Custom Order Ion Exchange Water Softener

Custom Order Ion Exchange Water Softener With Autotrol 255 Control Valve and 460i

Choose The Resin according to the type of problem that you are having with your water supply, kindly review the specs below and choose the right resin.

Ion exchange: which resin should I choose for my water softener?

Creating a custom order for an ion exchange water softener involves several steps to ensure that the system is tailored to meet specific water softening needs. Here’s a general guide:

Step 1: Water Analysis

• Hardness Level: Determine the grains per gallon (gpg) or parts per million (ppm) of calcium and magnesium.
• Iron Content: Check for iron content which can also be removed by some softeners.
• Other Contaminants: Identify any additional contaminants that need to be addressed.

Step 2: Determine Size and Capacity

• Daily Water Usage: Estimate the average daily water usage in your household or facility.
• Peak Flow Rate: Identify the peak flow rate (gallons per minute, gpm) to ensure the softener can handle usage during peak times.
• Grain Capacity: Calculate the total grain capacity needed by multiplying daily water usage by the hardness level.

Step 3: Choose the Type of System

• Single vs. Dual Tank: Decide whether a single-tank system or a dual-tank system is more appropriate based on your continuous water need.
• Metered vs. Timed: Choose between a metered system (regenerates based on actual usage) or a timed system (regenerates at set intervals).

Step 4: Resin and Media Selection

• Type of Resin: Choose the appropriate resin type (standard, fine mesh, or specialty resin) based on your water analysis.
• Brine Tank: Decide on the size and type of brine tank that will be used for regeneration.

Step 5: Control Valve

• Type: Choose a control valve that suits your needs (manual, semi-automatic, or fully automatic).
• Features: Look for features like flow rate display, regeneration settings, and bypass options.

Step 6: Additional Features

• Pre-filters: Consider adding pre-filters to remove sediment or chlorine before the water reaches the softener.
• Post-filters: Think about post-filters to further purify the softened water.
• Smart Features: Explore options for smart controls, such as Wi-Fi connectivity and remote monitoring.

Step 7: Installation and Maintenance

• Installation: Decide whether to install the system yourself or hire a professional.
• Maintenance Plan: Establish a maintenance plan for salt replenishment, resin bed cleaning, and other periodic checks.

Step 8: Compliance and Warranty

• Compliance: Ensure the system complies with local regulations and industry standards.
• Warranty: Check the warranty and understand the terms and conditions for parts and labor.

Step 9: Supplier and Manufacturer

• Reputation: Research and choose a reputable supplier and manufacturer.
• Support: Ensure they provide adequate support and guidance during and after installation.

Step 10: Place the Order

The percentage of cross-linking (e.g., 8% or 10%) refers to the degree to which the polymer chains in the resin are interconnected. Let's delve a bit into the characteristics and differences between high-capacity 10% cross-link resin and high-capacity 8% cross-link resin:

High Capacity 10% Cross Link Resin

1. Durability: Generally, a 10% cross-link resin tends to have a higher durability compared to an 8% cross-link resin because of the additional cross-linking. This makes it more resistant to physical and oxidative breakdown.

2. Capacity: While it is a high-capacity resin, the actual ion exchange capacity might be slightly lower than its 8% counterpart due to the additional cross-linking, which can reduce the number of available ion exchange sites.

3. Resistance to Fouling: The 10% cross-link resin typically has better resistance to fouling (from iron, manganese, etc.) and oxidation (from chlorine or chloramine) compared to 8% cross-link resin.

4. Price: Often, 10% cross-link resins are more expensive than 8% cross-link resins due to the additional material and processing required to achieve the higher cross-linking.

5. Applications: Ideal for applications where the resin will be exposed to higher levels of oxidants or where a longer resin life is desired.

High Capacity 8% Cross Link Resin

1. Capacity: 8% cross-link resins generally have a slightly higher ion exchange capacity compared to 10% cross-link resins because there are more available sites for ion exchange due to the lower degree of cross-linking.

2. Regeneration Efficiency: Typically, 8% cross-link resins might require less salt during regeneration, making them slightly more efficient in this regard.

3. Price: Generally less expensive than 10% cross-link resins, making them a cost-effective choice for many standard applications.

4. Physical Properties: While still durable, 8% cross-link resins may be somewhat less robust than 10% cross-link resins when exposed to oxidizing agents or fouling conditions.

5. Applications: Often used in standard residential and some commercial water softening applications where the water to be treated is not highly oxidizing and the resin is not expected to be exposed to harsh conditions.

Choosing Between 8% and 10% Cross Link Resin

• Water Quality: If the water contains oxidizing agents like chlorine or chloramines, or has a high fouling potential, a 10% cross-link resin might be preferable.

• Budget: If budget constraints are a significant factor, and the water to be treated is not highly challenging, an 8% cross-link resin might be a suitable choice.

• Application: For general water softening where the water is not highly oxidizing, an 8% cross-link resin is often adequate. For more demanding applications, a 10% cross-link resin might be worth the additional investment.

Always consider consulting with a water treatment specialist or a resin supplier to determine the most suitable resin type for a specific application, as the optimal choice can depend on various factors, including water quality, operating conditions, and system design

 

Question:

If you are researching water softener options you may have read about the different types of resin that can be used in a softening system. The ion exchange resin is the media that actually softens your water and so the quality of the resin inside your softener will in large part determine the life expectancy of the softener. So, what type of resin should you choose?

Answer:

In short, we recommend using the High Capacity 8% Cross Link Resin. However, you may have already read about 10% Cross Link Resin and Fine Mesh Resin. The next few paragraphs will explain the differences between these three options and why we are recommending the 8% Cross Link.

Most water softener dealers use what is called High Capacity 8% Cross Link Resin. In our experience, this type of resin will last for about 20-25 years on city water that is not pre-softened. If you live in or other another city that pre-softens the water, the life expectancy of your resin will be longer because the resin bed isn’t being exhausted as often. In most city water situations, the 8% Cross Link Resin is going to work the best.

If you own a home with a person well, we recommend Fine Mesh Resin, which is made up of smaller resin beads than the standard High Capacity Resin. The smaller bead size means that your water will have more surface area contact with the resin and therefore the resin will be able to better remove the added minerals that are present in unfiltered well water. For the Fine Mesh Resin, you will also need an upper flow basket for your water softener so that the resin beads do not “discharge” out of the softener when it regenerates.

You may have also read about High Capacity 10% Cross Link Resin. Lately, we have had a number of homeowners wondering if they need the 10% versus the 8% cross-link. The “cross-link” refers to the bonds inside the resin bead. The 10% resin has more bonds that hold the beads together so that they will last longer. Over time, resin beads will fracture and break down into a mush-like paste. When this eventually happens, either the resin or the entire softener system needs to be replaced. In our opinion, the additional links in the 10% resin are not worth the dramatic increase in cost. You may pay up to 30-50% more for this slightly higher-grade resin, but the added value you will get may only be for a couple of years.

 Autotrol 255 Control Valve and 460i Demand Control

The Autotrol 255 Control Valve and 460i Demand Control are popular components in water softening systems. Below is a general overview and some features of these components:

Autotrol 255 Control Valve

The Autotrol 255 control valve is widely used in water softening applications due to its reliability and durability. Here are some key features and aspects:

• Reliability: Known for its robustness and reliable performance in various water treatment applications.
• Flow Rates: Capable of handling various flow rates to accommodate different sizes of residential and light commercial water softeners.
• Bypass Valve: Often comes with a bypass valve, allowing you to bypass the softener for uses like outdoor watering.
• Ease of Service: Designed to be easy to service with replaceable parts and straightforward disassembly.

Autotrol 460i Demand Control

The Autotrol 460i is an electronic control that automates the regeneration cycle of a water softener. Some features and aspects include:

• Microprocessor Control: Utilizes a microprocessor to monitor and control regeneration cycles based on actual water usage, making it efficient and economical.
• LCD Display: Often features an LCD display that provides useful information such as time of day, days until the next regeneration, and current flow rates.
• Easy Programming: Allows for easy programming of regeneration settings and other parameters.
• Demand-Initiated Regeneration: Only regenerates when necessary based on water usage, saving salt and water.
• Power Interruption Protection: Typically has a feature that protects programmed settings in case of a power outage.

Using Them Together

When used together, the Autotrol 255 Control Valve and 460i Demand Control create an efficient and user-friendly water softening system:

• The 255 Control Valve manages the flow of water through the system, directing it through the resin tank during service and through the brine tank during regeneration.
• The 460i Demand Control determines when to initiate regeneration based on water usage, ensuring that the system only regenerates when necessary, thereby saving on salt and water usage.

Installation and Maintenance

• Installation: Ensure that the control valve and demand control are installed correctly, adhering to the manufacturer’s guidelines and local plumbing codes.
• Maintenance: Regular maintenance, such as checking for leaks, ensuring the brine tank is filled with salt, and occasionally cleaning the resin tank, will ensure longevity and optimal performance.
• Troubleshooting: Refer to the user manual for troubleshooting common issues and understand when to call a professional for service.

Note

Always refer to the specific user manuals and installation guides provided by the manufacturer (Autotrol) for detailed instructions and specifications. If you're unsure about any aspect of installation or maintenance, it's recommended to consult with a professional water treatment technician.

FEATURES/BENEFITS LCD displays the time of day Large

LCD display for simplified programming Time of day super capacitor backup for power loss

Queued regeneration is indicated by a flashing icon Easy installation with plug-in wiring harnesses

Easy electronic programming Displays the regeneration step and time remaining during regeneration Programming is stored in memory and will not be lost due to power outages

Adjustable Time of Regeneration History • Initial Setting Value System capacity and cycle step is calculated by the controller.

Day of Week or up to 99-days regeneration setting 12- volt AC operation Filter or conditioner setting in on control Calendar override

Mineral Tank w/255 Control Valve and 460 Demand Control, with By-Pass and Distributor

Time-tested Duraflow flapper provides frictionless sealing for longer service life

Fiber-reinforced polymer valve body for superior strength and durability, non-corrosive, and UV-resistant

Optical sensor for precision cycle positioning Designed with double backwash for reduced hardness leakage

Fully adjustable 5 or 8-cycle control for efficient and reliable water treatment system Continuous service flow rate of 15.5 GPM with a backwash of 6 GPM Backwash capability accommodates softener tanks up to 14" and filter up to 10" GPM in diameter

Designed for single or multiple tank systems Super capacitor for keeping time of day during a power outage

Environmental protective cover for water resistance, corrosion resistance, and UV stability

Programming stored in memory and will not be lost due to power outages History data for valve performance OPTIONS Filter or softener control valves

Fiber-reinforced polymer bypass valve Plumbing connections in .75"-1.25" NPT, BSP, and sweat

Variable reserve for increased efficiency Auxiliary switch kits Timer wall mount kits 460TC-

Three simple settings for time clock control. 460i- Three simple settings for metered control.

740- Simple economic electronic time clock control. 760- Simple economic electronic meter control.

742- Professional level time clock control with fully programmable cycle times and salt amount.

762- Professional level metered control with fully programmable cycle times and salt amount.

764- Professional level metered control with fully programmable cycle times and salt amount for multiple tank applications

 

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