Pentair AUTOTROL368 User guide

www.pentairaquaeurope.com
INSTALLER
MANUAL
AUTOTROL
368 (604-606)
RESIDENTIAL

Installer manual Autotrol 368 (604-606) - Table of Contents
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Table of Contents
1 Generalities..................................................................................... 5
1.1 Scope of the documentation ....................................................................... 5
1.2 Release management ................................................................................. 5
1.3 Manufacturer identifier, product ................................................................ 5
1.4 Abbreviations used...................................................................................... 6
1.5 Norms.......................................................................................................... 6
1.5.1 Applicable norms ................................................................................................ 6
1.5.2 Available certificates........................................................................................... 7
1.6 Procedure for technical support................................................................. 7
1.7 Copyright and Trademarks ......................................................................... 7
1.8 Limitation of liability.................................................................................... 7
1.9 Scan & Service application.......................................................................... 8
2 Safety .............................................................................................. 9
2.1 Safety pictograms definition ....................................................................... 9
2.2 Serial label location..................................................................................... 10
2.3 Hazards........................................................................................................ 10
2.3.1 Personnel ............................................................................................................ 10
2.3.2 Material ............................................................................................................... 11
2.4 Hygiene and sanitization ............................................................................. 11
2.4.1 Sanitary issues .................................................................................................... 11
2.4.2 Hygiene measures............................................................................................... 11
3 Description ...................................................................................... 12
3.1 Technical specifications .............................................................................. 12
3.2 Performance flow rate characteristics....................................................... 13
3.3 Outline drawing ........................................................................................... 13
3.4 Components description and location ........................................................ 14
3.5 System regeneration cycle (8-cycles operation) ........................................ 17
4 System sizing................................................................................... 19
4.1 Injector/DLFC/Refill flow controller - Valve configuration ........................ 19
4.2 Cycle time calculation ................................................................................. 19
4.3 Salt amount definition ................................................................................. 19
4.4 Injector flow rates ....................................................................................... 19
5 Installation ...................................................................................... 21
5.1 Safety notices for installation ..................................................................... 21
5.2 Installation environement ........................................................................... 21

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5.2.1 General ................................................................................................................ 21
5.2.2 Electrical ............................................................................................................. 21
5.2.3 Mechanical .......................................................................................................... 22
5.3 Integration constraints................................................................................ 22
5.4 Valve connection to piping........................................................................... 23
5.4.1 Top-mounted valve installation .......................................................................... 23
5.5 Block diagram and configuration example................................................. 25
5.6 Electrical connections................................................................................. 26
5.7 Drain line flow controller ............................................................................ 26
5.8 Bypassing .................................................................................................... 27
5.8.1 Bypass assembly................................................................................................. 27
5.9 Drain line connection .................................................................................. 28
5.10 Overflow line connection............................................................................. 30
5.11 Brine line connection .................................................................................. 31
6 Programming .................................................................................. 32
6.1 Display ......................................................................................................... 32
6.2 Commands .................................................................................................. 32
6.3 Programming mode chart........................................................................... 33
6.4 Time of day .................................................................................................. 34
6.5 Brine dosage ............................................................................................... 34
6.6 Time clock regeneration (604only)............................................................. 34
6.7 Volumetric regeneration (606only) ............................................................ 34
6.8 Calendar override setting (606only)........................................................... 35
6.9 System selection ......................................................................................... 35
6.9.1 Programmed settings ......................................................................................... 35
6.10 Resetting the controller .............................................................................. 36
6.11 History values.............................................................................................. 36
7 Commissioning................................................................................ 38
7.1 Water filling, draining and waterproofness inspection .............................. 38
7.1.1 Start up procedure .............................................................................................. 38
7.2 Sanitization .................................................................................................. 39
7.2.1 Disinfection of water softeners........................................................................... 39
7.2.2 Sodium or calcium hypochlorite ......................................................................... 39
7.2.3 Electro chlorination............................................................................................. 40
8 Operation......................................................................................... 41
8.1 Recommendations ...................................................................................... 41
8.2 Manual regeneration................................................................................... 41
8.3 To advance regeneration cycles.................................................................. 41

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8.4 To cancel a regeneration ............................................................................ 41
9 Maintenance .................................................................................... 43
9.1 General system inspection.......................................................................... 43
9.1.1 Water quality ....................................................................................................... 43
9.1.2 Mechanical Checks ............................................................................................. 43
9.1.3 Regeneration test................................................................................................ 43
9.2 Recommended maintenance plan .............................................................. 44
9.3 Recommendations ...................................................................................... 45
9.3.1 Use original spare parts...................................................................................... 45
9.3.2 Use original approved lubricants........................................................................ 45
9.3.3 Maintenance instructions ................................................................................... 45
9.4 Cleaning and maintenance.......................................................................... 45
9.4.1 First steps............................................................................................................ 45
9.4.2 Refill flow controller cleaning ............................................................................ 46
9.4.3 Injector and injector screen cleaning ................................................................. 46
9.4.4 Backwash flow controller cleaning .................................................................... 47
9.4.5 Manifold/bypass removal.................................................................................... 48
9.4.6 Motor and camshaft replacement ...................................................................... 49
9.4.7 Flappers cleaning or replacement ..................................................................... 50
9.4.8 Valve on tank assembly....................................................................................... 53
10 Troubleshooting .............................................................................. 54
11 Spare parts...................................................................................... 56
11.1 368 – 604/606 parts list ............................................................................... 56
12 Disposal........................................................................................... 58

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1 Generalities
1.1 Scope of the documentation
The documentation provides the necessary information for appropriate use of the product. It
informs the user to ensure efficient execution of the installation, operation or maintenance
procedures.
The content of this document is based on the information available at the time of publication. The
original version of the document was written in English.
For safety and environmental protection reasons, the safety instructions given in this
documentation must be strictly followed.
This manual is a reference and will not include every system installation situation. The person
installing this equipment should have:
• training in the Autotrol series, (604-606) controllers and water softener installation;
• knowledge of water conditioning and how to determine proper controller settings;
• basic plumbing skills.
This document is available in other languages on https://www.pentairaquaeurope.com/product-
finder/product-type/control-valves.
1.2 Release management
Revision Date Authors Description
A 11.07.2016 STF/FLA First edition.
B 23.05.2018 BRY/FLA Address change, Bleam information and valve on
tank assembly.
C 11.10.2019 STF General corrections.
D 09.10.2020 STF General corrections.
1.3 Manufacturer identifier, product
Manufacturer: Pentair International LLC
Avenue de Sevelin 18
1004 Lausanne
Switzerland
Product: Autotrol 368 (604-606)

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1.4 Abbreviations used
Assy Assembly
BLFC Brine Line Flow Controller
DF Down Flow
DLFC Drain Line Flow Controller
HW Hot Water
Inj Injector
QC Quick Connect
Regen Regeneration
SBV Safety Brine Valve
TC Time Clock
1.5 Norms
1.5.1 Applicable norms
Comply with the following guidelines:
• 2006/42/EC: Machinery Directive;
• 2014/35/UE: Low Voltage Directive;
• 2014/30/UE: Electromagnetic compatibility;
• 2011/65/UE: Restriction of use of certain hazardous substances in electrical and electronic
equipment (RoHS);
• UNI EN ISO9001.
Meets the following technical standards:
• IEC/EN 60335-1;
• IEC 61010-1;
• EN 55014-1;
• EN 55014-2;
• EN 61000-3-2: 2006 + A1: 2009 + A2: 2009;
• EN 61000-3-3: 2008;
• EN 61000-6-2: 2005;
• EN 61000-6-3: 2007 + A1: 2011;
• EN 61326-1.

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1.5.2 Available certificates
• CE;
• DM174;
• ACS.
Please find beside the certifications for some of our
product families. Please note that this list is not an
exhaustive list of all our certifications. In case of need
for more information please contact us.
1.6 Procedure for technical support
Procedure to follow for any technical support request:
1. Collect the required information for a technical assistance request.
ðProduct identification (see Serial label location [→Page10] and Recommendations
[→Page41]);
ðDescription of the device problem.
2. Please refer to the Troubleshooting [→Page54]. If the problem persists contact your
supplier.
1.7 Copyright and Trademarks
All indicated Pentair trademarks and logos are property of Pentair. Third party registered and
unregistered trademarks and logos are the property of their respective owners.
© 2020 Pentair. All rights reserved.
1.8 Limitation of liability
Pentair Quality System EMEA products benefit, under specific conditions, from a manufacturer
warranty that may be invoked by Pentair’s direct customers. Users should contact the vendor of
this product for applicable conditions and in case of a potential warranty claim.
Any warranty provided by Pentair regarding the product will become invalid in case of:
• installation done by a non-water-professional;
• improper installation, improper programming, improper use, improper operation and/or
maintenance leading to any kind of product damages;
• improper or unauthorized intervention on the controller or components;
• incorrect, improper or wrong connection/assembly of systems or products with this product
and vice versa;
• use of a non-compatible lubricant, grease or chemicals of any type and not listed by the
manufacturer as compatible for the product;
• failure due to wrong configuration and/or sizing.
Pentair accepts no liability for equipment installed by the user upstream or downstream of Pentair
products, as well as for process/production processes which are installed and connected around
or even related to the installation. Disturbances, failures, direct or indirect damages that are
caused by such equipment or processes are also excluded from the warranty. Pentair shall not
accept any liability for any loss or damage to profits, revenues, use, production, or contracts, or
for any indirect, special or consequential loss or damage whatsoever. Please refer to the Pentair
List Price for more information about terms and conditions applicable to this product.

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1.9 Scan & Service application
Scan & Service mobile application is the ideal support for the maintenance person in his daily
business. A simple scan of an identification (ID) label (1) present on the valve with a smartphone
gives an instantaneously access to all updated information related to the product, such as:
• valve’s and tanks detailed configuration;
• manuals;
• spare parts lists;
• troubleshooting recommendations;
• multi-lingual videos, detailing how to best service a part;
• informations about new products, latest technologies, novelties about the Blue Network
program, etc.
1. Download the application "Scan & Service" from or in a
smartphone(4).
2. Open the application "Scan & Service".
3. Scan the bleam(3) stuck on the valve(2).
4. Navigate to find information.

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2 Safety
2.1 Safety pictograms definition
DANGER
This combination of symbol and keyword indicates an imminently hazardous situation
that will result in serious or fatal injury if not avoided.
WARNING
This combination of symbol and keyword indicates a potentially hazardous situation
that can result in serious or fatal injury if not avoided.
CAUTION
This combination of symbol and keyword indicates a potentially hazardous situation
that can result in minimal or minor injury if not avoided.
Caution - material
This combination of symbol and keyword indicates a potentially hazardous situation
that can result in material damage if not avoided.
Prohibition
Mandatory advice to follow.
Mandatory
Applicable guideline, measure.
Info
Informative comment.

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2.2 Serial label location
Model
Part number
Electrical rating
Production date
Production order
Serial number
Mandatory
Ensure that the serial label and the safety labels on the device are completely legible
and clean!
If necessary, replace them with new labels in the same positions.
2.3 Hazards
All the safety and protection instructions contained in this document must be observed in order to
avoid temporary or permanent injury, damage to property or environmental pollution.
At the same time, any other legal regulations, accident prevention and environmental protection
measures, as well as any recognized technical regulations relating to appropriate and risk-free
methods of working which apply in the country and place of use of the device must be adhered to.
Any non-observation of the safety and protection rules, as well as any existing legal and technical
regulations, will result in a risk of temporary or permanent injury, damage to property or
environmental pollution.
2.3.1 Personnel
CAUTION
Risk of injury due to improper handling!
Only qualified and professional personnel, based on their training, experience and
instruction as well as their knowledge of the regulations, safety rules and operations
performed, are authorized to carry out necessary work.

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2.3.2 Material
The following points must be observed to ensure proper operation of the system and the safety of
user:
• be careful of high voltages present on the transformer (100 – 240V);
• do not put your fingers in the system (risk of injuries with moving parts and shock due to
electric voltage).
2.4 Hygiene and sanitization
2.4.1 Sanitary issues
Preliminary checks and storage
• Check the integrity of the packaging. Check that there is no damage and no signs of contact
with liquid to make sure that no external contamination occurred;
• the packaging has a protective function and must be removed just before installation. For
transportation and storage, appropriate measures should be adopted to prevent the
contamination of materials or the objects themselves.
Assembly
• Assemble only with components which are in accordance with drinking water standards;
• after installation and before use, perform one or more manual regenerations in order to
clean the media bed. During such operations, do not use the water for human consumption.
Perform a disinfection of the system in the case of installations for treatment of drinking
water for human use.
Info
This operation must be repeated in the case of ordinary and extraordinary
maintenance. It should also be repeated whenever the system remains idle for a
significant time.
Valid only for Italy
In case of equipment used in accordance with the DM25, apply all the signs and
obligations arising from the DM25.
2.4.2 Hygiene measures
Disinfection
• The materials used for the construction of our products meet the standards for use with
potable water; the manufacturing processes are also geared to preserving these criteria.
However, the process of production, distribution, assembly and installation, may create
conditions of bacterial proliferation, which may lead to odor problems and water
contamination;
• it is therefore strongly recommended to sanitize the products. See Sanitization [→Page39] ;
• maximum cleanliness is recommended during the assembly and installation;
• for disinfection, use Sodium or Calcium Hypochlorite and perform a manual regeneration.

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3 Description
3.1 Technical specifications
Design specifications/ratings
Valve body Glass-filled Noryl ®
Rubber components Compounded for cold water
Weight (valve with controller) 1.8 kg
Recommended operating pressure 1.4- 8.6 bar
Water temperature 1- 38°C
Ambient temperature* 2- 50°C
Refill flow rate 0.53L/min- 1.25L/min
*Recommended for indoor use only.
Flow rates (valve only)
Service at 1.05bar drop 3.77m3/h
Backwash at 1.09bar drop 0.62 m3/h
Service Kv= 3.68 (Cv= 4.25)
Backwash Kv= 0.48 (Cv= 0.55)
Valve connections
Tank Thread 63.5mm(2½")- 8, male
Inlet/Outlet Thread 19mm(¾") BSPT, male
Drain line 12.7mm(½") BSPT, male
Brine line 9.5mm(⅜") BSPT male
Riser tube[Ø] 27mm(1.05")
Riser tube length Flush to top of tank ±12.7mm(½")
Electrical
Controller Operating Voltage 12VAC (requires use of Pentair Water supplied
transformer)
Input Supply Frequency 50 or60Hz
Motor Input Voltage 12VAC
Controller Power Consumption 6W average
Protection rating IP23

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3.2 Performance flow rate characteristics
The graph shows the pressure drop created by the valve itself at different flow rates. It allows
predetermining the maximum flow rate going through the valve depending on the system settings
(inlet pressure etc). It also allows to determine the valve pressure drop at a given flow rate, and
therefore to evaluate the system pressure drop vs flow rate.
FLOW RATE VS PRESSURE DROP
Flow rate [m³/h]
Pressure drop [bar] Pressure drop [bar]
Flow rate [m³/h]
3.3 Outline drawing

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3.4 Components description and location
Time button
Display
Delayed regeneration indicator
Regeneration button
Camshaft indicator
Injector & screen
Refill flow controller
Valve connection
Cover locker
Salt button
Regeneration setting button
Flow indicator

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Meter cable (368/606 only)
90° Elbow
Drain
Cable gland (368/606 only)
Brine tank tube connection
Manifold connection
Bypass
Inlet
Locking bars
Outlet
Turbine (368/606 only)
Flow controller
Flow controller ball

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Flappers
Camshaft
Motor
Optical sensor
One-piece valve disc spring

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3.5 System regeneration cycle (8-cycles operation)
Service (downflow) — cycle C0
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 raw water being
exchanged on the resin beads against sodium ions. The water is conditioned as it passes through
the resin bed.
Backwash (upflow) — cycle C1
The flow of water is reversed by the valve and directed down the riser tube and up through the
resin bed. During the backwash cycle, the bed is expanded and debris are flushed to the drain,
while the media bed is remixed.
Brine draw (downflow) & slow rinse — cycle C2
The valve directs water through the brine injector and brine is drawn from the brine tank. The
brine is then directed down through the resin bed and up through the riser tube to the drain. The
hardness ions on the resin beads are replaced by sodium ions and are sent to the drain. The resin
is regenerated during the brine cycle. When the air check valve closes brine draw finishes, and
then the slow rinse phase starts.
Repressurization cycle — cycle C3
This cycle allows the air and water to hydraulically balance in the valve before continuing the
regeneration.
Rapid rinse (downflow) — cycle C4
The valve directs water down through the resin bed and up through the riser tube to the drain. Any
residual brine is rinsed from the resin bed, while the media bed is recompacted.
2nd Backwash (upflow) — cycle C5
2nd Rapid rinse (downflow) — cycle C6
Brine refill — cycle C7
Water is directed to the brine tank at a rate controlled by the refill flow controller, to prepare brine
for the next regeneration. During brine refill cycle, treated water is already available at the valve
outlet.
Info
For illustration purpose only. Always verify inlet and outlet marking on the valve.

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SERVICE
C0
BRINE/SLOW RINSE
C2
REPRESSURIZE
C3
BACKWASH
C1 and C5
RAPID RINSE
C4 and C6
BRINE REFILL
C7
Valve Valve
Valve
Valve
Valve
Valve
Outlet
Outlet
Outlet
Outlet
Outlet
Outlet
Inlet
Inlet
Inlet Inlet
Inlet
Inlet
Drain
Drain
Drain
From brine tank
To brine
tank

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4 System sizing
4.1 Injector/DLFC/Refill flow controller - Valve configuration
Vessel
diameter
[In]
Injector Flow
control
Refill flow
control
[gpm]
Backwash flow
control
[gpm]
Controller
Time Clock 604
Controller
Volumetric 606
6 E [yellow] 0.14 0.9 4001737 4001738
7 F [peach] 0.14 1.2 4001737 4001738
8 G [tan] 0.14 1.6 4001737 4001738
9 H [lt purple] 0.14 2.0 4001737 4001738
10 J [lt blue] 0.33 2.5 4001741 4001742
4.2 Cycle time calculation
The 600 series controller will automatically set the cycle time based on the program or so called
unit number selected when programming the system (see System selection [→Page35]). Make
sure the programmed unit# is corresponding to your actual system and valve configuration.
4.3 Salt amount definition
The salt amount is set in kilograms of salt use for each regeneration. This setting will greatly
influence the system. Make sure this setting is aligned with your actual system size and unit#
programmed.
4.4 Injector flow rates
The following graphs represent the injectors flow rate as a function of the inlet pressure for the
different injector sizes.

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TOTAL BRINE DRAW RINSE
Injector "E" (Yellow)
For 6" Tanks
Injector "F" (Peach)
For 7" Tanks
Injector "G" (Tan)
For 8" Tanks
Injector "H" (Light Purple)
For 9" Tanks
Injector "J" (Light Blue)
For 10" Tanks
Inlet pressure [bar] Inlet pressure [bar]
Inlet pressure [bar] Inlet pressure [bar]
Inlet pressure [bar]
Flow rate [l/min]Flow rate [l/min]
Flow rate [l/min] Flow rate [l/min]
Flow rate [l/min]