Autotrol Duplex Owner's manual

Duplex
Commercial Softeners
Installation, Operation
& Maintenance Guide
Manual 003.1

2
Contents
Page
1. Unpacking Instructions 3
2. Installation 4
Pre-installation checks
Fitting the bottom distribution systems
Adding the media
Fitting the valves
Brine tank connections
Hydraulic connections
Drain line flow connections
Electrical Connections
Programming the valves
Resetting the valve programming
In Service Display
3. Commissioning 8
Introduction
Regeneration
Service
4. Routine Maintenance 9
Weekly
5. Technical Information 9
Identifying your Softener
Programming and Operating Details
Installation layout
Troubleshooting

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Thank you for purchasing this Softener. We are sure that it will provide you with
trouble free service for many years to come. Please use the following pages to
assist you with the assembly and installation of your new system.
1. Unpacking.
PLEASE USE THE ACCOMPANYING PACKING DOCUMENTS TO CHECK THAT ALL
ITEMS ARE PRESENT AND CORRECT.
If any item is missing or damaged your carrier and supplier must be notified within 2 days of
receipt if a claim is to be made.
The main parts of the system include:
Salt
Base
Lower
Screen
Riser
Upper screen
Valve
Drain elbow
Brine line
Drain line
Brine tank
Containing
Brine pickups
Overflow

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2. Installation.
Please observe the regulations concerning the installation of your water softener. Check that
you have allowed space for access to the unit for possible future maintenance. This
installation may require plumbing work and will require an electrical outlet to be fitted near the
system. Only attempt this if you have the necessary skills.
2.1 Pre-installation checks.
The area needs to be level, frost free have access to electricity and an open drain. Check the
incoming water quality is within any parameters specified for that media (see technical
information at the back of the manual). In addition to this check the incoming water pressure
is between 2 and 8 bar (preferably approx. 4 bar) and the water temperature is between 3ºC
and 45ºC.
2.2 Fitting the Bottom Distribution Systems.
Fit the bottom distribution systems into the vessels – the bottom screens should be pre glued
to the riser tubes (fig A.1). If the system uses bottom laterals (typically 16” diameter and
above) these need to be assembled inside the vessels (fig A.2), Move the vessels to their final
positions as they will be difficult to move once the media has been added.
Fig A.1 Fig A.2 Fig A.3
2.3 Adding the Media.
Block the top of the riser tubes to stop media getting down the tubes (see fig A.3). Add about
1/3 by volume of water to the vessels so when the media is poured in it doesn’t damage the
bottom distribution systems. Add the media supplied but make sure there is free space left
above the media so when the system is backwashed the media can expand into the space
and any sediment or contaminants can be backwashed away (there may be media left over).
Unblock the riser tubes.
2.4 Fitting the Valves.
Add a small amount of silicone grease to the valves outer and inner o-rings (fig A.4 & 5).
Fig A.4 Fig A.5

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If top screens are supplied these should be attached next.
Slide the valves onto the riser tubes and gently push them
down onto the vessel treads. Screw the valves on until you
start to squeeze the main O rings and then finally give the
valves a final tighten by tapping the rear side of the valves
with the palm of your hand (fig A.6)
Fig A.6
2.5 Brine Tank Connections.
Attach the brine line tubing to the brine tank and valves using the connectors fitted to the
brine tank (Fig A.7), valve (Fig A.8), or air check bottle on 255 valve. (Fig A.9)
Fig A.7 Fig A.8 Fig A.9
2.5 Hydraulic Connections.
Interconnecting pipe work kits with bypasses and 1” BSP connections (Fig A.10) are supplied
for the ¾” or 1” valves; these can be connected using fixed or flexible pipe work.
Duplex systems with 2” valves do not come with interconnecting pipe work kits and will need
to be plumbed on site with connections to the 2” solvent weld tails provided.
Fig A.10
2.6 Drain Line Flow Connections.
Check the service and backwash flow rates (see technical information at the end of the
manual). If the service flow rates are exceeded then the softener will not give its full capacity
of soft water. The backwash flow rate should be limited by either internal or external drain line
flow controls (DLFCs). If the DLFC are external they should be listed on the packing
documents and should be screwed on to the waste connections of the valves. A drain hose
should then be attached which needs to terminate in an open drain (back pressure or a
kinked waste hose will cause the system to malfunction). If the DLFC is internal they will be
fitted inside the valves (normally used on vessels 10 inch diameter and smaller).

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2.7 Electrical connections.
All valves are low voltage valves with a 240V transformer.
With the power off connect the transformer provided to
240V supply. With the power OFF plug the flying lead into
the connecter of the master controller (Fig A.11). If you
have in line transformers this will need to be wired into a
fused switch. Ensure that the cables cannot get caught on
the camshafts or any of the valves moving parts.
Fig A.11
2.8 Connecting the Valves together.
The valves are connected together with the interconnecting
cable supplied, the loose end needs to be connected to the
other valve. (Fig A.12)
Fig A.12
2.9 Programming the Valve set.
This programming relates to the Autotrol 764 logix duplex valve sets.
The valve set should already have been set up with the basic settings in the factory. The only
settings you should need to enter are the time of day and day of the week. All settings are set
on the master controller.
When making these settings the controller may indicate ERR3 then ERR4 this is NOT a fault,
allow the cams to turn and settle back to the service and standby positions and continue
setting.
1. Down arrow. Used to scroll down or
increment through a group of choices.
2. Set. Used to accept a setting to store in
the memory.
3. Up arrow. Used to scroll up or increment
up through a group of choices.
4. Regenerate. Used to command the
controller to regenerate.
Initial Power Up.
Plug the transformer into the rear of the control panel; this is located to
the left top corner of the panel if viewing from the front. Once the power
is connected the display may briefly show the valve number for the
system (764). The valve type will be printed on the side of the valve
and should also appear on the delivery documentation.
Note. During the set up process the display may revert to service mode
(after 25 seconds).

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By repeatedly pressing the set button you can scroll to the part of the
set up programme you require.
You may receive an ERR3 / ERR4 message, if this happens allow the
cam shafts to turn for a few moments and this code should disappear. If
the cam does not move check that the Cam Shafts are fitted correctly
and that the optical sensors are in position.
Set Time.
Press the set button. The TIME should now be flashing, use the up and
down arrows to set the correct time of day (24hrs format). Once the
correct time has been selected, press the set button to confirm. The
following will then be displayed.
Set Day of the Week.
Press the set button to display the screen shown. The display will flash,
use the up and down buttons to advance the arrow to underneath the
correct day. Once under the correct day press the set button to confirm.
The following will then be displayed.
Time when system Regenerates.
This normally defaults to 2.00am but can easily be changed to a more
suitable time if required by pressing the square set button to start the
display flashing, adjusting the time using the up and down arrows then
press the square set button to confirm. The following will then be
displayed.
Calendar Override Days.
The system should have this pre-programmed to a suggested number
of days but this may need altering to suit your needs. This function
allows the filter bed to backwash regardless of usage; this is to ensure
that the filter bed remains fresh.
Press the set button to start the display flashing then alter the figure
using the up and down arrows, then press the set button to confirm the
setting.
Hardness Setting
The hardness setting will need to be set on site, the setting is in ppm.
Press the set button to start the display flashing and adjust the
hardness value up or down using the up and down arrows, when the
correct figure is displayed press the square button to set.
Capacity.
System capacity is displayed in kilograms of hardness removed before
regeneration is necessary. This should be factory set but should it
require setting you need to press the set button to start the display
flashing, then adjust the figure using the up and down arrows and press
the set button to confirm the figure. (see section 5.1)

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2.10 Resetting the Valve Programming.
Occasionally it maybe necessary to reset the valve to factory defaults.
The programmed valve type (softener) can be checked by pressing and holding the SET and
DOWN buttons simultaneously for 5 seconds. H0 and a resin volume is displayed e.g. H0
100, the valve has been set as a softener. If in doubt contact your supplier.
To reset the valve: with H0 displayed, press and hold the SET for 5 seconds
For 764 controllers valve type will now be shown e.g. 255A, 255P, 278A. Choose the
correct valve (255, A or P) and press the SET button, (A = Alternating & P = Parallel).
Three dashes will now show on screen, this is the resin volume per vessel and should
be set accordingly using the up and down arrows set the amount of resin applicable to
your system (see programming details)
It will now be necessary to reset the time, day, regeneration time and override days.
Alternating: One vessel in service and one in standby.
Parallel: Both vessels in service but only one will regenerate at a time.
2.11 In Service Display.764 Electronic Multi-Tank “A” Alternating Control:
Service display – The number of the tank in service and
alternating capacity remaining and flow rate with faucet icon
of tank in service
Tank in service.
764 Electronic Multi-Tank “P” Parallel Control:
Service display – Alternating three times
Capacity remaining for tank 1 with digit “1” displayed
Capacity remaining for tank 2 with digit “2” displayed
System flow rate (Tank 1 + Tank 2 added with faucet icon.
3. Commissioning the Softener
3.1 Introduction.
With the system fully plumbed and the valve programmed commissioning can start.
3.2 Regeneration.
When the system is fully functional the regeneration will happen at the pre-set time (see
programming the valve section). However, running a manual regeneration during
commissioning is the best way of removing air from the system, bedding in the media and
flushing the system through.
Make sure the water inlet and outlet are closed. Press and hold the regeneration button for 5
seconds. The cam will rotate to the backwash position (C1). Slowly half open the water inlet
to the system, and then slowly open the outlet to allow the air to be purged from the system.
Once this has been done you can fully open the inlet and outlet and allow the system to

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4202035013
SNo 08090137
Mis
0919-255-760
continue through the regeneration cycle, this will allow you to check for leaks and also purge
any remaining air from the system. After a backwash the system will move through a brine
draw routine, some pressure equalising and further rinse cycles before stopping in the service
position. This will have to be done for both vessels.
For new systems or after a media change it maybe necessary to run two regenerations to fully
charge the media (check the water at the end of the backwash is running clear).
To initiate a delayed regeneration press the regeneration button once quickly to start the
regen symbol flashing, this will start the backwash at the backwash pre-set time.
If during a regeneration cycle you need to skip through the cycle this can be done in the
following ways. To skip to the next stage press the square set button and up arrow together
for a second. To skip to the end of the cycle press and hold the square set button and up
arrow until the egg timer starts flashing.
3.3 Service.
Water flows into the valve at the top, down through the media and then up through the ‘riser’
tube in the middle of the vessel. As the water travels through the media the ion exchange
takes place. The valves and controllers are set to automatically regenerate when specified or
required.
4. Routine Maintenance.
The system is designed to run with the minimum of maintenance and does not normally
require much adjustment or work.
Weekly.
Check the salt level (this may need to be checked more regularly dependant on use)
Check there is no sign of damage or leaks,
Check the quality of the treated water.
5. Technical Information.
5.1 Identifying your Softener
Your softener will have a identification label fixed to the outer carton and the control
valve, this will look similar to the picture shown here.
The information listed can be read as follows:
Stock Number: Manufacturers part number.
Serial No: Serial No.
Id Code: Softener type identification code.
Configuration: Vessel size, Valve type & Controller type.
Identify the settings relevant to your softener from the chart below by looking at the
vessel size and controller type.

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Vessel Size 835 935 1035 1044 1054 1248 1354
Media Volume (each vessel) 20 25 30 40 50 60 75
Valve Type 255 255 255 255 255 255 255
Parameters
Time of day (HH:MM) P1
Day of week P2
Time of regeneration (HH:MM) P3
Calendar overide days P4
Salt ammount (gms) P6
Capacity (Kg) P7 1 1.2 1.5 2 2.5 3 3.8
Hardness (ppm) P8
Refill rate (gpm x 100) P14 33 33 33 33 33 33 33
Brine draw rate (gpm x 100) P15 18 18 22 26 26 38 50
Vessel Size 1354 1465 1665 1865 2160
Media Volume (each vessel) 75 100 125 200 250
Valve Type 278 278 278 278 278
Parameters
Time of day (HH:MM) P1
Day of week P2
Time of regeneration (HH:MM) P3
Calendar overide days P4
Salt ammount (gms) P6
Capacity (Kg) P7 3.8 5 6.2 8.8 11.2
Hardness (ppm) P8
Refill rate (gpm x 100) P14 130 130 130 130 130
Brine draw rate (gpm x 100) P15 56 56 67 84 84
Vessel Size 1665 1865 2160 2469 3072 3672
Media Volume (each vessel) 150 200 250 350 500 700
Valve Type 298 298 298 298 298 298
Parameters
Time of day (HH:MM) P1
Day of week P2
Time of regeneration (HH:MM) P3
Calendar overide days P4
Salt ammount (gms) P6
Capacity (Kg) P7 6.2 8.8 11.2 15 25 35
Hardness (ppm) P8
Refill rate (gpm x 100) P14 80 140 140 200 300 500
Brine draw rate (gpm x 100) P15 50 90 90 140 200 300
Set on site / factory default 2,00am
Set on site / factory default 14 days
150
Set on site
Set on site / factory default 14 days
150
Set on site
Set on site
Set on site
Set on site / factory default 14 days
150
Small Commercial Softeners
Set on site
Set on site
Set on site
Set on site
Set on site
Set on site / factory default 2,00am
Larger Commercial Softeners
Set on site / factory default 2,00am
5.2 Programming Details and Operating Data.

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Isolation Valve
Softener Outlet
Bypass Valve
Isolation Valve
Softener Inlet
Nonreturn valve
Directionof flow
5.3 Typical Installation layout.
Typical bypass setup using
three isolation valves plus
a non return valve.
Salt
Base
Lower
Screen
Riser
Upper screen
Valve
Drain elbow
Brine line
Drain line
Brine tank
Containing
Brine pickups
Overflow

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700 Series Controller Troubleshooting.
Problem Possible cause Solution
ERR 1 is displayed. Controller power has been Press the up arrow and the control
connected and the control is not should reset.
sure of the state of operation.
ERR 2 is displayed Controller power does not match Disconnect and reconnect the power.
50 or 60 Hz If the problem persists, obtain the
appropriate controller or AC adapter
for either 50 or 60 Hz power.
ERR 3 is displayed Controller does not know the Wait for two minutes for the
position of the camshaft. Camshaft controller to return to home position.
should be rotating to find home The hour glass should be flashing
position. on the display indicating the motor
is running.
Camshaft is not turning during Check that motor is connected.
ERR 3 display. Verify that the motor wire harness is
connected to the motor and
controller module. Verify the optical
sensor is connected and in place.
Verify that motor gear has engaged
cam gear.
If everything in connected, try
replacing in this order:
Wire harness
Motor
Optical sensor
Controller
If camshaft is turning for more than Verify that the optical sensor is in
five minutes to find home position. place and connected to wire.
Verify that the camshaft is
connected appropriately.
Verify that no dirt or rubbish is
clogging any of the cam slots.
If motor continues to rotate
indefinately replace the following in
this order:
Wire harness
Motor
Optical sensor
Controller
Four dashes displayed Power failure occurred Press SET to reset time display.
5.4 Troubleshooting.
Following you can find a guide as to the most common problems that may arise; please
consult this section before contacting you supplying dealer as most problems are easily
cured by following this information.

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System Troubleshooting
Problem Possible cause Solution
1. Regenerant Tank Overflow. a. Drain line restricted. a. Check the drain line is not blocked
or kinked.
See also 4. b. Uncontrolled refill flow rate b. Remove refill flow control to clean
ball and seat.
c. Air leak in regenerant line c. Check all connections in regenerant
line for leaks.
d. Drain control clogged with resin d. Clean drain control.
or other debris.
e. Sinking air check ball (255 only) e. Replace air check ball.
f. Incorrect drain control fitted. f. Too small of a drain control with a
larger injector may reduce draw rates.
g. Regenerant valve disc 1 being g. Remove obstruction.
held open.
h. Valve disc 2 not closed during h. Remove obstruction.
regenerant draw causing a refill.
2. Water flow from drain or a. Flapper valve return spring weak. a. Replace valve spring. (contact dealer)
regenerant line when in service. b. Debris stopping flapper valve b. Remove debris.
from closing.
3. Hard water after regeneration. a. Incorrect / failed regeneration. a. Repeat regeneration after checking
settings.
b. Leaking external bypass valve. b. Replace bypass (contact dealer)
c. O-Ring around riser damaged. c. Replace O Ring (contact dealer)
d. Capacity too low due to incorrect d. Check settings and adjust if required.
setting.
4. Will not draw regenerant or a. Low water pressure a. Fit pump (contact dealer)
intermittent or irregular draw. b. Drain line restriced. b. Check the drain line is not blocked
or kinked.
c. Injector plugged. c. Clean injector and screen.
d. Injector defective. d. Replace injector.
e. Flapper valve 2 &/or 3 not e. Remove debris, check flapper for
fully closed. closing or replace. (contact dealer)
f. Air check prematurly closed. f. Put control into refill C8, replace
or repair air check if needed. (contact
dealer)
5. System will not regenerate a. Power not connected. a. Connect power.
automatically. b. Defective motor b. Replace motor. (contact dealer)
c. Fouled or defective turbine c. Clean or replace turbine.
d. Defective turbine cable. d. Replace turbine cable.
6. System regenerated at the a. Settings incorrect. a. Correct settings.
wrong time.
7. No conditioned water after a. No salt in regenerant tank. a. Add salt to regenerant tank.
regeneration. (Salt must be above the water level)
b. Injector plugged. b. Clean injector and screen.
e. Air check closes prematurely. e. Check connections for air leaks and
check air check ball (255) floats.
See also 1.e. & 4.f.
8. Backwashes at excessively a. Incorrect drain controller used. a. Replace with correct size.
low or high rate. b. Debris affecting valve operation. b. Remove drain controller and clean.
volume to correct setting.

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System Troubleshooting
Problem Possible cause Solution
9. Valve will not draw brine. a. Low water pressure a. Fit pump (contact dealer)
b. Drain line restriced. b. Check the drain line is not blocked
or kinked.
c. Injector plugged. c. Clean injector and screen.
d. Injector defective. d. Replace injector.
e. Air check closes prematurely. e. Put control into brine draw C2 to
check. Repair or replace if needed.
10. Uses more or less salt than a. Foreign matter in valve causing a. Remove brine control and flush out
setting. incorrect flow rates. any debris. Put system through a
regeneration to flush valve.
11. No water flow display on a. Bypass valve in bypass. a. Open bypass.
metered valves. b. Meter probe not connected to b. Connect correctly.
control or turbine housing.
c. Restricted turbine rotation due c. Remove and clean turbine, Turbine
to foreign matter in turbine. should spin freely, if not replace.
12. Run out of conditioned water a. Impropper regeneration. a. Repeat regeneration after checking
between regenerations. the correct regenerant doseage is
set.
b. Incorrect regenerant setting. b. Set correct salt setting.
c. Incorrect hardness or capacity c. Set to correct values.
settings.
d. Water hardness has increased. d. Set hardness to new value.
e. Restricted turbine rotation e. See 11.c
Notes:

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Notes:

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Manual 003.1