255 Valve/ 400 Series Service
Contents
1. Le Lb Ndo ebind esuly 1se4 Le LI Ndo ysemyoeg y no uises eBueuox3 uo di SE SN6Z O uoiq s uidB uoneJjeueBe ES Lh ud6 uon 3 Buung ejes MOL Luntulxe 0 S Wes dL960 SL Wes QVI6OT yes JO qi D yes qi sureJ6 ou lolJd pales LAAHS VLva 39NVINHOJHISd YANALAOS YALVM ME poe p ho es jo ai ue 0 s cev oz g zoe SL Ayoede palen isd ajeg Mol4 891 NIS iai GE pa ey 1e do SJnSSeJd 00 0 9 uud6 ol adIMMas palen I2POW AUTOTROL 255 Valve 400 Series Service Manual e 3 EQUIPMENT INSTALLATION Autotrol 255 Valve Control Module Features 400 Series Control Optional i lid Cover Variable Brine uj Air Check Injector Access Plug Figure 1 Tank Adapter Module Features Optional Bypass Brine Line Fitting Connection 1 4 inch NPT Inlet Connection 3 4 inch or 1 inch NPT or BSPT mt Drain Connection h 3 8 inch or 1 2 inch NPT or BSPT Outlet connection 3 4 inch or 1 inch NPT or BSPT nd Tank Thread 2 1 2 inch 8 male Figure 2 System Regeneration Cycles 1 Service Downflow Untreated water is directed down through the resin bed and up through the riser tube The hardness ions attach themselves to the resin and are removed from the vvater The vvater is conditioned as it passes through the resin bed 2 Backyvash Upflovv The flovv of vvater is reverse2. 100V 50 Hz Operating Ambient Temperature 34 120 F 1 49 C 34 100 F 1 38 C For service or parts please contact your local professional water treatment dealer Operating Water Temperature SYSTEM SPECIFICATIONS CONTINUED Kuo Ayayes jenajejn 104 9 uoOo8S L9 PIS ISNV JSN 9 VOM Aq peuJeO pue p ls L SI yun siu uo pesn 8AJeA SUL 9ouBIIduuo 4994 Peal 10 ZZE ISNV ASN 8 vy plepuejs ISNV ASN sube YOM Aq palj 129 pue p ls l 00bb 8 z 297 NOHd GOZES UISUOSSIM 92XNEMI W PLOY Jed USID YHON 06 65 977 uoneniJ jenuepiseg HIV LN3d OT Von NI jenuepises JIB1U9d aeq ueAng 91B Je es 3ueuieJmnbes emoj jeeus ejep jonpold ees sued jueujeoejdeJ pue uyeeH 9IIdnd jo jueuniedeq elulojled sy Aq peynJeo swej yeay sn Jo suonipuoo 104 eonoN 1ueuoduj UOI1BUUJOJUI Ajuelem JO jenueul sJeuwo Jno Bag 891AJ8S pue Sed 10 J9 eep joJjoiny e20 Jno J9eJuo9 suononujsul BuruueJ604d pue dn jas Joy SIBhUBIA 8914188 pue UOHBIIB1SU ulejs s au o 1948344 Wasis au Jaye Jo alojaq UOHOSJUISID ejenbepe nou Aujenb uwouxun Jo Jo ejesun Ajjesibojoiqololtu si jeu Joie bunga Joj Deen aq o papuajul jou 9JB sulejs s SeJ Ajoedeo sJeueyos Jajem aq eonpeJ yeu sjueuiuejuoo Jeujo pue abesn Jayem sseupieu JejeM Bulpnjoul sJojoej uoneolidde jenpinipul o app Aoueroyje y uey ssa AjeordA SI 1 pejjejsur ueeq seu uu ls s y Jaye pe eluoe OUgIOIJ9 jenjoe ay
3. si Aoualoija jeuoneJedQ e eluoe ued Luajs s eui Aoueroyje ajqissod wnwxew y sjueseJdei jeet SYL pp ISNV JSN ul pequosep 1s 1 uojeJoqe e Aq painseaw si AOuapu 95esop yes pajejs y ye pijen Ajuo si Aoueroyje y jo yey pue eDesop yes yey je Ajroedeo ay Aoueroyje yey je eBesop yes ay J9US1JOS JejeM Y jo OUgIOIJ9 Deg SU bung pajsij sJ ueuj jes 9JOUJ JAJAP jou IIBUS pue yes jo wei6ojiy Jed peBueuoxe sseupueu 6301 Jo SUJBJ5 77 y Aouajeninba joey uo peseq yes jo punod Jad peBueuoxe sseupieu IB1O JO suje 0GCC yey sse JOU jo Aoueroyje jes paie e 9ABU jjeys sueuayos lejem Dag Aoueroyj3 uoneJedo sy ui pesn 18 eM pue uuq 1ueJeuefeiJ jo JUNOWE y 9ZIUUIUIUJ o papuajul suomeoyioeds eoueuuojed oyioeds uy salldwod osje uoiuw Jeueyos sq UOI1BJ9uS59 pejeniui puewap e si Jauayos Jajem payes oueroije uy e oqe peouaJeja1 eBesop yes ay Je pijen Ajuo ase pue py ISNV 4SN YM eouepJoooe ul peuluuejep osje alam shoqe Saul jes pI au ejep Iso Aq pejenuejsqns pue Doan se SUJIBIO eoueuuojied OIDSdS JO py ISNV 4SN 01 uuojuoo pue YOM Aq pasa ueeq SABU SUJg1S AS ous J9 eM 9SSU1 Sulejs s ezis SnoueA BY JO 9121 MOY SOIAJSS Dog BU JO 9506 ejes MOL Buse Ajoedeg g o S Jo Hd isd G Isdge je pasa 9AOdB sueis S IN SIBUBYOS J9 EM 10 ES lejos JO je ed DJOIUO UnIDOS ed yes eigeydeoov 86 LL 40 4 00L pe enjejeduie Bunejedo Jsjetunusojbdy 8 8 v 10 ISd GZL 0c ensseug Dunejedo
4. 0 v ae te I H k L CO clandes C2andCs UMS cSeMC tc Figure 3 NOTE All plumbing 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 Ifitis likely that supplementary water treating 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 A 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 from 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 it s connections including the drai
5. Air check valve closes prematurely Put control momentarily into brine slow rinse Replace or repair air check if needed Contact dealer System using more or less salt than regenerant setting Foreign matter in controller causing incorrect flow rates Remove brine control and flush out foreign matter Manually position control to brine slow rinse to clean controller after so doing position control to purge to remove brine from tank Intermittent or irregular brine draw Low water pressure Set pump to maintain 20 psi at softener Defective injector Replace injector Contact dealer No conditioned water after regeneration Control backwashes or Replace with correct size controller Contact purges at excessively low or high rate No salt in brine tank Add salt to brine tank Injector plugged Clean injector and screen Air check valve closes prematurely Incorrect drain controller used Put control momentarily into brine slow rinse Replace or repair air check if needed Contact dealer dealer Foreign matter affecting controller operation Remove drain controller and clean ball and seat 255 460i 460TC Troubleshooting Problem Cause Correction No water flow display when water is flowing Bypass valve in bypass Shift bypass valve to not in bypass position Meter probe disconnected or not fully connected to meter housin
6. Flush until clean Using a needle nose pliers pull injector straight out Flush water into the injector screen recess of the valve body to flush debris out through the injector recess Clean and flush the injector Lubricate the o rings on the injector injector cap and injector screen with silicone lubricant 10 Reinstall the injector injector cap and injector screen See IMPORTANT note 11 Plug the wall mount transformer into outlet reset time of day 12 Slowly open water supply valve or return bypass valvels to the not in bypass position 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 Injector es Injector cap amp Figure 20 Disinfection Of Water Conditioners The materials of construction of the modern vvater conditioner will not support bacterial growth nor will these materials contaminate a vvater supply During normal use a conditioner may become fouled vvith organic matter or in some cases vvith bacteria from the vvater supply This may result in an off taste or odor in the water Some conditioners may need to be disinfected after installation and some conditioners will require periodic disinfection during their normal life Depending upon the conditions of use the style of conditioner the type of ion exchanger and the disinfectant available a choice can be made a
7. TOTAL BRINE DRAW RINSE ma Injector K Pink For 12 inch Tanks bar 2 35 5 6 75 m7hr 1 20 0 25 1 00 0 20 0 80 0 15 0 60 m 0 10 4 0 20 0 05 0 00 LWR6151 0 00 20 40 60 80 100 120 PSI TOTAL BRINE DRAW RINSE Injector L Orange For 13 and 14 inch Tanks bar 2 3 5 5 6 75 myhr 1 50 0 30 1 00 0 20 0 75 0 50 0 10 0 25 0 00 LWR6164 ooo 20 40 60 80 100 120 PSI TOTAL BRINE DRAW RINSE AUTOTROL 255 Valve 400 Series Service Manual e 19 For Autotrol Product Warranties visit Autotrol para las garantias de los productos visite www pentairaqua com pro Pour Autotrol garanties produit visitez le site SY PENTAIR FILTRATION amp PROCESS 5730 NORTH GLEN PARK ROAD MILWAUKEE WI 53209 P 262 238 4400 WWW PENTAIRAQUA COM CUSTOMER CARE 800 279 9404 tech support pentair com All Pentair trademarks and logos are owned by Pentair Inc or its affiliates All other registered and unregistered trademarks and logos are the property of their respective owners Because we are continuously improving our products and services Pentair reserves the right to change specifications without prior notice Pentair is an equal opportunity employer 1018075 REV R FE14 O 2014 Pentair Residential Filtration LLC All Rights Reserved
8. in parts per million PPM to grains per gallon GPG use this formula Parts per Million Grains Per Gallon 17 1 TIME 0 o TIME HARDNESS d HARDNESS CAPACITY CAPACITY A a Figure 12 Figure 13 Figure 14 Capacity Setting Move the jumper to the set of pins next to the word CAPACITY Figure 15 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 Return the jumper to the top set of pins next to the word TIME and replace the access door The jumper must NOT be left on any pins other than the top pair next to the word TIME Otherwise the unit may show a blank display NOTE A spare jumper is located on the bottom set of pins In the event that the hardness or capacity setting must be changed simply follow the appropriate steps described above Calendar Override Setting 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 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 Disconnect power Place jumper back on TIME and reco
9. 3 4 inch BSPT Plastic Pipe Adapter Kit EE Tous 1001605 1 inch BSPT Plastic Pipe Adapter Kit Y utis do 3023824 3 4 inch BSPT S S Pipe Adapter Kit TAM du 3023828 1 inch NPT S S Pipe Adapter Kit pm 17 5 3023807 1 inch BSPT S S Pipe Adapter Kit Not Shown AUTOTROL 255 Valve 400 Series Service Manual e 13 TROUBLESHOOTING The technology upon which the Series 255 control 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 be very easily serviced The control module can be quickly replaced or adjustments can be made at the installation We recommend that you contact your local professional water treatment dealer for most concerns For parts mentioned refer to exploded views in the Replacement Parts section of this manual IMPORTANT Service procedures that require the water pressure to be removed from the system are marked with a after the possible cause Refer to Preventative Maintenance section for instructions Valve Troubleshooting Problem Cause Correction Brine tank overflow Uncontrolled brine refill flow rate Remove brine control to clean ball and seat Air leak in brine line to air check Check all connections in brine line for leaks Refer to instructions Drain control clogged with resin or other debris Clean drain control Flow
10. 7 X 7 T Indicator Knob Time Set Button Timer Transformer Locking Pin Plug Receptacle Spare Jumper Figure 11 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 12 Time of Day Setting With the jumper on the set of pins next to the word TIME Figure 13 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 NOTE The use of a small needle nose pliers will aid in moving the jumper The unit is factory set to regenerate at 2 00 a m 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 horizontal Figure 12 during operation NOTE NOTE Hardness Setting Move the jumper to the set of pins next to the word HARDNESS Figure 14 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
11. DM MEET O Ring EP IRAN Locking Bar S English Language AS French Language Koso German Language PR Italian Language PEE Japanese Language PARURE Spanish Language Lehr Screw No 8 x 9 16 inch CM Spring one pc 255 Item No QTY Part No Kits KREE 1001404 1 1040459 E ss 1041010 Valve Discs NT 1000250 Not Shown Description 0 Ring Group Tank Adapter 1010117 1 1010407 1 1010410 4 O Ring Group Piping Boss 1010431 1 1010411 2 13 16 inch Rubber Insert Optional Standard FLow control does not use Flow Control Ball 1030502 AUTOTROL 255 Valve 400 Series Service Manual e 11 255 SERIES NOTE Do not use pipe joint compound when threading pipe into the Noryl piping boss Use only plumber pipe tape Do not overtighten pipe into Noryl piping boss 12 e AUTOTROL 255 Valve 400 Series Service Manual 255 SERIES CONTINUED Item No QTY PartNo Description Tu EEN p a dna e atatea a 440i Assembly lobsolete Dod e ets Noses secs a Seg Moree 460i 460TC Assembly On RES e alma S Transformer wes 1000810 Japanese m 1000811 North American uM 1000812 Australian E 1000813 British CN 1000814 European EEGEN t s 1030234 Transformer Extension Cord 15 foot 4 5 m noua d es 1007776 Jumper Meter Adapter JANE ya ad 1032350 Kit Meter Adapter Dheut td e 1032351 Meter In
12. SY PENTAIR AUTOTROL 255 VALVE 400 SERIES CONTROLS SERVICE MANUAL www pentairaqua com TABLE OF CONTENTS MANUAL OVERVIEW eee nenea emana nenea 2 SAFETY INFORMATION ccc ee ere veren eee 2 SYSTEM SPECIFICATIONS seen 2 EQUIPMENT INSTALLATION 4 SYSTEM STARTU Peier krenna apt als a 6 PROGRAMMING sirit aana iee or a eae 6 SERVICE AND MAINTENANCE eens 9 255 VALVE amp TANK ADAPTER MODULE 10 200 SERIES Eu unra sn repetit ate p t eire t cde du 12 TROUBLESHOOTING ttt rentre tede 14 FLOW DIAGRAMS itte tree idees 16 FLOW DATA CHARTS sse aaa 17 MANUAL OVERVIEW How To Use This Manual This installation manual is designed to guide the installer through the process of installing and starting conditioners featuring the 400 series controllers This manual is a reference and will not include every system installation situation The person installing this equipment should have Training in the 400 series controllers and water conditioner installation Knowledge of water conditioning and how to determine proper control settings Basic plumbing skills The directional instructions left and right are determined by looking at the front of the unit SAFETY INFORMATION Electrical There are no user serviceable parts in the AC adapter motor or controller In the event of a failure these should be replaced Allelectrical connection
13. d by the control valve and directed down the riser tube and up through the resin bed During the backwash cycle the bed is expanded and debris is flushed to the drain 3 Brine Slow Rinse Downflowl The control directs vvater through the brine injector and brine is drawn from the regenerant tank The brine is then directed down through the resin bed and up through the riser tube to the drain The hardness ions are displaced by sodium ions and are sent to the drain The resin is regenerated during the brine cycle Brine draw is completed when the air check closes 4 e AUTOTROL 255 Valve 400 Series Service Manual 4 Fast Rinse Downflow The control directs water down through the resin bed and up through the riser tube to the drain Any remaining brine residual is rinsed from the resin bed 5 Brine Refill Downflow Brine refill occurs during a portion of the fast rinse cycle Water is directed to the regenerant tank at a controlled rate to create brine for the next regeneration 6 Repressurize Cycle No Flapper Open This cycle closes all flappers for a short time to allow the air and water to hydraulically balance in the valve before continuing the regeneration From Regenerant Tegner HH HIH H A S FE re E r rs 1 U
14. dicator knob COUNTERCLOCKWISE to CONDITIONED WATER f Run water from a nearby faucet until the water is clear and soft PROGRAMMING 440i Control obsolete Skipper Pins Day Arrow Skipper Wheel Time Arrow Indicator Knob Timer Timer Knob Locking Pin Figure 10 PROGRAMMING CONTINUED Programming 1 Set days of regeneration on skipper wheel Figure 11 e Pullall skipper pins outward away from control Rotate skipper wheel until day arrow points to current day or number 1 e Depress skipper pin s at dayls for which regeneration is desired 2 Set the time of day e Grasp timer knob and pull outward e Rotate in either direction until the timer arrow points to the actual time of day e Release timer knob NOTE With the time of day properly set the conditioner 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 horizontal Figure 11 during operation 460i Control PM Indicator NOTE Hour Time Display Water Flow Indicator Access Door BRINE SLOW RINSE N W Saba REFILL CONDITIONED WATER IANUAL REGENERATION PRESS BUTTON amp RELEASE AS E 4
15. e 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 horizontal Figure 16 during operation NOTE NOTE Days Setting Move the jumper to the set of pins next to the word DAYS Figure 18 Press the black TIME SET button until the desired number of days between regeneration is displayed The range is from 1 to 30 days Figure 1 Figure 17 Figure 18 Clock Setting Move the jumper to the set of pins next to the word CLOCK Figure 19 Press the black TIME SET button until the desired clock setting is displayed The clock range is 0 to 1 Select 0 for the standard AM PM clock or select 1 for a 24 hour clock Return the jumper to the top set of pins next to the word TIME and replace the access door The jumper must NOT be left on any pins other than the top pair next to the word TIME Otherwise the unit may show a blank display 8 e AUTOTROL 255 Valve 400 Series Service Manual NOTE A spare jumper is located on the bottom set of pins Common Features When using the 255 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 Salt Dial Adjustment Table 1 Suggested Salt Dial Settings Pounds of Salt For Various Size Softeners Capacity 05 0 75 1 0 125 1 5 1 75 2 0 S
16. etting FT FT FT FT FT FT FT Kilograins 12 4 5 16 9 0 5 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 11 5 17 0 14 0 12 0 48 14 0 10 5 17 0 60 15 0 This setting requires the use of XS extra salt cam and doubles the amount of the setting 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 screvvdriver into the white indicator knob and move pointer to proper salt setting Figure 13 NOTE To convert the salt settings from English to metric divide by 2 2 e g 12 pounds 2 2 5 5 kg of salt Figure 19 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 a
17. g Restricted meter turbine rotation due to foreign material in meter Fully insert probe into meter housing Remove meter housing free up turbine and flush with clean water Turbine should spin freely If not replace meter Contact dealer Defective meter probe Replace meter cable no meter cable for the 460TC Contact dealer Continuous regeneration Camshaft does not stop at the end of regeneration Misaligned optical sensor Replace optical sensor no sensor for the 460TC Contact dealer Run out of soft water between regenerations Improper regeneration Repeat regeneration making certain that correct salt dosage is used Incorrect salt setting Set salt control to proper level See salt setting chart Incorrect hardness or capacity settings Set to correct values See Programming section Water hardness has increased Set hardness or days to new value See Programming section Restricted meter turbine rotation due to foreign material in meter Remove meter housing free up turbine and flush with clean water Turbine should spin freely if not replace meter Contact dealer AUTOTROL 255 Valve 400 Series Service Manual e 15 FLOW DIAGRAMS 255 Valve Service Position 1 Hard Water al Soft Water Z Inlet gt gt Outlet Valve No 1 Closed 2 Open 3 Open 4 Closed 5 Closed 6 Closed i Mineral Tank Brin
18. h of the transformer cord an optional 15 foot 4 6 m extension is available see Figure 9 AN NT Figure 8 SYSTEM STARTUP Initial Startup After the vvater conditioning system is installed the conditioner should be disinfected before it is used to treat potable water Refer to the Disinfection of Water Conditioners section in this manual Complete the following steps to place the conditioner into operation 1 Remove control valve cover NOTE The following steps will require turning the indicator knob Figure 11 to various positions Insert a wide blade screwdriver into arrow slot in indicator knob and press in firmly With knob held in rotate COUNTERCLOCKWISE only until arrow or knob points to desired position Rotation is made much easier if you grasp the camshaft with your free hand and turn it at the same time Then permit knob to spring back out 2 Insert screwdriver into slot in indicator knob Figure 11 Press in and rotate knob COUNTERCLOCKWISE until arrow points directly to the word BACKWASH 3 Fill resin tank with water a With water supply off place the bypass valvels into the NOT IN BYPASS position b Open water supply valve very slowly to approximately the 1 4 open position IMPORTANT If opened too rapidly or too far resin may be lost In this 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 fl
19. ing Position LI Hard Water E soft water Inlet ZA ES A B 2 ZI 2 7 7 Outlet Valve No 1 Open 2 Closed 3 Closed 4 Open 5 Open 6 Closed Mineral Tank 16 e AUTOTROL 255 Valve 400 Series Service Manual S SN Brine Tank Backwash Position I Hard water Soft Water ZZ Inlet d Drain Valve No q x 1 Closed 2 Closed 3 Open 4 Open 5 Closed Bc Open Mineral Tank Slow Rinse Position MM Hard Water _ Soft Water Valve No 1 Open 2 Closed 3 Closed 4 Open 5 Open 6 Closed Mineral Tank Brine Tank FLOW DIAGRAMS CONTINUED Repressurize Position 33 Hard Water Soft Water Air Check ZzZ Z EZA N Inlet SS ZA 1 NN DX SSS OOOO Drain Control Drain Valve No li a 1 Closed 2 Closed 3 Closed 4 Open 5 Closed 6 Closed Mineral Tank Brine Refill Position Li Hard VVater Ll Soft water Inlet Valve No 1 Open 2 Open 3 Open 4 Closed 5 Closed 6 Closed Mineral Tank Brine Tank Fast Rinse Position Inlet Valve No 1 Closed 2 Open 3 Closed 4 Open 5 Open 6 Closed MI Hard Water Soft Water Jeder T REM woos Drain Control Drain d Mineral Tank Brine Tank FLOW DATA CHARTS 255 Valve Flow Data 16 14 12 10 Pressure Drop in PSI Oo Flow Ra
20. ing or dripping water at drain or brine line after regeneration Valve stem return spring weak Replace spring Contact dealer Hard water leakage after regeneration Improper regeneration Repeat regeneration after making certain correct salt dosage was set Leaking of external bypass valve Replace bypass valve Contact dealer O ring around riser pipe damaged Replace o ring Contact dealer Control will not draw brine Low water pressure Make correct setting according to instructions Restricted drain line Remove restriction Injector plugged Clean injector and screen Injector defective Replace injector and cap Contact dealer Valve disc 2 and or 3 not closed Remove foreign matter from disc and check disc for closing by pushing in on stem Replace if needed Contact dealer Air check valve prematurely closed Put control momentarily into brine refill Replace or repair air check if needed Contact dealer 14 e AUTOTROL 255 Valve 400 Series Service Manual TROUBLESHOOTING CONTINUED 255 440i Troubleshooting Problem Cause Correction Control will not draw brine Low water pressure Set pump to maintain 20 psi at softener Restricted drain line Change drain to remove restriction Injector plugged Clean injector and screen Injector defective Replace injector Contact dealer
21. it 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 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 conditioner EM Correct Way Drain Line Tube Figure 6 Standard commercial practices have been expressed here Local codes may require changes to these suggestions NOTE Brine Line Connection It will be necessary to install the brine tube and line to a fitting installed on the air check Apply plumber tape on all threaded connections Be sure all fittings and connections are tight so that premature checking does not take place Premature checking is when the ball in the air check falls to the bottom before all brine is drawn out of the brine tank See Placing Conditioner into Operati
22. mong the following methods Sodium or Calcium Hypochlorite Application These materials are satisfactory for use with polystyrene resins synthetic gel zeolite greensand and bentonites 5 25 Sodium Hypochlorite These solutions are commonly known as household bleach If stronger solutions are used such as those sold for commercial laundries adjust the dosage accordingly 1 Dosage g Polystyrene resin 1 2 fluid ounce 35 5 ml per cubic foot h Non resinous exchangers 0 8 fluid ounce 23 7 ml per cubic foot 2 Brine tank conditioners a Backwash the conditioner and add the required amount of hypochlorite solution to the well of the regenerant tank The regenerant tank should have water in it to permit the solution to be carried into the conditioner b Proceed with the normal regeneration Calcium Hypochlorite Calcium hypochlorite 70 available chlorine is available in several forms including tablets and granules These solid materials may be used directly without dissolving before use 1 Dosage a Two grains approximately 0 1 ounce 3 ml per cubic foot 2 Regenerant tank conditioners a Backwash the conditioner and add the required amount of hypochlorite to the well of the regenerant tank The regenerant tank should have water in it to permit the chlorine solution to be carried into the conditioner b Proceed with the normal regeneration AUTOTROL 255 Valve 400 Series Service Manual e 9 255 VALVE am
23. mount 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 PROGRAMMING CONTINUED Guest Cycle Manual Regeneration When abnormally high water usage exhausts your water conditioner s capacity ahead of schedule an extra regeneration can be achieved Depress the indicator knob on the 440i Figure 11 with a wide blade screwdriver and turn COUNTERCLOCKWISE to START to initiate a regeneration For the 460i simply depress the indicator knob Figure 12 It will take a few minutes for regeneration to start A normal regeneration will take approximately two hours SERVICE AND MAINTENANCE 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 valvels into bypass position 3 Relieve system pressure by opening valve No 5 at rear with a screwdriver 4 Using a screwdriver remove injector screen and injector cap Figure 16 Clean screen using a fine brush
24. n and overflow lines will ever be subjected to room temperatures under 34 F 1 C or over 120 F 49 C Do not install unit near acid or acid fumes 7 The use of resin cleaners in an unvented enclosure is not recommended EQUIPMENT INSTALLATION CONTINUED VVater Line Connection The installation of a bypass valve system is recommended to provide for occasions when the water conditioner must be bypassed for hard vvater or for servicing The most common bypass systems are the Autotrol Series 256 bypass valve Figure 4 and plumbed in globe valves Figure 5 Though both are similar in function the 256 Autotrol bypass offers simplicity and ease of operation Not in Bypass In Bypass gy SSVd esVdAg CC OJ C 2C DIO Figure 4 Autotrol Series 256 Bypass Valve Not in Bypass Figure 5 Typical Globe Valve Bypass System Drain Line Connection 1 Ideally located the unit will be above and not more than 20 feet 6 1 ml from the drain For such installations use an appropriate adapter fitting not supplied to connect 1 2 inch 1 3 cm plastic tubing to the drain line connection of the control valve 2 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 1 2 inch NPT drain connection 3 Ifthe un
25. nnect 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 AUTOTROL 255 Valve 400 Series Service Manual e 7 PROGRAMMING CONTINUED 460TC Control Hour Time Display PM Indicator Access Door BRINE T CONDITIONED WATER MANUAL REGENERATION PRESS BUTTON amp RELEASE _ St Spare Jumper MIU 7 Indicator Knob Time Set Button Timer Transformer Locking Pin Plug Receptacle Figure 15 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 16 Time of Day Setting With the jumper on the set of pins next to the word TIME Figure 17 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 NOTE The use ofa small needle nose pliers will aid in moving the jumper The unit is factory set to regenerate at 2 00 a m 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 hav
26. on section 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 7 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 6 BN TANK Overflow Fitting Installed Connect 1 2 inch 1 3 cm Tubing or Hose and Run to Drain Figure 7 Low Voltage Transformer Use only the included transformer for powering the 400 series timers Connect the plug of the transformer secondary cable to the mating socket on the control see Figure 8 Be certain that the transformer is plugged into a correct voltage source that is not controlled by a wall switch AUTOTROL 255 Valve 400 Series Service Manual e 5 EQUIPMENT INSTALLATION CONTINUED Increasing the Length of the Transformer Cord If it is necessary to extend the lengt
27. ow steadily from the drain open the water 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 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 6 e AUTOTROL 255 Valve 400 Series Service Manual Air Check Brine Line Figure 9 Control Valve 5 Putinto operation a Open water supply valve slowly to full open position b Carefully advance indicator knob COUNTERCLOCKWISE to center of FAST RINSE REFILL position and hold there until air check Figure 10 fills with water and water starts to flow through brine line into brine tank Do not run for more than two minutes c Advance indicator knob COUNTERCLOCKWISE until arrow points to the center of the BRINE SLOW RINSE position d 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 for at least three minutes If the water level does not recede or goes up or if air enters the transparent air check chamber and the ball falls and seats reference Troubleshooting section e Advance in
28. p TANK ADAPTER MODULE 10 e AUTOTROL 255 Valve 400 Series Service Manual 255 VALVE amp TANK ADAPTER MODULE CONTINUED ltem No QTY T pe N er 2 anto dus Suse ERN dk T uus Ds fam d EE bius 1 FE 2 Orc Tana Q ous 1 T m orant t e RS ile 2 WE T9 ED oet Mas rot E WEE joe reci Remeron T65 te Jer TT aan db Part No 1000232 1031950 1033024 1033025 1033026 1032969 1031391 1000226 1000209 1000210 1000211 1000212 1000213 1000214 1000215 1030502 1034261 1034263 1032970 1032971 1032972 1000269 1032416 1010154 1232370 1031 Description SE Valve Assembly w o Flow Controls gui Camshaft FAE Standard One Piece EEN Standard Segmented M ani tat Extra Salt Segmented uu Long Rinse Segmented EE Water Saver Segmented T Lever Locking Cam m Timer Locking Pin unn Screen Cap Assembly w O Ring puente deed n Drain Control Assembly w O Rings m No 7 1 2 gpm 4 5 Lpm di No 8 1 6 gpm 6 1 Lpm ebe No 9 2 0 gpm 7 6 Lpm s 2522 No 10 2 5 gpm 9 5 Lpm ip No 12 3 5 gpm 13 2 Lpm i pede No 13 4 1 gpm 15 5 Lpm inde No 14 4 8 gpm 18 2 Lpm SA Ball Flow control en Brine Refill Control ERE 1 to 10 lbs Salt denis 3 to 19 lbs Salt Set eS Injector Assembly with O Rings PACA A Injector White MM B Injector Blue EE C Injector Red DEEN Injector Cap with O Ring T i Lid Cover TEE Air Check Kit LENS O Ring EP
29. s must be completed according to local codes Useonly the power AC adapter that is supplied The power outlet must be grounded To disconnect power unplug the AC adapter from its power source Mechanical Do not use petroleum based lubricants such as petroleum jelly oils or hydrocarbon based lubricants Use only 100 silicone lubricants All plastic connections should be hand tightened Plumber s tape may be used on connections that do not use an O ring seal Do not use pliers or pipe wrenches All plumbing must be completed according to local codes Soldering near the drain line should be done before connecting the drain line to the valve Excessive heat will cause interior damage to the valve Do not use lead based solder for sweat solder connections 2 e AUTOTROL 255 Valve 400 Series Service Manual e The drain line must be a minimum of 1 2 diameter Use 3 4 pipe if the backwash flow rate is greater than 5 GPM 18 9 Lpm or the pipe length is greater than 20 feet 6 m Do not support the weight of the system on the control valve fittings plumbing or the bypass General Keep the media tank in the upright position Do not turn on side upside down or drop Turning the tank upside down will cause media to enter the valve Operating ambient temperature is between 34 F 1 C and 120 F 49 C Operating water temperature is between 34 F 19F and 100 F 38 C e Working water pre
30. ssure range is 20 to 125 psi 1 38 to 8 61 bar In Canada the acceptable working water pressure range is 20 to 100 psi 1 38 to 6 89 bar e Use only regenerant salts designed for water softening Do not use ice melting block or rock salts Follow state and local codes for water testing Do not use water that is micro biologically unsafe or of unknown quality e When filling media tank do not open water valve completely Fill tank slowly to prevent media from exiting the tank e When installing the water connection bypass or manifold connect to the plumbing system first Allow heated parts to cool and cemented parts to set before installing any plastic parts Do not get primer or solvent on O rings nuts or the valve CALIFORNIA PROPOSITION 65 WARNING VN te This product contains chemicals known to the State of California to cause cancer or birth defects or other reproductive harm SYSTEM SPECIFICATIONS The systems below have been tested and certified by the WQA to NSF ANSI Std 44 and NSF ANSI 372 for lead free compliance The 255 valve has been tested and certified by the WQA to NSF ANSI Std 61 Section 8 Mechanical Devices WQA Certified 255 460i Systems 255 460i 075 844 255 460i 100 948 Working Pressure 20 125 psi 1 38 8 61 bar Standard 12 Volt Transformer Input Electrical Rating 115V 60 Hz Optional 12 Volt Transformer Input Electrical Rating 115V 50 Hz 230V 50 Hz 230V 60 Hz 100V 60 Hz
31. stall Kit Piping Boss p lege anga bet tt Piping Boss Kit includes Hardware Se 3023763 3 4 inch NPT S S 3 8 inch NPT Drain EE 3023749 1 inch NPT S S 1 2 inch NPT Drain s 3023761 3 4 inch BSPT S S 3 8 inch BSPT Drain id 3023747 1 inch BSPT S S 1 2 inch BSPT Drain qe 1040279 3 4 inch NPT Noryl 1 2 inch NPT Drain S 1040280 1 inch NPT Noryl 1 2 inch NPT Drain zu 1040283 3 4 inch BSPT Noryl 1 2 inch BSPT Drain T 1040284 1 inch BSPT Noryl 1 2 inch BSPT Drain dise Tus 1040339 Piping Boss installation Kit Bypass Valve B unus Tus 1040769 Bypass Body Assembly with Install Kit isses Tene 1040524 Bypass Installation Kit Item No QTY PartNo Description Tube Adapter Kits C NS Ties 1001606 3 4 inch Copper Tube Adapter Kit ot UE 1001670 1 inch Copper Tube Adapter Kit a Ss Vast 1041210 1 1 4 inch Copper Tube Adapter Kit TE Vinay 1040547 90 degree Elbow Adapter Kit S acces tesis ducas 1001608 22 mm Copper Tube Adapter Kit CAPE UA TEE ds 1001613 3 4 inch CPVC Tube Adapter Kit sace R UE 1001614 1 inch CPVC Tube Adapter Kit KE ER 1001615 25 mm CPVC Tube Adapter Kit NEE Tasa 1001769 3 4 inch NPT Plastic Pipe Adapter Kit Da LERE 1001603 1 inch NPT Plastic Pipe Adapter Kit ee ha 1001604
32. te m hr 14 1 8 23 2 7 3 2 3 6 1 10 1 00 0 90 0 80 0 70 0 60 0 50 0 40 0 30 jeg doig ainssaid 0 20 LWR 5236 BW LWR 4630 SVC 2 4 6 8 10 12 14 16 Flow Rate in Gallons Per Minute AUTOTROL 255 Valve 400 Series Service Manual e 17 FLOW DATA CHARTS CONTINUED Injector Performance Graphs Injector F Peach For 7 inch Tanks bar 2 3 5 5 6 7 5 0 35 0 30 0 25 g 2 0 20 s 2 015 c 2 8 0 10 0 05 0 00 LWR6057 20 40 60 80 100 120 PSI TOTAL BRINE DRAW RINSE Injector G Tan For 8 inch Tanks bar 2 3 5 5 6 7 5 0 50 0 40 o 5 E S 030 3 Q B 0 20 T o 0 10 0 00 LWR6057 20 40 60 80 100 120 PSI TOTAL BRINE DRAW RINSE Injector H Light Purple For 9 inch Tanks bar 2 35 5 6 75 0 70 0 60 2 0 50 3 E 0 40 Qa 2 0 30 S O 0 20 0 10 0 00 LWR6151 20 40 60 80 100 120 PSI TOTAL BRINE DRAW RINSE 18 e AUTOTROL 255 Valve 400 Series Service Manual my hr 0 08 0 07 0 06 0 05 0 04 0 03 0 02 0 01 0 00 mj hr 0 11 0 10 0 09 0 08 0 07 0 06 0 05 0 04 0 03 0 02 0 01 0 00 m7hr 0 16 0 14 0 12 0 10 0 08 0 06 0 04 0 02 0 00 Gallons per Minute Gallons per Minute Gallons per Minute Injector J Light Blue For 10 inch Tanks bar 3 2 3 5 5 6 75 uad 0 80 0 18 0 16 0 60 0 14 0 12 0 10 0 40 0 08 0 06 0 20 od 0 02 0 00 LWR6151 0 00 20 40 60 80 100 120 PSI
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