Watts Autotrol 263 User Manual

™

Autotrol Performa Valve

With 400 Series Control

Water Conditioning Control System

Dealer Installation, Operation and Maintenance Manual

Table of Contents

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

Location Selection Water Line Connection Drain Line Connection Brine Line Overflow Line Connection

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

Electrical Connection

400 Series Control Settings. . . . . . . . . . . . . . . . . . . 6

440i

Programming

460i

Programming Time of Day Setting Hardness Setting Capacity Setting Calendar Override Setting

Common Features. . . . . . . . . . . . . . . . . . . . . . . . . . 7

Salt Dial Adjustment Guest Cycle Manual Regeneration

Removing the Valve Assembly for Servicing . . . . . . 9

Removing 440i or 460i for Servicing . . . . . . . . . . . . 9

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . 10

Injector Screw and Injector Water Meter

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Pressure Graphs . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Identification of Control Valving. . . . . . . . . . . . . . . 13

Valve Disc Principle of Operation . . . . . . . . . . . . . 13

Flow Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . 15

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Disinfection of Water Conditioners . . . . . . . . . . . . 21

Installation

Not in Bypass

In Bypass

Water

Conditioner

Out

Water

Conditioner

Out

Water

Not in Bypass

In Bypass

Water

Conditioner

Water

Conditioner

All plumbing and electrical connections must conform to local codes.

Inspect unit carefully for carrier shortage or shipping damage.

Location Selection

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.

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 brine tank, the location should be easily accessible.

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

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

If a check valve is installed, make certain the water heating unit is equipped with a properly rated temperature and pressure safety relief valve. Also, be certain that local codes are not violated.

5. Do not locate unit where it or its connections (including the drain and overflow lines) will ever be subjected to room temperatures under 34 or over 120

F (49oC).

F (1oC)

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

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

Figure 1 - Autotrol Series 1265 Bypass Valve

Figure 2 - Typical Globe Valve Bypass System

Drain Line Connection

Standard commercial practices are expressed

Note:

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).

4. Where the drain line is elevated but empties into a

Brine Tank

Overflow Fitting Installed

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

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.

Right Wa y

Figure 3

Overflow Line Connection

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

To connect overflow, locate hole on side of brine tank. Insert overflow fitting (not supplied) into tank and tighten with plastic thumb nut and gasket as shown (Figure 4). Attach length of 1/2-inch (1.3-cm) I.D. tubing (not supplied) to fitting and run to drain. Do not elevate overflow line higher than 3 inches (7.6 cm) below bottom of overflow fitting. Do not tie into drain line of control unit. Overflow line must be a direct, separate line from overflow fitting to drain, sewer or tub. Allow an air gap as per drain line instructions (Figure 3).

: Standard commercial practices have been

Note

expressed here. Local codes may require changes to these suggestions.

Brine Line Connection

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

Be sure all fittings and connections are tight.

Figure 4

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 first releasing the plastic clip from the back of the cover. Pull back of cover slightly outward and lift up.

: The following steps will require turning the

Note

indicator knob (Figure 5 and Figure 6) to various positions. Manually rotate the camshaft

COUNTERCLOCKWISE

points to desired position. (See manual regeneration sections for each control’s manual operation.)

2. Rotate indicator knob until it points directly to the word

3. Fill media tank with water.

A. With water supply off, place the bypass valve(s)

into the “not in bypass” position.

B. Open water supply valve very slowly to

approximately the 1/4 open position.

IMPORTANT:

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

D. Allow water to run to drain until clear. E. Turn off water supply and let the unit stand for

4. Add water to brine tank (initial fill).

With a bucket or hose, add approximately 4 gallons (15 liters) of water to brine tank. If the tank has a salt platform above the bottom of the tank, add water until the level is approximately 1 inch (25 mm) above the platform.

If opened too rapidly or too far, media

tank (water begins to flow steadily from the drain), open the main supply valve all the way.

about five minutes. This will allow all trapped air to escape from the tank.

only until indicator knob

COUNTERCLOCKWISE

BACKWASH

5. Place the conditioner into operation.

A. With the water supply valve completely open,

carefully advance the indicator knob

COUNTERCLOCKWISE BRINE REFILL

until water starts to flow through the brine line into the brine tank. Do not run for more than one or two minutes.

B. Advance the indicator knob

COUNTERCLOCKWISE

center of the

C. With the conditioner in this position, check to

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

D. Advance the indicator knob

COUNTERCLOCKWISE

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

position. Hold at this position

BRINE/SLOW RINSE

to the center of the

until it points to the

position.

Troubleshooting

to the

SERVICE

Electrical Connection

100 VAC, 115 VAC, and 230 VAC units:

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:

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.

Connect the plug of the transformer (supplied)

Remove twist

400 Series Control Settings

PM Indicator

Water Flow Indicator

Hour Time Display

Access Door

Indicator Knob

Time Set Button

Transformer Plug Receptacle

Jumper

Spare

Raised

Ta b

Jumper

Locking Pin

Timer

440i Control

Day Arrow

Indicator Knob

Programming

1. Set days of regeneration on skipper wheel (Figure 5).

•

2. Set the time of day.

•

: With the time of day properly set, the conditioner

Note

will regenerate at about 2:30 a.m. If you prefer to have the unit regenerate at an earlier or later time, simply set current time-of-day accordingly (e.g., to have the unit regenerate at 4:30 a.m.—two hours later—set the clock two hours earlier than the actual time of day.)

The Timer Locking Pin should always be

Note:

horizontal (Figure 5) during operation.

Skipper Pins

Timer

Locking Pin

Time Arrow

Skipper Wheel

Timer Knob

Figure 5

Pull all skipper pins outward (away from control).

Rotate skipper wheel until day arrow points to current day or number 1.

Depress skipper pin(s) at day(s) for which regeneration is desired.

Grasp timer knob and pull outward.

Rotate in either direction until the timer arrow points to the actual time of day.

Release timer knob.

460i Control

Figure 6

Programming

Plug the wall-mount transformer into a functioning electrical outlet that is not controlled by a switch. Plug the transformer into the transformer plug receptacle on the control.

Open the access door by pushing the raised tab on the door toward the left while pulling the tab out (Figure 6).

Time of Day Setting

With the jumper on the set of pins next to the word TIME (Figure 7), set the time of day to the closest hour by pressing the black TIME SET button. PM hours are indicated by a light next to the letters PM on the display window.

The use of a small needle-nose pliers will aid in

Note:

moving the jumper.

The unit is factory set to regenerate at 2:00 a.m.

Note:

If you prefer to have the unit regenerate at an earlier or later time, simply set the current time of day accordingly (e.g., to have the unit regenerate at 4:00 a.m.—two hours later—set the clock two hours earlier than the actual time of day).

The Timer Locking Pin should always be

Note:

horizontal (Figure 6) during operation.

Hardness Setting

Indicator Knob

Move the jumper to the set of pins next to the word HARDNESS (Figure 8). Press the black TIME SET button until the hardness of the incoming water supply is displayed. The hardness range is from 1 to 99 grains per gallon.

To change water hardness stated in parts per million (PPM) to grains per gallon (GPG) use this formula:

Parts per Million

17.1

Grains per Gallon

4. Depress the black TIME SET button. The numbers will roll from “0” to “15.” Release the switch at the desired number of days for the calendar override. For example, releasing the switch at “10” would program a 10-day calendar override.

5. Disconnect power.

6. Place jumper back on TIME and reconnect power.

7. The calendar override program is maintained during power outages by the NOVRAM circuitry.

8. To remove the calendar override, follow the same steps above and program back to “0.”

Common Features

When using the Performa valve with the 440i or 460i controls, there are several features and procedures that are unique to the 400 series controls. They are as follows:

Figure 7 Figure 8

Figure 9

Capacity Setting

Move the jumper to the set of pins next to the word CAPACITY (Figure 9). Press the black TIME SET button until the correct capacity value is displayed. The capacity range is 1 to 99 kilograins. Refer to the Suggested Salt Dial Settings table (8).

Return the jumper to the top set of pins next to the word TIME and replace the access door.

must NOT be left on any pins other than the top pair next to the word TIME.

a blank display.

A spare jumper is located on the bottom set of

Note:

pins.

In the event that the hardness or capacity setting must be changed, simply follow the appropriate steps described above.

Otherwise, the unit may show

The jumper

Calendar Override Setting

Salt Dial Adjustment

These models may be adjusted to produce maximum to minimum conditioning capacities by setting the salt dial, which controls the amount of salt used per regeneration. When desired, the minimum setting may be used on installations if the frequency of regeneration is increased to compensate for lower regenerated conditioning capacity. The installing dealer will set the unit for proper salt usage. Further adjustments are needed only if the hardness of the water supply changes or if water use changes dramatically. Capacity will need to be adjusted accordingly.

To adjust salt dosage, insert a small screwdriver into the white indicator knob and move pointer to proper salt setting (Figure 10).

To convert the salt settings from English to

Note:

metric, divide by 2.2 (e.g., 12 pounds ÷ 2.2 = 5.5 kg of salt).

1. Disconnect power.

2. Place jumper on Pin A and reconnect power.

3. Move jumper to Pin B. A zero will appear, indicating zero days of calendar override. All 460i controllers are preprogrammed in this manner at the manufacturer.

Figure 10

Table 1 – Suggested Salt Dial Settings (Pounds of Salt) For Various Size Softeners

Capacity

Setting

0.5 Ft

0.75 Ft

1.0 Ft

1.25 Ft

1.5 Ft

1.75 Ft

2.0 Ft

2.5 Ft

(Kilograins)

12 4.5——————— 16 9.05.5—————— 20 — 8.5 6.0 — — — — 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 48 ————28.0 60 ——————30.0

When using the 440i or 460i you must use Extra Salt cam and divide the suggested setting by 2 to accomplish these settings.

The amount of salt placed in the brine tank has nothing to do with the amount of salt used during the regeneration cycle. Water will dissolve and absorb salt only until it becomes saturated. A given amount of brine (salt-saturated water) contains a specific amount of salt. The salt dial controls the amount of brine used during the regeneration cycle (e.g., when set at 15 pounds (6.8 kg) the amount of brine the conditioner will use for each regeneration will contain 15 pounds (6.8 kg) of salt, etc.)

Never let the amount of salt in the brine tank be lower than the normal liquid level. Do not overload the brine tank with salt.

Guest Cycle

When abnormally high water usage exhausts your water conditioner’s capacity ahead of schedule, an extra regeneration can be achieved. Depress the

17.0 14.0 12.0 —

21.0

17.0 14.0

21.0

Manual Regeneration

Electricity is used only to run the control and to rotate the camshaft. All other functions are operated by water pressure. Therefore, in the event of a power outage, all the regeneration positions may be dialed manually by depressing the indicator knob and turning

COUNTERCLOCKWISE

(Figure 5 and Figure 6). The following cycle times should be used for proper regeneration:

BACKWASH BRINE/SLOW RINSE FAST RINSE/REFILL PURGE

Do not exceed 10 minutes for the

—14 minutes

—52 minutes

—10 minutes

—6 minutes

FAST RINSE/REFILL

cycle as this will cause excessive salt usage during the next regeneration and possibly a salt residue in the softened water.

indicator knob on the 440i (Figure 5) with a wide-blade screwdriver and turn

START

to initiate a regeneration. For the 460i, simply

COUNTERCLOCKWISE

depress the indicator knob (Figure 6). It will take a few minutes for regeneration to start. A normal regeneration will take approximately two hours.

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