®
™
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
2
Installation
Not in Bypass
In Bypass
B
Y
P
A
S
S
B
Y
P
A
S
S
B
Y
P
A
S
S
B
Y
P
A
S
S
Water
Conditioner
In
Out
Water
Conditioner
In
Out
Water
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
o
F (49oC).
o
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).
3
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
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
5
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.
6
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
7
Table 1 – Suggested Salt Dial Settings (Pounds of Salt) For Various Size Softeners
Capacity
Setting
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
3
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
1
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
1
17.0 14.0 12.0 —
1
21.0
1
17.0 14.0
1
21.0
1
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
to
depress the indicator knob (Figure 6). It will take a few
minutes for regeneration to start. A normal regeneration
will take approximately two hours.
3
8
Removing the Valve Assembly for
Indicator Arrow
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 10).
Figure 10
Figure 11
4. Remove the camshaft by carefully pushing the
securing tab, located at the rear of the camshaft,
away from the camshaft until the tab disengages
from the camshaft. Push the back of the camshaft
down and out to the inlet side of the valve
(Figure 12).
4. When used with a globe valve bypass, loosen and
detach the inlet, outlet, brine and drain lines from
the valve. If using the 1265 bypass, loosen and
remove valve from bypass as well as loosening and
removing the brine and drain lines.
5. Unscrew valve (counterclockwise) and remove
valve from tank.
6. To replace the control valve, reverse the above
procedure.
Removing 440i or 460i for Servicing
1. Unplug the power cord.
2. Remove cover.
3. Align the indicator arrow on the rear of the
camshaft with the top of the rear hoop of the top
plate (Figure 11).
Figure 12
5. Disengage the front of the camshaft from the
output gear of the control.
6. Remove the timer locking pin and lift the control
straight up and off of the valve.
7. To reinstall the camshaft and control, reverse the
above procedures.
9
Preventive Maintenance
Water Meter Maintenance
Injector Screen and Injector
Inspect and clean brine tank and screen filter on end of
brine pickup tube once a year or when sediment
appears in the bottom of the brine tank.
Clean injector screen and injector once a year:
1. Unplug the wall-mount transformer.
2. Shut off water supply or put bypass valve(s) into
bypass position.
3. Relieve system pressure by opening valve No. 7
(at rear) with a screwdriver (Figure 10).
4. Using a screwdriver, remove injector screen and
injector cap (Figure 13).
5. Clean screen using a fine brush. Flush until clean.
6. Using a needle-nose pliers, pull injector straight
out.
7. Flush water into the injector screen recess of the
valve body to flush debris out through the injector
recess.
8. Clean and flush the injector.
9. Lubricate the O-rings on the injector, injector cap
and injector screen with silicone lubricant
10. Reinstall the injector, injector cap and injector
screen.
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.
only
!
Note: A water meter is used only with the 460i control.
If you are using the 440i control, this section does not
pertain to your conditioner.
The metering device used with the 460i demand control
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 10).
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 13).
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.
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.
Injector Screen
Injector
Figure 13
Cap
Turb ine
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 on the control display.
*RoVer is a trademark of Hach Chemical Company.
10
Specifications
Inlet
2.5 inch (63 mm)
Drain
2.5 inch (63 mm)
Outlet
11.59 inch (294 mm)
8.74 inch (222mm)
2.88 inch (73 mm)
1.356 inch (34 mm)
3.37-inch (86 mm)
3.66-inch (93 mm)
5.76 inch (146 mm)
5.82 inch (148 mm)
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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
Brine 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). . . . . . . . 440i: Available in 6- or 7-day English, German, French, Italian, Spanish, Japanese
460i: Available in English, German, French, Italian, Spanish, Japanese
Brine Refill 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
2
) of bed area.
For tank sizes above 14 inches in diameter, use an external flow control.
11
Pressure Graphs
3
Injector #1031363
"A" in a 268 Valve
1.00
0.20
0.15
0.10
M /hr
0.05
0.00
0.75
0.50
GPM
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 #1031365
"C" in a 268 Valve
1.75
0.20
0.15
1.50
1.25
1.00
3
0.10
M /hr
0.05
0.00
0.75
GPM
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
0.30
0.25
0.20
0.15
3
M /hr
0.10
0.05
0.00
0.30
0.25
0.20
0.15
3
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
Injector #1031364
"B" in a 268 Valve
Tot al
Rinse
Brine Draw
PSI
bar
Injector #1030272
"D" in a 268 Valve
Total
Rinse
Brine Draw
PSI
bar
Backwash Number 7 8 9 10 12 13 14
Flow (GPM*) 1.2 1.6 2.0 2.5 3.5 4.1 4.8
Flow (LPM*) 4.5 6 .0 7.6 9.5 13.2 15.5 18.2
*Approximate flow rates at 60 psi (4.14 bar)
12
Identification of Control Valving
7 Backwash Drain Valves
5 Refill Valve
3 Inlet Valve
1 Brine Valve
6 Rinse Drain Valve
4 Outlet Valve
2 Bypass Valve
Valve Disc Principle of Operation
Flow Diagrams
1 Service Position
Hard Water
Soft Water
Inlet
Outlet
Drain
Valve
No.
1 - Closed
2 - Closed
3 - Open
4 - Open
5 - Closed
6 - Closed
7 - Closed
3
2
4
Mineral T ank
2 Backwash Position
Hard Water
Soft Water
1
5
6
7
Brine
Adjustment
Brine T ank
Valve
No.
1 - Closed
2 - Open
3 - Closed
4 - Open
5 - Closed
6 - Closed
7 - Open
Inlet
Outlet
Drain
2
4
Mineral T ank
3
1
5
7
6
Backwash
Flow
Control
Brine
Adjustment
Brine T ank
13
3 Brining/Slow Rinse Position
Hard Water
Soft Water
4 Purge Position
Hard Water
Soft Water
Inlet
Outlet
Drain
3
2
5
4
6
Valve
No.
1 - Open
2 - Open
3 - Closed
4 - Closed
5 - Closed
6 - Open
7 - Closed
Mineral T ank
5 Brine Refill Position
Hard Water
Soft Water
1
7
Brine
Adjustment
Valve
Inlet
Outlet
Drain
1
3
2
5
4
6
7
Brine
Adjustment
No.
1 - Closed
2 - Open
3 - Open
4 - Closed
5 - Closed
6 - Open
7 - Closed
Brine T ank
Mineral T ank
Brine T ank
Valve
No.
1 - Closed
2 - Closed
3 - Open
4 - Open
5 - Open
6 - Closed
7 - Closed
Inlet
Outlet
Drain
3
2
4
Mineral T ank
1
5
6
7
Brine
Adjustment
Brine T ank
14
Replacement Parts
Performa Valve
2
13
10
4
13
5
15
14
9
1
3
6
7
12
5
6
8
3
12
4
1
9
1
8
8
11
15
Parts List
g
y
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y
g
g
g
g
g
g
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Part
Code
1 1035606 Valve Assembly, w/o Flow Controls 1 8 Brine Refill Control (440i and 460i): 1
2 Camshaft: 1 1034263 3 to 19 Pounds Salt
3 1031391 Timer Lockin
4 Drain Control Assembl
5 1030502 Ball, Flow Control 2 1001614 1-inch CPVC Tube Adapter Kit
6 Injector Assembl
7 Injector Cap Assembl
No. Description Qty. Code
(440i, 460i) 1034261 1 to 10 Pounds Salt
1035625 440i, 460i Standard 9 1002449 Drain Fittin
1035627 440i, 460i Extra Salt ** 10 1000226 Screen/Cap Assembl
Pin 1 11 1010429 O-Rin
: 1 12 1035622 Tank Rin
1000209 No. 7 (1.2
1000210 No. 8 (1.6
1000211 No. 9 (2.0
1000212 No. 10 (2.5
1000213 No. 12 (3.5
1000214 No. 13 (4.1
1000215 No. 14 (4.8
1032970 “A” Injector - White 1001769 3/4-inch NPT Plastic Pipe Adapter Kit
1032971 “B” Injector - Blue 1001603 1-inch NPT Plastic Pipe Adapter Kit
1032972 “C” Injector - Red 1001604 3/4-inch BSPT Plastic Pipe Adapter Kit
1030272 “D” Injector - Green 1001605 1-inch BSPT Plastic Pipe Adapter Kit
1000217 “A” Cap 1001610 1-inch NPT Brass Pipe Adapter Kit
1000218 “B” Cap 1001612 1-inch BSPT Brass Pipe Adapter Kit
1000219 “C” Cap 14 1033444 Turbine Assembl
1030303 “D” Cap 15 1001580 Sprin
pm; 4.5 Lpm) 13 Plumbing Adapter Kits: 1
pm; 6.1 Lpm) 1001606 3/4-inch Copper Tube Adapter Kit
pm; 7.6 Lpm) 1001670 1-inch Copper Tube Adapter Kit
pm; 9.5 Lpm) 1041210 1-1/4-inch Copper Tube Adapter Kit
pm; 13.2 Lpm) 1001608 22-mm Copper Tube Adapter Kit
pm; 15.5 Lpm) 1001609 28-mm Copper Tube Adapter Kit
pm; 18.2 Lpm) 1001613 3/4-inch CPVC Tube Adapter Kit
: 1 1001615 25-mm CPVC Tube Adapter Kit
: 1 1001611 3/4-inch BSPT Brass Pipe Adapter Kit
* Valve Disc Kit:
* 1000062 I-Lid Cover 1
Part
No. Description Qty.
Elbow (3/4” hose barbed) 1
(460i only)1
, Flapper Valve
1041174 Standard
1041175 Severe Service
1
1
1
* Not Shown
** Soft water refill is not available with the extra salt cam
16
440i Control
y
y
460i Control
1265 Bypass
S
S
A
P
Y
B
3
1
2
Part
Code
1
2
S
S
A
P
Y
B
3
* 1000811
* 1000907
* 1034264
* Not Shown
No. Description Qty.
440i Control (6 da
460i Control
1040930 1265 B
Transformer (440i, 460i):
Transformer Extension Cord
15 feet (4.6 m)
Y-Splitter (run 2 units from
1 transformer)
pass
or 7 day)
1
1
1
1
1
1
17
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.
Valve Troubleshooting
Problem Possible Cause Solution
1. Control will not draw brine. a. Low water pressure.
b. Restricted drain line.
c. Injector plugged
d. Injector defective
e. Valve (2 and/or 4) not closed.
2. Brine tank overflow. a. Brine valve (1) being held open.
b. Uncontrolled brine refill flow rate
c. Valve (3 or 4) not closed during brine draw
d. Air leak in brine line.
3. System using more or less salt
than salt control is set for.
4. Intermittent or irregular brine
draw.
5. No conditioned water after
regeneration.
6. Control backwashes at
excessively low or high rate.
7. Flowing or dripping water at
drain or brine line after
regeneration.
8. Hard water leakage during
service.
a. Inaccurate setting.
b. Foreign matter in controller causing
c. Defective controller.
a. Low water pressure.
b. Defective injector
a. Unit did not regenerate.
b. No salt in brine tank.
c. Plugged injector
a. Incorrect backwash controller used.
b. Foreign matter affecting controller
a. Drain valve (5 or 6) or brine valve (1) held
b. Valve stem return spring on top plate
a. Improper regeneration.
b. Leaking of bypass valve
c. O-ring around riser tube
!
!
causing refill.
incorrect flow rates
!
!
!
operation
open by foreign matter or particle.
weak.
!
!
damaged
!
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.
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 brine line for leaks.
Refer to instructions.
a. Correct setting.
b. Remove variable salt controller and flush out
foreign matter. Manually position control to
brine draw to clean controller (after so doing,
position control to “purge” to remove brine
from tank).
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.
18
440i Control Troubleshooting
Problem Possible Cause Solution
1. Control will not regenerate
automatically.
2. Control regenerates at wrong
time of day.
a. Transformer or motor not connected.
b. Defective timer motor.
c. Skipper pins not down on timer skipper
d. Binding in gear train of timer.
a. Time set incorrectly. a. Correct time setting according to instructions.
460i Control Troubleshooting
Problem Possible Cause Solution
1. Clock does not display time of
day.
2. Clock does not display correct
time of day.
3. Time display continues to
advance.
4. Time display shows
something other than time of
day.
5. No water flow display when
water is flowing.
6. Control regenerates at wrong
time of day.
7. Timer stalled in regeneration
cycle.
8. Continuous regeneration.
Camshaft does not stop at the
end of regeneration.
a. Transformer cord unplugged.
b. No electric power at outlet.
c. Defective transformer.
d. Defective circuit board.
a. Outlet operated by switch.
b. Incorrect voltage or frequency (Hz).
c. Power outages.
a. Defective time set switch. a. Replace timer.
a. Electrical interference.
b. Defective circuit board.
a. Bypass valve in bypass.
b. Meter probe disconnected or not fully
c. Restricted meter turbine rotation due to
d. Defective meter probe.
e. Defective circuit board.
a. Power outages.
b. Clock set incorrectly.
a. Motor dead.
b. Motor runs backward.
c. No electric power at outlet.
d. Broken gear.
e. Defective switch.
f. Air leak in brine connections.
g. Binding of camshaft.
h. Water pressure greater than 125 psi
i. Defective circuit board.
a. Broken switch activator on gear.
b. Defective switch.
wheel.
connected to meter housing.
foreign matter in meter.
during regeneration.
a. Connect power.
b. Replace motor.
c. Depress pins for days regeneration required.
d. Replace timer.
a. Connect power.
b. Repair outlet or use working outlet.
c. Replace transformer.
d. Replace timer.
a. Use outlet not controlled by switch.
b. Replace timer with one of correct voltage and
frequency (Hz).
c. Reset clock.
a. Disconnect power to unit. Restore power and
reset time of day.
b. Replace timer.
a. Shift bypass valve to not-in-bypass position.
b. Fully insert probe into meter housing.
c. Remove meter housing, free up turbine and
flush with clean water. Do not disassemble
turbine from meter housing. Turbine should
spin freely. If not, replace meter
d. Replace timer.
e. Replace timer.
a. Reset clock to correct time of day.
b. Reset clock to correct time of day.
a. Replace timer.
b. Replace timer.
c. Repair outlet or use working outlet.
d. Replace timer.
e. Replace timer.
f. Check all junction points and make
appropriate corrections.
g. Remove foreign object obstruction from valve
discs or camshaft.
h. Install pressure regulator
i. Replace timer.
a. Replace timer.
b. Replace timer.
!
!
19
Problem Possible Cause Solution
9. Control will not regenerate
automatically or when button
is pressed.
10. Control will not regenerate
automatically but will
regenerate when button is
pressed.
11. Run out of soft water between
regenerations.
a. Electric cord 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.
b. Defective circuit board.
c. Incorrect hardness and capacity settings.
a. Improper regeneration.
b. Fouled softener resin.
c. Incorrect salt setting.
d. Incorrect harness 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.
Note: 1: Use of resin cleaners in an unvented enclosure is not recommended.
a. Connect power.
b. Repair outlet or use working outlet.
c. Replace timer.
d. Replace timer.
e. Replace timer.
f. Replace timer.
a. Same as Item 5.
b. Replace timer.
c. Set to correct values. See Programming
section.
a. Repeat regeneration, making certain that
correct salt dosage is used.
b. Use resin cleaner. See Note 1.
c. Set salt control to proper level. See Salt Setting
chart.
d. Set to correct values. See Programming
section.
e. Set hardness to new value. See Programming
section.
f. Remove meter housing, free us turbine and
flush with clean water. DO NOT
DISASSEMBLE TURBINE FROM METER
HOUSING. Turbine should spin freely, if not,
replace meter
g. Repair leaky plumbing and/or fixtures
!
!
20
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
2. Brine tank conditioners
a. Backwash the conditioner and add the required
amount of hypochlorite solution to the brine
well of the brine tank. (The brine tank should
have water in it to permit the solution to be
carried into the conditioner.)
b. Proceed with the normal regeneration.
Calcium Hypochlorite
Calcium hypochlorite, 70% available chlorine, is
available in several forms including tablets and
granules. These solid materials may be used directly
without dissolving before use.
1. Dosage
a. Two grains (approximately 0.1 ounce) per cubic
foot.
2. Brine tank conditioners
a. Backwash the conditioner and add the required
amount of hypochlorite to the brine well of the
brine tank. (The brine tank should have water in
it to permit the chlorine solution to be carried
into the conditioner.)
b. Proceed with the normal regeneration.
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.
1. Dosage
a. Polystyrene resin: 1.2 fluid ounces per cubic
foot.
b. Non-resinous exchangers: 0.8 fluid ounce per
cubic foot.
*Clorox is a registered trademark of The Clorox Company.
21
22 23
© Copyright 2001 Osmonics
Printed in USA P/N 1222945 Rev. C
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