Autotrol Performa Ultra Manuel utilisateur

Electronic Control System

Operation and Maintenance Manual

Autotrol Performa Ultra

™

Table of Contents

Performa Ultra . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Electronic Demand System . . . . . . . . . . . . . . . . . 3

Special Features

Control Features

Injector Selection

Riser Pipe Assembly

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Location Selection

Water Line Connection

Drain Line Connection

Brine Line Connection

Electrical Connection

Initial Brine Tank Fill

Placing Conditioner into Operation . . . . . . . . . . .7

Programming the Performa Ultra. . . . . . . . . . . . . 8

Calendar Override

Changing the System Number

Control Valving Identifications . . . . . . . . . . . . . . 10

Valve Disc Operation . . . . . . . . . . . . . . . . . . . . . 10

Pressure Characteristics . . . . . . . . . . . . . . . . . .10

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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

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

Valve System Assembly

Bypass Valve

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

Disinfection of Water Conditioners . . . . . . . . . .20

Performa Series Ultra Electronic Demand System

The two key components of the Performa Ultra

electronic demand system are the microprocessor, a

miniature computer located on the circuit board, and a

water meter located at the valve outlet. The flow of

conditioned water through the meter generates

electrical impulses that tell the computer the amount of

water being used.

Every evening, at 2:00 a.m., the past 7 days’ water

usage is statistically averaged to anticipate the amount

of water that will be used the next day. The computer

then determines if the water conditioner has enough

remaining capacity to supply the next day’s needs. If

not, the unit will regenerate.

If the water usage pattern changes, the computer

automatically compensates for the change and

regenerates only when needed. This results in higher

operating efficiency and lower salt usage than a

conventional conditioner operating on a fixed

regeneration schedule.

Special Features

Memory Retention

During a power outage, critical operating information in

the control’s memory is stored into the NOVRAM. This

data includes the time of day, water usage amounts,

and the number of days since the last regeneration. The

NOVRAM will retain the data in its memory. When

power is restored, the information is returned to the

microprocessor and operation resumes as if an outage

never occurred.

The time of day will be late by the length of the power

outage. Most power outages are less than one minute

in duration. Therefore, it may be months or years before

the time display would require resetting. If an outage of

one or more hours occurs, the time of day should be

reset...no other reprogramming is necessary.

The microprocessor calculates how much soft water

was used and adjusts the reserve capacity accordingly

at the end of each day. As a result, the reserve is kept

at a minimum for optimum economy.

Proportional Salting

The amount of salt used for each regeneration is

proportional to the amount of capacity used in the

previous service run. Since countercurrent

regeneration is utilized, brine passing through the lower

portion of the partially exhausted resin bed will not be

exchanged. The brine is utilized to regenerate only

the exhausted portion of the resin bed.

Self Adjusting Reserve

“Reserve”refers to the amount of soft water that may

be needed for the next 24 hours. The microprocessor

calculates how much soft water was used and adjusts

the reserve capacity accordingly at the end of each day.

As a result, the reserve is kept at a minimum for

optimum economy. The reserve amount is calculated

by multiplying the average past seven days’usage by

1.20. Regeneration decisions are based on the

calculated reserve.

In the event of unusually high water usage (twice or

more than the current daily average), the high usage

amount will be used as the reserve when the computer

performs its regeneration computation at 2:00 a.m.

This is done in anticipation of a second day of very high

usage.

Low or No Water Usage

The Performa Ultra is programmed to recognize a day

of very little or no water usage as an abnormality. It will

not use data from such a day to compute the average

usage. For example, if the family is on vacation for a

week, the prior average will be maintained. When

household activity resumes, the conditioner will

operate as if the vacation had not occurred.

Design Reliability

Solid-state electronics assure many years of trouble-

free performance. The metering system has only one

moving part... the rotating turbine that measures water

usage.

Control Features (Reference Figure 4)

Time Display

The correct time will continually appear in the time

display during normal conditioning operation.To

change the hour display, press the TIME SET BUTTON

until the present hour appears. The PM light will be on

when the time is between 12 noon and midnight. The

light is off during the a.m. hours.

Flow Indicator

The water flow indicator flashes whenever service

water is flowing through the valve. This allows an easy

determination of proper meter operation.

Hardness and Capacity Settings

Once the hardness and capacity settings have been

set, the information cannot be lost due to a power

outage and no reprogramming is necessary.

Guest Cycle

An extra regeneration can be achieved at any time by

pressing the INDICATOR KNOB. It will take a few

minutes for the regeneration to start and the unit will

return to CONDITIONED WATER when regeneration is

completed. This feature is beneficial when you expect

to use more than the normal amount of water, for

example: guest visits, extra heavy laundry days, or if

the unit has been operated without salt in the brine

tank.

Manual Regeneration

Electricity is used only to run the control and rotate the

camshaft. All other functions are operated by water

pressure. Therefore, in the event of a power outage, all

the various regeneration positions may be dialed

manually by pressing the INDICATOR KNOB with a

wide-blade screwdriver and turning

COUNTERCLOCKWISE.

Manual time cycles:

•Refill...5 minutes

•Brine and Rinse...2 hours

•Backwash...12 minutes

•Fast Rinse...4 minutes

Note: DO NOT advance the INDICATOR KNOB directly

to the CONDITIONED WATER position after a manual

regeneration or when servicing the conditioner.

Advance it short of the CONDITIONED WATER position

to just past the FAST RINSE position. The control will

then advance itself to the CONDITIONED WATER

position where the internal switch will turn the motor

off. The internal switch will not be operated and the

motor will continue to run if advanced directly to the

conditioned water position.

If power fails during a conditioner regeneration, the

cycle will be completed normally when the power is

restored.

Injector Selection

There are two injectors shipped with each valve:

•Low pressure, 20 to 60 psi (1.38 to 4.14 bar)

•High pressure, 61 to 120 psi (4.20 to 8.27 bar)

The low pressure injector has been factory installed in

the valve. The high pressure injector is located in a

plastic bag included with the valve. Check the water

pressure to determine which is the correct injector for

your installation.

The injectors are coded according to size by the

number of “bumps”molded onto the end of the

injector. To determine if you are using the correct

injector, check the resin tank diameter from the label on

the back of the valve and refer toTable 1. For the

location of the injector in the valve refer to item 6 in the

Replacement Parts section.

Table 1 - Systems Sizes

System

Number

Tank Size-Dia x Ht Resin Volume Injector (Bumps) Brine Control Backwash

Assembly

Inches Centimeters Cubic Feet Liters Low Pressure

20 to 60 PSI

High Pressure

61 to 120 PSI

07 x 35 18 x 89 .50 14 1032984(2) 1032976(1) 1033286 1000209

7 x 40 18 x 101

1 8 x 35 21 x 89 .66 18.6 1032979(3) 1032984(2)

1000210

28 x 40 21 x 101 .75 21

8 x 44 21 x 112

3 9 x 35 23 x 89 1032977(4) 1032979(3) 1000222 1000211

4 9 x 48 23 x 122 1.00 28.3

5 10 x 35 26 x 89 1032980(5) 1032977(4) 1000212

6 10 x 44 26 x 112 1.25 35.3

6 10 x 47 26 x 119 1.25 35.3 1032980(5) 1032977(4) 1000212

7 10 x 54 26 x 137 1.50 42

8 12 x 48 30 x 122 2.00 56.5 1032982(6) 1032980(5) 1000213

Riser Pipe Assembly

The dimensions provided in this section will make it

easy for assemblers to cut the riser pipes and to locate

the center screen when building the softener.

Outside Diameter

Inner Pipe 1.050 ± 0.004 in

26.670 ± 0.100 mm

Outer Pipe 1.315 ± 0.005 in

33.400 ± 0.130 mm

Wall Thickness

Inner Pipe 0.060 + 0.020 in

- .000 in

1.520 + 0.510 mm

- 0.000 mm

Outer Pipe 0.063 + 0.020 in

- 0.000 mm

1.600 + 0.510 mm

- 0.000 mm Figure 1

Table 2 - Injector Selection

Water Pessure

psi, (bar)

Resin Tank Diameter, inches (cm)

7 (18) 8 (21) 9 (23) 10 (25) 12 (30)

20 to 60

(1.38 to 4.14)

61 to 120

(4.20 to 8.27)

Table 3 - Injector Flow Rates

Injector P/N (“Bumps”) Brine Draw Rate Rinse Rate

gpm Lpm gpm Lpm

1032976 (1) 0.091 0.344 0.09 0.34

1032984 (2) 0.071 0.268 0.14 0.53

1032979 (3) 0.089 0.337 0.17 0.64

1032977 (4) 0.154 0.583 0.20 0.76

1032980 (5) 0.165 0.624 0.35 1.32

1032982 (6) 0.176 0.67 0.45 1.70

Installation

•All plumbing and electrical connections must

conform to local codes.

•Inspect unit carefully for carrier shortage or

shipping damage.

Location Selection

1. The distance between the unit and a drain should be

as short as possible.

2. If it is likely that supplementary water treatment

equipment will be required, make certain adequate

additional space is available.

3. Since salt must be added periodically to the 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.

IMPORTANT: 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 34oF (1oC)

or over 120oF (49oC).

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 ssytem is the 1265 Bypass

Valve, Figure 2.

Figure 2

Drain Line Connection

1. If ideally located, the unit will be above the drain and

not more than 20 feet (6.1 m) away. For such

installations connect an appropriate fitting and

1/2-inch (1.3 cm) tubing to the 3/4-inch NPT drain

line connection located on the rear of the valve

between the water connections.

2. If unit is located more than 20 feet (6.1 m) from the

drain, use 3/4-inch (1.9 cm) tubing for runs up to

40 feet (12.2 m). Also, purchase an appropriate

fitting to connect the 3/4-inch tubing to the

3/4-inch NPT female drain line connection fitting.

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 the

conditioner is not less than 40 psi (2.80 bar). You

may elevate the line an additional 2 feet (61 cm) for

each additional 10 psi (7.0 bar) inlet pressure.

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

drain below the level of the valve, form a

7-inch (18-cm) loop at the 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.

Not in Bypass In Bypass

Conditioner Conditioner

Water Water

In Out In Out

Figure 3

Note: Standard commercial practices have been

expressed here. Local codes may require changes to

these suggestions.

Brine Line Connection

Install an appropriate length of 3/8-inch OD flexible

plastic tubing (polyethylene) between the tube fitting on

the brine valve (in the brine tank) and the tube fitting on

the valve.

Electrical Connection

Plug the wall mount transformer into a wall outlet that

is not controlled by a switch. Plug the male “barrel

connector”into the bottom of the control.

Initial Brine Tank Fill

With a bucket or hose, add just enough conditioned

water to the brine tank to cover the screen located at

the end of the air check assembly at the bottom of the

brine tank.

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 the valve cover.

Note: The following steps will require turning the

indicator knob on the control, (Figure 4), to various

positions. Insert a wide blade screwdriver into the

arrow slot in the indicator knob and press in firmly. With

knob held in, rotate counterclockwise only until arrow

on 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 the indicator knob.

Press in and rotate the knob counterclockwise

until the arrow points directly to the word

Backwash.

3. Fill mineral tank with water.

a. With water supply off, place the bypass

valve(s) slowly 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, mineral

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

mineral tank (water begins to flow steadily from

the drain), close the main supply valve.

d. With the water supply off, let the unit stand for

5 minutes. This will allow all trapped air to

escape from the tank.

4. Open the water supply valve slowly to the fully

opened position.

5. Carefully advance the indicator knob

counterclockwise to the center of the fast rinse

position and remove the screwdriver. The control

will advance to the conditioned water position by

itself.

Programming the Performa Ultra

1. Plug the wall mount transformer into a functioning

electrical outlet that is not controlled by a switch.

Plug the transformer plug into the transformer plug

receptacle on the control.

Note: If the included transformer cord is not long

enough, a 15-foot extension is available.

Figure 4

PM Indicator

Hour Time Display Water Flow Indicator

Jumper Header

Indicator Knob

Time Set Button Spare Jumper

Access Door

Transformer Plug Receptacle

2. Remove the access door by flexing the removal tab

to the left (as facing the control) then gently pulling

the tab and door out and off the control (Figure 4).

3. With the jumper on the pins marked TIME

(Figure 5), set the time of day to the closest hour by

depressing the black TIME SET BUTTON. PM

hours are indicated by a light next to the letters PM

on the display window.

NOTE: The unit is factory set to regenerate at

2 a.m. If you prefer to have the unit regenerate at

an earlier or later time, simply set the current time

of day accordingly.

Example: To have the unit regenerate at 4 a.m.,

2 hours later, set the clock 2 hours earlier than the

actual current time.

4. Pull the jumper off the TIME pins and place it on

the pins marked HARDNESS (Figure 6). Press the

black TIME SET BUTTON until the correct

hardness 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 = Grains Per Gallon

17.1

5. Place the jumper on the pins marked CAPACITY

(Figure 7). Press the black TIME SET button until

the correct capacity value is displayed. The

capacity range is 6 to 47 kilograins. Refer to the

Salt and Capacity Setting chart (Table 4).

6. Place the jumper on the pins marked LBS of SALT

(Figure 8). Press the black TIME SET button until

the correct salt value is displayed. The salt range is

1 to 30 pounds. Refer to the Salt and Capacity

Setting chart (Table 4).

7. Return the jumper to the pins marked TIME and

close the access door. The pins marked A and B

are used for factory testing and are not used in

normal operation. The jumper must NOT be left

on any pins other than the pins next to the word

TIME. Failure to do this will cause the unit not to

operate. Please note that a spare jumper is located

in the position marked SPARE.

In the event that the hardness, capacity or salt setting

must be changed, simply follow steps 2 through 7.

Calendar Override

The override will initiate a regeneration at the

programmed interval if the water usage has not been

enough to initiate regeneration. For example, if a 463i

unit is programmed with a 10-day calendar override

and the home owner goes on vacation, after 10 days of

no usage, the system will regenerate automatically.

To set the calendar override:

1. Disconnect the power.

2. Move the jumper from the TIME pins to the Apins,

and reconnect the power.

3. Move the same jumper to the B pins. One zero will

appear, indicating zero days of calendar override.

All 463i units are preprogrammed in this manner.

4. Depress the TIME SET button. The numbers will

roll from 0 to 15. Release the button at the desired

number of days for the calendar override. For

example, releasing the button at 10 would program

a 10 day calendar override.

5. Disconnect the power.

6. Place the jumper back on the TIME pins and

reconnect the power.

The calendar override is maintained during power

outages by the NOVRAM circuitry. To remove the

calendar override, follow the same steps above and

program back to 0.

Figure 5 Figure 6

Figure 7 Figure 8

*In most cases, proportional brining will provide higher working efficiencies than standard brining.

Note: Settings other than those listed will result in improper operation of the water conditioner.

1 - Determine the system size based on the tank size and resin volume.

2 - Select the salt setting. Using lower pounds of salt offers greater salt efficiency than higher salt settings.

3 - Determine the capacity of the water conditioner by reading the cross point of the salt setting and system

number. Example: Salt Setting = 4 lbs., System No = 3, Capacity setting = 12,000 grains

Table 4 - Salt and Capacity Settings *

Salt

Setting

(lbs.)

System

2 & 3

System

4 & 5

System

2 6,000 8,000 8,000

3 8,000 9,000 10,000 11,000

4 10,000 11,000 12,000 14,000 15,000 16,000

5 10,000 13,000 13,000 16,000 17,000 18,000 21,000

6 11,000 13,000 14,000 18,000 20,000 20,000 23,000

7 12,000 14,000 15,000 19,000 21,000 22,000 24,000

8 13,000 15,000 16,000 21,000 22,000 24,000 26,000

9 16,000 17,000 22,000 24,000 26,000 28,000

10 17,000 18,000 24,000 26,000 28,000 29,000

11 25,000 28,000 30,000 31,000

12 26,000 29,000 31,000 33,000

13 30,000 32,000 34,000

14 31,000 34,000 36,000

15 32,000 36,000 38,000

16 33,000 37,000 39,000

17 38,000 40,000

18 39,000 40,000

19 40,000 41,000

20 41,000

21 42,000

22 42,000

23 43,000

24 44,000

25 44,000

26 45,000

27 45,000

28 46,000

29 46,000

30 47,000

Changing the System Number

1. Place one jumper on HARDNESS and one on LBS

of SALT.

2. Press TIME SET Button (Figure 4) until desired

system number (Table 1) is displayed.

3. Remove jumpers. Place one jumper on TIME pins

and one jumper on SPARE jumper pins (Figure 5).

Control Valving Indentifications

Figure 9

Valve Disc Operation

Figure 10

Removing 463i 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 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).

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.

1 Brine Valve

2 Bypass Valve

3 Inlet Valve

4 Outlet Valve

5 2nd T a nk T a p

7 Backwash Drain Valves

6 Rinse Drain

Valve

Indicator Arrow

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