5
Placing Conditioner into Operation
After all previous steps have been completed, the unit
is ready to be placed into operation. Follow these steps
carefully.
1. Remove control valve cover by first releasing the
plastic clip from the back of the cover. Pull back of
cover slightly outward and lift up.
Note
: The following steps will require turning the
indicator knob (Figure 5 and Figure 6) to various
positions. Manually rotate the camshaft
COUNTERCLOCKWISE
only until indicator knob
points to desired position. (See manual
regeneration sections for each control’s manual
operation.)
2. Rotate indicator knob
COUNTERCLOCKWISE
until it points directly to the word
BACKWASH
.
3. Fill media 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.
IMPORTANT:
If opened too rapidly or too far, media
may be lost. In the 1/4 open 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 main 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.
5. Place the conditioner into operation.
A. With the water supply valve completely open,
carefully advance the indicator knob
COUNTERCLOCKWISE
to the center of the
BRINE REFILL
position. Hold at this position
until water starts to flow through the brine line
into the brine tank. Do not run for more than one
or two minutes.
B. Advance the indicator knob
COUNTERCLOCKWISE
until it points to the
center of the
BRINE/SLOW RINSE
position.
C. 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 water level for at least three
minutes. If the water level does not recede, or if
it goes up, reference the
Troubleshooting
section.
D. Advance the indicator knob
COUNTERCLOCKWISE
to the
SERVICE
position and run water from a nearby faucet
until the water is clear and soft.
Electrical Connection
100 VAC, 115 VAC, and 230 VAC units:
Remove twist
tie from the power cord and extend cord to its full
length. Make sure power source matches the rating
printed on the control. Be certain a wall switch does not
control the outlet.
12 VAC:
Connect the plug of the transformer (supplied)
secondary cable to the mating socket at the rear or
bottom of the timer housing. Be certain the transformer
is secure and is plugged into a power source of correct
voltage that is not controlled by a wall switch.
6
400 Series Control Settings
440i Control
Figure 5
Programming
1. Set days of regeneration on skipper wheel (Figure 5).
•
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 5) during operation.
460i Control
Figure 6
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 6).
Time of Day Setting
With the jumper on the set of pins next to the word
TIME (Figure 7), 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 6) during operation.
Indicator Knob
Timer
Locking Pin
Time Arrow
Timer Knob
Day Arrow
Skipper Pins
Skipper Wheel
PM Indicator
Water Flow Indicator
Hour Time Display
Access Door
Indicator Knob
Time Set Button
Transformer Plug
Receptacle
Jumper
Spare
Raised
Tab
Jumper
Locking Pin
Timer
7
Hardness Setting
Move the jumper to the set of pins next to the word
HARDNESS (Figure 8). 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:
Capacity Setting
Move the jumper to the set of pins next to the word
CAPACITY (Figure 9). 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 (8).
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.”
Common Features
When using the Performa 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 10).
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).
Figure 10
Parts per Million
Grains per Gallon
17.1
=
Figure 7 Figure 8
Figure 9
Indicator Knob
8
1
When using the 440i or 460i you must use Extra Salt cam and divide the suggested setting by 2 to accomplish these settings.
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
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 5) with a wide-blade
screwdriver and turn
COUNTERCLOCKWISE
to
START
to initiate a regeneration. For the 460i, simply
depress the indicator knob (Figure 6). It will take a few
minutes for regeneration to start. A normal regeneration
will take approximately two hours.
Manual Regeneration
Electricity is used only to run the control and to rotate
the camshaft. All other functions are operated by water
pressure. Therefore, in the event of a power outage, all
the regeneration positions may be dialed manually by
depressing the indicator knob and turning
COUNTERCLOCKWISE
(Figure 5 and Figure 6). The
following cycle times should be used for proper
regeneration:
BACKWASH
—14 minutes
BRINE/SLOW RINSE
—52 minutes
FAST RINSE/REFILL
—10 minutes
PURGE
—6 minutes
Do not exceed 10 minutes for the
FAST RINSE/REFILL
cycle as this will cause excessive salt usage during the
next regeneration and possibly a salt residue in the
softened water.
Table 1 – Suggested Salt Dial Settings (Pounds of Salt) For Various Size Softeners
Capacity
Setting
(Kilograins)
0.5 Ft
3
0.75 Ft
3
1.0 Ft
3
1.25 Ft
3
1.5 Ft
3
1.75 Ft
3
2.0 Ft
3
2.5 Ft
3
12 4.5———————
16 9.05.5——————
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 — — — 23.0
1
17.0 14.0 12.0 —
48 ————28.0
1
21.0
1
17.0 14.0
60 ——————30.0
1
21.0
1
9
Removing the Valve Assembly for
Servicing
1. Unplug the power cord.
2. Shut off water supply or put bypass valve(s) into
bypass position.
3. Remove cover and with screwdriver, relieve tank
pressure by pushing open valve No. 7 (rear flapper)
on control as shown (Figure 10).
Figure 10
4. When used with a globe valve bypass, loosen and
detach the inlet, outlet, brine and drain lines from
the valve. If using the 1265 bypass, loosen and
remove valve from bypass as well as loosening and
removing the brine and drain lines.
5. Unscrew valve (counterclockwise) and remove
valve from tank.
6. To replace the control valve, reverse the above
procedure.
Removing 440i or 460i for Servicing
1. Unplug the power cord.
2. Remove cover.
3. Align the indicator arrow on the rear of the
camshaft with the top of the rear hoop of the top
plate (Figure 11).
Figure 11
4. Remove the camshaft by carefully pushing the
securing tab, located at the rear of the camshaft,
away from the camshaft until the tab disengages
from the camshaft. Push the back of the camshaft
down and out to the inlet side of the valve
(Figure 12).
Figure 12
5. Disengage the front of the camshaft from the
output gear of the control.
6. Remove the timer locking pin and lift the control
straight up and off of the valve.
7. To reinstall the camshaft and control, reverse the
above procedures.
Indicator Arrow
10
Preventive Maintenance
Injector Screen and Injector
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. 7
(at rear) with a screwdriver (Figure 10).
4. Using a screwdriver, remove injector screen and
injector cap (Figure 13).
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
only
!
10. Reinstall the injector, injector cap and injector
screen.
IMPORTANT:
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.
11. Plug the wall-mount transformer into outlet; reset
clock if necessary.
12. Slowly open water supply valve or return bypass
valve(s) to the “service” position.
Figure 13
Water Meter Maintenance
Note: A water meter is used only with the 460i control.
If you are using the 440i control, this section does not
pertain to your conditioner.
The metering device used with the 460i demand control
may require simple maintenance. In rare instances, the
turbine wheel of the water meter can collect small
particles of oxidized iron, eventually preventing the
wheel from turning.
1. Shut off the water supply or put the bypass valve(s)
into the bypass position.
2. Relieve pressure by opening the Backwash Drain
Valve (the seventh back from the control) with a
screwdriver (Figure 10).
3. Loosen and remove the pipe/tube adapters or
1265 bypass from the inlet and outlet of the valve
body.
4. Using a needle-nose pliers, remove the turbine
from the outlet housing. Grasp one of the four
vanes of the outer gland and pull straight out to
remove turbine assembly from the outlet of the
valve (Figure 13).
5. Carefully remove the turbine wheel from the
housing. Use a toothbrush to lightly scrub the iron
off the magnet. Iron buildup on the surfaces can be
removed by soaking the wheel in a mild sodium
hydrosulfite (such as RoVer*) solution for a few
minutes. Flush thoroughly with water.
6. Carefully reinstall the turbine wheel into the turbine
cage housing. Make sure that the shaft of the wheel
seats into the bearing of the cage. Reassemble the
turbine cage and check that the wheel rotates
freely.
7. Reinstall the turbine cage into the outlet of the
valve.
8. Reinstall the pipe/tube adapters or 1265 bypass to
the inlet and outlet of the valve.
9. Turn on the water supply or put the bypass valve(s)
into the service position and purge the air out of the
system.
To check for proper meter operation, open a
downstream faucet and observe the water flow
indication on the control display.
Injector
Injector Screen
Cap
Turbine
*RoVer is a trademark of Hach Chemical Company
.
11
Specifications
Hydrostatic Test Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 psi (20.69 bar)
Working Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-125 psi (1.38 - 8.62 bar)
Standard Electrical Rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115V 60 Hz
Optional Electrical Rating . . . . . . . . . . . . . . . . . . . . . . 115V 50 Hz, 230V 50 Hz, 200V 60 Hz, 24V 60 Hz, 24V 50 Hz,
100V 60 Hz, 100V 50 Hz, 12V 50 Hz/transformer, 12V 60 Hz/transformer
Electrical Cord (standard rating) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 inch (1.5 m) 3-wire with plug
Pressure Tank Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1/2 inch-8 male
Riser Pipe Diameter Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.050 inch OD (26.7 mm)
Riser Pipe Length . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1/8 ±1/8 inches (31.8 mm) higher than the top of mineral tank
Standard Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-inch (25.4-mm) copper tube adapters
Optional Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3/4-inch, 22-mm, and 28-mm copper tube adapters
3/4-inch BSPT, 1-inch BSPT, 1-inch NPT brass pipe adapters
3/4-inch, 1-inch, 25-mm CPVC tube adapters
Brine Line Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8-inch NPT male
Drain Line Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4-inch NPT male
Optional Bypass Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rotating handles, full 1-inch porting, reinforced Noryl
Control Module, Tank Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reinforced Noryl
Rubber Goods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compounded for cold water service
Program Clock (Timer). . . . . . . . 440i: Available in 6- or 7-day English, German, French, Italian, Spanish, Japanese
460i: Available in English, German, French, Italian, Spanish, Japanese
Brine Refill Control. . . . . . . . . . . . . . . . . . . . . . . 1 to 10 lbs (0.45 to 4.5 kg) of salt or 3 to 19 lbs (1.4 to 8.6 kg) of salt
Injector Size “A” White . . . . . . . . . . . . . . . .Nozzle 042-inch (1.1-mm) diameter, Throat .089-inch (2.3-mm) diameter
Injector Size “B” Blue . . . . . . . . . . . . . . . . Nozzle .052-inch (1.3-mm) diameter, Throat .099-inch (2.5-mm) diameter
Injector Size “C” Red. . . . . . . . . . . . . . . . . Nozzle .059-inch (1.5-mm) diameter, Throat .099-inch (2.5-mm) diameter
Injector Size "D" Green . . . . . . . . . . . . . . . Nozzle .071-inch (1.8-mm) diameter, Throat .147-inch (3.7-mm) diameter
Internal Backwash Controllers. . . . . . . . . . . . . . . . 7- through 14-inch (17.8- though 35.6-cm) diameter media tanks
All sizes to flow 4.5 gpm/sq ft (183 L/m/m
2
) of bed area.
For tank sizes above 14 inches in diameter, use an external flow control.
3.37-inch (86 mm)
3.66-inch (93 mm)
5.76 inch (146 mm)
5.82 inch (148 mm)
2.88 inch (73 mm)
2.5 inch (63 mm)
2.5 inch (63 mm)
11.59 inch (294 mm)
1.356 inch (34 mm)
8.74 inch (222mm)
Inlet
Outlet
Drain
12
Pressure Graphs
0.20
0.15
0.10
0.05
0.00
1.00
0.75
0.50
0.25
0.00
20 40 60 80 100 120
400 600 800 1000 1200 1400 1600 1800
Brine Draw
Rinse
Total
PSI
bar
M /hr
3
GPM
Injector #1031363
"A" in a 268 Valve
1.75
1.50
1.25
1.00
0.75
0.50
0.25
0.00
0.20
0.15
0.10
0.05
0.00
20 40 60 80 100 120
400 600 800 1000 1200 1400 1600 1800
Brine Draw
Rinse
Total
PSI
bar
M /hr
3
GPM
Injector #1031365
"C" in a 268 Valve
20 40 60 80 100 120
400 600 800 1000 1200 1400 1600 1800
Brine Draw
Rinse
Total
PSI
bar
M /hr
3
GPM
Injector #1031364
"B" in a 268 Valve
0.30
0.25
0.20
0.15
0.10
0.05
0.00
1.25
1.00
0.75
0.50
0.25
0.00
20 40 60 80 100 120
400 600 800 1000 1200 1400 1600 1800
PSI
bar
M /hr
3
GPM
Injector #1030272
"D" in a 268 Valve
0.30
0.25
0.20
0.15
0.10
0.05
0.00
2.25
2.00
1.75
1.50
1.25
1.00
0.75
0.50
0.25
0.00
Brine Draw
Rinse
Total
Backwash Number 7 8 9 10 12 13 14
Flow (GPM*) 1.2 1.6 2.0 2.5 3.5 4.1 4.8
Flow (LPM*) 4.5 6.0 7.6 9.5 13.2 15.5 18.2
*Approximate flow rates at 60 psi (4.14 bar)
13
Identification of Control Valving
2 Backwash Position
1 Brine Valve
2 Bypass Valve
3 Inlet Valve
4 Outlet Valve
5 Refill Valve
6 Rinse Drain Valve
7 Backwash Drain Valves
Flow Diagrams
Mineral Tank
Brine
Adjustment
Brine Tank
Mineral Tank
Drain
Inlet
Outlet
Hard Water
Soft Water
5
4
1
3
2
6
7
Mineral Tank
Brine
Adjustment
Brine Tank
Mineral Tank
Drain
Inlet
Outlet
Hard Water
Soft Water
5
4
1
3
2
6
7
Backwash
Flow
Control
Valve
No.
1 - Closed
2 - Closed
3 - Open
4 - Open
5 - Closed
6 - Closed
7 - Closed
Valve
No.
1 - Closed
2 - Open
3 - Closed
4 - Open
5 - Closed
6 - Closed
7 - Open
1 Service Position
Valve Disc Principle of Operation
14
3 Brining/Slow Rinse Position
4 Purge Position
Brine
Adjustment
Brine Tank
Mineral Tank
Drain
Inlet
Outlet
Hard Water
Soft Water
5
4
1
3
2
6
7
Brine
Adjustment
Brine Tank
Mineral Tank
Drain
Inlet
Outlet
Hard Water
Soft Water
5
4
1
3
2
6
7
Mineral Tank
Brine
Adjustment
Brine Tank
Mineral Tank
Drain
Inlet
Outlet
Hard Water
Soft Water
5
4
1
3
2
6
7
Valve
No.
1 - Open
2 - Open
3 - Closed
4 - Closed
5 - Closed
6 - Open
7 - Closed
Valve
No.
1 - Closed
2 - Open
3 - Open
4 - Closed
5 - Closed
6 - Open
7 - Closed
Valve
No.
1 - Closed
2 - Closed
3 - Open
4 - Open
5 - Open
6 - Closed
7 - Closed
5 Brine Refill Position
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