Transcript
Cat. No. 01023053 Rev. H 07/31/12 DCO # 013284
Installation, Operation, and Service Instructions with Parts Lists
CULLIGAN® High Efficiency Twin Water Softeners Models from 2010 Firmware Version 2.1.6
©2012 Culligan International Company
Attention Culligan Customer: Your local independently operated Culligan dealer employs trained service and maintenance personnel who are experienced in the installation, function and repair of Culligan equipment. This publication is written specifically for these individuals and is intended for their use. We encourage Culligan users to learn about Culligan products, but we believe that product knowledge is best obtained by consulting with your Culligan dealer. Untrained individuals who use this manual assume the risk of any resulting property damage or personal injury. NOTICE
Please send any suggestions for improving this manual to
[email protected] WARNING! Electrical shock hazard! Prior to servicing equipment, disconnect power supply to prevent electrical shock.
WARNING! If incorrectly installed, operated, or maintained, this product can cause severe injury. Those who install, operate, or maintain this product should be trained in its proper use, warned of its dangers, and should read the entire manual before attempting to install, operate, or maintain this product. Failure to comply with any warning or caution that results in any damage will void the warranty. CAUTION!
This product is not to be used by children or persons with reduced physical, sensory or mental capabilities, or lack of experience or knowledge, unless they have been given supervision or instruction.
CAUTION!
Children should be instructed not to play with this appliance.
CAUTION!
If the power cord from the transformer to the unit looks or becomes damaged, the cord and transformer should be replaced by a Culligan Service Agent or similarly qualified person in order to avoid a hazard.
WARNING! This device complies with Part 15 of the FCC rules subject to the two following conditions: 1) This device may not cause harmful interference, and 2) This device must accept all interference received, including interference that may cause undesired operation. This equipment complies with Part 15 of the FCC rules. Any changes or modifications not expressly approved by the manufacturer could void the user’s authority to operate the equipment. Changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment. CAUTION!
To reduce the risk of fire, use only No. 26 AWG or larger telecommunications line cord.
NOTE
This system is not intended for use with water that is microbiologically unsafe or of unknown quality without adequate disinfection either before or after the system.
NOTE
Check with your public works department for applicable local plumbing and sanitation codes. Follow local codes if they differ from the standards used in this manual. To ensure proper and efficient operation of the Culligan HE Softener to your full satisfaction, carefully follow the instructions in this manual.
Products manufactured and marketed by Culligan International Company (Culligan) and its affiliates are protected by patents issued or pending in the United States and other countries. Culligan reserves the right to change the specifications referred to in this literature at any time without prior notice. Culligan, Aqua-Sensor, Tripl-Hull, and SoftMinder are trademarks of Culligan International Company or its affiliates. Culligan International Company 9399 West Higgins Road, Suite 1100 Rosemont, Illinois 60018 1-847-430-2800 www.culligan.com
Installation, Operation and Service Instructions
Culligan® High Efficiency Twin Water Softeners Models from 2010 Firmware Version 2.1.6 Contents Introduction ........................................................................ 1
Error and Alert Messages ................................................ 67
Performance Specifications ............................................... 3
Diagnostics ...................................................................... 68
Preparation ........................................................................ 5
Troubleshooting ............................................................... 75
Basic Principles ................................................................. 8
Service............................................................................. 80
Controller Features .......................................................... 10
Electrical Schematic ........................................................ 84
Operation ......................................................................... 12
Remote Display Template ............................................... 85
Installation ....................................................................... 14
Menu Overview (Two-Line Display)................................. 86
Navigating the Menus and Keypad.................................. 29
Appendix A
Softener Capacities ................................... 90
First Time Setup .............................................................. 31
Appendix B
Aqua-Sensor Guidelines............................ 93
Customizing Set Up ......................................................... 34
Appendix C
Outdoor Four-Line Menu ........................... 94
Installing Accessories ...................................................... 42
Appendix D
HE Outdoor Installation ............................. 98
Manual Regeneration ...................................................... 57
Appendix E
Auxiliary Input and Output ....................... 104
Manual Cycling ................................................................ 59
Appendix F
Flow Diagrams ......................................... 109
Information....................................................................... 60
Appendix G
Quick Reference ..................................... 124
Final Startup .................................................................... 62
Appendix H
Program Log............................................ 131
Operation, Care and Maintenance .................................. 64
Parts .............................................................................. 132
Recommended Preventive Maintenance......................... 65
Index .............................................................................. 141
Cat. No. 01023053
Contents
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Culligan® High Efficiency Twin Softener
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Cat. No. 01023053
Introduction Read this Manual First Before you operate the Culligan® High Efficiency 1" Twin water softener systems, read this manual to become familiar with the device and its capabilities. Culligan High Efficiency 1" Twin water softener systems are designed to meet the needs of applications for high quality water. This manual contains important information about the unit, including information needed for installation, operating, and maintenance procedures. A troubleshooting section provides a guide for quick and accurate problem solving. In order for the water treatment system to continue to provide high quality water, you must develop a thorough understanding of the system and its operation. Review this manual before making any attempt to install, operate, or service the system. Installation or maintenance done on this system by an untrained service person can cause major damage to equipment or property damage. The Culligan HE 1" Twin Water Softeners with Soft-Minder® Meter and Aqua-Sensor® sensing device are tested and certified by the Water Quality Association (WQA) against NSF/ANSI Standard 372, CSA B483.1, and NSF/ANSI Standard 44 for the effective reduction of hardness (calcium and magnesium), barium, and radium 226/228, as verified and substantiated by test data. The Culligan HE 1" Twin water softener requires the use of a Culligan connector, PN 01023290 (plastic) or PN 01021077 (copper). The Culligan HE 1" Twin NC model has not been tested or certified by WQA and does not include the Culligan connector.
About this Manual This manual: Familiarizes the operator with the equipment Explains installation and setup procedures Provides basic programming information Explains the various modes of operation Gives specifications and troubleshooting information This publication is based on information available when approved for printing. Continuing design refinements could cause changes that may not be included in this publication.
Safe Practices Throughout this manual there are paragraphs set off by special headings.
Notice Notice is used to emphasize installation, operation or maintenance information which is important, but does not present any hazard. For example, NOTICE
The nipple must extend no more than 1 inch above the cover plate.
Caution Caution is used when failure to follow directions could result in damage to equipment or property. For example,
CAUTION!
Disassembly while under water pressure can result in flooding.
Warning Warning is used to indicate a hazard which could cause injury or death if ignored. For example,
WARNING! Electrical shock hazard! Unplug the unit before removing the timer mechanism or cover plates!
Cat. No. 01023053
Introduction
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The CAUTION and WARNING paragraphs are not meant to cover all possible conditions and situations that may occur. It must be understood that common sense, caution, and careful attention are conditions which cannot be built into the equipment. These MUST be supplied by the personnel installing, operating, or maintaining the system. Be sure to check and follow the applicable plumbing codes and ordinances when installing this equipment. Local codes may prohibit the discharge of acid or caustic solutions to drain. An extra solution tank should be used to neutralize the solution before discharging to drain. Use protective clothing and proper face or eye protection equipment when handling chemicals or power tools.
Serial Numbers The control valve serial number is located on the back of the timer case. The media tank serial number is located on the top surface of the tank. This publication is based on information available when approved for printing. Continuing design refinement could cause changes that may not be included in this publication. NOTE
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Do not remove or destroy the serial number. It must be referenced on request for warranty repair or replacement.
Culligan® High Efficiency Twin Softener
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Cat. No. 01023053
Performance Specifications Culligan High Efficiency Twin Softener—Downflow Regeneration Model
9" Model
Control Valve
10" Model
12" Model
14" Model
1” Reinforced Thermoplastic w/ HE Circuit Boards
Overall Conditioner Ht
56 in
62 in
Media Tank Design
60 in
73 in
Quadra-Hull™
Media Tank Dimensions (Dia x Ht)
9 x 48 in
10 x 54 in
12 x 52 in
14 x 65 in
Salt Storage Tank Dimensions (Dia x Ht)
18 x 43 in
18 x 43 in
18 x 43 in
24 x 42 in
Exchange Media, Type and Quantity
Cullex® Media, 1.0 ft3
Cullex Media, 1.5 ft3
Cullex Media, 2.0 ft3
Cullex Media, 3.0 ft3
Cullsan® Underbedding, 12 lb
Cullsan Underbedding, 15 lb
Cullsan Underbedding, 20 lb
Cullsan Underbedding, 25 lb
17,854 gr @ 4.0 lb
26,781 gr @ 6.0 lb
31,352 gr @ 7.0 lb
51,726 gr @ 12 lb
Underbedding, Type and Quantity Exchange Capacity @ Salt Dosage Per Recharge (per tank)
27,108 gr @ 8.0 lb
40,662 gr @ 12.0 lb
48,458 gr @ 16.0 lb
75,582 gr @ 24 lb
31,736 gr @ 12.0 lb
47,604 gr @ 18.0 lb
59,267 gr @ 24.0 lb
88,549 gr @ 36 lb
4,463 gr/lb @ 4 lb salt dosage
4,463 gr/lb @ 6 lb salt dosage
4,479 gr/lb @ 7 lb salt dosage
4,310 gr/lb @ 12 lb salt dosage
Freeboard to Media2
14.5 in
14.5 in
16 in
25 in
Freeboard to Underbedding3
44.5 in
47.5 in
46 in
59 in
Salt Storage Capacity
375 lb
375 lb
375 lb
600 lb
Rated Service Flow @ Pressure Drop
9.0 gpm @ 11 psi
9.4 gpm @ 12 psi
10.0 gpm @ 10 psi
10.6 gpm @ 11 psi
Auxiliary Flow Rate4
10.8 gpm @ 15 psi
11.0 gpm @ 15 psi
12.6 gpm @ 15 psi
12.8 gpm @ 15 psi
75 gpg
99 gpg
99 gpg
99 gpg
Efficiency rated dosage (per tank)
1
Total Hardness, Maximum Total Iron, Maximum
5 ppm
Hardness to Iron Ratio, Minimum
8 gpg to 1 ppm
Operating Pressure
20-125 psi (138–862 kPa)
Operating Pressure (Canada)
20-90 psi (138–621 kPa)
Operating Temperature
33-120°F (0–49°C)
Electrical Requirements
24V/60 Hz
Electrical Power Consumption, Min/Max
8.4 watts/21.6 watts
Drain Flow, Maximum5
2.5 gpm
2.5 gpm
3.0 gpm
5.3 gpm
Recharge Time, Average6 Recharge Water
78 minutes
67 minutes
62 minutes
76 minutes
Consumption, Average6
47 gallons
45 gallons
67 gallons
155 gallons
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The efficiency rated dosage is only valid at the stated salt dosage and is efficiency rated according to NSF/ANSI 44. 2 Measured from top of media to top surface of tank threads. (backwashed and drained). 3 Measured from top of underbedding to top surface of tank threads. 4 Auxiliary flow rates do not represent the maximum service flow rate used for determining the softener’s rated capacity and efficiency. Continuous operation at these flow rates greater than the maximum service flow rate might affect capacity and efficiency performances. 5 Backwash at 120 psi (830 kPa). 6 10 minute backwash, 4 lb 9” model, 6 lb. 10” model, 7 lb. 12” model or 12 lb. 14” model salt dosage. Cat. No. 01023053
Performance Specifications
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Culligan High Efficiency Twin Softener—Upflow Regeneration Model Control Valve Overall Conditioner Height
9" Model
10" Model
1” Reinforced Thermoplastic with HE Circuit Board 56 in
62 in
Media Tank Design Media Tank Dimensions (Dia x Ht)
Quadra-Hull™ 9 x 48 in
10 x 54 in
Salt Storage Tank Dimensions (Dia x Ht) Exchange Media, Type and Quantity
18 x 43 in Cullex® Media, 1.0 ft3
Cullex Media, 1.5 ft3
Cullsan® Underbedding, 12 lb
Cullsan Underbedding, 15 lb
17,854 gr @ 4.0 lb
26,781 gr @ 6.0 lb
27,108 gr @ 8.0 lb
40,662 gr @ 12.0 lb
31,736 gr @ 12.0 lb
47,604 gr @ 18.0 lb
Efficiency Rated Dosage (per tank)1
4,463 gr/lb @ 4 lb salt dosage
4,463 gr/lb @ 6 lb salt dosage
Proportional Brining Efficiency Rating (per tank)2
5250 gr/lb @ 4 lb salt dosage
5247 gr/lb @ 6 lb salt dosage
Freeboard to Media3
14.5 in
14.5 in
Freeboard to Underbedding4
44.5 in
47.5 in
Underbedding, Type and Quantity Exchange Capacity @ Salt Dosage Per Recharge (per tank)
Salt Storage Capacity
375 lb
Rated Service Flow @ Pressure Drop
9.0 gpm @ 11 psi
9.4 gpm @ 12 psi
Auxiliary Flow Rate5
10.8 gpm @ 15 psi
11.0 gpm @ 15 psi
Total Hardness, Maximum
30 gpg
Total Iron, Maximum
2 ppm
Hardness to Iron Ratio, Minimum
8 gpg to 1 ppm
20-125 psi (138–862 kPa)
Operating Pressure
20-90 psi (138–621 kPa)
Operating Pressure (Canada) Operating Temperature
33-120°F (0–49°C)
Electrical Requirements
24V/60 Hz
Electrical Power Consumption, Min/Max Drain Flow, Maximum6
8.4 watts/21.6 watts 2.5 gpm
2.5 gpm
Recharge Time, Average7 Recharge Water
78 minutes
67 minutes
Consumption, Average7
47 gallons
45 gallons
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The efficiency rated dosage is only valid at the stated salt dosage and is efficiency rated according to NSF/ANSI 44. The Proportional Brining Efficiency Rating assumes a 20 percent reserve capacity at the time of regeneration that is typical of what the manufacturer expects under real-world operation. Proportional brining is not measured by NSF/ANSI44, and so this claim is not, and can not, be rated to NSF/ANSI44. 3 Measured from top of media to top surface of tank threads. (backwashed and drained). 4 Measured from top of underbedding to top surface of tank threads. 5 Auxiliary flow rates do not represent the maximum service flow rate used for determining the softener’s rated capacity and efficiency. Continuous operation at these flow rates greater than the maximum service flow rate might affect capacity and efficiency performances. 6 Backwash at 120 psi (830 kPa). 7 10-minute backwash, 4lb 9” model, 6lb 10” model, 7lb 12” model, or 12lb. 14” model salt dosage. 2
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Culligan® High Efficiency Twin Softener
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Cat. No. 01023053
Preparation Component Description The water conditioner is shipped from the factory in a minimum of five cartons. Remove all components from their cartons and inspect them before starting installation.
Control Valve Assembly
Includes two High Efficiency control valves, meters, and bypass valves. Small parts packages will contain additional installation hardware, and the conditioner Owner’s Guide.
Media Tank
Includes two Quadra-Hull™ media tanks complete with Cullex® ion exchange resin, underbedding and outlet manifold (12" and 14" tanks are shipped without media inside the tank).
Salt Storage Tank Assembly
Includes salt storage container with support plate and Dubl-Safe™ brine refill valve and chamber.
Interconnecting Pipe (optional) Includes interconnecting pipe that is installed between the two control valves. Aqua-Sensor® Probe (optional) An eighth box will include the Aqua-Sensor Probe if so equipped.
Tools and Materials The following tools and supplies will be needed, depending on installation method. Observe all applicable codes. NOTE
Check and comply with your state and local codes. You must follow these guidelines. For installations in Massachusetts, the Commonwealth of Massachusetts Plumbing Code 248 CMR shall be adhered to. Consult your licensed plumber for installation of the system. This system and its installation must comply with state and local regulations. The use of saddle valves is not permitted.
All Installations Safety glasses Phillips screwdrivers, small and medium tip. Gauge assembly (PN 00-3044-50 or equivalent) Silicone lubricant (PN 00-4715-07 or equivalent)—DO NOT USE PETROLEUM-BASED LUBRICANTS A bucket, preferably light-colored Towels
Special Tools Torch, solder and flux for sweat copper connections Use only lead-free solder and flux for all sweat-solder connections, as required by state and local codes. Threading tools, pipe wrenches and thread sealer for threaded connections. Saw, solvent and cement for plastic pipe connections.
Materials Brine line, 3/8” (PN 01-0098-19 or equivalent) or 1/2” (PN 00-9018-00 or equivalent) Drain line, 1/2” (PN 00-3030-82, gray, semi-flexible; or PN 00-3319-46, black, semi-rigid; or equivalent) Thread sealing tape Pressure reducing valve (if pressure exceeds 125 psi [860 kPa], PN 00-4909-00 or equivalent) Pipe and fittings suited to the type of installation Water softener salt (rock, solar or pellet salt formulated specifically for water softeners)
Cat. No. 01023053
Preparation
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Application Water Quality Verify that raw water hardness and iron are within limits. Note the hardness for setting the salt dosage and recharge frequency.
Iron—A Common Water Problem The chemical/physical nature of iron found in natural water supplies is exhibited in four general types: 1.
Dissolved Iron—Also called ferrous or “clear water” iron. Up to 5 ppm of this type of iron can be removed from the water by the same ion exchange principle that removes the hardness elements, calcium and magnesium. Dissolved iron is soluble in water and is detected by taking a sample of the water to be treated in a clear glass. The water in the glass is initially clear, but on standing exposed to the air, it may gradually turn cloudy or colored as it oxidizes.
2.
Particulate Iron—Also called ferric or colloidal iron. This type of iron is an undissolved particle of iron. A softener will remove larger particles, but they may not be washed out in regeneration effectively and will eventually foul the ion exchange resin. A filtering treatment will be required to remove this type of iron.
3.
Organic Bound Iron—This type of iron is strongly attached to an organic compound in the water. The ion exchange process alone cannot break this attachment and the softener will not remove this type of iron.
4.
Bacterial Iron—This type of iron is protected inside a bacteria cell. Like the organic bound iron, it is not removed by a water softener.
When using a softener to remove both hardness and up to 5 ppm of dissolved iron it is important that it regenerates more frequently than ordinarily would be calculated for hardness removal alone. Although many factors and formulas have been used to determine this frequency, it is recommended that the softener be regenerated when it has reached 50 - 75% of the calculated hardness alone capacity. This will minimize the potential for bed fouling (iron removal claims have not been verified by the Water Quality Association). If you are operating a water softener on clear water iron, regular resin bed cleaning is needed to keep the bed from coating with iron. Even when operating a softener on water with less than the maximum of dissolved iron, regular cleanings should be performed. Clean every six months or more often if iron appears in your conditioned water supply. Use resin bed cleaning compounds carefully following the directions on the container. Hardness sample kits are available through your local Culligan dealer.
CAUTION!
Do not use where the water is microbiologically unsafe or with water of unknown quality without adequate disinfection before or after the unit.
Pressure If pressure exceeds 125 psi (860 kPa), install a pressure reducing valve (see materials checklist). On private water systems, make sure the minimum pressure (the pressure at which the pump starts) is greater than 20 psi (140 kPa). Adjust the pressure switch if necessary.
CAUTION!
The use of a pressure reducing valve may limit the flow of water in the household.
Temperature Do not install the unit where it might freeze, or next to a water heater or furnace or in direct sunlight. Outdoor installation is not recommended and voids the warranty. Use the Culligan Outdoor HE softener for outdoor installations. The Culligan Outdoor HE softener has been certified by Underwriter’s Laboratories for outdoor installation. If installing in an outside location, you must take the steps necessary to assure the softener, installation plumbing, wiring, etc. are as well protected from the elements (sunlight, rain, wind, heat, cold), contamination, vandalism, etc. as when installed indoors.
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Culligan® High Efficiency Twin Softener
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Cat. No. 01023053
Location Space Requirements Allow 6-12 inches (15-30 cm) behind the unit for plumbing and drain lines and 4 feet (1.3 meters) above for service access and filling the salt container.
Floor Surface Choose an area with solid, level floor free of bumps or irregularities. Bumps, cracks, stones and other irregularities can cause the salt storage tank bottom to crack when filled with salt and water.
Drain Facilities Choose a nearby drain that can handle the rated drain flow (floor drain, sink or stand pipe). Refer to the Drain Line Chart, Table 3 on page 22, for maximum drain line length. NOTE
Most codes require an anti-siphon device or airgap. Observe all local plumbing codes and drain restrictions. The system and installation must comply with all state and local laws and regulations.
Electrical Facilities A 10-foot cord and wall mount plug-in transformer are provided. The customer should provide a receptacle, preferably one not controlled by a switch that can be turned off accidentally. Observe local electrical codes. NOTE
PN 01020620 and PN 01018133 plug-in transformer are rated for indoor installations only.
NOTE
The softener works on 24 Volt/60 Hz power only. Be sure to use the included transformer. Be sure the electrical outlet and transformer are in an inside location to protect from moisture. Properly ground to conform with all governing codes and ordinances.
Cat. No. 01023053
Preparation
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Basic Principles What Is Hard Water? Water is said to be hard when it carries too high a concentration of calcium and magnesium. Acceptable water hardness levels will vary depending on the application.
Why Should Hardness Be Removed? Hard water causes scaling and etching which greatly impairs the life and efficiency of boilers, air-conditioning systems, cooling towers, water heaters, refrigeration plants and other equipment using water.
How Does It Work? The components of dissolved minerals are called ions. They carry either a positive or negative charge. Hardness ions of minerals dissolved in water carry a positive charge. These positively charged ions (cations) are attracted to a synthetic softening material called ion exchange resin. The heart of the softening system, therefore, is a deep bed of resin which draws calcium and magnesium ions, as well as ferrous iron, from the water as it passes through the resin bed.
Can The Resin Draw Out Hardness Ions Indefinitely? No. During normal operation, the resin becomes saturated with positive ions and functions less efficiently. When hardness leakage occurs, the resin should be regenerated to restore its efficiency.
How Do You Regenerate Resin? You regenerate a resin bed by removing the mineral ions through a process called ion exchange. This regeneration process occurs in four steps and takes approximately 80 to 90 minutes.
Backwash During the backwash step, raw water flows rapidly upward (in reverse direction to the service flow) through the resin bed to expand the bed and flush out accumulated dirt, sediment and other sources of turbidity.
Brine Draw The brine solution consisting of water and salt is drawn from a brine storage tank and allowed to flow slowly down through the resin bed. The brine solution removes the calcium and magnesium ions from the resin. This cycle can also be split into three “sub-cycles” which allow for the cost saving feature of brine reclaim.
Slow Rinse Brine draw is then followed by a raw water slow rinse. This rinse step will slowly remove most of the remaining brine, exchanged calcium and magnesium ions from the resin. This cycle can also be split into three “sub-titles” which allow for the cost saving feature of brine reclaim.
Fast Rinse Slow rinse is followed by a raw water flush, a very rapid down flow of raw water which removes the last traces of brine, and settles the resin bed.
Refill To make brine, water flows into the salt storage tank during the refill stage. Refill cycle length depends on the salt dosage.
How Often Must You Regenerate? Frequency must be determined for each installation based on the amount of water usage, its degree of hardness and the amount of resin through which it flows. In some cases it is necessary to utilize a resin cleaner when the raw water contains iron. Contact your local Culligan dealer for more information.
How Do You Control The Regeneration Process? The regeneration process for your water softener is controlled automatically either on a predetermined time, volume, or external signal basis through the use of the Culligan Smart GBE Controller with a flow meter or optional Aqua-Sensor probe. See the Installation chapter for further information. The regeneration process can also be initiated manually by the operator as required.
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Culligan® High Efficiency Twin Softener
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Cat. No. 01023053
Terms Brine—A solution of water and salt used to regenerate the resin. Distributor—A pipe with slits that allows the water to enter and leave inside the media tank. Media—The underbedding and resin the media tank holds. Regenerate—A process where the resin once exhausted of its softening capabilities is regenerated to soften again. Resin—The actual material that softens hard water, shaped like little beads. Underbedding—A gravel mixture that keeps the resin from entering the distributors.
Manifold
Freeboard (C)
Resin (Cullex) (A)
Gravel Underbedding (B)
Distributor
Figure 1. Brine tank. Cat. No. 01023053
Figure 2. Media tank. Basic Principles
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Controller Features Culligan High Efficiency Twin Controller (HE) The Culligan HE Twin softener is designed to operate a wide range of existing and new softener and filtration valves. The Smart Controller is designed to be both reliable and easy to use. The Smart Controller features a bright and easy-to-read display. New HE features: Optional wireless remote control. Optional telephone modem—calls for service and salt delivery. Automatically upgrades to latest firmware when it becomes available (if modem is installed). Automatically sets time and date. 5-year battery backup with real-time-clock. Supports Smart Brine Tank probe. Support for auxiliary outputs. The Smart Controller is a circuit board designed to mount onto the control valve attached to a water softener or filter. There are four other, optional, add-on modules in the Smart Controller family. These modules include:
Wireless Remote Control This remote control displays the current status of the water softener or filters and allows for remote control. It can be located up to 200 feet away from the HE controller (depending upon building construction materials).
Modem Board This module can be installed into either the HE controller or the Wireless Remote. It allows for the system to be remotely monitored detecting problems before they occur and to schedule salt delivery when it is needed.
RF Transmitter
MODEM BOARD RF BOARD 915MHz
MOTOR CONNECTOR
EXPANSION BOARD
PHONE POSITION SENSOR CONNECTION
AQUA SENSOR FLOW METER 2.5V
BRINE TANK
24V
This module is installed into BOTH the HE POWER controller and the Wireless Remote to allow them to communicate via Radio Frequency (RF) communications. In North America, these Figure 3. Smart Controller circuit board for the HE softener. modules communicate at 915 MHz and are designed to work without interference with other 915 MHz devices such as cordless telephones and baby monitors. Other frequencies are used in other countries.
Expansion Board This module can be installed into the Smart Controller to provide a variety of add-on capabilities such as: Control of Culligan ‘Power-Valves’ by a HE controller, operation of Twin-Tank Systems, and operation of external solenoid valves and relays (typically used in commercial applications). In addition to these add-on modules, there are several sensor and probe products which can be used with the Smart Controller including:
Aqua-Sensor Probe The Aqua-Sensor Probe measures the remaining capacity of the ion-exchange resin inside the resin tank and it measures the quality of the brine solution during regeneration. This probe provides the most efficient (lowest salt and water usage) means of controlling a water softener by delaying the regeneration until the resin capacity is exhausted.
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Culligan® High Efficiency Twin Softener
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Cat. No. 01023053
Smart Brine Tank Probe This probe monitors conditions inside the brine tank. It predicts when more salt needs to be added to the brine tank, and detects the presence of salt-bridging, eductor line plugging and brine tank overfilling.
Flow Meter The High Efficiency Twin softener can monitor any hall-effect type flow meter signal and use it as the basis of monitoring the amount of water flowing through the valve. The connectors used to install these add-on modules, as well as connectors for the HE Sensor Products, are shown in Figure 3.
Smart Controller Programming The programming for the Smart Controller is all menu based. There are six top level menus with additional options below each. The top level menus are: 1.
INFORMATION
2.
MANUAL MODE
3.
SET DATE/TIME
4.
ACCESSORIES
5.
ADV. SETUP
6.
DIAGNOSTICS
Here is a brief explanation of what you will find under each menu.
Menu/Submenu
Description
Information
Selecting this menu item will scroll through the operating information for the unit.
Manual Mode
Use this menu item to initiate a manual regeneration.
Set Time and Date
Use this menu item to make changes to the time and/or date. This is initially done during first time set up and the information is saved in memory even in the event of a power outage.
Accessories
Use this menu item to set up any installed accessories. This includes Aqua-Sensor®, beeper, Aux In, Aux Outputs, Smart Brine Tank sensor, Wireless Remote, Modem, Chlorinator, flow meter, service phoneline, and external filter.
Advanced Setup
This menu item allows customization of the unit. There are five sub-menus that offer customization settings.
System Setup
This menu allows customization of many of the initial setup information. Water Hardness, Iron, Salt Type, Resin Type and Line Pressure are among the settings.
Regeneration Setup
This menu allows customization of the salt dosage, reserve capacity, regeneration time and regeneration mode.
Cycle Times
This menu allows customization of the cycle times for the units.
Regeneration Trigger
This menu allows customization of what can trigger regeneration, the regeneration interval, predict mode and days of regeneration.
Diagnostics
Cat. No. 01023053
This menu allows diagnostics to be performed on sensors, wireless, progressive flow, motor control, data port, phone line (modem) and advanced statistics.
Controller Features
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Operation Modes of Operation Water Meter Mode In water meter mode, the Smart Controller keeps track of the quantity of water that has flowed through the resin bed. Based on the influent water hardness and the hardness capacity of the resin bed, a service life expectancy in the quantity of softened water is calculated and programmed into the control. When the set point is reached, regeneration is triggered. If the predict mode is not selected, the regeneration will start at the programmed time of regeneration. If Regeneration Days Interval (time clock backup) is set and the capacity has not been exhausted, the HE softener will regenerate when days since last regeneration equal time clock back up. In immediate mode the regeneration starts as soon as the regeneration signal is provided.
Aqua-Sensor® Mode The Aqua-Sensor is a conductivity probe that senses when a hardness front passes through the resin bed. It functions independently of the influent water hardness so therefore, is useful in conditions when the influent water hardness varies throughout the year. It provides for the most efficient mode of operation. In addition to sensing when a resin bed is exhausted, it can also be used to determine when the brine solution is rinsed from the resin bed during the Brine Draw / Slow Rinse cycle triggering the control to move to fast rinse. This patented feature provides water savings by optimizing the amount of rinse water required to completely rinse out the resin bed. NOTE
Only one Aqua-Sensor probe is used for HE Twin applications.
Regeneration Interval (Time Clock Backup Mode) This setting provides regeneration when a set period of time has elapsed. If the meter or Aqua-Sensor does not trigger regeneration prior to the time clock backup value, the time clock backup will trigger the regeneration.
Manual Regeneration Pressing and holding
for five (5) seconds will initiate a delayed regeneration. Pressing and holding
again for five
(5) seconds will cancel the delayed regeneration. Pressing and holding for ten (10) seconds will initiate an immediate regeneration. The regeneration statistics will not be updated if the last cycle of regeneration does not automatically complete. See page 57 for further details about the Manual Regeneration feature.
Bypass Mode The HE control can be bypassed for a preset time duration. See page 58 for further details about the Bypass feature.
Day-of-Week Regeneration A regeneration can be programmed to occur on any day (or any combination of days) of the week. If for example the “Tuesday Regeneration Trigger” and the “Friday Regeneration Triggers” are turned “ON”, then a regeneration will occur every Tuesday and Friday (in addition to any other regeneration triggers which may occur).
Predict Mode The Predict Mode is used in the flow meter mode to determine the optimum regeneration point. Before the regeneration starts, the control will compare the remaining capacity value with the average daily water use. If the average daily water usage is less than the remaining capacity, the controller will wait 24 more hours before regeneration. If the remaining capacity is less than the average daily water usage, the control will initiate regeneration. This works in delay mode only.
Pre-Rinse Mode The Pre-rinse mode is used to pre-rinse the softener resin bed or filter media. The pre-rinse in flow meter mode will occur after the control has sensed that no water has flowed through the control for a period of X hours (can be set through the programming menu). When the control is in this mode, once the X amount of hours have elapsed the control will cycle to the fast rinse position for the pre-set length of minutes and then return to the home or service position.
Down Flow Regeneration Water and regenerate flow downward through the media tank during regeneration. 12
Culligan® High Efficiency Twin Softener
12
Cat. No. 01023053
Up Flow Regeneration Water flow is downward and regenerate flow is upward through the media tank. Regeneration will be most effective in those parts of the resin bed which are treated with the freshest regenerate solution.
Proportional Brining The control monitors your softened water usage making only enough brine to regenerate that part of the resin bed that has been exhausted. In this way the amount of salt used relates directly to the amount of softened water used, making it more efficient and cost effective. Proportional brining can only be used with up-flow regeneration. The Aqua-Sensor or meter can be used to initiate a regeneration. NOTE
For proportional brining, refill is initiated two hours prior to regeneration.
Dial-a-Softness Dial-a-Softness is a manual adjustment built into the control valve that allows for variable hardness bypass into the softened water. The hard water bypass can be adjusted from 1–3 gpg. The Dial-a-Softness also increases the softener capacity in proportion to the percent hard water bypass (less salt used). See page 20 for more information.
Twin Configuration The Culligan HE Twin provides uninterrupted conditioned water 24 hours per day. Two independent mineral tanks provide a continuous flow of soft water; when one tank is exhausted, the second tank takes over as the first regenerates. This system is particularly good in situations where water is extremely hard. The HE Twin is available in various sizes to provide soft water for light commercial applications as well as large families.
High Efficiency Twin Accessory Guidelines Water Chemistry
SBT Probe
Modem
AquaSensor
Wireless Remote
Well Water System (Downflow Regeneration) A softener designed to handle the harsh water conditions of well water. The system includes standard Cullex Resin, Cullsan underbedding, designed for down-flow brining and standard tank dimensions.
OK
See Specifications
OK
OK
SSP Iron
OK
Chlorine Only JSJ 0 ppm Iron
OK
OK
NO
OK
JSJ SSP,URQ
OK
OK
Municipal Water System (Total Home) A softener specifically designed to reduce hardness and chlorine. The system includes standard Cullex Resin, carbon media, Cullsan underbedding, designed for down-flow brining and standard tank dimensions. High Efficiency System (Upflow Regeneration) Utilizes the latest advances in water technology to create one of the most efficient water softeners in the world. The system includes Cullex Resin, Cullsan underbedding, designed for upflow/proportional brining.
OK SSP Iron
OK
Proper Upflow Application Use of upflow brining is limited to a maximum of 30 gpg; above 30 gpg, use downflow. Use the eductor and nozzle sets listed in this manual.
Cat. No. 01023053
Operation
13
Installation NOTE
Read this section entirely before starting the installation. Follow all applicable plumbing and electrical codes.
With the exception of media containers, open the remaining containers, remove all the components, and inspect them before starting installation.
Placement Refer to Figure 4 for system placement. 1.
Set the media tank on a solid, level surface near water, drain and electrical facilities.
2.
Set the brine system on a flat, smooth, solid surface as near the media tank as possible.
Tank Assembly 9” and 10” tanks are filled with media at the factory. 1.
Before the unit can be connected to the plumbing, you must insert the manifold and load the media into the tank for 12” and 14” units.
CAUTION!
Do not lay the tank down unless a suitable lifting device is available. Personal injury and damage to the unit can result if dropped.
Position the Mineral Tank(s) Determine the location for the mineral tanks(s) prior to loading, because they will be difficult to move after the underbedding and gravel are loaded.
Treated Water Out
Hard Water In
To Hose Bibs
High Efficiency Twin
Drain Line
Heater
Air Gap (2X Pipe Diameter or 1 inch, whichever is larger)
Brine Tank
Water Meter or Pump
Figure 4. Membrane and housing.
14
Culligan® High Efficiency Twin Softener
14
Cat. No. 01023053
Load the Tank (12" and 14" Tanks) 1.
Position the tank so that the Culligan® logo is in the front.
2.
Remove the inlet strainer.
3.
Install the outlet manifold into the tank (Figure 5).
4.
Cover the tops of the manifolds with a clean rag.
5.
Using a large-mouth funnel, load the Culligan underbedding through the top of the tank. CAUTION!
DO NOT allow the outlet manifold to move when loading the media. The manifold must remain vertical to ensure a good seal at the gasket. Rap the tank near the bottom with a rubber mallet to level the sand.
6.
Load the tank with the Cullex® ion exchange resin. Leveling is not required.
7.
Remove the funnel.
8.
Install the inlet strainer making sure to thread the strainer until it bottoms out on the tank thread. Failure to install the strainer correctly can cause the control to leak.
Aqua-Sensor® Installation 1.
Measure the sensor cable length as shown in Figure 5 and Table 1 (the Aqua-Sensor cord is set at the factory for a 9” tank).
Tank Model
Dimension Y
9” Quadra-Hull™ Tank
40"
10” Quadra-Hull Tank
44"
12” Quadra-Hull Tank
42"
14” Quadra-Hull Tank
52" Table 1. HE Twin cable lengths.
NOTE
Only one Aqua-Sensor probe is used for HE Twin applications.
2.
Loosen the small Aqua-Sensor Plug; a needle-nose pliers works best. See Figure 6.
3.
Moisten the cable sheath and slide the cable grip up or down to the proper cable length.
4.
Tighten the small Aqua-Sensor plug so that the fitting cannot slide along the cable.
Small Aqua-Sensor® Plug
Figure 5. HE Softener tank.
Figure 6. Aqua-Sensor plug.
Cat. No. 01023053
Installation
15
NOTE
There must be no kinks or bends in the cable.
5.
Insert the probe and cable through the Aqua-Sensor port.
6.
Tighten the Aqua-Sensor plug into the Aqua-Sensor port.
NOTE
Follow the Aqua-Sensor programming procedures—see page 42.
NOTE
The media tank must be backwashed so that the Aqua-Sensor probe can fall into the proper position. See “Recommended Aqua-Sensor® Start-Up Procedure” on page 63.
Mount the Control Valve See Figure 7 for an illustration on mounting the control valve to the tank. 1.
Assemble the O-rings, located in the parts pack, to the tank adapter.
2.
The valve adapter O-ring sits on the first step on the adapter. See Figure 8.
NOTE
Do not push the top O-ring down to the flange surface on the adapter.
NOTE
The larger of the two O-rings in the parts should be positioned between the adapter and the valve. Do not stretch the smaller O-ring onto the top of the tank adapter.
3.
Lubricate only the top O-ring on the tank adapter and the outlet manifold o-ring with silicone lubricant.
4.
Screw the adapter into the tank until the adapter bottoms out on the tank flange.
NOTE 5. NOTE 6. NOTE
The adapter only needs to be tightened hand-tight to the tank flange. Align the manifold with the center opening in the valve, and firmly press the valve onto the adapter. Make sure to push the valve straight down onto the manifold. If the valve is cocked, it may cause the O-ring to slip off the manifold. Assemble the tank clamp to the control, and tighten the clamp screw. The clamp and valve will be able to rotate on the tank until pressure is applied.
Add O-Rings
O-Ring
Figure 7. Mounting the control valve. 16
Culligan® High Efficiency Twin Softener
Figure 8. Valve adapter O-ring. 16
Cat. No. 01023053
Backwash Flow Control, Eductor Nozzle—Throat Use the recommended backwash flow control, eductor nozzle, and eductor throat to be used for various size tanks. Refer to Figure 9 through Figure 12 and instructions below for changing the backwash flow control, eductor nozzle, and eductor throat.
Eductor Nozzle and Throat Replacement Refer to Figure 9 and the instructions below when changing the eductor nozzle and throat. 1.
Remove the eductor cap clip.
2.
Remove the eductor cap.
3.
Remove the eductor assembly.
4.
Remove the eductor screen from the assembly
5.
Remove the blue nozzle and replace it with the correct nozzle. See Table 2.
6.
Make sure to put the O-ring on the nozzle.
7.
Replace the eductor throat if required.
8.
Reverse the procedure to reassemble.
Unit
Backwash Flow
Nozzle
Throat
Brine Refill Flow
9" Upflow
2.5–3.1 gpm (#2 Brown)*
Blue*
Gray*
0.45 gpm
10" Upflow
2.5–3.1 gpm (#2 Brown)*
Blue*
White*
0.45 gpm
9" Downflow
2.5–3.1 gpm (#2 Brown)*
Blue*
Light Brown*
0.45 gpm
10" Downflow
2.5–3.1 gpm (#2 Brown)*
Beige
Light Brown*
0.45 gpm
12" Downflow
3.0–3.2 gpm (#3 Green)
Beige
Light Brown
0.8 gpm
14" Downflow
5.3 gpm (Black)
Green
Blue
0.8 gpm
* Shipped assembled inside the control standard from factory Table 2. Flow Restrictors NOTE
For upflow models, the backwash and fast rinse default times are set at five (5) minutes.
NOTE
Observe the orientation of the arrow on the eductor cap. The arrow faces down for downflow regeneration applications; the arrow faces up for upflow/proportional brining regeneration applications.
Clip
Throat Eductor Cap
Screen Nozzle
Figure 9. Removing the eductor nozzle and throat. Cat. No. 01023053
Installation
17
Backwash Flow Control Replacement Refer to Figure 10 through Figure 12, Table 2, and instructions below to replace the backwash flow control. 1.
Remove the cover by releasing the cover fastener from the control valve. See Figure 10 and Figure 11.
2.
Remove the drain clip and pull the drain elbow straight off. See Figure 12.
3.
Remove the backwash flow control located behind the elbow.
4.
Install the correct backwash flow control. See Table 2.
5.
Reverse the procedure to reassemble.
NOTE
The number on the flow control should face into the valve body.
NOTE
Do not re-install the cover until the drain line tubing is connected.
A
Figure 10.
HE softener cover fastener clip.
Brine Elbow
Figure 11.
Removing the HE softener cover.
Filter
Clips
Drain Elbow Flow Control
Figure 12. 18
Culligan® High Efficiency Twin Softener
Removing the drain elbow and brine elbow. 18
Cat. No. 01023053
Attaching the Cover Once the drain and brine line is connected re-attach the cover. Refer to the instructions below and Figure 13 through Figure 15. 1.
Insert the two pins on the top of the cover into the two holes on top of the frame; the cover should be slightly angled. See Figure 13.
2.
Rotate the cover downward inserting the two pins on the side of the cover into the two holes on side of the frame. See Figure 14.
3.
Attach the cover fastener onto the control valve. See Figure 15.
Figure 13.
Cover fastener clip.
Figure 14.
Reattaching the HE softener cover.
Push down into place A
Cover Fastener Figure 15.
Cat. No. 01023053
Reattaching the cover fastener.
Installation
19
Dial-a-Softness Dial-a-Softness is a manual adjustment built into the control valve that allows for variable hardness bypass into the softened water. The hard water bypass can be adjusted to produce 1–3 gpg hardness bleed. Shipped from the factory the Dial-a-Softness knob is set to the “SOFTEST” position (no hard water bypass). See Figure 16. To set the Dial-a-Softness: 1.
Locate the Dial-a-Softness knob on the control valve.
2.
Set the Dial-a-Softness knob to position A, B, or C as outlined in the table below, based on raw water hardness; this should produce a 1–3 gpg hardness bleed.
Letter on Dial-a-Softness Knob
NOTE
Figure 16.
Dial-a-Softness knob.
1–3 gpg Hardness Bleed
SOFTEST
0
A
Greater than 20 gpg
B
Between 10–20 gpg
C
Less than 10 gpg
The HE must take into account the adjusted capacity if the Dial-a-Softness was changed. See Advanced System Set-up to update the Dial-a-Softness setting.
Plumbing Connections Shipped with each softener is a Culligan® bypass valve, which is used to connect the softener to the plumbing system. The bypass allows the softener to be isolated from the water service line if service is necessary while still providing water to the home. The bypass valve can be directly plumbed into the system, or can be connected with the following optional sweat connection kits. P/N 01010783
1” Sweat Copper Adapter Kit
P/N 01016564
3/4” Sweat Copper Adapter Kit
P/N 01016565
3/4” Elbow Sweat Copper Adapter Kit
P/N P1018757
1” NPT Plastic Elbow Adapter Kit
P/N P1018758
1” NPT Plastic Installation Kit
CAUTION!
Close the inlet supply line and relieve the system pressure before cutting into the plumbing! Flooding could result if not done!
CAUTION!
When making sweat connections, use care to keep heat away from the plastic nuts used to connect the plumbing to the bypass. Damage to these components may result otherwise.
Bypass Valve Installation Refer to Figure 17 and the instructions below to connect the meter, bypass valve, and interconnecting pipe.
20
1.
All HE units are equipped with a Soft-Minder® meter. The meter is installed on the outlet side of the control valve #2 (the meter is located in control valve #1 small parts kit). Connect the HE Twin meter wire harness to the meter (the meter wire harness is located in control valve #2 small parts kit). The meter body fits in the same space as the coupling between the control valve and the bypass. Make sure the arrow on the flow meter is pointing in the direction of the flow.
2.
The bypass valve connects directly to the control valve with the meter and coupling and two assembly pins. Lubricate all O-rings on the couplings/meter with silicone lubricant.
Culligan® High Efficiency Twin Softener
20
Cat. No. 01023053
3.
Connect the interconnecting pipe. The interconnecting pipe is connected to the outlet of Control #1 and the inlet of Control #2. Assembly Pin
MAIN VALVE #1
Brine Connection
SLAVE VALVE #2
Coupling Bypass
Brine Connection
Bypass
Coupling Connected to Circuit Board on Valve #1
Connected to Flow Meter on Valve #2
Interconnecting Pipe Flow Meter
Figure 17. NOTE
Bypass valve assembly.
If the ground from the electrical panel or breaker box to the water meter or underground copper pipe is tied to the copper water lines and these lines are cut during installation of the bypass valve, an approved grounding strap must be used between the two lines that have been cut in order to maintain continuity. The length of the grounding strap will depend upon the number of units being installed. In all cases where metal pipe was originally used and is later interrupted by the bypass valve to maintain proper metallic pipe bonding, an approved ground clamp c/w not less than #6 copper conductor must be used for continuity. Check your local electrical code for the correct clamp and cable size.
To bypass, turn the blue knob clockwise (see directional arrow on end of knob) until the knob stops as shown. DO NOT OVERTIGHTEN! (Figure 18). To return to service, turn the blue knob counter-clockwise (see directional arrow on the end of knob) until the knob stops as shown. DO NOT OVERTIGHTEN! (Figure 19) About 1-1/4”
A screwdriver shank may be used in the slot as a lever for extra turning force if needed.
Figure 18.
Cat. No. 01023053
Turn blue bypass knob clockwise.
Figure 19.
Turn bypass knob counter-clockwise.
Installation
21
Drain Line Connection Refer to Table 3 for drain line length and height limitations under the applicable tank size. 1.
Remove 1/2” pipe clamp from the small parts pack included with the control.
2.
Route a length of 1/2” drain line from the drain elbow to the drain.
3.
Fasten the drain line to the elbow with the clamp.
4.
Secure the drain line to prevent its movement during regeneration. When discharging into a sink, or open floor drain, a loop in the end of the tube will keep it filled with water and will reduce splashing at the beginning of each regeneration.
NOTE
Waste connections or drain outlets shall be designed and constructed to provide for connection to the sanitary waste system through an air gap of two pipe diameters or 1 inch, whichever is larger.
NOTE
Note: Observe all plumbing codes. Most codes require an anti-siphon device or air gap at the discharge point. The system and installation must comply with state and local laws and regulations.
Operating Pressure
0 ft (0 m)
2 ft (0.6 m) 4 ft (1.2 m) 6 ft (1.8 m) 8 ft (2.4 m)
10 ft (3 m)
30 psi (210 kPa)
60 ft (18 m)
50 ft (15 m)
30 ft (9 m)
15 ft (5 m)
Not allowable
Not allowable
40 psi (279 kPa)
100 ft (30 m)
90 ft (27 m)
70 ft (21 m)
50 ft (15 m)
30 ft (9 m)
12 ft (4 m)
50 psi (349 kPa)
145 ft (41 m)
115 ft (35 m)
80 ft (24 m)
80 ft (24 m)
60 ft (18 m)
40 ft (12 m)
100 ft (30 m)
100 ft (30 m)
85 ft (26 m)
60 ft (18 m)
140 ft (43 m)
120 ft (37 m)
60 psi (419 kPa) 80 psi (559 kPa)
Normal installation should not require
100 psi (699 kPa)
more than 100 ft (30 m) of drain line
150 ft (46 m)
Table 3. Height of Discharge Above Floor Level Operating
Brine System Assembly—Duplex Models Models using a common brine tank should be assembled as follows: 1.
Cut off approximately two inches of brine tubing, then attach the tubing to the brine safety valve. See Figure 20.
2.
Connect the center leg of the duplex tee (provided in the small parts pack) to the other end of the tubing.
3.
Connect the brine line tubing from each softener to the two remaining ends of the duplex tee. The nut and insert are provided in the small parts pack.
DUPLEX TEE
To Brine Line Adapter fitting softener unit
POLYPRO. NUT TUBING INSERT
To Brine Line Adapter fitting softener unit
TUBING
NUT—PLASTIC
POLYPRO. INSERT
Figure 20. 22
Culligan® High Efficiency Twin Softener
Brine system assembly. 22
Cat. No. 01023053
Fill The Salt Storage Container Fill the salt storage container with water until the level reaches about one (1) inch above the salt support plate. Pour salt into the container. Fill with salt to within a few inches of the top.
Brine Valve “A” Dimension The brine valve contains a brine float which can serve as a backup refill shutoff in the event of a failure, such as a power outage when in the refill position. The float level should be set based on the salt dosage setting. Refer to Figure 21. Remove nut retaining brine valve to brine chamber.
2.
Lift the brine valve from the brine chamber.
3.
Find the correct “A” dimension from “Appendix A, Softener Capacities”, Table 11.
4.
Set the distance from the top of the filter screen to the base of the float accordingly. The slight difference in height when the float is pulled up or down is negligible.
5.
Re-install into brine chamber and replace nut.
“A” Dimension
1.
Figure 21. Cat. No. 01023053
Brine valve “A” dimension. Installation
23
Circuit Board Connections Refer to the instructions below to make connections to the HE Twin circuit board:
WARNING! Disconnect all electrical power to the unit before making electrical connections.
NOTE 1.
CAUTION!
Grip all connections to the circuit board by the connecting terminals for assembly and disassembly. Failure to do so could result in damage to the wire leads or connecting terminals.
CAUTION!
Do not touch any surfaces of the circuit board. Electrical static discharges might cause damage to the board. Handle the circuit board by holding only the edges of the circuit board. Mishandling of the circuit board will void the warranty.
Observe all state and local electrical codes. Remove the electrical enclosure from both control valves. First remove the electrical enclosure screw and then gently remove the enclosure from the control. Refer to Figure 22 and below instructions. Electrical Enclosure Screw
24 Volt Power Cord
Flow Meter Wire Harness Aqua-Sensor Wire Harness and 2.5 Volt Power Cord
Figure 22.
24
Flow Meter Harness Motor Cable and Gearbox Position Cable from Control #2
Circuit board connections.
2.
Remove the 24 Volt power supply wire harness from the circuit board. See Figure 23.
3.
Grip the circuit board from the edges and gently rotate it to the back of the enclosure (you are disengaging the circuit board from the two support pins on the bottom of the enclosure).
4.
Remove the circuit board from the enclosure. See Figure 24.
5.
Remove the meter cable from the circuit board.
6.
Remove the plastic plugs from the enclosure.
7.
Connect the auxiliary board to the main board. See Figure 25. The auxiliary board is shipped inside the HE Twin control #2 carton.
Culligan® High Efficiency Twin Softener
24
Cat. No. 01023053
NOTE
If additional accessories are to be connected to the circuit board (such as the Smart Brine Tank Probe or a phone line for modem) insert both the Aqua-Sensor 2.5 Volt power supply wire harness and the Aqua-Sensor sensor probe wire harness through the third hole on the enclosure.
NOTE
The wire connectors must be connected to the circuit board properly. The wires must exit the plug-in connector opposite of the raised white base of the circuit board connector. Failure to properly connect any of the connectors will result in a malfunction of the circuit board operation. Support Bracket
24 Volt Power Supply Cord Support Bracket
Figure 23.
Cat. No. 01023053
Circuit board power supply.
Figure 24.
Circuit board removal.
Installation
25
Figure 25.
Circuit board connections.
8.
Connect the motor cable, gear box position cable and meter cable from HE Twin Control #2 to the auxiliary board and main board. One connector of the flow meter harness connects to the main circuit board; the other connector of the flow meter harness connects to the auxiliary board. See Figure 25.
9.
If installing an Aqua-Sensor, set up the 2.5 VAC power now. a.
Locate the Aqua-Sensor power cord packed in the small parts pack. It has two spade terminals on one end of the cable and the circuit board connector on the other end.
b.
The power connection to the circuit board should be inserted INSIDE the controller. The spade terminals should be connected to the transformer.
c.
Discard the dummy connector on the 2.5VAC circuit board pins.
d.
Connect the Aqua-Sensor power cord to the 2.5VAC pins on the circuit board.
e.
Connect the other end of the power cord, with the spade terminals, to the two 2.5 VAC terminals on the transformer (Figure 26).
10. Pull any excess cable wire out of the enclosure and route the wiring inside the enclosure to avoid any interference. CAUTION!
26
Verify wiring from the terminals to circuit board are correct before applying power to the control. 24 VAC power must not be applied to the 2.5 VAC terminals of the circuit board. Connecting 24 VAC to the 2.5 VAC connection on the circuit board will damage the circuit board.
Culligan® High Efficiency Twin Softener
26
Cat. No. 01023053
Blue
Black Red White
PHONE
Connector Plug
Power to circuit board 2.5VAC only required for Aqua-Sensor installations
METAL TABS Connect to white connector on main power cord
Power to circuit board 24V
2.5V
24VAC on TRANSFORMER
Figure 26.
2.5 VAC Aqua-Sensor® power connection.
11. Insert the circuit board back into the enclosure. a.
Angle the circuit board opposite the front enclosure and into the support bracket on the side of the enclosure.
b.
Gently push down and rotate forward until you hear a click (the pins on the bottom of the enclosure being inserted into the circuit board).
c.
Check to make sure the circuit board is rigidly fastened.
12. Reattach the electrical enclosure cover to the control valve. a.
Align the circuit board in the enclosure with the three support brackets on the control valve frame. See Figure 27.
b.
Push the enclosure onto the control valve, inserting the circuit board edge in the slots on the control valve frame and the screw on the enclosure with the hole on the cover.
Cat. No. 01023053
Installation
27
Align with slot on fr e boar dge of ame c d in the e ircuit nclo sure
Inse r into t screw hold o er o n enclo n co ntro sure l va lve
Align circu slot on fr it bo ard ame wit in th h e en edge o clos ur e f Align circu slot on fr it bo ard ame wit in th h e en edge o clos ure f
Figure 27.
28
Attaching enclosure cover to control valve.
c.
Screw the enclosure on the control.
d.
Attach the strain relief fittings to the Aqua-Sensor probe, 2.5 VAC power cord and wire harnesses from HE Twin control #2 and insert into the enclosure.
e.
Connect the 24 Volt power cord to the two 24 VAC terminals on the transformer.
Culligan® High Efficiency Twin Softener
28
Cat. No. 01023053
Navigating the Menus and Keypad
UP button
CHECK MARK or OK button
CANCEL (X) button
DOWN button
UP ARROW
button: scrolls up the menu
DOWN ARROW
CHECK MARK changed setting
button: scrolls down the menu
button: selects the highlighted option, opens a new screen, or accepts a
CANCEL or EXIT
NOTE
Hold down the button.
button: returns to the previous screen or cancels a changed setting
button to quickly scroll through the setting without repeatedly pressing the
or
Basic Menu Operation SOFTENING JAN-01-12 12:01P
1.
This is the home screen. Press
>1)INFORMATION 2)MANUAL MODE
2.
This is the main menu. The cursor/pointer (>) shows where you are in the menu.
3.
Use or to scroll through the menu. The selection cursor scrolls down to the next line or displays the next screen.
4.
Press
2)MANUAL MODE >3)SET DATE/TIME Cat. No. 01023053
or
or
to display the main menu.
to select the item next to the cursor. Navigating the Menus and Keypad
29
SET MONTH JAN
5.
SET MONTH >JAN
6.
SET MONTH >FEB
7.
to select a new value. The screen displays the new setting value next to Press the cursor.
8.
Press to select the next available value. You may press through all available options for this setting.
SET MONTH FEB
9.
Press to accept the selected screen value. The screen displays the value, no longer preceded by the cursor.
SET DAY 1
10. Press
2)MANUAL MODE >3)SET DATE/TIME
11. Press to exit from the setting without saving changes. The screen displays the parent menu (such as the main menu).
SOFTENING JAN-01-12 12:01P
12. Press
NOTE
30
The controller screen displays a setting title and value. Here we see the current value for the month setting is January.
Press
to select the item. The screen displays a cursor next to the value. This
indicates that the value may be changed by pressing the
or
button.
or
to scroll
to scroll to the next setting.
to display the home screen.
Unplugging the Culligan HE water softener will not affect any of the control settings (the control must be plugged in for at least 15 minutes). Once programmed, the settings will be stored indefinitely.
Culligan® High Efficiency Twin Softener
30
Cat. No. 01023053
First Time Setup First Time Setup Procedure When a new controller is first powered on, the screen will display the first time setup message. The Smart Controller is designed to simplify the setup and installation process by making some default recommendations during the initial setup. These default settings are designed to be appropriate for most common installations.
Default Settings
Downflow Brining2 Blue/Beige Eductor1 0 PPM Iron1 > 40 psi water pressure1 NaCl Salt1 Time of Regen = 2:00 AM2 Regen Time = Delayed2
Dosage (calculated)2 Predict Mode OFF3 30% Reserve Capacity2 Regen Interval Days = OFF3 Day-of-week Regen = OFF3 Pre-Rinse Mode = OFF1
1= these items are changed on the Main Menu / Advanced / System Setup Menu 2= these items are changed on the Main Menu / Advanced / Regen Setup Menu 3= these items are changed on the Main Menu / Advanced / Regen Trigger Menu
If at any time you need to re-run the First Time Setup, refer to the Menu Information section. After completing the plumbing connections to the water softener, turn on and program the Smart controller.
Screen Display FIRST TIME SETUP PRESS DOWN ARROW S/N:00025526
Range
Procedure 1.
N/A
When a new controller is first turned on, the screen displays FIRST TIME SETUP. Press to view and change (if necessary) the softener configuration.
2. N/A
The screen displays the serial number for the HE Controller. Press
NOTE
FWR216LT21 Jan 4 2012 SET MONTH JAN
SET DAY 1 SET YEAR 2012 CLOCK TYPE 12 HR Cat. No. 01023053
N/A
JAN–DEC
1–31
3.
to view the next setting.
If this unit will be installed with a modem, it is required that this electronic ID number be reported to Culligan on the Web site myculligan.com.
The screen displays the firmware version for the HE Controller. Press
4.
The screen displays the first date setting for the HE Controller.
5.
Press
6.
The screen displays the default day setting. Press and then
2009–2030
7.
8.
or
and then
to change the value.
or
to change the value.
The screen displays the clock type setting. Press and then
or
to change the value.
The screen displays the default year setting. Press and then
12 HR or 24 HR
to view the next setting.
or
to change the value. First Time Setup
31
Screen Display SET HOUR 12PM SET MINUTES 0 UNIT TYPE SOFTENER VALVE TYPE HE 1 Twin
UNITS US INCH
Range 12PM–11PM 0–23
0–59
Procedure 9.
then
HE 1, HE 1.25, HE 1.5, HE 1 Twin, HE 1.5 Twin, 4-Cycle, 5-Cycle, Plat Plus U.S. Inch, Metric
10. The screen displays the minutes setting. Press
or
to change the value.
11. The screen displays the unit type setting. Keep this setting at the default, SOFTENER. Press
to view the next setting.
12. The screen displays the valve type setting. Press
13. The screen displays the units of measure setting. Press or
and then
to change the setting.
14. The screen displays the installation type setting. Keep this at
Residential, Commercial
BRINING TYPE Downflow
Downflow, Upflow, Proportional
15. The screen displays the brining type setting. Press
TANK DIAMETER 9
9, 10, 12, 14
16. The screen displays the tank diameter setting. Press
HARDNESS GPG 25 (1056 GAL)
1–170 (20628–260)
SOFTENING JAN-01-12 12:01P
32
the default, Residential. Press
and then
or
N/A
Culligan® High Efficiency Twin Softener
or
and then to change the value to HE 1 Twin and view the next setting.
INSTALL TYPE Residential
Initializing JAN-01-12 12:01P
and
to change the value.
and then Softener, Filter, or Resin+Carbon
or
The screen displays the hour setting. Press
and then
to view the next setting.
or
to change the value.
to change the value.
17. The screen displays the water hardness setting in grains per or
gallon. Press
and then
to change the value.
18. When the setup is complete, the circuit board microprocessor automatically calculates softener capacity and “homes” the control valve. The screen displays the initializing status and the current date and time, and then transitions to the home screen. 19. The screen displays the current state (the display alternates between Softening and the next programmed reconditioning) and the date/time set for the unit. This is the default home screen.
32
Cat. No. 01023053
Menu Default Use this procedure to default the board to factory settings and begin the first time setup. 1.
Power down the control.
2.
Power up the control while continuing to hold
3.
Release
4.
The controller then restarts, lights up the display screen, and then displays FIRST TIME SETUP.
5.
Follow the FIRST TIME SETUP process.
and
and
for at least ten (10) seconds.
. The display should be blank; if it is not, go back to step 1.
Menu Lockout It is possible to lock the keypad of the controller so that users will only have access to the INFORMATION, MANUAL MODE, and SET DATE/TIME menu screens. The system can be locked from the home screen by pressing simultaneously and holding them down for 10 seconds. Repeating this process will unlock the keypad.
Cat. No. 01023053
and
First Time Setup
33
Customizing Set Up There may be times when the installer would prefer to override the default regeneration selections. See Advanced Setup Menu, Regeneration Setup Menu or Regeneration Trigger Menu for information on changing default selections.
Advanced Setup Menu The following settings can be changed or customized using the Advanced System Setup menu: Valve Type
Tank Diameter
Hardness
Units
Iron
Pre-Rinse Mode
Line Pressure
Dial-a-Softness
Salt Type
Twin Pre-Rinse
NOTE
The control must be returned to the HOME screen if settings are changed.
System Setup NOTE
Default values are shown for each setting.
Screen Display
Range
Procedure
SOFTENING JAN-01-12 12:01P
N/A
1.
From the HOME screen, press
>1)INFORMATION 2)MANUAL MODE
1–6
2.
The screen displays the main menu. Press to select 5)ADV. SETUP.
>1)SYSTEM SETUP 2)REGEN SETUP
3. 1–4
The screen displays the advanced setup menu. The menu includes SYSTEM SETUP, REGEN SETUP, CYCLE TIMES, and REGENTRIGGER.
4.
Press
VALVE TYPE HE 1 Twin
TANK DIAMETER 9 UNITS US INCH SALT TYPE NACL
34
HE 1, HE 1.5, HE 1 Twin, 4-Cycle, 5-Cycle, or Plat Plus 9, 10, 12, 14
5.
to select 1)SYSTEM SETUP.
The screen displays the valve type setting specified during the first-time setup. This setting cannot be changed. Press view the next setting.
6.
U.S. Inch, Metric
7.
NaCL, KCL
8.
to
The screen displays the tank diameter setting. Press or
Culligan® High Efficiency Twin Softener
to view the main menu.
and then
to change the value.
The screen displays the units of measure setting. Press or
and then
to change the setting.
The screen displays the salt type setting. Press and then
or
to change the setting.
34
Cat. No. 01023053
Screen Display IRON PPM 0
Range
Procedure 9.
0–5
The screen displays the iron present in parts per million. This value can be obtained from an onsite test or a water analysis.
NOTE
LINE PRESSURE ABOVE 40 PSI DIAL-A-SOFTNESS SOFTEST
or
Press
Above 40 psi, Below 40 psi
U.S. Inch, Metric
and then
to change the setting.
Capacity is reduced 10% for every 1 ppm of iron. or
10. The screen displays the line pressure setting. Press and then
to change the setting.
11. The screen displays the Dial-a-Softeness setting. If the Dialor
a-Softness knob has been adjusted, press then
and
to change the setting.
See page 20 for an explanation of the Dial-a-Softness setting.
HARDNESS GPG 25 (1056 GAL)
1–170 (20628–260)
12. The screen displays the water hardness setting in grains per gallon (U.S. units). This value can be obtained from an onsite test or a water analysis. Press change the value.
TWIN PRERINSE 5
PRERINSE MODE OFF
0–5
Off, On
1–240
and then
to
13. The screen displays the HE Twin prerinse mode setting, which specifies the the duration of rinsing the standby tank prior to going online. Press value.
or
and then
to change the
14. The screen displays the prerinse mode setting, which specifies the unit drain intervals and durations. Press and then
RINSE IF NO FLOW FOR 24
or
or
to change the value from OFF to ON.
15. The screen displays the rinse interval. If prerinse mode is ON, the unit will drain if no flow is detected for the duration of this interval. Press value.
or
and then
to change the
>1)SYSTEM SETUP 2)REGEN SETUP
16. The customized setup is complete. The screen displays the advanced setup menu.
SOFTENING JAN-01-12 12:01P
17. Press screen.
Cat. No. 01023053
to save the settings and display the home
Customizing Set Up
35
Regeneration Setup The following settings can be changed and/or customized using regeneration setup: Salt Dosage
Regeneration Mode
Reserve Capacity
Regeneration Lockout
Time of Regeneration
Power Up Regeneration
NOTE
If any settings are changed the controller must be returned to the HOME screen.
Screen Display
Range
Procedure
SOFTENING JAN-01-12 12:01P
N/A
1.
From the HOME screen, press
>1)INFORMATION 2)MANUAL MODE
1–6
2.
The screen displays the main menu. Press to select 5)ADV. SETUP.
1)SYSTEM SETUP >2)REGEN SETUP
3. 1–4
The screen displays the advanced setup menu. The menu includes SYSTEM SETUP, REGEN SETUP, CYCLE TIMES, and REGENTRIGGER.
4.
Press
5.
The screen displays the salt dosage setting. The salt dosage contributes to calculating the resin capacity and is also used when a Smart Brine Tank sensor is installed to help calculate
SALT DOSAGE 7.7
3–375
to view the main menu.
to select 2)REGEN SETUP.
salt usage and salt remaining. Press
or
and then
to change the value; the higher the dosage, the higher the capacity. Refer to the appendix of the unit’s installation manual for information about setting the salt dosage.
RESERVE CAPACITY 30% (316 GAL)
0–99
6.
The screen displays the reserve capacity setting. This setting is generally used for a single-delay system. For a single HE softener the typical setting is 30 percent reserve capacity. Press
BRINING TYPE Downflow
Downflow, Upflow, Proportional
7.
TIME OF REGEN 2:00AM
12:00AM– 11:59PM
8.
REGEN MODE DELAYED
Delayed, Immediate
9.
to change the value.
The screen displays the brining type setting. See page 11 for an or
and then
If Proportional is selected, any manually initiated regeneration will be performed assuming that remaining capacity equals zero (0) percent.
The screen displays the regeneration scheduled time setting. Press
or
and then
to change the setting.
The screen displays the regeneration mode setting. Press or
NOTE
Culligan® High Efficiency Twin Softener
and then
explanation of brining types. Press to change the setting. NOTE
36
or
and then
to change the setting to IMMEDIATE.
If IMMEDIATE is selected then change the Reserve Capacity setting. 36
Cat. No. 01023053
Screen Display POWER UP REGEN 3 PLUS HOURS
Range
Procedure
No, 3 Plus Hours
10. The screen displays the regeneration power up setting. This setting specifies whether to initiate an immediate regeneration after a power outage longer than three hours. Press and then
Regen Lockout FOR 0
0–12
or
to change the setting.
11. The screen displays the regeneration lockout setting. This setting is not applcable for the HE softener. Press default setting at zero (0).
to keep the
1)SYSTEM SETUP >2)REGEN SETUP
12. The regeneration setup is complete. The screen displays the advanced setup menu.
SOFTENING JAN-01-12 12:01P
13. Press screen.
Cat. No. 01023053
to save the settings and display the home
Customizing Set Up
37
Cycle Times Setup The following settings can be changed and/or customized using the cycle times setting: Backwash Time Brine Draw/Slow Rinse Time Fast Rinse Time Use the same procedure to change the values of other cycle times setup settings. Press unless otherwise instructed. After changing the setting, press will display the next system setting from the menu.
to scroll through the settings,
to accept the displayed screen value. The HE Controller
NOTE
The control must be returned to the HOME screen if settings are changed.
NOTE
For upflow controls the backwash and fast rinse default times are set at five (5) minutes.
Screen Display
Range
Procedure
SOFTENING JAN-01-12 12:01P
N/A
1.
From the HOME screen, press
>1)INFORMATION 2)MANUAL MODE
1–6
2.
The screen displays the main menu. Press to select 5)ADV. SETUP.
2)REGEN SETUP >3)CYCLE TIMES
3. 1–4
The screen displays the advanced setup menu. The menu includes SYSTEM SETUP, REGEN SETUP, CYCLE TIMES, and REGENTRIGGER.
4.
Press
5.
The screen displays the cycle times setting. If USE DEFAULTS is selected, the program calculates the cycle times based on hardness and resin volume. Select CUSTOM to set the backwash, brine draw-rinse, fast rinse, and fill times. Press
CYCLE TIMES USE DEFAULTS
Use Defaults, Custom
to select 3)CYCLE TIMES.
or
BACKWASH TIME 10 MIN
0–150
6.
to view the main menu.
and then
to change the value.
The screen displays the backwash time setting, in minutes. The default value is ten (10) minutes. Press
or
and then to change the value; however, in general you will not need to change this setting.
BRINE DRAW-RINSE 66 MIN
0–150
7.
The screen displays the brine draw-rinse setting. For residential softener applications this value should be 66 minutes. or and then to extend the time if the Press brine is not properly rinsing out within this duration.
FAST RINSE-TIME 10 MIN
38
8. 0–150
Culligan® High Efficiency Twin Softener
The screen displays the fast rinse time setting. For residential softener applications this value should be set to 10 minutes. Press
to keep the default setting at 10.
38
Cat. No. 01023053
Screen Display FILL TIME 377 SEC
Range 0–9000
Procedure 9.
The screen displays the fill time setting, based on the salt dosage. Press
NOTE
to keep the calculated setting.
DO NOT change this setting. Changing the fill time will NOT adjust the salt dosage setting.
2)REGEN SETUP >3)CYCLE TIMES
10. The regeneration setup is complete. The screen displays the advanced setup menu.
SOFTENING JAN-01-12 12:01P
11. Press screen.
Cat. No. 01023053
to save the settings and display the home
Customizing Set Up
39
Regeneration Triggers The following settings can be changed and/or customized using Regeneration Trigger: Predict Mode
Flow Meter Aqua-Sensor
Day of Regeneration
®
Regeneration Interval (Time Clock Backup) Use the same procedure to change the values of other regeneration triggers setup settings. Press the DOWN ARROW button to scroll through the settings, unless otherwise instructed. After changing the setting, press the CHECK MARK button to accept the displayed screen value. The Smart Controller will display the next system setting from the menu. NOTE
The control must be returned to the HOME screen if settings are changed.
Screen Display
Range
Procedure
SOFTENING JAN-01-12 12:01P
N/A
1.
From the HOME screen, press
>1)INFORMATION 2)MANUAL MODE
1–6
2.
The screen displays the main menu. Press to select 5)ADV. SETUP.
3)CYCLE TIMES >4)REGENTRIGGER
3. 1–4
The screen displays the advanced setup menu. The menu includes SYSTEM SETUP, REGEN SETUP, CYCLE TIMES, and REGENTRIGGER.
4.
Press
5.
The screen displays the flow meter regeneration trigger setting, which allows an optional flow meter to trigger the controller to initiate regeneration. If set to CAN TRIGGER, the flow meter counts the gallons of softened water until reaching the batch value, which triggers regeneration. A water meter may be used only to monitor flow rate and total usage but not to trigger regeneration. A system may also have both a water meter and Aqua-Sensor installed and able to trigger regeneration; either can trigger regeneration, and then the system is re-
FLOW METER CAN TRIGGER
Can Trigger, Cannot Trigger
to view the main menu.
to select 4)REGENTRIGGER.
set when regeneration is complete. Press then NOTE
AQUASENSOR CAN TRIGGER
Can Trigger, Cannot Trigger
6.
or
and
to change the value. See page 125 for further details about setting up a meter as a backup for an Aqua-Sensor.
The screen displays the Aqua-Sensor regeneration trigger setting, which allows an optional Aqua-Sensor to trigger the controller to initiate regeneration. A system may also have both a water meter and Aqua-Sensor installed and able to trigger regeneration; either can trigger regeneration, and then the system is reset when regeneration is complete. Press or
40
Culligan® High Efficiency Twin Softener
and then
to change the value.
40
Cat. No. 01023053
Screen Display REGEN DAYS INT 0
Range
Procedure 7.
0–99
The screen displays the regeneration interval, which sets up a time clock backup for the installed trigger device. Press or
NOTE
PREDICT MODE OFF
8. On, Off
and then
to change the setting.
See page 12 for a more detailed explanation of the regeneration interval.
The screen displays the predict mode, which is used in the flow meter to determine the optimum regeneration point. Prior to regeneration the control compares the remaining capacity with the average daily water usage. If the average daily water usage is less than remaining capacity, then the controller will delay regeneration 24 hours. Reduce the RESERVE CAPACITY setting when using predict mode. Press then
NOTE
MONDAY REGEN OFF
On, Off Monday –Sunday
9.
or
and
to change the setting. See page 12 for a more detailed explanation of the predict mode.
The screen displays the scheduled regeneration setting. Select ON for the displayed day to initiate regeneration on that day regardless of the meter or Aqua-Sensor. Press and then
or
to change the setting for each day.
3)CYCLE TIMES >4)REGENTRIGGER
10. The regeneration setup is complete. The screen displays the advanced setup menu.
SOFTENING JAN-01-12 12:01P
11. Press screen.
Cat. No. 01023053
to save the settings and display the home
Customizing Set Up
41
Installing Accessories The following HE accessories, if installed, are set up using the 4) ACCESSORIES menu. 1.
Aqua-Sensor Probe
2.
Setting the Beeper Mode
3.
Setting the Display Contrast
4.
Auxiliary Input (not used for HE applications)
5.
Auxiliary Outputs (not used for HE applications)
6.
Smart Brine Tank Sensor
7.
Wireless Remote
8.
Modem
9.
Chlorinator (not currently used for HE applications)
10. Flow Meter 11. Service Phone Number 12. External Filter
1) AQUASENSOR (Aqua-Sensor® Probe) Screen Display
Range
Procedure
SOFTENING JAN-01-12 12:01P
N/A
1.
From the HOME screen, press
3)SET DATE/TIME >4)ACCESSORIES
1–6
2.
The screen displays the main menu. Press select 4)ACCESSORIES.
>1)AQUASENSOR 2)BEEPER
1–12
3.
The screen displays the accessories menu. Press 1)AQUASENSOR.
AQUASENSOR NOT INSTALLED
Not Installed Installed
4.
5. On, Off
SOFTENING JAN-01-12 12:01P
42
Culligan® High Efficiency Twin Softener
to
to select
The screen displays the installation status of the wireless remote. Press to change the state to installed. The Smart Controller can then communicate with Aqua-Sensor.
NOTE
AQUASENSOR DEBUG OFF
to view the main menu.
The Aqua-Sensor probe is installed during the final startup procedure. See page 63.
The screen displays the Aqua-Sensor debugging tool status. Keep this setting at OFF; the tool is accessible only at the factory. Press
6.
Press screen.
to return to the accessories menu. to save the settings and display the home
42
Cat. No. 01023053
2) BEEPER (Setting the Beeper Mode) Screen Display
Range
Procedure
SOFTENING JAN-01-12 12:01P
N/A
1.
From the HOME screen, press
3)SET DATE/TIME >4)ACCESSORIES
1–6
2.
The screen displays the main menu. Press select 4)ACCESSORIES.
1)AQUASENSOR >2)BEEPER
1–12
3.
The screen displays the accessories menu. Press 2)BEEPER.
Always Off Always On 12 HR Warnings 24 HR Warnings
4.
BEEPER MODE ALWAYS OFF
Beeper Mode Display
to view the main menu.
to
to select
The screen displays the beeper mode settings. Press or
and then
to change the setting. See Table 1.
Beeps When Key is Pressed
Alarm Beeps
ALWAYS ON
Always
Never
ALWAYS OFF
Never
Never
12 HOUR WARNINGS
Always
Between 8 AM–8 PM
24 HOUR WARNINGS
Always
Always
Table 1. Beeper mode settings.
SOFTENING JAN-01-12 12:01P
5.
Press screen.
to save the settings and display the home
3) SET CONTRAST (Setting the Display Contrast) Screen Display
Range
Procedure
SOFTENING JAN-01-12 12:01P
N/A
1.
From the HOME screen, press
3)SET DATE/TIME >4)ACCESSORIES
1–6
2.
The screen displays the main menu. Press select 4)ACCESSORIES.
to
2)BEEPER >3)SET CONTRAST
1–12
3.
The screen displays the accessories menu. Press select 3)SET CONTRAST.
to
SET CONTRAST 2
4. 1–5
The screen displays the contrast settings, ranging from 1 (lightest/no LCD contrast) to 5 (darkest/high LCD contrast).
SOFTENING JAN-01-12 12:01P Cat. No. 01023053
5.
and then
to view the main menu.
Press
or
to change the setting.
Press screen.
to save the settings and display the home
Installing Accessories
43
4) AUX IN (Installing Auxiliary Inputs) 5) AUX OUTPUTS (Installing Auxiliary Outputs) See “Auxiliary Input and Output” on page 103 for information about programming auxiliary inputs and outputs.
6) SBT SENSOR Installing the Smart Brine Tank (SBT Probe) in to the Brine Tank 1.
Place the smart brine probe on top of the brine plate as shown in Figure 28.
2.
Loop the two zip ties thru the holes in the probe housing and loop the zip ties around the outside of the brine well as shown in Figure 29.
NOTE
IMPORTANT! Tighten zip ties securely to prevent movement.
3.
Use a zip tie to snug the top of the brine tank probe against the top of the brine well.
4.
Route the Smart Brine Tank cable through the hole provided for the brine tubing. See Figure 30.
5.
Route the smart brine tank probe cable to an appropriate opening in the valve control housing. Use the strainrelief plug provided with the SBT probe for installation.
6.
Plug the SBT probe connector into the circuit board at the position labeled Brine Tank. See Figure 31.
Smart Brine Tank Probe Connection
Figure 28.
Figure 29.
Figure 30.
Figure 31.
NOTE
If the SBT probe is installed in an existing brine tank, or in a tank other than one provided, be sure that the probe is completely out of the brine at the end of the brine draw. Otherwise the probe will malfunction.
NOTE
When adding salt to a brine tank that is using the SBT probe, add enough salt to completely bury the probe.
Configuring the Smart Brine Tank (SBT) Probe Settings After the Smart Brine Tank Probe is installed, it is necessary to configure some settings. NOTE
In order for proper probe functioning, it is required that prior to selecting INSTALLED on the menu the probe must be physically installed into the brine tank and that the brine tank be filled with a minimum of 16" depth of salt. Failure to take these steps will result in the screen displaying ERROR MESSAGE. If these steps were not followed, go to the menu shown below and select UNINSTALLED, then press then to return to the HOME SCREEN. Once the probe is installed correctly and salt is added to the brine tank return to these menus and change the setting back to INSTALLED.
44
Culligan® High Efficiency Twin Softener
44
Cat. No. 01023053
Screen Display
Range
Procedure
SOFTENING JAN-01-12 12:01P
N/A
1.
From the HOME screen, press
3)SET DATE/TIME >4)ACCESSORIES
1–6
2.
The screen displays the main menu. Press select 4)ACCESSORIES.
5)AUX OUTPUTS >6)SBT SENSOR
1–12
3.
The screen displays the accessories menu. Press
to view the main menu.
to
to select 6)SBT SENSOR.
SBT SENSOR NOT INSTALLED
Not Installed Installed
TANK DIAMETER 9
9, 10, 12, 14
4.
The screen displays the installation status of the Smart Brine Tank sensor. Press to change the state to installed. The Smart Controller can then communicate with the SBT sensor.
5.
The screen displays the tank diameter setting. Press or and then to increase or decrease the tank diameter, which is used to estimate the number of days the brine tank has salt. Culligan 16” brine tank = 250 lb. salt capacity Culligan 18” brine tank = 375 lb. salt capacity Culligan 24” brine tank = 650 lb. salt capacity
SALT GEOMETRY Pellet/cube
SOFTENING JAN-01-12 12:01P
Cat. No. 01023053
Pellet/Cube, Rock/Solar, Special, Block/ Brick
6.
The screen displays the salt geometry (the shape of the softening salts) setting. Press change the value.
7.
Press screen.
or
and then
to
to save the settings and display the home
Installing Accessories
45
7) WIRELESS REM (Wireless Remote) WARNING! Disconnect all electrical power to the unit before servicing. Bypass the unit and relieve system pressure before attempting repair.
CAUTION!
1.
Grip all connections to the circuit board by the connecting terminals for assembly and disassembly. Failure to do so could result in damage to the wire leads or connecting terminals.
Select a location for the wireless remote monitor (Figure 32). The location must be near an electrical outlet. If a modem is used in the remote, then the location should also be near a standard RJ-11 type telephone wall jack. 5 3/8”
MODEM CONNECTION SCREWS
POWER CONNECTION
Figure 32. CAUTION!
Do not touch any surfaces of the circuit board. Electrical static discharges may cause damage to the board. Handle the circuit board by holding only the edges of the circuit board. Keep replacement boards in their special anti-static bags until ready for use. Mishandling of the circuit board will void the warranty.
2.
Use the Hole Drilling Template as a guide to drilling two holes to mount the remote monitor (see Figure 46 on page 84). If drilling into wall board, drill two 5/16” diameter holes and insert the plastic drywall anchors into the holes securing them with the two #10 screws provided. If drilling into a solid surface, drill two 7/32” holes into the surface and screw the two #10 screws into the holes. In either case, leave a gap of approximately 3/32” between the head of the screw and the wall.
3.
(Optional) If a modem is to be installed into the remote monitor, refer to the modem information on page 50.
4.
Connect the power cord to the bottom of the remote monitor. If a modem is to be used in the remote, plug a standard telephone extension cord into the bottom of the remote monitor.
5.
Hang the remote monitor on the two screws.
6.
Disconnect power to the softener. Open the control and connect the RF board into the controller circuit board. Make sure the RF board is fully seated into all of the sockets (see Figure 33). Reconnect power.
NOTE
46
Wireless remote monitor.
The printed Culligan logo will appear upside down on the RF board.
Culligan® High Efficiency Twin Softener
46
Cat. No. 01023053
Back of GBE Board
RF Board (note orientation) Figure 33.
RF board location on GBE board.
7.
Install RF board into unit controller. Line up pins in RF board and press firmly into black connectors. Note orientation of RF board (see Figure 33).
8.
Follow the directions on the next page to program BOTH the main and remote monitor units so they can communicate with each other. If a modem is installed in the remote, it is also necessary to follow the directions in the next section of this manual to configure the main controller to use the modem in the remote.
Wireless Remote Setup This setup is completed using the wireless remote device.
Screen Display
Range
Procedure
SOFTENING JAN-01-12 12:01P
N/A
1.
From the HOME screen, press
3)BEEPER >4)SETUP
1–6
2.
The screen displays the main menu. Press select 4)SETUP.
>1)RF SETUP 2)MODEM SETUP
1–2
3.
The screen displays the accessories menu. Press 1)RF SETUP.
4.
The screen displays the channel number setting. Press
CHANNEL # 1
RF FREQUENCY 915MHz
1–254
Cat. No. 01023053
to
to select
or and then to to select the channel number of the control valve. The CHANNEL # for the control valve must be the same as the CHANNEL # for the Remote Display. 5. 915, 869, 433
The screen displays the radio frequency (RF). Do not change the setting from 915 MHz RF frequency for North America installations. Press
SOFTENING JAN-01-12 12:01P
to view the main menu.
6.
Press screen.
to return to the setup menu.
to save the settings and display the home
Installing Accessories
47
Control Valve Setup Now set up the control valve to prompt the Smart Controller to communicate with the installed wireless remote.
Screen Display
Range
Procedure
SOFTENING JAN-01-12 12:01P
N/A
1.
From the HOME screen, press
3)SET DATE/TIME >4)ACCESSORIES
1–6
2.
The screen displays the main menu. Press select 4)ACCESSORIES.
6)SBT SENSOR >7)WIRELESS REM
1–12
3.
The screen displays the accessories menu. Press
REMOTE DISPLAY NOT INSTALLED
CHANNEL # 1
RF FREQUENCY 915MHz
to view the main menu.
to
to select 7)WIRELESS REM. Not Installed Installed
4.
1–254
5.
The screen displays the installation status of the wireless remote. Press to change the state to installed. The Smart Controller can then communicate with the remote. The screen displays the tank diameter setting. Press or and then to to select the channel number of the control valve. The CHANNEL # for the control valve must be the same as the CHANNEL # for the Remote Display.
6. 915, 869, 433
The screen displays the radio frequency (RF). Do not change the setting from 915 MHz RF frequency for North America installations. Press
SOFTENING JAN-01-12 12:01P
7.
Press screen.
to return to the accessories menu.
to save the settings and display the home
Check Signal Strength Check the signal strength once the control valve and wireless remote are setup. On the Smart Controller, go to the Main Menu/Advanced setup/Diagnostics/Test Wireless to check signal strength. The signal strength indicator (SSI) will show a value of between 0 and 8. If the SSI is at least 4, then the installation is complete. It the SSI drops below 4, then it may be necessary to select an alternate location within distance for the wireless remote.
Screen Display
Range
Procedure
SOFTENING JAN-01-12 12:01P
N/A
1.
From the HOME screen, press
5)ADV. SETUP >6)DIAGNOSTICS
1–6
2.
The screen displays the main menu. Press
2)CHECK SENSORS >3)TEST WIRELESS
1–9
48
to view the main menu.
to select 6)DIAGNOSTICS.
Culligan® High Efficiency Twin Softener
3.
The screen displays the diagnostics menu. Press to select 3)TEST WIRELESS.
48
Cat. No. 01023053
Screen Display
Range
Procedure
WIRELESS TEST 0 / 14
4.
The screen displays the status of the wireless test, such as the test number and total number of attempts.
WIRELESS TEST RSSI=5
5.
Press to display the results of the wireless test, the received signal strength indicator (RSSI).
SOFTENING JAN-01-12 12:01P
6.
Press screen.
to save the settings and display the home
8) MODEM NOTE 1.
The modem can be installed into either the back of the main controller or the back of the remote control board. The functionality of the modem is the same in either installation. Unplug the wireless remote before installing the modem into the back of the GBE board or the back of the remote. See Figure 34 and Figure 35.
WARNING! Disconnect all electrical power to the unit before servicing. Bypass the unit and relieve system pressure before attempting repair.
CAUTION!
Grip all connections to the circuit board by the connecting terminals for assembly and disassembly. Failure to do so could result in damage to the wire leads or connecting terminals.
CAUTION!
Do not touch any surfaces of the circuit board. Electrical static discharges may cause damage to the board. Handle the circuit board by holding only the edges of the circuit board. Keep replacement boards in their special anti-static bags until ready for use. Mishandling of the circuit board will void the warranty.
2.
Make sure all of the pins at all four connectors are aligned between the modem board and the main controller board. Make sure that the modem board is fully seated into all four sockets.
3.
When all connections have been made restore power.
4.
Connect the modem to the telephone line by plugging a standard RJ-11 phone extension cord into the modem board.
NOTE
The HE Twin is designed to plug into an analog telephone line (standard residential phone line). This includes phone lines connected to most residential VoIP (voice over Internet) phone systems and to residential DSL phone systems. If you are connecting the HE to a DSL phone system, follow the DSL provider recommended method to connect standard phones to the DSL service. Many systems recommend or require the use of DSL line filters between the phone jack and the device.
NOTE
Try to place the HE Twin Softener or Remote Display near a telephone jack. A splitter might be needed if the jack is already in use.
Cat. No. 01023053
Installing Accessories
49
Installing on the GBE Board Open the controller cover and locate the modem connection on the back of the board (see Figure 34). Insert line modem board (part number 01020747) into the socket on the back of the board. Make sure that all of the pins in all four connectors are aligned and make sure the modem is fully seated into all of the sockets.
Installing In the Remote Open the remote monitor housing by removing the two screws and squeezing the sides of the monitor housing slightly. Insert the modem board (P/N 01020747) into the socket on the back of the remote board (see Figure 35). Make sure that all of the pins in all four connectors are aligned and make sure the modem is fully seated into all of the sockets. Snap the two halves of the remote housing back together using light finger pressure and insert the two screws.
Figure 34.
Back of GBE board.
Figure 35.
Back of remote board.
Modem Setup Using Controller Screen Display
Range
Procedure
SOFTENING JAN-01-12 12:01P
N/A
1.
From the HOME screen, press
3)SET DATE/TIME >4)ACCESSORIES
1–6
2.
The screen displays the main menu. Press select 4)ACCESSORIES.
50
Culligan® High Efficiency Twin Softener
50
to view the main menu.
to
Cat. No. 01023053
Screen Display 7)WIRELESS REM >8)MODEM TEL MODEM NOT INSTALLED MODEM LOCATION IN MAIN CONTROL
Range 1–12
Procedure 3.
The screen displays the accessories menu. Press to select 8)MODEM.
Not Installed Installed
In Main Control In Remote
4.
The screen displays the installation status of the modem. Press to change the state to installed if a telephone modem is installed inside the Smart Controller.
5.
The screen displays the modem location setting. Press to change the location.
NOTE
CALL FREQUENCY EVERY 10 REGENS
0–25
6.
Change this setting only if a modem is installed.
The screen displays the call frequency setting. Press or
and then
to increase or decrease the frequency.
The default value of EVERY 10 REGENS can be changed from 0 to 25 successful regenerations. If set to 1, the unit will call in the following morning after each regeneration. The interval can also be set to 0, meaning the unit would NEVER call in unless there was a problem detected. It is recommended for a typical installation the default value of EVERY 10 REGENS is used. 7.
TIME ZONE GMT 00:00
The screen displays the time zone setting. Press and then
or
to change the time zone.
When using a modem, the controller will occasionally access the Internet to synchronize the date and time. In order to do this correctly, you must specify the time zone in which the controller is installed. The time zone is classified as a number of hours ahead or behind Greenwich Mean Time (GMT). The GMT offset for some common cities is listed below:
GMT Offset New York
DEALER ID >_
8 digits, 0–9 plus blank
8.
Chicago
-6:00 (CST)
Denver
-7:00 (MST)
Los Angeles
-8:00 (PST)
London
0:00
Paris
0:00
Rome
+1:00
The screen displays the dealer identification setting, an eightor and then to change digit number. Press each digit of the dealer ID. When the final digit is entered press
Cat. No. 01023053
-5:00 (and anywhere in EST)
to accept the entire dealer ID.
Installing Accessories
51
Screen Display DATA PHONE # 18884137028
Range 15 digits, 0–9 plus *, #, -, and comma
Procedure 9.
The screen displays the data phone number, up to fifteen digits. Press
or
and then
to change each digit of
the phone number. When the final digit is entered press accept the entire phone number.
to
Provide a telephone number to be called by the unit. Typically, the unit dials a local access number. These local access numbers, for nearly every area code around the globe, can be found at http://www.myculligan.com/technical/tech_ref-gbeboards.asp. The unit can be programmed with the default tollfree access number; use a local number whenever possible.
SOFTENING JAN-01-12 12:01P
10. Press
to display the home screen.
Test Modem This menu attempts to send a test message. The screen indicates whether or not this process is successful. Sending a test message will also update the time and date on the Smart controller to the correct time. If the modem is installed on the main controller (as opposed to installed in the remote control) then this testing process will also check to see if there is an updated version of firmware available on the Culligan servers. After conducting a phone line test, it is important to verify that the new time and date settings on the controller are correct. If the new time setting has the incorrect value for the hours it is likely that the time zone setting on the control is incorrect. The time zone setting found under the Main Menu / Accessories / Modem screen is displayed in the format of GMT +/- X hours. See “Installing In the Remote” on page 50.
Screen Display
Range
Procedure
SOFTENING JAN-01-12 12:01P
N/A
1.
From the HOME screen, press
5)ADV. SETUP >6)DIAGNOSTICS
1–6
2.
The screen displays the main menu. Press
8)USE DATA PORT >9)TEST PHONELIN
1–9
to select 6)DIAGNOSTICS.
MODEM TEST Sending pls wait SOFTENING JAN-01-12 12:01P
52
to view the main menu.
Culligan® High Efficiency Twin Softener
3.
The screen displays the diagnostics menu. Press to select 9)TEST PHONELIN.
4.
The screen displays the status of the test before displaying the results. Do not press any buttons before the test is complete or the controller will return to the Diagnostics menu.
5.
Press screen.
to save the settings and display the home
52
Cat. No. 01023053
Possible Results MODEM TEST ERROR NO TONE!!
MODEM TEST NOT POSSIBLE NOW
MODEM TEST CHECKING FOR NEW FW
MODEM EMAIL SUCCESS
MODEM TEST TIME SET SUCCESS
MODEM TEST NO NEW FW
Modem Setup From Remote Display This setup is completed using the wireless remote device.
Screen Display
Range
Procedure
SOFTENING JAN-01-12 12:01P
N/A
1.
From the HOME screen, press
3)BEEPER >4)SETUP
1–6
2.
The screen displays the main menu. Press select 4)SETUP.
to
1)RF SETUP >2)MODEM SETUP
1–2
3.
The screen displays the setup menu. Press 2)MODEM SETUP.
to select
TELEPHONE MODEM INSTALLED LOCAL ISP PHONE 18884137028
4.
to view the main menu.
The screen displays the installation status of the modem. Press to change the state to installed if a telephone modem is installed inside the Smart Controller.
5.
The screen displays the data phone number, up to fifteen digits. Press
or
and then
to change each digit of
the phone number. When the final digit is entered press accept the entire phone number.
1)RF SETUP >2)MODEM SETUP
6.
The screen displays the setup menu. Press settings and display the home screen.
to
to save the
7) CHLORINATOR The Chlorinator accessory is currently not used for North American applications.
Cat. No. 01023053
Installing Accessories
53
10) FLOW METER (External Flow Meter) Screen Display
Range
Procedure
SOFTENING JAN-01-12 12:01P
N/A
1.
From the HOME screen, press
3)SET DATE/TIME >4)ACCESSORIES
1–6
2.
The screen displays the main menu. Press select 4)ACCESSORIES.
9)CHLORINATOR >10)FLOW METER
1–12
3.
The screen displays the accessories menu. Press
FLOW METER 47.00 PULS/GAL
0.1–500
to view the main menu.
to
to select 8)FLOW METER. The screen displays the flow meter settings for the device connected to the controller. Do not change this setting. Press the next setting. NOTE
4.
LOW FLOW LIMIT 1
1–500
HIGH FLOW LIMIT 9
1–500
HE Twin softeners and filters are set at 47.0 Puls/ Gallon.
The screen displays the low flow limit in gallons per minute. or and then to change the limit. See the Press flow profiles for more information about this setting.
5.
SOFTENING JAN-01-12 12:01P
to view
The screen displays the high flow limit in gallons per minute. or and then to change the limit. See the Press flow profiles for more information about this setting.
6.
Press screen.
to save the settings and display the home
Flow Profiles This feature allows you to monitor the amount of time that a softener or filter is in different flow ranges. Select flow ranges by setting the LOW FLOW LIMIT and HIGH FLOW LIMIT when programming the controller. See the following example.
Programming Flow Profiles for a 9" Softener The low flow limit can be set to any low value. Consider setting it at the minimum flow rate (1 gpm), then set the high flow limit at the unit’s rated peak flow, in this example 10 gpm. The controller will first take the high flow limit and subtract the low flow limit: 10 –1 = 9. It then divides this into four equal divisions, 9 + 4 = 2.25, and tracks six separate values or flow profiles. The flow profile values are displayed in minutes. Profile 1 is any flow below the low flow limit (<1 gpm). Profile 2 is any flow between 1–3.25 gpm. Profile 3 is any flow between 3.26–5.51 gpm. Profile 4 is any flow between 5.52–7.77 gpm. Profile 5 is any flow between 7.78–10 gpm. Profile 6 is any flow above the high flow limit (>10 gpm). View flow profiles through the DIAGNOSTICS menu. Go to the ADVANCED STATS menu, then the FLOW STATS menu, and then scroll down to the FLOW PROFILE R1–R6 setting. The values displayed are the number of minutes the flow rate has been in that range. 54
Culligan® High Efficiency Twin Softener
54
Cat. No. 01023053
11) SERVICE PHONE (Service Phone Number) If the Modem is not installed it is possible, in addition to displaying the error message, to display a message that reads “Call Culligan at: XXXXXXXXXX” where the telephone number XXXXXXXXXX can be programmed by the dealership (typically programmed to be the telephone number of the dealership).
Screen Display
Range
Procedure
SOFTENING JAN-01-12 12:01P
N/A
1.
From the HOME screen, press
3)SET DATE/TIME >4)ACCESSORIES
1–6
2.
The screen displays the main menu. Press select 4)ACCESSORIES.
10)FLOW METER >11)SERVICE PHON
1–12
3.
The screen displays the accessories menu. Press
SERVICE TEL >_
to view the main menu.
to
to select 9)SERVICE PHON. 15 digits, 0–9 plus *, #, -, and comma
4.
The screen displays the service phone number, a fifteen-digit or and then to change each dignumber. Press it of the phone number. When the final digit is entered press to accept the entire phone number.
SOFTENING JAN-01-12 12:01P
Cat. No. 01023053
5.
Press screen.
to save the settings and display the home
Installing Accessories
55
12) EXT. FILTER (External Filter) The unit can provide alarm feedback for a sediment or carbon filter installed upstream of the unit. The Auxiliary filter alarm can be initiated based on flow or time. To use this feature it is necessary to specify the total lifetime totalized capacity of the auxiliary filter or days. Once set, it will begin to track the total gallons or days. Once the total capacity reaches the specified lifetime totalized gallons or days, the system will display the alarm message “Change Auxiliary Filter” on the main display as well as the remote display and via the telephone modem if these secondary devices are used.
CHANGE AUXILIARY FILTER NOTE
1.
When the screen displays CHANGE AUXILIARY FILTER, press main menu.
to view the
Once the auxiliary filter has been replaced, the auxiliary filter alarm must be reset by returning to the same menu: Main Menu—>Accessories—>Auxiliary Flow Alarm.
Screen Display
Range
Procedure
SOFTENING JAN-01-12 12:01P
N/A
1.
From the HOME screen, press
3)SET DATE/TIME >4)ACCESSORIES
1–6
2.
The screen displays the main menu. Press select 4)ACCESSORIES.
11)SERVICE PHON >12)EXT. FILTER
1–12
3.
The screen displays the accessories menu. Press
Not Installed Installed
FILTER CAPACITY FLOW BASED
Flow Based Time Based
FILTER CAPACITY 100000
0–100000000
FILTER CAPACITY 365
1–999
No Yes
SOFTENING JAN-01-12 12:01P
56
to
to select 10)EXT. FILTER.
EXT FILTER ALRM NOT INSTALLED
RESET CAPACITY NO
to view the main menu.
Culligan® High Efficiency Twin Softener
4.
The screen displays the installation status of the external filter. If a filter is installed, press installed.
5.
The screen displays the filter capacity basis. Press and then
6.
to change the setting.
or
and then
to change the setting.
If time based, the screen displays the filter capacity in days. Press
8.
or
If flow based, the screen displays the filter capacity in gallons. Press
7.
to change the state to
or
and then
to change the setting.
The screen displays the reset capacity, a confirmation query. or and then to change the setting from Press NO to YES when the alarm is first set up and when the cartridge filter is replaced.
9.
Press screen.
to save the settings and display the home
56
Cat. No. 01023053
Manual Regeneration Follow either procedure to bypass the softener or to initiate a manual regeneration at the control valve or the remote display. NOTE
In multi-tank systems, the regeneration request is sent to the master control. It will allow the unit to regenerate at the next available time.
NOTE
Once regeneration is initiated the status can be changed only after the process is complete or by resetting the motor control in the Diagnostics menu.
Quick Manual Regeneration Delayed Regeneration Screen Display
Range
SOFTENING JAN-01-12 12:01P
N/A
REGEN TONITE JAN-01-12 12:01P
Regen Tonite
REGEN OFF JAN-01-12 12:01P
Regen Off
Procedure 1.
From the HOME screen, press seconds. Release the
and hold for about three (3)
button.
2.
The screen displays REGEN TONITE on the first line of the display. The system will regenerate at a scheduled time.
3.
and hold for at To cancel a delayed regeneration, press leave five (5) seconds. The screen displays the new status.
Immediate Regeneration Screen Display
Range
SOFTENING JAN-01-12 12:01P
N/A
REGEN NOW JAN-01-12 12:01P
Regen Now
REGENERATING JAN-01-12 12:01P
N/A
Cat. No. 01023053
Procedure 1.
From the HOME screen, press (10) seconds.
2.
The screen displays REGEN NOW on the first line of the display. The softener will initiate an immediate regeneration as soon as you release the
3.
and hold for at least ten
button.
The first line of the screen displays REGENERATING.
Manual Regeneration
57
Standard Manual Regeneration Screen Display
Range
Procedure
SOFTENING JAN-01-12 12:01P
N/A
1.
From the HOME screen, press
1)INFORMATION >2)MANUAL MODE
1–6
2.
The screen displays the main menu. Press 2)MANUAL MODE.
Regen Off Regen Now Regen Tonite Bypass
3.
The screen displays the manual regeneration menu. Press
MANUAL MODE REGEN NOW
or
and then
to view the main menu.
to select
to change the setting.
REGEN NOW is the default. REGEN OFF specifies that the softener will not regenerate. REGEN TONITE specifies that the softener will regenerate that night at 2:00 a.m. (or at the preset regeneration time). The screen displays two status messages: SOFTENING and REGEN TONITE. BYPASS specifies a preset time when the softener will be bypassed. Press to select the total time the softener is to be in the bypass state.
MANUAL BYPASS OFF
Off 30 (min) 60 90 120 180 Manual Bypass
SOFTENING JAN-01-12 12:01P
58
Culligan® High Efficiency Twin Softener
4.
5.
The screen displays the manual bypass duration. This specifies the total time the softener is to be in the bypass state. Press
or
Press screen.
to save the settings and display the home
and then
58
to change the setting.
Cat. No. 01023053
Manual Cycling Manual cycling can be performed only when the unit has completed the PRE-RINSE cycle or while it is already within any portion of the REGENERATION process. If the unit is currently regenerating, the name of the current cycle position and the number of minutes remaining in the current cycle position will be displayed.
Screen Display
Range
Procedure
SOFTENING JAN-01-12 12:01P
N/A
1.
From the HOME screen, press
5)ADV. SETUP >6)DIAGNOSTICS
1–6
2.
The screen displays the main menu. Press
4)TEST PROGFLOW >5)MOTOR CONTROL
1–9
to select 6)DIAGNOSTICS.
3.
The screen displays the diagnostics menu. Press to select 5)MOTOR CONTROL.
SELECT MOTOR TANK1 CAUTION!
to view the main menu.
Tank 1 Tank 2
4.
Select either TANK1 (for the main motor) or TANK2 (for the auxiliary motor).
Select the correct tank. Advancing the wrong tank during regeneration might cause regeneration/cycle problems and throw the controls out of synchronization. 5.
MOTOR AT POS 1 UP:FWD DWN:REV
If the control is not in regeneration, the screen displays the motor control status. If cycling during service, press cycle the control valve without stopping. Press motor to another position (such as from 1 to 2).
Position Indicator
Gearbox Status
MOTOR AT 1
Service position
MOTOR AT 2
Backwash position
MOTOR AT 3
Brine Draw position
MOTOR AT 4
Fast Rinse position
MOTOR AT 5
Fill position
MOTOR AT 6
Bypass position
Figure 36.
BACKWASH MIN LEFT NEXT CYCLE
Next Cycle End Regen Now End/Cancel Trig
6.
Cat. No. 01023053
Using Tank 1 Using Tank 2 Regenerating
Gearbox position indicator.
If cycling during regeneration, press
or
and then
to change the regeneration setting. NOTE
USING TANK 1 JAN-01-12 12:01P
to to
to move the
7.
Manual regeneration may trigger false error messages on systems using Aqua-Sensor and/or SBT probes. Ignore the error messages; the errors will be cleared after the next normal regeneration.
to save the settings and display the home Press screen. The screen displays the current cycle status. Manual Cycling
59
Information The following information can be displayed at the control valve or remote display. These settings are read-only. Press to scroll through the settings. Press
or
Screen Display
to view the previous setting.
Range
Procedure
SOFTENING JAN-01-12 12:01P
N/A
1.
From the HOME screen, press
>1)INFORMATION 2)MANUAL MODE
1–6
2.
The screen displays the main menu. Press 1)INFORMATION.
3.
If a Salt Brine Tank probe is installed, the screen displays the salt level status. The status is OK unless the SBT probe detects a low salt level. The screen displays Low if the salt falls
SALT TANK LEVEL Low OK, Low
salt. Press
0–100
4.
0–no limit
CURRENT FLOWRATE 10.0 GPM
0–no limit
TODAY’S USAGE 100 GAL
0–no limit
AVERAGE DAILY 310 GAL
0–no limit
NEXT REGEN ON JAN-05
N/A
TOTAL WATER USED 10000 GAL
60
5.
to select the next information screen.
The screen displays the softening capacity remaining, displayed as a percentage of the total capacity. During manually initiated regeneration, assume 0 percent remaining capacity. Press
REMAIN CAPACITY 700 GAL
to select
to view the estibelow the normal operating level. Press mated number of days left of operation based on remaining
..SALT REMAINING APPROX 1 DAYS REMAIN CAPACITY 100%
to view the main menu.
to select the next information screen.
The screen displays the softening capacity remaining, measured in gallons (liters). Press screen.
6.
The screen displays the current flow rate, measured in gallons (liters) per minute. Press screen.
7.
to see the next information screen.
The screen displays average water usage for this configuration. Press
9.
to see the next information
The screen displays today’s water usage, measured in gallons (liters). Press
8.
to see the next information
to see the next information screen.
The screen displays the date of the next regeneration, based on average daily water usage. Press formation screen.
to see the next in-
10. The screen the total water used for this configuration. Whole 0–no limit
Culligan® High Efficiency Twin Softener
numbers are displayed above 100 gallons. Press the next information screen.
60
to see
Cat. No. 01023053
Screen Display EXT FILT CAP REM 20000 GAL
Range 0–no limit
Procedure 11. If an external filter is used, the screen displays the remaining capacity of the filter. When the remaining capacity reaches zero, the system triggers the External Filter Alarm. Press to return to the main menu.
SOFTENING JAN-01-12 12:01P
Cat. No. 01023053
12. Press screen.
to save the settings and display the home
Information
61
Final Startup Recommended Meter Start-Up Procedure 1.
Close the main water supply valve.
2.
Set the Cul-Flo-Valv® to the bypass position.
3.
Ensure that all faucets at the installation site are closed.
4.
Direct the drain line discharge into a bucket where flow can be observed.
5.
Plug the transformer into a 120 Volt, 60 Hz, single-phase receptacle. The screen displays FIRST TIME SETUP (see page 31).
6.
Complete the First Time Setup.
7.
Open the main supply valve.
8.
Initiate an immediate regeneration to move the control into the BACKWASH position.
9.
Refer to the section on manual cycling for information on cycling the control through its positions.
10. When in the BACKWASH position, slowly rotate the bypass to the soft water position until water flows. 11. Allow the tank to fill slowly until water flows from the drain line. 12. When flow to drain is established, open the bypass fully. Watch the drain line discharge for signs of resin. If signs of resin particles appear, reduce the flow. Increase the flow again when resin no longer appears in the discharge. 13. After the BACKWASH runs clear, step the control to the REFILL position to fill the brine tank and purge air from the brine line. 14. Complete the installation and cleanup. 15. Sanitize the unit as you leave the installation site (See “Sanitizing Procedure” on page 65). 16. Initiate an immediate regeneration, or set to regenerate at the preset time.
62
Culligan® High Efficiency Twin Softener
62
Cat. No. 01023053
Recommended Aqua-Sensor® Start-Up Procedure NOTE
You might find it useful to pre-test the sensor probe in your shop using the test detailed on page 78. The same test setup can be used in the field.
1.
Close the main water supply valve.
2.
Install the sensor probe into the tank.
3.
Set the Cul-Flo-Valv® to the BYPASS position.
4.
Ensure that all faucets at the installation site are closed.
5.
Direct the drain line discharge into a bucket where flow can be observed.
6.
Plug the transformer into a 120 Volt, 60 Hz, single-phase receptacle (make sure to connect both 24V and 2.5V properly).
7.
Complete FIRST TIME SETUP (see page 31). The Aqua-Sensor probe is to be set to NOT INSTALLED during the initial Start-Up Procedure.
8.
Open the main supply valve.
9.
Initiate an immediate regeneration to move the control into the BACKWASH position.
10. Refer to the section on manual cycling for information on cycling the control through its positions. 11. When in the BACKWASH position, slowly rotate the bypass to the soft water position until water flows. 12. Continue BACKWASH until the drain effluent is clear and the Aqua-Sensor probe is placed in the resin bed—at least 10 minutes (use a white foam coffee cup to occasionally collect a sample of backwash water; the stark white of the cup will show the presence of color throw and resin fines). 13. Continue or repeat the BACKWASH cycle if needed. 14. After the backwash water runs clear, step the control to the REFILL position to fill the brine tank and purge air from the brine line. 15. Unplug the control and connect the Aqua-Sensor to the circuit board. 16. Reconnect the power and INSTALL the Aqua-Sensor Probe (Main Menu/ Accessories/ AquaSensor) 17. Check the condition of the Aqua-Sensor (Main Menu/ Diagnostics/ Checksensors) 18. Press the Program key and program the control to the desired settings. 19. Complete installation and cleanup. 20. Sanitize the unit as you leave the installation (see “Sanitizing Procedure” on page 65). 21. Initiate an immediate regeneration. The thorough backwashing process should have cleared the fines and color-throw from the tank. The probe should settle into the resin bed during the first couple of minutes of backwashing.
Cat. No. 01023053
Final Startup
63
Operation, Care and Maintenance Before Leaving The Installation Site 1.
Sanitize the water softener. See the following page.
2.
Ensure that the brine tank has water to the level of the float. Add water to the tank with a hose or put the unit into a full recharge so that the brine refill cycle will fill the tank with the proper amount of water.
3.
The water heater will hold hard water for several days. Advise the customer that the existing water volume in the tank will need to be used before the hot water is soft. If soft hot water is required immediately, refer to the water heater owner’s manual for the proper method of draining the water heater.
4.
Explain the operation of the softener to the customer. Make sure the customer knows that there will be new sounds associated with the recharging of the unit. Advise the customer to periodically check and replenish the salt supply.
5.
Fill in the hardness and number of people, and then sign and date the corresponding performance data sheet. Leave the Owner’s Guide with the customer.
6.
Attach the appropriate data plate label located in the Parts Pack onto the back of the control.
7.
Clean up the unit and installation site, removing any soldering, or pipe threading, residues from the equipment and surrounding area with a damp towel.
Use of Bypass Valve Depending on where the particular installation was made, the outside sill cocks may or may not be served by conditioned water. Ideally, all lines not requiring soft water should be taken off upstream of the softener. This is not always possible, however, due to the difficulty or expense of rearranging the piping. Bypass the softener if: 1.
The outside lines do not bypass the water softener and the water is to be used for lawn sprinkling or other outside uses (use softener internal or external softener bypass valve).
2.
Water is not used for several days (use softener internal or external bypass valve).
3.
You wish to inspect or work on the valve or brine system (use softener external bypass valve).
4.
A water leak from the valve is evident (use softener external bypass valve).
Three-Valve Bypass To bypass, close the inlet and outlet valves, and open the bypass valve. Reverse the process to get soft water once again. Be sure to close the bypass valve completely to avoid mixing hard water with soft water. CAUTION!
If the media tank is to remain attached to the control valve, close only the inlet valve, then open the bypass valve. This will prevent pressure from increasing in the media tank due to warming.
Care and Cleaning Protect the operation and appearance of the water conditioner by following these precautions:
64
1.
Do not place heavy objects on top of the conditioner cover.
2.
Use only mild soap and warm water to clean the exterior of the unit. Never use harsh abrasive cleaners or compounds which contain acid or bleach.
3.
Protect the conditioner and drain line from freezing temperatures.
4.
Reset the time, if required, after any interruption of electrical power to keep the unit on its normal schedule.
Culligan® High Efficiency Twin Softener
64
Cat. No. 01023053
Recommended Preventive Maintenance Sanitizing Procedure A water softener in daily use on a potable water supply generally requires no special attention other than keeping the salt tank filled. Occasionally, however, a unit may require sanitization under one of the following conditions: At start-up time. After standing idle for a week or more. On private supplies, the appearance of off-tastes and odors, particularly if musty or “rotten egg” (caused by harmless sulfate-reducing bacteria). NOTE
If the water supply contains iron, regenerate the softener before sanitizing to remove iron from the resin. CAUTION!
Hazard from toxic fumes! Chlorine bleach and common iron control chemicals may generate toxic fumes when mixed. If the unit uses Culligan Sofner-Gard® or other compounds containing sodium hydrosulfite, sodium bisulfite, or any other reducing agent, disconnect the device feeding the chemical(s) and manually regenerate the unit before sanitizing.
1.
Remove the brine tank cover.
2.
Pour directly into the brine chamber 1/3 to 1/2 cup of common household bleach (5.25% sodium hypochlorite) for each cubic foot of resin in the tank.
3.
Manually start recharge. Allow the unit to complete the recharge cycle automatically.
If tastes and odors return frequently, even after sanitization, a continuous chlorination system may be needed. Send a water sample to a qualified laboratory for bacterial analysis.
Analyzing the System Analyzing the system involves three basic steps: 1.
Check the system in all cycle positions.
2.
Compare the data to normal operating data.
3.
Determine which component may cause the problem (troubleshooting).
If steps 1-3 did not reveal the problem, initiate a regeneration cycle and manually cycle the valve to brine draw (#2 position). Allow the unit to complete the brine draw cycle and observe how the system reacts. Although it may be possible to solve a specific problem simply by changing a component, analyzing the entire system can reveal additional problems which would otherwise require extra service calls. “Parts changing” is not the same as service.
Checking the System The following tools are needed to collect data: 1.
Hardness, iron and chlorine test kits
2.
Thermometer
3.
Pressure gauge, 0-120 psi
4.
5-Gallon bucket and watch
5.
Calculator
The customer can provide most data. By collecting data prior to a service call, a “first guess” about the cause of the problem can be made and the need for any special parts can be determined. If the problem is as simple as lack of salt in the brine tank, a service call may not be needed at all.
Cat. No. 01023053
Recommended Preventive Maintenance
65
Application Problems Many service problems are not due to equipment malfunction, but rather to misapplication or environmental conditions.
The Operation & Performance Specifications See “Performance Specifications” on page 3. Provides the limits of water characteristics for the Culligan High Efficiency water softeners. If the water characteristics fall outside these limits, additional water treatment equipment may be required, or the water characteristics should be brought inside the limits. The system flow rates and exchange capacities are also listed.
Appendix A, Table 10—Flow Rates The backwash, brine, and slow rinse flows should not differ from those in Appendix A, page 90 by more than 15 percent.
Appendix A—Softener Salt Dosage/Capacities This table shows the gallon capabilities for each unit as a function of salt dosage. If the hardness or water usage has increased, a higher salt dosage, more frequent regeneration, or a larger softener may be needed. NOTE
The rate at which brine is drawn from the brine tank should not differ by more than 5 percent. The refill rate should be as close as possible to the rate shown in Appendix A, page 88; high or low pressure installations may require the substitution of a different refill flow control.
If there are no apparent general problems or environmental problems, refer to “Troubleshooting” on page 75.
Recommended Preventive Maintenance Inspection Schedule The Culligan HE water softener has been designed to provide a good, consistent service life. Routinely inspecting the system may help avoid potentially costly breakdowns related to circumstances outside of the control of the dealer and/or user.
Component
Suggested Inspection Frequency
Reason for Maintenance
Entire System
At Start-up, after infrequent use (idle for one week or more) or every 3–6 months if on a private water supply.
On private supplies, the appearance of off-tastes and odors, particularly if musty or “rotten egg” (caused by harmless sulfate-reducing bacteria) may indicate a need for the system to be sanitized. See “Sanitizing Procedure” on page 65.
Backwash Flow Controller
Every 12 months or every time service is performed on the system.
Build up of sediment, iron and/or other foreign materials (found in some water supplies but not necessarily all) could negatively affect system performance. Monitor item for normal or unexpected wear.
Brine eductor nozzle and throat
Every 12 months or every time service is performed on the system.
Build up of sediment, iron and/or other foreign materials (found in some water supplies but not necessarily all) could negatively affect system performance. Monitor item for normal or unexpected wear.
Softening Media
Every 2–3 years
Chlorinated water supplies can breakdown and destroy resin material. Resin material may also perform poorly if subjected to other materials (sediment, iron, alum, etc.) found in some water supplies (but not necessarily all).
Table 1. Recommended preventive maintenance inspection schedule.
66
Culligan® High Efficiency Twin Softener
66
Cat. No. 01023053
Error and Alert Messages The following error messages may display on both the HE controller display as well as the Remote Display (if connected).
Problem Found JAN-01-12 12:01P
1.
When the controller identifies an error, it is programmed to attempt to correct the error without user input. If the problem persists, the HOME SCREEN displays PROBLEM FOUND. Press
Motor Home Err
->Clear Errors
to display any additional errors present.
2.
Press
3.
and to view action: CLEAR ERRORS, GO TO MENU, or EXIT. If Press you select CLEAR ERRORS, the controller checks the error status and attempts to clear the error. If the error still exists, the home screen displays PROBLEM FOUND. If the error no longer exists the screen displays SYSTEM OK.
->Go To Menu
Error
to display the first error present.
Reason for Error
Comment/ Clearing Error Message
Salt Bridging
Brine tank has low concentration of brine but still appears to have solid salt.
Use a tool to break up any salt bridge inside the brine tank
No Remote Signal
Main board is not receiving a signal from the remote.
Remote is off, out of range or on a different channel from the main board. If interference is suspected, try moving the remote closer or switching to a different channel on both the main and remote units
Motor Home Err
Motor did not move when it should. The control home position could not be found. Valve could not initialize motor positioning.
Use manual motor control to see if motor is actually working and not jammed. Use Diagnostics/ Sensor menu to verify that the optical or sensor is working. Verify the valve type for the control (HE = HE 1).
Brine Blocked
The flow rate of brine or water to or from the brine tank is fully or partially blocked.
Check brine line for blockages or air leaks. Check eductor and eductor screen for blockages
Replace Ext Filt
Total gallons through the secondary filter (i.e. “Big Blue” filter) has exceeded the specified capacity of the Big Blue.
Replace optional filter cartridge. Reset the external filter media life at Main Menu/ Accessories/ Ext. Filter menu
Check Brine Tank
Aqua-Sensor did not detect brine during the regeneration cycle.
Check brine tank and add salt if necessary. Check Z ratio of the AquaSensor at Main Menu/ Advanced / Diagnostics/ Sensors
This message is displayed if an error has been detected that requires servicing and no modem installed in the system.
Call the number shown. If possible, place this call using a phone that will allow you to see and enter changes to the main controller if required by the service technician during the call
Pos Sensor Err
The motor is directed to run but no change in position is detected.
Check the motor using manual motor control and the position sensors using Main Menu/ Advanced/ Diagnostics Sensors
Few Days Salt
This is a prediction of the number of days until it will be necessary to add salt to the brine tank.
Salt can be added to the brine tank at any time. It is recommended that the brine tank be filled to approximately 2/3 full.
Low Salt Level
Salt level is low; less than 15 days of salt remaining.
Contact Culligan dealer for salt delivery or fill brine tank with salt.
Low Battery
Battery needs replacement.
Replace with Panasonic Model# CR 2032 3V battery (see page 84).
Call Culligan at xxx-xxx-xxxx
Too much water in brine tank. Plugged drain line flow control (Unit will not draw brine). Brine Overfill
Check eductor; check for brine draw.
Plugged eductor system (Unit will not draw brine).
Clean drain line flow control.
Slow leak to brine line.
Clean eductor screen and nozzle
Faulty eductor piston.
Replace eductor piston
Power outage while control was in refill position. No Brine In Tank
Failure to refill brine tank. Refill restrictor plugged. Air in brine line causes float to slam shut.
Clean or replace refill restrictor. Verify all tubing connections are properly assembled.
Aqua Sens Probe
An Aqua-Sensor was “Installed” but main board detects the Aqua-Sensor is not connected. The board might not be detecting the 2.5V power supply
Check connection of Aqua-Sensor to the main board.
Cat. No. 01023053
Error and Alert Messages
67
Diagnostics There are a large number of diagnostic menu screens to aid in setup and troubleshooting of the HE water softener system, including the following diagnostic menus: 1. Advanced Statistics 2.
Check Sensors
3.
Test Wireless Remote
4.
Test Progressive Flow (not applicable for HE applications)
5.
Motor Control
6.
Auxiliary Output Statistics (not applicable for HE applications)
7.
Auxiliary Output Test (not applicable for HE applications)
8.
Use Data Port (for future use)
9.
Test Phone Line
Advanced Statistics Flow Statistics Screen Display
Range
Procedure
SOFTENING JAN-01-12 12:01P
N/A
1.
From the HOME screen, press
5)ADV. SETUP >6)DIAGNOSTICS
1–6
2.
The screen displays the main menu. Press
>1)ADVANCED STAT 2)CHECK SENSORS
1–9
3.
The screen displays the diagnostics menu. Press 1)ADVANCED STAT.
>1)FLOW STATS 2)REGEN STATS
1–6
4.
The screen displays the advanced statistics menu. Press to select 1)FLOW STATS.
5.
The screen displays the TOTALIZED FLOW in gallons since
to view the main menu.
to select 6)DIAGNOSTICS.
TOTALIZED FLOW 50000 CURRENT FLOWRATE 6.7 FLOW PROFILE R1 30
the unit was installed. Press 6.
to display the next statistic.
The screen displays the CURRENT FLOWRATE in gallons per minute since the unit was installed. Press the next statistic.
7.
FLOW PROFILE R3 90 68
Culligan® High Efficiency Twin Softener
8.
to display
The screen displays the R1 FLOW PROFILE in minutes. The flow profile is the amount of time the the unit spends within different flow ranges (see page 54). R1 is the amount of time that flow was below the low flow limit. Press next statistic.
FLOW PROFILE R2 50
to select
to display the
The screen displays the R2 FLOW PROFILE, the amount of time that flow was between the LOW FLOW LIMIT and approximately 25 percent of the HIGH FLOW LIMIT. Press display the next statistic.
9.
to
The screen displays the R3 FLOW PROFILE, the amount of time that flow was between approximately 25 and approximately 50 percent of the HIGH FLOW LIMIT. Press play the next statistic. 68
to dis-
Cat. No. 01023053
Screen Display
Range
Procedure 10. The screen displays the R4 FLOW PROFILE, the amount of time that flow was between 50 and 75 percent of the HIGH
FLOW PROFILE R4 100
FLOW LIMIT. Press
to display the next statistic.
11. The screen displays the R5 FLOW PROFILE, the amount of time that flow was between approximately 75 percent of the
FLOW PROFILE R5 5
HIGH FLOW LIMIT and the HIGH FLOW LIMIT. Press display the next statistic.
to
12. The screen displays the R6 FLOW PROFILE, the amount of
FLOW PROFILE R6 5
time that flow was above the HIGH FLOW LIMIT. Press return to the advanced statistics menu.
SOFTENING JAN-01-12 12:01P
13. Press screen.
to
to save the settings and display the home
Regeneration Statistics Screen Display
Range
Procedure
SOFTENING JAN-01-12 12:01P
N/A
1.
From the HOME screen, press
5)ADV. SETUP >6)DIAGNOSTICS
1–6
2.
The screen displays the main menu. Press
>1)ADVANCED STAT 2)CHECK SENSORS
1–9
3.
The screen displays the diagnostics menu. Press 1)ADVANCED STAT.
>1)FLOW STATS 2)REGEN STATS
1–6
4.
The screen displays the advanced statistics menu. Press
to select 6)DIAGNOSTICS.
5.
The screen displays the TOTALIZED REGENERATIONS since the unit was installed. Press statistic.
REGENS IN LAST 14 DAYS: 5
6.
DAYS SINCE LAST REGEN: 1
7.
Cat. No. 01023053
to select
to select 2)REGEN STATS.
TOTAL REGENS 100
LAST REGEN ON JAN-01
to view the main menu.
The screen displays the number of regenerations in the past 14 days. Press
8.
to display the next statistic.
The screen displays the number of days since the last regeneration. Press
Jan–Dec 01–31
to display the next
to display the next statistic.
The screen displays the date of the last regeneration of the unit (in this example, January 1, 2012). Press the next statistic.
to display
Diagnostics
69
Screen Display LAST REGEN TRIG Manual
Range Manual, Meter, Aqua-Sensor, (Day), Aux Input, Power Outage
Procedure 9.
The screen displays the device that triggered the last regeneration. Press
to display the next statistic.
10. The screen displays the time elapsed, in minutes, since the last pause. This is helpful when diagnosing external accesso-
LAST BD/SR TIME 57 MIN
ries. Press
to display the next statistic.
11. The screen displays the time elapsed since the last fill time of
LAST FILL TIME 420 SEC
the unit, in seconds. Press tistics menu.
SOFTENING JAN-01-12 12:01P
12. Press screen.
to return to the advanced sta-
to save the settings and display the home
Tank Statistics Screen Display
Range
Procedure
SOFTENING JAN-01-12 12:01P
N/A
1.
From the HOME screen, press
5)ADV. SETUP >6)DIAGNOSTICS
1–6
2.
The screen displays the main menu. Press
>1)ADVANCED STAT 2)CHECK SENSORS
1–9
3.
The screen displays the diagnostics menu. Press 1)ADVANCED STAT.
2)REGEN STATS >3)TANK STATS
1–6
4.
The screen displays the advanced statistics menu. Press
to select 6)DIAGNOSTICS.
REMAIN CAPACITY 700 GAL TOTAL CAPACITY 1000 GAL TOTAL WATER USED 10000 SOFTENING JAN-01-12 12:01P
70
to view the main menu.
Culligan® High Efficiency Twin Softener
to select
to select 3)TANK STATS. 5.
The screen displays the remaining capacity of the unit, in gallons, before the regeneration signal is triggered. Press display the next statistic.
6.
The screen displays the total capacity of the unit, in gallons. Press
7.
to display the next statistic.
The screen displays the total water used by the unit since it was installed. Press menu.
8.
to
Press screen.
to return to the advanced statistics
to save the settings and display the home
70
Cat. No. 01023053
Firmware Version Screen Display
Range
Procedure
SOFTENING JAN-01-12 12:01P
N/A
1.
From the HOME screen, press
5)ADV. SETUP >6)DIAGNOSTICS
1–6
2.
The screen displays the main menu. Press
>1)ADVANCED STAT 2)CHECK SENSORS
1–9
3.
The screen displays the diagnostics menu. Press 1)ADVANCED STAT.
3)TANK STATS >4)FW VERSION
1–6
4.
The screen displays the advanced statistics menu. Press
to view the main menu.
to select 6)DIAGNOSTICS.
to select
to select 4)FW VERSION. 5.
FWR216LT21 Jan 4 2012
The screen displays the latest firmware version of the unit controller circuit board. Press statistics menu.
SOFTENING JAN-01-12 12:01P
6.
Press screen.
to return to the advanced
to save the settings and display the home
Serial Number Screen Display
Range
Procedure
SOFTENING JAN-01-12 12:01P
N/A
1.
From the HOME screen, press
5)ADV. SETUP >6)DIAGNOSTICS
1–6
2.
The screen displays the main menu. Press
>1)ADVANCED STAT 2)CHECK SENSORS
1–9
3.
The screen displays the diagnostics menu. Press 1)ADVANCED STAT.
4)FW VERSION >5)SERIAL NUMBER
1–6
4.
The screen displays the advanced statistics menu. Press
S/N:00025526
to select 6)DIAGNOSTICS.
Cat. No. 01023053
to select
to select 5)SERIAL NUMBER. 5.
The screen displays the serial number of the unit controller circuit board. Press
SOFTENING JAN-01-12 12:01P
to view the main menu.
6.
Press screen.
to return to the advanced statistics menu.
to save the settings and display the home
Diagnostics
71
Last Power Up Screen Display
Range
Procedure
SOFTENING JAN-01-12 12:01P
N/A
1.
From the HOME screen, press
5)ADV. SETUP >6)DIAGNOSTICS
1–6
2.
The screen displays the main menu. Press
>1)ADVANCED STAT 2)CHECK SENSORS
1–9
3.
The screen displays the diagnostics menu. Press 1)ADVANCED STAT.
5)SERIAL NUMBER >6)LAST POWER UP
1–6
4.
The screen displays the advanced statistics menu. Press
to view the main menu.
to select 6)DIAGNOSTICS.
to select
to select 6)LAST POWER UP. 5.
LAST POWER UP JAN-01-12 11:02A
The screen displays the date and time when the unit was last powered on. This can be helpful if there was a power outage to see how long the unit has been powered on. Press return to the advanced statistics menu.
SOFTENING JAN-01-12 12:01P
6.
Press screen.
to
to save the settings and display the home
Check Sensors Screen Display
Range
Procedure
SOFTENING JAN-01-12 12:01P
N/A
1.
From the HOME screen, press
5)ADV. SETUP >6)DIAGNOSTICS
1–6
2.
The screen displays the main menu. Press
1)ADVANCED STAT >2)CHECK SENSORS
1–9
3.
The screen displays the diagnostics menu. Press select 2)CHECK SENSORS.
MAINBRD OPT SENS NO LIGHT
Light No Light
4.
The screen displays the status of the optical sensor. There is NO LIGHT when the control is in a cycle position. The screen displays LIGHT when the control is changing cycle (motor
to select 6)DIAGNOSTICS.
moving). Press
FLOW METER 0
72
to view the main menu.
Culligan® High Efficiency Twin Softener
5.
to
to display the next sensor.
The screen displays the current pulses per second of the flow meter. Press
to display the next sensor.
72
Cat. No. 01023053
Screen Display AQS->SUP VOLTAGE 2.5VAC: PASS
Range Not Installed, Pass, Fail
Procedure 6.
The screen displays the Aqua-Sensor supply voltage. The status is PASS when the circuit board detects 2.5VAC connected to the board. The status is FAIL when the 2.5VAC is either not connected to the circuit board or the transformer is defective. Press
AQS->SIM TEST PASS
Pass, Fail
7.
to display the next sensor.
The screen displays the Aqua-Sensor simulator test that analyzes the Aqua-Sensor circuits on the circuit board. The status is PASS when the circuits on the board are functional. The status is FAIL when the circuit board detects a problem with the Aqua-Sensor circuits. Press
AQS->Zr:1.029 Zm:0.000 00.0% I
0.900–1.400
8.
to display the next sensor.
The screen displays the Aqua-Sensor troubleshooting statistics. Z-Ratio (impedance ratio)—Number calculated by microprocessor on measured voltage values that are converted to a digital representation. This is the value that the control monitors in order to determine need for regeneration and salt rinse-out. Z-Minimum (minimum impedance ratio)—Reference point that the Z-ratio is compared to, in order to initiate a regeneration. This number is reset after every successful regeneration. Z-Increase Percent (impedance ratio increase)—During service, this number represents the percent increase or z-ratio over z-minimum. A regeneration is initiated when it reaches 7.5% or more for at least 6 minutes.
See page 91 for additional information on Aqua-Sensor troubleshooting. Press
SBT->SM:OP SL:OP FR1:OP FR2:OP
BL, OP
9.
to display the next sensor.
The screen displays the Smart Brine Tank probe troubleshooting statistics. The SBT probe has four sensors within it. The Check sensor screen displays the current status (opened = “OP”, or blocked =“BL”) for all four sensors. The expected outputs from the SBT probe inside the brine tank are shown in Table 4 while the expected outputs from an SBT probe “in air” are shown in the Table 5. Press
SBT AVG T3 0
to display the next sensor.
10. The screen displays additional Smart Brine Tank probe troubleshooting statistics. In addition to the four sensors, the SBT probe takes a measurement during each regeneration cycle called T3. This measurement varies from system to system, but is typically between 30 and 120 seconds for a residential system. When the SBT is turned from UNINSTALLED to INSTALLED on the Accessories menu, the baseline value of T3 is erased and the system will use the next three regeneration cycles to compute a new T3 baseline number. Press display the next sensor.
Cat. No. 01023053
to
Diagnostics
73
Screen Display
Range
Procedure 11. The screen displays additional Smart Brine Tank probe troubleshooting statistics. During each subsequent regeneration, the new T3 is compared to the baseline T3 number. If the new T3 exceeds the baseline T3 by more than 30% then the system will display a “Brine Line Blockage – Check Brine Line” error message. The baseline T3 value is displayed on the diag-
SBT Last T3 30
nostic screen after the SBT sensor screen. Press to the advanced statistics menu.
SOFTENING JAN-01-12 12:01P
12. Press
to return
to display the home screen.
Displays BL
Displays OP
Salometer
Brine at least 1 inch above the salt plate.
Salt level is less than 1" above the salt plate
Salt Level
Salt level less than 8” above the salt plate
Normal Operation. Salt level greater than 8” above the salt plate
Flow Rate #1
Water level in brine tank is below salt plate
Water level in brine tank is more than 1” above salt plate
Flow Rate #2
Water level in brine tank is more than 1” above salt plate
Water level in brine tank is below salt plate
Table 4. Expected Readings on the Sensor/Diagnostic screen when the SBT probe is installed inside the brine tank.
Normally
Probe Inverted
Salometer
OP
BL
Flow Rate #1
BL
OP
Flow Rate #2
OP
BL
Table 5. Expected Readings from the SBT probe when the probe is sitting in air (not installed in the brine tank).
Test Wireless See “7) WIRELESS REM (Wireless Remote)” on page 46.
Test Progressive Flow Progressive flow is not used for HE units.
Motor Control Diagnostic See page 57 for an overview of the motor control.
Aux Out Status Auxiliary Outputs are not used for HE units.
Aux Out Test Auxiliary Outputs are not used for HE units. See page 104 for a brief overview.
Use Data Port Data Port is for future use.
Test Phone Line See “Test Modem” on page 52 for an overview of the CHECK PHONE LINE (modem) diagnostic menus. 74
Culligan® High Efficiency Twin Softener
74
Cat. No. 01023053
Troubleshooting Problem or Symptom 1.
2.
3.
Unit has blank display.
Softener fails to automatically initiate a regeneration.
Regeneration occurs at incorrect time.
Cause A. Unit has no power.
A. Verify that unit is connected to a constant power source (Not an outlet on a switch).
B. Defective plug-in transformer.
B. Replace plug-in transformer.
A. Electrical service to the unit has been disrupted.
A. Verify that unit is connected to a constant power source (Not an outlet on a switch).
B. Soft-Minder® meter not properly recording total gallons used. The flow meter connection and operation can be verified using the test mode setting on the circuit board.
B. Verify that meter cable is plugged into circuit board. Verify that meter cable is snapped into flow meter housing. Verify that flow meter has not become plugged with debris.
C. Aqua-Sensor® probe not sensing hardness front. The Aqua-Sensor connection and operation can be verified using the test mode setting on the circuit board with Aqua-Sensor simulator.
C. Verify that Aqua-Sensor connector is properly connected to circuit board and 2.5VAC is properly connected to circuit board. Verify that Aqua-Sensor probe is working. Clean probe if necessary.
D. Incorrect programming.
D. Refer to the ‘Programming’ section and verify all settings.
A. Timer setting incorrect.
A. Reset timer.
B. Timer flashing.
B. Reset timer and verify that unit is connected to a constant power source.
C. Circuit board set to immediate regeneration.
C. Set circuit board to delayed regeneration.
D. Incorrect programming.
D. Refer to the ‘Programming’ section and verify all settings.
4.
Error message is displayed.
5.
Hard water to service. A. Salt or Chemical storage tank is The root cause of hard empty. water to service may also lead to problems B. Eductor screen or nozzle plugged. such as Iron or Hardness bleed in softener. C. Incorrect programming (Salt dosage too low for influent hardness).
6.
Loss of water pressure
Solution
See “Error and Alert Messages” on page 67. A. Add salt or chemical to storage tank and verify that proper level of salt or chemical is maintained. B. Clean or replace eductor nozzle and/or screen. C. Refer to the ‘Programming’ section and verify that settings are correct.
D. Insufficient water flowing to salt storage tank.
D. Verify that refill settings are correct and clean the refill flow restrictor.
E. Internal seal leak.
E. Replace pistons.
F. Excessive water usage.
F. Verify that programming is correct. For Time Clock units increase regeneration frequency.
G. Unconditioned water in water heater tank.
G. Flush water heater to fill tank with conditioned water.
A. Control and/or resin bed plugged with debris or iron build-up.
A. Clean control and increase frequency of regenerations or length of backwash. Plant recondition if necessary.
B. Inlet manifold plugged.
B. Remove control from tank and clean inlet manifold. Check if eductor screen/nozzle are also plugged.
C. Control plugged with foreign material C. Clean control. broken loose from recent plumbing work. Cat. No. 01023053
Troubleshooting
75
Problem or Symptom
Cause
Solution
7.
Loss of mineral to drain.
A. Improper drain line flow control.
A. Ensure that the control has the proper drain line flow control (see Table 3 on page 22).
B. Air in water system.
B. Ensure that brine is working properly.
8.
Mineral to service.
A. Plumbing connected to control backwards.
A. Verify that plumbing is properly connected to the tank.
B. Defective outlet manifold.
B. Replace outlet manifold.
9.
Water in storage tank up to float.
A. Plugged drain line flow control (Unit will not draw brine).
A. Clean drain line flow control.
B. Plugged eductor system (Unit will not draw brine).
B. Clean eductor screen and nozzle.
C. Slow leak to brine line. Faulty eductor piston.
C. Replace brine piston.
D. Power outage while control was in refill position.
D. Verify that items A-C are not the cause for the extra water in the storage tank.
10. Excessive water in salt storage tank (Water above brine valve float).
A. Faulty brine valve; float shut-off fail- A. Clean brine valve, replace stem seat, or ure. When the brine valve is faulty, replace brine valve. one of the items listed under Problem 9 is also required in order to produce excessive water in the storage tank.
11. Unit fails to refill storage tank.
A. Refill restrictor plugged.
A. Clean or replace refill restrictor.
B. Air in brine line causes float to slam shut (float rod is rigid).
B. Verify that all tubing connections are properly assembled.
12. Unit fails to draw brine or A. Drain line flow control is plugged. chemical. B. Plugged eductor system.
A. Clean drain line flow control. B. Clean or replace eductor screen or nozzle.
C. Line pressure too low.
C. Increase line pressure to a minimum of 20 psi (210 kPa).
D. Internal control leak.
D. Replace pistons and/or brine piston.
E. Drain line too long or restricted.
E. Verify proper drain line length. See ‘Flow Rate and Drain Line Charts’.
F.
F.
Eductor is drawing air into system.
Verify that all tubing connections are properly assembled.
13. Unit uses an excessive amount of salt or chemical.
A. Incorrect programming.
A. Refer to ‘Programming’ section and verify all settings.
B. Excessive water in storage tank.
B. Refer to Problems 9 & 10.
14. Continuous flow to drain
A. Internal seal leak.
A. Replace pistons.
B. Piston or brine piston jammed in position.
B. Replace pistons or brine piston.
C. Power failure while unit was in regeneration.
C. Restore power to unit. Verify that unit is connected to a constant power source.
A. Inadequate Brine/Rinse setting for desired salt dosage.
A. Refer to the ‘Programming’ section and verify all settings.
B. Low water pressure lengthens brine draw time.
B. Increase line pressure to a minimum of 20 psi (210 kPa).
C. Too much brine in the storage tank.
C. Refer to Problems 9 & 10.
15. Salt water to service
76
Culligan® High Efficiency Twin Softener
76
Cat. No. 01023053
Brine System Analysis 1.
2.
WATER LEVEL in the brine tank a.
Empty
b.
Below level of safety valve
c.
At level of safety valve float
SAFETY VALVE in brine tank a.
Fiberglass rod travels up and down freely (approximately 1/2")
b.
Fiberglass rod is rigid
If the brine system is functioning properly, there will be water in the brine tank, but the level should be below the safety valve float and the fiberglass rod should travel freely. If these conditions do not exist, one of the following conditions will indicate the nature of the problem: 1.
NO WATER IN BRINE TANK—ROD TRAVELS FREELY. The flow control is plugged. Remove refill flow control. Clean or replace.
2.
NO WATER IN BRINE TANK—ROD IS RIGID. Air or water slammed the safety valve closed before water could enter the tank. Clean parts at the base of the brine safety valve and also make sure that the seat of the check valve in the brine line is clean. Check for possible air leaks in the brining system.
3.
WATER IN BRINE TANK UP TO SAFETY VALVE FLOAT—ROD IS RIGID. There are possible causes: a.
Brine piston is not in service position when control is in service or brine piston seals are defective. Remove brine line while in service. There should be no flow to brine tank.
b.
Refill flow rate is too high or refill time length is too long. Check refill flow rate and compare to specification in Table 9 on page 90.
Aqua-Sensor® Troubleshooting The following procedure will help you diagnose problems in units equipped with Aqua-Sensor® sensing device. Because many sensor problems are actually regeneration problems, it contains a combination of sensor diagnostics and routine control valve and brine system checks. Refer to the Troubleshooting Flow chart for the recommended sequence and Appendix B for suggested Aqua-Sensor® application guidelines and “Check Sensors” on page 72.
Testing
AQS->SUP VOLTAGE 2.5VAC: PASS AQS->SIM TEST PASS
1.
Verify there is 2.5VAC power supply at the High Efficiency circuit board for the Aqua-Sensor.
2.
Record the program and statistical information (last slow rinse, Z ratio, Z minute, and Z increase %) before beginning this procedure.
3.
Unplug the unit.
4.
Remove the Aqua-Sensor cable from the board.
5.
Connect the Soft-Minder Meter/Aqua-Sensor Tester (same as Aqua-Sensor, Part No. 01017705) to the board. The color of the wire on the far right, as you look at the back of the board, should be white.
6.
The toggle switch can be in the Balanced or Unbalanced position.
7.
Apply power to the unit.
8.
Go to the Aqua-Sensor troubleshooting screen (Main Menu—>Diagnostics—>Check Sensors).
9.
The screen displays a pass/fail message for the supply voltage and simulator test, checking the Aqua-Sensor circuit and the Z ratio.
10. The board is good if the screen displays 2.5VAC: PASS and SIM TEST: PASS.
Cat. No. 01023053
Troubleshooting
77
Sensor Probe Resin Test The Probe Resin Test uses fully regenerated, but previously used, Cullex® resin to simulate a balanced environment. Run this test only on a circuit board that has passed the Circuit Board Test with simulator device.
Preparation You will need a container that can hold enough regenerated Cullex resin to completely immerse the probe’s electrodes without making contact with the container’s sidewall. A section of PVC pipe, either 2” or 3”, makes a suitable chamber for testing either residential or commercial probes. 1.
Cut a piece of pipe about 18 inches long and close the bottom end with a cap or a flat piece of PVC (which can also serve as a base)
2.
Close the other end with a cap that has been drilled and tapped for a 1” PVC pipe plug, or use a reducing adapter and plug.
3.
Fill the chamber with used, regenerated Cullex resin and soft water; the water level should be at least one inch above the resin (when not in use, plug the end to prevent spillage of resin and water)
Probe Test 1.
Remove the probe from the resin tank. Make sure pressure is relieved on tank before removing probe.
2.
Visual inspection a.
Look for discoloration (brown film or blue spots) on electrode fins.
b.
If discolored, try cleaning the probe (Sofner-Gard™ chemical or white vinegar). The fins can be lightly scrubbed with a soft toothbrush.
Testing AQS->Zr:0.000 Zm:0.000 00.0% I
1.
Submerge both cells of the probe into the resin.
2.
Go to the Zratio information screen (Main Menu—>Diagnostics—>Check Sensors).
3.
Allow the Zratio to stabilize and then write down what is displayed on the screen. The number should be between 0.900 and 1.300 for regenerated resin.
4.
Pull the upper cell out of the resin and allow the Zratio to stabilize. The Zratio should be higher by at least 10 percent from the previous reading. Ignore the Zmin and %Increase information; Zmin is set only after a successful regeneration, and %Increase compares the current Zratio to Zmin.
Resin and Regeneration If the circuit board and the probe pass all tests, the condition of the resin or the regeneration process may actually be to blame.
78
1.
While the probe is out of the tank, take a sample of resin and examine it for breakage (fines) and fouling.
2.
Remove the power to the control.
3.
Return the probe to the tank and reconnect it to the circuit board.
4.
Power up the control and verify that the program matches the settings recorded at the beginning of the procedure. Also, make sure that the settings are correct for the application. It is recommended that the brine rinse time be left at the time calculated by the microprocessor automaticly (increases for higher salt dosages or low inlet pressure conditions) to assure adequate rinse time. The Automatic Rinse Time feature will shorten the actual rinse time as it detects the passage of the salt from the tank. Setting the time at too short a value could prevent complete rinse-out and cause daily regeneration.
5.
Backwash the unit for 2–3 minutes after installing the probe to eliminate any air pockets in the unit.
6.
Check the unit for regeneration function (salt dosage, brine draw, rinse and refill).
Culligan® High Efficiency Twin Softener
78
Cat. No. 01023053
Aqua-Sensor® Troubleshooting Flowchart Regenerates Nightly
Never Regenerates
Check water usage; is it higher than expected?
2.5 VAC power supplied?
Problem:
Diagnostics Sequence:
Check Brine Draw/Slow Rinse time in minutes. The value is calculated by the microprocessor based on inputs
Check salt dosage; high salt dosages can extend rinse out
Check eductor nozzle and screen for plugging or fouling
Is there salt in the brine tank?
Does the unit draw brine properly?
Initiate a manual regeneration; is the water soft?
Test circuit board & probe
Check Resin
function. Short salting could cause reduced capacity
Test circuit board & probe
Check pistons for internal leak
Figure 37.
Cat. No. 01023053
Aqua-Sensor troubleshooting flowchart.
Troubleshooting
79
Service Familiarize yourself with the replacement procedures and component parts thoroughly before attempting any repair.
WARNING! Disconnect all electrical power to the unit before servicing. Bypass the unit and relieve system pressure before attempting repair.
Circuit Board 1.
Remove the electrical enclosure from the control valve. Remove the electrical enclosure screw, and then gently remove the enclosure from the control. See Figure 38. Electrical Enclosure Screw
24 Volt Power Cord
Flow Meter Wire Harness
Accessories
Aqua-Sensor Wire Harness and 2.5 Volt Power Cord
Figure 38.
HE enclosure and electrical enclosure screw.
2.
Remove the 24 Volt power supply wire harness from the circuit board. See Figure 39.
3.
Grip the circuit board from the edges and gently rotate it to the back of the enclosure (disengage the circuit board from the two support pins on the bottom of the enclosure).
4.
Remove the circuit board from the enclosure.
5.
Remove all connected wires from the board.
6.
To install a new circuit board, follow steps 1–5 in reverse order.
7.
Reprogram the circuit board.
Figure 39. CAUTION!
80
Circuit board removal.
Do not touch any surfaces of the circuit board. Electrical static discharges may cause damage to the board. Handle the circuit board by holding only its edges. Keep replacement boards in their special anti-static bags until ready for use. Mishandling of the circuit board will void the warranty.
Culligan® High Efficiency Twin Softener
80
Cat. No. 01023053
CAUTION!
The wire connectors must be connected to the circuit board properly. The wires must exit the plug-in connector opposite of the raised white base of the circuit board connector.
CAUTION!
Take extra care when connecting the 2.5 vac and 24 vac power. Failure to connect properly will result in damage to the circuit board.
Drive Motor 1.
Remove the HE electrical enclosure. See the circuit board replacement instructions to remove the electrical enclosure.
2.
Remove the motor retainer rod by squeezing the snap release end of the rod. See Figure 40.
3.
Disconnect the two motor power wires from the motor—note that the black wire is placed in the bottom position.
4.
Firmly pull the motor straight outward. It may be necessary to gently tap on the motor body to get the motor to release.
5.
In order to insert the new motor into the gearbox, it is necessary to get the “flat” on the motor shaft to line up with the “flat” in the gearbox drive-gear. The easiest way to do this is to hold the motor in Figure 40. Drive motor. position, attempting to push it into the drive gear, while causing the motor shaft to turn by using the Advanced Setup\Diagnostics\Manual Motor Control menu. (Alternatively, if you remove water pressure from the valve, and/or remove the gearbox from the valve body, you can turn insert a large screw driver into the drive gear and use the screwdriver to rotate the drive gear so that the flat on the drive gear lines up with the flat on the motor shaft.)
6.
Once the motor is fully inserted, re-install the motor retainer rod and motor wire harness.
Motor Harness
Motor
Replace the Gearbox 1.
Remove the HE electrical enclosure. See the circuit board replacement instructions to remove the electrical enclosure.
2.
Remove water pressure (put the manual bypass valve to BYPASS and then use manual motor control to position the valve in the bypass position.)
3.
If you are replacing only the gearbox, but not the wire harness, then remove the motor using the instructions under “Replace the Drive Motor” and remove the optical sensor from the gearbox by removing the two small Phillips head screws on the optical sensor board.
4.
Remove the four large Phillips head screws which attach the gearbox to the valve body. See Figure 41.
5.
Install the new gearbox by reversing the directions listed above. Take care to make sure that the four large Phillips screws are fully inserted and tight.
Cat. No. 01023053
Gearbox
Figure 41.
Gearbox.
Service
81
Replace the Pistons 1.
Remove the HE electrical enclosure. See the circuit board replacement instructions to remove the electrical enclosure.
2.
Follow the directions to replace the gearbox (see “Replace the Gearbox” on page 81).
3.
Using fingers or pliers, pull the six pistons out of the valve body. Also remove the brine piston. See Figure 42.
4.
There is a spring snap-fit onto the bottom of each of the six main pistons. You can remove these springs and re-use them by snapping them onto the bottom of a new piston. When attaching a spring to the piston, take care to orient the spring so that the spring and piston are aligned and straight. If after assembly the two components are not straight, un-snap the spring, rotate it 180 degrees and re-snap it; it should now be straight.
5.
Replace the gearbox following the remaining steps listed under “Replace the Gearbox.”
Optical Sensor
Motor
Motor Retainer
Figure 42.
Pistons.
Inspect/Clean/Replace the Eductor 1.
Remove water pressure from the valve.
2.
Remove the plastic clip from the upper service port opening (this port is located on the side of the valve body, just above the eductor plug). See Figure 43.
Nozzle
Filter Eductor Eductor Plug
Figure 43. 3. 82
Eductor nozzle.
Remove the eductor plug retainer rod.
Culligan® High Efficiency Twin Softener
82
Cat. No. 01023053
4.
Remove the eductor cap.
5.
Use the notched end of the retainer rod to extract the eductor assembly from the valve body. Use moderate pulling force to overcome the O-ring resistance.
6.
Unscrew the eductor filter from the eductor body.
7.
Use a small screw driver to extract the eductor nozzle from inside the eductor body.
8.
Re-assemble the valve by reversing these instructions. Take care when re-inserting the eductor cap—there is an arrow molded into the eductor cap. If the cap is installed with the arrow pointing “UP” then the valve is cofigured for Upflow brining. If the arrow is pointing “DOWN” then the valve is configured for Downflow brining.
Inspect/Clean the Brine Line and Backwash Flow Control 1.
Relieve water pressure from the valve.
2.
Remove the cover by releasing the cover fastener from the control (see page 18).
3.
Remove the snap clip which retains the brine line adapter and drain line.
NOTE
[outdoor enclosures only] This is easier to do if you first remove the wingscrews that retain the HE electronics enclosure.) See Figure 44.
4.
Remove the brine line adapter and drain connector.
5.
Unscrew the brine line filter from the inner end of the brine line adapter and drain line flow control from the drain connector.
NOTE 6.
The number of the flow control should face into the valve body.
Brine Elbow
Filter
Clips
Drain Elbow Flow Control
Re-assemble by reversing the directions above.
Figure 44.
Brine line.
Remove/Inspect/Replace the Dial-a-Softness Knob 1.
Relieve water pressure from the valve.
2.
Remove the DAS clip. See Figure 45.
3.
Center the notch on the DAS stem with the DAS dial.
4.
Remove the DAS dial.
5.
Turn the DAS stem clockwise approximately three full revolutions.
6.
To reinstall the DAS, reverse the above instructions.
DIAL STEM
CLIP
Figure 45.
Cat. No. 01023053
Dial-a-Softness.
Service
83
Electrical Schematic
84
Culligan® High Efficiency Twin Softener
84
Cat. No. 01023053
Remote Display Template
5.450
Remote Display Template
Figure 46. Cat. No. 01023053
Hole drilling template Remote Display Template
85
Menu Overview (Two-Line Display) ),5677,0(6(783 35(66'2:1$552:
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'$3)AUX IN
AUX INPUT >REGEN TRIGGER
(1)
AUX INPUT >6
2)
1) AUX OUT 1 >2) AUX OUT 2
(“normally on” Type)
(“repeat cycle” Type)
AUX 2 OUTPUT TYPE >NORMALLY OFF
AUX 2 OUTPUT TYPE >NORMALLY ON
AUX 2 OUTPUT TYPE >REPEAT CYCLE
AUX 2 VALV POS >SERVICE
AUX 2 VALV POS >SERVICE
AUX 2 VALV POS >SERVICE
AUX2 OUT DELAY >0 MINS
AUX2 OUT ACTIVE >360 SEC
Cat. No. 01023053
AUX2 OUT DELAY >0 MIN
AUX2 OUT OFF >0 MIN
AUX OUT 2 >0 GAL
AUX2 OUT ACTIVE >360 SEC
Appendix E Auxiliary Input and Output
106
Relay Board/Aux5 Setup The GBE board offers support for the Culligan Chlorinator/Relay board (PN 01022238). See Figure 58. To use the chlorinator/relay board, install it onto the back of the GBE board. See Figure 59.
ALARM RELAY BOARD
PLUG IN HERE
BACK OF GBE BOARD
Figure 58.
Alarm Relay board.
Figure 59.
Alarm Relay Board—>Smart Controller.
Install the Chlorinator under the Main Menu /Accessories menu. From the Chlorinator Accessory menu select Chlorinator for standard chlorinator behavior.
SOFTENING JAN-01-12 12:01P
1.
From the HOME screen, press
3)SET DATE/TIME >4)ACCESSORIES
2.
The screen displays the main menu. Press 4)ACCESSORIES.
7) MODEM >8) CHLORINATOR
3.
The screen displays the main menu. Press 8)CHLORINATOR.
CHLORINATOR >INSTALLED
4.
to change the state to installed if a Chlorinator board is installed Press inside the Smart Controller.
107 Culligan® High Efficiency Twin Softener
to view the main menu.
107
to select
to select
Cat. No. 01023053
CHLORINATOR >CHLORINATOR
5.
Press
or
and then
to specify how the alarm relay board is used.
Chlorinator—Used to control a chlorinator. Not used in commercial/industrial applications. Error Status—This mode of operation occurs when the relay board is plugged into the GBE board chlorinator socket. When Error Status is selected, this relay is in the Normally Open position when the GBE board has power AND there are no errors present (“Problem Found” is not showing on the Home screen). The relay is in the Normally Closed Position when the HE is either powered OFF or when there is an error present on the GBE board. Network—currently not used. Normally On—Sets up relay to be Aux5. For this option, select cycle, delay time and duration. In this mode, the relay is energized through all cycles EXCEPT the cycle you designate. Further, it will delay de-energizing the relay for the duration designated. It will de-energize during that cycle for the amount of time you set after the delay. Normally Off—Sets up relay to be Aux5. For this option, select cycle, delay time, and duration. In this mode, the relay is NOT energized through all cycles EXCEPT the cycle you designate. Further, it will delay energizing the relay for the duration designated. It will be energized during the selected cycle for the amount of time you set after the delay. Repeat Cycle—Sets up relay to be Aux5. For this option, select cycle, delay time, “on” time, and “off” time. Once the relay energizes in the selected cycle, it will repeat the “on” time and “off” time settings until the cycle ends. Time Interval— the relay is energized at a specified start and stop time. For this option, select a daily start and end time. The auxiliary board will be energized every day from the start time until the end time. You can not select certain days, only a daily/every day option. LAMP
24VAC SUPPLY
3-HD
2-HC
1-COM
RELAY
NORMAL OPERATION: Terminals 1 and 2 are connected, leaving the lamp circuit open (lamp off) ERROR CONDITION: Terminals 1 and 3 are connected, completing the lamp circuit (lamp on)
ALARM SIGNAL PCB
Figure 60.
Cat. No. 01023053
Example of customer wiring to the GBE Alarm Signal Output.
Appendix E Auxiliary Input and Output
108
Appendix F Flow Diagrams Flow Valve Piston Locations The flow valve controls the movement of untreated and treated product during downflow and upflow regeneration cycles. Figure 61 identifies each piston as installed. In this cycle (downflow service), the P1 and P2/P3 valves are open; the P4, P5, P6, and PR valves and the Brine Piston are closed.
Pistons P1 P2/P3 P4 P5 P6 Brine PR
PR
P2/P3
P5
Inlet Outlet Backwash Rinse Bypass — Refill
Brine Piston
P4
Figure 61.
P1
P6
Valve piston locations.
The cycle sequence is different for downflow regeneration than for upflow regeneration. Note the regeneration cycle sequence for downflow and upflow regeneration.
Downflow Regeneration Cycle Sequence 1.
Service
2.
Backwash
3.
Brine Draw/Slow Rinse
4.
Fast Rinse
5.
Refill (Brine)
6.
Bypass
See page 110 through page 116 for Downflow Regeneration flow diagrams.
Upflow Regeneration Cycle Sequence 1.
Service
2.
Backwash
3.
Brine Draw/Slow Rinse
4.
Fast Rinse
5.
Refill (Brine)
6.
Bypass
See page 117 through page 123 for Upflow Regeneration flow diagrams. Cat. No. 01023053
Appendix F Flow Diagrams
109
Down Flow Regeneration—Service Raw water is allowed in the inlet to the top of the tank. The water is run through the resin up the manifold to the outlet. The water to the outlet should be soft if the system is operating properly.
Conditioned Water
Tank Inlet
P4 P6
To Drain
P1
Raw Water
Brine Piston
P2 P3
P5
PR
To Brine Tank
Hard Water Softened Water Drain Brine Diluted Brine
Tank Outlet
Figure 62.
Down flow regeneration—service.
Service
110 Culligan® High Efficiency Twin Softener
Piston
Position
P1
Open
P2/3
Open
P4
Closed
P5
Closed
P6- Bypass Piston
Closed
Brine Piston
Closed
PR-Refill Piston
Closed 110
Cat. No. 01023053
Down Flow Regeneration—Backwash Raw water is directed down the center of the manifold, up through the resin, out the top of the tank to drain. The water to drain should be hard.
Bypassed Water
Tank Inlet
P1
To Drain
P4 P6 Raw Water
Brine Piston
P2 P3
PR
P5
To Brine Tank
Hard Water Softened Water Drain Brine Diluted Brine
Tank Outlet
Figure 63.
Down flow regeneration—backwash.
Backwash Piston Position
Cat. No. 01023053
P1
Closed
P2/3
Open
P4
Open
P5
Closed
P6- Bypass Piston
Open
Brine Piston
Closed
PR-Refill Piston
Closed Appendix F Flow Diagrams
111
Down Flow Regeneration—Brine Draw Raw water is directed from the inlet through the nozzle and into the throat. A vacuum is created and concentrated brine is educted (drawn). The raw water and concentrated brine combine, enter the mineral tank, and pass through the resin, up the manifold and to the drain. Once all of the brine has been educted and the brine valve seats, the unit goes into slow rinse. Hard water is allowed to service during regeneration.
Bypassed Water
Tank Inlet
P4
P1
To Drain
P6 Raw Water
Brine Piston
P5 P2 P3
PR
To Brine Tank
Hard Water Softened Water Drain Brine Diluted Brine
Tank Outlet
Figure 64.
Down flow regeneration—brine draw.
Brine Draw Piston Position P1
112 Culligan® High Efficiency Twin Softener
Closed
P2/3
Closed
P4
Closed
P5
Open
P6- Bypass Piston
Open
Brine Piston
Open
PR-Refill Piston
Closed 112
Cat. No. 01023053
Down Flow Regeneration—Slow Rinse Raw water is directed from the inlet through the nozzle and into the throat. A vacuum is created but the brine valve has seated, so no brine is educted. The raw water enters the mineral tank, passes through the resin, up the manifold and to the drain. Hard water is allowed to service during regeneration.
Bypassed Water
Tank Inlet
P4
P1
To Drain
P6 Raw Water
Brine Piston
P5 P2 P3
PR
To Brine Tank
Hard Water Softened Water Drain Brine Diluted Brine
Tank Outlet
Figure 65.
Down flow regeneration—slow rinse.
Slow Rinse Piston Position P1
Cat. No. 01023053
Closed
P2/3
Closed
P4
Closed
P5
Open
P6- Bypass Piston
Open
Brine Piston
Open
PR-Refill Piston
Closed Appendix F Flow Diagrams
113
Down Flow Regeneration—Fast Rinse Raw water is directed from the inlet to the top of the tank, down the resin, up the manifold, and out to drain. Hard water is allowed to Service during regeneration.
Bypassed Water
Tank Inlet
P4
To Drain
P1 P6 Raw Water
Brine Piston
P5 P2 P3
PR
To Brine Tank
Hard Water Softened Water Drain Brine Diluted Brine
Tank Outlet
Figure 66.
Down flow regeneration—fast rinse.
Fast Rinse
114 Culligan® High Efficiency Twin Softener
Piston
Position
P1
Open
P2/3
Closed
P4
Closed
P5
Open
P6- Bypass Piston
Open
Brine Piston
Closed
PR-Refill Piston
Closed 114
Cat. No. 01023053
Down Flow Regeneration—Refill To make the brine, water flows into the salt storage area during the fill stage. Fill cycle length depends on the salt dosage. Use soft water for refill.
Conditioned Water
Tank Inlet
P4
To Drain
P6 P1 Raw Water
Brine Piston Soft Water to Fill Brine Tank
P2 P3
PR P5
To Brine Tank
Hard Water Softened Water Drain Brine Diluted Brine
Tank Outlet
Figure 67.
Down flow regeneration—refill.
Refill
Cat. No. 01023053
Piston
Position
P1
Open
P2/3
Open
P4
Closed
P5
Closed
P6- Bypass Piston
Closed
Brine Piston
Closed
PR-Refill Piston
Open Appendix F Flow Diagrams
115
Down Flow Regeneration—Bypass The HE control can be bypassed for a preset time duration. Raw water is allowed in the inlet of the control and internally bypassed to the outlet of the control (hard water is allowed to service).
Bypass Water
Tank Inlet
P1
P4
To Drain
P6 Raw Water
Brine Piston
P2 P3
PR
P5
To Brine Tank
Hard Water Softened Water Drain Brine Diluted Brine
Tank Outlet
Figure 68.
Down flow regeneration—bypass.
Bypass
116 Culligan® High Efficiency Twin Softener
Piston
Position
P1
Closed
P2/3
Closed
P4
Closed
P5
Closed
P6- Bypass Piston
Open
Brine Piston
Closed
PR-Refill Piston
Closed 116
Cat. No. 01023053
Up Flow Regeneration—Service Raw water is allowed in the inlet to the top of the tank. The water is run through the resin up the manifold to the outlet. The water to the outlet should be soft if the system is operating properly.
Conditioned Water
Tank Inlet
P6
P4
To Drain
P1 Raw Water
Brine Piston
P2 P3 P5
PR
To Brine Tank
Hard Water Softened Water Drain Brine Diluted Brine
Tank Outlet
Figure 69.
Up flow regeneration—service.
Service
Cat. No. 01023053
Piston
Position
P1
Open
P2/3
Open
P4
Closed
P5
Closed
P6- Bypass Piston
Closed
Brine Piston
Closed
PR-Refill Piston
Closed Appendix F Flow Diagrams
117
Up Flow Regeneration—Backwash Raw water is directed down the center of the manifold, up through the resin, out the top of the tank to drain. The water to drain should be hard.
Bypassed Water
Tank Inlet
P1
To Drain
P4
P6 Raw Water
Brine Piston P2 P3 P5
PR
To Brine Tank
Hard Water Softened Water Drain Brine Diluted Brine
Tank Outlet
Figure 70.
Up flow regeneration—backwash.
Backwash
118 Culligan® High Efficiency Twin Softener
Piston
Position
P1
Closed
P2/3
Open
P4
Open
P5
Closed
P6- Bypass Piston
Open
Brine Piston
Closed
PR-Refill Piston
Closed 118
Cat. No. 01023053
Up Flow Regeneration—Brine Draw Raw water is directed from the inlet through the nozzle and into the throat. A vacuum is created and concentrated brine is educted (drawn). The raw water and concentrated brine combine, enter the mineral tank, and pass through the resin, up the manifold and to the drain. Once all of the brine has been educted and the brine valve seats, the unit goes into slow rinse. Hard water is allowed to service during regeneration.
Bypassed Water
Tank Inlet
P1 P6
To Drain
P4
Raw Water
Brine Piston
P2 P3
P5
PR
To Brine Tank
Hard Water Softened Water Drain Brine Diluted Brine
Tank Outlet
Figure 71.
Up flow regeneration—brine draw.
Brine Draw
Cat. No. 01023053
Piston
Position
P1
Closed
P2/3
Closed
P4
Open
P5
Closed
P6- Bypass Piston
Open
Brine Piston
Open
PR-Refill Piston
Closed Appendix F Flow Diagrams
119
Up Flow Regeneration—Slow Rinse Raw water is directed from the inlet through the nozzle and into the throat. A vacuum is created but the brine valve has seated, so no brine is educted. The raw water enters the mineral tank, passes through the resin, up the manifold and to the drain. Hard water is allowed to service during regeneration.
Bypassed Water
Tank Inlet
P1 P6
To Drain
P4
Raw Water
Brine Piston
P2 P3
PR
P5
To Brine Tank
Hard Water Softened Water Drain Brine Diluted Brine
Tank Outlet
Figure 72.
Up flow regeneration—slow rinse.
Slow Rinse
120 Culligan® High Efficiency Twin Softener
Piston
Position
P1
Closed
P2/3
Closed
P4
Open
P5
Closed
P6- Bypass Piston
Open
Brine Piston
Open
PR-Refill Piston
Closed 120
Cat. No. 01023053
Up Flow Regeneration—Fast Rinse Backwash is followed by a fast flow of water down through the resin tank. The fast flow packs the resin bed and gets it ready for return to service.
Bypassed Water
Tank Inlet
P4
To Drain
P1
P6 Raw Water
Brine Piston
P5 P2 P3
PR
To Brine Tank
Hard Water Softened Water Drain Brine Diluted Brine
Tank Outlet
Figure 73.
Up flow regeneration—fast rinse.
Fast Rinse
Cat. No. 01023053
Piston
Position
P1
Open
P2/3
Closed
P4
Closed
P5
Open
P6- Bypass Piston
Open
Brine Piston
Closed
PR-Refill Piston
Closed Appendix F Flow Diagrams
121
Up Flow Regeneration—Refill To make the brine, water flows into the salt storage area during the fill stage to make brine for the next regeneration sequence. Use soft water for refill. Fill cycle length depends on the salt dosage. There is an approximately two-hour pause while the unit is making brine. The unit will continue to be in the service position and will continue to soften water.
Conditioned Water
Tank Inlet
P6
P4
To Drain
P1 Raw Water
Brine Piston
P2 P3
PR P5
To Brine Tank
Hard Water Softened Water Drain Brine Diluted Brine
Tank Outlet
. Figure 74.
Up flow regeneration—refill.
Refill
122 Culligan® High Efficiency Twin Softener
Piston
Position
P1
Open
P2/3
Open
P4
Closed
P5
Closed
P6- Bypass Piston
Closed
Brine Piston
Closed
PR-Refill Piston
Open 122
Cat. No. 01023053
Up Flow Regeneration—Bypass The HE control can be bypassed for a preset time duration. Raw water is allowed in the inlet of the control and internally bypassed to the outlet of the control (hard water is allowed to service).
Bypassed Water
Tank Inlet
P1
P4
To Drain
P6 Raw Water
Brine Piston
P2 P3
P5
PR
To Brine Tank
Hard Water Softened Water Drain Brine Diluted Brine
Tank Outlet
Figure 75.
Up flow regeneration—bypass.
Bypass
Cat. No. 01023053
Piston
Position
P1
Closed
P2/3
Closed
P4
Closed
P5
Closed
P6- Bypass Piston
Open
Brine Piston
Closed
PR-Refill Piston
Closed
Appendix F Flow Diagrams
123
Appendix G Quick Reference Quick Reference—First Time Setup For a 9" High Efficiency Twin Softener with Meter Hardness: 20 gpg Downflow regeneration No other accessories connected No default settings need to be changed NOTE
The HE Twin softener installation may require additional steps depending on which accessories are connected. Follow the installation procedure prior to first time setup, including: softener placement; tank assembly; control valve mounting; bypass valve installation; plumbing connection; and start up. 1.
PRESS DOWN ARROW
S/N: 00000123
FWR216LT21 Jan
2.
3.
4 2012
SET MONTH
When the screen displays FIRST TIME SETUP, press to view and change (if necessary) the softener configuration.
FIRST TIME SETUP
4.
VALVE TYPE
Press
HE 1 Twin
The screen displays the firmware version for the HE Controller.
UNITS
Press
>US INCH
then 5.
6.
7.
to change the value.
8. SET HOUR
9.
and
or
and then to change the value if necessary.
INSTALL TYPE
or
and
BRINING TYPE
14. The screen displays the installation type. Press to keep the default and view the next setting.
Downflow
TANK DIAMETER
15. The screen displays the tank diameter. Press
9
then HARDNESS GPG 25 (1056 GAL)
JAN-01-12 12:01P
and
16. The screen displays the water hardness setting in grains per gallon. Press then
Initializing
or
to change the value.
or
and
to change the value.
17. The circuit board initializes and finds the HOME position.
to change the value.
The screen displays the hour setting. Press then
13. The screen displays the installation type. Press to keep the default and view the next setting.
Residential
to change the value.
The screen displays the hour then
>12
or
The screen displays the clock
setting. Press
>12PM
12. The screen displays the units of measure for the controller. Press
to change the value.
and then
SET MINUTES
and
type setting. Press
>12 HR
and
The screen displays the year then
CLOCK TYPE
or
setting. Press
>2012
type. Press to change the value to HE 1 Twin.
The screen displays the day setthen
SET YEAR
or
to change the value.
ting. Press
>1
11. The screen displays the valve
The screen displays the month setting. Press
>JAN
SET DAY
to view the next setting.
setting. Press to keep the default and view the next setting.
>SOFTENER
The screen displays the serial number for the HE Controller. to view the next setting.
10. The screen displays the unit type
UNIT TYPE
or
and
SOFTENING JAN-01-12 12:01P
18. The screen displays the home screen. The first time setup is complete.
to change the value.
124 Culligan® High Efficiency Twin Softener
124
Cat. No. 01023053
Quick Reference—Aqua-Sensor® Application For a 9" High Efficiency Twin Softener with Aqua-Sensor and Meter Hardness: 20 gpg No other accessories connected No default settings need to be changed NOTE
The HE Twin softener installation may require additional steps depending on which accessories are connected. Follow the installation procedure prior to first time setup, including: softener placement; tank assembly; control valve mounting; bypass valve installation; plumbing connection; Aqua-Sensor probe installation; and start up. After installation, run First Time Setup, program the Aqua-Sensor accessory, and program the Soft-Minder meter as a backup to the Aqua-Sensor probe. Reduce reserve capacity to approximately 10%, OR use the Aqua-Sensor probe to initiate regeneration 100% of the time (the conditioner will still monitor flow-related data such as flow rate, average water usage, etc.)
Set Up Aqua-Sensor SOFTENING
1.
JAN-01-12 12:01P
3)SET DATE/TIME
From the HOME screen, press
2.
3.
1.
to select 5)ADV.
1)SYSTEM SETUP >2)REGEN SETUP
2.
to select 2)REPress GEN SETUP.
3.
For a single HE softener the typical setting is 30 percent re-
to
The screen displays the acces-
RESERVE CAPACITY >30% (303 GAL)
serve capacity. Press
sories menu. Press to select 1)AQUASENSOR.
2)BEEPER
From the main menu, press SETUP.
The screen displays the main menu. Press select 4)ACCESSORIES.
4)ACCESSORIES >5)ADV. SETUP
to view the main menu.
>4)ACCESSORIES
>1)AQUASENSOR
Set Up Soft-Minder as a Back Up to Aqua-Sensor
or to 10.
to change the value
Use Aqua-Sensor to initiate regeneration 100% AQUASENSOR NOT INSTALLED
4.
Press to change the state to installed.
4)ACCESSORIES
4.
Press menu.
5.
From the main menu, press
>5)ADV. SETUP
AQUASENSOR DEBUG
5.
to return to the main
to select 5)ADV.
Keep this setting at OFF. Press
SETUP.
to return to the accessories menu.
OFF
3)CYCLE TIMES >4)REGENTRIGGER
6.
to select Press 4)REGENTRIGGER.
7.
Press or to change the value to CANNOT TRIGGER.
8.
Press to display the home screen.
SOFTENING JAN-01-12 12:01P
6.
Press to display the home screen. FLOW METER CANNOT TRIGGER
SOFTENING JAN-01-12 12:01P
Cat. No. 01023053
Appendix G
Quick Reference
125
Quick Reference—Upflow/Proportional Brining Application For a 9" High Efficiency Twin Softener with Aqua-Sensor and Meter Hardness: 20 gpg Upflow/Proportional regeneration No other accessories connected No default settings need to be changed NOTE
The part number for the HE upflow control is 01023111. The HE downflow control is not designed for upflow regeneration—see the manual for the steps to convert an HE downflow control to an upflow control.
NOTE
The HE Twin softener installation may require additional steps depending on which accessories are connected. Follow the installation procedure prior to first time setup, including: softener placement; tank assembly; control valve mounting; bypass valve installation; plumbing connection; and start up. After intallation, run First Time Setup and then setup upflow/proportional brining.
Up Flow Regeneration Water flow is downward and regenerate flow is upward through the media tank. The significance of this is that regeneration will be most effective in those parts of the resin bed which are treated with the freshest regenerate solution.
Proportional Brining The control monitors your softened water usage making only enough brine to regenerate that part of the resin bed that has been exhausted. In this way the amount of salt used relates directly to the amount of softened water.
Set Up Upflow/Proportional Brining SOFTENING JAN-01-12 12:01P
1.
From the HOME screen, press
4)ACCESSORIES
1.
From the main menu, press
>2)REGEN SETUP
2.
Press
BRINING TYPE
3.
Press
to view the main menu.
to select 5)ADV. SETUP.
>5)ADV. SETUP
1)SYSTEM SETUP
>PROPORTIONAL
NOTE
to select 2)REGEN SETUP.
to change the setting to PROPORTIONAL.
If Proportional is selected, any manually initiated regeneration will be performed assuming that remaining capacity equals zero (0) percent.
SOFTENING JAN-01-12 12:01P
4.
Press
to display the home screen.
126 Culligan® High Efficiency Twin Softener
126
Cat. No. 01023053
Quick Reference—Smart Brine Tank Probe For a 9" High Efficiency Twin Softener with Meter Hardness: 20 gpg Smart Brine Tank Probe connected 18” Brine Tank is used (375 lb. capacity) No default settings need to be changed NOTE
The HE Twin softener installation may require additional steps depending on which accessories are connected. Follow the installation procedure prior to first time setup, including: softener placement; tank assembly; control valve mounting; bypass valve installation; plumbing connection; and start up. After intallation, run First Time Setup and then setup the Smart Brine Tank Sensor.
NOTE
In order for proper probe functioning, it is required that prior to selecting INSTALLED on the menu the probe must be physically installed into the brine tank and that the brine tank be filled with a minimum of 16" depth of salt. Failure to take these steps will result in the screen displaying ERROR MESSAGE. If these steps were not followed, go to the menu shown below and select UNINSTALLED, then press the CHECK MARK button and return to the HOME SCREEN. Once the probe is installed correctly and salt is added to the brine tank, return to these menus and change the setting to INSTALLED.
Set Up Smart Brine Tank Probe SOFTENING
1.
From the HOME screen, press
2.
The screen displays the main menu. Press
3.
Press
>NOT INSTALLED
4.
to change the state to installed. The Smart Controller can then communicate Press with the SBT sensor.
TANK DIAMETER
5.
Press or and then to increase or decrease the tank diameter, which is used to estimate the number of days the brine tank has salt.
JAN-01-12 12:01P
to view the main menu.
3)SET DATE/TIME >4)ACCESSORIES
to select 4)ACCESSORIES.
5)AUX OUTPUTS >6)SBT SENSOR
to select 6)SBT SENSOR.
SBT SENSOR
>16
Culligan 16” brine tank = 250 lb. salt capacity Culligan 18” brine tank = 375 lb. salt capacity Culligan 24” brine tank = 650 lb. salt capacity SALT GEOMETRY Pellet/cube
6.
Press salts).
or
7.
Press
to display the home screen.
and then
to change the salt geometry (the shape of the softening
SOFTENING JAN-01-12 12:01P
Cat. No. 01023053
Appendix G
Quick Reference
127
Quick Reference—Remote Display For a 9" High Efficiency Twin Softener with Meter Hardness: 20 gpg Downflow regeneration Remote display connected NOTE
The HE Twin softener installation may require additional steps depending on which accessories are connected. Follow the installation procedure prior to first time setup, including: softener placement; tank assembly; control valve mounting; bypass valve installation; plumbing connection; remote display installation; and start up. After intallation, run First Time Setup.
Set Up Remote Display/Control Valve SOFTENING
1.
JAN-01-12 12:01P
3)SET DATE/TIME
Check Signal Strength
From the HOME screen, press to view the main menu.
2.
to
6)SBT SENSOR >7)WIRELESS REM
REMOTE DISPLAY
Press to select 7)WIRELESS REM.
4.
to change the Press state to installed. The Smart Controller can then communicate with the remote.
5.
Press
or
and then
to select the channel number of the control valve. The CHANNEL # for the control valve must be the same as the CHANNEL # for the Remote Display.
>1
to view the main menu.
5)ADV. SETUP >6)DIAGNOSTICS
>3)TEST WIRELESS
2.
Press select 6)DIAGNOSTICS.
3.
to select 3) Press TEST WIRELESS.
4.
The signal strength indicator (SSI) will display a value between zero (0) and 8. If the SSI is at least 4 then the installation is complete. It might be necessary to change the location of the remote (closer to the HE softener) to improve the signal. Press any button to return to the diagnostics menu.
WIRELESS TEST 0 / 14
WIRELESS TEST RSSI=5
5.
to
SOFTENING JAN-01-12 12:01P
RF FREQUENCY
From the HOME screen, press
2)CHECK SENSORS
3.
>NOT INSTALLED
CHANNEL #
1.
JAN-01-12 12:01P
The screen displays the main menu. Press select 4)ACCESSORIES.
>4)ACCESSORIES
SOFTENING
6.
Do not change the RF Frequency in North American installations.
7.
to display the Press home screen.
915MHz
6.
Press to display the home screen.
SOFTENING JAN-01-12 12:01P
128 Culligan® High Efficiency Twin Softener
128
Cat. No. 01023053
Quick Reference—Modem Control Valve For a 9" High Efficiency Twin Softener with Meter Hardness: 20 gpg Downflow regeneration Modem connected in control NOTE
The HE Twin softener installation may require additional steps depending on which accessories are connected. Follow the installation procedure prior to first time setup, including: softener placement; tank assembly; control valve mounting; bypass valve installation; plumbing connection; modem installation, progamming, and testing; remote display installation; and start up. After intallation, run First Time Setup.
Set Up Remote Display/Control Valve DATA PHONE #
9.
>_8884137028 SOFTENING
1.
JAN-01-12 12:01P
3)SET DATE/TIME
From the HOME screen, press
entered press to accept the entire phone number
to view the main menu.
2.
The screen displays the main menu. Press lect 4)ACCESSORIES.
>4)ACCESSORIES
Press or and then to change each digit of the phone number. When the final digit is
SOFTENING JAN-01-12 12:01P
to se-
10. Press screen.
to display the home
Test the Modem 7)WIRELESS REM >8)MODEM
TEL MODEM
3.
4.
>NOT INSTALLED
Press lect 8)MODEM.
to se-
SOFTENING
1.
JAN-01-12 12:01P
to change the Press state to installed if a telephone modem is installed inside the Smart Controller.
From the HOME screen, press to view the main menu.
5)ADV. SETUP
to se-
2.
Press lect 6)DIAGNOSTICS.
>9)TEST PHONELIN
3.
Press TEST PHONELIN.
MODEM TEST
4.
The screen displays the status of the test before displaying the results. Do not press any buttons before the test is complete or the controller will return to the Diagnostics menu.
5.
Press screen.
>6)DIAGNOSTICS
MODEM LOCATION >IN REMOTE
CALL FREQUENCY >EVERY 10 REGENS
5.
6.
Press location.
to change the
or and then Press to increase or decrease the frequency if necessary.
8)USE DATA PORT
Sending pls wait
MODEM EMAIL SUCCESS
TIME ZONE GMT >-05:00
7.
or and then Press to change the time zone.
to select 9)
SOFTENING DEALER ID >1234567_
8.
Press or and then to change each digit of the dealer ID. When the final digit is entered
JAN-01-12 12:01P
to display the home
press to accept the entire dealer ID. Cat. No. 01023053
Appendix G
Quick Reference
129
For a 9" High Efficiency Twin Softener Hardness: 20 gpg Downflow regeneration No other accessories connected No default settings need to be changed NOTE
The HE Twin softener installation may require additional steps depending on which accessories are connected. Follow the installation procedure prior to first time setup, including: softener placement; tank assembly; control valve mounting; bypass valve installation; plumbing connection; electrical connection; and start up.
SOFTENING
1.
4)ACCESSORIES
From the HOME screen, press to view the main menu.
JAN-01-12 12:01P
1.
HARDNESS GPG >25 (1056 GAL)
to select 5)ADV. SETUP.
TWIN PRERINSE >5
2.
to select 1)SYSTEM Press SETUP.
3.
The valve type setting can not be changed from HE 1 Twin. Press
2)REGEN SETUP
HE 1 Twin
TANK DIAMETER
4.
or and then Press to change the tank diameter.
5.
and then to Press change the units of measure for the controller.
6.
or and then Press to change the salt type setting.
7.
or and then Press to change the the iron present in parts per million.
8.
Press
>US INCH
SALT TYPE >NACL
IRON PPM >0
LINE PRESSURE
9. >SOFTEST
or and then 11. Press to change the HE Twin prerinse mode setting, which specifies the the duration of rinsing the standby tank prior to going online.
or and then 12. Press to change the value from OFF to ON.
RINSE IF NO FLOW
13. Press
or
or
and then
to change the duration of this interval.
>FOR 24
and then
to change the line pressure setting.
>ABOVE 40 PSI
DIAL-A SOFTNESS
to change the water hardness setting from 25 to 20.
to view the next next setting.
>9
UNITS
and then
>OFF
PRERINSE MODE VALVE TYPE
or
From the main menu, press
>5)ADV. SETUP
>1)SYSTEM SETUP
10. Press
If the Dial-a-Softness knob has been adjusted, press and then setting.
130 Culligan® High Efficiency Twin Softener
or
to change the
130
Cat. No. 01023053
Appendix H Program Log Program Log Use this log to record the program settings for any Smart Controller (GBE) controlled softener or filter. Circle or enter the observed value. Make additional copies to keep on file near the installation and with your local Culligan dealer. Program Date: ___________ Installer: _____________________________ Site Location: ____________________ Smart Controller ESN: _____ Firmware Version: _____________________ Regeneration Initiation (check all that apply):
First Time Setup
Time Clock
Meter
Aqua-Sensor
Total Capacity
Day
Reserve Capacity
S Only
Year
Brining Type
S Only
12 Hr/24 Hr
Regen Mode
Minutes Unit Type Valve Type
HE 1, HE 1.25, HE 1.5, HE 1 Twin, HE 1.5 Twin, 4-Cycle, 5-Cycle, Plat Plus
Regen Lockout
S Only
Media Life
F Only
Brining Type
S Only
Downflow, Upflow, Proportional
S Only S Only
Hardness
S Only
Media Life
F Only
Total Capacity
F Only
Aux Input
Normal/Alarm
Aux2 Output Type
Normally On Normally Off Repeat Cycle
Aux2 Out Active
Cycle Times
Aux2 Out Off Aux3 Output Type
Brine Draw-Rinse Fast Rinse Time
Repeat Cycle Normally On Normally Off Repeat Cycle
Aux3 Valv Pos
Fill Time
Aux3 Out Delay Aux3 Out Active Aux3 Out Off
Regeneration Triggers Flow Meter
HE 1, HE 1.5, HE 1 Twin, 4-Cycle, 5-Cycle, Plat Plus
S Only
Always On Always Off 12 Hr. Warnings 24 Hr. Warnings
Backwash
Tank Diameter
Valve Type
S Only
ON/OFF
Aux2 Out Delay
Residential, Commercial
Advanced Setup
Installed/Not Installed
Aux2 Valv Pos
US Inch/Metric
Install Type
Beeper Mode
Delayed/Immediate
Power Up Regen Softener/Filter/R+C
Units
Debug
Time of Regen
Hour
Filter Other
Accessories
Regeneration Setup
Month
Clock Type
Softener Aqua-Sensor
Aqua-Sensor
SBT Sensor
Can/Cannot Can/Cannot
S Only
OFF/ON
S Only
Predict Mode
Installed/Not Installed
Tank Diameter Salt Geometry
Regen Interval
Repeat Cycle
Remote Display
S Only S Only
Pellet/Rock/ Brick/Special
S Only
Installed/Not Installed
Regen On Channel #
Units
US Inch/Metric Radio Frequency
Multitank System
Single Twin Progress Flow Alternating Unbal Prog Flow
On Remote Display Remote Display
915 Installed/Not Installed
Modem Location
Main Control/ In Remote
Installed/Not Installed Call Frequency
Prog Flow Trip Progress Flow
Modem
Channel # Master/Slave (_____)
Rinse If No Flow Rinse For
915 Dealer ID
Small Tank Trip Prerinse Mode
Time Zone GMT Radio Frequency
OFF/ON
Date Phone # Chlorinator
Installed/Not Installed
Power Level On Time Meter
Installed/Not Installed
Puls/Gal Low Flow Limit High Flow Limit Service Phone # Ext Filter
Installed/Not Installed
S Only
Yes/No
S Only
Filter Capacity Reset Capacity
Cat. No. 01023053
S Only
Appendix H Program Log
131
25
56
83
20
18
132 Culligan® High Efficiency Twin Softener 19
24
57
82
17
54
55
51
14
70
53
16
12 11
15
72
51
1
6
71
2
7 9
69
2
41
10
4
28
64
61
PISTON DETAIL
60
23 5
29
8
QUAD-RING GROOVE
O-RING GROOVES
25
132 63
62
65
BRINE PISTON DETAIL
31
28
23
84
32
18 20
17 33
QUAD-RING GROOVE
O-RING GROOVES
19
24
14
35
41
1
71
6
O-RING GROOVES
42
2
PLUG EDUCTOR HOUSING
CONTROLLER DETAIL
16
12 11
15
34
1
7
31
9
N-m)
23
2
72
28
10
32
41
40
29
4
39
23
70
42
38
5 8
71
47
31
47
37
69
N-m)
29 23 28 32
Parts
High Efficiency Twin Indoor Assembly
Cat. No. 01023053
Item
Part No.
Description
01023111
HE Control Valve, Dowflow, Complete
01023115
HE Control Valve, Upflow, Complete
01022746
HE Twin Control Valve #2, Dowflow, Complete
01023279
HE Twin Control Valve #2, Upflow, Complete
01023020
Valve Body
2
01022791
Piston Rebuild Kit, Includes 6ea Piston assem-blies and 1ea Brine Piston Assembly
4
01020440
Gear Box Assembly, Downflow
1
Item
Part No.
Description
P1023712
Eductor Throat with O-rings, Upflow, Gray (9" Tanks), 10ea/Kit
P1023713
Eductor Throat with O-rings, Upflow, White (10" Tanks), 10ea/Kit
46
P1020603
Eductor Throat O-ring, Large, 10ea/Kit
47
P1020428
Eductor Throat O-ring, Small, 10ea/Kit
48
P1013894
Eductor Nozzle w/ O-ring, Blue (9” & 10” tanks), 10ea/Kit
P1013895
Eductor Nozzle w/ O-ring, Beige (10” & 12” tanks), 10ea/ Kit
01022234
Gear Box Assembly, Upflow
00447752
Eductor Nozzle w/ O-ring, Green (14” tanks)
5
01020240
Gearmotor
49
P0308438
O-ring, Eductor Nozzle, 10ea/Kit
6
P1020415
Retainer, Gearmotor, 10ea/Kit
50
P1020256
Screen, 10ea/Kit
7
01020420
Wire Harness w/ Optical Sensor
51
01014153
Tank Adapter Assy, 1” valve to tank less O-Rings
01022752
Wire Harness w/ Optical Sensor, Control #2
52
01013958
Tank Adapter, 1” Valve
01022735
Wire Harness, Motor
53
P1013959
Tank Clamp, 1” Valve
01022751
Wire Harness, Motor, Control #2
54
P1013669
Tank Clamp Pin, 1” Valve
9
P1020433
Optical Sensor Screw, 10ea/Kit
55
P0318383
Tank Clamp Screw, 1” Valve/3/4” bkt
10
P1020517
Gear Box Assembly Screw, 10ea/Kit
56
P1014848
O-ring, Large, Valve to Tank Adapter
11
P1020289
Dial-a-Softness Knob, 10ea/Kit
57
P0440052
O-ring, Valve Adapter to ACME Tank
12
P1020427
Dial-a-Softness Assembly w/ O-Rings, 10ea/Kit
60
P1020431
Main Piston O-ring, 25ea/Kit
13
P0440268
O-Ring, Brine & Drain Elbow, 10ea/Kit
61
P1020430
Main Piston Quad Ring, 25ea/Kit
14
P1020487
Eductor Plug Assembly w/ O-Rings, 10ea/Kit
62
P1020426
Brine Piston O-ring 25ea/Kit
15
P1020290
Eductor Plug Retainer, 10ea/Kit
63
P1021881
Brine Piston Quad Ring 25ea/Kit
16
P1023051
Dial-a-Softness Locking Plug, 10ea/Kit
64
P1020252
Main Piston Spring, 10ea/Kit
17
P1020291
Dial-a-Softness Locking Plug Retainer
65
P1020286
Brine Piston Spring 10ea/Kit
18
P1020581
Brine Elbow Assembly, 10ea/Kit
69
01018760
Bypass Valve, Rotary
19
P1020432
Retainer, Brine & Drain Elbow, 10ea/Kit
70
P1009075
Retaining Clip, 1” Bypass valve
20
P1023021
Drain Elbow Assembly, 10ea/Kit
71
01014033
Coupling Kit - 1” Bypass
23
01023014
Enclosure Frame
72
P1009099
O-ring, Couplings/Meters
24
P0331635
Backwash Flow Control, #2 Brown (9" & 10" Tanks), 10ea/Kit
82
01011188
Meter Kit - 1” w/wire harness
P0331636
Backwash Flow Control, #3 Green (12" Tanks), 10ea/Kit
83
01024840
Wire Harness, Meter, 48"Long
8
P0401031
Backwash Flow Control, Black (14" Tanks), 10ea/ Kit
84
P1023699
Half Ball w/ Post, Upflow Only, 10ea/Kit (only upflow models)
25
01023066
Control Valve Cover
85
P1023695
Spring, Upflow Only, 10ea/Kit (only upflow models)
28
P0318383
Enclosure Screw, 10ea/Kit
86
01021077
Interconnecting Pipe & Fittings, Copper
29
P1023122
Retainer for Enclosure Screw, 10ea/Kit
01023290
Interconnecting Pipe & Fittings, Plastic
31
P1000372
Strain Relief Fitting, 10ea/Kit
*
P0451701
Hose Clamp, Drain
32
P1006498
Plug, 10ea/Kit
*
01018249
1 1/4” Straight Through Adapter
34
P1021162
O-ring, Eductor Plug Assembly, Large, 10ea/Kit
*
01018755
Rebuild Kit - 1”/1-1/4” Rotary Bypass
35
P1020424
O-ring, Eductor Plug Assembly, Small, 10ea/Kit
*
P1019646
Replacement O-Ring for Bypass Valve Stem, 50ea/Kit
37
01017134
Power Cord
*
01010783
1” Copper Adapter Kit, (1” Bypass)
38
P1017264
Power Cord Connector, 10ea/Kit
*
01016564
3/4” Copper Adapter Kit (1” Bypass)
39
01023448
Electronics Enclosure Kit less Circuit Board
*
01016565
3/4” Elbow Copper Adapter Kit (1” Bypass)
01023589
Electronics Enclosure Kit less Circuit Board, Control #2
*
P1018757
1” NPT Female Elbow Kit (1” Rotary Bypass)
40
01023447
Replacement Circuit Board
*
01018757
1” NPT Female Elbow Kit (1” Rotary Bypass)
41
P1023112
Circuit Board Label, 10ea/Kit
*
P1009856
Gasket, Copper Plumbing Adapters
P1023276
Circuit Board Label, Control #2, 10ea/Kit
*
01018133
Transformer, Dual Output
P1020497
Keypad with Connector, 10ea/Kit
*
01020620
Transformer, Dual Output w/ 6' Power Cord
P1022796
Eductor Throat with O-rings, Downflow, Tan (9, 10 & 12" Tanks), 10ea/Kit
P1022723
Eductor Throat with O-rings, Downflow, Blue (14" Tanks), 10ea/Kit
42 45
Cat. No. 01023053
* Not shown
Parts
133
14
34
35
O-RING GROOVES
83
53*
72
134 Culligan® High Efficiency Twin Softener
56
49
52*
45
52 & 53 UPFLOW ONLY
82
48
57
46
70
54
55
50
47
53
12
71
10
21
51
9
13
22
14
23
69
8 14
41
42
24 50
51
1
5 6
3
ELECTRONICS HOUSING
28
2
48
45
PISTON DETAIL
44
7
40
43
134 17
15
39
12
4
86
11
QUAD-RING GROOVE
O-RING GROOVES
14
22
9
23
10
8
34
13
72
14
24 50
51
70
2
5 6
71
71
28
47
46
3
49
BRINE PISTON DETAIL
67
7
4
O-RING GROOVES QUAD-RING GROOVE
High Efficiency Twin Outdoor Assembly
Cat. No. 01023053
Item
1 2 3
Part Number
Description
01020442
High Efficiency, Downflow Regeneration—Complete
01022508
High Efficiency, Upflow Regeneration—Complete
01022776
Outdoor High Efficiency, Downflow Regeneration—Complete
01022781
Outdoor High Efficiency, Upflow Regeneration—Complete
Eductor Nozzle w/ O-ring, Beige (10” & 12” tanks), 10ea/ Kit
00447752
Eductor Nozzle w/ O-ring, Green (14” tanks)
33
P0308438
O-ring, Eductor Nozzle, 10ea/Kit
34
P1020256
Filter Screen, 10ea/Kit
35
P1020424
O-ring, Eductor Plug Assembly, Small, 10ea/Kit
39
01022800
Electronics Enclosure Kit less Circuit Board
01023589
Electronics Enclosure Kit less Circuit Board, Control #2 Replacement Circuit Board Kit
Outdoor HE Twin Control #2, Upflow Regen—Complete
01020251
Valve Body
40
01020745
41
P1023112
Circuit Board Label, 10ea/Kit
01022791
Piston Rebuild Kit, Includes 6ea Piston Assemblies and 1ea Brine Piston Assembly
P1023276
Circuit Board Label, Control #2, 10ea/Kit
42
P1020497
Keypad with Connector, 10ea/Kit
43
P1020508
PCB Screw, 10ea/Kit
44
P1020431
Main Piston O-ring, 25ea/Kit
45
P1020430
Main Piston Quad Ring, 25ea/Kit
46
P1020426
Brine Piston O-ring 25ea/Kit
47
P1021881
Brine Pston Quad Ring 25ea/Kit
48
P1020252
Main Piston Spring, 10ea/Kit
49
P1020286
Brine Piston Spring 10ea/Kit
50
P1020415
Gear Motor Retainer 10ea/Kit
51
01014153
Adapter Assy, 1” valve to tank w/o O-ring
52
01013958
Tank Adapter, 1” Valve
53
P1013959
Tank Clamp, 1” Valve
54
P1013669
Tank Clamp Pin, 1” Valve
55
P0318383
Tank Clamp Screw, 1” Valve
56
P1014848
O-ring, Large, Valve to Tank Adapter
57
P0440052
O-ring, Valve Adapter to ACME Tank
67
01018760
Bypass Valve - 1”/1-1/4” Rotary
70
P1009075
Retaining Clip, 1” Bypass valve
71
01014033
Coupling Kit - 1" Bypass
72
P1009099
O-ring, Couplings/Meters
82
01011188
Meter Kit - 1" w/wire harness
83
01024840
Wire Harness, Meter, 48"Long
84
P1023699
Half Ball w/ Post, Upflow Only, 10ea/Kit (only upflow models)
Gear Box Assembly less Motor—Downflow Regeneration
01022735
Wire Harness for Motor
01022752
Wire Harness for Motor, Control #2
01020420
Wire Harness with Optical Sensor
01022751
Wire Harness with Optical Sensor, Control #2
*
01017134
Power Cord
6
P1020433
Sensor Assembly Screw, 10ea/Kit
7
P1020517
Gearbox Assembly Screw, 10ea/Kit
8
P1020289
Dial-a-Softness Knob, 10-pack
9
P1020427
Dial-a-Softness Rebuild Kit, 10-pack
10
P1021162
Eductor Plug O-ring, 10ea/Kit
11
P1020487
Eductor Plug Assembly with O-rings, 10ea/Kit
12
P1020290
Eductor Plug Clip, 10ea/Kit
13
01020489
Bypass Plug Assembly with O-rings, 10ea/Kit
14
P1020291
Bypass Clip, 10ea/Kit
15
01020581
Brine Elbow Assembly with O-rings, 10ea/Kit
P1018871
Insert, Brine Line Connector, 3/8”
P1002205
Nut, Brine Line Connector, 3/8”
16
P1020432
Brine/Drain Clip, 10ea/Kit
17
P1017758
Drain Elbow Assembly, 10ea/Kit
18
P0440268
O-ring, Drain and Brine Elbow, 10ea/Kit
19
P1020556
Wing Screw, 10ea/Kit
20
01020495
Electronic Enclosure Arm
21
P0331635
Backwash Flow Control, #2 (Brown), 9” & 10” Tanks, 10ea/Kit
P0331636
Backwash Flow Control, #3 (Green), 12” Tanks, 10ea/Kit
P0401031
Backwash Flow Control, (Black), 14” Tanks, 10ea/Kit
01021040
Enclosure Tray—Outdoor
23
01021041
Enclosure—Outdoor
*
P1022777
Screw for Outdoor Enclosure, 10ea/Kit
24
01020590
Enclosure Plug
28
01020240
Motor
01022796
Eductor Throat with O-rings, Tan (9, 10 & 12" Tanks), 10ea/Kit
29
P1013895
01023283
Gear Box Assembly less Motor—Upflow Regeneration
22
Description
Outdoor HE Twin Control#2, Downflow Regen—Complete
01020440
5
Part Number
01023280
01022234 4
Item
01022723
Eductor Throat with O-rings, Blue (14" Tanks), 10ea/Kit
30
P1020603
Eductor Throat O-ring, Large, 10ea/Kit
31
P1020428
Eductor Throat O-ring, Small, 10ea/Kit
32
P1013894
Eductor Nozzle w/ O-ring, Blue (9” & 10” tanks), 10ea/ Kit
Cat. No. 01023053
85
P1023695
Spring, Upflow Only, 10ea/Kit (only upflow models)
86a
01021077
Interconnecting pipe, copper
86b
01023290
Interconnecting pipe, plastic
*
P0451701
Hose Clamp, Drain
*
01018249
1 1/4” Straight Through Adapter
*
01018755
Rebuild Kit - 1”/1-1/4” Rotary Bypass
*
01010783
1” Copper Adapter Kit, (1” Bypass)
*
01016564
3/4” Copper Adapter Kit (1” Bypass)
*
01016565
3/4” Elbow Copper Adapter Kit (1” Bypass)
*
01018757
1” NPT Female Elbow Kit (1” Rotary Bypass)
*
P1009856
Gasket, Copper Plumbing Adapters
*
01018133
Transformer, Dual Output
*
01020620
Transformer, Dual Output w/ 6' Power Cord
* Not shown Parts
135
B
1
2
3
DON'T ASSEMBLE PLACE IN SHIPING CARTON
4
Remote Display and Smart Brine Tank Sensor
Figure 76.
Remote display and brine tank sensor.
Item
Part No.
Description
1 2 3 4
01020553 01020749 01020750 01020611 01020447 01020747
Remote Display Remote Display Circuit Board RF Board Transformer Smart Brine Sensor Modem
136 Culligan® High Efficiency Twin Softener
136
Cat. No. 01023053
Tank Assembly Item Part No. 1
Description
Qty
01016617
Tank Assembly, 9” w/ Fillport, Complete
01016618
Tank Assembly, 10” w/ Fillport, Complete
01017192
Tank Assembly, 12” w/ Fillport, Complete, Less Media
01017194
Tank Assembly, 14” w/ Fillport, Complete, Less Media
01016351
Tank Assembly, 9” w/o Fillport, Complete
01016352
Tank Assembly, 10” w/o Fillport, Complete
01016349
Tank Replacement, 9”, w/ Fillport, Empty
01016350
Tank Replacement, 10”, w/ Fillport, Empty
01016520
Tank Replacement, 12”, w/ Fillport, Empty
01016522
Tank Replacement, 14”, w/ Fillport, Empty
01016347
Tank Replacement, 9”, w/o Fillport, Empty
01016348
Tank Replacement, 10”, w/o Fillport, Empty
01009847
Top Strainer - Fine Slot
01011195
Top Strainer - Wide Slot
1
3
01009099
O-Ring, Manifold
1
4
01016176
Outlet Manifold - 9”
1
4
01014539
Outlet Manifold - 10”
1
4
01014540
Outlet Manifold - 12”
1
4
01016429
Outlet Manifold - 14”
1
5
P1017434
O-Ring, Plug and Sensor
2
6
01015122
Plug
1
7
01018763
Aqua-Sensor® Probe
1
8
01016174
Culligan Emblem
1
8
2
High Efficiency Municipal Replacement Media Packs (Includes, underbedding, Cullex, and Carbon) Part Number
Description
Media Quantity Cullex Carbon Cullsan
01019848
Culligan Total Home Advanced Media Replacement Kit for 9” Tanks (2 boxes)
0.8 ft3
6 lbs
12 lbs
01019849
Culligan Total Home Advanced Media Replacement Kit for 10” Tanks (2 boxes)
1.0 ft3
8 lbs
15 lbs
01019850
Culligan Total Home Advanced Media Replacement Kit for 12” Tanks (2 boxes)
1.5 ft3
12 lbs
20 lbs
01019851
Culligan Total Home Advanced Media Replacement Kit for 14” Tanks (2 boxes)
2.3 ft3
18 lbs
25 lbs
Cat. No. 01023053
Parts
137
16" and 18" Brine System
2
Item
Part No.
-
01018705
Brine System, 250 lb
-
01018715
Brine System, 375 lb
1
01018709
Replacement Tank, 250 lb
01018716
Replacement Tank, 375 lb
2
01018704
Cover, 250 lb
01018717
Cover, 375 lb
01018707
Salt Plate, 250 lb
01018713
Salt Plate, 375 lb
4
01018707
Brine Chamber, 250 lb & 375 lb
5
01018706
Brine Valve
3
3 5
Description
1
4
Figure 77.
16" and 18" brine system.
138 Culligan® High Efficiency Twin Softener
138
Cat. No. 01023053
Brine Valve Assembly
Figure 78.
Cat. No. 01023053
Item
Part No.
Description
-
01018706
Brine Valve
1
01018710
BLFC Elbow - 0.45 gpm
01018711
BLFC Elbow - 0.8 gpm
2
P1020194
Brine Well Cap - 24 Pack
3
P1020196
3/8” Compression Nut - 24 Pack
4
P1018871
3/8” Insert - 25 Pack
5
P1012091
Retaining Clip - 24 Pack
6
P1020192
Pin - 24 Pack
7
P1020193
5/16” Nut - 24 Pack
8
P1020190
Overflow Fitting w/ Nut - 24 Pack
9
P1020195
3/8” Nut - 24 Pack
10
P1020198
Air check Assembly - 24 Pack
11
P1020197
Float - 24 Pack
Brine valve assembly.
Parts
139
24" Brine System Item
Part No.
Description
1 2 3 4 5
01018720 01018718 01018719 01018909 01018708 01018706
Brine System, 650 lb Replacement Tank, 650 lb Cover, 650 lb Salt Plate, 650 lb Brine Chamber Brine Valve
2
3
5
1
4
Figure 79.
140 Culligan® High Efficiency Twin Softener
140
24" Brine system.
Cat. No. 01023053
Index A Accessories 11 Advanced Setup 11 Advanced Statistics 68 Advanced System Setup Menu 34 All Installations 5 Analyzing the System 65 Application 6 Application Problems 65 Aqua-Sensor® 67, 77 Aqua-Sensor® Application Guidelines 93 Aqua-Sensor® Mode 12 Aqua-Sensor plug 15 Aqua-Sensor Probe 42, 10, 5, 10 Aqua-Sensor® Start-Up Procedure 63 Aqua-Sensor Troubleshooting Flowchart 79 Aqua Sens Probe 67 Auxiliary Input/Output Setup 104 Auxiliary Output 104 AUX Inputs 105, 106 Aux Output Option 1 104 Aux Output Option 2 104 Aux Output Option 3 104 Aux Out Status 74 Aux Out Test 74
B Backwash 8 Backwash Flow Control 17, 83, 99 Backwash Flow Control Replacement 17, 18, 19 Bacterial Iron 6 Basic Menu Operation 29 Basic Principles 8 Beeper Mode 43 blue bypass knob 21, 101 Brine 9 Brine Blocked 67 Brine Draw 8 Brine Line 83 %ULQH2YHU¿OO Brine Systems 138, 140 Brine tank 9 Brine Tank 44 Brine Valve 138 Brine Valve “A” Dimension 23, 103 Brine valve tubing 102 Cat. No. 01023053
Bypass Valve 64 Bypass valve assembly 21, 101 Bypass Valve Installation 20, 26, 27, 100
C Call Culligan 55 Call Culligan at 67 Check Brine Tank 67 Checking the System 65 CHECK MARK button 29 Check Sensors 72 Check Signal Strength 48 Chlorinator 106 Circuit Board 80 Circuit Board Connections 23, 24 Component Description 5 &RQ¿JXULQJWKH6PDUW%ULQH7DQN (SBT) Probe Settings 44 Controller Features 10 Control Valve 16, 98 Control Valve Assembly 5 Culligan Global Softener 3 &XOOLJDQ+LJK(I¿FLHQF\&RQWUROler 10 Customizing the Setup 34 Cycle Times 11
D Day-of-Week Regeneration 12 Diagnostics 11 Dial-a-Softness 12, 13, 18, 19 Dial-a-Softness Knob 20, 83, 100 Distributor 9 DOWN ARROW button 29 'RZQÀRZ5HJHQHUDWLRQ Down Flow Regeneration 12, 109 Down Flow Regeneration—Backwash 111 Down Flow Regeneration—Bypass 116 Down Flow Regeneration—Fast Rinse 114 'RZQ)ORZ5HJHQHUDWLRQ²5H¿OO 115 Down Flow Regeneration—Regenerant Draw 112 Down Flow Regeneration—Slow Rinse 113 Drain Facilities 7 Drain Line Connection 101 Drive Motor 81
E Eductor 17, 82 Eductor Nozzle Replacement 17, 17 Eductor Nozzle—Throat 17 Electrical Connection 26 Electrical Facilities 7 Electrical Installation 34 Expansion Board 10 External Flow Meter 54
F Fast Rinse 8 Few Days Salt 67 Final Startup 62 Firmware Version 71 First Time Setup 124 First Time Setup Procedure 31 Floor Surface 7 Flow Meter 11 Flow Restrictors 17 Flow Statistics 68
G GBE Board 50 GBE features 10 Gearbox position indicator 59 GMT offset 51
H Hardness vs. Salt Dosage 93 Height of Discharge Above Floor Level Operating 22, 102 HE Twin cable lengths 15, 90 +LJK(I¿FLHQF\6HULHV$FFHVVRU\ Guidelines 13 +LJK(I¿FLHQF\6HULHV6RIWHQHU² 'RZQÀRZ5HJHQHUDWLRQ +LJK(I¿FLHQF\6RIWHQHU²8SÀRZ5HJHQHUDWLRQ +LJK(I¿FLHQF\7ZLQ,QGRRU$Vsembly 132 +LJK(I¿FLHQF\7ZLQ2XWGRRU$Vsembly 134 Hole Drilling Template 46
I Information 11, 60, 11 Installation 14 Installing In the Remote 50 Iron 6 Index
141
Last Power Up 72 Load the Tank 15 Location 7 Low Battery 67 Low Salt Level 67
Pressure , 14, 20, 26, 27, 64, 65, 6 Preventative Maintenance Inspection Schedule 66 Probe Test 78 Program Log 131 Proportional Brining 13
M
Q
main menu 29 Manual Cycling 59 Manual Mode 11 Manual Regeneration 12, 57 Materials 5 Maximum Allowable Drain Line Length 90 Media 9 Media Tank 5 Menu Default 33 Menu Lockout , 33, 33 Meter Start-Up Procedure 62 Mineral Tank 14 Modem 55 Modem Board 10 Modes of Operation 12 Motor Home Err 67 Motor Position Error 67 Mount the Control Valve 16
Quick Manual Regeneration 57 Quick Reference 124
L
N Navigating the Menus and Keypad 29 No Brine In Tank 67 1R5H¿OO No Remote RF Signal 67 No Remote Signal 67 Normally Off 104 Normally On 104
O Operation 12
P Particulate Iron 6 3HUIRUPDQFH6SHFL¿FDWLRQV Placement 14 Plumbing Connections 20, 100 Position Sensor Error 67 Possible Results 52 Predict Mode 12 Preparation 5 Pre-Rinse Mode 12 142 Culligan® High Efficiency Twin Softener
R Recommended Aqua-Sensor® Start-Up Procedure 62 Recommended Meter Start-Up Procedure 62 Regenerate 9 Regeneration Interval 12 Regeneration Setup 11 Regeneration Statistics 69 Regeneration Trigger 11 Regeneration Triggers 39 Regeneration Triggers Setup 39 Remote 50 Remote Display 134, 135 remote monitor 46, 50 Repeat Cycle 104 Replace Aux Filter Media 67 Replace Ext Filt 67 re-run First Time Setup 31 Resin 9 Resin and Regeneration 78 RF board 46 RF Transmitter 10
S Salt Bridging 67 Salt Storage Container 23, 102 Salt Storage Tank Assembly 5 Sanitize the System 94 Sanitizing Procedure 64 SBT Probe 44 Serial Number 71, 72, 74 Serial Numbers 2 Service 111, 112, 113, 114, 115 Set Time and Date 11 Setup 50 Signal Strength 48 Slow Rinse 8 Smart Brine Tank 44 Smart Brine Tank Probe 11 142
Smart Brine Tank (SBT) Probe Settings 44 Smart Brine Tank Sensor 136 Space Requirements 7 Special Tools 5 Standard Manual Regeneration 58 System Setup 11
T Tank Assembly 14 Tank Statistics 70 Temperature 6 Test Modem 57 Test Phone Line 74 Test Progressive Flow 74 Test Wireless 74 Three-Valve Bypass 64 Time Clock Backup Mode 12 Tools and Materials 5 top level menus 11 Total Home Advanced 140
U Underbedding 9 UP ARROW button 29 8SÀRZ3URSRUWLRQDO%ULQLQJ$Splication 126 8SÀRZ5HJHQHUDWLRQ Up Flow Regeneration 13 Up Flow Regeneration—Backwash 118 Up Flow Regeneration—Bypass 122 Up Flow Regeneration—Fast Rinse 121 8S)ORZ5HJHQHUDWLRQ²5H¿OO Up Flow Regeneration—Regenerant Draw 119, 122 Up Flow Regeneration—Slow Rinse 120 Use Data Port 74
W Water Meter Mode 12 Water Quality 6 Wireless Remote 46 Wireless Remote Control 10 Wireless Remote Setup 48
X xxx-xxx-xxxx 67 Cat. No. 01023053
Cat. No. 01023053
Index
143
