 70 1 30 Percent of capacity

0 to 1 1 0

Minimum

Increments

Default Units of Measure Notes

Must be set to 46 for Performa 960

FA operation

Select Regenerant Draw value from

Table 9 and enter that number.

Skip this parameter to accept the

default or enter a value.

Skip this parameter to accept the

default or enter a value.

Skip this parameter to accept the

default or enter a value.

0 = U.S., 1 = Metric. Skip this

parameter to accept U.S. or enter 1

for Metric.

0 = 12-hour clock, 1 = 24-hour

clock. Skip this parameter for a 12-

hour clock or enter 1 for a

24-hour clock.

0 = no calendar override. Skip this

parameter for no calendar override

or enter a value.

0 = variable reserve, 1 = fixed

reserve, 2 = variable reserve with

immediate regen, 3 = fixed reserve

with immediate regen. Skip this

parameter to accept the default or

enter a different reserve type.

Description depends on the value

entered for P15. Skip this

parameter to accept the default or

enter a different value.

0 = none, 1 = Regenerant Dosage/

Capacity change locked out . Skip

this parameter to accept the default or enter 1 to lock out

Regenerant Dosage/Capacity

change.

Loads in factory default values. Do

not change this parameter.

Performa 960 FA Level II Parameters

The Level II Parameters are P6 through P19 in Table 8.

The Operating and Maintenance Manual for this product does not mention these parameters, so the end user does not normally have access to these values. To access Level II Parameters, simultaneously press and hold the DOWN ARROW (↓) and UP ARROW (↑) button for three seconds.

Use the UP ARROW (↑) button or the DOWN ARROW (↓) button to move from one parameter to the next . The display cycles through the “P” numbers shown in Table 5 and Table 8 When you reach P19, the display will go back to P1.

When the parameter number you want to change is displayed, press the LEFT ARROW (←) button to display the data assigned to that parameter. Press the SET button and the far right digit on the display starts flashing. If you want to change this number, press the UP ARROW (↑) button or the DOWN ARROW (↓) button. To skip the number without changing, press the left arrow button. When the number is correct, press the SET button. The numbers stop flashing and the control accepts the new setting. If the new setting was not accepted, the display will show the previous setting. Refer to Table 8 for allowable values for that parameter.

To change or view other parameters, press the LEFT ARROW (←) button to have the display show “P” numbers. Now use the UP ARROW (↑) button or the DOWN ARROW (↓) button to move to the parameter number you wish to change.

To exit the Level II programming mode, simultaneously press and hold the DOWN ARROW (↓) and UP ARROW (↑) buttons for three seconds, or wait 30 seconds without pressing a button. The control starts alternating the display between Time of Day and Capacity.

Refill Controller

• Parameter P6 is used by the Performa 960 FA control

to calculate the refill dwell time and provide accurate regenerant ref ill volumes. Ref ill controller must be set to 46 for proper system operation. The default value in P6 is 33. Press the set button and enter 46.

Regenerant Draw Value

• Parameter P7 is used by the control to calculate the

regenerant draw time. The default value of 25 was selected for a “B” injector with low water pressure or an “A” injector with moderate water pressure. If this

does not match your installation, press the SET button and enter a new value. Refer to Table 9 for the correct value. The injector cap is labeled with the injector letter. The injector is color coded for easy identification. Next, determine the typical water pressure for this installation. The Regenerant Draw value is an estimate of the flow rate of regenerant through the injector. This rate varies with water pressure and injector type as shown in Table 9. The control calculates the regenerant draw time using this value and the Regenerant Dosage. The regenerant draw time is added to the Slow Rinse Time (P10) to determine the total Regenerant Draw/Slow Rinse Time.

Table 9 - Regenerant Draw Value

Injector Color

A White 19 26 31

B Blue 24 30 37

C Red 29 37 40

D Green 32 48 60

Regenerant Draw Value at:

30 psi 50 psi 70 psi

• This control does not use parameter P8. No entry is

needed for this parameter.

• Parameter P9 is used to set the backwash time in

minutes. The default in P9 is 14 minutes. If a different backwash time is desired, press the SET button and enter a new value.

Slow Rinse Time

• Parameter P10 determines the slow rinse time. The

default value for P10 is 40 minutes. If a different slow rinse time is desired, press the SET button and enter a new value.

• Parameter P11 determines the fast rinse time. The

default value is 4 minutes. If a different fast rinse time is desired, press the SET button and enter a new value.

• Parameter P12 selects the units of measure. Be sure

that this is set to the correct value before entering any data for parameters P3, P4, or P5.

• Parameter P13 selects the clock display mode. If the

12 hour mode is selected, a PM indicator is used. If the 24 hour mode is selected, the PM indicator is not used.

• Parameter P14 is used to set the calendar override

feature. The default value is zero. If set to zero, the feature is disabled. Refer to Calendar Override, on page 17 for more information on the calendar override feature.

• Parameter P15 selects a variable reserve type, 0 to 13.

For more information see Reserve Options below.

• Parameter P16 is used to calculate the initial average

daily water usage values. The control multiplies the

total capacity by the percentage entered for Parameter P16 and uses that value as the initial average daily usage for each day of the week until water usage establishes new averages. The default is set for 30% of the capacity. In most installations this is acceptable.

• Parameter P17 has been preset to 0. Do not change

this setting. P17 must be set to 2 for Performa 960 FA

operation.

• Parameter P18 allows the installer to lock the

Regenerant Dosage and Capacity values so they cannot be changed. When Parameter 18 is set to 1, those two settings can only be viewed when the control is in the Level II mode. The settings will be skipped when the control is in the Level I mode. When Parameter 18 is set to zero, the Regenerant Dosage and Capacity can be viewed and changed in either Level I or Level II.

• Parameter P19 is used at the factory to enter default

values. This parameter does not need to be changed. Using this parameter will erase the values for all other parameters and replace them with default values. Improper regenerations will occur if P19 is set to a 0 or

3. P19 should be set on default number 99.

Regeneration

When the control begins a regeneration, the display will alternate between Time of Day and Regen Time Remaining. The Regen Time Remaining is shown in minutes. The control will start and stop an internal motor which drives the cam gear through the various regeneration positions. The control uses the information entered in the parameters shown in Table 8 to determine how long each part of the cycle should last.

If power fails during a regeneration cycle, the cycle completes normally when the power is restored.

Note: The REGEN button is only active when the display is alternating between Time of Day and Capacity. When programming Level I or II parameters, the REGEN button is not active.

The Regen Time Remaining in regeneration will continue to count down until the cam gear reaches the Service position.

show the Regen Time Remaining as an indication that the second regeneration will be performed. When the first regeneration is complete, the second one will begin and the display will alternate between Time of Day and Regen Time Remaining.

Automatic Regeneration

There are two ways to have the control automatically initiate a regeneration: calendar override or normal metered water usage.

Calendar Override

This feature is set in parameter P14. It can be set for 1 to 30 days. If it is set to zero, this feature is disabled. When this feature is active, the control keeps track of the number of days since the last regeneration and when that number equals the value set in P14, a regeneration is automatically started at the T ime of Regeneration set in P2.

Normal Metered Water Usage

The control compares the water usage to the calculated volume capacity of the system.The control uses the Capacity parameter P5 divided by the Factor A parameter P3 to calculate the volume capacity of the system. It also uses a reserve value to determine if a regeneration is necessary. If the water usage since the last regeneration is greater than the system capacity minus the reserve, a regeneration is needed.

Reserve Options

There are two types of reserve options for this control: fixed reserve and historical water usage pattern. They are selected with parameter P15.

Fixed Reserve

When the fixed reserve is selected, the control multiplies the maximum system capacity by the percent value set in parameter P16 and uses the result as a reserve.

Manual Regeneration

To initiate a manual regeneration, press the REGEN button. Thi s butt on is lo cated on the fro nt of the co nt rol. When yo u press the REGEN button, the control performs a full regeneration of the conditioner.

Water Usage Pattern

Since a new installation has no history of water usage, the control multiplies the percent of capacity value set in parameter P16 by the total system capacity to determine starting average for each day of the week. The factory set default value for P16 is 30 which means that 30% of the total system capacity is used for the starting average for each day.

Program parameter P15 is also used to select whether the control waits until the Time of Regeneration set in parameter P2 to start a regeneration, or if the control should begin a regeneration immediately when the capacity remaining is less than the reserve.

Preventive Maintenance

Injector Screen and Injector

Inspect and clean regenerant tank and screen filter on end of regenerant pickup tube once a year or when sediment appears in the bottom of the regenerant 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. 7 (at rear) with a screwdriver (Figure 9).

4. Using a screwdriver, remove injector screen and injector cap (Figure 10).

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 only!

Removing the Valve Assembly for Servicing

1. Unplug the power cord.

2. Shut off water supply or put bypass valve(s) into bypass position.

3. Remove cover and with screwdriver, relieve tank pressure by pushing open valve No. 7 (rear flapper) on control as shown (Figure 9).

Figure 9

4. When used with a globe valve bypass, loosen and detach the inlet, outlet, regenerant and drain lines from the valve. If using the 1265 bypass, loosen and remove valve from bypass as well as loosening and removing the regenerant and drain lines.

10. Reinstall the injector, injector cap and injector screen.

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.

11. Plug the wall-mount transformer into outlet; reset clock if necessary.

12. Slowly open water supply valve or return bypass valve(s) to the “service” position.

Injector Screen

Turbine

Injector

Figure 10

Cap

5. Unscrew (counterclockwise) and remove valve from tank.

6. To replace the control valve, reverse the above procedure.

Water Meter Maintenance

The metering device used with the 960 demand controls may require simple maintenance. In rare instances, the turbine wheel of the water meter can collect small particles of oxidized iron, eventually preventing the wheel from turning.

1. Shut off the water supply or put the bypass valve(s) into the bypass position.

2. Relieve pressure by opening the Backwash Drain Valve (the seventh back from the control) with a screwdriver (Figure 9).

3. Loosen and remove the pipe/tube adapters or 1265 bypass from the inlet and outlet of the valve body.

4. Using a needle-nose pliers, remove the turbine from the outlet housing. Grasp one of the four vanes of the outer gland and pull straight out to remove turbine assembly from the outlet of the valve (Figure 10).

5. Carefully remove the turbine wheel from the housing. Use a toothbrush to lightly scrub the iron off the magnet. Iron buildup on the surfaces can be removed by soaking the wheel in a mild sodium hydrosulfite (such as RoVer*) solution for a few minutes. Flush thoroughly with water.

*RoVer is a tra demark of Hach Chemic al Company.

Ta b

Figure 11

4. Relieve system pressure by opening the Backwash Drain Valve (the seventh valve back from the control) with a screwdriver, Figure 12.

6. Carefully reinstall the turbine wheel into the turbine cage housing. Make sure that the shaft of the wheel seats into the bearing of the cage. Reassemble the turbine cage and check that the wheel rotates freely.

7. Reinstall the turbine cage into the outlet of the valve.

8. Reinstall the pipe/tube adapters or 1265 bypass to the inlet and outlet of the valve.

9. Turn on the water supply or put the bypass valve(s) into the service position and purge the air out of the system.

To check for proper meter operation, open a downstream faucet and observe the water flow indication, blinking colon, on the control display.

Removing the Control

Complete the following steps to remove the 960 ProSoft control for servicing:

1. Unplug the wall-mount transformer.

2. Shut off the water supply or put the bypass valve(s) into bypass position.

3. Remove the rear cover by depressing the two tabs provided on the cover, Figure 11. Lift the front of the cover and remove to expose the valve body.

Figure 12

5. To remove the camshaft or to reinstall it, the arrow on the rear of the cam shaft must be pointing at the line on the rear “hoop” of the top plate. This occurs when the cycle indicator is rotated to the refill position. Press down on the back of the camshaft to disengage it from the rear “hoop” of the top plate, Figure 13. Slide the camshaft back to disengage it from the timer, Figure 14.

Figure 13

Figure 14

6. Disconnect the turbine probe from the turbine assembly.

7. Lift the control off the valve, Figure 15. To replace the control, reverse the above procedure. Note that the camshaft needs to be positioned correctly before it can be inserted into the back of the control. There is a locating arrow on the camshaft. Position the arrow on the top of the shaft and slide the camshaft into the control. Push up on the end of the camshaft, furthest from the timer, snapping it into place.

Figure 15

Specifications

Hydrostatic Test Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 psi (20.69 bar)

Working Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-125 psi (1.38 - 8.62 bar)

Standard Electrical Rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115V 60 Hz

Optional Electrical Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115V 50 Hz, 230V 50 Hz, 200V 60 Hz, 24V 60 Hz, 24V 50 Hz,

100V 60 Hz, 100V 50 Hz, 12V 50 Hz/transformer, 12V 60 Hz/transformer

Electrical Cord (standard rating) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 inch (1.5 m) 3-wire with plug

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

Riser Pipe Diameter Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.050 inch OD (26.7 mm)

Riser Pipe Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1/8 ±1/8 inches (31.8 mm) higher than the top of mineral tank

Standard Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-inch (25.4-mm) copper tube adapters

Optional Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1/4-inch, 3/4-inch, 22-mm, and 28-mm copper tube adapters

3/4-inch BSPT, 1-inch BSPT, 1-inch NPT brass pipe adapters

3/4-inch, 1-inch, 25-mm CPVC tube adapters

Regenerant Line Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8-inch NPT male

Drain Line Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4-inch NPT male

Optional Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotating handles, full 1-inch porting, reinforced Noryl

Control Module, Tank Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Reinforced Noryl

Rubber Goods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compounded for cold water service

Program Clock (Timer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 960: Available in English, German, French, Italian, Spanish, Japanese

Regenerant Ref ill Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 to 10 lbs (0.45 to 4.5 kg) of salt or 3 to 19 lbs (1.4 to 8.6 kg) of salt

Injector Size “A” White. . . . . . . . . . . . . . . . . . . . . . . . . . . .Nozzle .042-inch (1.1-mm) diameter, Throat .089-inch (2.3-mm) diameter

Injector Size “B” Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Nozzle .052-inch (1.3-mm) diameter, Throat .099-inch (2.5-mm) diameter

Injector Size “C” Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Nozzle .059-inch (1.5-mm) diameter, Throat .099-inch (2.5-mm) diameter

Injector Size “D” Green . . . . . . . . . . . . . . . . . . . . . . . . . . Nozzle .071-inch (1.8-mm) diameter, Throat .147-inch (3..7-mm) diameter

Internal Backwash Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- through 14-inch (17.8- though 35.6-cm) diameter media tanks

All sizes to flow 4.5 gpm/sq ft (183 L/m/m

For tank sizes above 14 inches in diameter, use an external flow control.

) of bed area.

Pressure Graphs

Injector #1031363

"A" in a 268 Valve

Injector #1031364

"B" in a 268 Valve

M /hr

0.20

0.15

0.10

0.05

0.00

0.20

0.15

0.10

M /hr

0.05

0.00

1.00

Tot al

0.75

0.50

GPM

0.25

0.00 20 40 60 80 100 120

400 600 800 1000 1200 1400 1600 1800

PSI

bar

Injector #1031365

"C" in a 268 Valve

Rinse

Brine Draw

1.75

1.50

Tot al

1.25

1.00

0.75

GPM

0.50

Rinse

Brine Draw

0.25

0.00

20 40 60 80 100 120

400 600 800 1000 1200 1400 1600 1800

PSI

bar

0.30

0.25

0.20

0.15

M /hr

0.10

0.05

0.00

0.30

0.25

0.20

0.15

M /hr

0.10

0.05

0.00

1.25

1.00

0.75

GPM

0.50

0.25

0.00

20 40 60 80 100 120

400 600 800 1000 1200 1400 1600 1800

2.25

2.00

1.75

1.50

1.25

1.00

GPM

0.75

0.50

0.25

0.00

20 40 60 80 100 120

400 600 800 1000 1200 1400 1600 1800

Tot al

Rinse

Brine Draw

PSI

bar

Injector #1030272

"D" in a 268 Valve

Total

Rinse

Brine Draw

PSI

bar

Backwash Number7 8 9 10121314

Flow (GPM*) 1.2 1.6 2.0 2.5 3.9 4.1 4.8

Flow (LPM*) 4.5 6.0 7.6 9.5 14.76 15.5 18.2

*Approximate flow rates at 60 psi (414 kPa)

Identification of Control Valving

7 Backwash Drain Valves

5 Refill Valve

3 Inlet Valve

1 Regenerant Valve

2 Bypass Valve

Valve Disc Principle of Operation

6 Rinse Drain Valve

4 Outlet Valve

Flow Diagrams

1 Service Position

Hard Water Soft Water

Inlet

Outlet

Val ve No. 1 - Closed 2 - Closed 3 - Open 4 - Open 5 - Closed 6 - Closed 7 - Closed

Drain

2 Backwash Position

Hard Water Soft Water

Brine Adjustment

Inlet

Outlet

Val ve No. 1 - Closed 2 - Open 3 - Closed 4 - Open 5 - Closed 6 - Closed 7 - Open

Drain

Backwash Flow Control

Brine Adjustment

Mineral Tank

Brine Tan

Mineral Tank

Brine Tan

3 Brining/Slow Rinse Position

Hard Water Soft Water

4 Purge Position

Hard Water Soft Water

Inlet

Outlet

Drain

Valv e No. 1 - Open 2 - Open 3 - Closed 4 - Closed 5 - Closed 6 - Open

Mineral T ank

7 - Closed

5 Regenerant Refill Position

Brine Adjustment

Inlet

Outlet

Drain

Brine Adjustment

Valv e No. 1 - Closed 2 - Open 3 - Open 4 - Closed 5 - Closed

Brine T ank

6 - Open 7 - Closed

Mineral T ank

Brine T ank

Val ve No. 1 - Closed 2 - Closed 3 - Open 4 - Open 5 - Open 6 - Closed 7 - Closed

Inlet

Outlet

Hard Water Soft Water

Drain

Mineral T ank

Brine Adjustment

Brine T ank

Replacement Parts

Performa Valve

Parts List

Part

Code

1 1035807 Valve Assembly, w/o Flow Controls 1 11 1035622 Tank Ring 1 2 1035615 960 Standard Camshaft: 1 12 Plumbing Adapter Kits: 1 3 Drain Control Assembly: 1 1001606 3/4-inch Copper Tube Adapter Kit

4 1030502 Ball, Flow Control 1 1001603 1-inch NPT Plastic Pipe Adapter Kit 5 Injector Assembly: 1 1001604 3/4-inch BSPT Plastic Pipe Adapter Kit

6 1000269 Injector Cap Assembly: 1 13 1033444 Turbine Assembly 1 7 Regenerant Refill Control 1 14 1001580 Spring, Flapper Valve

8 1002449 Drain Fitting Elbow (3/4” hose barbed) 1 * Valve Disc Kit: 9 1000226 Screen/Cap Assembly 1 1041174 Standard

10 1010429 O-Ring 1 1041175 Severe Service

No. Description Qty. Code

1000209 No. 7 (1.2 gpm; 4.5 Lpm) 1001670 1-inch Copper Tube Adapter Kit 1000210 No. 8 (1.6 gpm; 6.1 Lpm) 1041210 1-1/4-inch Copper Tube Adapter Kit 1000211 No. 9 (2.0 gpm; 7.6 Lpm) 1001608 22-mm Copper Tube Adapter Kit 1000212 No. 10 (2.5 gpm; 9.5 Lpm) 1001613 3/4-inch CPVC Tube Adapter Kit 1000213 No. 12 (3.5 gpm; 13.2 Lpm) 1001614 1-inch CPVC Tube Adapter Kit 1000214 No. 13 (4.1 gpm; 15.5 Lpm) 1001615 25-mm CPVC Tube Adapter Kit 1000215 No. 14 (4.8 gpm; 18.2 Lpm) 1001769 3/4-inch NPT Plastic Pipe Adapter Kit

1032970 “A” Injector - White 1001605 1-inch BSPT Plastic Pipe Adapter Kit 1032971 “B” Injector - Blue 1001611 3/4-inch BSPT Brass Pipe Adapter Kit 1032972 “C” Injector - Red 1001610 1-inch NPT Brass Pipe Adapter Kit 1030272 “D” Injector - Green 1001612 1-inch BSPT Brass Pipe Adapter Kit

1000222 .33 gpm 15 1030372 Cover 1

Part

No. Description Qty.

* Not Shown

960 ProSoft Control

1265 Bypass

Performa ProSoft

Performa

Part

Code

1 2 3 * 1000811 * 1000907

* 1034264

* Not Shown

No. Description Qty.

960 ProSoft Control

1040930 1265 Bypass

Transformer

Transformer Extension Cord

15 feet (4.6 m)

Y-Splitter (run 2 units from

1 transformer)

1 1 1 1 1

Troubleshooting

The technology upon which the Autotrol Performa control valve 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 very easily be serviced. 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. To remove water pressure from the system, put the bypass valve or three-valve bypass into the bypass position and open the backwash drain valve (the seventh valve back from the control) with a screwdriver. Restore system water pressure when the service work is completed.

Valve Troubleshooting

Problem Possible Cause Solution

1. Control will not draw regenerant. A. Low water pressure. B. Restricted drain line. C. Injector plugged ! D. Injector defective ! E. Valve (2 and/or 4) not closed.

2. Regenerant tank overflow. A. Regenerant valve (1) being held open.

B. Uncontrolled regenerant refill flow rate ! C. Valve (3 or 4) not closed during regenerant

draw causing refill.

D. Air leak in regenerant line.

3. System using more or less salt

than salt control is set for.

4. Intermittent or irregular

regenerant draw.

5. No conditioned water after

regeneration.

6. Control backwashes at

excessively low or high rate.

7. Flowing or dripping water at

drain or regenerant line after regeneration.

8. Hard water leakage during

service.

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 regenerant tank.

C. Plugged injector ! A. Incorrect backwash controller used. B. Foreign matter affecting controller

operation !

A. Drain valve (5 or 6) or regenerant valve (1)

held open by foreign matter or particle.

B. Valve stem return spring on top plate weak. A. Improper regeneration.

B. Leaking of bypass valve ! C. O-ring around riser tube

damaged !

A. Set pump to maintain 30 psi at conditioner. B. Remove restriction. C. Clean injector and screen. D. Replace injector. E. Remove foreign matter from disc and check disc

for closing by pushing in on stem. Replace if needed.

A. Manually operate valve stem to flush away

obstruction. B. Remove variable salt controller to clean. C. Flush out foreign matter by holding disc open and

manually operating valve stem. D. Check all connections in regenerant line for leaks.

Refer to instructions. A. Correct setting.

B. Remove variable salt controller and flush out

foreign matter. Manually position control to

regenerant draw to clean controller (after so

doing, position control to “purge” to remove

regenerant from tank). C. Replace controller. A. Set pump to maintain 30 psi at conditioner. B. Replace both injector and injector cap. A. Check for power. B. Add salt. C. Clean injector. Flush with water. A. Replace with correct size controller. B. Remove controller and ball. Flush with water.

A. Manually operate valve stem to flush away

obstruction. B. Replace spring.

A. Repeat regeneration making certain that the

correct salt dosage is set. B. Replace O-ring. C. Replace O-ring.

960 Control Troubleshooting

Alarms

The Model 960 continuously monitors itself and sounds an alarm if it detects something wrong. The alarm is a beep that is on for one second and then off for nine seconds.

When the alarm sounds, the display shows the letters “Err” with a number from 1 to 4. The table below lists the Err numbers, a description of each error, the cause of the error, and the solutions. To silence the alarm, press any button on the control. If the error still exists, the control will go back to the alarm condition after 30 seconds.

Model 960 Alarms

Indication Description Cause Solution

Err1 Electronics Failure Control settings need

reprogramming.

Err2 Improper start of

regeneration (limit switch closed when it should be open).

Valve camshaft has been manually rotated during a regeneration. Valve camshaft has been manually rotated out of “regeneration complete” position.

Faulty motor. Faulty motor drive. Faulty switch.

Err3 Improper finish of

regeneration (limit switch open when it should be closed).

Valve camshaft has been manually rotated out of “regeneration complete” position.

Faulty motor. Faulty motor drive. Faulty switch.

Err4 Improper control settings (one

or more settings out of the

One or more settings out of the allowable range.

allowable range).

Press any key to load default values. Refer to “Programming the Model 960 Control”. Press any key to silence the alarm. (Note: Alarm automatically clears at “TIME OF REGEN”.)

The control will turn the motor on and drive the camshaft to the proper location.

Replace the control. Replace the control. Replace the control. The control will turn the motor on and drive

the camshaft to the proper location.

Replace the control. Replace the control. Replace the control. Hardness: Adjust range: 3 to 250. Capacity: Adjust range: 0.1 to 140.0.

Refill control: Adjust range: 1 to 99. Regenerant draw value: Adjust range per

Table 4.

Problem Possible Cause Solution

1. Capacity display stays at 9999 even through there is water usage.

2. Timer beeps when left arrow button is pressed.

3. Timer does not respond to REGEN button.

4. Timer does not display time of day.

5. Timer does not display correct time of day.

a. Total system capacity was calculated to be

a value greater than 9999.

A. Button is only active in the programming

mode.

A. Button is not active in the programming

mode. A. Transformer is unplugged. B. No electric power at outlet. C. Defective transformer. D. Defective circuit board. A. Outlet operated by a switch.

B. Power outages.

A. As the water usage continues, the remaining

capacity will drop below 9999 and then other values will be shown.

A. Refer to the Programming section.

A. Refer to the Regeneration section.

A. Connect power. B. Repair outlet or use working outlet. C. Replace transformer. D. Replace control. A. Use outlet not controlled by switch. B. Reset Time of Day.

Problem Possible Cause Solution

6. No water flow display when water is flowing (colon does not blink).

7. Control display is frozen at Regen Time Remaining.

8. Control regenerates at the wrong time of day.

9. Timer stalled in regeneration cycle.

10. Continuous regeneration. Camshaft does not stop at the end of regeneration.

11. Control does not regenerate automatically or when REGEN button is depressed.

12. Control does not regenerate automatically but does regenerate when RE GEN button is depressed.

13. Run out of soft water between regenerations.

A. Bypass valve in bypass position. 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. Back to back regenerations were requested. A. Refer to the Manual Regeneration section.

A. Power outages. B. T ime of day set incorrectly. C. T ime of regeneration set incorrectly. A. Motor not operating. B. Motor runs backwards. C. No electric power at outlet. D. Incorrect voltage or frequency (Hz).

E. Broken gear. F. Defective switch. G. Air leak in regenerant connections (pressure

locked flapper).

H. Binding of camshaft.

I. Water pressure greater than 125 psi during

regeneration. J. Defective circuit board. A. Broken projection on drive gear. B. Defective switch.

A. Transformer unplugged. B. No electric power at outlet. C. Defective motor. D. Broken gear. E. Binding in gear train. F. Defective switch. A. If water flow display is not operative, refer to

item 5 in this table. B. Incorrect hardness and capacity settings.

C. Defective circuit board. A. Improper regeneration.

B. Fouled resin bed. C. Incorrect salt setting.

D. Incorrect hardness or capacity settings.

E. Water hardness has increased.

F. Restricted meter turbine rotation due to

foreign material in meter housing !

G. Excessive water usage below 1/5 gallon per

minute.

A. Shift bypass valve into service position. B. Fully insert probe into meter housing.

C. Remove meter housing, free up turbine and flush

with clean water. Turbine should spin freely. If not ,

refer to the Water Meter Maintenance section. D. Replace control. E. Replace control.

A. Reset time of day to correct time of day. B. Reset time of day to correct time of day. C. Reset time of regeneration. A. Replace control. B. Replace control. C. Repair outlet or use working outlet. D. Replace timer and/or transformer with one of

correct voltage and frequency (Hz). E. Replace control. F. Replace control. G. Check all junction points and make appropriate

corrections. H. Remove foreign object obstruction from valve

discs or camshaft. I. Install pressure regulator to reduce pressure.

J. Replace control. A. Replace control.

B. Replace control.

A. Connect power. B. Repair outlet or use working outlet. C. Replace control. D. Replace control. E. Replace control. F. Replace control. A. Refer to item 5 in this table.

B. Set new control values. Refer to the Programming

section. C. Replace control. A. Repeat regeneration making certain that correct

salt dosage is used. B. Use resin cleaner. C. Set salt control to proper level. Refer to the

Programming section in this manual. D. Set to correct values. Refer to the Programming

section in this manual. E. Set to new value. Refer to the Programming

section in this manual. F. Remove meter housing, free up turbine, and flush

with clean water. Turbine should spin freely, if not ,

replace meter. G. Repair leaky plumbing and/or fixtures.

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. However, the normal conditions existing during shipping, storage and installation indicate the advisability of disinfecting a conditioner after installation, before the conditioner is used to treat potable water. In addition, during normal use, a conditioner may become fouled with organic matter or in some cases with bacteria from the water supply.

Thus every conditioner should be disinfected after installation, some will require periodic disinfection during their normal life, and in a few cases disinfection with every regeneration would be recommended.

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.

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 Bleach*. If stronger solutions are used, such as those sold for commercial laundries, adjust the dosage accordingly.

2. Regenerant tank conditioners A. Backwash the conditioner and add the required

amount of hypochlorite solution to the regenerant well of the regenerant tank. (The regenerant 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. Regenerant tank conditioners A. Backwash the conditioner and add the required

amount of hypochlorite to the regenerant well of the regenerant tank. (The regenerant tank should have water in it to permit the chlorine solution to be carried into the conditioner.)

B. Proceed with the normal regeneration.

1. Dosage A. Polystyrene resin: 1.2 fluid ounces per cubic foot.

B. Non-resinous exchangers: 0.8 fluid ounce per

cubic foot.

Printed in USA P/N 1227756 Rev. E

GE DX400 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual