Operations Manual Models: 268 Co-Current Conditioner 263 Three-Cycle Filter
Table of Contents 2 Rev A How To Use This Manual 3 General Warnings And Safety Information 4 System Operation Cycle Functions 6 Equipment Installation 8 Valve Layout 8 Control Layout 9 Location Selection 10 Water Line Connection 12 Drain Line 14 Regenerant Line Connection 15 Overflow Line Connection 16 Electrical Connection 18 Valve Camshaft 19 Disinfection Of Water Conditioners 20 Ultramax Controller 22 Display Icons 23 Keypad — Buttons 24 Things You Might Need to Know
How To Use This Manual This installation manual is designed to guide the installer through the process of installing and starting conditioners featuring the Ultramax series controllers. This manual is a reference and will not include every system installation situation.
General Warnings And Safety Information Electrical There are no user-serviceable parts in the AC adapter, motor, or controller. In the event of a failure, these should be replaced. • All electrical connections must be completed according to local codes. • Use only the power AC adapter that is supplied. • The power outlet must be grounded. • To disconnect power, unplug the AC adapter from its power source.
General • Observe all warnings that appear in this manual. • Keep the media tank in the upright position. Do not turn upside down or drop. Turning the tank upside down will cause media to enter the valve. • Operating ambient temperature is between 34°F (1°C) and 120°F (49°C). • Operating water temperature is between 34°F (1°F) and 100°F (38°C). • Working water pressure range is 20 to 120 psi (1.38 to 8.27 bar). In Canada the acceptable working water pressure range is 20 to 100 psi (1.38 to 6.
System Operation Cycle Functions 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.
Cycle Water Flows From Regenerant Tank SERVICE BACKWASH BRINE/SLOW RINSE To Regenerant Tank REPRESSURIZE System Operation Cycle Functions FAST RINSE BRINE REFILL 7 Rev A
Equipment Installation Valve Layout One Piece Valve Disc Spring Valve Discs Control Module Mount Refill Controller Injector and cap Regenerant Tube Connection Optical Sensor Camshaft Motor Outlet Drain Inlet Backwash Drain Control 8 Rev A Injector Screen Filter Equipment Installation
Control Layout Ultramax Controller LCD Display PM MIN LBS KG x100 Down Button Manual Regen Button Set Button Up Button Refill Sensor Probe Outlet Lockout Connection Secondary Valve Motor Control (not used) AC Adapter (low voltage) Input Main Motor & Optical Sensor Connection Turbine Input or Dry Contact Signal Input Control Layout 9 Rev A
Location Selection Location of a water treatment system is important. The following conditions are required: • Level platform or floor • Room to access equipment for maintenance and adding regenerant (salt) to tank. • Ambient temperatures over 34°F (1°C) and below 120°F (49°C). • Water pressure below 120 psi (8.27 bar) and above 20 psi (1.4 bar). • In Canada the water pressure must be below 100 psi (6.89 bar). • Constant electrical supply to operate the controller.
return to normal. A protective cover should assist with high temperature applications. Location Selection • Insects — The controller and valve have been designed to keep all but the smallest insects out of the critical areas. Any holes in the top plate can be covered with a metal foil ductwork tape. The top cover should be installed securely in place. • Wind — The Ultramax cover is designed to withstand a 30 mph (48 Kph) wind when properly installed on the valve.
Water Line Connection A bypass valve system should be installed on all water conditioning systems. Bypass valves isolate the conditioner from the water system and allow unconditioned water to be used. Service or routine maintenance procedures may also require that the system is bypassed. The illustrations below show the two common bypass methods.
WARNING: Do not use tools to tighten plastic fittings. Over time, stress may break the connections. When the 1265 bypass valve is used, only hand tighten the nuts. WARNING: Do not use petroleum grease on gaskets when connecting bypass plumbing. Use only 100% silicone grease products when installing any Autotrol brand valve. Non-silicone grease may cause plastic components to fail over time. WARNING: Several tube adapters are available to connect the valve to the water plumbing. See Parts List.
Drain Line Drain Line Connection NOTE: Standard commercial practices are expressed here. Local codes may require changes to the following suggestions. Check with local authorities before installing a system. 1. The unit should be above and not more than 20 feet (6.1 m) from the drain. Use an appropriate adapter fitting to connect 1/2-inch (1.3 cm) plastic tubing to the drain line connection of the control valve. 2. If the backwash flow rate exceeds 5 gpm (22.7 Lpm) or if the unit is located 20-40 feet (6.
Regenerant Line Connection (not used with 3-cycle filter system) The regenerant line from the tank connects to the valve. Make the connections and hand tighten. Be sure that the regenerant line is secure and free from air leaks. Even a small leak may cause the regenerant line to drain out, and the conditioner will not draw regenerant from the tank. This may also introduce air into the valve causing problems with valve operation.
Overflow Line Connection (not used with 3-cycle filter system) In the event of a malfunction, the regenerant TANK OVERFLOW will direct “overflow” to the drain instead of spilling on the floor. This fitting should be on the side of the cabinet or regenerant tank. Most tank manufacturers include a post for the tank overflow connector. To connect the overflow line, locate hole on side of tank. Insert overflow fitting into tank and tighten with plastic thumb nut and gasket as shown (Figure 5).
Figure 6 Regenerant Tank Check Valve* (not used with 3-cycle filter system) * Furnished as an option from system manufacturer.
Electrical Connection All Ultramax controllers operate on 12-volt alternating current power supply. This requires use of the GE Water Technologies supplied AC adapter. A variety of AC adapters are available for different applications. These AC adapters are available from your supplier.
Valve Camshaft The front end of the camshaft has an indicator cup. The cup has slots in the outer periphery and numbers on the inside face (Figure 7). The numbers can be seen with the cover off, from the front over the top of the controller. The number at the top indicates which regeneration cycle is currently in progress.
Valve Disc Operation Figure 8 - Ultramax Valve 6 Rinse Drain 4 Outlet Valve 2 Bypass Valve 7 Backwash Drain Valves 3 Inlet Valve 5 Refill Valve 1 Regenerant Valve 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. During normal use, a conditioner may become fouled with organic matter, or in some cases with bacteria from the water supply.
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 [3 mL]) per cubic foot. 2. Regenerant tank conditioners A. Backwash the conditioner and add the required amount of hypochlorite to the well of the regenerant tank.
Ultramax Controller Power Loss Memory Retention The Ultramax series controllers feature battery-free time and date retention during the loss of power. This is designed to last a minimum of 8 hours depending on the installation. The controller will continue to keep time and day in dynamic memory while there is no AC power. The controller will not track water usage on volumetric demand controls in the event of a power failure.
Display Icons Figure 9 1 10 4 9 2 PM MIN LBS KG x100 3 4 5 7 6 8 NOTE: In normal operation and during programming, only a few of the icons will actually be displayed. 1. Displays amount of conditioning capacity remaining. 2. "PM" indicates that the time displayed is between 12:00 noon and 12:00 midnight (there is no AM indicator). PM indicator is not used if clock mode is set to 24-hour. 3. When "MIN" is displayed, the value entered is in minute increments. 4.
Keypad — Buttons 1 2 4 3 1. DOWN arrow. Generally used to scroll down or increment through a group of choices. 2. SET. Used to accept a setting that normally becomes stored in memory. Also used together with the arrow buttons. 3. UP arrow. Generally used to scroll up or increment through a group of choices. 4. Regen. Used to command the controller to regenerate. Programming Conventions The Ultramax controller is programmed using the buttons on the keypad.
Things You Might Need to Know Things You Might Need to Know • When the controller is first plugged in, it may display a flashing Err 3 and scrolling "Call Dealer for Service" message. This means that the controller is rotating to the home position. The Err 3 will clear when the control reaches the home position. • The preset default time of regeneration is 2:00 AM. If you want to change it, see the Level II Programming section.
Programming Overview The Ultramax Series controller is designed to operate by setting the Time of Day, Day of the Week, and the Hardness. The remaining settings are set at the factory using a Model Number. The controller menu has three levels: Level I Basic — This level is easily accessed by the user. Only the Time of Day, Day of Week and Time of Regeneration can be changed in Level I. Level II Professional — This level allows the installer to change settings such as hardness, capacity, and cycle times.
• Setting Day of Week After setting the Time of Day the banner display will show the word “Day” followed by an abbreviated day of the week. SU = Sunday MO = Monday TU = Tuesday WE = Wednesday TH = Thursday FR = Friday SA = Saturday Use the UP or DOWN arrow buttons to change the flashing day of week. Press the SET button when the current day of week is flashing.
Level II Programming Level II program parameters are those parameters used to fine-tune a conditioners operation. These are accessible by pressing and holding the UP and DOWN buttons until the display goes blank. Then release the buttons. Calendar Override is the first Level II parameter displayed.
NOTE: Regeneration on specific day is used to provide regeneration when water demands are not steady. Example: If the weekdays have low usage and the weekend is high, then regeneration every three days will not meet the requirements. The calendar override days between regeneration must be set to zero to enable regeneration on specific days.
The controller is capable of displaying 6 different languages. They are as follows: 1 = English 2 = Spanish 3 = French 4 = Italian 5 = Flemish 6 = German Press the SET button and select the desired language using the UP or DOWN buttons. Press the SET button to accept the selection. • Setting Clock Mode The controller can be programmed to operate with a 12- or 24-hour clock. Program the clock mode to "12" for a 12-hour clock or "24" for a 24-hour clock.
• Operation Type This parameter displays the controller type and is preset at the factory: 268 softener, 263 filter. • Setting the Service Interval The service interval feature is an option that will allow the installer to program the unit to ask for maintenance after a programmed duration. The feature is programmed from 0 (zero) to 99 months.
• Setting the Chlorine Generator/Salt Check (conditioner only) The controller has the capability to produce a low level of chlorine during the brine draw stage of regeneration. It can also sense if there is any brine present during the time when brine draw is occurring.
Level III Programming Historical information can be retrieved from the controller be pressing the SET and DOWN buttons simultaneously, with the controller in the home position. Release both buttons when the controller displays MODEL NUMBER. Press the UP or DOWN buttons to navigate to each setting. The readout will scroll across the top of the display and the value will be displayed below the readout. Upon completing the initial programming procedure the average daily usages will display the same value.
Placing Conditioner Into Operation Conditioner and Filter Start-Up After you have performed the previous initial power-up steps, you will need to place the conditioner into operation. Follow these steps carefully, as they differ from previous Autotrol valve instructions. NOTE: The control valve can be started-up even if power is not yet available to the controller. The valve must be connected to the water supply.
WARNING: If opened too rapidly or too far, media may be lost out of the tank into the valve or the plumbing. In the ¼ open position, you should hear air slowly escaping from the valve drain line. B. When all of the air has been purged from the media tank (water begins to flow steadily from the drain line), open the main supply valve all of the way. This will purge the final air from the tank. C. Allow water to run to drain until the water runs clear from the drain line.
9. Engage the refill cycle to prime the line between the regenerant tank and the valve (conditioner only). A. Slowly open the main water supply valve again, to the fully open position. Be sure not to open too rapidly as that would push the media out of the media tank. B. Advance the controller to the regenerant tank Refill position. From the Backwash 1 cycle, press and hold the SET button. This will display the current cycle.
Performa Exploded View 4 20 7 18 6 11 5 3 16 22 2 8 17 12 1 9 10A 23 14 15 11 10B 21 19 13 Warning: Do not use the flow control ball with #10A.
Performa Parts List Code Part No. Description Qty.
Troubleshooting Ultramax Series Controller Troubleshooting Problem Possible Cause Solution ERR 1 is displayed. Program settings have been corrupted. Press any key and reset model number. ERR 3 is displayed. Controller does not know the position of the camshaft. Camshaft should be rotating to find Home position. Wait for two minutes for the controller to return to Home position. The hourglass should be flashing on the display indicating the motor is running.
System Troubleshooting Problem 1. Brine tank overflow. Possible Cause a. Uncontrolled brine refill flow rate. b. Air leak in brine line to air check. c. Drain control clogged with resin or other debris. 2. Flowing or dripping water at drain or brine line after regeneration. 3. Hard water leakage after regeneration. 4. Control will not draw brine. Solution a. Remove brine control to clean ball and seat. b. Check all connections in brine line for leaks. Refer to instructions. c. Clean drain control. a.
9. Intermittent or irregular regenerant draw. 10. No conditioned water after regeneration. a. Low water pressure. b. Defective injector. a. Set pump to maintain 20 psi at conditioner. b. Replace injector. (Contact dealer.) a. No regenerant in regenerant tank. b. Injector plugged. c. Air check valve closes prematurely. a. Add regenerant to regenerant tank. 11. Backwashes or purges at excessively low or high rate. a. Incorrect drain controller used. a. Replace with correct size controller.
Rev A Troubleshooting
UltraMax System Configurations Upon initial start-up of the UltraMax controller, the software will request a pre-determined model number. This model number populates the default values within the controller, allowing for quick and easy set-up of the software without entering several levels of data. The table below shows the pre-determined model numbers for the controller and the associated primary valve functions for each number. Use the UP and DOWN buttons to scroll through the available model numbers.
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