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

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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

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 productmanuals@culligan.com

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

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]

[661.4]

1700

[0.27]

34.5 [876] 38.5

1.18

[4.47]

1.18

[4.47]

2.36

[8.93]

[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]

[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.

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

FEED (1/2" TUBE)

FROM MEMBRANE

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.

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

to change the value and see the next setting.

or and

POWERON MODE

OFFLINE

Running

Offline

SYSTEM UNITS

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

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)

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

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

Switch Inputs

Several switch types may be installed in an RO system, including

• Low Pressure Switch

• Pretreatment Lockout Switch

• Float (Level Control) Switch

See “GBE RO Controller Wiring” on page 102 for a diagram of all three switches.

Low Pressure Switch

The GBE RO Controller is equipped with a low pressure switch to protect the pump from starvation/cavitation. If the inlet pressure switch goes LOW and stays there for at least XX seconds (set at setup/accessories/switch inputs), the pump will turn off. For a positive displacement pump, XX should be specified at 1–5 seconds. The controller keeps track of how many times this happens: if fewer than five times since the most recent of either midnight or the last time the operator manually selected GO TO RUNNING from the main menu, then the system will attempt to restart. If this is the fifth time it has happened, then the system goes to OFFLINE and throws the LOW INLET PRESSURE error condition.

NOTE This five-time counter on the number of restarts allowed resets to zero every night at midnight and

every time that the operator selects YES from the Main Menu/Go to Running screen.

The pressure switch is prewired at the factory to the GBE RO controller AUX board POSITION (J1) pins utilizing pins 2 and 4. The switch is factory set to 18 psi. The pressure can be adjusted from 6 psi to 30 psi by turning the knurled ring on the body of switch clockwise to increase the pressure and counter-clockwise to decrease. One revolution is approximately

6.5 psi.

Pretreatment Lockout

The GBE RO controller allows an external contact closure to cause the RO to go into a “pre-treat lockout” condition. If the GBE RO controller state was in any state other than OFFLINE, the state will change to STANDBY as soon as the pretreat lockout is engaged. When pretreat lockout is disengaged, the system will either move to STARTING or stay in STANDBY based upon the status of the float switches and the settings specified at main menu/ setup/ accessories/ switch inputs.

The pretreat lockout can be engaged by either a normally open or normally closed input signal to the pretreat lockout terminals from the main menu/setup/accessories/switched inputs menus. The factory default is that CLOSED will specify pretreat lockout.

Note that the pre-treat lockout input switch must move to, and stay in its new position for a continuous period of at least two (2) seconds for the pretreat lockout to be triggered

Timeclock controlled softeners, such as the Hi-Flo treatment, they should be duplexed, or regenerated by a timeclock so that regeneration can occur when the unit is not in

operation.

3, do not offer pretreatment lockout. If these units are used for pre-

Cat. No. 01021713

First Time Setup 27

Wiring for Softeners and Filters with MVP Controller

For these systems, you must add a 24V relay P/N 01016156, to provide the pretreatment contact.

MVP to Relay: Connect a wire from Terminal 5 of the relay to the left terminal of P8 (Aux 2) on the MVP circuit board. Connect another wire from terminal 1 of the relay to the right terminal of P8. Refer to Figure 18.

LCD

SW6 Dip Switch

P11 Battery P6 Motor

P9 Power

2.5VAC 24V

MVP

Aux1

P7 Sol

Valve

Aux2

Cam

Aqua Sensor

Flow Meter

Relay

Comm

GROC BOARD

Figure 18. MVP to GBE RO controller relays.

28 Culligan® Series G1 Reverse Osmosis

28 Cat. No. 01021713

Wiring for Softeners and Filters with GBE RO Controller

For these systems, you must add a 24 VAC relay, part number 01016156, to provide the pretreatment contact.

GBE to Relay: Connect a wire from terminal 5 of the relay to the left terminal of Aux 4 on the GBE softener/filter circuit board. Connect another wire from terminal 1 of the relay to the right terminal of Aux 4. Refer to Figure 19.

Relay to GBE RO controller: Connect a wire from the POSITION (J2), PIN 3 terminal on the AUX board to terminal 3 on the relay. Connect another wire from the POSITION (J2), PIN 4 terminal on the AUX board to terminal 4 on the relay. Use the GBE RO controller Aux cable kit, P/N 01021830, to connect cables to the GBE RO controller board.

J5 J6

GBE SOFTENER/FILTER

J16

AUX OUT 4

J17

J10

Relay

GROC BOARD

Cat. No. 01021713

Figure 19. GBE to GBE RO controller relays.

First Time Setup 29

Float Level Control

P/N: XXXXXXXX rev. X VENDOR: XXXXXX DATE CODE: WK/YY HEX FILE: XXXXXXXX rev. X

Remote Display RF Board Connector

Modem Connectors

Product Flow Meter (J1)

The GBE RO controller provides a Level Control High switch as well as a Level Control Low switch. You can use the Level Control High switch alone, or with the Level Control Low switch.

The Level Control connections are located on the GBE RO controller board. They are labeled POSITION (J12) on the main GBE RO controller board. Pin 4 is common and Pin 2 is for HIGH level and Pin 3 is for LOW level.

These switches can be specified to be either “OPEN WHEN LEVEL IS ABOVE SWITCH” or “CLOSED WHEN LEVEL IS ABOVE SWITCH” when the level of water is above the switches. Both switches must have the same OPEN or CLOSED specification. For example, you can specify (main menu/setup/accessories/switch inputs) that the float switches will be CLOSED when the level of water is above the level of the switches. The system assumes that a float switch is “off” when the water is below the switch and it is on when the state of the switch matches to user specified OPEN or CLOSED condition. Use the GBE RO controller switch accessory kit (P/N 01022360) to connect Float Switch and Pretreatment Lockout to the controller board. The kit contains four connectors (P/N 01021838) with wire leads. See page 102 for wiring information.

Float Switch (J12)

Plug into J12

and Pretreat Lockout

Connectors for Float Switch

Figure 21. J12 float switch.

Figure 20. GROC plug-on connector with wire leads.

4 3 2 1

Storage Tank Setup When Using Both a High and Low Level Float Switch (Two Floats)

When two floats are used, the behavior of the controller is such that it will switch from RUNNING to STANDBY when the water reaches the upper float switch and it changes state from being off to on. The system will stay in STANDBY until the LOWER float switch transitions from on to off. When this LOWER switch transitions from on to off, the system will switch back into RUNNING unless it is also in Pretreat Lockout at this point in which case it will transition to RUNNING when the Pretreat Lockout disengages.

In order for the system to operate correctly using two float switches, it is necessary to specify a value of 0 (zero) as the Hi Float Restart Delay time (main menu/steup/accessories/switch inputs).

Storage Tank Setup When Using a Single High Level Float Switch

Connect the level control to the FLTHI terminals. The system will switch from RUNNING to STANDBY when the water reaches the upper float switch and it changes state from being off to on. The system will transition back to RUNNING a specified number of minutes after the upper float switch transitions from on back to off. The specified number of minutes to delay must be greater than 0 (zero). If it is specified as zero, then the system will operate as described in the previous paragraph for two-float switches. The delay can be specified in whole minutes up to a maximum of 999 minutes. Note that it is necessary to select this delay carefully, based upon the size of the storage tank and the maximum rate of draw-down on the storage tank in comparison to the maximum rate of producing RO water or it is possible that the storage tank could run dry.

NOTICE Do not apply power to these terminals. Use dry contacts only.

30 Culligan® Series G1 Reverse Osmosis

30 Cat. No. 01021713

Basic Operation

After the first-time setup has been completed, the RO system will be online (RUNNING) or offline (OFFLINE). You can change the operation status of the system from the main menu on the Global RO Controller.

RUNNING JAN-01-12 12:01A

Go To Running

>1)GO TO RUNNING

2)GO TO OFFLINE

3)INFORMATION

4)SETUP

1. This is the home screen. Press any button except to display the main menu.

2. Press to select 1)GO TO RUNNING.

GO TO RUNNING

STARTING JAN-01-12 12:01P STARTUP FLUSH

RUNNING JAN-01-12 12:01A

Go To Offline

1)GO TO RUNNING >2)GO TO OFFLINE

3)INFORMATION

4)SETUP

GO TO OFFLINE

3. The GROC screen displays the GO TO RUNNING command. Press or

and then (select NO to cancel the command and return to the main menu).

4. The screen displays the status of the unit as it initiates the startup process.

5. The home screen displays the operational status (RUNNING).

1. Press to select 1)GO TO OFFLINE.

2. The GROC screen displays the GO TO OFFLINE command. Press or

and then (select NO to cancel the command and return to the main menu).

to change the value to YES if you want the system to start running

to change the value to YES if you want the system to stop running

OFFLINE JAN-01-12 12:01A

Cat. No. 01021713

3. The screen displays the main menu. Press repeatedly to return to the home screen, which displays the operational status (OFFLINE).

Basic Operation 31

Setup

After completing the first time setup for the RO, you must also complete the system setup for flush modes, accessories, and error limits before completing the initial startup.

Flow Meter K-Factor setting is required during setup. All other RO settings are optional depending on the accessories installed. The RO controller does not require any specific setup to run unless accessories are installed or will be installed. RO accessories include:

Accessory Global RO Controller (GROC) Setting

Flush Valves Setup—>Flush Modes

Flow Meters Setup—>Accessories—>Flow Meters

Modem Setup—>Accessories—>Modem

Wireless Remote, RF Board Setup—>Accessories—>Wireless Rem—>Channel #

Level Controls Setup—>Accessories—>Switch Inputs

Repressurization System Setup—>Accessories—>Switch Inputs

Pretreatment Lockout Setup—>Accessories—>Switch Inputs

Pressure Transducers (G2, G3 only) Setup—>Accessories—>Press Gauges

System Setup

Set Up Time/Date

If the unit loses time for some reason, you can use this setting to reset the correct date and time. Please note that if you have a modem installed and connected to the phone line, the unit will check for the correct time each time it calls in.

RUNNING JAN-01-12 12:01P

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

1) GO TO RUNNING

2) GO TO OFFLINE

3) INFORMATION >4) SETUP

2. Press to scroll to 4) SETUP.

3. Press to select the SETUP menu.

>1) TIME/DATE

2) LANGUAGE

3) POWERON MODE

4. Set Time/Date is the first menu item, so press to select 1) SET TIME/DATE. The screen displays the first setting that can be changed.

4) FLUSH MODES

Time/Date Settings

Screen Display Range Procedure

SET

MONTH JAN

Jan–Dec

1. The screen displays the month setting. Press

and then

to change the value and see the next setting.

SET

DAY 1

32 Culligan® Series G1 Reverse Osmosis

1–31

2. The screen displays the day setting. Press

then

to change the value and see the next setting.

32 Cat. No. 01021713

or and

Screen Display Range Procedure

SET YEAR

2012

CLOCK TYPE

12 HR

SET HOUR

12PM

2010–2040

12 or 24

12AM–11PM

3. The screen displays the year setting. Press

then

4. The screen displays the clock type setting. Press

5. The screen displays the hour setting. Press

then

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.

or and

SET

MINUTES 25

DAYLIGHT SAVING

YES

0–59

YES

6. The screen displays the minutes setting. Press

and then

7. The screen displays whether you observe daylight savings

time where the RO unit is installed. Press

then menu.

to change the value and see the next setting.

or and

to change the value and return to the Time/Date

RUNNING JAN-01-12 12:01P

8. Press to return to the home screen.

Set Up Language

Use the language setting to change the displayed language on the RO controller.

NOTE Ensure the units of measure (US, Metric) are appropriate. See page 21 to change if necessary.

RUNNING JAN-01-12 12:01P

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

1) GO TO RUNNING

2) GO TO OFFLINE

3) INFORMATION >4) SETUP

1) TIME/DATE >2) LANGUAGE

3) POWERON MODE

4) FLUSH MODES

Cat. No. 01021713

2. Press to scroll to 4) SETUP.

3. Press to select the SETUP menu.

4. Press to select 2)LANGUAGE. The screen displays the last selected lan-

guage of the RO controller.

Setup 33

LANGUAGE

ENGLISH

1) HEURE/DATE >2) LANGUE

3) EN MARCHE

4) MODES FLUSH

Set Up Power On Mode

RUNNING JAN-01-12 12:01P

1) GO TO RUNNING

2) GO TO OFFLINE

3) INFORMATION >4) SETUP

1) TIME/DATE

2) LANGUAGE >3) POWERON MODE

4) FLUSH MODES

5. Press or and then to change the display to your preferred language.

6. The screen displays the setup menu in the selected language of the RO controller.

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. Set Time/Date is the first menu item, so press to select 3)POWERON MODE.

POWERON MODE

5. Press or and then to select Power On Mode options.

OFFLINE

RUNNING

OFFLINE

RUNNING JAN-01-12 12:01P

6. Press to return to the home screen.

The RO system will start whenever power is supplied.

The RO system will go into standby when power is supplied to the unit.

Flush Modes

The GBE RO controller can be programmed to operate up to six different flush modes. Multiple flush modes can be specified and operating at any one time. If any one or more flush modes are calling for flushing to happen at a certain time, the flush will take place. Some flush modes require additional plumbing and components such as solenoid valves.

Startup Flush

In this mode the fast flush solenoid (SV-2) opens for a specified number of minutes each time that the pump turns on.

Standby Flush

In this mode any time that the system state is in STANDBY, the inlet AND fast flush solenoids open for a specified number of minutes every specified number of hours. This is a line-pressure-level flush (ie the pump does NOT turn on during this flush).

34 Culligan® Series G1 Reverse Osmosis

34 Cat. No. 01021713

Time Trigger Flush

'UDLQ

3XPS

In this mode, any time that the system state is in RUNNING, the fast flush solenoid (SV-2) will open for a specified number of minutes every specified number of hours. Note that the pump is ON during this flush.

Flow Trigger Flush

In this mode, any time that the system state is in RUNNING, the fast flush solenoid (SV-2) will open for a specified number of minutes every specified number of PRODUCT RO water generated. Note that the pump is ON during this flush.

Quality Flush

If this mode is enabled, the product diversion solenoid (SV-3, NOT INCLUDED) is opened as soon as the pump turns on when the RO system is RUNNING. This solenoid will remain open until the measured product TDS drops below the specified quality flush TDS setpoint or until the quality flush time period expires. If the TDS does not drop below the setpoint during this period, the unit will switch to OFFLINE and the “product TDS High” error will be thrown. The Quality Flush solenoid valve is wired to the AUX board on the GBE RO controller at terminal AUX4. The solenoid valve must be 24 VAC.

7'6

7R 6HUYLFH

69

,QOHW

9DOYH

3XPS

0(0%5$1( +286,1*6

Figure 22. RO quality flush.

69

At startup, SV1 opens, and then the pump turns on. SV3 opens while the system monitors the product TDS level. The user programs the maximum allowable product TDS and the number of minutes allowed following startup to reach the allowable TDS level. Usually at startup, the TDS level starts high and then drops. If the level drops below the allowable level within the allowed time, then SV3 will close, and the unit is now in service. If the allowable TDS level cannot be reached, the unit will shut down and generate an error message.

Permeate Flush

If this mode is enabled, the permeate flush solenoid (SV-3, NOT INCLUDED) is opened as soon as the pump turns off. This solenoid will remain open until the permeate flush time period expires and permits water from an optional permeate storage tank to flush the membranes. The Permeate Flush solenoid valve is wired to the AUX board on the GBE RO controller at terminal AUX4 (G1). The solenoid valve must be 24 Volt.

&KHFN

9DOYH

69

)(('

69

&KHFN

9DOYH

69

'UDLQ

Cat. No. 01021713

Figure 23. RO permeate flush.

Setup 35

At shutdown, the pump turns off and SV1 closes. Then fast flush solenoid valve SV2 and permeate valve SV3 open for a programmed number of minutes. During this time, RO product water stored either in an elevated atmospheric tank or in a pressurized storage tank floods through the pump and the feed side of the membrane, and then SV2 and SV3 close. This process provides RO-quality water during shutdown on both sides of the membrane to keep the membrane clean. This process also ensures that the RO will provide high quality product water the next time the pump is turned on.

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

Flush Mode RO Pump Inlet Valve Waste (Fast) Flush Valve Product Flush Valve

Start Up On Open Open Closed

Standby Off Open Open Closed

Time On Open Open Closed

Flow On Open Open Closed

Quality On Open Closed Open

Permeate Off Closed Open Open

Table 3. RO pump and valve states during flush modes.

Any time that a Flush is actually taking place while the system state is RUNNING, the system will ignore the following error limits: delivered product TDS high, %recovery low, %recovery high, %reject low, membrane pressure drop, pump feed pressure low. Once the flush ends, the error checking will resume. If the inlet pressure switch reports LOW pressure for at least XX (XX is programmable at 1-30 seconds, at the main menu/setup/accessories/switch inputs menu) continuous seconds, even if this is during or even partially during a flush time, the system will still recognize this instance as an error condition, and it will begin the LOW PRESSURE process.

Flush Mode Setup

RUNNING JAN-01-12 12:01P

1) GO TO RUNNING

2) GO TO OFFLINE

3) INFORMATION >4) SETUP

1) TIME/DATE

2) LANGUAGE

3) POWERON MODE >4) FLUSH MODES

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. Set Time/Date is the first menu item, so press to select 4)FLUSH MODES.

36 Culligan® Series G1 Reverse Osmosis

36 Cat. No. 01021713

Flush Mode Settings

Screen Display Range Procedure

>1) STARTUP

2) STANDBY

3) TIME TRIGGER

4) FLOW TRIGGER

START UP MODE

OFF

FLUSH DURATION

MINUTES

STANDBY MODE

OFF

FLUSH DURATION

MINUTES

Startup

Standby

Time Trigger

Flow Trigger

Qual Flush

Perm Flush

Off

1–180

Off

1–180

5. The screen displays the Flush Modes menu. Press

to scroll through the menu and then setting.

6. The screen displays the Start Up Mode setting. This will flush

the drain prior to starting the pump. Press

then sure flush.

7. If startup mode is set to ON, the screen displays the flush

duration of the drain. Press change the value and then return to the Flush Mode menu.

8. The screen displays the Standby Mode setting. This will flush the drain when the unit is in standby mode. Standby mode may be triggered manually, by a STORAGE TANK FULL error, by a pretreatment lockout command, or other states. This

is a low pressure flush. Press change the value if necessary.

9. If standby mode is set to ON, the screen displays the flush du-

ration setting. Press value and then display the next setting.

to change the value if necessary. This is a line pres-

or and then to

or and then to change the

to select a flush mode

or and

or and then to

FLUSH EVERY

HOURS

TIME TRIG MODE

OFF

FLUSH DURATION

MINUTES

FLUSH EVERY

HOURS

Cat. No. 01021713

1–24

Off

1–180

1–24

10. If standby mode is set to ON, the screen displays the flush in-

terval setting. Press value and then return to the Flush Mode menu.

11. The screen displays the Time Trigger Mode setting. A flush will be triggered after a specified amount of time has passed.

Press necessary.

12. If time trigger mode is set to ON, the screen displays the flush

duration setting. Press the value and then display the next setting.

13. If time trigger mode is set to ON, the screen displays the flush

interval setting. Press the value and then return to the Flush Mode menu.

or and then to change the value if

or and then to change the

or and then to change

Setup 37

Screen Display Range Procedure

FLOW TRIG MODE

OFF

FLOW TRIG MODE

OFF

FLUSH DURATION

MINUTES

FLUSH EVERY

100

GALLONS

QUAL FLUSH MODE

DISABLE

Off

1–180

100–1000

Disable

14. The screen displays the Flow Trigger Mode setting. Press

or and then to change the value and see the flow

trigger mode settings.

15. The screen displays the Flow Trigger Mode setting. If the system is running, the unit will flush after generating a specified

amount of reverse osmosis water. Press

then

16. If flow trigger mode is set to ON, the screen displays the flush

duration setting. Press the value and then display the next setting.

17. If flow trigger mode is set to ON, the screen displays the flush

interval setting. Press the value and then return to the Flush Mode menu.

18. The screen displays the Quality Flush Mode setting. When the system is running, the system sends all water to drain until a preset quality is reached, at which time the water will flow to the product outlet. This is a high pressure flush (pump is on). The quality flush mode is disabled and can not be changed. Press any button to return to the Flush Mode menu.

to change the value if necessary.

or and then to change

or and

PERM FLUSH

OFF

FLUSH DURATION

SECONDS

RUNNING JAN-01-12 12:01P

38 Culligan® Series G1 Reverse Osmosis

1–180

21. Press to return to the home screen.

Off

19. The screen displays the Permeate Flush setting. This flush requires an optional solenoid valve and permeate storage tank

from where the flush water is drawn. Press

then

20. If permeate flush mode is set to ON, the screen displays the

flush duration setting. Press change the value and then display the next setting.

to change the value if necessary.

or and then to

38 Cat. No. 01021713

or and

Switch Inputs Programming

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

Switch Inputs Settings

Screen Display Range Changing the Setting

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 4)SWITCH INPTS. The screen displays the switch inputs settings.

PRESSURE SWITCH NORMALLY OPEN

PS Sw

Delay: 5

SECONDS

SV1 Delay:

SECONDS

PRETREAT SWITCH NORMALLY OPEN

FLOAT SWITCHES NORMALLY OPEN

Normally Open

Normally Closed

0–9,#

each digit

0–300

Normally Open

Normally Closed

Normally Open

Normally Closed

Used with the inlet pressure switch. Standard pressure switch is

normally open. Press state if necessary.

Sets the pressure switch delay time. This is the number of seconds

the low pressure must exist before activating the switch. Press

or and then to change.

The number of seconds elapsed from the inlet solenoid valve (SV-

1) opening until the motor starts. Press to change.

Used with the inlet pressure switch. Standard pressure switch is

normally open. Press state if necessary.

Used to set whether float switches (level control) are normally open or closed. There are two float switch contacts; they both must

be normally open or closed. Press change the state if necessary.

or and then to change the

or and then

or and then to change the

or and then to

Cat. No. 01021713

Setup 39

Screen Display Range Changing the Setting

FS Hi

Delay: 0

MINUTES

RUNNING JAN-01-12 12:01P

Used only when using the float switch high contacts. This sets how

0–120

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

long the float switch stays closed after transitioning from high to low level.

40 Culligan® Series G1 Reverse Osmosis

40 Cat. No. 01021713

Accessories

5 3/8”

There are several components of the G1 RO that can be configured from the Accessories manu, including:

• Wireless Remote

• Modem

• Flow Meter

• Pressure and Level Control Switches

• Pressure Gauges

• Total Dissoved Solids Probes

• Error or Status Monitor

• SV3 or Target TDS Monitor

Wireless Remote

1. Select a location for the wireless remote monitor (Figure 24). 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.

MODEM CONNECTION

SCREWS

Figure 24. Wireless remote monitor.

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. 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 page 46 for installation and setup.

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. Plug into 120V outlet.

6. Disconnect power to the RO unit. Open the control.

POWER CONNECTION

Cat. No. 01021713

Accessories 41

Figure 25. RF board location on GROC 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 25). Make sure the RF board is fully seated into all of the socket. Reconnect power.

8. Follow the directions on the next page to program BOTH the main and remote monitor units to communicate with each other. If modem has been 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

Begin the wireless setup using the wireless remote device.

RUNNING JAN-01-12 12:01P

1) INFORMATION >2) SETUP

3) DIAGNOSTICS

>1) RF SETUP

2) MODEM SETUP

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

2. Press to select 2)SETUP.

3. Press to select 1)RF SETUP.

Wireless Remote Settings

Screen Display Range Changing the Setting

CHANNEL #

RF FREQUENCY 915 Mhz

RUNNING JAN-01-12 12:01P

42 Culligan® Series G1 Reverse Osmosis

1–254

433, 869,

or 915

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

Press valve. The CHANNEL # for the RO controller must be the same as the CHANNEL # for the Remote Display.

Use this setting to select the correct radio frequency. Do not change the RF frequency for North America installations.

or and then to select the channel number of the control

42 Cat. No. 01021713

GBE-Wireless Communication Setup

Now set up the RO controller to communicate with the wireless remote.

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

REMOTE DISPLAY NOT INSTALLED

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

2. Press to scroll to 4) SETUP.

3. Press

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

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

6. Press or and then to change the state to INSTALLED.

to select the SETUP menu.

CHANNEL #

RF FREQUENCY 915 Mhz

RUNNING JAN-01-12 12:01P

7. Press or and then to select the channel number of the control valve. The CHANNEL # for the RO controller must be the same as the CHANNEL # for the Remote Display.

8. Use this setting to select the correct radio frequency. Do not change the RF frequency for North America installations..

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

Cat. No. 01021713

Accessories 43

Check Signal Strength Between the GBE RO Controller and Remote

Check the signal strength once the RO controller and wireless remote are set up.

RUNNING JAN-01-12 12:01P

1) GO TO RUNNING

2) GO TO OFFLINE

3) INFORMATION >4) SETUP

3) POWERON MODE

4) FLUSH MODES

5) ACCESSORIES >6)DIAGNOSTICS

>1) TST WIRELESS

2) TESTPHONELIN

3) USE DATA PORT

4) TEST APP

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 6)DIAGNOSTICS.

5. Press to select 1)TST WIRELESS. The screen displays the wireless test

screen.

WIRELESS TEST 0 / 188

RSSI=5

RUNNING JAN-01-12 12:01P

6. The screen displays the test number and total number of attempts and the received signal strength indicator (RSSI). The system will continue to test the signal strength until you press any button to return to the diagnostics menu.

The signal strength indicator (RSSI) will show a value of between 0 and 8. If the RSSI 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 for the wireless remote.

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

44 Culligan® Series G1 Reverse Osmosis

44 Cat. No. 01021713

Modem

NOTE The modem can be installed into either the back of the RO controller or the back of the remote control

board. The functionality of the modem is the same in either installation.

NOTE Use of the modem kit requires a one-year subscription to either a Level 1 or Level 2 Telecom package.

Self-service registration is available at www.myculligan.com.

1. Before installing the modem into the back of the RO Controller board or the back of the remote, the RO Controller circuit board or the remote must first be powered off.

2. When handling all circuit boards, take care to only touch the edges of the circuit boards—not the metal pins. The electronics on all circuit boards can be damaged by static electricity.

3. 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.

4. When all connections have been made restore power.

5. Connect the modem to the telephone line by plugging a standard RJ-11 phone extension cord into the modem

board.

NOTE The GBE RO Controller 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 RO 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 RO Controller or Remote Display near a telephone jack. A splitter might be needed if

the jack is already in use.

Installing the Modem on the GBE RO Controller Board

Open the controller cover and locate the modem connection on the back of the board (see Figure 26). Insert line modem board (part number 01020307) 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.

Cat. No. 01021713

Figure 26. Back of GROC board.

Accessories 45

Installing the Modem 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 01020307) into the socket on the back of the remote board (see Figure 27). 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 27. Modem installed on back of remote board.

GBE RO Controller Modem Setup

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

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

5. Press to select 2)MODEM. The screen displays the modem settings.

to select the SETUP menu.

46 Culligan® Series G1 Reverse Osmosis

46 Cat. No. 01021713

GROC Modem Settings

Screen Display Range Changing the Setting

TELEPHONE MODEM INSTALLED

MODEM CONNECTION LANDLINE

MODEM LOCATION IN MAIN CONTROL

TIME ZONE GMT

+00:00

Installed,

Not

Installed

LandLine

CellModem

In Main Control

In Remote

0 to +12 or

-12

Press is installed inside the Smart Controller.

Press See the note on the previous page about analog and digital phone lines.

Press Change this setting only if a modem is installed.

Press location with respect to Greenwich Mean Time (GMT).

When using a modem, the controller will occasionally access the Internet to synchronize the date and time. In order to do this correctly, the control must be told which time zone it is installed in. The time zone is specified as so many hours ahead or behind GMT time. The GMT offset for some common cities is listed below:

or and then to select INSTALLED if a telephone modem

or and then to change the Modem connection setting.

or and then to change the Modem Location setting.

or and then to specify the time zone of the RO Controller

GMT Offset

New York -5:00 (and anywhere in EST)

Chicago -6:00 (CST)

Denver -7:00 (MST)

Los Angeles -8:00 (PST)

London 0:00

Paris 0:00

Rome +1:00

CALL FREQUENCY DAILY

CALL TIME 4:30AM

Cat. No. 01021713

Daily

On Error

Daily&Error

Monthly &

Error

12:00AM–

11:30PM

Press sending data via modem.

Press via modem. The time changes in increments of 30 minutes.

or and then to specify the frequency of the RO controller

or and then to specify when the RO controller sends data

Accessories 47

Screen Display Range Changing the Setting

DATA PHONE # >18884137028

DEALER ID

00000000

15 digits

8 digits

Press to change the Data Phone Number setting. Press or and

then

move to the next digit. Press is necessary to provide a telephone number to be called by the unit. Typically, it is desired that the unit call a local access number. These local access numbers, for nearly every area code around the globe, can be found from the My Culligan website at http://www.myculligan.com/technical/tech_ref-gbe-boards.

asp. The unit can also be programmed with the default toll-free access num-

ber. Use a local number whenever possible.

Press to increase or decrease each digit of the Dealer ID and select the next digit.

Press ership’s account number.

to increase or decrease each digit of the Data phone number and

when the correct Data phone # is displayed. It

to change the Dealer ID setting. Press or and then

when the correct Dealer ID is displayed. The Dealer ID is your deal-

RUNNING JAN-01-12 12:01P

6. Press to save the settings and return to 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 / Setup / Accessories / Modem screen is displayed in the format of GMT +/- X hours. See “GBE RO Controller Modem Setup” on page 46.

RUNNING JAN-01-12 12:01P

1. From the HOME screen, press to view the main menu.

1) GO TO RUNNING

2) GO TO OFFLINE

3) INFORMATION >4) SETUP

2. Press to scroll to 4) SETUP.

3. Press to select the SETUP menu.

3) POWERON MODE

4) FLUSH MODES

5) ACCESSORIES

4. Press to select 6)DIAGNOSTICS.

>6) DIAGNOSTICS

1) TST WIRELESS >2) TESTPHONELIN

3) USE DATA PORT

5. Press to select 2)TESTPHONELIN. The screen displays the modem test screen.

4) TEST APP

48 Culligan® Series G1 Reverse Osmosis

48 Cat. No. 01021713

MODEM TEST Emailing now Please Wait ...

6. Press to begin testing the modem telephone line. The screen displays the sta-

tus 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.

Possible Modem Test Results

MODEM TEST ERROR NO TONE!!

MODEM TEST NOT POSSIBLE NOW TRY LATER!

MODEM EMAIL SUCCESS

Modem Setup From Remote Display

This setup is completed using the wireless remote device.

RUNNING JAN-01-12 12:01P

1) INFORMATION >2) SETUP

3) DIAGNOSTICS

1)RF SETUP >2)MODEM SETUP

GBE RO Controller Modem Settings (on Remote)

Screen Display Range Changing the Setting

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

2. Press to select 2)SETUP.

3. From the Setup menu, press to select 2)MODEM SETUP. The screen dis-

plays the modem settings. Use these to set up the communication between the wireless remote and the Culligan servers.

MODEM TEST TIME

SET SUCCESS

TELEPHONE MODEM NOT INSTALLED

CALL FREQUENCY DAILY

DATA PHONE # 18884137028

1)RF SETUP >2)MODEM SETUP

Cat. No. 01021713

Installed

Not Installed

Daily

On Error

Daily&Error

Monthly & Error

0–9,#

each digit

1–2

The screen displays the installation status of the modem. Press

to change the state to installed if a telephone modem is in-

stalled inside the RO remote display.

Press controller sending data via modem.

The screen displays the data phone number, up to fifteen digits.

Press

number. When the final digit is entered press tire phone number.

The screen displays the setup menu. Press tings and display the home screen.

or and then to specify the frequency of the RO

or and then to change each digit of the phone

to accept the en-

to save the set-

Accessories 49

TDS Programming

The Global RO Controller uses one TDS probe, measuring the product water. The probe is connected via the SBT terminal J20 on the GROC board. The probes are factory installed and calibrated. If the measured TDS levels exceed the maximum allowed in the product water (see page 26), the RO controller displays an error condition (see “PRODUCT

TDS TOO HIGH” on page 63).

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

3) FLOW METERS

4) SWITCH INPTS

5) PRESS GAUGES >6) TDS

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 6)TDS. The screen displays the switch inputs settings.

TDS Probe Settings

Screen Display Range Changing the Setting

TDS PROBE:

NONE

ACTUAL TDS OUT

PPM

TEMP OFFSET

0 F

TEMP COMP VALUE:

0.025

RUNNING JAN-01-12 12:01P

None

Product

Both

0–6000 (TDS1)

0–200 (TDS2)

-50–50

N/A

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

For the G1 RO, there is only one TDS probe, so the correct setting is PRODUCT. For the G2 and G3 RO, the correct setting is BOTH.

Press

Disconnect the TDS probe from the RO plumbing and submerge it

into a solution of known TDS. Press value.

Use this value to make minor corrections to the displayed temperature value. For example if you use a handheld temperature device that shows the water temperature two degrees warmer, change this value to 2 to compensate.

Please do not change this value unless you are told to do so by Culligan Rosemont. This value changes the slope used to interpret the temperature.

or and then to change the state if necessary.

or to enter the actual TDS

50 Culligan® Series G1 Reverse Osmosis

50 Cat. No. 01021713

Alarm Outputs

UG IN

ALARM

Alarm Relay Board

The GBE RO controller board offers support for the Culligan Alarm Relay board (P/N 01022238). See Figure 28. To use the alarm relay board, install it onto the back of the GBE RO controller board. See Figure 29.

RELAY BOARD

PL HERE

BACK OF GBE BOARD

Figure 28. Alarm Relay board.

Figure 29. Alarm Relay board install to GROC.

The alarm relay board is plugged into the GBE RO controller board alarm relay socket. When Error Status is selected on the GBE RO controller, this relay will be in the Normally Open position when the controller board has power on AND there are no errors present (i.e. “Problem Found” is not showing on the Home screen.) The relay will be in the Normally Closed Position when the controller is either powered OFF or there is an error present on the controller board.

LAMP or BUZZER

NORMAL OPERATION: Terminals NO and NC are connected, leaving the lamp circuit open (lamp off)

24VAC SUPPLY

RELAY

ERROR CONDITION: Terminals NO and COM are connected,

ALARM SIGNAL PCB

completing the lamp circuit (lamp on)

Figure 30. Example of customer wiring to the GROC Alarm Signal Output

RUNNING JAN-01-12 12:01P

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

Cat. No. 01021713

Accessories 51

1) GO TO RUNNING

2) GO TO OFFLINE

3) INFORMATION >4) SETUP

2. Press to scroll to 4) SETUP.

3. Press to select the SETUP menu.

2) LANGUAGE

3) POWERON MODE

4) FLUSH MODES

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

>5) ACCESSORIES

4) SWITCH INPTS

5) PRESS GAUGES

6) TDS

5. Press to select 4)SWITCH INPTS. The screen displays the switch inputs settings.

>7) RELAY MODE

Relay Mode Settings

Screen Display Range Changing the Setting

RELAY MODE: ERROR STATUS

FLOW TRIGGER

Gals

Error Status

Network

Pulsed Output

1–9999

Select Error Status to use board as an alarm relay. See below for more information.

Network selection is not used.

Select Pulsed Output to use the relay to control a chemical feed pump.

Press

When using this relay to turn a chemical feed pump on and off, specify the number of gallons of product water produced after the relay is turned

on. Press

or and then to change the state if necessary.

or to enter the actual TDS value.

GROC Alarm Signal Output

The GBE RO controller Alarm Signal Output is provided through three screw terminals located on the alarm relay board. These terminals provide a pair of dry contacts rated at 30VDC x 10A. One dry contact is open and one is closed at all times as defined in Table 4 below.

When GBE RO Controller is… Contact A

(screw terminals NO & NC)

Operating Normally Continuity Open circuit

In “Error Condition” or when the GBE RO controller is not powered on

Table 4. GBE RO controller dry contact configurations in normal and error conditions.

Open circuit Continuity

(screw terminals NO & COM)

Contact B

A simple error alarm can be constructed by routing a customer supplied power source thru the Alarm Signal Output contact terminals NO and NC as shown in Figure 30. The indicating light will be ON any time that the GBE RO controller is either not powered on, or if it is in an “error condition.” Alternatively, the Alarm Signal Output contact terminals can be wired to a customer supplied PLC or SCADA system to provide an indication to the customer of the status of the GBE RO controller-controlled equipment.

52 Culligan® Series G1 Reverse Osmosis

52 Cat. No. 01021713

Multiple Unit ROs

The GBE RO controller supports two multi-unit modes: Two Pass and Alternating.

When in two-pass or alternating mode, the system is configured to support two GBE RO controllers that are connected together using the communication cable (P/N 01016327). See Figure 31. One of these boards is set as the master, controlling the operations of the other unit, also known as the slave. The slave unit performs as a sensing device.

Two-Pass RO

When in Two-Pass RO mode, the primary unit, identified as the master, issues commands to control the secondary unit, identified as the slave.

FFLOW IFLOW PFLOW

Figure 31. Two-pass RO process.

Two-Pass RO Start Up Sequence

When configured for two-pass RO, the master unit runs a start up sequence described as follows:

• The SV1 on the GBE master opens

• The system waits for the amount of time set on the master as “SV1 Delay”

• If the pressure-switch-1 shows that pressure is present, then the GBE master turns on the pump for the first unit.

• The system waits for the amount of seconds set on the master as the “PASS 2 DELAY”.

• If the pressure-switch-2 shows that pressure is present at pressure-switch-2 then the master sends an operation

command to the slave unit that turns on the second pass pump.

The master will turn off the slave’s motor output any time it detects that one of the inlet pressure switches is off for more than the specified “PS SW DELAY”. After the slave unit pump turns off, the master will wait three (3) seconds and then turn off the master pump. The units follow the same procedure if operating conditions trigger the PTLO or the Tank Full switches.

G1 Series Two-Pass Pairings

NOTE The RO G1 Series Two-Pass requires that the unit have the firmware version FWR202LT04 with a born-

on-date no earlier than FEB 01 2013.

For hardware, plumbing, and wiring, order the following:

Required Kit Part Numbers

Two-Pass Offerings Feed TDS>500 Feed TDS<500

G1 2L(master), 2S(slave) 01025957 01025959

G1 3L(master), 3S(slave) 01025957 01025959

G1 4L(master), 4S(slave) 01025957 01025959

G1 2F(master), 3L(slave) 01025957 01026007

Cat. No. 01021713

Accessories 53

Duplex-Alternating RO Mode

Connector for Additional Units (used for certain multiple unit configurations)

The GBE RO controller controller is capable of coordinating the alternating operation of two RO units plumbed in parallel. This operation mode is designed for situations where RO redundancy is desired. As long as both RO units remain functional, the controllers will direct one of the units, called “Unit A,” to be in the “ready-to-run” mode for a one hour block of time beginning at the top of the hour. During that one hour block, Unit A will produce RO water as long as the storage tank is NOT full and as long as there is no pre-treatment-lockout condition in effect. During this first hour, Unit B will be in standby mode. At the beginning of the next hour, control switches to Unit B and Unit A will switch to Standby. During that second hour, Unit B will produce RO water as long as the storage tank is NOT full, and as long as there is no pre-treatment-lockout condition in effect. The units will continue to switch over control at the top of each hour indefinitely.

For example, the master RO pumps on even hours (12:00 to 1:00, 2:00 to 3:00, 4:00 to 5:00, etc.), and the slave RO pumps on odd hours (1:00 to 2:00, 3:00 to 4:00, 5:00 to 6:00, etc.).

If at any time while in duplex-alternating mode either Unit A or Unit B stops functioning, or enters an “error state” (for example if the product TDS exceeds the maximum allowable product TDS level) then the other unit will take over operation and will continue to operate as a single stand-alone mode until an operator clears the error on the first unit.

If at any time while in duplex-alternating mode the two units lose communication with each other (for example if the communication cable is cut or becomes unplugged), then both units will switch into single stand-alone mode until communications are re-established and an operator instructs the units to return to duplex alternating mode using the GROC menu screens.

In Alternating-Mode, each RO unit has its own GROC controller. A standard communication cable (P/N 01016327) is used to connect the two GROC controllers together as shown in Figure 32 and the units are plumbed as shown in Figure

33. It is necessary for each RO unit have its own independent storage tank level (or pressure) switch. If a pre-treatment

lockout system is to be used, each RO must also have its own independent dry contact closure signal from the pre-treatment system wired to the individual GROC controllers.

When either unit is the “running” unit, it operates as a single unit.

Unit #1 (Master) Unit #2 (Slave)

Figure 32. Wiring for two-pass and alternating mode.

54 Culligan® Series G1 Reverse Osmosis

54 Cat. No. 01021713

35(75($7

6<67(0

&21752//(5

37/2 $

81,7 $

&$%/(

&20081,&$7,21

37/2 %

81,7 %

Figure 33. RO duplex alternating plumbing.

81,7 %

+,*+ /(9(/

6:,7&+

81,7 $ +,*+ /(9(/ 6:,7&+

Cat. No. 01021713

Accessories 55

Alternating RO Unit Settings

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

5) PRESS GAUGES

6) TDS

7) RELAY MODE >8) MULT UNIT RO

Screen Display Range Changing the Setting

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 8)MULT UNIT RO. The screen displays the multiple unit RO settings.

MULTI UNIT RO SINGLE

MUL UNIT RO ROLE MASTER

Single

Two Pass RO

Alternating

Master

Slave

Press configuration.

For Two-Pass configuration, refer to the Series G1 RO Two-Pass Kit manual (P/N 01026027).

If you select Alternating, press MASTER if the selected RO will control the functions of the entire RO system. Select SLAVE if the selected RO will be controlled by the master RO.

NOTE The Master RO must be set up first.

or and then to select the RO system

or and then to select

56 Culligan® Series G1 Reverse Osmosis

56 Cat. No. 01021713

SV3 (Solenoid Valve) Mode/TDS Target

Drain

Solenoid valve SV3 is physically connected to the mini-aux board AUX4. When connected to AUX4, the TDS probe is set up as PRODUCT.

NOTE Unlike SV1 and SV2, which operate at line voltage (115VAC for G1, 230VAC for M2), SV3 must be a 24V

solenoid valve such as P/N 01021310.

SV3 has three possible modes of operation: quality flush, permeate flush, and TDS target.

NOTE Quality and Permeate Flush are disabled in TDS Target mode.

TDS Target

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. The average TDS measurements of the RO product water are taken once per second, over an interval specified by the “TDS Target Time.” The controller opens and closes valve SV3 every few seconds in order to produce product water with a TDS level near the programmed value.

Figure 34. Target TDS.

For hardware, plumbing, and wiring details, order P/N 01025749 (Kit, Target TDS, 1-Series).

Cat. No. 01021713

Accessories 57

Error Limits

Setting Error Limits

Limits can be set for various operating parameters. If these limits are exceeded, the GBE RO Controller will trigger an error message and shut down the RO system. User intervention is required to restart the RO system. If the modem option is installed, this error will be transmitted when the system calls in.

RUNNING JAN-01-12 12:01P

1) GO TO RUNNING

2) GO TO OFFLINE

3) INFORMATION >4) SETUP

4) FLUSH MODES

5) ACCESSORIES

6) DIAGNOSTICS >7) ERROR LIMITS

Error Limits Settings

Press or and then to change the value if necessary.

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 7)ERROR LIMITS.

Screen Display Range Procedure

MAX RECOVER%

90%

MIN RECOVER%

10%

MAX IN TEMP

120F

MIN IN TEMP

33F

MAX TDS OUT

250

PPM

0–100

0–200 This is the maximum allowable temperature for the system.

33–100 This is the minimum allowable temperature for the system.

1–500

The system’s recovery changes as operating parameters fluctuate and membranes age. Set this value to the maximum allowable recovery. As the recovery increases, product quality decreases (TDS increases).

Set this to trigger an alarm if the recovery falls below the setting. A very low recovery can indicate membrane fouling or a mis-adjusted system.

Select the highest total dissolved solids in the product water (lowest product quality) accepted by the G1 or M2 RO. Product water that exceeds the maximumTDS level will trigger an error condition, HIGH TDS OUT (see page 63).

58 Culligan® Series G1 Reverse Osmosis

58 Cat. No. 01021713

MAX PUMPTIME

Hours/Day

0–23

Specify the maximum number of hours per day that the pump is to run. If the value is set to 0 then this feature is ignored. If the value is non-zero then each day (at the time of the daily email) the system checks to see if, within the past 24 hours, the pump run time has exceeded the specified number of hours. If the number of hours HAS EXCEEDED the specified limit, the system will continue to operate, but the error flag corresponding to the maximum number of pump hours per day will be sent in the email message and the message “Max Pump hrs/day” will show along with the “Problem Found” message on the home screen.

MIN N FLOW

0.00

GPM

STD PRESSURE

120

PSI

RUNNING JAN-01-12 12:01P QUAL FLUSH

Specify the minimum flow rate in gallons per minute at a normal-

0–250

1–1000

5. Press to return to the home screen. The screen displays any additional

modes in progress that are triggered by an error state. For example, the RO system will have a quality flush if TDS exceeds the Max TDS Out.

ized temperature of 77°. If the flow rate drops below the minimum, the GROC will display an error limit message.

NOTE If the MIN N FLOW value is left at zero, this error

level will be ignored, and it will not be displayed in the Information screen.

If the minimum normalized flow setting is specified (any number other than zero), then specify the standard pressure across the membranes at the normalized temperature of 77° (p1-p2)/2

Cat. No. 01021713

Error Limits 59

System Operating Information

At any time, you can view the system operation information. The information includes settings and performance data.

>1)GO TO RUNNING

2)GO TO OFFLINE

3)INFORMATION

4)SETUP

Information Settings

NOTE When you display any Information screen, it will stay on the display until changed by the operator.

Screen Display Range Procedure

1. Press to select 3)INFORMATION.

FFLOW 0.00 PGM DFLOW 0.00 GPM PFLOW 0.00 GPM RECOVERY 0.0 %

TDS PPM TDS IN = 1075 TDS OUT = 192 % REJ = 82

TDS AVERAGE

PPM

RECOVERY 0.0%

PFLOW 0.00 GPM TDS OUT = 169

ACTUAL NFLOW:

0.00

GPM

0.00–??

0–999

0–??

0.00–?? 0–999

0.00–??

The screen displays Feed Flow, Reject Flow(waste), Product Flow, and Recovery. Flow Meters must be installed for this screen to display values.

If the RO is offline/not running, the screen displays FLOW METERS DISABLE.

G2/G3 only: this screen shows the TDS of the incoming and product water as well as the percent rejected. The TDS sensors must be installed for this screen to display values.

If the RO is offline/not running, the screen displays TDS DISABLE.

When SV3 is selected, the RO controller information screen displays the TDS average in ppm. This should be the average TDSout value over the last 10 cycles of “TDS Target Time.”

Alternate information screen showing recovery, rejection, product flow and product TDS.

If the RO is offline/not running, the screen displays FM OR TDS DISABLE.

This is the normalized product flow (flow at 77°F)

NOTE: This value is displayed only if the Min NFlow Error limit is greater than zero.

P IN 122 PSI P OUT 124 PSI dP -2 PSI

Actual Temp:

91 F

PS1 = OPEN PTLO = OPEN FS HI = OPEN FS LO = OPEN

60 Culligan® Series G1 Reverse Osmosis

Incoming (G2 Plus and G3 only) pressure and waste pressure are shown and the pressure differential (dP) is calculated. The screen displays DISABLE if no pressure gauges are connected.

If the RO is offline/not running, the screen displays PRESS GAUGES DISABLE.

The screen displays the temperature of the product water.

Indicates whether the pressure switch, pretreatment lockout, high float switch or low float switch is open or closed (if installed).

60 Cat. No. 01021713

Screen Display Range Procedure

TOTAL FEED WATER

GALLONS

TOTAL PROD WATER

GALLONS

PUMPING TIME

HOURS

ERROR: 1 Water Press Low JAN-01-12 12:01P

FWR202LT04 Jan 30 2012

S/N:00000000

Displays the total number of incoming untreated water gallons since the unit was put into service.

Displays the total number of product water gallons since the unit was put into service.

Displays the total number of hours the unit has been in service (running) since the unit was put into service.

The screen displays the last one to five errors flagged by the unit. If no errors are flagged the display reads NONE.

The screen displays the firmware version, firmware installation date, and the GROC board serial number.

HISTORICAL DATA JAN 01 REJ=97% REC=50 DP = 77 PSI

CLEAR HIST DATA?

100–1000

Yes

The GROC has a built in data logging feature which takes a “snapshot” at the start of each month. The first time each month that the system has been in a “RUNNING” state for a continuous 10 minute block of time, the system will save the current values of:

Totalized gallons since new

Current % recovery

Current % rejection

Current Product TDS

Current water temperature

This data is stored on the local GROC board. The snapshots from the first three months are always stored with the most recent 24-month snapshots. This historical data is available even if the modem option is not used. If the historical data has been cleared, the screen displays NONE.

Press

from the screen. Press menu.

Erase this data ONLY when replacing the membranes.

to change setting to Yes, which clears historical data

again; the program returns to the main

Cat. No. 01021713

System Operating Information 61

Service and Maintenance

Serial Numbers

The Culligan G Series units have a serial number located directly behind the electronic controller on the side panel. Do not remove or destroy these serial number labels.

They must be referenced if you require repairs or parts replacement under warranty.

Troubleshooting

Problem Probable Cause Solution

1. Unit is set to Go to Running but unit does not start.

2. Unit running but not holding high pressure.

3. Unit running but poor quality (less than 95% rejection)

4. Low quantity of product water. A.-D. Same as 3. A.-D. Same as 3.

5. Excessive noise. A. Air in the plumbing. A. Check fittings for leaks. Purge air from

6. Inadequate product pressure (direct feed systems)

A. No power to unit. A. Check circuit breaker.

B. Low feed pressure. B. Correct low pressure condition.

C. Inlet solenoid failure C. Replace solenoid

D. Prefilter fouled. D. Replace cartridge

A. Pump malfunction. A. Replace pump.

B. System pressure control valve malfunction.

C. Concentrate flow too high. C. Check and adjust concentrate flow, re-

D. Product flow too high. D. Test modules.

A. Low pump pressure. A. See 2.

B. Module failure. B. Replace modules. Check product line

C. Concentrate throttling valve open.

D. Poor seal on endcap. D. Check o-rings inside endcap. Replace

E. Cold water. E. Install additional modules.

B. Misaligned pump. B. Remove pump and check for bearing

C. Harmonic vibration. C. Install a pressure regulator ahead of the

D. Low feed pressure. D. Increase feed pressure above 20 psig.

A. Low quantity of product water. A. See 4.

B. Demand for product water exceeds unit capacity.

B. Replace valve.

place tubing on A.

over pressurization.

C. Throttle valve down.

o-rings if necessary.

system.

wear.

prefilter.

B. Install additional modules.

62 Culligan® Series G1 Reverse Osmosis

62 Cat. No. 01021713

Error Codes

When the G Series RO Controller encounters an error, the screen displays a PROBLEM FOUND message. Press to scroll to the error message.

STANDBY JAN-01-12 1:55P Problem Found No Remote Signal

REJECTION RATE LOW

RECOVERY RATE HIGH

RECOVERY RATE LOW

PRODUCT TDS TOO HIGH

NO REMOTE SIGNAL

FEED QUALITY LOW

All of the above conditions initiate an alert that will be sent back to the dealership if the telemetry (modem) options are set up, and the RO will shut down. User intervention is required to restart the RO. See Installing Modem for information about setting up this feature. Additional fees apply.

This message is triggered when the rejection rate goes below the value set in MIN REJECT %. This indicates the membranes should be cleaned.

This message is triggered when the recovery percentage goes above the value set in MAX RECOVERY %. This could indicate a change in water chemistry, temperature, or accidental setting change.

This message is triggered when the recovery percentage goes below the value set in MIN RECOVERY %. This could indicate a change in water chemistry, temperature, accidental setting change, or that the membrane is fouling.

This message is triggered when the product TDS goes above the value set in MAX TDS OUT. This indicates that the membranes may be getting fouled and are losing their rejection capability.

This message is triggered when the system and the wireless remote lose contact. An optional wireless remote must be installed to see this message.

In a multiple-RO configuration, the master will command the slave to turn off its aux output if the feed quality input signal reported by the slave remains triggered for more than 5 minutes.

Cat. No. 01021713

Service and Maintenance 63

Diagnostics

RUNNING JAN-01-12 12:01P

1) GO TO RUNNING

2) GO TO OFFLINE

3) INFORMATION >4) SETUP

3) POWERON MODE

4) FLUSH MODES

5) ACCESSORIES >6) DIAGNOSTICS

>1) TST WIRELESS

2) TESTPHONELIN

3) USE DATA PORT

4) TEST APP

Test Wireless Remote

>1) TST WIRELESS

2) TESTPHONELIN

3) USE DATA PORT

4) TEST APP

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 6)DIAGNOSTICS. The screen displays the diagnostics menu.

5. The screen displays the diagnostics menu.

6. Press to select 1)TST WIRELESS. The screen displays the wireless test screen.

WIRELESS TEST 0 / 188

RSSI=5

Test Phone Line

1) TST WIRELESS >2) TESTPHONELIN

3) USE DATA PORT

4) TEST APP

MODEM TEST Emailing now Please Wait ...

7. The screen displays the test number and total number of attempts and the received signal strength indicator (RSSI). The system will continue to test the signal strength until you press any button to return to the diagnostics menu.

8. Press to select 2)TESTPHONELIN. The screen displays the modem test screen.

9. Press to begin testing the modem telephone line. 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.

64 Culligan® Series G1 Reverse Osmosis

64 Cat. No. 01021713

Possible Results

MODEM TEST ERROR NO TONE!!

Use Data Port

1) TST WIRELESS

2) TESTPHONELIN >3) USE DATA PORT

4) TEST APP

MINI REPORT Sending ...

MINI REPORT Sent!

Test App

1) TST WIRELESS

2) TESTPHONELIN

3) USE DATA PORT >4) TEST APP

MODEM TEST NOT POSSIBLE NOW TRY LATER!

10. Press to select 3)USE DATA PORT. The screen displays the data report status screen.

11. Press to to send the mini report.

12. The RO controller displays the message delivery status. Press to exit the screen. See Appendix A regarding report data.

13. Press to select 4)TEST APP. This diagnostic is used only for factory testing.

MODEM EMAIL SUCCESS

MODEM TEST TIME

SET SUCCESS

TEST APP OFF

Cat. No. 01021713

This diagnostic is used only for factory testing.

Service and Maintenance 65

Prefilter Cartridge Replacement

The prefilter cartridges should be changed when the pressure drop across the prefilter increases by 15 psi (103 kPa). Refer to the diagram in the installation section.

CAUTION! The pressure after the prefilter should not be less than 15 psi (103 kPa), or the pump

might be damaged.

Replacing the Prefilter Cartridge

1. Turn the unit OFF, then shut off the inlet water supply.

2. Unscrew the filter bowl.

3. Remove the old cartridge.

4. Clean the filter bowl with a damp cloth, rinse thoroughly.

5. Remove the wrappers from a new cartridge (10" P/N 01022387, 20" P/N 01000222). Install the cartridge in the bowl, making sure it seats in the bottom of the bowl.

6. Check the O-ring seal for dryness and cuts. Replace the seal if necessary and use silicone lube as needed.

CAUTION! Do not use petroleum-based lubricants, which destroy the synthetic rubber seal.

7. Screw the filter bowl back onto the filter head.

8. Turn on the inlet water supply.

Membrane Replacement

Replace an element that has been damaged or cannot be cleaned. (Refer to Figure 35).

1. Turn off the system. Allow pressure to be completely relieved. Turn main feed line to RO off.

2. Remove retaining clips from both ends of all vessels. Do not dispose of retaining rins. They will be needed during replacement.

3. Remove end caps from all vessels, with the tubing remaining in place. Note placement of the caps to assure re-installation in the same orientation.

4. Remove the RO element from the housing. Note orientation of membranes to assure re-installation in same orientation. Brine seal will be facing the incoming feed to the vessel. Flow direction is indicated by the arrow on the outside of the membrane vessel.

5. Check the o-ring seals on the element and end plug, and the element brine seal for damage. If an O-ring is cut or crimped, it may have caused high flow and poor quality. Replace the O-rings and retest before replacing the entire element.

6. Remove a new element from its plastic bag. Lightly lubricate the O-rings with a silicone-based lubricant or use a mixture of 70% glycerin and 30% water.

CAUTION! DO NOT use a petroleum-based lubricant, because it will damage the synthetic rubber

and the membrane.

7. Make sure the brine seal is located in the direction of the incoming feed to that vessel according to the flow arrow and the original membrane orientation.

66 Culligan® Series G1 Reverse Osmosis

66 Cat. No. 01021713

8. Lubricate the O-ring on the end plugs with a silicone-based lubricant or use a mixture of 70% glycerin and 30%

Screws

water. Re-install the end plugs in to the vessels same as the original orientation. Reinstall the retaining clips.

9. Refer to the section on Initial Startup for information on flushing the shipping solution form the new elements.

NOTE Do not forget to record the new values for flow, pressure, temperature, and TDS.

Retaining Rings

End Cap

O-Rings

Housing

FLOW

Membrane

Brine Seal

Figure 35. G Series membrane.

Pump Replacement

The pump should be replaced when it cannot develop the pressure required to maintain the appropriate pressure. The most common cause of pump failure is inadequate pressure to the pump inlet. Therefore, correct any low inlet pressure problem before replacing the pump to prevent damage to the new pump. Replace the pump when it cannot develop the pressure required to maintain the desired product flow rate, up to the maximum pump pressure of 225 psig.

To replace the pump:

1. Turn the unit OFF, then shut off the inlet water supply.

2. Remove the tubing from the pump inlet and outlet.

3. While holding the bottom of the pump with one hand, loosen the screw on the coupling band securing the pump

to the motor. The pump will drop down. Remove the coupling band.

4. Examine the pump shaft. If it is broken or rounded, remove the old shaft and install a replacement shaft, P/N

01000331. Examine the slot in the motor. If the slot is damaged, replace the motor.

5. Remove the plumbing fittings from the old pump, apply fresh Teflon tape, and install the fittings in the new

pump. (Skip this step if replacing only the shaft.)

6. Place the coupling band over the shaft end of the new pump. Insert the pump shaft into the slot in the motor.

7. Observe the alignment of the pump against the motor, making certain the pump and motor flanges are in com-

plete contact and are not skewed.

Cat. No. 01021713

Service and Maintenance 67

8. Make sure the clamp is fully seated around the entire circumference of the pump and motor flanges. Tighten the coupling screw fully, then loosen the screw 1/4 to 1/2 turn.

9. Rotate the pump so that the inlet and outlet ports point to the right. Verify that the pump is still aligned properly to the motor.

CAUTION! If the pump is not properly aligned, the pump bearings will wear prematurely.

10. Tighten the coupling screw using 15 to 30 inch-pounds of torque, then attach the inlet and outlet.

Motor Replacement

1. Disconnect the pump from the motor as outlined in steps 1-4 in pump replacement section.

2. Disconnect the motor cord from the old motor.

3. Remove the pump and motor assembly from the mounting bracket by removing the four (4) nuts, lock-washers and washers, holding the motor onto the motor mounts.

4. Mount the new motor onto the motor mounts and secure with nuts and washers.

5. Wire the motor cord connections to the new motor as indicated on the wiring schematic on the motor label for 110 volt operation.

6. Reinstall the pump, fittings and tubing following steps 7 through 10 as outlined in the pump replacement section on page 67.

NOTICE Some replacement motors may be prewired for 220 Volt operation at shipment. Refer to wiring

schematic on the motor label and verify that the motor is wired for 110 Volt operation.

68 Culligan® Series G1 Reverse Osmosis

68 Cat. No. 01021713

Sanitizing Modules

The modules may need sanitizing if either of the following conditions exist:

• The RO system is subject to biofouling and the operator wants to reduce the cleaning frequency.

• The water treatment application limits the microbial count in the product water.

CAUTION! The bottom of the tank must be higher than the pump on the RO unit to prevent cavita-

tion of the pump when solution is drawn from the tank.

NOTICE Replace the prefilter cartridges if they are discolored by iron.

The frequency of sanitization will depend on the frequency of biofouling or excess microbial counts. Once the frequency of the problem has been determined, sanitization can be scheduled for preventative maintenance. To sanitize the system, obtain a tank which will hold the sanitizing solution volume.

NOTE When cleaning the 1-series RO units that use brass pumps and solenoid valves, do not use a cleaning

agent with a pH below 5.0.

CAUTION! Always use caution when handling any chemical. Refer to the material safety data

sheet for recommendations in the safe handling of this chemical. The MSDS is available from the manufacturer of the chemical. Use the proper protective safety equipment.

CAUTION! Local codes may prohibit the discharge of hazardous materials to drain. If necessary,

an extra tank can be used to neutralize the solutions before discharge to drain.

Prepare Equipment for Sanitizing

1. Prepare the cleaning solution (see Table 5 and Table 6) with permeate water for a five-gallon solution.

2. Choose OFFLINE from the product status menu.

3. Disconnect the product line from service and direct the line into a drain.

4. Turn off the inlet water supply.

Max Temp 45°C (113°F) pH Range Max Temp 35°C (95°F) pH Range Max Temp 25°C (77°F) pH Range

5–10.5 5–12 5–13

Table 5. pH range and temperature limits during cleaning.

Cat. No. 01021713

Service and Maintenance 69

Cleaner

Foulant

Inorganic Salts (e.g. CaCO

Sulfate Scales (CaSO

Metal Oxides (Iron)

Inorganic Colloids (Silt)

Silica Alternative Preferred

Biofilms Alternative Preferred

Organic Alternative Preferred

)

0.1% (W) NaOH and pH 12,

35°C max. or 1% (W) Na4EDTA

and pH 12, 35°C max.

Preferred

Table 6. Cleaning solutions.

0.1% (W) NaOH and pH 12,

35°C max. or 0.025% (W) Na-

DSS and pH 12, 35°C max.

Preferred

1.0% (W) Na2S2O4, 25°C and pH 5

Preferred

Service the Filter and Tubing

1. Remove the sediment filter from the cartridge.

2. Install the bowl without the filter.

3. Connect the tubing from the solution bucket to the feed flowmeter.

4. Change the pressure switch setting from NORMALLY OPEN to NORMALLY CLOSED. See “Switch Inputs

Settings” on page 39.

5. Disconnect the concentrate tubing from the membrane to the motor panel and direct the tubing to the drain.

Draw the Sanitizing Solution Through the Unit

1. Choose GO TO RUNNING from the main menu to turn on the unit

2. Allow about half of the sanitizing solution to be drawn through the system.

CAUTION! If the unit vibrates severely, the pump may be cavitating. Turn the power switch OFF.

Raise the bucket to ensure adequate pressure to the pump.

3. Choose GO TO OFFLINE from the main menu.

4. Allow the unit to sit undisturbed for at least two hours.

NOTICE If the unit is going to be left unused for up to three months, allow the solution to remain in the unit.

If the unit will remain unused for longer than three months, sanitize the unit every three months.

Flush the Unit

1. Connect the inlet water supply.

2. Choose GO TO RUNNING from the main menu.

3. Slowly close the recirculation and drain valves until the system operating pressure increases to normal pressure.

NOTE Increase the pressure no faster than 5 psi per second.

70 Culligan® Series G1 Reverse Osmosis

70 Cat. No. 01021713

4. Allow the unit to run for at least 30 minutes. Check the product water until the pH for the concentrate and prod-

uct remains stable for five (5) minutes and the TDS is greater than 95 percent rejection.

5. Choose GO TO OFFLINE from the main menu.

6. Connect the concentrate tubing from the membrane to the motor panel.

7. Reconnect the product tubing to the service line. Install the new sediment filter.

8. Change the pressure switch setting to NORMALLY OPEN.

The system is now ready for use.

Testing

If the product flow calculations or NFLOW values show a loss of flow, or the product quality has become poor, one or more elements will require cleaning or replacement. Because poor performance might be due to only one element, test the product flow and quality from individual housings.

To test each element:

1. Disconnect the product tubing from the housing to be tested.

2. Choose GO TO RUNNING from the main menu.

3. Measure the product flow and TDS from the test element.

4. Choose GO TO OFFLINE from the main menu.

5. Reinstall the tubing.

6. Continue testing the elements as needed to determine which should be cleaned or replaced.

Cleaning

During the operation of any reverse osmosis system, dissolved solids and particulate matter are concentrated inside the module element. If these contaminants are present in relatively low concentrations, the concentrate flow from the system flushes them to drain. In most cases, water pretreatment such as filters and softeners will prevent the deposit of these contaminants.

When these deposits occur, there will be a decrease in the product water flow and quality. When these symptoms become excessive, the modules must be cleaned before they are permanently damaged.

To determine when cleaning is needed, compare the current system performance to the performance of the system when the reverse osmosis elements were new. Use Table 7 to obtain data and compare the performance of the system, “new” and “now” (record the data in pencil).

Test Data Feed Product Concentrate

New Now New Now New Now

Flow (gpm)

TDS (ppm)

Pressure (psi)

Temp. (°F)

Table 7. System performance—new vs. present.

NOTICE If new data is not available, use the specifications listed earlier in these instructions. However,

keep in mind that the new elements may have exceeded these specifications, so performance may have decreased even if the unit still exceeds specifications.

In addition to differences in product flow and quality (TDS), determine whether there were any changes in concentrate water flow, feed water TDS, feed water temperature and feed or product pressures. Changes in these values provide clues to indicate the cause of any problems with the product water.

Cat. No. 01021713

Service and Maintenance 71

If there were changes in feed water temperature or pressure, the product water flow rates will have to be converted to flow rates under standard conditions (77° F and 200 psig) in order for any comparison to be valid. Refer to the Product Flow Calculation section to calculate flow rates under standard conditions, then compare the converted values. A decrease in the product water flow may have been due only to a decrease in temperature or pressure, in which case cleaning would not be indicated.

If any change in the performance of the elements was not due to a change in operating conditions, it may be time to clean the elements. In general clean the elements:

1. When the product flow rate decreases by 10% (or when the feed pressure must be increased by 10% to maintain the same product flow), or

2. When the percent of rejection decreases below specification.

NOTICE Because strong chemicals are used to clean the elements, maintenance cleaning is not recom-

mended. If the elements need to be cleaned frequently (more than twice a year), the pretreatment may be inadequate. Obtain a current water analysis and test the Silt Density Index and the Total Chlorine level of the water on-site to review what changes in pretreatment may be needed.

When cleaning is required, the type of material which is fouling the element should be identified, if possible. Refer to Table 8 to determine the possible causes of the performance change.

Percent

Rejection

Low Hardness Scale Hardness Scale (light) or Iron Membrane Damage

High Silt or Biofouling — Membrane Damage (light)

For example, if the product flow is low but the percent rejection is normal, the likely causes of the problem are silt or biofouling. Please note that if the product flow rate has increased (with no increase in temperature or pressure) the likely reason is damage to the membrane, which cannot be repaired by cleaning.

Once the foulant has been identified, choose the recommended cleaning chemical(s) from Table 9.

Membrane Problem Cleaning Chemical

Hardness Scale Hydrochloric acid, phosphoric acid

Iron Hydrochloric acid, phosphoric acid

Silt Phosphoric acid and sodium hydroxide

Biofouling Phosphoric acid and sodium hydroxide

Because phosphoric acid can be used by itself or in combination with sodium hydroxide to clean almost all types of foulants, it is generally recommended over hydrochloric acid when choosing a “stock” acid.

NOTICE Some municipal surface water supplies are treated with alum. Aluminum fouling results in low flow

and, occasionally, in low rejection. If aluminum fouling is suspected, use only hydrochloric acid.

Use a pH meter to prepare acid and caustic solutions, and to monitor pH changes as the solutions react with any foulants.

Materials required:

1. Solution tank (50 gallon capacity, minimum), to prepare and store the chemical solution.

2. Tank stand, to elevate solution tank to level above pump.

3. Tubing 1/2” O.D. to connect cleaning adapter ahead of Pre-filter.

4. A pH meter.

5. A pre-filter cartridge (P/N 00955004).

Before proceeding record the “NOW” values in Table 7.

Low Normal High

Table 8. Performance change possible causes.

Table 9. Recommended membrane cleaning chemicals.

Flow

72 Culligan® Series G1 Reverse Osmosis

72 Cat. No. 01021713

Prepare the Equipment for Cleaning

1. Choose GO TO OFFLINE from the main menu.

2. Place the solution tank on the tank stand. Connect the tubing to the cleaning adapter then place the other end

of the tubing at the bottom of the solution tank.

NOTICE The tubing length should be as short as possible to prevent excessive pressure drop. Cut the tub-

ing as required to minimize the length.

3. Remove the product tubing from the service connection and place the end in the solution tank. The concentrate

tubing should still be directed to drain.

4. Replace the Pre-filter cartridge.

5. Choose GO TO RUNNING from the main menu.

6. Fill the tank with 30-40 gallons of RO product water.

CAUTION! DO NOT turn on the RO system unless water can flow from the product and waste

lines.

NOTE Soft water is an acceptable substitute for RO water. When the solution tank is filled, direct the prod-

uct tubing to drain. Next, open the pump system pressure control valve until the system pressure is approximately 50 psig.

7. Choose GO TO OFFLINE from the main menu. Remove wires from terminals 3 and 4 (Pressure switch) and

install a jumper wire across those two terminals.

8. Open the cleaning valve to allow feed water to displace air in the cleaning tubing, then close the inlet water

shutoff valve.

Clean the Tank

1. Choose GO TO RUNNING from the main menu.

CAUTION! If the pump is noisy, cavitation is occurring and the pump will be damaged. Turn the

power switch OFF and check for any obstructions to flow. Reduce the pump pressure as required to prevent cavitation.

2. Record the pump pressure and measure the product water flow at low pressure. This flow will be used to esti-

mate if cleaning has been successful. Turn the power switch to OFF.

3. Add enough acid to the solution tank until the pH is between 2.0 and 2.5.

NOTE If the foulant to be removed is silt or a biofilm, use phosphoric acid.

WARNING! Acid and Sodium Hydroxide are strong chemicals that must be handled carefully to

avoid injury. Wear protective clothing and have a source of water nearby to flush any spills.

CAUTION! Local codes may prohibit the discharge of acid and caustic solutions to drain. If

necessary, an extra tank can be used to neutralize the solutions before discharging to drain.

4. Choose GO TO RUNNING from the main menu. After approximately 5 gallons have been drawn from the solu-

tion tank, Choose GO TO OFFLINE from the main menu.

5. Allow elements to soak for 15 minutes. Choose GO TO RUNNING from the main menu. Draw another 5 gallons

from the solution tank. Choose GO TO OFFLINE from the main menu.

Cat. No. 01021713

Service and Maintenance 73

6. Remove the end of concentrate tubing from the drain and place it in the solution tank.

7. Choose GO TO RUNNING from the main menu. Allow the acid solution to circulate for 30 minutes. During recirculation, monitor the pH of the solution. If the pH rises above 3.0, add acid to reduce the pH to 2.0.

CAUTION! The temperature of the chemical solution will rise as it is recirculated. If the temper-

ature exceeds 95°F, turn the power switch to OFF and allow the solution to cool to prevent damage to the RO elements.

NOTE A plastic gallon jug filled with ice may be placed in the solution to cool it.

8. When 30 minutes have passed, adjust the system pressure to the pressure recorded in Step 9. Measure the product flow rate, then compare this flow to the flow recorded in Step 9. If cleaning is successful a noticeably higher product flow should now be observed.

9. Choose GO TO OFFLINE from the main menu. If the cleaning was for removal of hardness scale or iron only, go to “Finish Cleaning Procedure”

Clean Silt or Biofouling

1. If the cleaning was for silt or biofouling, take a 250 ml sample of phosphoric acid solution and carefully add sodium hydroxide until the pH is at least 12. If the solution turns cloudy, it contains hardness and/or iron. Discard the contaminated acid and prepare a fresh 30 gallons of phosphoric acid solution.Add sodium hydroxide to the phosphoric acid solution. The pH of the solution should be increased to 11.0-11.5.

NOTE The result is an alkaline solution of tri-sodium phosphate (TSP), a common ingredient in detergents.

2. If the solution remains clear, then direct the concentrate tubing to drain, then choose GO TO RUNNING from the main menu. Check that the unit is drawing chemical solution.

CAUTION! If the pump is noisy, cavitation is occurring and the pump will be damaged. Choose

GO TO OFFLINE from the main menu and check for any obstructions to flow. Reduce

the pump pressure as required to prevent cavitation..

3. After approximately 5 gallons have been drawn from the solution tank, choose GO TO OFFLINE from the main menu.

4. Allow the elements to soak for 15 minutes. Turn the power switch to ON. Draw another 5 gallons from the solution tank. Choose GO TO OFFLINE from the main menu.

5. Remove the end of concentrate tubing from the drain and place it in the solution tank. Choose GO TO RUNNING from the main menu. Allow the alkaline solution to circulate for 30 minutes. During recirculation monitor the pH of the solution. If the pH drops below 10.0 add sodium hydroxide to increase the pH to 11.5.

NOTE If the caustic solution becomes dark brown (like coffee), it probably is saturated with organic material.

Discard the solution and prepare a fresh batch of phosphoric acid and sodium hydroxide.

For more accurate testing, use a Hach Model DE-2 detergent test kit or equivalent to ensure that the product water is less than 0.05 ppm detergent.

A plastic gallon jug filled with ice may be placed in the solution tank to cool the solution.

CAUTION! The temperature of the chemical solution will rise as it is recirculated. If the tempera-

ture exceeds 95°F, choose GO TO OFFLINE from the main menu and allow the solution to cool to prevent damage to the RO elements.

74 Culligan® Series G1 Reverse Osmosis

74 Cat. No. 01021713

Finish Cleaning Procedure

1. When 30 minutes have passed, adjust the system pressure to the pressure recorded during low pressure.

Measure the product flow rate, then compare this flow to the flow recorded during low pressure. If cleaning is successful a noticeably higher product flow should now be observed.

2. Choose GO TO OFFLINE from the main menu. Remove the concentrate and product tubing from the solution

tank and direct them both to drain. Choose GO TO RUNNING from the main menu to draw most of the remaining cleaning solution from the tank.

CAUTION! Do not allow the unit to draw air from the tank, or the pump will be damaged.

3. Choose GO TO OFFLINE from the main menu. Close the cleaning valve, reconnect the wires to the pressure

switch, then open the feed water valve.

4. Choose GO TO RUNNING from the main menu and flush the cleaning solution from the unit for 30 minutes or

until the pH levels of the concentrate water and the product water remain constant.

CAUTION! Soft water must be used to flush the caustic solution, or hardness will precipitate. If

soft water is not available, use temporary portable exchange softener tanks.

5. Adjust the system pressure to the normal value. Measure all flows, TDS levels, pressures, and temperature.

Compare these values with the “new” and “now” values to determine if cleaning has been successful. If cleaning has not been successful, contact the service department at Culligan International Company for suggestions on alternate cleaning chemicals. If cleaning has been successful, note which chemicals were effective. Use the same chemical(s) when the unit is cleaned again.

6. Replace the Pre-filter cartridge.

7. After cleaning and rinsing have been completed, connect the product tubing to the service line. Remove the

jumper installed and reconnect the pressure switch. Rinse the cleaning tank and tubing with fresh water.

Cat. No. 01021713

Service and Maintenance 75

GBE RO Controller Menu Structure

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76 Culligan® Series G1 Reverse Osmosis

76 Cat. No. 01021713

Cat. No. 01021713

GBE RO Controller Menu Structure 77

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FWR***LT04 MON DD YEAR

Cat. No. 01021713

GBE RO Controller Menu Structure 79

G1 RO Parts Diagrams and Lists

Series G1 Major Components and Water Connections

From Membrane Product 1/2” Tube

System Product 1/2” Tube

Figure 36. G1 RO front view.

To Membrane Feed 1/2” Tube

System Waste 3/8” Tube

From Membrane Concentrate 3/8” Tube

System Inlet 1/2” Tube

80 Culligan® Series G1 Reverse Osmosis

Figure 37. G1 RO rear view.

80 Cat. No. 01021713

G1 RO Series 2S 3S 4S 2L 3L 4L 1F 2F

Item Part No. Description Qty Qty Qty Qty Qty Qty Qty Qty

1 01024508 Motor Panel Assembly, G1-2S, 3S, 4S 1 1 1

1 01024517 Motor Panel Assembly, G1-2L, 3L 1 1

1 01024518 Motor Panel Assembly, G1-4L 1

1 01024519 Motor Panel Assembly, G1-1F, 2F 1 1

2 01021992 Assembly, Feed, G1 1 1 1 1 1 1 1 1

3 01021993 Assembly, Return, G1 1 1 1 1 1 1 1 1

4 01021994 Assembly, Drain w/Solenoid Flush, G1 1 1 1 1 1 1 1 1

5 01024512 Assembly, Product Flow Meter, G1 1 1 1 1 1 1

5 01024520 Assembly, Product Flow Meter, G1-1F, 2F 1 1

6 01021997 Assembly, Pressure Gauge, G1/Q1/V1 1 1 1 1 1 1 1 1

7 01022855 Pump, Rotary Vane, Brass, 100 GPH 1 1 1

7 01023798 Pump, Rotary Vane, Brass, 165 GPH 1 1

7 01023800 Pump, Rotary Vane, Brass, 190 GPH 1

7 01022106 Pump, Rotary Vane, Brass, 330 GPH 1 1

8 01022856 Motor, 1/3 HP, 115V, 1725 RPM, Nema

Frame 48Y, Carbonator Mount Style

8 01022107 Motor, 3/4 HP, 115V, 1725 RPM, Nema

Frame 48Y, Carbonator Mount Style

9 01022033 V-Band, Pump/Motor 1 1 1 1 1 1 1 1

10 01021033 Flow Meter, Inlet, 1/2" NPT—see page 22 1 1 1 1 1 1 1 1

– 01022706 Flow Meter, Inlet, 1/2" NPT 1 1 1

11 01025480 Filter Housing, 10" BB 1 1 1 1 1 1 1 1

12 01022387 Cartridge Filter, 5 micron, 10" 1 1 1 1 1 1 1 1

13 01022145 U-Bend, PI 1 1 1 1 1 1 1 1

14 01022144 Check Valve, Inline 1 1 1 1 1 1 1 1

15 01024455 Bracket Kit, Wall Mount 1 1 1 1 1 1

15 01024484 Bracket Kit, Wall Mount 1 1

16 01023412 Assembly, Membrane Housing, Single,

2.5"x21"

16 01023417 Assembly, Membrane Housing, Single,

2.5"x40"

16 01022875 Assembly, Membrane, Single, 4”x40” 1 2

17 01021977 GROC Controller—see page 10. 1 1 1 1 1 1 1 1

18 01025825 Cable, Meter, 48"L w/ Strain Relief 1 1 1 1 1 1 1 1

1 1 1

1 1 1 1 1

2 3 4

Cat. No. 01021713

G1 RO Parts Diagrams and Lists 81

Feed Assembly and Solenoid Cable

Figure 38. Manual feed assembly (includes solenoid cable).

Item Part No. Description Quantity

01021992 Assembly, Feed (items 1–8)

1 — Tee, 1/2", Threaded, PVC Sch. 80 1

2 — Male Adapter, 1/2" Spigot x NPT, Sch. 80 4

3 — Elbow, 1/2" Soc, PVC Sch. 80 1

4 — Bushing, 1/2 x 1/4, SxT, PVC Sch. 80 1

5 01023380 Solenoid Assy, 120V/60Hz with bullet connectors 1

— 01023070 Solenoid Coil, Repl, 110-120V/50–60Hz 1

6 01007604 Pressure Gauge, 1/4" NPT, 0–200 PSI, Liquid filled 1

7 — Tee, 1/2" Socket, PVC Sch. 80 1

8 — Plug, 1/2", Spig 1

9 01024477 Cable, Solenoid, E1/M1/G1 1

82 Culligan® Series G1 Reverse Osmosis

82 Cat. No. 01021713

Return/Recycle Assembly and Pressure Transducer

To Pump Inlet

Figure 39. Return/Recycle assembly with pressure transducer.

Item Part No. Description Quantity

01021993 Assembly, Return (items 1–11)

1 — 1/2" Sch.80 Pipe, 3.5" length 1

2 — Tee, 1/2” Socket, PVC Sch.80 1

3 — Tee, 1/2", Threaded, PVC Sch.80 1

4 — Male Adapter, 1/2" Spigot x NPT, Sch.80, Spears 861-005 1

5 — Bushing, 1/2"x1/4", TxT, PVC Sch.80 1

6 01024302 Switch, Adjustable Pressure, 6–30 PSI 1

7 — Bushing, 1/2”x1/4”, SxT, PVC Sch.80 1

8 — Stem Adapter, 1/2T x 1/2 Stem, Polypropylene 1

9 — Elbow, Union, 1/2 Tube, Polypropylene 1

10 — Elbow, 1/2” Soc, Sch.80, Spear 806-005 1

11 — Connector, Male, 1/4 NPT x 3/8 Tube, PI, Polypropylene 1

12 01022370 Cable, Pressure, Transducer, 39"L 1

Cat. No. 01021713

G1 RO Parts Diagrams and Lists 83

Drain Assembly with Fast Flush Solenoid Valve

From Last Membrane

(Concentrate)

To Return Assembly

Out To Drain

Figure 40. G1 drain assembly with fast flush solenoid valve.

Item Part No. Description Qty

01021994 Drain Assembly (items 1–18)

1 01022013 Needle Valve, 1/4" FNPT, Brass 2

2 — Nipple, 1/4 x Close, PVC Sch. 80, TBE 1

3 — Tee, 3/8", Socket, PVC Sch. 80 2

4 — Bushing, 3/8 x 1/4, SxT, PVC Sch. 80 2

5 — Pipe, 3/8", Sch. 80, Length 1.75" 2

6 — Elbow, 3/8 Soc x FNPT, Sch. 80, Spears 807-003 1

7 — Bushing, 1/2 x 3/8, TxT, PVC Sch. 80 1

8 — Nipple, 3/8 x Close, PVC Sch. 80, TBE 1

9 — Bushing, 3/8 x 1/4, SxS, PVC Sch. 80 1

10 — Connector, Male, 1/4 NPT x 3/8 Tube, PI, Polypropylene 2

11 — Tee, Union, 3/8 Tube, Polypropylene, PI 1

12 — Tube, 3/8", cut length 3" 1

13 — Tube, 3/8", cut length 2" 2

14 — Nipple, 1/4 x 1-3/4, PVC Sch. 80, TOE 1

15 — Stem Adapter, 1/4T x 3/8 Stem, Polypropylene 1

16 — Connector, Male, 1/2 NPT x 3/8 Tube, PI, Polypropylene 1

17 — Elbow, Union, 3/8 Tube, PI, Polypropylene 1

18 01023380 Solenoid Valve, 1/2” NPT, 120V/60Hz, Wiring Harness 1

01023070 Replacement Coil for Solenoid

19 01024477 Cable, Solenoid 1

84 Culligan® Series G1 Reverse Osmosis

84 Cat. No. 01021713

Product Assembly

11.53

REF.

NOTE DIRECTION OF FLOW METER

Product from Membrane Assy

Figure 41. G1 Product Assembly.

Product Outlet

For G1 2S, 3S, 4S, 2L, 3L, 4L

Item Part No. Description Qty

01024512 Assembly, Product Flow Meter, G1

1 — Nipple, 1/2"x5, PVC Sch. 80, TBE 1

01021033 Adapter Assembly, Flow Meter,

3 — Tee, 1/2", Threaded, PVC Sch. 80 1

4 — 1/2"-1/2" NPT Tube, Male Connector 2

5 01024516 Sensor, TDS, 24"L with 5 Pos Conn 1

6 01025827 Harness, Meter, 28" Long 1

7 01022706 Nozzle, Flow Meter 1

1/2" NPT

For G1 1F, 2F

Item Part No. Description Qty

01024520 Assembly, Product Flow Meter, G1-1F,

1 — Nipple, 1/2"x5, PVC Sch. 80, TBE 1

01021033 Adapter Assembly, Flow Meter,

3 — Tee, 1/2", Threaded, PVC Sch. 80 1

4 — 1/2"-1/2" NPT Tube, Male Connector 2

5 01024516 Sensor, TDS, 24"L with 5 Pos Conn 1

6 01025827 Harness, Meter, 28" Long 1

7 — NOT USED

1/2” NPT

Cat. No. 01021713

G1 RO Parts Diagrams and Lists 85

System Pressure Gauge Assembly

Figure 42. Pressure Gauge Assmbly.

Item Part No. Description Quantity

01021997 System Pressure Gauge Asembly

1 — Bushing, 1/2"x1/4", TxT, PVC Sch. 80 1

2 — Tee, 1/2”, Threaded, PVC Sch. 80 1

3 — 1/2”-1/2” NPT Tube, Male Connector 2

4 01007604 Pressure Gauge 1

86 Culligan® Series G1 Reverse Osmosis

86 Cat. No. 01021713

Membrane Vessel

Housing

Screws

Retaining Rings

End Cap

O-Rings

FLOW

Membrane

Brine Seal

Figure 43. Membrane vessel.

Item Part No. Description 1S 2S 3S 4S 2L 3L 4L 1F 2F

01023417 Assy, Membrane Housing, Single, 2.5"x40" 2 3 4

01023412 Assy, Membrane Housing, Single, 2.5"x21" 1 2 3 4

01022875 Assy, Membrane Housing, Single, 4"x40" 1 2

1 01022666 Housing, 2.5"x21"Membrane 1 2 3 4

1 01022825 Housing, 2.5"x40"Membrane 2 3 4

1 01022877 Housing, Filter, FRP 4" End Port 1 2

2 01024288 Membrane, 2.5"x21" 1 2 3 4

2 01024289 Membrane, 2.5"x40" 2 3 4

2 01024290 Membrane, 4"x40" 1 2

3 01023071 End Cap Assy 2.5" 2 4 6 8 4 6 8

3 01023073 End Cap Assy 4" 2 4

4 01023072 O-Ring kit 2.5" 1 2 3 4 2 3 4

4 01023074 O-Ring Kit 4" 1 2

01023411 Clamps, RO Housings, 2.5" 1 2 3 4 2 3 4

01023075 Clamps, RO Housings, 4" 2 4

Housing assemblies do not include membranes.

Cat. No. 01021713

G1 RO Parts Diagrams and Lists 87

Feed Flow Meter Sub-Assembly

Figure 44. G1 feed flow meter sub-assembly.

Item Part No. Description Qty.

01021033 Feed Flow Meter 1

1 P1009099 O-ring, Meter #126 2

2 01021877 Meter Body Assembly with Impaller, O-Rings 1

3 01022706 Nozzle for low flow (used on feed flow meter for G1-2S, 3S, 4S) 1

88 Culligan® Series G1 Reverse Osmosis

88 Cat. No. 01021713

2S/2L Sub-Assembly

Note

orientation

of flow

PRODUCT

Used Only When Mounting on Floor Stand

FEED

Top View

A = to Feed Port B = to Recirculating Assy C = to Center Port (Product)

Figure 45. 2S/2L sub-assembly.

Bottom View

Item Part No. Description Quantity

01023412 Assembly, Membrane Housing, Single, 2.5"x21" (2S)

01023417 Assembly, Membrane Housing, Single, 2.5"x40" (2L)

01023907 Kit, Tube and Fittings, 2S, 2L (includes items 1–8)

1 — Elbow, Union, 3/8 Tube, PI, Polypropylene 3 EA

2 — Tube, 3/8", cut length 3" 1 EA

3 — Tube, 1/2", Length 3.5" 1 EA

4 — Stem Adapter, 1/4Tx3/8 Stem, Polypropylene 6 EA

5 — Elbow, Union, Reducing, 1/2 x 3/8, PI, Polypropylene 2 EA

7 — Elbow,1/2 Stem x 1/2T,PI 1 EA

8 — Plug, 1/4" NPT, PVC Sch 80 2 EA

Cat. No. 01021713

— Tee, Union, Reducing, 1/2 Ends, 3/8 Branch, PI,

Polypropylene

G1 RO Parts Diagrams and Lists 89

1 EA

3S/3L Sub-Assembly

Note orientation

of flow

For Recirculating Assembly on Motor Panel

Used Only When Mounting on Floor Stand

Bottom View

PRODUCT

Top View

FEED

A = to Feed Port B = to Recirculating Assy C = to Center Port (Product)

Figure 46. 3S/3L sub-assembly.

Item Part No. Description Qty

01023412 Assembly, Membrane Housing,

01023417 Assembly, Membrane Housing,

01023908

— Elbow, Union, 3/8 Tube, PI,

— Tube, 3/8", cut length 4.4"

— Tube, 1/2", Length 4.25"

— Stem Adapter, 1/4Tx3/8 Stem,

Single, 2.5"x21"

Single, 2.5"x40"

Kit, Tube and Fittings, 3S, 3L

(includes items 1–9)

Polypropylene

5 EA

2 EA

9 EA

Item Part No. Description Qty

— Fitting, Union, Reducing, 1/2 x

3/8, PI, Polypropylene

— Tee, Union, Reducing, 1/2 Ends,

3/8 Branch, PI, Polypropylene

— Elbow,1/2 Stem x 1/2T,PI

— Plug, 1/4" NPT, PVC, Sch 80

— Elbow, 3/8" stem, 3/8 tube

2 EA

1 EA

3 EA

90 Culligan® Series G1 Reverse Osmosis

90 Cat. No. 01021713

4S/4L Sub-Assembly

Note Orientation

of Flow

Used Only When Mounting on Floor Stand

PRODUCT

Bottom View

Top View

FEED

A = to Feed Port B = to Recirculating Assy C = to Center Port (Product)

Figure 47. 4S/4L sub-assembly.

Item Part No. Description Qty

01023412 Assembly, Membrane Housing,

01023417 Assembly, Membrane Housing,

01023909

— Elbow, Union, 3/8 Tube, PI,

— Tube, 3/8", cut length 4.4"

— Tube, 1/2", Length 4.25"

Single, 2.5”x21”

Single, 2.5"x40"

Kit, Tube and Fittings, 4S,4L

cludes items 1–8)

Polypropylene

(in-

7 EA

3 EA

Item Part No. Description Qty

— Stem Adapter, 1/4Tx3/8 Stem,

Polypropylene

— Elbow, Union, Reducing, 1/2 x

3/8, PI, Polypropylene

— Tee, Union, Reducing, 1/2 Ends,

3/8 Branch, PI, Polypropylene

— Elbow,1/2 Stem x 1/2T,PI

— Plug, 1/4” NPT, PVC, Sch 80

2 EA

3 EA

1 EA

4 EA

Cat. No. 01021713

G1 RO Parts Diagrams and Lists 91

G1-1F Sub-Assembly

92 Culligan® Series G1 Reverse Osmosis

Figure 48. G1-1F sub-assembly.

92 Cat. No. 01021713

Item Part No. Description Quantity

01022875 Assembly, Membrane Housing, Single, 4.0"x40"

01023922 Kit, Tube and Fittings, 1F (includes items 1–7)

—

Elbow, Union, Reducing, 1/2 x 3/8, PI, Polypropylene 1 EA

Elbow, Plug In, 3/8" stem, 3/8 tube 3 EA

Elbow, Union, 1/2 Tube, Polypropylene 2 EA

Stem Adapter, 1/2Tx1/2 Stem, Polypropylene 3 EA

Plug, 1/2" NPT, PVC Sch 80 1 EA

BUSHING,3/4x1/2,TxT,PVC SCH.80, 2 EA

Carton, Tubing and Fittings Kit 1 EA

Cat. No. 01021713

G1 RO Parts Diagrams and Lists 93

G1-2F Sub-Assembly

94 Culligan® Series G1 Reverse Osmosis

Figure 49. G1-2F sub-assembly.

94 Cat. No. 01021713

Item Part No. Description Quantity

01022875 Assembly, Membrane Housing, Single, 4.0"x40"

01023914 Kit, Tube and Fittings, 2F (includes items 1–8)

1 — Elbow, Union, Reducing, 1/2 x 3/8, PI, Polypropylene 1 EA

2 — Elbow, Union, 1/2 Tube, Polypropylene 4 EA

3 — Stem Adapter, 1/2Tx1/2 Stem, Polypropylene 6 EA

4 — Plug, 1/2" NPT, PVC Sch 80 2 EA

5 — BUSHING,3/4x1/2,TxT,PVC SCH.80, 4 EA

6 — Tee, Union, 1/2 Tube, PI, Polypropylene 1 EA

7 — Elbow,1/2 Stem x 1/2T,PI 1 EA

8 — Tube, 1/2", Length 7.5" 2 EA

Cat. No. 01021713

G1 RO Parts Diagrams and Lists 95

Controller Sub-Assembly

Figure 50. G1 Controller front panel.

Figure 51. G1 Controller main and auxiliary boards.

96 Culligan® Series G1 Reverse Osmosis

96 Cat. No. 01021713

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

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

G1 RO Features

G1 RO Series Specifications

G1 RO System Configurations

G1 RO Installation

GBE RO Controller Program Data

First Time Setup

Basic Operation

Setup

Accessories

Error Limits

System Operating Information

Service and Maintenance

GBE RO Controller Menu Structure

G1 RO Parts Diagrams and Lists