GE DX400 User Manual

™

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.

+ 22 hidden pages