AQUATROL POWERFLO AQT-290 User manual

AQT290
POWERFLO SERIES
SERVICE MANUAL
CONTROL VALVES

General Residential Installation 4
AQT-290 Timer Start-up Setting Procedures 5
AQT-290 Timer Delay Start-up Setting Procedures 6
Regeneration Cycle Program Setting Procedures 7
Downflow Diagrams 8
Dimensional Drawings 11
Body Valve Assembly 12
Body Valve Assembly Parts List 13
Upper Control Drive Assembly 14
Upper Control Drive Assembly Parts List 15
Lower Control Drive Assembly 16
Lower Control Drive Parts List 17
170 Brine System Assembly 18
170 Brine System Assembly Parts List 19
Troubleshooting 20
Wiring Diagram 22
Notes 23
TABLE OF CONTENTS
AQUATROL | P.O. Box 2235 Chino Hills, CA 91709 • USA
CONTROL VALVES

Page 4
CONTROL VALVES
General Residential
Installation
Installation Instructions
1. Place the softener tank where you want to install the unit making sure the unit is level and on a rm base.
(Maximum 4 feet apart for twin units.)
2. All plumbing should be done in accordance with local plumbing codes. The pipe size for the drain line should be the same size as the
drain line ow control female connection. Water meters are to be installed on soft water outlets. Twin units with (1) one meter shall be
installed on common soft water outlets of units.
3. Solder joints near the drain must be done prior to connecting the Drain Line Flow Control tting. Leave at least 6" between the DLFC
and solder joints when soldering when the pipes are connected on the DLFC. Failure to do this could cause interior damage to the
DLFC.
4. Teon tape is the only sealant to be used on the drain tting. The drain from twin units may be run through a common line.
5. Make sure that the oor is clean beneath the salt storage tank and that it is level
6. Place approximately 1" of water above the grid plate (if used) in your salt tank. Salt may be place in the unit at this time.
7. On units with by-pass, place in by-pass position. Turn on main water supply. Open a cold soft water tap nearby and let run a few
minutes or until the system is free from foreign material (usually solder) that may have resulted from the installation.
8. Place the by-pass in service position.
9. Manually index the softener control into "service" position and let water ow into the mineral tank. When water ow stops, open a
cold water tap nearby and let run until air pressure is relieved.
10. Electrical: All electrical connections must be connected according to codes. Use electrical conduit if applicable. See Wiring Diagram
section for more information.
11. Plug into power supply
Water Pressure Minimum 25 PSI
Electrical Supply Uninterrupted AC. Check voltage compatibility
Existing Free of any deposits or build-ups inside pipes
Softener Locate close to drain and connect according to plumbing codes
Bypass Valves Always provide for bypass valve if unit is not equipped with one
CAUTION
Do not exceed 120 PSI water pressure
Do not exceed 100°F water temperature
Do not subject unit to freezing conditions

Page 5
CONTROL VALVES
AQT-290 Timer
Start-up Setting Procedures
How To Set Days On Which Water Conditioner Is To
Regenerate:
Rotate the skipper wheel until the number "1" is at the red pointer.
Set the days that regeneration is to occur by sliding tabs on the
skipper wheel outward to expose trip ngers.
Each tab is one day. Finger at red pointer is tonight.
Moving clockwise from the red pointer, extend or retract ngers to
obtain the desired regeneration schedule.
How To Set The Time Of Day:
Press and hold the blue button in to disengage the drive gear.
Turn the large gear until the actual time of day is at the time of day
pointer.
Release the blue button to again engage the drive gear.
How To Manually Regenerate Your Water Condi-
tioner At Any Time:
Turn the manual regeneration knob clockwise.
This slight movement of the manual regeneration knob engages
the program wheel and starts the regeneration program.
The black center knob will make one revolution in the following
approximately three hours and stop in the position shown in the
drawing.
Even though it takes three hours for this center knob to complete
one revolution, the regeneration cycle of your unit might be set
only one half of this time.
In any event, conditioned water may be drawn after rinse water
stops owing from the water conditioner drain line.
How To Adjust Regeneration Time:
1. Disconnect the power source.
2. Locate the three screws behind the manual regeneration knob
by pushing the blue button in and rotating the 24 hour dial
until each screw appears in the cut out portion of the manual
regeneration knob.
3. Loosen each screw slightly to release the pressure on the time
plate from the 24 hour gear.
4. Locate the regeneration time pointer on the inside of the 24
hour dial in the cut out.
5. Turn the plate so the desired regeneration time aligns next to
the raised arrow.
6. Push the blue button in and rotate the 24 hour dial. Tighten
each of the three screws.
7. Push the blue button and locate the pointer one more time to
ensure the desired regeneration time is correct.
8. Reset the time of day and restore power to the unit.

Page 6
CONTROL VALVES
AQT-290 Timer Delay
Start-up Setting Procedures
Typical Programming Procedure
Calculate the gallon capacity of the system, subtract the necessary reserve requirement and set the gallons required by lifting the gallon
dial and rotating it so that the number of gallons required is aligned with the white dot on the program wheel gear. Release and check for
rm engagement with gear.
Note: To set meter capacity at initial start-up, either:
1. Rotate the manual regeneration knob one full revolution.
or
2. Rotate the program wheel manual clockwise and align white dot with capacity arrow.
This procedure must be followed any time the program wheel setting is changed.
How To Set The Time Of Day:
Press and hold the white button in to disengage the drive gear.
Turn the large gear until the actual time of say is opposite of the time of day pointer.
Release the white button to again engage the drive gear.
How To Manually Regenerate Your Water Conditioner At Any Time:
Turn the manual regeneration knob clockwise one "click".
This slight movement of the manual regeneration knob engages the program wheel and starts the regeneration program.
The black center knob will make one revolution in the following approximately three hours and stop in the position shown in the drawing.
Even though it takes three hours for this center knob to complete one revolution, the regeneration cycle of your unit might be set for only
on half of this time.
In any event, conditioned water may be drawn after rinse water stops owing from the water conditioner drain line.
Immediate Regeneration Times:
These timers do not have a 24 hour gear. Setting the gallons on the program wheel and manual regeneration procedure are the same as
previous instructions.
NOTE:
To set meter capacity
rotate manual knob
1-360º revolution to
set the gallons.

Page 7
CONTROL VALVES
How To Set The Regeneration Cycle Program:
The regeneration cycle program on your water conditioner has been factory preset, however, portions of the cycle or program may be
lengthened or shortened in time to suit local conditions.
Timer Setting Procedure:
How To Change The Length Of The Backwash Time:
The program wheel as shown in the drawing is in the service position. As you look at the numbered side of the program wheel, the group
of pins starting at zero determines the length of time your unit will backwash.
For example: If there are six pins in this section, the time of backwash will be 12 min. (2 min. per pin).To change the length of backwash
time, add or remove pins as required. The number of pins times two equals the backwash time in minutes.
How To Change The Length Of Brine And Rinse Time:
The group of holes between the last pin in the backwash section and the second group of pins determines the length of time that your
unit will brine and rinse (2 min. per hole).
To change the length of brine and rinse time, move the rapid rinse group of pins to give more or fewer holes in the brine and rinse section.
Number of holes times two equals brine and rinse time in minutes.
How To Change The Length Of Rapid Rinse:
The second group of pins on the program wheel determines the length of time that your water conditioner will rapid rinse (2 min. per pin)
To change the length of rell time, add or remove pins at the higher numbered end of this section as required. The number of pins times
two equals the rapid rinse time in minutes.
How To Change The Length Of Brine Tank Rell Time:
The second group of holes in the program wheel determines the length of time that your water conditioner will rell the brine tank (2 min.
per hole).
To change the length of rell time, move the two pins at the end of the second group of holes as required.
The regeneration cycle is complete when the outer microswitch is tripped by the two pin set at the end of the brine tank rell section.
The program wheel, however, will continue to rotate until the inner micro-switch drops into the notch on the program wheel.
Regeneration Cycle
Program Setting Procedures

Page 8
CONTROL VALVES
Downow
Flow Diagrams
1) Service Position
Hard water enters unit at valve inlet and ows down
through the mineral in the mineral tank. Conditioned water
enters center tube through the bottom distributor, then
ows up through the center tube, around the piston, and
out the outlet of the valve.
2) Backwash Position
Hard water enters unit at valve inlet - ows through
service adapter for bypass, and up through coupling to
regenerating valve piston - down the center tube - through
the bottom distributor and up through the mineral -
around the piston and out the drain line. If optional no
hard water bypass piston is used water ow to outlet is
prevented by an extended section of the service piston
which closes the outlet port from bypass water until the
end of rapid rinse.
Air Check
Brine Level
Salt Level
Brine Tank
Flow Control
Brine Valve
Resin Tank
Inlet
Outlet
Drain
Resin Level
Air Check
Brine Level
Salt Level
Brine Tank
Flow Control
Brine Valve
Resin Tank
Inlet
Outlet
Drain
Resin Level

Page 9
CONTROL VALVES
Downow
Flow Diagrams
3) Brine Position
Hard water enters unit at valve inlet - ows up into injector
housing and down through nozzle and orice to draw brine
from the brine tank - brine ows down through mineral
and enters the center tube through bottom distributor -
ows up through center tube - around the piston and out
through the drain line.
4) Slow Rinse Position
Hard water enters unit at valve inlet - ows up into injector
housing and down through nozzle and around orice -
around the piston - down through mineral - enters center
tube through bottom distributor - ows up through center
tube - around piston and out through the drain line.
Air Check
Brine Level
Salt Level
Brine Tank
Flow Control
Brine Valve
Resin Tank
Inlet
Outlet
Drain
Resin Level
Air Check
Brine Level
Salt Level
Brine Tank
Flow Control
Brine Valve
Resin Tank
Inlet
Outlet
Drain
Resin Level

Page 10
CONTROL VALVES
Water Conditioner
Flow Diagrams
5) Rapid Rinse
Hard water ows through the regenerating valve directly
down through the mineral into the bottom distributor and
up through the center tube.
6) Slow Rinse Position
Hard water enters unit at valve inlet - ows up into injector
housing and down through nozzle and around orice -
around the piston - down through mineral - enters center
tube through bottom distributor - ows up through center
tube - around piston and out through the drain line.
Air Check
Brine Level
Salt Level
Brine Tank
Flow Control
Brine Valve
Resin Tank
Inlet
Outlet
Drain
Resin Level
Air Check
Brine Level
Salt Level
Brine Tank
Flow Control
Brine Valve
Resin Tank
Inlet
Outlet
Drain
Resin Level

Page 11
CONTROL VALVES
Dimensional
Drawings

Page 12
CONTROL VALVES
Body Valve
Assembly
1
4
6
2
3
7
5
8
9
15
14
12
13
10
11
10
16
No Hard Water Bypass Piston

Page 13
CONTROL VALVES
Body Valve
Assembly Parts List
Item No. Quantity Part No. Description
1 1 A-14749-01 Body, Valve Upper, AQT 290
2 1 A-11208 O-ring, Body Seal, Base
3 2 A-11710 O-ring, Body Seal, Riser Tube
4 1 A-14751 Coupling, AQT-290 Upper-Lower
5* 1 DLFC Button/Washer
6 1 A-60699-00 DLFC Brass, F 3/4" X F 3/4", No Washer
7 1 A-14750-01 Body, Valve Lower, 2", AQT-290
8 1 A-13577 O-ring, Body, Riser Tube
9 1 A-13575 O-ring, Body, Base
10 2 A-11224 Screw, Valve Mounting
11 1 A-12248 Cap, 1" NPT
12 1 A-60090-HF Piston HW, Assy, AQT-275 & AQT-290 Upper
13 1 A-60121-10 Seals & Spacers, Kit, AQT275 & AQT-290 Upper
14 1 A-60128 Seals & Spacers, Kit, AQT-290 Lower
15 1 A-60103 Piston HW, Assy, AQT-290 Lower
16 1 A-60104 Piston NH, Assy, AQT-290 Lower
* DLFC Button / Washer Options
A-17943 DLFC Washer Flow 8 gpm
A-17944 DLFC Washer Flow 9 gpm
A-16529 DLFC Washer Flow 10 gpm
A-16735 DLFC Washer Flow 12 gpm
A-16736 DLFC Washer Flow 15 gpm
A-16528 DLFC Washer Flow 20 pm
A-16737 DLFC Washer Flow 25 gpm

Page 14
CONTROL VALVES
Upper Control Drive
Assembly
13
23
24
29
17
1
678910 11
12
13
14
18
19
20
21
22
15
16
25
13
26
27
32
33 34
31
30
28
5
4
3
2
76






PN A-60160
Drive Cam Assy

Page 15
CONTROL VALVES
Item No. Quantity Part No. Description
1 1 A-07190F Transformer, 24V, 60Hz, for Mechanical and NX
2 1 A-13547 Strain Relief, Cord, Back Plate
3 2 A-10300 Screw, Hex, Back Plate-Timer
4 1 A-19691 Plug, Back Plate
5* 1 Timer, Mechanical
6 2 A-10302 Insulator, Micro Switch
7 3 A-10218 Micro Switch
8 2 A-14923 Screw, Mirco Switch
9- 14 1 A60160 Drive Cam Assy, AQT-275, 285 & Upper 290
15 1 A-60219 Cover, Valve
16 1 A-60219-01 Cover, Panel, Polycarbonate
17 2 A-10231 Screw, Hex, Bracket Motor
18 1 A-10774 Braket, Motor
19 2 A-10157 Bushing
20 1 A-16044-3G Gear Drive, AQT-275, 285 & Upper 290
21 1 A-10158 Axis Drive, AQT-275, 285 & Upper 290
22 1 A-16043-3G Pinion Drive, AQT-275, 285 & Upper 290
23 1 A-10338 Roll Pin
24 3 A-10016S Screw, Motor Mounting
25 1 A-14923-01 Screw, Mirco Switch Single
26 1 A-12777 Cam, Shut-o Valve
27 1 A-30018F Motor 24V, AQT-275, 285, 290 Up, 315, 390 Up & Low
28 3 A-02002 Screw
29 1 A-11826-01 Bracket, Brine Valve Side
30 2 A-10299 Screw, Terminal Strip
31 1 A-15226 Terminal Strip
32 1 A-18697 Back Plate
33 4 A-02115 Back Plate, Knob Screw
34 1 A-19048 Cable Gland Connector
Upper Control Drive
Assembly Parts List

Page 16
CONTROL VALVES
Lower Control Drive
Assembly
1
2
3 4 5
9
10
11
12
6
7
14
15
16
17
18
19
20
13
8
45
9
6
7
8
PN A-60160-01
Lower Drive Cam Assy

Page 17
CONTROL VALVES
Item No. Quantity Part No. Description
1 1 A-07190F Back Plate, AQT-290 Lower
2 1 A-14769 Braket, Motor
3 3 A-10016S Screw, Motor Mounting
4 - 9 1 A-60160-01 Lower Drive Cam Assy
10 1 A-11805 Screw, Micro Switch
11 1 A-10218 Micro Switch
12 1 A-10302 Insulator, Micro Switch
13 1 A-18724 Window
14 1 A-18708-2 Cover, AQT-290 Lower
15 1 A-18744 Screw, Cover
16 2 A-14430-01 Washer, Window
17 2 A-14430 Screw, Window
18 2 A-11224 Screw, Motor Bracket, AQT-290 Lower
19 1 A-30017F Motor 24V, AQT-290 Lower
20 1 A-19048 Cable Gland Connector
Lower Control Drive
Assembly Parts List

Page 18
CONTROL VALVES
170 Brine System
Assembly
13
22
16
21
20
19
18
17
15
14
1
23
4
5
6
7
8
9
10
11
12
PN 1 - 22 -------- A-60034 --- Brine Valve, Short Stem, Less BLFC, 1/2”for AQT-285
PN 14 - 22 ------ A-60381 --- Inyector Body, 1/2” for AQT-285

Page 19
CONTROL VALVES
170 Brine System
Assembly Parts List
Item No. Quantity Part No. Description
1 1 A-15517 Stem Guide, Brine Valve
2 1 A-10250 Retaining Ring
3 1 A-04003F Washer
4 1 A-15310 Spring, Brine Valve
5 1 A-14797 Stem, Brine Valve
6 1 A-14790 Body, Brine Valve
7 1 A-13201 O-Ring
8 1 A-14785 BLFC, Retainer
9** 1 A-120XX BLFC, Button
10 1 A-15413-01 Fitting Brine Line
11 1 A-15415 Fitting Insert
12 1 A-15414 Fitting Nut, Brass
13 1 A-15413 Fitting, Elbow
14 1 A-16460 Tube, Brine Valve
15***-16*** 1 A-14801-XXC Injector Assy
17 2 A-10229 Injector Cover Gasket
18 1 A-11893 Injector Cover
19 1 A-14804 Screw, Injector Cover
20 1 A-10227-170 Screen, Injector
21 1 A-17777 Injector, Body
22 1 A-14805 Injector, Body Gasket
** BLFC Button Options
A-12085 BLFC Button - 1.2 gpm
A-12086 BLFC Button - 1.5 gpm
A-12087 BLFC Button - 2.0 gpm
A-12088 BLFC Button - 2.4 gpm
A-12089 BLFC Button - 3.0 gpm
A-12090 BLFC Button - 3.5 gpm
A-12091 BLFC Button - 4.0 gpm
A-12092 BLFC Button - 5.0 gpm
*** Injectors
A-14801-03C Injector Assy, #3C, Yellow (18" & 20" Tank)
A-14801-04C Injector Assy, #4C, Green (21" Tank)
A-14801-05C Injector Assy, #5C, White (24" Tank)
A-14801-06C Injector Assy, #6C, Red (30" and 36" Tank)

Page 20
CONTROL VALVES
Troubleshooting
Problems, Cause & Corrections
Problem Cause Correction
1) Softener fails to regenerate. A) Electrical service to unit has been
interrupted.
A) Assure permanent electrical service
(check fuse, plug, pull chain or switch).
B) Timer is defective. B) Replace timer.
C) Power failure. C) Reset time of day.
2) Hard water. A) By-pass valve is open. A) Close by-pass valve.
B) No salt in brine tank. B) Add salt to brine tank and maintain salt
level above water level.
C) Injector screen plugged. C) Clean injector screen.
D) Insucient water owing into brine
tank.
D) Check brine tank ll time and clean
brine line ow control if plugged.
E) Hot water tank hardness. E) Repeated ushing of the hot water tanks
required.
F) Leak at distributor tube. F) Make sure distributor tube is not
cracked. Check O-ring and tube pilot.
G) Internal Valve Leak. G) Replace seals and spacers and/or piston.
H) Service Adapter did not return to
service.
H) Check drive motor and switch.
3) Unit used too much salt. A) Improper salt setting. A) Check salt usage and salt setting.
B) Excessive water in brine tank. B) See problem No. 7.
4) Loss of water pressure. A) Iron buildup in line to water conditioner. A) Clean line to water.
B) Iron buildup in water conditioner. B) Clean control and add mineral cleaner
to mineral bed. Increase frequency of
regeneration.
C) Inlet of control plugged due to foreign
material broken loose from pipes by recent
work done on plumbing system.
C) Remove piston and clean control.
5) Loss of mineral through drain line. A) Air in water system. B) Assure that well system has proper
air eliminator control. Check for dry well
conditions.
B) improper size drain line ow control. B) Check for proper drain rate.
6) Iron in conditioned water. A) Fouled mineral bed. A) Check backwash, brine draw and
brine tank ll. Increase frequency of
regeneration. Increase backwash time.
7) Excessive water in brine tank. A) Plugged drain line ow control. A) Clean ow control.
B) Plugged injector system. B) Clean injector and screen.
C) Timer not cycling. C) Replace timer.
D) Foreign material in brine valve. D) Replace brine valve seat and clean valve.
E) Foreign material in brine line ow
control.
E) Clean brine line ow control.