Culligan G1 Series, G1-2S, G1-3L, G1-4L, G1-1F Installation, Operation And Service Instructions

CULLIGAN

Cat. No. 01021713

Rev. E 04/02/13

DCO 013630

Installation,

Operation and

Service

Instructions

®

Series G1 Reverse Osmosis

Water Treatment Systems

Models from 2011

©2013 Culligan International Com pa ny

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 [e-mail]

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 equipment 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.culliganmatrixsolutions.com

Culligan®

Installation

and

Operation

Instructions

Series G1 Reverse Osmosis

Water Treatment Systems

Models From 2011

Contents

Introduction ........................................................................ 1

G1 RO Features ................................................................ 2

G1 RO Series Specifications ............................................. 4

G1 RO System Configurations .......................................... 5

G1 RO Installation ............................................................. 6

GBE RO Controller Program Data................................... 19

First Time Setup .............................................................. 20

Basic Operation ............................................................... 31

Setup ............................................................................... 32

Accessories ..................................................................... 41

Error Limits ...................................................................... 58

System Operating Information ......................................... 60

Service and Maintenance ................................................ 62

GBE RO Controller Menu Structure ................................ 76

G1 RO Parts Diagrams and Lists .................................... 80

Flow Diagram .................................................................. 99

Electrical Installation ...................................................... 101

GBE RO Controller Wiring ............................................. 102

Remote Display Template ............................................. 103

Appendix A G1 RO International ............................. 104

Appendix B Basic Principles ...................................... 121

Appendix C Menu and Key Navigation ...................... 123

Appendix D Quick Programming Guide .................... 125

Appendix E Data Port Output .................................... 129

Appendix F Programming Log ................................... 133

Index .............................................................................. 134

Cat. No. 01021713

i

Units of Measure Conversion: U.S. to Metric

Convert From To Multiplication Factor

gallons per minute (gpm) liters per minute (l/min) 3.785

gallons per day (gpd) cubic meters per hour (m^3/hr) 0.000158

gallons (gal) liters (l) 3.785

pounds per square inch (psi) bar 0.0689

degrees Fahrenheit (F) degrees Centigrade (C ) (F-32) x 0.556

pounds (lbs) kilograms (kg) 0.4536

Inches (in) millimeters (mm) 25.4

parts per million (ppm) mg/l 1.00

ii Culligan® Series G1 Reverse Osmosis

ii Cat. No. 01021713

Introduction

Read this Manual First

Before you operate the Culligan® Series G1 reverse osmosis systems, read this manual to become familiar with the
device and its capabilities.

®

Culligan
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.

About this Manual

This manual:

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.

Series G1 reverse osmosis systems are designed to meet the needs of applications for high quality water. This

• 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

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!

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.

Cat. No. 01021713

Introduction 1

G1 RO Features

The Series G1 Reverse Osmosis systems are the direct result of Culligan’s long time experience in membrane appli­cations around the world. From process water for any size business to treating water for an entire city, Culligan has the
knowledge and the range of products you need to get the job done.

The Series G1 reverse osmosis system is sized to serve many small-to-medium-sized applications that require high-qual­ity reverse osmosis water. It is designed with the flexibility to closely match your treatment requirements from 0.35 to 2.8
gallons per minute (500 to 4,000 gallons per day). Mount the system on a wall to save floor space, or install it on the floor
using an optional floor stand. A rich standard feature set with multiple options can satisfy virtually any application. Select
the right size and choose any options needed to complete your system.

Key G1 RO System Features

• Simple System Integration

• Global Product Platform

• Flexible Configurations

• Quick Delivery/Easy Installation

• Exclusive Culligan Advanced Electronics

• Multiple Languages

• Historical Operating Data

• Alarm Recognitions

• US Standard and Metric Readings

• Remote Monitoring Options for connection to a control room PLC

• Telemetry Options

• Real Time Clock: tracks date and time has five-year battery back up.

• TDS Probe: TDS probe measures product water quality.

• Remote Alarm Output Connection (Optional): Provides either a N.O. or N.C. Dry Contacts. This feature can be

used to activate an alarm or programmed into a customers (DCS) building alarm system.

GBE RO Controller Features

System Computes Normalized Flow

The system computes normalized flow and can be set to trigger an alarm if the normalized flow drops below a specified
limit.

Power Up Mode

The system can be configured to either go to standby mode or to automatically return to making RO water in the event of
power loss and restoration.

Storage Tank and Pressure Logic

The system has the ability to monitor high and low level switches in an atmospheric storage tank and a pressure switch in
a pressurized storage tank to automatically put the system into standby mode when the tank is full.

Pretreatment Lockout

Allows for single softener or filter pretreatment that can be set to go into regeneration or backwash cycle at low water use
periods and have the RO in standby until cycle is completed. RO product water tank would need to be sized correctly
based on flow demand if continuous RO product water is required.

GBE Historical Data

The GBE RO Controller stores basic performance data over the lifetime of the membranes as an aid to optimizing RO
performance and determining when the membranes need to be cleaned or replaced.

2 Culligan® Series G1 Reverse Osmosis

2 Cat. No. 01021713

Flush Options

The system offers six different membrane flush modes to improve performance and extend membrane life.

NOTE Quality Flush and Permeate Flush are mutually exclusive optional features.

Target TDS

The RO system keeps track of the average product water TDS whenever the RO system is operating, mixing lower quality
water with product water to meet the average product water TDS.

Communications via Modem

An optional modem and monitoring service can be used to remotely monitor the RO performance over time. This service
can also be used to alert the customer and the Culligan dealer in the event that an alarm or error condition occurs.

Wireless Remote Communication

An optional wireless remote can display the current operational status and performance statistics up to 200 feet from the
G1 RO system.

PLC Outputs Available

The GBE Controller collects data once per minute and then streams the data to a customer-owned PLC for data collection
or monitoring. Customer would have to write code to take text information and convert the data for their data collection
system. For more information, see Culligan P/N 01021512 Advanced Communication Manual.

This data, once converted from a text stream, can easily be imported to an excel spreadsheet and the data logged can
then be graphed and trended.

Cat. No. 01021713

G1 RO Features 3

G1 RO Series Specifications

NOTE Specifications for G1 RO 230V (international) are in Appendix A on page 104.

G1-2S G1-3S G1-4S G1-2L G1-3L G1-4L G1-1F G1-2F

Nominal Capacity, GPD [m³/hr]* 500

[0.08]

Dimensional, Series G1 Units

Width - in [mm] 34.5 [876] 38.5

Depth - in [mm] 8.7 [221]

Height - in [mm] 34.8 [884] 45.5 [1156]

Operating Weight, lb [kg] 81 [37] 92 [42] 96 [44] 88 [40] 103 [47] 111 [50] 97 [44] 129 [59]

Unit Connections

Inlet (Tube) - in. 1/2

Product (Tube) - in. 1/2

Concentrate (Tube) - in. 3/8

Electrical

Motor Horsepower, hp [kW] 0.333 [0.25] 0.75 [0.56]

Power Requirement (VAC/Hz/phase) 115/60/1

Full Load Current, amp (@115V) 8 12

Hydraulic - Prefilter

Housing Quantity 1

Cartridge Rating, micron 5

Cartridge Length - in [mm] 10 [254]

Hydraulic - RO

RO Housing Quantity 2 3 4 2 3 4 1 2

RO Element Quantity 2 3 4 2 3 4 1 2

RO Element Size - in 2.5x21 2.5x40 4x40

RO Array 1:1 1:1:1 1:1:1:1 1:1 1:1:1 1:1:1:1 1 1:1

Product Flow - gpm [L/min]* 0.35

[1.32]

Concentrate Flow - gpm [L/min]* 0.35

[1.32]

Required Inlet Feed Flow gpm [L/min] 0.7

[2.65]

Pump Flow @ 150 psi, gpm [Lmin] 1.6 [6.06] 2.7 [10.44]

Maximum Module Feed Pressure psig [kPa] 150 [1034]

Nominal Module Feed Pressure psig [kPa]† 100

[689]

Max. Product Pressure psig [kPa] 40 [275.6]

Inlet Pressure Min., dynamic psig [kPa] 20 [137.8]

Maximum, dynamic psig [kPa] 50 [344.5]

Operating Temp °F [°C] 33-100 [1-38]

Recovery (%)*

Design 50 50 50 50 50 50 25 50

Minimum 40 40 40 40 40 40 15 40

Salt Rejection, Nominal (%) 98

†Calculated using a 0.85 fouling factor

*Nominal capacity based on new RO membranes operating on a properly pretreated feed water of 500 ppm TDS as NaCl,
77 °F (25 °C), Silt Density Index (SDI) below 3, and supplying water to atmosphere. Productivity will vary depending on
the actual feed water quality and temperature.

4 Culligan® Series G1 Reverse Osmosis

750

[0.12]

0.52

[1.97]

0.52

[1.97]

1.04

[3.94]

103

[709.7]

1000

[0.16]

[978]

0.69

[2.61]

0.69

[2.61]

1.38

[5.22]

104

[716.6]

1200

[0.19]

0.83

[3.14]

0.83

[3.14]

1.66

[6.28]

96

[661.4]

1700

[0.27]

34.5 [876] 38.5

1.18

[4.47]

1.18

[4.47]

2.36

[8.93]

97

[668.3]

2200

[0.35]

[978]

1.53

[5.79]

1.53

[5.79]

3.06

[11.58]

3.1 [11.73]

101

[695.9]

4 Cat. No. 01021713

2000

[0.32]

34.5 [876]

1.40

[5.30]

4.17

[15.78]

5.56

[21.04]

5.6 [21.2]

95

[654.6]

4000

[0.63]

2.8

[10.6]

2.78

[10.52]

5.56

[21.04]

101

[695.9]

G1 RO System Configurations

A G1-4L is pictured in Figure 1 and Figure 2. Width of membrane rack varies with model. See parts section on page 80
for a list of component part numbers.

MOUNTING BRACKETS

MEMBRANE FEED PRESSURE

GBE RO CONTROLLER

RECIRCULATION CONTROL

INLET FEED PRESSURE

TDS SENSOR

PRODUCT FLOW METER

MEMBRANES

WASTE CONTROL

Figure 1. G1 RO front view.

MOTOR

PRODUCT WATER OUTLET

Cat. No. 01021713

PUMP

FAST FLUSH SOLENOID

INLET SOLENOID

WASTE WATER OUTLET

PRESSURE SWITCH

FEED FLOW METER

FEED WATER INLET

PREFILTER

Figure 2. G1 RO back view.

G1 RO System Configurations 5

G1 RO Installation

Unpacking the G1 RO

This manual, the warranty, and registration card are packed in the control assembly box. Please complete the registration
card and mail it promptly.

NOTICE Examine each component carefully to check for loose or damaged parts. Report any apparent or

concealed shipping damage to the freight carrier immediately.

Materials Required

To install the system, the following items are required:

• Level

• Drill

• Screws for mounting the bracket for the main plumbing assembly

• Screwdrivers, including a small, flat-bladed (1/8” wide) screwdriver for wiring

• Adjustable wrench

• Tubing;

All—Nat 1/2” Feed Water and Product Water Tubing, P/N 00901801
All—Nat 3/8” Product Concentrate (Waste) Water Tubing, P/N 00444973

• 1-Gallon Bucket calibrated for taking flow rates

• Stopwatch

• Calculator

• Clean rags

• Thermometer

• Portable Total Dissolved Solids meter

• Safety glasses

Unpacking

The G1 reverse osmosis unit requires some assembly. Please check your order thoroughly to make sure you have the
following items. Refer to the table for box quantities.

• Pump/Motor Panel

• Housing Assemblies

• Membranes

• Fitting Kit

Location

The Series G1 unit is designed for wall mounting so that all components are accessible for maintenance and monitoring.

The wall you choose for mounting the unit must be capable of supporting at least 130 pounds. See the assembly section
below for installation detail.

A 120 VAC/60 Hz/1 Phase grounded electrical receptacle with 15 amp fuse protection is required for use with the six-foot,
three-wire power cord.

NOTICE Do NOT use any bolt size smaller than 1/4" diameter.

The unit must be located near a drain able to handle 10 gallons per minute (37.9 liters/min). This is in addition to the flow
from any other water treatment equipment.

CAUTION! The system must not be located near any corrosive chemicals which may cause fail-

ure of the plastic or metal parts of the unit. In addition, do not locate the unit where the
temperature may exceed the feed water temperature limits.

6 Culligan® Series G1 Reverse Osmosis

6 Cat. No. 01021713

Assembly

Bracket

Concrete Wall Installation

Refer to Figure 3 to install the G1 RO system to a concrete wall. Place the unit against the wall, level the unit and mark
the wall through the mounting holes. Drill the holes in the wall and mount the unit. Horizontal holes are on 16" centers.
Vertical holes are on 2" centers.

Wall Mounting Kit (optional)

If the wall is not concrete and wall mounting is necessary, a wall mounting bracket kit is available. The bracket has holes
for mounting on 18” and 20”centers. Use bracket P/N 01023017 for all models.

Place the bracket adapter on the wall with the flat side towards the wall. Level the bracket adapter and mark the wall
through the appropriate holes. Drill holes in the wall. Assemble the wall brackets to the bracket adapter. Mount the adap­ter and wall brackets to the wall. Mount the pump/motor assembly and the membrane assembly to the brackets.

Align with 20" studs

Align with 18" studs

Mount
To Wall

Wall Mount
Bracket Adaptor

Mounting

Figure 3. G1 RO wall mount bracket kit, P/N 01022077 (included with unit) and optional bracket adapter.

Stand Mounting (optional)

If the RO unit requires floor mounting, a rigid steel stand (P/N 01021987, Figure 4) is available. Wall mount brackets are
used with floor stand to mount unit and membranes.

NOTE DIRECTION

ANGLED FACE UP

LANYARD

NOTE DIRECTION

ANGLED FACE UP

BOLT HEADS

THIS SIDE

Cat. No. 01021713

Figure 4. G1 RO floor assembly.

G1 RO Installation 7

Pump/Motor Panel

Mounting Bracket

Pressure

Hang the pump motor panel on the mounting bracket. The top edge of panel hooks on to the bracket. See Figure 5.

Motor Panel

Figure 5. Pump motor panel hanging on mounting bracket.

Fittings

Locate the Membrane Fitting Kit that was shipped with the unit. This kit includes all the fittings needed to connect the
membranes to the pump/motor panel. Refer to Figure 11 on page 13 through Figure 15 on page 17 for the model
you are installing and follow the tubing diagram. Detailed drawings of the fittings and housings can be found in the parts
section.

Prefilter Cartridge

1. Locate the prefilter cartridge packed with the main unit.

2. Unscrew the prefilter bowl.

3. Lubricate the seal ring with silicone lubricant as required.

4. Remove the paper wrapper from the cartridge, place the cartridge in the bowl, and screw the bowl onto the
head.

Inlet

Figure 6. Installing the Prefilter.

Relief
Button

Outlet

Filter Cartridge

8 Culligan® Series G1 Reverse Osmosis

8 Cat. No. 01021713

Feed Flow Meter

Screws

1. Install the feed flow meter on the prefilter.

2. Install the flow meter cable.

2

1

Figure 7. Feed flow meter installed on prefilter.

Membranes

Before mounting the membrane housings, the membranes must be inserted into the housings. Take care to not damage
the end cap O-rings or membrane brine seal.

The membranes are shipped in a sealed package. Use extreme caution when opening the package with a sharp instru­ment. Any damage to the membrane can cause poor quality coming from the unit.

1. The membrane housings have directional arrows on them that indicate direction of flow. Install the membranes

in the direction of flow. Open the housing end opposite the direction of flow.

2. Remove the end caps from all vessels by removing the two Allen head screws that hold down the retaining

clips. The clips are pushed into an internal groove in the housing, so completely remove the screws so the clip
can be slid out of the groove. Note placement of the caps to assure reinstallation in the same orientation.

3. Check the O-ring seals on the membrane and end plug, and the membrane brine seal for damage. If an O-ring

is cut or crimped, it may cause high flow and poor quality. Replace any suspicious O-rings.

Cat. No. 01021713

Retaining Rings

End Cap

O-Rings

Housing

FLOW

Membrane

Brine Seal

Figure 8. Membrane and its housing.

G1 RO Installation 9

4. Remove a new membrane from its plastic bag. Lightly lubricate the O-rings with a silicone-based lubricant or

TO MEMBRANE

use a mixture of 70% glycerin and 30% water.

CAUTION! Do not use a petroleum-based lubricant. It will damage the synthetic rubber and the

membrane.

5. Install the membrane in the same direction as indicated by the arrow on the outside of the membrane vessel.
The brine seal end should go in last.

6. Repeat for the remaining membrane housings. There may be from one to four housings on each model.

G1 Tubing Configuration

A

FEED (1/2" TUBE)

FROM MEMBRANE

C

PRODUCT 1/2" TUBE

B
FROM MEMBRANE

CONCENTRATE 3/8" TUBE

SYSTEM PRODUCT
OUTLET 1/2" TUBE

SYSTEM INLET
1/2" TUBE

SYSTEM WASTE
(CONCENTRATE) 3/8" TUBE

Figure 9. G1 tubing configuration.

WARNING! The system must be grounded. An improperly grounded unit could cause injury from

electrical shock!

10 Culligan® Series G1 Reverse Osmosis

10 Cat. No. 01021713

Plumbing Installation

Low Flow Nozzle

Refer to the appropriate tubing installation instructions (Figure 11 on page 13 through Figure 15 on page 17) for
further information.

Feed Water Connections

Connect tubing to the Feed water inlet. Observe the following:

1. To minimize pressure loss, the tubing size should be at least 1/2”.

2. Install an optional pressure gauge (P/N D1006272) before the pre-filter. This allows you to measure the pres-

sure differential across the filter cartridge.

3. Install a tee, with a shutoff valve on the branch, before the feed flow meter to provide a connection for introduc-

ing cleaning solutions.

4. If necessary, install a pressure regulator (50 psi downstream max. setting) in the inlet plumbing, to assure con-

stant pressure and to prevent harmonic vibration.

5. Install a shutoff valve in the inlet plumbing to simplify maintenance and service.

6. If the feed water can be used for a short period, install bypass plumbing around the unit.

Figure 10. Feed meter and nozzle.

Concentrate Water Connections

1. Direct 3/8" piping to drain from the outlet of the unit.

2. To prevent siphoning of the water in the unit to drain, raise the concentrate piping above the level of the mod-

ules and provide an anti-siphon loop.

WARNING! An air gap must be provided between the end of the concentrate tubing and the drain

to prevent back-siphoning of drain contents.

Cat. No. 01021713

G1 RO Installation 11

Product Water Connections

The product water exits the unit at the product flow meter on the back side of the unit. Connect the product tubing to the
fitting on the flow meter assembly. The product water flow meter contains a nozzle that is used with all models EXCEPT
G1-1F and G1-2F.

CAUTION! This unit produces high quality product water. This water can be contaminated by

plumbing following the unit or it can corrode the plumbing. Use only plumbing compo­nents of inert material that are compatible with the application.

The connection of the main product tubing to service plumbing will depend on how the product water will be stored.

CAUTION! Reverse osmosis elements will fail immediately if pressurized product water is allowed

to flow backward into the Series G1 unit.

12 Culligan® Series G1 Reverse Osmosis

12 Cat. No. 01021713

2S/2L Tubing Assembly Instructions

1/2" TUBE FOR FEED

USED FOR FLOOR

STAND APPLICATION

1/2" TUBE

FOR PRODUCT

REMOVE CAPS
ON 3/8" STEMS

INSERT 1/2"X3/8" ELBOW
OVER 3/8" STEM

3/8" TUBE FOR RECIRCULATION/WASTE

INSERT 3/8"X3/8" ELBOW
OVER 3/8" STEM

INSERT PRODUCT FITTING
ASSEMBLY OVER 3/8" STEMS

NOTE DIRECTION
OF FLOW

Cat. No. 01021713

REMOVE CAPS
ON 3/8" STEMS

INSERT FEED FITTING
ASSEMBLY OVER 3/8" STEMS
(BOTTOM SIDE OF MEMBRANES)

Figure 11. RO 2S/2L tubing assembly instructions.

G1 RO Installation 13

3S/3L Tubing Assembly Instructions

STAND APPLICATION

NOTE DIRECTION

OF FLOW

3/8 STEM ELBOWS, TO

BE INSERTED INTO

RECIRCULATION ASSEMBLY

ON MOTOR PANEL (M1/G1-ONLY)

3/8" TUBE FOR

RECIRCULATION/WASTE

INSERT 1/2"X3/8" ELBOW

OVER 3/8" STEM

1/2" TUBE FOR FEED

USED FOR FLOOR

INSERT FEED FITTING

ASSEMBLY OVER

3/8" STEMS

1/2" TUBE

FOR PRODUCT

Figure 12. RO 3S/3L tubing assembly instructions.

REMOVE CAPS

INSERT PRODUCT FITTING

ASSEMBLY OVER 3/8" STEMS

ON 3/8" STEMS

REMOVE CAPS

ON 3/8" STEMS

INSERT 3/8" FITTING ASSEMBLY

OVER 3/8" STEM

ASSEMBLY OVER 3/8" STEMS

(BOTTOM SIDE OF MEMBRANES)

INSERT FEED FITTING

14 Culligan® Series G1 Reverse Osmosis

14 Cat. No. 01021713

4S/4L Tubing Assembly Instructions

NOTE DIRECTION OF FLOW

REMOVE CAPS

ON 3/8" STEMS

INSERT 3/8"X3/8" ELBOW

OVER 3/8" STEM

3/8" TUBE FOR RECIRCULATION/WASTE

INSERT FEED FITTING

ASSEMBLY OVER 3/8" STEMS

INSERT 1/2"X3/8" ELBOW

OVER 3/8" STEM

1/2" TUBE FOR FEED

1/2" TUBE FOR PRODUCT

USED FOR FLOOR STAND APPLICATION

REMOVE CAPS

ON 3/8" STEMS

INSERT FEED FITTING

ASSEMBLIES OVER 3/8" STEMS

(BOTTOM SIDE OF MEMBRANES)

Cat. No. 01021713

Figure 13. RO 4S/4L tubing assembly instructions.

G1 RO Installation 15

1F Tubing Assembly Instructions

Figure 14. RO 1F tubing assembly instructions.

16 Culligan® Series G1 Reverse Osmosis

16 Cat. No. 01021713

2F Tubing Assembly Instructions

Cat. No. 01021713

Figure 15. RO 2F tubing assembly instructions.

G1 RO Installation 17

Pressurized Storage Tank

The product water can be stored in a pressurized storage tank with the reverse osmosis unit controlled by a pressure
switch. Use the same components used for direct feed (see Figure 16). The pressure switch needs to be wired to the con­trol panel as a float switch (see Figure 57 on page 105 for G1 standard wiring). A pressurized water storage kit is avail­able for the G1 under P/N D1013880 (110V) or P/N D1018976 (220V). Connect the product tubing to a bulkhead fitting at
the top of the storage tank such as P/N 01005095 (2-gallon), P/N 01004776 (3-gallon), or P/N 01004765 (9-gallon).

Non-Pressurized Product Water Storage Tank

Depending on the type of application, a level control may be required to turn the unit off when the storage tank is full.
Install the level control according to the instructions provided with the control. See “GBE RO Controller Basic sub-panel

wiring.” on page 105 for electrical connections.

NOTICE If a repressurization pump is used, an additional level control is recommended to prevent the

pump from running dry if the storage tank is empty.

To maintain high water quality, a hydrophilic air vent filter, vacuum breaker, pop-off valve, ultraviolet lamp, and pressure
relief valve may be required.

Direct Feed

If the product water is to be used directly, without storage, a few precautions are necessary to prevent damage to the
elements. Install a pressure gauge, pressure relief valve, and a normally-open (“dump”) solenoid in the product water
line as shown in Figure 16, or use pressurized storage kit (P/N D1013880). The pressure gauge will allow the operator to
monitor the product water pressure. The relief valve, which should be set to open at 40 psig, will prevent the product water
pressure from exceeding 40 psi. The dump solenoid will relieve all pressure when the unit is off.

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Figure 16. Direct feed connection.

Wire the direct feed/pressurized storage solenoid valve in parallel with the motor.

Valve SV4 closes when the RO pump runs; SV4 opens when the pump stops, allowing all membrane back proessure to
be relieved.

NOTICE Product back pressure will decrease the net pressure pushing water through the reverse osmosis

elements. Therefore, the flow of product water will decrease.

18 Culligan® Series G1 Reverse Osmosis

18 Cat. No. 01021713

GBE RO Controller Program Data

Program Data Input

There are a few items to note that can make programming the Culligan® Global RO Controller easier:

Slew Rates This term refers to the speed at which the display moves through the input of material. For ex-

ample, holding down the up arrow key for (5) seconds when inputting minutes for Time of Day
will cause the minutes to pass in (10) minute blocks of time. Press the up arrow or down arrow
keys for shorter periods (less than 5 seconds) will slow the rate. To move through the program­ming slowly, do not hold down the up arrow or the down arrow keys.

Beeper A beeper is available to assist the user by providing an audible tone (about 70 decibels) to signi-

fy valid (one beep) and invalid (three beeps) key presses. The beeper can be deactivated in the
programming mode. (If error occurs, beep will still sound even if set to “No” programming.)

Programming
Mode Timeout

Program Input
Acceptance

If there is no keypad activity for a one (1) minute period while in the programming mode, the
controller will exit the programming mode and return to the main display. Any setting that was
changed prior to the control timing out will revert to the original value. Pressing the CHECK
MARK button saves the setting.

For programming information to be accepted, the check mark key must be depressed prior to

programming mode timeout.

Cat. No. 01021713

GBE RO Controller Program Data 19

First Time Setup

First Time Setup Procedure

If at any time you need to re-run the First Time Setup, refer to “Menu Default—Rerun First Time Setup” on page 22.

After completing the plumbing connections to the water softener, turn on and program the Global RO Controller.

Select Language (English, French, Italian, Spanish)

LANGUAGE

ENGLISH

1. Apply power to the unit. When a new controller is first turned on, the screen dis-

plays LANGUAGE. Press
gin first time setup in your preferred language.

NOTE You also can change the language setting after first-time setup from

the Setup menu. See “Set Up Language” on page 33.

or and then to change the value and be-

Serial Number

FIRST TIME SETUP
PRESS DOWN ARROW

S/N:00012345

FWR***LT04

1. Plug in the wall transformer. When a new controller is first turned on, the screen

displays FIRST TIME SETUP. Press

2. The screen displays the serial number and firmware version and date installed for

this GROC. Press
ting, month.

to accept this information. The screen displays the first set-

.

MON DD YEAR

NOTE The S/N, firmware, and date displayed in this manual are examples only.

NOTE If this unit will be installed with a modem, it is required that this electronic serial number be reported to

Culligan on the IQR form.

Setting Up Date and Time

SET

MONTH JAN

1. The screen displays the month setting. Press to accept this information and
view the day setting.

SET

MONTH >JAN

SET

MONTH >FEB

2. 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

3. Press to select a new value. The screen displays the new setting value next to
the cursor.

4. Press to select the next available value. You may press or to scroll
through all available options for this setting.

SET

DAY 1

20 Culligan® Series G1 Reverse Osmosis

5. Press to accept the selected screen value. The controller accepts the new val­ue and displays the next setting.

or button.

20 Cat. No. 01021713

Other First Time Setup Settings

Screen Display Range Procedure

SET

DAY 1

SET YEAR

2012

CLOCK TYPE

12 HR

SET HOUR

12PM

SET

MINUTES 25

1–31

2010–2040

12 or 24

12AM–11PM

0–59

1. The screen displays the day setting. Press

then

2. The screen displays the year setting. Press

then

3. The screen displays the clock type setting. Press

4. The screen displays the hour setting. Press

then

5. The screen displays the minutes setting. Press

and then

to change the value and see the next setting.

to change the value and see the next setting.

and then to change the value and see the next setting.

to change the value and see the next setting.

to change the value and see the next setting.

or and

or and

or and

or

or

POWERON MODE

OFFLINE

Running

Offline

SYSTEM UNITS

US INCH

US INCH

METRIC

Completed First Time Setup

STARTING
JAN-01-12 12:01P

RUNNING
JAN-01-12 12:01P

Cat. No. 01021713

1. When the setup is complete, the circuit board microprocessor automatically calcu-

lates the water conditioner capacity. The screen displays the initializing status and
the current date and time, and then transitions to the home screen.

2. The screen displays the current state of the RO system (RUNNING or OFFLINE)

and the date/time set for the unit. This is the default home screen.

6. The screen displays the selected status of the RO when pow-

ered on. Press
ue and see the next setting.

7. The screen displays the units of measure setting. Press

or and then to change the value and complete the

first-time setup.

NOTE This setting does not automatically change to metric

if you select a language other than English.

or and then to change the val-

First Time Setup 21

Menu Lockout

J7

J5 J6

4 = n/c, 3 = ground, 2 = flow pulse signal, 1 = 5 VDC supply

It is possible to lock the keypad of the Global RO controller so that users will only have access to the INFORMATION, GO
TO RUNNING, and GO TO OFFLINE menu screens.

To lock the system, press and hold

NOTE Menu lockout may be completed only from the home screen.

and for 10 seconds. Repeat this process to unlock the keypad.

Menu Default—Rerun First Time Setup

Below is the procedure to default the board to factory settings and begin the first time setup.

1. Power down the control.

2. Press and hold

3. Power up the control while continuing to hold

4. Release

5. Power down the control.

6. Power up the control again. The screen lights up for two seconds and then displays the home screen.

7. Follow the first time setup process.

and .

and for at least five (5) seconds.

and . The display should be blank—if not go back to step 1.

Flow Meters

There are two flow meters on the G1 RO system, the feed flow meter (FM1) and the product flow meter (FM2). Before
using the G1 RO it is necessary to first calibrate both flow meters. See Table 1.

Connect the wires of both flow meters to the CIB board using the 4 - pin connections provided. The feed flow meter con­nects to FM1 (J11) and the product flow meter connects to FM2 (J12). See Figure 17.

The pins are:

Pin 4 = not connected

Pin 3 = ground

Pin 2 = flow pulse signal

Pin 1 = 5 VDC power supply

NOTE Pin 1 on the GBE board is identified with a small WHITE dot.

J16

J17

J10

J1—PRODUCT
FLOW

J15—INLET FLOW

METER

The 4 - Pin Connections are:

NOTE: Pin 1 is identified with a small WHITE dot.

Figure 17. Flow Meter Connections on GBE Board

22 Culligan® Series G1 Reverse Osmosis

22 Cat. No. 01021713

METER

1. Start with both the recirc valve and the waste valves fully open (turn the valve all the way in a counter-clockwise
direction).

2. Start the RO.

3. When the pump turns on, slowly close the waste and recirc valves clockwise.

4. Try to close the waste valve until the flow rates to product and to drain are approximately even, then begin to
close the recirc valve, to bring the membrane feed pressure within the range of 80–120 psi.

5. Set the K-Factor for both FM1 and FM2 at the values listed in Table 1. See “G1 Tubing Configuration” on page

10.

6. On the GBE RO controller, select 3)INFORMATION and observe the FFLOW and PFLOW rates.

7. Using a stopwatch and a bucket, measure and record the time elapsed (in seconds) to fill a one-gallon bucket
with product water.

8. Meaure and record the time elapsed (in seconds) to fill a one-gallon bucket with waste water.

NOTE Convert your stopwatch readings to minutes (for gallons per minute) by dividing the number of sec-

onds by 60. For example, if you measure 45 seconds to fill a 1-gallon bucket, the fill time is 45/60 = 0.75
minutes, and the flow rate is 1/0.75 = 1.33 gpm.

Feed Flow Meter Product Flow Meter

Model FM1 Initial Nozzle Needed/K Factor FM2 Initial Nozzle Needed/K Factor

2S 500 500
3S 500 500
4S 500 500

2L 80 500
3L 80 500

4L 80 500
1F 80 80
2F 80 80

Table 1. K factor for FM1 and FM2.

9. Calculate the values for “A” and “B” using the following equations:

A =

(FM1 INITIAL) x (FFLOW DISPLAYED)

FFLOW ACTUAL

Where
FM1 INITIAL is from Table 1
FFLOW DISPLAYED

is displayed on the GBE RO controller

FFLOW ACTUAL = (Actual Product Flow) + (Actual Waste), in gallons per minute

(FM2 INITIAL) x (PFLOW DIS-

B =

PLAYED)

PFLOW ACTUAL

Where
FM2 INITIAL is from Table 1
PFLOW DISPLAYED is displayed on the GBE RO controller
PFLOW ACTUAL = (Actual Product), in gallons per minute

10. Use the directions in the next section to change the K factor for FM1 to the value for A, and then change the K
factor for FM2 to the value calculated for B.

11. Verify that the displayed values of FFLOW and PFLOW in the information screen on the GBE RO controller
match the actual measured flow rates from steps 7 and 8 while the RO is running.

Cat. No. 01021713

First Time Setup 23

RUNNING
JAN-01-12 12:01P

1) GO TO RUNNING

2) GO TO OFFLINE

3) INFORMATION
>4) SETUP

2) LANGUAGE

3) POWERON MODE

4) FLUSH MODES
>5) ACCESSORIES

1) WIRELESS REM

2) MODEM
>3) FLOW METERS

4) SWITCH INPTS

1. From the default home screen, press . The screen displays the main menu.

2. Press to scroll to 4) SETUP.

3. Press to select the SETUP menu.

4. Press to select 5)ACCESSORIES. The screen displays the ac­cessories menu.

5. Press to select 3)FLOW METERS. The screen displays the flow meter
settings.

24 Culligan® Series G1 Reverse Osmosis

24 Cat. No. 01021713

Flow Meter Settings

Screen Display Range Changing the Setting

FLOW METERS
INSTALLED

Installed

Not Installed

The screen displays the installation status of the flow meter. Press

to change the state to installed if a flow meter is in-

stalled in the RO system.

FM1 K FACTOR

80.0

0–9999

Press
calculated value for the flow meter FM1 and/or FM2.

or and then to change the K-Factor to the

RUNNING
JAN-01-12 12:01P

6. Press to save the settings and return to the home screen.

12. Once all the desired flows are set, allow the system to run for approximately 30 minutes, and then record the
following measurements using the units gauges (U), GROC information screens (G), and your instruments (I):

a. Feed Flow Rate, gpm (G)

b. Feed Water Temperature, °F (I)

c. Feed Water SDI (I)

d. Feed TDS, ppm (I)

e. Inlet Pressure, psig (U)

f. System (pump outlet) pressure, psig (U)

g. Product TDS, ppm (G)

h. Product Flow, gpm (G) x TCF

i. Product Temperature, °F (G)

j. Product Pressure, psig (I)

k. Concentrate (waste) flow, gpm (a–h)

l. % Recovery (see page 121)

m. % Rejection (see page 121)

1

TCF = Temperature Correction Factor. Refer to Table 2 on page 26 for this value.

1

=

NOTICE The Global RO Controller has a feature which records historical data. The intial startup data is kept

in the controllers memory. It is still a good idea to record the values on a separate sheet of paper
and keep the data near the unit in case of electrical problems.

13. Choose GO TO OFFLINE from the main menu. Connect the product tubing to the service plumbing.

14. Test the operation of the pressure switch by closing the inlet water supply valve. The unit should shut off imme­diately.

CAUTION! If the unit does not shut off, turn the unit OFF immediately to prevent pump damage.

Disconnect electrical power source, then check the wiring and replace the switch, if
necessary.

15. Open the inlet water supply valve. The unit should restart.

16. If connected, test the storage tank level control shutdown and the pretreatment lockout function.

Cat. No. 01021713

First Time Setup 25

Normal Operation

During normal operation, the system usually will start up and shut down based on signals from a level control or pressure
switch. Adjust the feed pressure as required (no higher than 150 psig) to maintain a constant product flow. Record the
performance data regularly and compare it to the performance on initial start up. If any changes are noticed, the product
flow should be normalized to determine if cleaning is required (see Product Flow Calculations below).

Product Flow Calculations

The product flow rate depends primarily on feed water pressure, product water pressure, and temperature. All 1-Series
RO water conditioners have specified nominal flow rates based on approximately 105 psig net pressure and 77°F temper­ature. However, in most applications the temperature and pressure are lower, so the product flow rate is lower than the
nominal flow rate. The actual flow rate must be converted to flow under standard conditions, then compared to the initial
performance (also converted to standard conditions) to determine whether the system is still working properly.

To convert the data to standard conditions,

1. Measure the product flow. Example: 1000 ml/min

2. Measure the feed pressure. Example: 120 psig

3. Measure the product pressure. Example: 5 psig

4. Subtract the product pressure from the feed pressure. Example: 115 psig

5. Divide the product flow by the result from step 4. Example: 1000 ÷ 115 = 8.69 ml/min/psi

6. Multiply the result from step 5 by 105. Example: 8.69 x 105 = 913 ml/min

7. Measure the temperature of the feed water, then determine the temperature correction factor from Table 2.
Example: At a temperature of 55°F , the factor is 1.54.

Temp. °F Temp. °C Correction Factor Temp. °F Temp. °C Correction Factor

40 4.4 2.12 75 24 1.04
45 6.7 1.90 80 27 0.95
50 10 1.71 85 29 0.86
55 13 1.54 90 32 0.79
60 16 1.39 95 35 0.72
65 18 1.26 100 38 0.66
70 21 1.14

Table 2. Temperature Correction Factors

8. Multiply the result of step 6 by the temperature correction factor. Example: 913 ml/min x 1.54 = 1406 ml/min.

NOTICE To convert ml/min to gallons per day, multiply by 0.38. For example, 1406 ml/min x 0.38 = 534 gpd.

9. Compare the current standardized flow to the initial standardized flow. If the flow has decreased by 15% or
more, it is time to clean the elements.

Example: If the initial standardized flow was 570 gpd, and the current standardized flow is 470 gpd, the flow has
decreased by 100 gpd, or 18% (100/570) = 0.18. The elements should be cleaned.

10. If the problem cannot be corrected with the troubleshooting guide and assistance is required, please have the
following information available when calling the Culligan dealer:

• Product flow rate

• Concentrate flow rate

• Feed pressure

• Product water quality

• Feed water quality

• Feed water temperature

• Prefilter outlet (and inlet if the optional prefilter inlet gauge was installed)

• Product pressure

26 Culligan® Series G1 Reverse Osmosis

26 Cat. No. 01021713