Hellenbrand 3000 Series User manual

Service Manual
HELLENBRAND WATER CENTER
404 Moravian Valley Road • Waunakee, Wisconsin 53597
hellenbrandwatercenter.com • [email protected]
©2012
Series 3000
An Autotrol 255 Valve/400 Series Control

TABLE OF CONTENTS
SAFETY INFORMATION............................................................ 2
VALVE ILLUSTRATION ........................................................ 5
SYSTEM REGENERATION CYCLES .......................................... 6
INSTALLATION ......................................................................... 6
DISINFECTION OF WATER CONDITIONERS ............................ 8
PLACING CONDITIONER INTO OPERATION............................ 9
400 SERIES CONTROL SETTINGS ........................................... 10
PREVENTIVE MAINTENANCE.................................................. 13
REPLACEMENT PARTS FOR AUTOTROL 255 CONTROL......... 14
REPLACEMENT PARTS ........................................................... 16
TROUBLESHOOTING ............................................................... 18
VALVE SPECIFICATIONS ......................................................... 20
The systems below have been tested
and certified by the WQA to NSF/ANSI
Std. 44 and NSF/ANSI 237 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
255-560i-100-948
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2 • Autotrol®255 Valve / 400 Series Controls Service Manual SE12

WATER SOFTENER PERFORMANCE DATA SHEET
Model 255-460i-075-844 255-460i-100-948 Rated Service Flow (gpm) 6.0 10.0 Pressure Drop at Rated Service Flow Rate (psi) 9.0 15.0 Rated Capacity (grains @ lb. of salt) 15, 362 @ 3.75
21,197 @ 7.5
23,148 @ 10.5
20,483 @ 5.0
28,263 @ 10.0 30,865 @ 14.0
Rated Efficiency (grains/lb Salt @ lb. of salt) 4,096/lb. salt @ 3.75 4,096/lb. salt @ 5.0 Maximum Flow Rate During Regeneration (gpm) 1.7 2.1 Sybron C-249NS Ion Exchange Resin (cu. ft) 0.75 1.0 Backwash - GPM 1.7 2.1 Fast Rinse/Purge - GPM 1.7 2.1 Operating Pressure:20 -125 psi or 1.4 – 8.8 kg/Centimeter
2
, Operating Temperature: 34 - 100° F or 1.1 – 38° C
Acceptable Salt Type: Sodium Chloride – Pellet or solar salt for water softeners All Systems above tested at 35psi +/- 5 psi, pH of 7.5 +/- 0.5, Capacity Testing Flow Rate = 50% of the rated service flow rate for the various size systems.
These water softener systems have been tested by WQA and conform to NSF/ANSI 44 for specific performance claims as verified and substantiated by test data. The rated salt efficiencies above were also determined in accordance with NSF/ANSI 44 and are only valid at the salt dosage referenced above. An efficiency rated water softener is a demand initiated regeneration (DIR) softener which also complies with specific performance specifications intended to minimize the amount of regenerant brine and water used in its operation. Efficiency rated water softeners shall have a rated salt efficiency of not less that 3350 grains of total hardness exchanged per pound of salt (based on NaCl equivalency) (477 grams of total hardness exchanged per kilogram of salt), and shall not deliver more salt than its listed rating. The rated efficiency of the water softener, the salt dosage at that efficiency, the capacity at that salt dosage and that of the efficiency is only valid at the stated salt
dosage. Efficiency is measured by a laboratory test described in NSF/ANSI 44. The test represents the maximum possible efficiency the system can achieve. Operational efficiency is the actual efficiency achieved after the system has been installed. It is typically less than the efficiency due to individual application factors including water hardness, water usage, and other contaminants that reduce the water softener’s capacity. These systems are not intended to be used for treating water that is microbiologically unsafe or of unknown quality without adequate disinfection before or after
the system. Refer to the system Installation and Service Manuals for set-up and programming instructions.
Contact your local Autotrol dealer for parts and service. See your owner’s manual for warranty information. Important Notice: For conditions of use, health claims certified by the California Department of Public Health and replacement parts, see product data sheet Iowa Requirement:
Seller: ______________________________________________________________ Date: _________________________ Buyer: ______________________________________________________________ Date: _________________________
Tested and Certified by WQA against NSF/ANSI Standard 44 & NSF/ANSI 372 for “lead free” compliance. The valve used on this unit is Tested and Certified by WQA to NSF/ANSI Std. 61 Section 8 for Material Safety Only
PENTAIR Residential Filtration, LLC
5730 North Glen Park Road Milwaukee, Wisconsin 53209
PHONE: [phone]
Pentair Residential Filtration, LLC
Autotrol®255 Valve / 400 Series Controls Service Manual SE12 • 3

SAFETY INFORMATION
Please review this entire Installation and Operation manual
before installing unit.
• We recommend that this water conditioning unit be
installed by a trained professional water treatment dealer.
Follow all local codes for plumbing this unit.
• Follow local electrical codes. Install a correctly sized
electrical bonding jumper between the inlet and outlet
pipes when these devices are installed in metallic
plumbing systems.
• Inspect this unit carefully for carrier shortage or shipping
damage before beginning installation of unit.
• This system is not intended to be used for treating water
that is microbiologically unsafe or of unknown quality
without adequate disinfection before or after the system.
• This system is to be used only for potable water.
• Use only lead-free solder and flux, as required by
federal and state codes, when installing soldered copper
plumbing.
• Use caution when sweat joining metal pipes near this
water conditioning system. Heat can adversely affect the
plastic used in this system and bypass valve.
• Use only silicone grease for lubrication of this unit.
• Use only the power transformers supplied with this
conditioning systems control valve unit.
• Do not allow this water conditioning unit to freeze.
Damage from freezing will void this water conditioning
unit’s warranty.
• Do not store flammable or volatile chemicals near this
water conditioning unit.
• For the purpose of plumbing system sizing, only the rated
service (i.e. "Normal") flow and corresponding pressure
loss may be used. The rated service flow rates are the
flow rates at which the performance capabilities of these
devices were evaluated.
Contact your local Professional Water Dealer for system
service, and to obtain Autotrol replacement parts for this
control valve unit.
4 • Autotrol®255 Valve / 400 Series Controls Service Manual SE12

VALVE ILLUSTRATION
Autotrol 255 Valve Control Module
400 Series Control
Variable Brine
Control
Injector Access Plug
Air Check
Optional i-lid Cover
Figure 1
Tank Adapter Module
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Optional Bypass
Figure 2
Brine Line Fitting
Connection 1/4-inch NPT
Air Check
Tank Thread 2-1/2-inch - 8 Male
Inlet Connection 3/4-inch
or 1-inch NPT or BSPT
Drain Connection 3/8-inch
or 1/2-inch NPT or BSPT
Outlet Connection 3/4-inch
or 1-inch NPT or BSPT
Autotrol®255 Valve / 400 Series Controls Service Manual SE12 • 5

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 water.
The water is conditioned as it passes through the resin bed.
2. Backwash (Upflow):
The flow of water is reversed 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 (Downflow):
The control directs water 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. 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.
SERVICE BACKWASH BRINE/SLOW RINSE FAST RINSE
From Regenerant
Tank
To Regenerant
Tank
BRINE REFILL
REPRESSURIZE
C0 C1 and C6 C2 and C3 C4 C5 and C7 C8
Figure 3
INSTALLATION
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. If it is 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.
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 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 drain and overflow lines) will ever be subjected to room
temperatures under 34°F (1°C) or over 120°F (49°C).
6. Do not install unit near acid or acid fumes.
7. The use of resin cleaners in an unvented enclosure is not
recommended.
6 • Autotrol®255 Valve / 400 Series Controls Service Manual SE12

Water Line Connection
The installation of a bypass valve system is recommended to
provide for occasions when the water conditioner must be
bypassed for hard water or for servicing.
The most common bypass systems are the Autotrol® Series
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.
INSTALLATION continued
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Figure 4 Autotrol Series 256 Bypass Valve
Water
Conditioner
Water
Conditioner
Not in Bypass 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 m) 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. If the unit is located where the drain line must be elevated,
you may elevate the line up to 6 feet (1.8 m) providing the
run does not exceed 15 feet (4.6 m) and water pressure
at conditioner is not less than 40 psi (2.76 bar). You may
elevate an additional 2 feet (61 cm) for each additional 10
psi (0.69 bar).
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.
CAUTION 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.
Drain Line Tube
Correct Way
Drain
Figure 6
NOTE: Standard commercial practices have been
expressed here. Local codes may require changes
to these suggestions.
Brine Line Connection
It will be necessary to install the brine tube and line to a fitting
installed on the air check. Use 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
Operation 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).
Brine 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 Controls Service Manual SE12 • 7

Increasing the Length of the Transformer Cord
If it is necessary to extend the length of the transformer cord,
an optional 15-foot (4.6-m) extension is available (see Figure 9).
INSTALLATION continued
Figure 8
Figure 9
DISINFECTION OF WATER CONDITIONERS
The materials of construction of the modern water conditioner
will not support bacterial growth, nor will these materials
contaminate a water supply. In addition, during normal use, a
conditioner may become fouled with organic matter, or in some
cases with bacteria from the water supply. This may result in
an off-taste or odor in the water.
Thus, your conditioner may need to be disinfected after
installation. Some conditioners will require periodic
disinfection during their normal life. Consult your installing
dealer for more information on disinfecting your conditioner.
Depending upon the conditions of use, the style of conditioner,
the type of ion exchanger, and the disinfectant available, a
choice can be made among the following methods.
Sodium or Calcium Hypochlorite
Application
These materials are satisfactory for use with polystyrene
resins, synthetic gel zeolite, greensand and bentonites.
5.25% Sodium Hypochlorite
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
A. Polystyrene resin; 1.2 fluid ounce per cubic foot.
B. Non-resinous exchangers; 0.8 fluid ounce per cubic
foot.
2. Brine tank conditioners
A. Backwash the conditioner and add the required amount
of hypochlorite solution to the brine well of the brine
tank. The brine tank should have water in it to permit
the solution to be carried into the conditioner.
B. Proceed with the normal regeneration.
Calcium Hypochlorite
Calcium hypochlorite, 70% available chlorine, is available in
several forms including tablets and granules. These solid
materials may be used directly without dissolving before use.
1. Dosage
A. Two grains (approximately 0.1 ounce) per cubic foot.
2. Brine tank conditioners
A. Backwash the conditioner and add the required amount
of hypochlorite to the brine well of the brine tank. The
brine tank should have water in it to permit the chlorine
solution to be carried into the conditioner.
B. Proceed with the normal regeneration.
8 • Autotrol®255 Valve / 400 Series Controls Service Manual SE12

PLACING CONDITIONER INTO OPERATION
Initial Start-Up
After the water 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 (Figures 11, 12, and 16) 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 (Figures 11,
12, and 16). 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 valve(s) into the
“NOT IN BYPASS” position.
B. Open water supply valve very slowly to approximately
the 1/4 open position.
CAUTION 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 flow 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.
Control Valve
Air Check
Brine Line
Figure 10 - Control Valve
5. Put into 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 indicator knob COUNTERCLOCKWISE to
CONDITIONED WATER.
F. Run water from a nearby faucet until the water is clear
and soft.
Autotrol®255 Valve / 400 Series Controls Service Manual SE12 • 9

400 SERIES CONTROL SETTINGS
440i Control (obsolete)
Day Arrow Skipper Pins Skipper Wheel
Indicator Knob Timer
Locking Pin
Time Arrow Timer Knob
Figure 11
Programming
1. Set days of regeneration on skipper wheel (Figure 11).
• Pull all skipper pins outward (away from control).
• Rotate skipper wheel until day arrow points to current
day or number 1.
• Depress skipper pin(s) at day(s) for which regeneration is
desired.
2. Set the time of day.
• Grasp timer knob and pull outward.
• Rotate in either direction until the timer arrow points to
the actual time of day.
• 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.)
NOTE: The Timer Locking Pin should always be horizontal
(Figure 11) during operation.
460i Control
PM Indicator
Water Flow
Indicator Hour Time Display
Access Door
Indicator Knob
Timer Locking
Pin
Time Set Button
Transformer Plug
Receptacle
Raised
Tab
Jumper
Spare
Jumper
Figure 12
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.
NOTE: 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).
NOTE: The Timer Locking Pin should always be horizontal
(Figure 12) during operation.
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 in parts per million (PPM) to
grains per gallon (GPG) use this formula:
Parts per Million
17.1 = Grains per Gallon
10 • Autotrol®255 Valve / 400 Series Controls Service Manual SE12

400 SERIES CONTROL SETTINGS
continued
Figure 13
460TC
DAYS
CLOCK
PM Indicator Hour Time Display Access Door
Raised
Tab
Jumper
Spare
Jumper
Transformer Plug
Receptacle
Time Set Button
Timer Locking
Pin
Indicator Knob
460TC Control
Figure 16
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 of a small needle-nose pliers will aid in
moving the jumper.
NOTE: 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).
NOTE: The Timer Locking Pin should always be horizontal
(Figure 16) during operation.
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 days.
TIME
DAYS
CLOCK
TIME
DAYS
CLOCK
TIME
DAYS
CLOCK
Figure 14 Figure 15
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.
5. Disconnect power.
6. Place jumper back on TIME and reconnect power.
7. The calendar override program is maintained during power
outages by the NOVRAM circuitry.
8. To remove the calendar override, follow the same steps
above and program back to “0.”
Figure 17 Figure 18 Figure 19
Autotrol®255 Valve / 400 Series Controls Service Manual SE12 • 11

400 SERIES CONTROL SETTINGS
continued
Figure 20
The amount of salt placed in the brine tank has nothing to do
with the amount of salt used during the regeneration cycle.
Water will dissolve and absorb salt only until it becomes
saturated. A given amount of brine (salt-saturated water)
contains a specific amount of salt. The salt dial controls the
amount of brine used during the regeneration cycle (e.g., when
set at 15 pounds (6.8 kg) the amount of brine the conditioner
will use for each regeneration will contain 15 pounds (6.8 kg) of
salt, etc.)
Never let the amount of salt in the brine tank be lower than the
normal liquid level. Do not overload the brine tank with salt.
Guest Cycle (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.
Table 1 - Suggested Salt Dial Settings (Pounds of Salt) For Various Size Softeners
Capacity
Setting
(Kilograins)
.5 Ft3.75 Ft31.0 Ft31.25 Ft31.5 Ft31.75 Ft32.0 Ft3
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.
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.
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
These models may be adjusted to produce maximum to
minimum conditioning capacities by setting the salt dial, which
controls the amount of salt used per regeneration. When
desired, the minimum setting may be used on installations if
the frequency of regeneration is increased to compensate for
lower regenerated conditioning capacity. The installing dealer
will set the unit for proper salt usage. Further adjustments
are needed only if the hardness of the water supply changes
or if water use changes dramatically. Capacity will need to be
adjusted accordingly.
To adjust salt dosage, insert a small screwdriver into the white
indicator knob and move pointer to proper salt setting (Figure
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).
12 • Autotrol®255 Valve / 400 Series Controls Service Manual SE12

PREVENTIVE 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 valve(s) 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).
5. Clean screen using a fine brush. Flush until clean.
6. Using a needle-nose pliers, pull injector straight out.
7. Flush water into the injector screen recess of the valve body
to flush debris out through the injector recess.
8. Clean and flush the injector.
9. Lubricate the O-rings on the injector, injector cap and
injector screen with silicone lubricant.
10. Reinstall the injector, injector cap and injector screen. See
CAUTION below.
11. Plug the wall-mount transformer into outlet; reset time of
day.
12. Slowly open water supply valve or return bypass valve(s) to
the “not in bypass” position.
CAUTION 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.
Screen
Injector
Injector Cap
Figure 21
Autotrol®255 Valve / 400 Series Controls Service Manual SE12 • 13

REPLACEMENT PARTS FOR AUTOTROL 255
CONTROL
Valve Body
18
6
7
21
19
17
2
1516
5
4
1
9
10
7
8
12
20 20
20
13
22
14
Item No. QTY Part No. Description
1.................1........ 100232 ...............Valve Assembly, w/o Flow Controls
2.................1....................................Camshaft:
............................ 1031950 .............Standard, One-Piece
............................ 1033024 .............Standard, Segmented
............................ 1033025 .............Extra Salt, Segmented
............................ 1033026 .............Long Rinse, Segmented
............................ 1032969 .............Water Saver, Segmented
4.................1........ 1031391 .............Timer Locking Pin
5.................1........ 1000226 .............Screen/Cap Assembly w/O-Ring
6.................1....................................Drain Control Assembly w/O Rings:
............................ 1000209 .............No. 7 (1.2 gpm; 4.5 Lpm)
14 • Autotrol®255 Valve / 400 Series Controls Service Manual SE12

Item No. QTY Part No. Description
............................ 1000210 .............No. 8 (1.6 gpm; 6.1 Lpm)
............................ 1000211 .............No. 9 (2.0 gpm; 7.6 Lpm)
............................ 1000212 .............No. 10 (2.5 gpm; 9.5 Lpm)
............................ 1000213 .............No. 12 (3.5 gpm; 13.2 Lpm)
............................ 1000214 .............No. 13 (4.1 gpm; 15.5 Lpm)**
............................ 1000215 .............No. 14 (4.8 gpm; 18.2 Lpm)**
7.................2........ 1030502 .............Ball, Flow control
8.................1....................................Brine Refill Control:
............................ 1034261 .............1 to 10 lbs Salt
............................ 1034263 .............3 to 19 lbs Salt
9.................1....................................Injector Assembly with O-Rings:
............................ 1032970 ............."A" Injector - White
............................ 1032971 ............."B" Injector - Blue
............................ 1032972 ............."C" Injector - Red
10...............1........ 1000269 .............Injector Cap with O-Ring
12...............1........ 1032416 .............Air Check Kit
13...............1........ 1010429 .............O-Ring BN
14...............1........ 1010428 .............O-Ring EP
15...............1....................................Locking Bar:
............................ 1031402 .............English Language
............................ 1031403 .............French Language
............................ 1031404 .............German Language
............................ 1031405 .............Italian Language
............................ 1031406 .............Japanese Language
............................ 1031407 .............Spanish Language
16...............1........ 1003093 .............Screw, No. 8 x 9/16 inch
17...............1........ 1235341 .............Spring, one pc 255
18...............1........ 3019870 .............i-Lid Cover
19...............1........ 3019873 .............Lever, Locking Cam
Kits:
20......................... 1001404 .............O-Ring Group: Tank Adapter, 1010117 (1), 1010407 (1), 1010410 (4)
21......................... 1040459 .............O-Ring Group: Piping Boss 1010431 (1), 1010411 (2)
22......................... 1041010 .............13/16 Rubber Insert (Optional)
Valve Discs:
*........................... 1000250 .............Standard
* Not Shown
** Flow control does not use Flow Control Ball (1030502).
REPLACEMENT PARTS FOR AUTOTROL 255
CONTROL continued
Autotrol®255 Valve / 400 Series Controls Service Manual SE12 • 15

REPLACEMENT PARTS
TOSET
TIMEOFDA
Y
PULLKNOB
ANDROT
A
TE
MANUAL REGENERAION:
PRESSKNOBANDTURNCOUNTER-
CLOCKWISETO"ST
ART" Ð RELEASE
6PM
3PM
9AM
6AM
3AM
NOON
MIDNIGHT
BACKWASH
ST
ART
CONDITIONED
WATER
FASTRINSE/
REFILL
BRINE/
DAY
SLOWRINSE
B
Y
P
A
S
S
B
Y
P
A
S
S
440i 460i/460TC
Piping Boss
Meter Adapter
256 Bypass Valve
123 1
1
2
1
2
2
Note: Do not use pipe joint compound when
threading pipe into the Noryl piping boss. Use only
plumber tape. Do not overtighten pipe into Noryl
piping boss.
Item No. QTY Part No. Description
1.................1....................................440i Assembly (obsolete)
2.................1....................................460i/460TC Assembly
3.................1....................................Transformer:
............................ 1000810 .............Japanese
............................ 1000811 .............North American
............................ 1000812 .............Australian
............................ 1000813 .............British
............................ 1000814 .............European
*........................... 1030234 .............Transformer Extension Cord 15 foot (4.5 m)
255 Series Accessories
16 • Autotrol®255 Valve / 400 Series Controls Service Manual SE12

Piping Boss
Item No. QTY Part No. Description
1.................1....................................Piping Boss Kit (includes Hardware):
............................ 3023763 .............3/4-inch NPT, S.S. 3/8-inch NPT Drain
............................ 3023749 .............1-inch NPT, S.S. 1/2-inch NPT Drain
............................ 3023761 .............3/4-inch BSPT, S.S. 3/8-inch BSPT Drain
............................ 3023747 .............1-inch BSPT, S.S. 1/2-inch BSPT Drain
............................ 1040279 .............3/4-inch NPT, Noryl 1/2-inch NPT Drain
............................ 1040280 .............1-inch NPT, Noryl 1/2-inch NPT Drain
............................ 1040283 .............3/4-inch BSPT, Noryl 1/2-inch BSPT Drain
............................ 1040284 .............1-inch BSPT, Noryl 1/2-inch BSPT Drain
2.................1........ 1040339 .............Piping Boss Installation Kit
REPLACEMENT PARTS continued
Meter Adapter
Item No. QTY Part No. Description
1.................1........ 1032350 .............Kit, Meter Adapter
2.................1........ 1032351 .............Meter Install Kit
Bypass Valve
Item No. QTY Part No. Description
1.................1........ 1040769 .............Bypass Body Assembly with Install Kit
2.................1........ 1040524 .............Bypass Installation Kit
Bypass Valve
Item No. QTY Part No. Description
*.................1........ 1001606 .............3/4-inch Copper Tube Adapter Kit
*.................1........ 1001670 .............1-inch Copper Tube Adapter Kit
*.................1........ 1041210 .............1-1/4-inch Copper Tube Adapter Kit
*.................1........ 1040547 .............90 Degree Elbow Adapter Kit
*.................1........ 1001608 .............22-mm Copper Tube Adapter Kit
*.................1........ 1001613 .............3/4-inch CPVC Tube Adapter Kit
*.................1........ 1001614 .............1-inch CPVC Tube Adapter Kit
*.................1........ 1001615 .............25-mm CPVC Tube Adapter Kit
*.................1........ 1001769 .............3/4-inch NPT Plastic Pipe Adapter Kit
*.................1........ 1001603 .............1-inch NPT Plastic Pipe Adapter Kit
*.................1........ 1001604 .............3/4-inch BSPT Plastic Pipe Adapter Kit
*.................1........ 1001605 .............1-inch BSPT Plastic Pipe Adapter Kit
*.................1........ 3023824 .............3/4-inch BSPT S.S. Pipe Adapter Kit
*.................1........ 3023828 .............1-inch NPT S.S. Pipe Adapter Kit
*.................1........ 3023807 .............1-inch BSPT S.S. Pipe Adapter Kit
* Not Shown
Autotrol®255 Valve / 400 Series Controls Service Manual SE12 • 17

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.
NOTE: 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.
Problem Possible Cause Solution
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.
Flowing 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.)
Valve Troubleshooting
18 • Autotrol®255 Valve / 400 Series Controls Service Manual SE12

TROUBLESHOOTING continued
Problem Possible Cause Solution
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.)
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 doing so 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.
No salt in brine tank. Add salt to brine tank.
Injector plugged. Clean injector and screen.
Air check valve closes prematurely. Put control momentarily into brine/slow rinse.
Replace or repair air check if needed. (Contact
dealer.)
Control backwashes or purges
at excessively low or high rate.
Incorrect drain controller used. Replace with correct size controller. (Contact
dealer.)
Foreign matter affecting controller
operation.
Remove drain controller and clean ball and seat.
255/440i Troubleshooting
Problem Possible Cause Solution
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 housing.
Fully insert probe into meter housing.
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.)
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 after making certain correct
salt dosage was set.
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.)
255/460i/460TC Troubleshooting
Autotrol®255 Valve / 400 Series Controls Service Manual SE12 • 19

Working Pressure..................................................................................20-120 psi (1.38 - 8.27 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, 100V 50 Hz
Operating Ambient Temperature...........................................................34 °F to 120 °F (1 °C to 49 °C)
Operating Water Temperature...............................................................34 °F to 100 °F (1 °C to 38 °C)
VALVE SPECIFICATIONS
Pentair Residential Filtration LLC
5730 North Glen Park Road
Milwaukee, WI, 53209-4454
USA
262.238.4400 Phone
www.pentairaqua.com 1018075 Rev P SE12