Water Boss 255 User Manual
Series 255 Valve / 960 Control
Water Conditioning Control System
Dealer Installation, Operation and Maintenance Manual
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Location Selection
Water Line Connection
Drain Line Connection
Brine Line Connection
Brine Tank Overflow Connection
Placing Conditioner into Operation . . . . . . . . . 6
Initial Start-Up
Connecting the Control
Programming the Model 960 Control . . . . . . . 7
Level I Parameters
Level II Parameters
Special Notes for Level II Parameters
Refill Control Valve
Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . 12
Manual Regeneration
Automatic Regeneration
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removing the Control
Preventive Maintenance . . . . . . . . . . . . . . . . 15
Injector Screen and Injector
Water Meter
Disinfection of Water Conditioners . . . . . . . . 16
Sodium Hypochlorite 5.25%
Calcium Hypochlorite
Specifications. . . . . . . . . . . . . . . . . . . . . . . . .17
Pressure Graphs. . . . . . . . . . . . . . . . . . . . . . . 18
Control Valving Identification . . . . . . . . . . . . . 19
Valve Disc Operation . . . . . . . . . . . . . . . . . . . 19
Flow Diagrams . . . . . . . . . . . . . . . . . . . . . . . . 19
Replacement Parts. . . . . . . . . . . . . . . . . . . . .21
Splicing the Low Voltage Transformer Cord. .24
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 25
Alarms
Troubleshooting Procedures
IMPORTANT:
The plug-in transformer for t his equipment is rated for
indoor use only.
IMPORTANT:
Never attempt to work on this control while standing in
or near water without disc onnecting electrica l power to
the control.
2
Introduction
The Model 960 control provides sophisticated,
demand-based water conditioning by incorporating a
microprocessor and a water meter to electronically
monitor the amount of water used daily. This fully
programmable control allows you to fine tune the
conditioner’s operation to meet your customer’s
application. The Series 255 valve combines design
simplicity with reinforced Noryl* construction to provide
an uncommonly reliable appliance. The inherent
reliability of the system means a long life of efficient,
trouble-free water conditioning. If maintenance
becomes necessary, the Series 255/960 water
conditioning system offers a unique separation
capability illustrated in this manual.
*Noryl is a trademark of General Electric Company
Special Features
•
Memory Retention.
critical operating information in the control’s
memory is stored in a special electronic device.
This information includes the time of day, water
usage amounts, daily average water usage, all
programming data and the number of days since
the last regeneration. When power is restored, the
information is returned to the microprocessor and
operation res umes as if a n outag e never occurr ed.
The time of day will be late by the length of the
power outage. If an outage of one or more hours
occurs, the time of day sh ould be reset but no ot her
reprogramming is necessary. The optional
non-rechar geable b attery backup fea ture wi ll allow
the control to keep track of time and any water
usage for up to two days during a power outage.
•
Fully programmable regeneration cycle times.
The control is factory programmed with typical
regeneration cycle times for easy installation. The
control allo ws the Backwash, Rinse, and Purge
cycle times to be set by the installer to fine tune the
conditioner’s operation.
•
Automatic double regenerations for exhausted
resin beds.
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.
•
Selectable reserve options.
programmed to operate with one of four different
reserve options (see Parameter P15, Table 3). The
options include starting a regeneration only at a
specific time of day or having an immediate
regeneration when the capacity is exhausted. The
control can also have a fixed reserve which is a
percentage of the total system capacity or a
If the water usage exceeds 150% of
During a power outage,
The control can be
variable reserve which adjusts the reserve
depending upon the water usage patterns of your
customer.
•
Separate Time of Day and Time of Regeneration
settings.
regeneration time for easy install a tion, but the
installer may set the regeneration to occur at any
time of the day.
•
WQA S-101 features.
programmed to freeze the values for Salt Amount
and Capacity so the cu stomer can’t alte r them after
installation (see Parameter P18, Table 3).
•
Selectable 12-or 24-hour clock.
P13, Table 3.)
•
Selectable U.S. or metric units of measur e.
grains per gallon of hardness, pounds of salt, and
kilograins of capacity for U.S. units. Use mill igrams
per liter of hardnes s, kilograms of salt and
kilograms of capacity for metric units (see
Parameter P12, Table 3).
•
Selectable calendar overri de.
available to automatically regenerate the
conditioner if the water usage hasn’t caused a
regeneration. The default value is zero which
disables this feature (see Paramete r P14, Table 3).
•
Design reliability.
many years of trou ble-free performance. The
metering system has only one moving part, t he
rotating turbine that measures water usage and
generates electrical pulses that are counted by the
microprocessor to determine the need to
regenerate.
•
Guest cycle.
achieved at any time by pressing the REGEN
button on the Model 960 front panel. It takes just a
few minutes for the regeneration to start. The
regeneration takes about two hours. This feature is
beneficial when the cust omer expects t o use mor e
than the normal amount of water; for example,
guest visits or an extra heavy laundry day.
•
Manual double regeneration.
regenerations can be run by pressing the REGEN
push button after the first regeneration has been
running for at least one minute. This can be used to
recharge the resin bed that has operated without
salt for an extended period of time.
The control defaults to a 2:00 a.m.
The control can be
(See Parameter
Use
One to 30 days are
Solid-state electronics assure
An extra regeneration can be
Back-to-back
Superior Design
• Fewer parts than any control system of
comparable function and most controls of lesser
function.
• The valve may be indexed manually with or without
power to any one of its service or regeneration
positions. The Regeneration Cycle Indicator on the
3
control face plate indicates control valve po sition.
• No dynamic seals that could cause leakage
through wear or fatigu e.
• Control accepts Noryl brass manifold or modular
bypass valve without modification, offering
complete versati lity and easy plumbing for any
installation.
• Brining control valve built into system eliminates
need for an external brine valve.
• Drain flow control is built into the valve to control
backwash and fast rinse flow rates.
Superior Operation
• Direct acting system functions independently of
water pressure. No pistons or diaphragms that
require a minimum water pressure to operate.
• Five-cycle operation provides for downflow
conditioned water, upflow backwash, downflow
brining and slow rinse, downflow fast rinse, and
refill of the brine tank.
• Valve discs are held closed by water pressure and
are leak tight. Valve seats are in a vertical position,
which is the position least vulnerable to plugging.
• System operation cannot get out of phase or
sequence. The control always returns to a fixed
conditioned water position after regeneration.
• Bypass water is automatically available during
regeneration.
Air Check
Figure 1 - Control
Optional Bypass
Brine Line Fitting Connection 1/4-inch NPT
Inlet Connection 3/4-inch or 1-inch NPT or BSPT
Drain Connection 3/8-inch or 1/2-inch NPT or BSPT
Outlet Connection 3/4-inch or 1-inch NPT or BSPT
Tank Thread 2-1/2-inch - 8 Male NPSM
Figure 2 - Tank Adapter
4
Installation
All plumbing must co nf orm t o loc al co des . In sp ect th e
unit carefully for carrier shortage or shipping damage.
Location Selection
The following considerations must be taken into
account when selecting the location for the water
conditioning system.
• Locate the system as close to a drain as possible.
• If supplementary water treating equipment is
required, make sure that adequate additional
space is available. Locate the brine t a nk in an
accessible place so that salt can be easily added.
• Do not install any unit closer than 10 feet (3 m) of
piping between the outlet of the conditioner and
the inlet of a water heater. Water heaters can
transmit heat back down the cold water pipe into
the 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 prevent hot water
damage. A positive way to prevent hot water from
flowing from a heat source to the conditioner is to
install a check valve in the soft water piping from the
conditioner. If a check valve is installed, make sure that
the water heating unit is equipped with a properly rated
temperature and pressure safety relief valve. Always
conform to local codes.
• Do not locate the unit in an area where the
temperature ever falls below 34
o
120
F (49oC).
o
F (1oC) or over
• Do not install the unit near acid or acid fumes.
• Do not expose the unit to petroleum products.
Water Line Connection
5
water pressure at the conditioner is not less than 40 psi
Brine Tank
Overflow Fitting
Installed
Connect 1/2-in. (13 cm)
I.D. Tubing or Hose and Run
to Drain
(2.8 bar). You may elevate an additional 2 feet (61 cm)
for each additional 10 psi (0 .7 bar).
Where drain line is elevated but empties into a drain
below the level of the control valve, form a 7-inch
(18-cm) loop at the far end of the line so that the bottom
of the loop is level with the drain line connection. This
will provide an adequate siphon trap (Figure 5).
Where a drain empties into an overhead sewer line, a
sink-type trap must be used.
IMPORTANT:
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.
Standard commercial practices have been
Note:
expressed here. Local codes may require changes to
these suggestions.
Never connect the drain line into a drain,
Brine Line Connection
Install an appropriate fitting onto the 1/4-inch male NPT
connection on the air check, Figure 7, and install a
length of flexible tubing between the air check fitting
and the brine pickup tube at the brine tank.
Make sure that all fittings and connections are
Note:
vacuum tight so that premature checking does not take
place. Pr emature checking occ urs wh en the ba ll i n th e
air check falls to the bottom before all brine is drawn
out of the brine tank. Refer to the
section in this manual for additional information.
Troubleshooting
Brine Tank Overflow Line Connection
In the event of a malfunction, the brine tank overflow
connection directs overflow to the drain instead of
spilling it on the floor where it could cause water
damage. Complete the foll owing step s to conn ect the
overflow fitting to the brine tank:
1. Locate the fitting hole on the side of the br ine tan k.
2. Insert the overflow fitting (not supplied) into the
tank and tighten with the plastic thumb nut and
gasket as illustrated in Figure 6.
3. Attach a length of 1/2-inch (1.3-cm) tubing (not
supplied) to the fitting and run to the drain.
Figure 6 - Overflow Line Connection
Do not elevate the overflow line higher than
Note:
3 inches (7.6 cm) below the bottom of the overflow
fitting. Do not tie into the drain line of the control unit.
The overflow line must be a direct, separate line from
the overflow fitting to the drain, sewer , or tub. Allow an
air gap as in the drain line connection, Figure 5.
Placing Conditioner into Operation
Initial Start-Up
After the water conditioning system is installed, the
conditioners should be disinfected before they are
used to treat potable water. Refer to the
Water Conditioners
the following step s to place the conditioner into
operation:
1. Remove the rear valve cover by pulling back on the
tab located on the lower rear edge of th e cover.
Next, lift the cover off the valv e, Figure 10.
2. Grasp the camshaft an d rotate it
COUNTERCLOCKWISE
of the control) until the indicator on the
regeneration cycle indicator points directly to the
word
BACKWASH
3. Fill the mineral tank with water. Turn the water
supply off and place the bypass valve(s) into the
“not in bypass” position. Open the water supply
valve
very slowly
position.
IMPORT ANT:
rapidly or too far , resin may be lost. In the
position, you should hear air escaping slowly from the
drain line.
If the water supply valve is opened too
section in this manual. Complete
(as viewed from the fr ont
.
to approximately the 1/4 open
Disinfection of
BACKWASH
4. When all of the air is purged from the tank (water
begins to flow stead ily fr om the dr ain), slowly op en
the main supply valve all the way. Allow the water
to run into the drain until clear. Turn off the water
supply and wait for about five minutes to allow all
trapped air to escape from the tank.
6
5. Add water to the brine tank (initial fill). With a
bucket or hose, add approximately 4 gallons
(15 liters) of water to the brine tank. If the tank has
a salt platform above the bottom of the tank, add
water until the l evel is approximat ely 1 inch (25 mm)
above the platform.
Figure 7 - Air Check
Open the water supply valve slowly to the fill open
position. Carefully rotate the camshaft
COUNTERCLOCKWISE
regeneration cycle indicator points directly to the
center of the
air check (Figu re 7) fills w ith wa te r an d wate r flo ws
through the brine line into the brine tank. Do not run for
more than two minutes. Rotate the camshaft
COUNTERCLOCKWISE
the center of the
Check that water is being drawn from the brine tank.
The water level in the brine tank will recede very slowly .
Observe the water level for at least three minutes. If the
water level does not recede, if it goes up, or if air enters
the transpar ent air check chamber and the ba ll falls and
seats, refer to the
manual.
REFILL
BRINE/SLOW RINSE
until the indicator on the
position and hold there until the
until the indicator points to
position.
Troubleshooting
section in this
Connecting the Control
The control has default values for mos t parameters that
were set at the factory, but there are key items that
need to be entered at the time of installation:
• Time of Day
• Time of Regeneration
• Hardness
• Salt Amount
• Capacity of the Unit
• Refill Controller Value
• Brine Draw Rate
Determine from Tables 1 and 3 what these values
should be before applying power to the control. It is
also helpful to read the
Control
When the conditioner is operational, complete the
following steps to connect the Model 960 control:
section if you want to set other parameters.
• Connect the control to the wall transformer
cable. The power con nection is located on the
underside of the c ontrol on the left sid e (refer t o
Figure 1). Insert the barrel style connector into
the power plug.
• Plug the wall-mount transformer into an
electrical outlet that is not controlled by a wall
switch.
• If the cord length of the transformer is too short,
an optional 15-foot low voltage extension cord
may be purchased (contact your original
equipment dealer for details) o r the wire ma y be
spliced as shown in Figure 19 on page 24.
Programming the Model 960
When the water is being drawn from the brine tank,
rotate the camshaft
indicator points to
from a nearby faucet until the water is clear and soft.
COUNTERCLOCKWISE
REGEN COMPLETE
until the
. Run water
Figure 8 - Faceplate of 960 Control
Programming the Model 960 Control
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.
7
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 ar e active, look for a
comment in the NO TES column of Tables 1 and 3 . It will
reference another parameter that selects which units
are active. For exam ple, Parameter P12 (Table 3)
selects U.S. units if it is set to
to “1.
”
and metric if it is set
“0”
Level I Parameters (Table 1)
Level I Parameters are identified as t hose t hat h ave 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 which are explained in the Series 960
Operation and Maintenance Manual, R-360 (P/N
1017934). In general, pressing the down arrow (↓)
button displays the Level I Parame ters in t he foll owi ng
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
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.
If you press and hold either the up arrow (↑)
Note:
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
numbers stop flas hing and the con trol acce pts the new
setting. After approximately 30 seconds, the control
starts alternating the displ ay between Time of Day and
Capacity .
button and the far right number on the
SET
button. The
SET
If a beep sounds , the new setting is not accepted
Note:
because it was outside the allowable range. The old
value will be displayed.
Time of Day
Press the
of Day with the minutes digit blinking. If you want to
change this number, press the up arrow (↑) button to
increase the n umber 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
button. The display will show the Time
SET
button to enter the value.
SET
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
number. Press the
2:00 a.m. is acceptable, press the down arrow (↓)
button.
SET
button and change the
SET
button to enter the value. If
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
button and ente r a ne w value . Any va lue b et ween
SET
3 and 250 grains per gallon (30 and 2500 milligrams per
liter) is allowed. Press the
value.
button to enter the new
SET
Salt Amount
Salt Amount is the next value displayed. The default
value for Salt Amount is 6 pounds (2.5 kilograms) of
salt; refe r to Table 2.
This is the total amount of salt for a regeneration,
Note:
not pounds per cubic foot. If 6 pounds is not
acceptable, press the
numbers. If 6 pounds is acceptable, press the down
arrow (↓) button.
button and change the
SET
Capacity
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 amount. The default value is
1.0 kilograin (0.1 kilogram). If this is not acceptable,
press the
between 0.1 and 140 kilograins (.01 and
14.00 kilograms) is allowed.
button and enter a new value. An y value
SET
8
If the calculation for the system capacity
Note:
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. The display will
alternate between the Time of Day and Capacity if no
keys are pr essed for 30 second s. The Capacity valu e is
Table 1 - Programming Parameters
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 Table 3 for details concerning allowable val ues,
defaults, and parameter descriptions. The
programming procedure is the same for all of these
parameters.
Parameter
Name Description
P1
P2
P3
P4 Salt amount
P5
Time of day
AM or PM
Time of day
of
regeneration
Hardness of
water
Capacity of
unit
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
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
1
10
0.5
0.1
0.1
0.01
Default
10
100
6
2.5
1.0
0.1
Grains/gallon
Units of
Measure
mg/L
Pounds
Kilograms
Kilograins
Kilograms
Notes
Range depends on value
selected for P13. Enter th e
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 defau lt
depends on value selected
for P12. Refer to Table 2.
Unit of measure depends on
value selecte d for P12. Enter
the unit capacity.
Table 2 - Suggested Salt Settings
(
Pounds of Salt for Various Size Conditioners)
Resin Bed Volume
Kilograins of
Hardness
Capacity
0.5 ft
3
0.75 ft
3
1.0 ft
3
1.25 ft
3
1.5 ft
3
1.75 ft
3
2.0 ft
Setting
124.5- -----
169.05.0----20-8.56.0---24 - 14.0 8.5 7.0 - - 30 - - 15.0 11.0 9.0 - 32 - - 18.5 12.5 10.0 9.0 35 - - - 16.0 12.0 10.0 9.0
40 - - - 23.0 17.0 14.0 12.0
48 - - - - 28.0 21.0 17.0
3
9
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