Culligan Gold Series, Gold 9"", Gold 10"", Gold 12"", Gold 14 Installation & Operation Instructions

Download

Cat. No. 01018853

Rev. C 08/20/07

DCO # 10083

Installation,

Operation &

Service Instructions

with Parts List

Culligan Gold Series Water Softener

Models from 2006

™

Attention Culligan Customer:

The installation, service and maintenance of this equipment should be rendered by a qualiﬁed and trained service technician. 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.

Warning! 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.

This system is not intended to be used for treating water that is microbiologically unsafe or of unknown quality without adequate disinfection before or after the system.

Culligan International Company

9399 W. Higgins Road, Suite 1100

Rosemont, Illinois 60018

847.430.2800

www.culligan.com

ii Culligan Gold Series® Water Softener

Service Instructions

Culligan Gold Series Water Softener

Installation,

Operation &

with Parts List

™

Models from 2006

Table of Contents Page

Important Safety Information ..........................................i

Introduction ....................................................................2

Performance Speciﬁcations ...........................................3

Preparation ....................................................................4

Basic Principles

Flow Diagrams ...............................................................8

Controller Features ......................................................13

Operation .....................................................................14

Installation ...................................................................16

Programming ...............................................................23

Statistical Data .............................................................35

Manual Cycling ............................................................40

.............................................................6

Table of Contents Page

Final Start-up ...............................................................41

Care and Maintenance

Recommeded Preventative Maintenance ....................44

Error Codes .................................................................46

Diagnostics Troubleshooting

Service .........................................................................58

Wiring Schematics .......................................................61

Appendix A - Flow Rates & Capacities ........................62

Appendix B - Aqua-Sensor® Application Guidelines ....65

Service Parts ...............................................................66

..................................................................48

................................................43

...........................................................50

Table of Contents 1

Introduction

Read this Manual First

Before you operate the Culligan Gold Series™ Water Softening System, read this manual to become familiar with the device and its capabilities.

Watch for Special Paragraphs

Please read the special paragraphs in this manual. Examples are shown below.

The Culligan Gold Series Water Softeners are tested and certiﬁed by WQA against NSF/ANSI Standard 44 for the effective reduction of hardness (calcium and magnesium) and barium/radium as tested and substantiated by test data.

The Culligan Gold Series Water Softeners are tested and certiﬁed by WQA against NSF/ANSI Standard 61 for material requirements.

For installations in Massachusetts, the Commonwealth of Massachusetts Plumbing Code 248 CMR shall be adhered to. Consult your licensed plumber for installation of the system. This system and its installation must comply with state and local regulations. The use of saddle valves is not permitted.

Safe Practices

Throughout this manual there are paragraphs set off by special headings.

Note: Check and comply with your state and local codes. You must follow these guidelines.

Note: Note is used to emphasize installation, operation or maintenance information which is important, but does not present any

hazard. Example:

Note: 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. 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. Example:

Warning! Electrical shock hazard! Unplug the unit before removing the cover or accessing any internal control parts.

Serial Numbers

The control valve serial number is located on the back of the timer case.

The media tank serial number is located on the top surface of the tank.

This publication is based on information available when approved for printing. Continuing design reﬁnement could cause changes that may not be included in this publication.

Note: Do not remove or destroy the serial number. It must be referenced on request for warranty repair or replacement.

Products manufactured and marked 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, Flo-Pak and Soft-Minder are trademarks of Culligan International Company or its afﬁliates.

2 Culligan Gold Series® Water Softener

Performance Speciﬁcations

Control Valve 9” Model

1” Reinforced

Thermoplastic

10” Model

1” Reinforced

Thermoplastic

12” Model

1” Reinforced

Thermoplastic

14” Model

1” Reinforced

Thermoplastic

Overall Conditioner Ht 54 in 60 in 58 in 71 in

Media Tank Design Quadra-Hull

Media Tank

9 x 48 in 10 x 54 in 12 x 52 in 14 x 65 in

™

Quadra-Hull Quadra-Hull Quadra-Hull

Dimensions (Dia x Ht)

Salt Storage Tank

16 x 43 in or 18 x 43 in 18 x 43 in 18 x 43 in 24 x 42 in

Dimensions (Dia x Ht)

Exchange Media, Type

Cullex® Media, 1.0 ft

Cullex Media, 1.5 ft

Cullex Media, 2.0 ft

Cullex Media, 3.0 ft

and Quantity

Underbedding, Type and Quantity

Exchange Capacity @ Salt Dosage Per Recharge

Efﬁciency rated

dosage

Freeboard to Media

Freeboard to Underbedding

Cullsan®

Underbedding, 12 lb

19,086 gr @ 4.0 lb 26,301 gr @ 8.0 lb

30,787 gr @ 12.0 lb

4,770 gr/lb

@ 4 lb salt dosage

Cullsan Underbedding,

15 lb

28,629 gr @ 6.0 lb

39,451 gr @ 12.0 lb

46,180 gr @ 18.0 lb

4,770 gr/lb

@ 6 lb salt dosage

Cullsan Underbedding,

20 lb

35,614 gr @ 8.0 lb 51,659 gr @ 16.0 lb 60,523 gr @ 24.0 lb

4,450 gr/lb

@ 8 lb salt dosage

14.5 in 14.5 in 16 in 25 in

44.5 in 47.5 in 46 in 59 in

Cullsan Underbedding,

25 lb

53,540 gr @ 12.0 lb 77,660 gr @ 24.0 lb 90,986 gr @ 36.0 lb

4,460 gr/lb

@ 12 lb salt dosage

Salt Storage Capacity 250 lb or 375 lb 375 lb 375 lb 600 lb

Rated Service Flow @

9.0 gpm @ 14 psi 9.4 gpm @ 15 psi 10.0 gpm @ 15 psi 10.6 gpm @ 15 psi

Pressure Drop

Total Hardness,

75 gpg 99 gpg 99 gpg 99 gpg

Maximum

Total Iron, Maximum 5 ppm 5 ppm 5 ppm 5 ppm

Hardness to Iron Ratio,

8 gpg to 1 ppm 8 gpg to 1 ppm 8 gpg to 1 ppm 8 gpg to 1 ppm

Minimum

Operating Pressure 20-125 psi 20-125 psi 20-125 psi 20-125 psi

Operating Pressure

20-90 psi 20-90 psi 20-90 psi 20-90 psi

(Canada)

Operating Temperature 33-120°F 33-120°F 33-120°F 33-120°F

Electrical

24V/60 Hz 24V/60 Hz 24V/60 Hz 24V/60 Hz

Requirements

Electrical Power

3 Watts/35 Watts 3 Watts/35 Watts 3 Watts/35 Watts 3 Watts/35 Watts

Consumption, Min/Max

Drain Flow, Maximum

Recharge Time, Average

Recharge

1.6 gpm 1.6 gpm 2.6 gpm 6.6 gpm

68 min 57 min 52 min 55 min

Water

Consumption, Average

35 gal 46 gal 51 gal 176 gal

1 The efﬁciency rated dosage is only valid at the stated salt dosage and is efﬁciency rated according to NSF/ANSI 44. 2 Measured from top of media to top surface of tank threads. (backwashed and drained). 3 Measured from top of underbedding to top surface of tank threads. 4 Backwash at 120 psi (830 kPa). 5 10 minute backwash, 4 lb 9” model, 6 lb. 10” model, 7 lb. 12” model or 12 lb. 14” model salt dosage.

Performance Speciﬁcations 3

Preparation

Component Description

The water conditioner is shipped from the factory in a minimum of four cartons. Remove all components from their cartons and inspect them before starting installation.

Control Valve Assembly - Includes the regeneration control valve and the Accusoft contain additional installation hardware, and the conditioner Owner’s Guide.

Media Tank - Includes Quadra-Hull™ media tank complete with Cullex® ion exchange resin, underbedding and outlet manifold (12” and 14” tanks are shipped without media).

Salt Storage Tank Assembly - Includes salt storage container with support plate and Dubl-Safe™ brine reﬁll valve and chamber.

Bypass Valve - Includes the molded bypass valve, the interconnecting couplings, and the assembly pins.

Tools and Materials

The following tools and supplies will be needed, depending on installation method. Observe all applicable codes.

Note: Check and comply with your state and local codes. You must follow these guidelines.

Plus Controller. Small parts packages will

All Installations

• Safety glasses

• Phillips screwdrivers, small and medium tip.

• Gauge assembly (PN 00-3044-50 or equivalent)

• Silicone lubricant (PN 00-4715-07 or equivalent) - DO NOT USE PETROLEUM-BASED LUBRICANTS

• A bucket, preferably light-colored

• Towels

Special Tools

• Torch, solder and ﬂux for sweat copper connections

• Use only lead-free solder and ﬂux for all sweat-solder connections, as required by state and local codes.

• Threading tools, pipe wrenches and thread sealer for threaded connections.

• Saw, solvent and cement for plastic pipe connections.

Materials

• Brine line, 3/8” (PN 01-0098-19 or equivalent) or 1/2” (P/N 00-9018-00 or equivalent)

• Drain line, 1/2” (PN 00-3030-82, gray, semi-ﬂexible; or PN 00-3319-46, black, semi-rigid; or equivalent)

• Thread sealing tape

• Pressure reducing valve (if pressure exceeds 125 psi [860 kPa], PN 00-4909-00 or equivalent)

• Pipe and ﬁttings suited to the type of installation

• Water softener salt (rock, solar or pellet salt formulated speciﬁcally for water softeners)

Application

Water quality - Verify that raw water hardness and iron are within limits. Note the hardness for setting the salt dosage and

recharge frequency.

Iron is a common water problem. The chemical/physical nature of iron found in natural water supplies is exhibited in four general types:

1. Dissolved Iron - Also called ferrous or “clear water” iron. Up to 5 ppm of this type of iron can be removed from the water by the same ion exchange principle that removes the hardness elements, calcium and magnesium. Dissolved iron is soluble in water and is detected by taking a sample of the water to be treated in a clear glass. The water in the glass is initially clear, but on standing exposed to the air, it may gradually turn cloudy or colored as it oxidizes.

4 Culligan Gold Series® Water Softener

2. Particulate Iron - Also called ferric or colloidal iron. This type of iron is an undissolved particle of iron. A softener will remove larger particles, but they may not be washed out in regeneration effectively and will eventually foul the ion exchange resin. A ﬁltering treatment will be required to remove this type of iron.

3. Organic Bound Iron - This type of iron is strongly attached to an organic compound in the water. The ion exchange process alone cannot break this attachment and the softener will not remove this type of iron.

4. Bacterial Iron - This type of iron is protected inside a bacteria cell. Like the organic bound iron, it is not removed by a water softener.

When using a softener to remove both hardness and up to 5 ppm of dissolved iron it is important that it regenerates more frequently than ordinarily would be calculated for hardness removal alone. Although many factors and formulas have been used to determine this frequency, it is recommended that the softener be regenerated when it has reached 50 - 75% of the calculated hardness alone capacity. This will minimize the potential for bed fouling (iron removal claims have not been veriﬁed by the Water Quality Association or Underwriters Laboratories).

If you are operating a water softener on clear water iron, regular resin bed cleaning is needed to keep the bed from coating with iron. Even when operating a softener on water with less than the maximum of dissolved iron, regular cleanings should be performed. Clean every six months or more often if iron appears in your conditioned water supply. Use resin bed cleaning compounds carefully following the directions on the container. Hardness sample kits are available through your local Culligan dealer.

Caution! Do not use where the water is microbiologically unsafe or with water of unknown quality without adequate disinfection before or after the unit.

Pressure - If pressure exceeds 125 psi (860 kPa), install a pressure reducing valve (see materials checklist). On private water systems, make sure the minimum pressure (the pressure at which the pump starts) is greater than 20 psi (140 kPa). Adjust the pressure switch if necessary.

Caution! The use of a pressure reducing valve may limit the ﬂow of water in the household.

Temperature - Do not install the unit where it might freeze, or next to a water heater or furnace or in direct sunlight. Outdoor

installation is not recommended and voids the warranty. Use the Culligan Outdoor Gold Series softener for outdoor installations. The Culligan Outdoor Gold Series softener has been certiﬁed by Underwriter’s Laboratories for outdoor installation. If installing in an outside location, you must take the steps necessary to assure the softener, installation plumbing, wiring, etc. are as well protected from the elements (sunlight, rain, wind, heat, cold), contamination, vandalism, etc. as when installed indoors.

Location

Space requirements - Allow 6-12 inches (15-30 cm) behind the unit for plumbing and drain lines and 4 feet (1.3 meters) above

for service access and ﬁlling the salt container.

Floor surface - Choose an area with solid, level ﬂoor free of bumps or irregularities. Bumps, cracks, stones and other irregularities can cause the salt storage tank bottom to crack when ﬁlled with salt and water.

Drain facilities - Choose a nearby drain that can handle the rated drain ﬂow (ﬂoor drain, sink or stand pipe). Refer to the Drain Line Chart, Table 3 (page 21), for maximum drain line length.

Note: Most codes require an anti-siphon device or airgap. Observe all local plumbing codes and drain restrictions. The system and installation must comply with all state and local laws and regulations.

Electrical facilities - A 10-foot cord and wall mount plug-in transformer are provided. The customer should provide a receptacle, preferably one not controlled by a switch that can be turned off accidentally. Observe local electrical codes.

Note: P.N. 01012956 and P.N. 01018133 plug-in transformer are rated for indoor installations only. P.N. 01015972 plug-in transformer is rated for indoor/outdoor installations. (Non-Aqua-Sensor®)

Note: The softener works on 24 volt - 60 Hz power only. Be sure to use the included transformer. Be sure the electrical outlet and transformer are in an inside location to protect from moisture. Properly ground to conform with all governing codes and ordinances.

Preparation 5

Basic Principles

Brine Tank Cover

Brine Tank

Salt Plate

Brine Valve

Brine Chamber

Terms

Brine - A solution of water and salt used to regenerate the resin.

Distributor - A pipe with slits that allows the water to enter and leave inside the media tank.

Media - The underbedding and resin the media tank holds.

Regenerate - A process where the resin once exhausted of its softening capabilities is revitalized to soften again.

Resin - The actual material that softens hard water, shaped like little beads.

Underbedding - A gravel mixture that keeps the resin from entering the distributors.

Brine Tank - Figure 1

Refer to section “Filling the Salt Storage Container”, page 21 for proper Brine Tank usage.

Media Tank - Figure 2

The letters underneath the component’s description refer to the values listed on Appendix A, Table 2

- Media Volumes and Freeboard.

6 Culligan Gold Series® Water Softener

What is Hard Water?

Water is said to be hard when it carries too high a concentration of calcium and magnesium. Acceptable water hardness levels will vary depending on the application.

How Does it Work?

The components of dissolved minerals are called ions. They carry either a positive or negative charge. Hardness ions of minerals dissolved in water carry a positive charge. These positively charged ions (cations) are attracted to a synthetic softening material called ion exchange resin.

The heart of the softening system, therefore, is a deep bed of resin which draws calcium and magnesium ions, as well as ferrous iron, from the water as it passes through the resin bed.

Can the Resin Draw Out Hardness Ions Indeﬁnitely?

No. During normal operation, the resin becomes saturated with positive ions and functions less efﬁciently. When hardness leakage occurs, the resin should be regenerated to restore its efﬁciency.

How Do You Regenerate Resin?

You regenerate a resin bed by removing the mineral ions through a process called “ion exchange”. This regeneration process occurs in four steps and takes approximately 50 to 70 minutes. Each of the following steps are graphically depicted on pages 8 - 12.

1. Backwash - During the backwash step, raw water ﬂows rapidly upward (in reverse direction to the service ﬂow) through the resin bed to expand the bed and ﬂush out accumulated dirt, sediment and other sources of turbidity.

2. Brine Draw - The brine solution consisting of water and salt is drawn from a brine storage tank and allowed to ﬂow slowly down through the resin bed. The brine solution removes the calcium and magnesium ions from the resin.

3. Slow Rinse - Brine draw is then followed by a raw water slow rinse. This rinse step will slowly remove most of the remaining brine, exchanged calcium and magnesium ions from the resin.

4. Fast Rinse - Slow rinse is followed by a raw water ﬂush, a very rapid down ﬂow of raw water which removes the last traces of brine, and settles the resin bed.

How Often Must You Regenerate?

Frequency must be determined for each installation based on the amount of water usage, its degree of hardness and the amount of resin through which it ﬂows. In some cases it is necessary to utilize a resin cleaner when the raw water contains iron. Contact your local Culligan dealer for more information.

How Do You Control the Regeneration Process?

The regeneration process for the water softener is controlled automatically either on a predetermined time, volume, or external signal basis through the use of the Culligan Accusoft Plus controller with optional Aqua-Sensor® or ﬂow sensor. The regeneration process can also be initiated manually by the operator as required.

Basic Principles 7

Flow Diagrams

Service

Refer to Figure 3

Raw water is allowed in the inlet to the top of the tank. The water is run through the resin up the manifold to the outlet. The water to the outlet should be soft if the system is operating properly.

Figure 3

8 Culligan Gold Series® Water Softener

Backwash

Refer to Figure 4

Raw water is directed down the center of the manifold, up through the resin, out the top of the tank to drain. The water to drain should be hard.

Figure 4

Flow Diagrams 9

Regenerant Draw

Refer to Figure 5

Raw water is directed from the inlet through the nozzle and into the throat. A vacuum is created and concentrated brine is educted (drawn). The raw water and concentrated brine combine, enter the mineral tank, and pass through the resin, up the manifold and to the drain. Once all of the brine has been educted and the brine valve seats, the unit goes into slow rinse. Hard water is allowed to service during regeneration.

Figure 5

10 Culligan Gold Series® Water Softener

Slow Rinse

Refer to Figure 6

Raw water is directed from the inlet through the nozzle and into the throat. A vacuum is created but the brine valve has seated, so no brine is educted. The raw water enters the mineral tank, passes through the resin, up the manifold and to the drain. Hard water is allowed to service during regeneration.

Figure 6

Flow Diagrams 11

Fast Rinse/Reﬁll

Refer to Figure 7

Raw water is directed from the inlet, through the eductor and inlet to the top of tank, down the resin, up the manifold, out to drain and brine line until the correct amount of water is in the brine tank. Hard water is allowed to service during regeneration.

Figure 7

12 Culligan Gold Series® Water Softener

FAST

RINSE

& REFILL

Controller Features

The Culligan Gold Series™ control’s primary function is to initiate and control the regeneration process via methods that are most convenient and cost effective for the customer while offering many operation features and beneﬁts.

Features

• Power Source

Electrical power required for the control is 24-VAC 50/60 Hz. A plug-in

transformer (120v/24v) is provided

• Battery Backup

Battery backup is available as an optional ﬁeld add-on. The battery backup

will maintain the time of day for a minimum of 4 weeks using a 3.6V 1/2AAlithium type battery as supplied by Culligan (PN 01013839).

• EEPROM

Saves programmed and statistical functions.

• Lock/Unlock

Allows the control to be easily locked out from inadvertent program changes or

abuse. This feature can be disabled if desired.

• Time of Day

Displays current time in either 12 hour (AM/PM) or 24 hour format.

• Regeneration Interval

Provides an ability to initiate a time clock back-up operated system on a

number of days (range from 1 to 99 days).

• Program Beeper

Emits an audible beep when key pads are depressed to help identify valid

(short beep) or invalid (3 short beeps) key pad touches. Can be enabled or disabled as desired.

Figure 8

Controller Features 13

Operation

Modes of Operation

Water Meter Mode

In water meter mode, the controller keeps track of the quantity of water that has ﬂowed through the resin bed. Based on the inﬂuent water hardness and the hardness capacity of the resin bed, a service life expectancy in the quantity of softened water is calculated and programmed into the control. When the set point is reached, regeneration is triggered. In delay regeneration mode, if the predict mode is turned on, the average daily water usage will be compared to the remaining capacity at the regeneration delay time to predict if another day’s water usage can occur before requiring regeneration. If enough capacity is not present then the regeneration will occur at that time. If the predict mode is not selected, the regeneration will start at time of regeneration. If time clock backup is set and the capacity has not been exhausted, the softener will regenerate when days since last regeneration equal time clock back up. In immediate mode the regeneration starts when the capacity is exhausted.

Aqua-Sensor® Mode

The Aqua-Sensor is a conductivity probe that senses when a hardness front passes through the resin bed. It functions independently of the inﬂuent water hardness so therefore, is useful in conditions when the inﬂuent water hardness varies throughout the year. It provides for the most efﬁcient mode of operation. In addition to sensing when a resin bed is exhausted, it can also be used to determine when the brine solution is rinsed from the resin bed during the Brine Draw / Slow Rinse cycle triggering the control to move to fast rinse. This patented feature provides water savings by optimizing the amount of rinse water required to completely rinse out the resin bed.

Time Clock Backup Mode

This setting is used as a backup feature for either the meter or Aqua-Sensor modes of regeneration. It provides regeneration when a set period of time has elapsed. If the meter or Aqua-Sensor does not trigger regeneration prior to the time clock backup value, the time clock backup will trigger the regeneration.

Manual Regeneration

Pressing and holding the regen button for 3 seconds will initiate regeneration. The beeper is to give one beep at the start of manual regeneration (cam starts to turn). In delay mode, pressing and releasing the regen button will light the regen icon for regeneration to occur at the set delay time. Pressing and releasing the regen button again will turn off the regen icon. This function is active in the Service mode and Diagnostic mode. In the diagnostic mode, toggling the “Up” key will advance to the next valve position while the regeneration is in process until home is reached. The information will not be updated if the last cycle of regeneration does not automatically complete (The “Up” key is pressed to cycle the control to the next position).

Predict Mode

The Predict Mode is used in the ﬂow meter mode to determine the optimum regeneration point. Before the regeneration starts, the control will compare the remaining capacity value with the average daily water use. If the average daily water usage is less than the remaining capacity, the controller will wait 24 more hours before regeneration. If the remaining capacity is less than the average daily water usage, the control will initiate regeneration. This works in delay mode only. At any time, if the total capacity value is reached, the control will initiate an immediate regeneration (Unless “delay” is set in the hidden menu; in this case, the control will always wait until the time of regeneration to regenerate).

14 Culligan Gold Series® Water Softener

Efﬁciency Mode

Water softeners historically use an optimum time range to control the Regeneration cycle steps with a minimum and maximum time required to perform each step dependent on the salt being used, the hardness total and iron level. Culligan typically uses the maximum time range to ensure effective Regeneration. However, if the iron content of the water to be softened is zero, and the hardness level is less than 20 gpg, Culligan has developed a new set of regeneration times geared to reducing salt and water usage. These times are deﬁned under a new operating mode coined “Efﬁciency Mode” (Not available if DIP switches #6 or #9 are on). When in Efﬁciency mode, the control will reﬁll for a higher salt dosage once every 10 regenerations according to tank size as shown in the following table.

Tank Sizes Salt Dosages (lbs)

9 x 48 10

10 x 54 15

12 x 52 20

14 x 65 30

Pre-Rinse Mode

The Pre-rinse mode is used in the Time Clock, Flow Meter, and Aqua Sensor® softener modes, as well as in Flow Meter Filter mode, to pre-rinse the softener resin bed or ﬁlter media DIP switch 9 must be set to “on”. The pre-rinse in ﬂow meter mode will occur after the control has sensed that no water has ﬂowed through the control for a period of X hours (can be set through the programming menu). When the control is in this mode, once the X amount of hours have elapsed the control will cycle to the fast rinse position for the pre-set length of minutes and then return to the home or service position. For Time Clock or Aqua Sensor modes the pre-rinse will occur at a ﬁxed time then return to the home or service position.

Note: Be sure to set the brine safety level ﬂoat to the proper position when using this mode since the reﬁll step also occurs in the fast rinse position. failure to do so will result in a higher salt dosage than anticipated.

Operation 15

Installation

Note: Read this section entirely before starting the installation. Follow all applicable plumbing and electrical codes.

With the exception of media containers, open the remaining containers, remove all the components, and inspect them before starting installation.

Placement

Refer to ﬁgure 9 for system placement.

• Set the media tank on a solid, level surface near water, drain and electrical facilities.

• Set the brine system on a ﬂat, smooth, solid surface as near the media tank as possible.

Tank Assembly

Before the unit can be connected to the plumbing the manifold distributors must be assembled and the underbedding and resin must be loaded into the tank for 12” and 14” tanks.

Caution! Do not lay the tank down unless a suitable lifting device is available. Personal injury and damage to the unit can result if dropped.

Position the Mineral Tank(s)

Determine the location for the mineral tanks(s) prior to loading, since they will be difﬁcult to move after the underbedding and gravel are loaded.

16 Culligan Gold Series® Water Softener

Figure 9

Loading the Tank (12” and 14” Tanks)

Small Aqua-Sensor

Plug

1. Position the tank so that the Culligan® logo is in the front.

2. Remove the inlet strainer.

3. Install the outlet manifold into the tank (Figure 10).

4. Cover the tops of the manifolds with a clean rag.

5. Using a large-mouth funnel, load the Culligan underbedding through the top of the tank.

Caution! DO NOT allow the outlet manifold to move when loading the media. The manifold must remain vertical to ensure a good seal at the gasket. Rap the tank near the bottom with a rubber mallet to level the sand.

6. Aqua-Sensor® Installation (optional device)

A. Measure the sensor cable

length as shown in Figure 10 and Table 1 (the Aqua-Sensor cord is set at the factory for a 9” tank).

B. Loosen the small Aqua-Sensor

Plug, a needle-nose pliers works best.

C. Moisten the cable sheath and

slide the cable grip up or down to the proper cable length.

D. Tighten the small Aqua-Sensor

plug so that the ﬁtting cannot

Dimension “X” is the exposed length the Aqua-

Sensor

cord (cord length from the Aqua-Sensor plug to the circuit board connector). You can then verify the Aqua-Sensor probe is inserted to the proper depth by conﬁrming dimension “X” is at the corrected length.

Tank Model X Y

9” Quadra-Hull™ Tank 34 1/2” 40”

10” Quadra-Hull Tank 30 1/2” 44”

12” Quadra-Hull Tank 32 1/2” 42”

14” Quadra-Hull Tank 22 1/2” 52”

Table 1

slide along the cable.

Note: There must be no kinks or bends in the cable.

E. Insert the probe and cable through the Aqua-Sensor port.

7. Load the tank with the Cullex® ion exchange resin. Leveling is not required. Remove the funnel.

8. Install the inlet strainer making sure to thread the strainer until it bottoms out on the tank thread. Failure to install the strainer correctly can cause the control to leak.

Figure 10

Figure 11

Installation 17

Mount the Control Valve

Valve - Adapter O-ring

Tank Adapter

Adapter - Tank O-ring

Tank Clamp

See Figure 12 for a visual on mounting the control valve to the tank.

• Assemble the o-rings, located in the parts pack, to the tank adapter.

• The valve adapter o-ring sits on the ﬁrst step on the adapter. See Figure 13.

Note: Do not push the top o-ring down to the ﬂange surface on the adapter.

Note: The larger of the two o-rings in the parts part goes between the adapter and the valve, do not stretch the smaller

o-ring onto the top of the tank adapter.

• Lubricate only the top o-ring on the tank adapter, and the outlet manifold o-ring with silicone lubricant.

• Screw the adapter into the tank until the adapter bottoms out on the tank ﬂange.

Note: The adapter only needs to be tightened hand-tight to the tank ﬂange.

• Align the manifold with the center opening in the valve, and press the valve onto the adapter ﬁrmly.

Note: Make sure to push the valve straight down onto the manifold. If the valve is cocked, it may cause the o-ring to slip off the manifold.

• Assemble the tank clamp to the control, and tighten the clamp screw.

Note: The clamp and valve will be able to rotate on the tank until pressure is applied.

Figure 13

Figure 12

18 Culligan Gold Series® Water Softener

Flow Control Eductor Nozzle

Listed below is the recommended eductor nozzle to be used at various salt dosages.

Refer to Figure 14 for a visual on changing the eductor nozzle and the backwash ﬂow control.

Table 2 - Flow Restrictors

Unit Backwash Flow Nozzle Throat Brine Reﬁll Flow

9” 2.0 gpm (#2 Brown) Blue* Light Brown* 0.45 gpm

10” 2.0 gpm (#2 Brown) Beige Light Brown 0.45 gpm

12” 3.5 gpm (#3 Green) Beige Light Brown 0.8 gpm

14” 5.5 gpm (Black) Green Blue 0.8 gpm

* Standard from factory

Eductor Nozzle Replacement:

• Remove the three screws on the eductor cap and remove the cap.

• Remove the eductor assembly.

• Remove the eductor screen from the assembly

• Remove the blue nozzle and replace it with the beige nozzle. Make sure to put the o-ring on the correct nozzle.

• Reverse the procedure to reassemble. To prevent leaks, ensure that the gasket is in the proper position.

Backwash Flow Control Replacement:

• Remove the drain clip and pull the drain elbow straight off.

• Remove the backwash ﬂow control located behind the elbow.

• Install the correct backwash ﬂow control.

Note: The number on the ﬂow control should face into the valve body.

• Reverse the procedure to reassemble.

Note: Dip switch #5 is to be in the “off” position for 9” and 10” Tanks (0.45 gpm reﬁll ﬂow control). Dip switch 5 is to be in the “on” position for 12” and 14” tanks (0.80 gpm brine reﬁll ﬂow control).

Plumbing Connections

Shipped with each softener is a Culligan® bypass valve, which is used to connect the softener to the plumbing system. The bypass allows the softener to be isolated from the water service line if service is necessary while still providing water to the home. The bypass valve can be directly plumbed into the system, or can be connected with the following optional sweat connection kits.

• P/N 01010783 1” Sweat Copper Adapter Kit

• P/N 01016564 3/4” Sweat Copper Adapter Kit

• P/N 01016565 3/4” Elbow Sweat Copper Adapter Kit

Caution! Close the inlet supply line and relieve system pressure before cutting into the plumbing! Flooding could result if not done!

Caution! When making sweat connections, use care to keep heat away from the plastic nuts used to connect the plumbing to the bypass. Damage to these components may result otherwise.

Installation 19

Bypass Valve Installation

About 1-1/4”

A screwdriver shank may be used in the slot as a lever for extra turning force if needed.

Bypass

Assembly Pin

Brine Connection

Coupling or Meter Body

Coupling

Assembly Pin

The bypass valve connects directly to the control valve with a pair of couplings and two assembly pins (Figure

15). Lubricate all o-rings on the couplings with silicone lubricant.

On Soft-Minder® meter controls, the meter replaces the coupling on the outlet side of the control. The meter body ﬁts in the same space as the coupling between the control valve and the bypass. Make sure that the arrow on the ﬂow meter is pointing in the direction of ﬂow (Figure 15).

Note: If the ground from the electrical panel or breaker box to the water meter or underground copper pipe is tied to the copper water lines and these lines are cut during installation of the bypass valve, an approved grounding strap must be used between the two lines that have been cut in order to maintain continuity. The length of the grounding strap will depend upon the number of units being installed. In all cases where metal pipe was originally used and is later interrupted by the bypass valve to maintain proper metallic pipe bonding, an approved ground clamp c/w not less than #6 copper conductor must be used for continuity. Check your local electrical code for the correct clamp and cable size.

To bypass, turn the blue knob clockwise (see directional arrow on end of knob) until the knob stops as shown. DO NOT OVERTIGHTEN! (Figure 16a).

To return to service, turn the blue knob counter-clockwise (see directional arrow on the end of knob) until the knob stops as shown. DO NOT OVERTIGHTEN! (Figure 16b)

Figure 15

Figure 16a

Drain Line Connection

Refer to Table 3, under the applicable tank size for drain line length and height limitations.

• Remove 1/2” pipe clamp from the small parts pack included with the control.

• Route a length of 1/2” drain line from the drain elbow to the drain.

• Fasten the drain line to the elbow with the clamp.

• Secure the drain line to prevent its movement during regeneration. When discharging into a sink, or open ﬂoor drain, a loop in the end of the tube will keep it ﬁlled with water and will reduce splashing at the beginning of each regeneration.

Note: Waste connections or drain outlets shall be designed and constructed to provide for connection to the sanitary waste system through an air gap of 2 pipe diameters or 1 inch, whichever is larger.

Note: Observe all plumbing codes. Most codes require an anti-siphon device or air gap at the discharge point. The system and installation must comply with state and local laws and regulations.

20 Culligan Gold Series® Water Softener

Figure 16b

Height of Discharge Above Floor Level Operating - Table 3

“A” Dimension

Operating Pressure 0 ft (0 m) 2 ft (0.6 m) 4 ft (1.2 m) 6 ft (1.8 m) 8 ft (2.4 m) 10 ft (3 m)

30 psi (210 kPa) 60 ft (18 m) 50 ft (15 m) 30 ft (9 m) 15 ft (5 m) Not allowable Not allowable

40 psi (279 kPa) 100 ft (30 m) 90 ft (27 m) 70 ft (21 m) 50 ft (15 m) 30 ft (9 m) 12 ft (4 m)

50 psi (349 kPa) 145 ft (41 m) 115 ft (35 m) 80 ft (24 m) 80 ft (24 m) 60 ft (18 m) 40 ft (12 m)

60 psi (419 kPa) 100 ft (30 m) 100 ft (30 m) 85 ft (26 m) 60 ft (18 m)

80 psi (559 kPa)

100 psi (699 kPa)

Normal installation should not require

more than 100 ft (30 m) of drain line

140 ft (43 m) 120 ft (37 m)

150 ft (46 m)

Fill The Salt Storage Container

Fill the salt storage container with water until the level reaches about 1 inch above the salt support plate. Pour salt into the container. Fill with salt to within a few inches of the top.

Brine Valve “A” Dimension

The Culligan Gold Series™ unit contains a brine ﬂoat which can serve as a backup reﬁll shutoff in the event of a failure, such as a power outage when in the reﬁll position. The ﬂoat level should be set based on the salt dosage setting. Refer to Figure 17.

• Remove nut retaining brine valve to brine chamber.

• Lift the brine valve from the brine chamber.

• Find the correct “A” dimension from Appendix A, Table 5.

• Set the distance from the top of the ﬁlter screen to the base of the ﬂoat accordingly. The slight difference in height when the ﬂoat is pulled up or down is negligible.

• Re-install into brine chamber and replace nut.

Aqua-Sensor® Probe and Soft-Minder® Meter Connection

To connect the probe or meter leads refer to Figure 21 and proceed as follows:

• Remove the timer case from the back plate.

• Snap the circuit board holding plate off the back plate to provide access to the back of the circuit board.

• Remove the plastic plug from the backplate.

• Slip the sensor probe lead or meter cable through the hole and toward the circuit board.

Note: The strain relief located on the back of the wire connection for the Aqua-Sensor probe may have to be removed in order to ﬁt it through the backplate. Replace the strain relief if you need to remove it for assembly.

• Connect the lead to the circuit board. The Aqua-Sensor probe terminal is labeled “Aqua-Sensor” while the Soft-Minder meter terminal is labeled “Flow Meter”.

• Pull any excess cable wire back out of the enclosure, and route the wiring inside the enclosure to avoid any interference with moving parts.

• Locate the strain relief bushing in the parts pack. Place it on the cable at the point of entry to the rear of the timer plate and push it into the hole.

Note: The wire connectors must be connected to the circuit board properly. The wires must exit the plug-in connector opposite of the raised white base of the circuit board connector. Failure to properly connect any of the connectors will result in a malfunction of the circuit board operation.

Dip Switches

Optional Battery

Figure 18

Power

Motor

Installation 21

Cam

Switches

Aqua-

Sensor

Figure 17

Soft-

Minder

Meter

Connect the Brine Line

• Measure a length of brine line sufﬁcient to reach from the brine tank to the brine ﬁtting, with no sharp bends. For easier access to the ﬂoat it is recommended to add an extra four feet (1.3 meters) of length to the brine line. Cut both ends of the brine line squarely and cleanly.

• Slip the white nut over one end of the tubing and press the plastic insert into the end of the tubing (Figure 19). Connect to the brine valve and tighten nut.

• Remove white nut and plastic insert from the small parts pack.

• Slip the white nut over one end of the tubing and press the plastic insert into the end of the tubing (Figure 19). Connect to the brine connection on the valve and tighten nut.

Figure 19

Electrical Connection

Note: Observe all state and local electrical codes.

The power cord needs to be connected to the plug-in transformer. Figure 20 shows the cord attachment to the transformer. The Aqua-Sensor® probe requires a 2.5 VAC power source. This source is provided via two of the posts on the 24V/2.5V transformer. Two leads from the transformer must be wired to the 2.5 VAC terminal on the circuit board. The wire connector from the Aqua-Sensor probe is simply plugged in the circuit board (Figure 21).

Caution! Failure to connect power to the correct terminals will damage the circuit board!

Power to circuit board, 2.5 VAC for Aqua-Sensor installation

Figure 20

22 Culligan Gold Series® Water Softener

2.5 VAC Aqua-

Sensor

Power

Figure 21

24 VAC

Power

White

Red

Black

Blue or Green

Aqua-Sensor Wiring

Programming

Switch Deﬁnitions

The circuit board is shipped with all DIP switches in the off position. Prior to programming the controller some DIP switches may need to be moved to the ON position. Because each switch serves a speciﬁc purpose, please review the following information, moving the required switches to an ON position as necessary for each controller in the system. The deﬁnitions and purpose are as follows:

Switch No. Abbreviation Deﬁnition Purpose

1 R/T Run / Test Off - Allows controller to function in a normal, operational mode.

On - Places controller in test mode to verify operation of the board components software.

2 SO / FI Softener /

Filter

3 4C / 5C Valve

Selection

4 - / other Valve

Selection

Override

5 S / F Standard

Reﬁll / Fast

Reﬁll

6 D / I Demand /

Immediate

7 E / M English /

Metric

8 12 / 24 12 Hour

Clock / 24

Hour Clock

9 – / ADV Advanced

Features

Off / On

10 – / TCB Time Clock

Back-up

Disabled /

Enabled

Off - The unit shall be operated as a softener.

On - The unit shall function as a ﬁlter. The default time programmed for cycle #2 shall be 2 minutes.

Off - 4 cycle Gold.

On - 5 cycle Platinum / 7125.

Off -

On - 4 or 5 cycle auto-detect “other” mode.

Off - The 0.45 gpm reﬁll ﬂow control is used to control the reﬁll ﬂow rate. Set in the off position for 9” and 10” units.

On - The 0.80 gpm reﬁll ﬂow control is used to control the reﬁll ﬂow rate. Set in the on position for 12” and 14” units.

Off - Regeneration of a unit will occur at a user-selected time of day.

On - Regeneration shall occur immediately upon a controller receiving a valid regeneration initiation signal, regardless of the time of day.

Off - The unit will function in standard English dimensions.

On - The unit will function in standard metric dimensions.

Off - All time keeping functions shall be based on an AM/PM basis. The AM or PM icon shall be lit in the display as appropriate.

On - Time keeping functions shall work on a 24-hour clock (military time). The AM/PM display icons will be disabled.

Off - The Predict Mode and Pre-Rinse Mode will not be activated. (Efﬁciency will be active)

On - The Predict Mode and Pre-Rinse Mode will be activated. (Efﬁciency will not be active)

Off - The time clock backup option is not enabled.

On - Allows the user to enable the time clock function of the control as a backup regeneration initiation option. This feature is used as a back up to a primary device such as a ﬂow meter, Aqua-Sensor®.

Table 4

Dip #3 Dip #4 Control

Off Off Gold

On Off Platinum

Off On Other

On On Other

Note: Dip Switch 5 is to be in the “Off” Position for 9” and 10” tanks (0.45 gpm brine reﬁll ﬂow control). Dip Switch 5 is to be in the “On” position for 12” and 14” tanks (0.80 gpm brine reﬁll ﬂow control).

Table 5

Programming 23

Keypad Functions

Program Key

Display

Regeneration Key

Information Key

Toggle Down

Display Back lit LCD display.

Program Key Depress to enter and move through the programming steps.

Regeneration Key Press and hold the key for three (3) seconds to initiate an immediate regeneration.

When pressed during programming the time of day, this key will allow the user to toggle between the hours and minutes setting of timing program segments.

Information Key Each time depressed, the Information key will display statistical information such a ﬂow rate, time of

day. Use with the Toggle Down key to display other statistical information.

Toggle Down Key In the programming mode this key will move the user through the programming function in a descending

mode. If depressed for greater than three seconds, the rate at which the display scrolls through data will increase.

Toggle Up Key In the programming mode this key will move the user through the programming function in an ascending

mode. If depressed for greater than three seconds, the rate at which the display scrolls through the data will increase.

This key will also allow the user to manually step through the cycles of regeneration.

Toggle Up

24 Culligan Gold Series® Water Softener

Table 6

Programming Menus

The programming menus will vary depending on which devices are connected to the circuit board and dip switch settings. The program menu can be divided into two sections; inputs and outputs. The outputs are calculated based on selected inputs and can be viewed and customized, if desired. The “Program” key allows the user to scroll through and save each setting. Each value is set by using the “up” and “down” arrow keys to increment or decrement. Pressing the “Program” key after value selection saves the selected value. At the end of the inputs section, the user is prompted to “view” the outputs. At this point the user has the option to view and/or customize any calculated output value. The control recognizes any deviation from the calculated values and will prompt the user to “save” custom settings, if desired. To exit the programming mode, repeatedly press the “Program” key until the display returns to time of day display. The following tables outline all of the input/output programming displays, range limits, default settings and hidden menus on pages 26-27.

Programming 25

Inputs

Settings Display Range Limits Default Comments

Beeper

Time of Day

Time of Regen

Meter Factor

Regen Interval

Hardness

Iron

Low Pressure

Salt Type

Predict Mode

Pre-Rinse

Mode

Pre-Rinse

Duration

Pre-Rinse

Hours

Pre-Rinse Time

Efﬁciency

Mode

Gold Tank Size

5-cyc Tank

Size

View

BEEP Y

TOD

TOR

MTR 50.0

DAYS 03

HRD 25

IRON N

LOWP N

Toggle Y / N Y Enables/disables the key press beeper (ERR/

12:00 am-11:59 pm

(12hr)

00:00-23:59 (24hr)

12:00 am-11:59 pm

(12hr)

00:00-23:59 (24hr)

0.5 – 500 50.0

Days - 1 to 99 days 3 days

1 – 99 English 25 - English

Toggle Y or N N

SALT NACL or KCL

PRED N

Toggle Y or N N

PRE -- RINSE.N

Toggle Y or N

RINS 5

HRS0 24

TIME

GOLD 9

SCYC 10

VIEW N

01 – 15 05

1 – 240 24

12:00 am-11:30 pm

(12hr)

00:00-23:30 (24hr)

Toggle

Yes or No

9”, 10”, 12”, 14” 9”

10”, 12”, 14”, 16” 10”

Toggle Y or N N

12:00 pm

12:00

2:00 am

02:00

NaCl

5:00 am

05:00

Alert code beeps can’t be disabled)

12 / 24 hour function set with dip # 8.

Adjustable in 30 minute increments only.

Only active with Flow meter connected and dip # 4 on (other).

Active in Time Clock Mode OR Flow Meter - A/S with dip #10 on

Only active if dip # 4 is off AND dip # 7 is on (N/A in Filter mode)

Only active if dip # 4 is off with ﬂow meter connected (N/A in Filter mode)

Only active if dip # 4 is off.

If pressure is less than 40psi, choose “Y”

Only active if dip # 4 is off with ﬂow meter connected (N/A in Filter mode)

Only active if dip # 9 on AND dip # 6 is off with ﬂow meter connected (N/A in Filter mode)

Only active if dip # 9 is on

Only active if dip # 9 is on with Pre-Rinse mode is set to “Yes”

Only active if dip # 9 is on with Pre-rinse mode set to “Yes” AND ﬂow meter connected

Only active if dip # 9 is on with Pre-rinse set to “Yes”; Adjustable in 30 minute increments only; Available only in TimeClock and AquaSensor mode (not ﬂow meter mode)

Available only if dip # 4 is off with ﬂow meter connected; Iron = N; Hardness <= 20 (English hardness units)

“Efﬁciency Mode” icon lit when enabled (Not available with dips #6or 9 on, or in Filter mode)

Only displayed if dip # 4 is off with a ﬂow meter connected (N/A in Filter mode)

Only active if dip # 4 is off.

If custom output settings are being used, then pressing the “Information” key will recalculate outputs based on current inputs, and exit from the inputs menu

26 Culligan Gold Series® Water Softener

Outputs

Settings Display Range Limits Default Comments

Salt Dosage

Cycle 1 time

Cycle 2 time

Cycle 3 time

Filter Media

Life

Total

Capacity

Set Point-

MAXCAP

Batch

Capacity

Save

DOSAGE

LIFE N

MAXCAP

BATCH

SAVE N

3 – 64 Lbs

1.5 – 29.0 kg

1 to 99 minutes 10 min.

1 to 150 minutes

1 to 40 minutes Calculated based

Toggle (Y or N) N Enable/disable the ﬁlter media life feature (ﬁlter

1 – 999,999

(can’t be set

less than

BATCH)

1 – 999,999

(can’t be set greater than

MaxCap)

Toggle (Y or N) N Only active when the control detects customized

Calculated based

on tank size

(5 min efﬁciency

mode)

Softener mode-

calculated based on

tank size, dosage,

and pressure

Filter mode-

2 minutes

on dosage and dip

# 5 (Gold)

999,999 (other or

ﬁlter); calculated

otherwise

870 (other or Filter);

Calculated for

(Gold, Plat or Euro

softeners)

Only active if dip # 4 is off (N/A in Filter mode); If this is changed, then the appropriate outputs get recalculated (brine rinse, reﬁll and capacities).

Calculated only with dip # 4 off; add 10 minutes to calculation for A/S mode

Fast Rinse/Reﬁll on Gold.

Calculated value for Gold with dip # 4 off.

Operation ONLY)

-Set point to trigger immediate regeneration.

-Only active with ﬂow meter connected.

-Triggers “CHANGE MEDIA” alert in Filter mode.

-Only active with ﬂow meter connected.

-For Gold, Platinum and Europe, the value shown is calculated by control; value may be overridden by user by setting ‘defaults’ to ‘no’

outputs that differ from the last time through the menu; selecting “Y” saves customized settings; selecting “N” re-calculates outputs based on current inputs.

Hidden Menu Items

Settings Display Range Limits Default Comments

Delay / Immed.

Lock / Unlock

DELAY DELAY or

UNLOCK UNLOCK or

IMMED

LOCK

Immed.

Unlock

-Accessible from time display by pressing and holding “Up” and “Down” keys together for 5 seconds; sets whether a regeneration should occur immediately or delayed after a 3 hour or longer power outage; (not while in programming menu).

-If set to Delay, when Maxcap is reached, an immediate regeneration will NOT happen. It will always wait until Tor.

-Lock or unlock access to program changes

-Accessible from time of day display by pressing and holding the “Up” and “DOWN” keys together for 5 seconds; (not while in programming menu)

Programming 27

Display Icons

The display is to be backlit and have the icons as shown below.

Custom LCD Display

Six standard 12-segment alpha-numeric characters, a decimal separating the ﬁrst and second character, a colon separating the second and third character positions, AM, PM, REGEN, EFFICIENCY MODE, TODAY’S, AVG DAILY, WATER USAGE, SOFTWATER, REMAINING, %, MINS, BACKWASH, BRINE RINSE, FAST RINSE, /, REFILL, GALLONS, LITERS, FLOW RATE, GPM, LPM Icons

A further description of each programming setting and the corresponding display is outlined below. For a display that has an icon that is displayed solid for the 2 second time period prior to bringing up the settings, the settings menu can be reached prior to the two second time out by pressing the “Up” or “Down” key.

• Beeper Setting - This setting is used to turn the beeper on or off for each key press actuation. The display will show “bEEP X” where X is either “Y” or “N”. The “Y” or “N” will be toggled with the “Up” and “Down” keys. Setting the Beep option to “N” will only disable the beeper for key press actuation. The beeper will still be active for error and alarm codes.

Pressing the “Program” key will save the setting and move to the next programming

step.

• Time of Day - This setting is used to program the current time of day. When in this step the display will ﬁrst show “tod” for two seconds.

After “tod” is displayed, “12:00 PM” will display (or the current set time if already

programmed) and the minutes will ﬂash. The minutes are adjusted with the “Up” or “Down” key until the correct value is displayed.

Press the “Regen” key to ﬂash the hours.

Adjust with the “Up” or “Down” key until the correct time is displayed.

Pressing the “Program” key will save setting and

move to the next programming step. Pressing “Regen” will move back to the minutes adjust.

• Time of Regeneration - This setting is used to program the time at which a regeneration is to occur in the delay mode, or in immediate mode with time clock backup on. The display will ﬁrst show “tor” for two seconds.

After “tor” is shown the display will then show the default of 2:00 AM (or the current

programmed time of regeneration if already set). The time can be adjusted in 30 minute increments by pressing the “Up” or “Down” keys.

Pressing the “Program” key will save the setting and move to the next programming

step.

Minutes Flashing Hours Flashing

Time Flashing

28 Culligan Gold Series® Water Softener

• Day(s) of Week Regeneration - In the time clock mode only (Meter or Aqua-Sensor® not connected), the following optional days of the week setting will be available to trigger regeneration. The display will show “dAYoWK” for 2 seconds followed by “NO”. The “Up” or “Down” key will toggle “yes” or “no” (default is NO). A “yes” response will indicate that the control is to perform a regeneration on speciﬁc days of the week.

Pressing “Program” will save and advance to the next step. If “NO” was chosen, then the control will only initiate

regenerations based upon the interval (in number of days) and the display will show as shown in Regeneration Interval below.

If “YES” was chosen, then the speciﬁc days

of the week to regenerate will be selected as follows:

The display will show “dAY” for two seconds

followed by “SUN N”. The “regen” key toggles the days of the week and the “Up” and “Down” keys toggle “Y or N”.

Pressing the “Program” key saves and advances to the next step.

If any of the days were set to “yes”, the display

will show “SETDAY” followed by “SUN”. This selects the current day of the week. The “Up” or “Down” key toggles through the days of the week and pressing the “Program” key saves the setting and advances to the next programming step.

If ALL of the days were set to “no”, then speciﬁc day of week regens will be canceled and will appear as shown in

Regeneration Interval below, and the interval will be set in number of days.

Pressing the “Program” key saves the setting and advances to the next programming step.

SUN N

SUN

Note:

1. If any day of the week is set to “yes”, the regeneration interval in number of days (“Days 03”) will no longer appear when going through the programming menu at a later time. To go back from speciﬁc day of week regeneration to interval in number of days, choose “NO” at “dAYoWK”.

2. If a DIP switch is changed anytime (other than run/test dip # 1) after the control has been programmed to regenerate on any speciﬁc day, all settings will revert back to default (“dAYoWK” = NO); speciﬁc days to regenerate and current day will have to be reprogrammed.

• Regeneration Interval - This setting is used to set the days between regeneration in time clock mode. It is also active in meter or Aqua-Sensor mode if the time clock backup DIP switch # 10 is set to on. The display will show “REGEN” icon and “dAYS” as well as the numbers to change. Adjust the value with the “Up” or “Down” keys.

Pressing the “Program” key will save the setting and move to the next programming

step.

Programming 29

• Hardness Setting - This setting is used to set the hardness (grains) of the inﬂuent water supply. For English Units the display will show the Hardness default of “Hrd 25” (or the previously programmed value). Adjust the value with the “Up” or “Down” keys.

(These settings will not get saved to EEPROM until the ‘Program’ key is pressed while

at the “tank size” programming step)

• Iron Setting (ﬂow meter only) - This setting is used to set the iron level of the inﬂuent water supply. The display will show “Iron” in the left most digits and the iron default setting (or the previously programmed value) in the far right digit. The display will only appear if a ﬂow meter is connected to the circuit board and the control is set to Gold. If the iron level is set to “Y”, the Efﬁciency Mode is inactive. Adjust the value with the “Up” or “Down” keys.

Pressing the “Program” key will temporarily store the setting and move to the next

programming step. (This setting will not get saved to EEPROM until the ‘Program’ key is pressed while at the “tank size” programming step)

• Pressure Setting - This setting is used to set the inﬂuent water pressure. The display will show “LowP” in the left most digits and the pressure default setting in the far right digit. If the pressure is less than 40 psi, chose “Y”. By choosing “Y” the brine Rinse time will be extended. Adjust the value with the “Up” or “Down” keys.

Pressing the “Program” key will temporarily store the setting and move to the next

programming step.

• Salt Type (ﬂow meter only) - This setting is used to select the regeneration salt type (softener mode only). This display will only appear if dip # 4 is off. The display will show “SALt” for 2 seconds. Then display the default ‘NACL’. Pushing the “Up” or “Down” keys will change to ‘KCL’.

Pressing the “Program” key will temporarily store the setting and move to the next programming step. (This setting will not

get saved to EEPROM until the ‘program’ key is pressed while at the “tank size” programming step)

• Predict Mode (ﬂow meter only) - This setting will only be displayed if dip # 9 is on, dip # 6 is off, and a ﬂow meter is connected. Only available in softener mode. The display will show “PRED” in the left most characters and toggle between “Y” and “N” in the right most character with the “Up” and “Down” keys.

Pressing the “Program” key will save the setting and move to the next programming

step.

• Pre-Rinse Mode - This setting will only be active if dip # 9 is on. The display will show “PRE-” for two seconds and then “RINSE” in the left most characters of the display. When “RINSE” is shown the right most character of the display will ﬂash “N” and toggle to “Y” with the use of the “Up” or “Down” keys.

Pressing the “Program” key will save the setting and move to the next programming step.

30 Culligan Gold Series® Water Softener

• Pre-Rinse Time Duration - This setting is used to set the length of time that the control will be in the fast rinse position before returning to the Service (Home) position. The display will show “RINS” and XX where XX is the length in minutes that the control is to pre-rinse as well as the “FAST RINSE” icon. Adjust the XX value with the “Up” and “Down” keys.

Pressing the “Program” key will save the setting and move to the next programming

step.

• Pre-Rinse Hours - This setting will only be active if the Pre-Rinse mode is set to ‘Yes’ and a ﬂow meter is attached to the control. The display will show “HOUR” in the left most characters and “XX” in the right most digits where “XX” represents the hours setting from 01 - 99. The hours setting is adjusted with the “Up” and “Down” keys.

Pressing the “Program” key will save the setting and move to the next programming

step.

• Pre-Rinse Time of Day - This setting will only be active if the Pre-Rinse mode is set to ‘Yes’ and the control is operating in time clock or Aqua-Sensor

mode (without a meter). The Display will show “TIME” for 2 seconds and then the ﬂashing time display as in the time of regeneration display. The time can be adjusted in 30 minute increments with the “Up” and “Down” keys.

Pressing the “Program” key will save the setting and move to the next programming step.

• Efﬁciency Mode (ﬂow meter only) - Efﬁciency mode will only be active if the conditions as explained earlier are met (Not available if DIP switch # 6 or DIP switch # 9 are on). The “EFFICIENCY MODE” Icon will be displayed with a default of “YES”. Toggle between “YES” and “NO” with the “Up” or “Down” key.

Pressing the “Program” key will temporarily store the setting and move to the next

programming step. (This setting will not get saved to EEPROM until the ‘program’ key is pressed while at the “tank size” programming step).

• Gold Tank Sizes (Meter / AS / TC) - This setting is used to determine what size tank the control is connected to. It will only appear if DIP Switch 3 is set to Gold and dip # 4 is off. The display will ﬁrst show “GOLD” with the tank size default (or the previously programmed value). Adjust the tank size with the “Up” or “Down” keys.

Pressing the “Program” key will save all input settings to EEPROM and moves to the

next programming step (‘View’).

Time Flashing

Programming 31

• View - This setting is used to allow the programmer to view the calculated values for salt dosage, cycle times, batch capacity, and total capacity. These values may be changed at this time. The display will show “VIEW N”. The “Y” or “N” will be toggled with the “Up” and “Down” keys. The default for this item shall always be “N” and does not get saved in EEPROM. The programmer must always toggle to “Y” in order to view these items. Pressing the “Information “ key at this menu will re-calculate outputs, based on saved inputs.

Note: “Save” does not appear if no value is changed.

9999 99 OOO8 7O

If “View Y” is chosen, then pressing the “Program” key will display the value for salt dosage; repeated presses of the

program key will display cycle times, batch capacity, and total capacity.

Pressing the “Program” key after viewing “Batch” will exit the programming menu..

If “View N” is chosen, then pressing the “Program” key will exit the programming menu. If any values were changed from

calculated values, then “Save” prompt appears. If “Save N” is chosen, the calculated values go back in. The user must choose “Save Y” to save custom values.

• Salt Dosage - This setting is used to set the salt dosage. It will only be accessible to be set if dip # 4 is off and ‘View’ was set to ‘Y’. The display will ﬁrst show “dOSAGE” for two seconds and then display the default (or previously programmed value). The proper units (lbs or kg) will appear according to dip # 7 setting (English/Metric). Adjust the salt dosage with the “Up” or “Down” keys.

Note: This setting also appears during Aqua-Sensor® Programming.

Pressing the “Program” key will save the setting and move to the next programming step.

• Cycle 1 Time - This setting is used to program the cycle 1 time that is usually backwash. The time of the cycle is kept in minutes. The display will show the “BACKWASH” and “MINS” icons and the cycle time in the right most digits. Adjust the value with the “Up” or “Down” keys.

Note: This setting also appears during Aqua-Sensor® Programming.

Pressing the “Program” key will save the setting and move to the next programming

step.

• Cycle 2 Time - This setting is used to set the time in minutes for cycle 2. This cycle is brine draw / slow rinse for softeners. The display will show the “BRINE RINSE” and “MINS” icons and the cycle time in the right most digits. Adjust the value with the “Up” or “Down” keys.

Note: This setting also appears during Aqua-Sensor® Programming.

Pressing the “Program” key will save the setting and move to the next programming

step.

KG 3.O

32 Culligan Gold Series® Water Softener

• Cycle 3 Time - This cycle is the Fast Rinse/Reﬁll for softeners. The display will show the “Fast Rinse/Reﬁll” and “Mins” icons and the cycle time in the far right digits.

Note: This setting can not be adjusted! It’s based on salt dosage.

Pressing the “Program” key will move to the next programming step.

• Total Capacity Set Point (Max Capacity) - This setting is used to program a value that corresponds to the maximum capacity that can be expected from a unit before it is completely exhausted. If the unit reaches this set point an immediate regeneration will occur even if dip # 6 is set to delay mode (If hidden menu is set to “Delay” the control will NEVER trigger an immediate regeneration, even if dip # 6 is set to delay. This setting will only appear if a ﬂow meter is connected to the circuit board. Adjust the value with the “Up” or “Down” keys. The display will show the “REGEN” icon and “MAXCAP” for two seconds and then display the “REGEN” and “GALLONS” or “LITERS” (depending on DIP switch # 7 setting) icons and the setting numbers to adjust.

Note: “Maxcap” can not be set lower than “batch”.

Pressing the “Program” key will save the setting and move to the next programming

step.

• Batch Set Point - This setting is used to set the trip point for regeneration when in ﬂow meter operation. It will only appear if a ﬂow meter is connected, dip # 3 is set to Gold, or dip 4 set to ‘other’. The programmed setting displays the actual set point to trigger regeneration. The display will show the “REGEN” icon and “batch” for two seconds and then display the “REGEN” and “GALLONS” or “LITERS” (depending on dip # 7 setting) icons and the setting numbers to adjust. Adjust the value with the “Up” or “Down” keys.

9999 99

Note: “Batch” can not be set higher than “maxcap”.

Pressing the “Program” key will save the setting and exit the programming menu.

• Save - This setting is used to save customized outputs. Selecting “Y” saves customized settings; selecting “N” recalculates outputs based on current inputs.

Note: This option does not appear if outputs are unchanged.

Pressing the “Program” key will move to the next programming step.

OOO8 7O

Programming 33

Hidden Menu

• Power Outage - The power outage option

can be toggled off and on by pressing and holding “Up” and “Down” keys simultaneously for 5 seconds. This option sets whether a regeneration should occour immediately or delayed after a 3 hour or longer power outage. Also, it determines whether an immediate regeneration occurs when Maxcap is reached.

Pressing the “Program” key will save and go to the next hidden menu option.

• Program Lock - The program lock can be toggled off and on by pressing the “Up” and “Down” keys. The display will show “UNLOCK” or “LOCK” depending on the last setting. When locked, the only program menus that can be changed are ‘beeper’, TOD, and TOR. The other menus will appear as normal but their values will not be able to be changed.

Pressing the “Program” key will return to the regular time of day display in standard service mode.

Programming Mode Timeout

If no key activity occurs for a period of 180 seconds (3 minutes) while in programming mode, the mode will time out, exit the programming mode and return to time of day display. Any setting that wasn’t saved by pressing the ‘Program’ key prior to the control timing out will revert back to the previous value. (The few settings that had temporarily stored values will revert back to their previous setting UNLESS the ‘Program’ key was pressed at the ‘Tank Size’ display.)

Regen Time Remaining

Upon exiting the programming menu, the current ‘Time of Day’ should be displayed on the display. If the unit is in regeneration, pressing the “Regen” key will display how much total regeneration time remains. The display will stay active until the “Regen” key is pressed again, or the regeneration ends (In Aqua-Sensor mode, the total regeneration time remaining includes the full brine rinse time, but will adjust accordingly upon auto rinse out).

Information Functions

While in the Information functions, all keys are active. The statistical functions are reached by pressing the “Information” key. The information will have two operational modes; a standard information mode and a service information mode. Repetitive presses of the “Information” key will cycle through the standard information mode until cycled back to time of day display. The service mode information will be entered by an initial key press of the “Information” key and then successive presses of the “Down” key. While in the service mode information, the functions will repeatedly cycle through the menus until the “Information” key is pressed again. The following table outlines the Information function display, range limits and default setting:

34 Culligan Gold Series® Water Softener

Statistics

Information Menus

The appearance of information menus will vary based on connected devices and dip settings.

The information menus can also be divided into two sections; standard and service. The standard information mode can be accessed by pressing the information key repeatedly. For Aqua-Sensor mode, the display will only “Aqua-Sensor”. When a ﬂow meter is connected, the displays will show ﬂow rate, % capacity remaining, daily usage and average daily usage.

The service information goes into more detail and allows the service tech to see important historical information; total water usage, number of regens, days since last regeneration, last brine rinse time and impedance ratios. The following tables outline all of the statistical programming displays:

Accessed by pressing the “Information” key repeatedly

Standard Statistics Display Range Limits Comments

Aqua Sensor

Flow Rate

Capacity Remaining (%)

Today’s Water Usage

Avg. Daily Water Usage

AQUA SENSOR

0.0

100

02 50

0 I 50

N/A

0 to 999.0

0 – 100% % of batch capacity remaining, active only with ﬂow meter

0 – 9999 Water usage from 12:00AM – 11:59PM

0 – 9999 Average Daily Water Usage over the last 7 Days

Display shows ‘Aqua-Sensor’, until ‘information’ key is pressed or function times out.

Based on meter factor setting, updated every second, active only with ﬂow meter

Statistics 35

Accessed by pressing the “Information” key once, then the “Down” key repeatedly

Service Statistics Display Range Limits Comments

Flow Rate

Capacity Remaining

Filter Media Life Remaining

Total Flow/Life Unit

Today’s Water Usage

Avg. Daily Water Usage

No. of Regens in last 14 days

Number of days since last Regen

Total No. of Regens

Last brine rinse time

Z Ratio

(read as x.xxx with decimal point after ﬁrst digit)

Z MIN

(read as x.xxx with decimal point after ﬁrst digit)

Z% Increase

0.0

0008 70

LIFE

TOTAL

02 50

0 I 50

14 DAY

DAYS 03

TOTA L R

LST 00

ZRATIO

1075

ZMIN 1075

Z INCR %

07.5

0 to 999.0 Same as above

0 – 999,999 Remaining gallons (liters) until batch capacity is reached

0 – 999,999 -ONLY active in ﬁlter mode with ‘Life’ option set to ‘Y’.

-Remaining gallons (liters) until ‘total ﬂow for life of unit’ reaches the value of ‘total capacity set point’, indicating the end of the ﬁlter media life.

1 – 999,999 Only active with ﬂow meter connected

0 – 9999 Same as above

0 to 99 -Days counter is to be updated at 12:00 am ONLY when dip #

6 is on AND dip # 10 is off; Otherwise, update at TOR

-regens in last 14 days is updated after completion of regeneration (full time out of reﬁll cycle).

0 to 99 -Days counter is to be updated at 12:00 am ONLY when dip #

6 is on AND dip # 10 is off; Otherwise, update at TOR

-After a regeneration is complete (full time out of reﬁll cycle), the counter resets to 0.

0 to 999,999 Counter incremented after completion of regeneration (full time

out of reﬁll cycle)

0 to 99 Only active if Aqua-Sensor connected

0000 to 9999

0.00 to 99.9 %

[Shows current Z ratio]

Impedance ratio only active with A/S; updates every 30 seconds; “1075” would be read as a ratio of 1.075.

[Used as reference during service]

Impedance minimum only active with A/S; gets reset after a successful regeneration; this is the reference point the control compares Zratio to in order to detect the need for regeneration during service cycle; “1075” would be read as a ratio of 1.075.

[Indicates the increase of the Z Ratio above the Z Minimum during a service cycle]

Impedance ratio percent increase only active with A/S; number only applies while in service, NOT regeneration; updates every 30 seconds like Z ratio.

36 Culligan Gold Series® Water Softener

Once either of the information menus is entered the information shown for each display is outlined below:

• Time Clock (standard information) - This display will only show when in time clock mode (no meter or Aqua-Sensor attached). The display will alternate between ‘time’ and ‘clock’ every second until the ‘Information’ key is pressed or until the function times out.

• Aqua Sensor (standard information) - This display will only show when in Aqua-Sensor mode (no meter attached). The display will alternate between ‘aqua’ and ‘sensor’ every second until the ‘Information’ key is pressed or until the function times out.

• Flow Rate (standard information) - This display will only show if the ﬂow meter is attached to the control. The display shall show the current ﬂow rate of the water passing through the control. The display will show the “FLOW RATE” and “GPM” or “LPM” icons and the current ﬂow rate passing through the ﬂow meter for as long as the “Down” key or “Information” key is not pressed.

This display shall never time out, as opposed to the rest of standard information (10 minutes).

• Capacity Remaining (%)(standard information) - This display will only show if the ﬂow meter is attached to the control. The display shows the percent capacity remaining in the batch before regeneration will be triggered. The display will show the “SOFTWATER”, “REMAINING” and “%” icons for softeners. This display shall never time out, as opposed to the rest of standard information (10 minutes).

• Capacity Remaining (gal/L) (service information) - This display will only show if the ﬂow meter is attached to the control. The display shows the gallons or liters of capacity remaining in the batch before regeneration will be triggered. The display will show the “SOFTWATER”, “REMAINING”, and “GALLONS” or “LITERS” icons (depending on DIP Switch # 7 setting) for softeners.

• Total Flow/Life of Unit (service information)

- This display will only show if the ﬂow meter is

attached to the control. The display will show a ﬂow totalizer. The total amount of ﬂow that has passed through the unit since it was installed will be maintained. The display will ﬁrst show “totAL” for 2 seconds and then display the “GALLONS” or “LITERS” icon (depending on dip # 7 setting) and the totalizer value for 10 seconds. This 2 and 10 second cycle should repeat until the “Information” key or “Down” key is pressed, or the information time out brings the display back to time of day. If in ﬁlter mode with ‘LIFE’ option set to ‘Y’, pressing and holding the “REGEN” key for 10 seconds at the previous display will reset this value back to zero.

• Today’s Water Usage (standard information) - This display will only show if the ﬂow meter is attached to the control. The display will show the accumulated ﬂow of water for the current day. The value is to start totaling at 12:00 AM and reset to 0 at 11:59:59 PM. The display will show the “TODAY’S”, “WATER USAGE” and “GALLONS” or “LITERS” icons (depending on dip#7 setting) and the total days ﬂow based on the “K” factor and number of pulses received from the ﬂow meter.

• Average Daily Water Usage (standard information) - This display will only show if the ﬂow meter is attached to the control. The display will show a running 7-day average of daily water usage. The display will show the “AVG DAILY”, “WATER USAGE” and “GALLONS” or “LITERS” (depending on dip # 7 setting) icons and the averaged ﬂow value.

098 7 6 5

Statistics 37

• Number of Regenerations in Last 14 Days

(service information) - This display will show

the number of regenerations that have occurred in the last 14 days. The display will ﬁrst show “14dAY” for two seconds and then display the number of regenerations that have occurred.

• Number of Days since Last Regeneration (service information) - This display shows the number of days that have elapsed since the last regeneration. The display will show “DAYS XX” where XX is the number of days that have elapsed since the unit completed its last regeneration.

• Total Number of Regenerations for Life of Unit (service information) - This display will

show the total number of regenerations that have occurred since installation. The display will show “totALR” for two seconds and then display the total number of regenerations.

• Aqua-Sensor® Information – Last Slow Rinse Time (service information) - This display will appear only if an Aqua-Sensor is attached. The duration of the most recent brine rinse cycle time should be displayed. This time should be displayed (and saved in EEPROM) regardless of how the cycle ended; whether it ended by the auto rinse out feature, by advancing out of the cycle manually, or by the cycle timing out. The display will show the “MINS”, “BRINE RINSE” icons and “LASt XX” where XX would be the time in minutes of the last slow rinse cycle.

OOOO 8 7

• Z-Ratio (impedance ratio) - Number caculated by microprocessor on measured voltage values that are converted to a digital representation. This is the value that the control monitors in order to determine need for regeneration and salt rinse-out.

• Z-Minimum (minimum impedance ratio) -

Reference point that the Z-ratio is compared to, in order to initiate a regeneration. This number is reset after every sucessful regeneration.

• Z-Increase Percent (impedance ratio increase) - Durring service, this number

represents the percent increase or z-ratio over z-minimum. A regeneration is initiated when it reaches 7.5% or more for at least 6 minutes.

Z RATIO I075

Z MIN I070

Z INCR % 07.5%

38 Culligan Gold Series® Water Softener

Manual Cycling

Information Function Timeout

If no key activity occurs for a period of 600 seconds (10 minutes) while in information functions mode, the mode will time out and return to the time of day display. An exception is that the ﬂow rate and % capacity remaining will not time out but will remain displayed until a key is pressed. Pressing the “Information” key after the last standard information display will return the unit back to the time display.

Manual Control Cycling

The control can be manually cycled through a regeneration to troubleshoot the control or verify that the set-up is complete. When a control is manually cycled back to the service position, the statistical counters of capacity remaining, days since last regeneration, last slow rinse time and the number of regenerations in the last 14 days and the life of the unit are not to be reset or updated. If the control is allowed to time out from the last position back to service (Home), the applicable statistical counters are to be reset or updated. A manual cycling of the control can be accomplished by following the steps as outlined below.

1. While in the service mode, press the “Information” key.

2. Press the “Up” key to display the current motor position.

3. Press and hold the “Regen” key for 3 seconds until the regeneration is started. Once regeneration is active, the “Regen” key will be ignored until the control returns to the service or “home” position.

4. The REGEN icon will ﬂash and the motor will move the control to Backwash position.

5. Press the “Up” key to cycle to the next position and remain there until the cycle times out or the control is manually indexed.

6. Continue to press the “Up” key until the control returns to the service (Home) position. In order to step through the cycles again, repeat at step 3.

Note: If the “Down” key is pressed at any time, the control will move back to the ﬁrst item in the information menu. Pressing the “Up” key from the information menu would move the display back to the current diagnostic cycle. The “Up” key will be ignored once the control returns back to the home position.

Backwash

• Press and hold the REGEN key for 5 seconds; the control should move to the BACKWASH position.

• The cycle time remaining appears at the right of the display.

Brine Rinse

• Press the “Up” key; the control should move to the BRINE RINSE position.

• The brine rinse time is determined by the model, tank size and salt dosage (unless dip switch # 4 is on).

• The brine rinse time is calculated value.

Fast Rinse/Reﬁll

• Press the “Up” key.

• If a 4-cycle control, it will move to the FAST RINSE/REFILL position; the time is determined by salt dosage.

Home

• Press the “Up” key.

• The control will return to the Home position.

Note: The regeneration indicator will display “F” (ﬂow meter), “A” (Aqua-Sensor®), “t” (time clock) or “M” (manual). If the “REGEN” icon is lit, then the indicator stands for what mode initiated regeneration. If the “REGEN” icon is NOT lit, then the indicator stands for what triggered the last regeneration.

Manual Cycling 39

Final Start-Up

Regeneration

There are several conditions that will cause the control to trip a regeneration. The “REGEN” enunciator will light when the control has signaled for a regeneration. The “REGEN” enunciator will ﬂash while the control is in regeneration. The following are conditions that will call for regeneration:

1 When the Soft-Minder® meter has recorded the passage of a predetermined number of gallons. 2 When the Aqua-Sensor® Probe senses the hardness in the Cullex Media. 3 At the preset time, when the number of days without a regeneration is equal to the Timeclock Backup setting. 4 At the preset time, when the “Regen” button is depressed once. “Regen” will light. 5 Immediately, when the “Regen” button is depressed for three seconds. “Regen” will light and blink. 6 Immediately, if power to the unit has been off for more than 3 hours and time of day has been restored.

An override function is to exist to allow for the control to initiate a delayed regeneration if DIP switch # 6 is set to ‘delay’. To initiate the override function simultaneously press and hold the “Up” and “Down” keys for 3 seconds while in the service mode. The display will show the program of power up as “dELAY” or IMMEd” with “IMMEd” being the default.

Toggle the setting with the “Up” or “Down” key and save the setting and exit by pressing the “Program” key. If set to delayed, then after a >3hr power outage the “regen” icon will light and the regeneration will begin when the timer reaches the next programmed time of regeneration. If set to immediate, the regeneration will begin as soon as the control completes the homing cycle. If DIP switch 6 is set to “ON”, the unit will begin a regeneration immediately for instances 1 and 2. With DIP switch 6 set to “OFF”, the regeneration will not begin until the preset regeneration time.

Note: If set to immediate mode as timeclock or timeclock backup, the unit will initiate regeneration at 12:00 AM. In the delay mode, “REG” indicator will light at Time of Regeneration and regeneration will occur at delayed time.

Note: If set to “Delay”, the unit will NOT do an immediate regeneration when Maxcap is reached.

Recommended Meter Start-Up Procedure

• Close the main water supply valve.

• Set the Cul-Flo-Valv® to the bypass position.

• Ensure that all faucets at the installation site are closed.

• Direct the drain line discharge into a bucket where ﬂow can be observed.

• Plug the transformer into a 120 Volt, 60 Hz, single-phase receptacle.

• Wait for the control to energize the motor and home itself.

• Set the timer to the correct time of day.

• Open the main supply valve.

• Initiate an immediate regeneration to move the control into the backwash position.

• Refer to the section on manual cycling for information on cycling the control through its positions.

• When in the backwash position, slowly shift the bypass to the soft water position until water ﬂows.

• Allow the tank to ﬁll slowly until water ﬂows from the drain line.

• When ﬂow to drain is established, open the bypass fully. Watch the drain line discharge for signs of resin. If signs of resin particles appear, reduce the ﬂow. Increase the ﬂow again when resin no longer appears in the discharge.

• When the unit is ﬁlled with water, return the timer to the service position and proceed with setting the microprocessor. Refer to the programming section.

• Sanitize the unit as you leave the installation site (See Sanitizing Procedure on page 41).

Note: Unplugging the Culligan Gold Series™ water softener will not affect any of the control settings (the control must be plugged in for at least 10 minutes). Once programmed in, the settings will be stored indeﬁnitely. In the event of a power failure the time-of-day setting will be stored for 12 hours maximum. If longer time storage is necessary, a battery backup is available.

40 Culligan Gold Series® Water Softener

Recommended Aqua-Sensor® Start-Up Procedure

Note: You may ﬁnd it useful to pre-test the sensor probe in your shop using the test detailed in the section titled “Sensor Probe Resin Test.” The same test setup can be used in the ﬁeld.

• Close the main water supply valve.

• Install the sensor probe into the tank but do not connect the sensor to the control at this time.

• Set the Cul-Flo-Valv® to the bypass position.

• Ensure that all faucets at the installation site are closed.

• Direct the drain line discharge into a bucket where ﬂow can be observed.

• Plug the transformer into a 120 Volt, 60 Hz, single-phase receptacle (make sure to connect both 24V and 2.5V properly).

• Wait for the control to energize the motor and home itself.

• Open the main supply valve.

• Initiate an immediate regeneration to move the control into the backwash position.

• Refer to the section on manual cycling for information on cycling the control through its positions.

• When in the backwash position, slowly shift the bypass to the soft water position until water ﬂows.

• Continue backwash until the drain efﬂuent is clear – at least 10 minutes (use a white foam coffee cup to occasionally collect a sample of backwash water; the stark white of the cup will show the presence of color throw and resin ﬁnes).

• Continue or repeat the backwash cycle if needed (while in the backwash step, you can pull the plug on the control and allow it to run as long as needed).

• After the backwash water runs clear, step the control to the Fast Rinse/Reﬁll position to ﬁll the brine tank and purge air from the brine line.

• Unplug the control and connect the sensor to the circuit board.

• Reconnect the power; the control will home again.

• To check the condition of the sensor, press the Information key, followed by the up key (the screen at right appears, HM alternating with the time remaining in the sensor lockout period – should be 00); with a sensor connected the A enunciator should appear in the second digit from the left.

• Press the Program key and program the control to the desired settings.

• Complete installation and cleanup.

• Sanitize the unit as you leave the installation (see sanitizing procedure on page 41).

• Initiate a regeneration or set to go at a preset time.

The thorough backwashing process should have cleared the ﬁnes and color-throw from the tank. The probe should settle into the resin bed during the ﬁrst couple of minutes of backwashing.

Final Start-Up 41

Operation, Care & Maintenance

Before Leaving The Installation Site

• Sanitize the water softener. See sanitizing procedure on page 41.

• Ensure that the brine tank has water to the level of the ﬂoat. Add water to the tank with a hose or put the unit into a full

recharge so that the brine reﬁll cycle will ﬁll the tank with the proper amount of water.

• The water heater will hold hard water for several days. Advise the customer that the existing water volume in the tank will need to be used before the hot water is soft. If soft hot water is required immediately, refer to the water heater owner’s manual for the proper method of draining the water heater.

• Explain the operation of the softener to the customer. Make sure the customer knows that there will be new sounds associated with the recharging of the unit. Advise the customer to periodically check and replenish the salt supply.

• Fill in the hardness and number of people, and then sign and date the corresponding performance data sheet. Leave the Owner’s Guide with the customer.

• Attach the appropriate data plate label located in the Parts Pack onto the back of the control.

• Clean up the unit and installation site, removing any soldering, or pipe threading, residues from the equipment and

surrounding area with a damp towel.

Use of Bypass Valve

Depending on where the particular installation was made, the outside sill cocks may or may not be served by conditioned water. Ideally, all lines not requiring soft water should be taken off upstream of the softener. This is not always possible, however, due to the difﬁculty or expense of rearranging the piping.

Bypass the softener if:

1. The outside lines do not bypass the water softener and the water is to be used for lawn sprinkling or other outside uses.

2. Water is not used for several days.

3. You wish to inspect or work on the valve or brine system.

4. A water leak from the valve is evident.

Three-Valve Bypass

To bypass, close the inlet and outlet valves, and open the bypass valve. Reverse the process to get soft water once again. Be sure to close the bypass valve completely to avoid mixing hard water with soft water.

Caution! If the media tank is to remain attached to the control valve, close only the inlet valve, then open the bypass valve. This will prevent pressure from increasing in the media tank due to warming.

Care and Cleaning

Protect the operation and appearance of the water conditioner by following these precautions:

1. Do not place heavy objects on top of the conditioner cover.

2. Use only mild soap and warm water to clean the exterior of the unit. Never use harsh abrasive cleaners or compounds which contain acid or bleach.

3. Protect the conditioner and drain line from freezing temperatures.

4. Reset the time, if required, after any interruption of electrical power to keep the unit on its normal schedule.

42 Culligan Gold Series® Water Softener

Recommended Preventative Maintenance

Sanitizing Procedure

A water softener in daily use on a potable water supply generally requires no special attention other than keeping the salt tank ﬁlled. Occasionally, however, a unit may require sanitization under one of the following conditions:

• At start-up time.

• After standing idle for a week or more.

• On private supplies, the appearance of off-tastes and odors, particularly if musty or “rotten egg” (caused by harmless sulfate-reducing bacteria).

Note: If the water supply contains iron, regenerate the softener before sanitizing to remove iron from the resin.

Caution! Hazard from toxic fumes! Chlorine bleach and common iron control chemicals may generate toxic fumes when mixed.

• If the unit uses culligan sofner-gard® or other compounds containing sodium hydrosulﬁte, sodium bisulﬁte, or any other reducing agent, disconnect the device feeding the chemical(s) and manually regenerate the unit before sanitizing.

• Do not use this procedure if the softener salt contains iron control additives.

1. Remove the brine tank cover.

2. Pour directly into the brine chamber 1/3 to 1/2 cup of common household bleach (5.25% sodium hypochlorite) for each cubic foot of resin in the tank.

3. Manually start recharge. Allow the unit to complete the recharge cycle automatically.

If tastes and odors return frequently, even after sanitization, a continuous chlorination system may be needed. Send a water sample to a qualiﬁed laboratory for bacterial analysis.

Analyzing the System

Analyzing the problem involves three basic steps:

1. Check the system in all cycle positions.

2. Compare the data to normal operating data.

3. Determine which component may cause the problem (troubleshooting).

4. If steps 1-3 did not reveal the problem, initiate a regeneration cycle and manually cycle the valve to brine draw (#2 position). Allow the unit to complete the brine draw cycle and observe how the system reacts.

Although it may be possible to solve a speciﬁc problem simply by changing a component, analyzing the entire system can reveal additional problems which would otherwise require extra service calls. “Parts changing” is not the same as service.

Check the System

The following tools are needed to collect data:

1. Hardness, iron and chlorine test kits

2. Thermometer

3. Pressure gauge, 0-120 psi

4. 5-Gallon bucket and watch

5. Calculator

The customer can provide most data. By collecting data prior to a service call, a “ﬁrst guess” about the cause of the problem can be made and the need for any special parts can be determined. If the problem is as simple as lack of salt in the brine tank, a service call may not be needed at all. At the end of Appendix A is a recommended system data sheet that will assist the troubleshoot process.

Recommended Preventative Maintenance 43

Application Problems

Many service problems are not due to equipment malfunction, but rather to misapplication or environmental conditions.

The Operation & Performance Speciﬁcations (page 3 of this manual) provides the limits of water characteristics for the Culligan Gold Series™ water softeners. If the water characteristics fall outside these limits, additional water treatment equipment may be required, or the water characteristics should be brought inside the limits. The system ﬂow rates and exchange capacities are also listed.

Appendix A, Table 4 - Flow Rates. The backwash, brine, and slow rinse ﬂows should not differ from those in Appendix A, Table 3 - Flow Rates by more than 15%.

Appendix A, Table 5 - Salt Dosage/Capacity shows the gallon capabilities for each unit as a function of salt dosage. If the hardness or water usage has increased, a higher salt dosage, more frequent regeneration, or a larger softener may be needed.

Note: The rate at which brine is drawn from the brine tank should not differ by more than 5%. The reﬁll rate should be as close as possible to the rate shown in Appendix A, Table 4 - Flow Rates; high or low pressure installations may require the substitution of a different reﬁll ﬂow control.

If there are no apparent general problems or environmental problems, refer to pages 46 - 53.

Recommended Preventative Maintenance Inspection Schedule

The Culligan Gold Series commercial water softener has been designed to provide a good, consistent service life. Routinely inspecting the system may help avoid potentially costly breakdowns related to circumstances outside of the control of the dealer and/or user.

Component Suggested Inspection Frequency Reason for Maintenance

Entire System At Start-up, after infrequent use (idle

for one week or more) or every 3 - 6 months if on a private water supply.

On private supplies, the appearance of off-tastes and odors, particularly if musty or “rotten egg” (caused by harmless sulfate-reducing bacteria) may indicate a need for the system to be sanitized. See page 39.

Backwash Flow Controller

Brine eductor nozzle and throat

Softening Media Every 2 - 3 years Chlorinated water supplies can breakdown and destroy resin

Table 7

44 Culligan Gold Series® Water Softener

Every 12 months or every time service is performed on the system.

Build up of sediment, iron and/or other foreign materials (found in some water supplies but not necessarily all) could negatively affect system performance. Monitor item for normal or unexpected wear.

Build up of sediment, iron and/or other foreign materials (found in some water supplies but not necessarily all) could negatively affect system performance.Monitor item for normal or unexpected wear.

material. Resin material may also perform poorly if subjected to other materials (sediment, iron, alum, etc.) found in some water supplies (but not necessarily all).

Error Codes and Alerts

The Gold control has enhanced error handling. When the control detects an error in the operation of the valve, it will make an attempt to at least try to ﬁnd and stay in service position, where it will generate a speciﬁc error code depending on the type of failure as shown in the table below, as well as sound an audible beep.

Alert codes are speciﬁc to Aqua-Sensor mode and ﬁlter mode only. These do not stop the control from operating; they just alert the customer to call Culligan. Other regeneration triggers will still be valid.

When an error code is detected, the control will attempt to ﬁnd and stay in service position and display the appropriate error code. If the control fails to detect service position, it will eventually stop the motor and display the appropriate error code. The error code display will have additional information indicating what the program was when the error was ﬁrst detected. The appropriate regeneration cycle icon (backwash, brine rinse, fast rinse/reﬁll, or “H” for home) will be lit indicating whether the control was in that position when the error occurred (icon not ﬂashing), or whether the control was advancing to that cycle (icon ﬂashing). The “Regen” icon will indicate whether the control was in a regeneration cycle or not. If the letter “P” is in the display, the error occurred during a “pre-rinse” cycle. In order to manually clear an error code (after correcting the problem), push and hold the “Program” key for 10 seconds. After the 10 seconds, the control will clear the error code, beep once, and cycle the valve to service position. Other methods of manually clearing the error code are powering down the control for 60 seconds or toggling dip#1. While in error mode, the control will not function. When returning from Error mode, the control shall use the values stored in EEPROM unless another dip switch was toggled or device program was changed. In these cases, the programmed values would revert back to the defaults.

The alert codes are cleared differently depending on which one is detected. The two alert codes are “Check Salt” and ‘Change Media’.

‘Check Salt’ is enabled only when an Aqua-Sensor is connected and goes into effect when no brine is detected during the brine rinse cycle. If the control detects no brine during the brine rinse cycle of regeneration, it will complete that regeneration and set the control to regenerate again. If the control detects no brine during the brine rinse cycle for the second time, the “Check Salt” alert will be displayed at the end of the regeneration cycle. The control will beep every 10 minutes to alert the customer. The z-minimum statistic will not be reset at the start of service since a good regeneration did not occur, thus the Aqua-Sensor will no longer be a valid regeneration trigger. Until the alert is cleared, the control will function normally and will only accept regeneration triggers via manual button press, time clock backup or meter. The only way to clear this alert is to successfully draw brine during a brine rinse cycle.

‘Change Media’ is optional. It can only be enabled with the control set in Filter Mode with ‘Life’ option set to ‘Yes’. This alert is triggered when the total gallons used reaches the media life setpoint. It can be cleared by pressing and holding the ‘Regen’ button for 10 seconds while at the ‘Life remaining’ display in information menu. After clearing the ‘Change Media’ alert, the total gallons and total regens information reset back to zero.

Error Code Description Mode of Detection Comments

Err 1

No cam switch action detected (motor failure to start).

Err 2

Detected the next step in the cam switch sequence when not expected (motor failure to stop).

Err 3

Detected a combination of switches that is not in the expected sequence (intermittent/faulty connection; misaligned switches).

Err 4

Control type mismatch.

If the control fails to see any switch action while trying reach the desired state within 2 minutes of driving the motor. The control will attempt to start the motor 3 times for 2 minutes each time with a 10-second ‘pause’ period between each attempt.

If the control detects changes in the cam inputs that match the next step in the expected sequence when the motor is not supposed to be turning.

If the control detects changes in the cam inputs that don’t match the next step in the expected sequence.

1. If dip # 3 is set for ‘5 cycle’ and 4 cycle valve is detected.

2. If dip # 3 is set for ‘Gold’ and 5-cycle valve is detected.

3. If one type of switch sequence is already established and the other sequence is later detected.

Table 8

All error codes can be cleared manually by:

1. Pressing and holding the “PROGRAM” button for 10 seconds.

2. Powering down the control for 60 seconds.

3. Toggle dip#1 on and off.

Beeping only occurs between the hours of 8:00am and 8:00pm.

Beeping can be silenced by pressing any key.

Error Codes and Alerts 45

Examples of enhanced error codes:

Error Code Display What it means:

-Err 2

-In regeneration

-While in brine rinse cycle

-Err 1

-In regeneration

-While advancing to backwash cycle

-Err 3

-In service

-While in home position

-Err 3

-In Pre-Rinse cycle

-While advancing to home position

-Err 4

-In service

-While seeking home position (initializing)

-Err 3

-In regeneration

-While in fast rinse/reﬁll cycle

Table 8

Display Alert Code Description Mode of Detection Comments

CHECK SALT

CHANGE

MEDIA

Table 9

A/S mode; control detected no brine during brine rinse cycle.

Filter mode; total gallons equals the media life setpoint.

A very distinct signal is expected from the probe during brine rinse; lack of this signal means no brine was detected.

With ‘Life” set to yes, the maxcap is the media life; once total gallons reaches this number, the alert is triggered.

Once this alert is triggered, the A/S is no longer a valid regen trigger. The alert can only be cleared after a successful regeneration of the resin bed.

Can be cleared by pressing and holding the ‘regen’ button for 10 seconds while ‘Life remaining’ statistic is displayed; resets total gallons and total regens information.

46 Culligan Gold Series® Water Softener

Diagnostics

-Soft Water to Service (solid)

-Sensing Need for Regen (flashing)

-(Replaced by Left Digit of Time Remaining in Brine Rinse)

using the 5th and 6th digits)

Diagnostic Functions

While in the diagnostic functions mode all keys will be active. The mode is entered by pressing the “Information” key, then the “Up” key. These functions are used to perform diagnostics on the control during regeneration. The display shows the “REGEN” icon solid (if a regeneration is pending) or ﬂashing (if in regeneration). The display is to show Current Cycle along the bottom (4-cycle valve: Backwash, Brine Rinse, Fast Rinse/Reﬁll; 5-cycle valve: Backwash, Brine Rinse, Fast Rinse, Reﬁll). The program of the motor output is to be shown in the 3rd digit from the right. The center bar of the digit will light for the motor being powered. The cycle time remaining will be displayed in the two rightmost end digits along with the “MINS” icon. When in home position, the two rightmost digits will alternate displaying “HM” (with “MINS” icon off), and time remaining (with “MINS” icon on) 2 seconds each. If an Aqua-Sensor is connected, the 20-minute stabilization delay time will be displayed here after a regeneration (only if regeneration is allowed to be completed on its own). If a ﬂow meter is attached, the far left digit will show “F” solid, and ﬂash if the control is getting a ﬂow signal from the ﬂow meter. If an Aqua-Sensor is attached, the second digit from the left will show “A”. The “A” will be solid for a balanced condition, and ﬂash for an unbalanced condition. A typical display for this function is shown below.

Last Regeneration Trigger

The fourth digit from the left can be “F” (Flow Meter), “A” (Aqua-Sensor®), “t” (time clock) or “M” (Manual). If the “REGEN” icon is off, this letter stands for what triggered the last regeneration. If regen icon is on, this letter stands for what armed it.

Diagnostics 47

Test Mode

In this mode the control can be put through a performance test to verify the operation of the control’s components and software.

Note: Device connections and DIP settings before entering Test Mode. Upon exiting test mode, if a device connection or DIP switch setting is different from when Test Mode was entered, the control’s program settings will default accordingly.

Switching DIP #1 on from “R” (run) to “T” (test) enters Test Mode. When entering Test Mode, all current program settings, DIP switch settings and statistical data are saved. When exiting test mode, the valve will home itself. The test sequence is shown in the table below.

User Action Desired Result Functionality Tested

Switch DIP #1 on All LCD segments on DIP switch #1 and Test Mode Entry

Press any button Software version displayed (ERRSUM displayed

if software integrity check fails)

Press any button Blank Display (unless devices connected) Exit Software Integrity check

The actions below can be done in any sequence

Switch DIP #2 on Display to show “2” DIP switch #2 input

Switch DIP #2 off “2” disappears

Repeat for each DIP #3-10 Display to show corresponding DIP number DIP switch inputs

Press PROGRAM button Display to show “11” and run motor for 15

seconds

Press UP button Display to show “12” UP button input

Press DOWN button Display to show “13” DOWN button input

Press REGEN button Display to show “14” REGEN button input

Press INFORMATION button Display to show “15” (“EE” displayed if

EEPROM memory check fails)

Close “Home” Cam Switch Display to show “H” “Home” Cam Switch input

Open “Home” Cam Switch “H” disappears

Close “Position” Cam Switch Display to show “P” “Position” Cam Switch input

Open “Position” Cam Switch “P” disappears

Connect Flow Meter Display to show “gpm” icon when connected Flow Meter ‘Detect’ input

Provide flow pulses “gpm” icon flashes when pulses are present Flow Meter ‘Signal’ input

Connect Aqua-Sensor Simulator Device or Probe (probe must be in the resin bed)

“Balance” Aqua-Sensor Simulator Device

“Unbalance” Aqua-Sensor Simulator

Display to show “REGEN” icon when connected and “OK” if Aqua-Sensor circuitry is operating within proper range

“REGEN” icon to stop flashing within 30 seconds and “OK” indication should remain

“REGEN” icon to flash within 30 seconds and “OK” indication should remain

Software Integrity check

PROGRAM button input and motor output

INFORMATION button input and EEPROM memory check

Aqua-Sensor ‘Detect’ input and Digital Aqua-Sensor circuitry check

Aqua-Sensor ‘Signal’ input

Table 10

When exiting test mode, if the dip switches or sensors have not changed, the control is to restore all values from EEPROM. If the dip switch or sensors have changed the values should reset to factory defaults. In either case the valve will home itself.

48 Culligan Gold Series® Water Softener

Troubleshooting Guide

Problem or Symptom Cause Solution

1. Unit has blank display.

2. Softener fails to automatically initiate a regeneration.

3. Regeneration occurs at incorrect time.

4. Error message is displayed.

5. Hard water to service. The root cause of hard water to service may also lead to problems such as Iron or Hardness bleed in softener.

6. Loss of water pressure

A. Unit has no power. A. Verify that unit is connected to a constant

power source (Not an outlet on a switch).

B. Defective plug-in transformer. B. Replace plug-in transformer.

A. Electrical service to the unit has been

disrupted.

B. Soft-Minder® meter not properly recording

total gallons used. The ﬂow meter connection and operation can be veriﬁed using the test mode setting on the circuit board.

C. Aqua-Sensor® probe not sensing hardness

front. The Aqua-Sensor connection and operation can be veriﬁed using the test mode setting on the circuit board with AquaSensor simulator.

D. Incorrect programming. D. Refer to the ‘Programming’ section and verify

A. Timer setting incorrect. A. Reset timer.

B. Timer ﬂashing. B. Reset timer and verify that unit is connected

C. Circuit board set to immediate regeneration. C. Set circuit board to delayed regeneration by

D. Incorrect programming.

A. Jammed seal pack or brine piston (ERR 1). A. Replace the seal pack or brine piston

B. Defective cam microswitches or harness

(ERR 1, ERR 2, or ERR 3).

C. Defective drive motor (ERR 1). C. Replace the drive motor.

A. Salt or Chemical storage tank is empty. A. Add salt or chemical to storage tank and

B. Eductor screen or nozzle plugged. B. Clean or replace eductor nozzle and/or

C. Incorrect programming (Salt dosage too low

for inﬂuent hardness).

D. Insufﬁcient water ﬂowing to salt storage

tank.

E. Internal seal leak. E. Replace seal pack.

F. Excessive water usage. F. Verify that programming is correct. For Time

G. Unconditioned water in water heater tank. G. Flush water heater to ﬁll tank with conditioned

A. Control and/or resin bed plugged with debris

or iron build-up.

B. Inlet manifold plugged. B. Remove control from tank and clean inlet

C. Control plugged with foreign material broken

loose from recent plumbing work.

A. Verify that unit is connected to a constant

power source (Not an outlet on a switch).

B. Verify that meter cable is plugged into circuit

board. Verify that meter cable is snapped into ﬂow meter housing. Verify that ﬂow meter has not become plugged with debris.

C. Verify that Aqua-Sensor connector is properly

connected to circuit board and 2.5VAC is properly connected to circuit board. Verify that Aqua-Sensor probe is working. Clean probe if necessary.

all settings.

to a constant power source.

ﬂipping dip switch 6 to the OFF position.

D. Refer to the ‘Programming’ section and verify

all settings.

B. Replace cam microswitches or harness.

verify that proper level of salt or chemical is maintained.

screen.

C. Refer to the ‘Programming’ section and verify

that settings are correct.

D. Verify that reﬁll settings are correct and clean

the reﬁll ﬂow restrictor.

Clock units increase regeneration frequency.

water.

A. Clean control and increase frequency of

regenerations or length of backwash. Plant recondition if necessary.

manifold. Check if eductor screen/nozzle are also plugged.

C. Clean control.

Troubleshooting

Troubleshooting 49

Troubleshooting Guide – Continued

Problem or Symptom Cause Solution

7. Loss of mineral to drain.

8. Mineral to service. A. Control connected to tank backwards. A. Verify that control is properly mounted to the

9. Water in storage tank up to ﬂoat.

10. Excessive water in salt storage tank (Water above brine valve ﬂoat).

11. Unit fails to reﬁll storage tank.

12. Unit fails to draw brine or chemical.

13. Unit uses an excessive amount of salt or chemical.

14. Continuous ﬂow to drain

15. Salt water to service

A. Improper drain line ﬂow control. A. Ensure that the control has the proper drain

line ﬂow control (see Table 3, page 21).

B. Air in water system. B. Ensure that brine is working properly.

tank.

B. Defective outlet manifold. B. Replace outlet manifold.

A. Plugged drain line ﬂow control (Unit will not

draw brine).

B. Plugged eductor system (Unit will not draw

brine).

C. Slow leak to brine line. Faulty eductor

piston.

D. Power outage while control was in reﬁll

position.

A. Faulty brine valve; ﬂoat shut-off failure.

When the brine valve is faulty, one of the items listed under problem 9 is also required in order to produce excessive water in the storage tank.

A. Reﬁll restrictor plugged. A. Clean or replace reﬁll restrictor.

B. Air in brine line causes ﬂoat to slam shut

(ﬂoat rod is rigid).

A. Drain line ﬂow control is plugged. A. Clean drain line ﬂow control.

B. Plugged eductor system. B. Clean or replace eductor screen or nozzle.

C. Line pressure too low. C. Increase line pressure to a minimum of 20 psi

D. Internal control leak. D. Replace seal pack and/or eductor piston

E. Drain line too long or restricted. E. Verify proper drain line length. See ‘Flow

F. Eductor is drawing air into system. F. Verify that all tubing connections are properly

A. Incorrect programming. A. Refer to ‘Programming’ section and verify all

B. Excessive water in storage tank. B. Refer to problems 9 & 10.

A. Internal seal pack leak. A. Replace seal pack.

B. Seal pack or brine piston jammed in

position.

C. Power failure while unit was in regeneration. C. Restore power to unit. Verify that unit is

A. Inadequate Brine/Rinse setting for desired

salt dosage.

B. Low water pressure lengthens brine draw

time.

C. Too much brine in the storage tank. C. Refer to problems 9 & 10.

A. Clean drain line ﬂow control.

B. Clean eductor screen and nozzle.

C. Replace eductor piston.

D. Verify that items A-C are not the cause for

the extra water in the storage tank.

A. Clean brine valve, replace stem seat, or

replace brine valve.

B. Verify that all tubing connections are properly

assembled.

(210 kPa).

assembly.

Rate and Drain Line Charts’.

assembled.

settings.

B. Replace seal pack or brine piston.

connected to a constant power source.

A. Refer to the ‘Programming’ section and verify

all settings.

B. Increase line pressure to a minimum of 20 psi

(210 kPa).

50 Culligan Gold Series® Water Softener

Brine System Analysis

1) WATER LEVEL in the brine tank

a) Empty

b) Below level of safety valve

c) At level of safety valve ﬂoat

If the brine system is functioning properly, there will be water in the brine tank, but the level should be below the safety valve ﬂoat and the ﬁberglass rod should travel freely. If these conditions do not exist, one of the following conditions will indicate the nature of the problem:

1. NO WATER IN BRINE TANK – ROD TRAVELS FREELY. The ﬂow control is plugged. Remove reﬁll ﬂow control. Clean or replace.

2. NO WATER IN BRINE TANK – ROD IS RIGID. Air or water slammed the safety valve closed before water could enter the tank. Clean parts at the base of the brine safety valve and also make sure that the seat of the check valve in the brine line is clean. Check for possible air leaks in the brining system.

3. WATER IN BRINE TANK UP TO SAFETY VALVE FLOAT – ROD IS RIGID. There are three possible causes:

a. Brine piston is not in service position when control is in service or brine piston seals are defective. Remove brine line

while in service. There should be no ﬂow to brine tank.

b. Reﬁll ﬂow rate is too high or reﬁll time length is too long. Check reﬁll ﬂow rate and compare to speciﬁcation in Appendix

A, Table 3 - Flow Rates.

2) SAFETY VALVE in brine tank

a) Fiberglass rod travels up and down freely (approximately 1/2”)

b) Fiberglass rod is rigid

Aqua-Sensor® Troubleshooting

The following procedure will help you diagnose problems in units equipped with Aqua-Sensor® sensing device. Because many “sensor problems” are actually regeneration problems, it contains a combination of sensor diagnostics and routine control valve and brine system checks. Refer to the Troubleshooting Flow chart on page 50 for the recommended sequence and Appendix B for suggested Aqua-Sensor® application guidelines.

Circuit Board Test

1. Verify there is 2.5 VAC power supply at the Culligan Gold Series™ circuit board for the Aqua-Sensor®.

2. Record program, DIP switch settings and statistical information (last slow rinse, Z ratio, Z minute and Z increase %) before beginning this procedure.

3. Unplug the unit.

4. Remove the Aqua-Sensor® cable from the board.

5. Move DIP switch(es) to Test Mode. DIP switch 1 ON, all others OFF

6. Connect Soft-Minder® Meter/Aqua-Sensor® Tester (same as the Aqua-Sensor®, P/N 01017705) to board. The color of the wire on the far right as you look at the back of the board should be white.

7. Move toggle to Balanced position.

8. Apply power; all segments should be lit on display.

9. Press any key. The software version should be displayed.

10. Press any key. Display should go blank except for solid “regen” icon and “OK” indicator. The “Regen” icon should stop ﬂashing within 30 seconds. The “OK” indicator means the control has sucessfully self-tested the Aqua-Sensor circuitry. If “OK” does not appear, then replace the circuit borard.

11. Toggle to unbalanced position. Regen icon should ﬂash.

12. If regeneration icon does not ﬂash when balanced and ﬂashes when unbalanced, then the board is good.

Troubleshooting 51

Optional Service Test

If desired, the circuit board can also be tested while in the Service mode.

1. Unplug control.

2. Disconnect probe and connect Soft-Minder Meter/Aqua-Sensor® Simulator (P/N 01017705) and set to the “balanced” position.

3. Plug in the control.

4. Press the “Information” key once and then repeatedly press the “down” key until “z-ratio” is displayed. Wait 30 seconds for the reading to stablize.

5. With the simulator device set to “Balaced”, the “Z-ratio” should read between 900 and 1130.

6. Set the simulator device to “Unbalaced” and wait 30 seconds for the reading to stabilize. The “Z-ratio” should read between 1130 and 1250.

Sensor Probe Resin Test

The Probe Resin Test uses fully regenerated, but previously used, Cullex® resin to simulate a balanced environment. Run this test only on a circuit board that has passed the Circuit Board Test with simulator device.

Preparation

You will need a container that can hold enough regenerated Cullex resin to completely immerse the probe’s electrodes without making contact with the container’s sidewall. A section of PVC pipe, either 2” or 3”, makes a suitable chamber for testing either residential or commercial probes.

1. Cut a piece of pipe about 18 inches long and close the bottom end with a cap or a ﬂat piece of PVC (which can also serve as a base)

2. Close the other end with a cap that has been drilled and tapped for a 1” PVC pipe plug, or use a reducing adapter and plug.

3. Fill the chamber with used, regenerated Cullex resin and soft water; the water level should be at least one inch above the resin (when not in use, plug the end to prevent spillage of resin and water)

Probe Test

1. Remove the probe from the resin tank. Make sure pressure is relieved on tank before removing probe.

2. Visual inspection

a. Look for discoloration (brown ﬁlm or blue spots) on electrode ﬁns.

b. If discolored, try cleaning the probe (Sofner-Gard chemical or white vinegar). The ﬁns can be lightly scrubbed with a soft

toothbrush.

52 Culligan Gold Series® Water Softener

Testing

1. Set the chamber in a stand so that it is vertical.

2. Remove the top plug and lower the probe to be tested into the chamber until it bottoms, then lift it up an inch or so; the electrodes must not touch the sides of the chamber

3. Unplug the control and place the softener control into the test mode (Set Dip switch 1 to the ON) position

4. Connect the sensor to the control circuit board

5. Plug the control in again (in test mode)

6. With the probe fully immersed in the resin, the “Regen” icon should stop ﬂashing within 30 seconds.

7. Now lift the probe so that the upper cell pair is out of the resin and water mixture; it should now be unbalanced and you should observe the “Regen” icon ﬂashing within 30 seconds.

8. At the completion of the test, disconnect the power from the control, reinstall the sensor into the resin tank, return the control to the RUN position (Dip switch 1 in the OFF position) and set any other Dip switches to activate the desired feature(s)

9. Restore the control’s power (it will home) and reprogram to the desired settings. Put the unit into regeneration to settle the probe into the resin.

Note: Disregard the appearance or disappearance of the “OK” indicator; this only applies to testing with an Aqua-Sensor® simulator device.

Resin and Regeneration

If the circuit board and the probe pass all tests, the condition of the resin or the regeneration process may actually be to blame.

1) While the probe is out of the tank, take a sample of resin and examine it for breakage (ﬁnes) and fouling.

2) Remove the power to the control.

3) Return the probe to the tank and reconnect it to the circuit board.

4) Power up the control and verify that the program matches the settings recorded at the beginning of the procedure. Also, make sure that the settings are correct for the application. It is recommended that the brine rinse time be left at the time calculated by the microprocessor automaticly (increases for higher salt dosages or low inlet pressure conditions) to assure adequate rinse time. The Automatic Rinse Time feature will shorten the actual rinse time as it detects the passage of the salt from the tank. Setting the time at too short a value could prevent complete rinse-out and cause daily regeneration.

5) Backwash the unit for 2 - 3 minutes after installing the probe to eliminate any air pockets in the unit.

6) Check the unit for regeneration function (salt dosage, brine draw, rinse and reﬁll).

Troubleshooting 53

Aqua-Sensor Troubleshooting Flowchart

Problem:

Diagnostics Sequence:

Regenerates

Nightly

Check water

usage; is it higher

than expected?

Check Brine Draw/Slow

Rinse time in minutes

(Menu 6). The value

calculated by the

microprocessor

based on inputs

Check salt

dosage; high salt

dosages can

extend rinse out

Check eductor

nozzle and screen

for plugging or

fouling

Never

Regenerates

2.5 VAC power supplied?

Is there salt in the

brine tank?

Does the unit

draw brine

properly?

Initiate a manual

regeneration; is

the water soft?

Test circuit board

& probe

Check Resin

54 Culligan Gold Series® Water Softener

Check brine reﬁll

function. Short

salting could cause

reduced capacity

Test circuit board

& probe

Check seal pack

for internal leak

Check Resin

Circuit Board Troubleshooting

Most circuit board problems are caused by outside inﬂuences and it is not the board itself. Replacing the board may seem to work only because the cause hasn’t been reproduced.

Let’s start with what to check when you come upon a circuit board problem:

1. Are those switches aligned too far away to the cam? There should be a small as possible gap between the switches and the cam so that a “wobbling cam” doesn’t accidentally open the switch.

2. Has the seal pack been checked for free movement? Feedback and experience has demonstrated that seal packs that are over-tightened create drag on the motor and delays that would result in an error code: If the motor never stops (still runs after the desired position is sensed, causing unexpected switch closures) OR if the motor gets stuck “timing out” and the control never sees any switch action.

3. Are all the wiring terminals tightly connected? Sometimes a loose or poorly connected wire can give feedback to the board that would result in an error code or default.

4. After checking all of these possibilities you should run the diagnostics (test mode) on the board.

Listed below are some other rare circuit board behaviors and their explanations:

Board skips the service position or only stops for a second in service before advancing to the backwash position

Board has been armed for regeneration. Let the board time out of the last cycle OR reset and reprogram the board.

Motor goes round and round Only one of two things can happen when this is the case; it can ﬁnd its desired position or it gives you an error code. So, Let It Run until you ﬁnd out which will occur.

• If the motor still runs or there is power to motor after the error code is displayed, then the triac is likely bad – change the board.

• If the error code is displayed and the motor is stopped (no power to the motor), check switches, cam and wire harness – the board got a signal it wasn’t supposed to or a connection failed.

The board repeatedly defaults, resets or gains time

Look at the power supply or source. Most of these issues are caused by the power source, so-called “dirty power” having noise interference or incorrect voltage. This could be erratic ﬂuctuations caused by other heavy power draws, poor wiring, low voltage wiring running along high voltage, having active electrical storms that causes “corruption” of the EEPROM. Consider the use of a surge protector or an uninterruptible power supply after you see this repeatedly.

If you suspect the power source is causing problems, take a voltage reading at the outlet, at the power connection on the board, and on the motor leads while the motor is running. We are looking for a consistent range of 108-132 volts at the receptacle and 22-28 volts on the board. Also, the wall transformer is only used to step down the voltage; it is not used for protection or ﬁltering the power source.

Troubleshooting 55

Service

Familiarize yourself with the replacement procedures and component parts thoroughly before attempting any repair.

Warning! Disconnect all electrical power to the unit before servicing. Bypass the unit and relieve system pressure before attempting repair.

Circuit Board

To replace the AccuSoft™ Plus circuit board, refer to the parts list and proceed as follows:

1. Remove the timer cover by unsnapping it from the back plate.

2. Unhook the circuit board mounting plate by lifting the top snap and removing from the backplate.

3. Remove all connected wire leads from the board.

Caution! Grip all connections to the circuit board by the connecting terminals for assembly and disassembly. Failure to do so could result in damage to the wire leads or connecting terminals.

4. Unsnap the circuit board from the mounting plate. See Figure 22.

Caution! Do not touch any surfaces of the circuit board. Electrical static discharges may cause damage to the board. Handle the AccuSoft™ 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.

5. The new circuit board can be installed by reversing the steps 1-4 above. When reassembling the mounting plate to the backplate, it is easiest to hook the top snap ﬁrst and then gently push the base in until it snaps into place.

Caution! The wire connectors must be connected to the circuit board properly. The wires must exit the plug-in connector opposite of the raised white base of the circuit board connector.

Caution! Extra care should be taken when connecting the 2.5 vac and 24 vac power. Failure to connect properly will result in damage to the circuit board.

56 Culligan Gold Series® Water Softener

Figure 22

Refer to Figure 23 for assembly and disassembly of the various valve components listed below.

Drive Motor Assembly

1. Remove the drive motor cam switches by removing the one screw holding the switches to the motor

2. Remove the E-ring holding the drive motor cam to the camshaft with a ﬂat tip screwdriver.

3. Lift the cam off the shaft.

4. Remove the screw above the eductor piston assembly.

5. Loosen the two screws holding the yoke support plate and the motor to the control valve.

6. Remove the yoke support plate and yoke by gently pulling them down.

7. Fully remove the two screws holding the motor to the control. The motor will pull away from the control.

Note: Care should be taken to not damage the brine piston if it is not going to be replaced. The brine piston will need to be twisted slightly in order to remove it from the motor die casting.

This procedure can be followed in the reverse order to reassemble the motor to the control. When reassembling the scotch yoke, the yoke must slide into the yoke support plate prior to pushing the assembly up into the piston end and follower. Figure 24 shows proper assembly of the yoke into the support plate.

Note: The seal pack may need to be repositioned in order for the follower to be inserted into the yoke, using the motor and backplate to push the seal pack fully into the valve is helpful in aligning the yoke. Make sure that the follower is in the follower slot on the yoke, and that the end of the piston rod is held in the end of the yoke.

Note: When attaching the support plate be certain to push up on the plate until the two mounting screws bottom in the Ushaped channels of the support plate.

Figure 23

Service 57

Seal Pack Assembly

Follow the instructions for the replacing drive motor assembly through step 7, then continue as follows:

1. With the drive motor set aside, ﬁrmly pull the seal pack assembly from the valve body.

2. Lightly lubricate the o-rings of the replacement seal pack with silicone grease.

3. Reverse the procedure for reassembly.

Note: Use only silicone grease; petroleum-based lubricants will cause the degradation of the rubber components.

Caution! Do not twist the seal pack upon insertion. This can cause the outer o-rings to pinch, cut, or crimp.

Eductor Piston/Eductor Sleeve Assembly

Follow the instructions for the replacing drive motor assembly through step 7, then continue as follows:

1. With the drive motor set aside, ﬁrmly pull the eductor piston & sleeve assembly from the valve body.

2. Lightly lubricate the o-rings of the replacement piston & sleeve assembly with silicone grease.

3. Reverse the procedure for reassembly.

Note: Use only silicone grease; petroleum-based lubricants will cause the degradation of the rubber components.

Note: The eductor piston & sleeve assemblies are unique to the softener, ﬁlter, and controls. Refer to the parts list to ensure that the proper assembly is used.

Figure 24

58 Culligan Gold Series® Water Softener

Wiring Schematic

Sensor

Meter

Brown

Red

Yellow

Battery

Switch Assembly

Power 24V

OPT 2.5V (Sensor)

Motor

Motor and power wires are not polarity ensitive.

Rear View Circuit Board

Wiring Schematic 59

Appendix A

Table 1 - Dimension “X” is the exposed length the Aqua-Sensor® cord (cord length from the Aqua-Sensor plug to the circuit

board connector). You can then verify the Aqua-Sensor probe is inserted to the proper depth by conﬁrming dimension “X” is at the corrected length.

Model X Y

9” Quadra-Hull™ Tank 34 1/2” 40”

10” Quadra-Hull Tank 30 1/2” 44”

12” Quadra-Hull Tank 32 1/2” 42”

14” Quadra-Hull Tank 22 1/2” 52”

Table 2 - Maximum Allowable Drain Line Length

Operating

Pressure

30psi (210 kPa) 60 ft (18 m) 50 ft (15 m) 30 ft (9 m) 15 ft (5 m) Not allowable Not allowable

40 psi (279 kPa) 100 ft (30 m) 90 ft (27 m) 70 ft (21 m) 50 ft (15 m ) 30 ft (9 m) 12 ft (4 m)

50 psi (349 kPa) 145 ft (41 m) 115 ft (35 m) 80 ft (24 m) 80 ft (24 m) 60 ft (18 m) 40 ft (12 m)

60 psi (419 kPa) 100 ft (30 m) 100 ft (30 m) 85 ft (26 m) 60 ft (18 m)

80 psi (559 kPa)

100 psi (669 kPa) 150 ft (46 m)

0 ft (0m) 2 ft (0.6m) 4 ft (1.2m) 6ft (1.8m) 8ft (2.4m) 10ft (3m)

Normal Installation should not require

more than 100 ft (30 m) of drain line

140 ft (43 m) 120 ft (37 m)

Table 3 - Media Volumes and Freeboard

Model Cullex® (ft3) (A) Cullsan (lbs) (B) Freeboard (in)* (C)

9” 1.0 12 14.5

10” 1.5 15 14.5

12” 2.0 16 16

14” 3.0 25 20

* Measured from the top of the resin to the top surface of tank threads.

Table 4 - Flow Rates

Model Service Backwash/Fast Rinse Brine Draw Slow Rinse Reﬁll

9” 9.0 gpm @ 13 psi 1.6 - 2.2 gpm 0.44 gpm 0.27 gpm 0.45 gpm

10” 9.6 gpm @ 15 psi 1.6 - 2.2 gpm 0.44 gpm 0.27 gpm 0.45 gpm

12” 10.0 gpm @ 15 psi 2.6 - 4.0 gpm 0.93 gpm 0.27 gpm 0.80 gpm

14” 10.6 gpm @ 16 psi 5.5 - 6.7 gpm 1.85 gpm 1.35 gpm 0.80 gpm

60 Culligan Gold Series® Water Softener

Table 5 - Capacities

Gold 9” x 48”

Hard-

ness

Grains

10 6 59 4 54 2284 2284 1599 2101 1827 1827 1279 1681 9 3/8 7 1/2

15 7 62 5 43 1666 1666 1166 1533 1333 1333 933 1226 10 7/8 8 1/2

20 8 65 6 32 1343 1343 940 1236 1074 1074 752 988 12 1/4 9 1/2

25 8 65 6 32 1074 X 752 X 859 X 601 X 12 1/4 9 1/2

30 9 68 7 21 948 X 664 X 758 X 531 X 13 5/8 10 1/2

35 9 68 7 21 812

40 10 70 8 10 743 X 520 X 594 X 416 X 15 11 1/2

50 11 73 8 59 614 X 430 X 491 X 344 X 15 12 1/2

60 12 76 9 48 524 X 367 X 419 X 293 X 17 3/4 13 1/2

70 13 79 10 37 455 X 319 X 364 X 255 X 19 1/8 14 1/2

80 14 82 11 26 400 X 280 X 320 X 224 X 20 1/2 15 1/2

90 15 85 12 15 354 X 248 X 283 X 198 X X 16 1/2

Salt

Dosage

lbs.

5 6 59 4 54 4567 4567 3197 4202 3654 3654 2558 3362 9 3/8 7 1/2

Brine

Rinse

Time

Min.

Reﬁll Time Total

Capacity

Min. Sec. STD EFF STD EFF STD EFF STD EFF 250 lb375

NaCl KCl “A”

Capacity to

Signal

X 568 X 650 X 455 X 13 5/8 10 1/2

Total

Capacity

Capacity to

Signal

Dimension

Gold 10” x 54”

Hard-

ness

Grains

5 9 60 7 21 6284 6284 4399 5781 5027 5027 3519 4625 10 1/2

10 10 62 8 10 3294 3294 2306 3030 2635 2635 1845 2424 11 1/2

15 11 63 8 59 2293 2293 1605 2110 1835 1835 1285 1688 12 1/2

20 11 63 8 59 1720 1720 1204 1582 1376 1376 963 1266 12 1/2

25 12 65 9 48 1432 X 1002 X 1145 X 802 X 13 1/2

30 13 67 10 37 1237 X 866 X 990 X 693 X 14 1/2

35 14 69 11 26 1096 X 767 X 877 X 614 X 15 1/2

40 15 70

50 16 72 13 4 813 X 569 X 650 X 455 X 17 1/2

60 18 76 14 42 711 X 498 X 569 X 398 X 19 1/2

70 19 77 15 31 623 X 436 X 498 X 349 X 20 1/2

80 21 81 17 9 565 X 396 X 452 X 316 X 22 1/2

90 23 84 18 47 517 X 362 X 413 X 289 X 24 1/2

Salt

Dosage

lbs.

Brine

Rinse

Time

Reﬁll Time Total Capacity Capacity to

Min. Sec. STD EFF STD EFF STD EFF STD EFF

12 15 988 X 692 X 791 X 554 X 16 1/2

NaCl KCl “A”

Total Capacity Capacity to

Signal

Dim

375

lb.

Appendix A 61

Gold 12” x 52”

Hard-

ness

Grains

5 12 56 5 36 8171 8171 5720 7517 6537 6537 4576 6014 13 1/2

10 13 58 6 4 4277 4277 2994 3935 3421 3421 2395 3147 14 1/2

15 14 60 6 32 2973 2973 2081 2735 2378 2378 1665 2188 15 1/2

20 15 62 7 0 2317 2317 1622 2132 1854 1854 1298 1706 16 1/2

25 16 63 7 28 1920 X 1344 X 1536 X 1075 X 17 1/2

30 17 65 7 56 1652 X 1156 X 1322 X 925 X 18 1/2

35 18 67 8 24 1459 X 1021 X 1167 X 817 X 19 1/2

40 19

50 22 74 10 16 1123 X 786 X 899 X 629 X 23 1/2

60 24 78 11 12 970 X 679 X 776 X 543 X 25 1/2

70 26 81 12 8 856 X 599 X 685 X 480 X 27 1/2

80 28 85 13 4 766 X 536 X 613 X 429 X 29 1/2

90 30 88 14 0 692 X 484 X 554 X 388 X 31 1/2

Salt

Dosage

lbs.

Brine

Rinse

Time

Min.

69 8 52 1312 X 918 X 1049 X 734 X 20 1/2

Reﬁll Time Total Capacity Capacity to

Min. Sec. STD EFF STD EFF STD EFF STD EFF

NaCl KCl “A”

Total Capacity Capacity to

Signal

Dim

375

lb.

Gold 14” x 65”

Hard-

ness

Grains

5 18 52 8 24 12889 12889 9022 11858 10311 10311 7218 9486 10 1/2

10 19 53 8 52 6630 6630 4641 6100 5304 5304 3713 4880 11

15 21 54 9 48 4655 4655 3259 4283 3724 3724 2607 3426 12

20 23 55 10 44 3654 3654 2558 3362 2923 2923 2046 2689 13

25 24 55 11 12 3654 X 2558 X 2388 X 1672 X 13 3/4

30 26 56 12 8 2582 X 1807 X 2066 X 1446 X 15

35 27 57 12 36 2252 X 1576 X 1801 X 1261 X 15 1/2

40 29

50 32 59 14 56 1690 X 1183 X 1352 X 946 X 18 3/8

60 36 61 16 48 1465 X 1026 X 1172 X 820 X 20 1/2

70 39 63 18 12 1282 X 897 X 1025 X 718 X 22 1/2

80 42 64 19 36 1137 X 796 X 910 X 637 X 24

90 45 66 21 0 1018 X 713 X 815 X 571 X 25 3/4

Salt

Dosage

lbs.

Brine

Rinse

Time

Min.

58 13 32 2032 X 1422 X 1626 X 1138 X 16 1/2

Reﬁll Time Total Capacity Capacity to

Min. Sec. STD EFF STD EFF STD EFF STD EFF

NaCl KCl “A”

Total Capacity Capacity to

Signal

Dim

650

lb.

62 Culligan Gold Series® Water Softener

Appendix B

Aqua-Sensor® Application Guidelines

Parameter Value

Hardness (gpg as CaCO3) 4 - 99 (See Notes 1 & 2)

Soluble iron (ppm as Fe) < 2 (See Note 3)

Manganese (ppm as Mn) < 0.5 (See Note 4)

Hardness versus Salt Dosage See Table 1 and Note 2

TDS to Hardness Index TDS hardness (as CaCO3) <10 (i.e., hardness must be at

least 10% of TDS; see Note 5)

Temperature, °F Any within equipment’s operating range

Alum and phosphate Anecdotal evidence indicates potential foulant; effect has not

been conﬁrmed experimentally

Commercial cell: distance between sensing and reference cell pairs

Residential cell: distance between sensing and reference cell pairs

Hardness vs. Salt Dosage

Avoid using maximum salt dosages. The sensor doesn’t require high salt dosages to operate effectively. Below ia a table with suggested salt dosages at various hardness ranges. Maximum dosages defeat the purpose salt efﬁciency feature of the AquaSensor® sensing device, prolong rinse times and daily regeneration may occur. It is also important the correct eductor nozzle is used to ensure proper salt dosages.

Hardness (gpg as CaCO3) Recommended Salt Dosage (lbs/ft3)

7-10 5-6

10-15 6-8

15-25 8-9

25-50 9-11

50-75 11-12

75-99 12-16

6 inches (See Note 2)

3 inches (See Note 2)

Notes:

1 Although the Aqua-Sensor device has been used successfully on water with hardness as low as 3 gpg, there is an increased

risk of missed signal (no regeneration) when the hardness less than 6 gpg.

2 For each tank diameter, there is a speciﬁc volume of resin in the space between the cell pairs. The capacity of that resin is

inﬂuenced by hardness and salt dosage. Any combination of ﬂow rate and hardness that causes the hardness front to pass through that volume of resin in less than 6 minutes will result in the sensor failing to detect the need to regenerate.

3 If precipitated or bound iron is present it must be removed before the softener.

4 Manganese can deposit on the sensor electrodes, particularly on the upper pair, causing missed signals (no regeneration).

Periodic cleaning may be needed to maintain satisfactory performance.

5 Adequate signal strength has been demonstrated at ratios as high 14 but signal strength diminishes with decreasing TDS to

hardness index.

Appendix B 63

Control

Parts List

64 Culligan Gold Series® Water Softener

34 01-0130-31 Cam

35 00-4452-46 Roll Pin

Item Part No. Description

36 01-0141-79 Drive Motor & Bracket Assembly 24V/60Hz

37 01-0017-84 Screw

38 00-3183-54 Nut

39 00-4452-21 Bellcrank

40 00-4435-59 Roll Pin

41 01-0126-49 Follower

42 01-0126-48 Yoke

43 01-0126-47 Bracket

44 00-3184-52 Screw

45 01-0188-52 Circuit Board

46 01-0164-76 Circuit Board Mounting Plate

47 01-0164-78 Timer Label

49 01-0140-26 Cover

50 01-0140-30 Hinge

51 01-0164-75 Door

52 01-0139-58 Tank Adapter

53 01-0139-59 Tank Clamp

54 01-0136-69 Clamp Pin

55 00-318-383 Screw

56 01-0148-48 O-Ring

57 00-4400-52 O-Ring

63 01-0080-66 Coupling

64 01-0080-69 Meter Bearing

65 01-0080-67 Impeller

66 01-0080-65 Snap-In Retainer

67 01-0090-99 O-Ring

* 01-0181-33 Wall Mount Transformer

68 01-0090-75 Assembly Pins

69 01-0141-53 Adapter Assembly (Includes Items 52 - 55)

* 01-0147-34 Wire Harness, Cam

* P0-4517-01 Hose Clamp, Drain

* 01-0128-44 Flow Meter Harness

70 01-0187-60 1-1/4” Bypass Assembly

71 01-0111-88 Flow Meter Assembly w/ Harness

* 01-0138-39 Back-up Battery

‡ Recommended Spare Parts

* Not Illustrated

1 01-0139-76 Control Valve

— 01-0188-57 Control Valve Assembly - Gold Series

Item Part No. Description

‡* P0-4479-86 O-Ring, Eductor Sleeve, Small O-Ring (25/Kit)

‡2 01-0130-83 Seal Pack Assembly

‡* P0-3084-07 O-Ring, Eductor Sleeve, Large O-Ring (25/Kit)

‡3 01-0136-06 Eductor Sleeve and Eductor Piston Assembly

4 P1-0187-75 Connector Brine Line

‡* P0-4487-50 Screen, Eductor Sleeve (10/Kit)

‡* 00-4479-87 O-Ring, Eductor Piston (10/Kit)

Control Parts List

00-4010-31 Backwash Restrictor (black), 14” Tanks

P0-3316-36 Backwash Restrictor, #3 (green), 12” Tanks

P1-0022-05 Nut, PP, 3/8” (25/Kit)

7 P0-3316-35 Backwash Restrictor, #2 (brown), 9” & 10” Tanks (10/Kit)

5 P1-0188-71 Insert, PP, 3/8” (25/Kit)

8 00-4468-35 Drain Elbow Assembly w/O-Ring

9 00-4473-87 Retainer, Drain Elbow

‡10 P0-3084-38 O-Ring, Eductor Nozzle and Throat (10/Kit)

01-0141-42 Eductor Throat w/O-Ring , 14” Tank

‡11 00-3084-37 O-Ring, Eductor Throat

‡12 00-4012-48 Eductor Throat w/O-Rings (light brown), 9”, 10” & 12” Tanks

00-4477-52 Eductor Nozzle (green), 14” Tank

* 00-4460-39 Eductor Nozzle Beige, 10” & 12” Tanks

‡13 00-4460-38 Eductor Nozzle - Blue, 9” & 10” Tanks

14 P0-4452-69 Eductor Screen (10/Kit)

16 00-4010-22 Eductor Port Cover

17 00-4486-87 Screw

18 00-4481-28 Retainer, Rear Body Plug

20 00-4481-26 Rear Body Plug

21 01-0140-27 Control Back Plate

22 01-0139-66 Plug, 1.000” Snap-in

23 01-0064-98 Plug, .562” Snap-in

24 01-0171-34 Power Cord

25 01-0003-72 Strain Relief

30 00-4486-86 Screw

‡15 00-4457-97 Gasket

Parts List 65

‡19 P0-4449-14 O-Ring, Rear Seal (10/Kit)

‡29 01-0032-44 Switch

31 00-3184-55 Screw

32 00-4010-40 Switch Bracket

33 P1-0130-43 Retaining E-Ring (10/Kit)

Service Parts Kits

Item Part No. Description

01-0162-67 Power Valve Seal Rebuild Kit

2 Seal Pack

3 Eductor Sleeve w/ O-Rings

3 Brine Piston w/ O-Rings

01-0162-66 PV Eductor Rebuild Kit

12 Light Brown Eductor w/ O-Ring

13 Blue Restrictor w/ O-Ring

13 Beige Restrictor w/ O-Ring

14 Eductor Screen

15 Eductor Port Gasket

7 Black Flow Control (1.2 gpm)

7 Brown Flow Control (2.0 gpm)

7 Green Flow Control (3.5 gpm)

8 Drain Elbow Assembly w/ O-Ring

01-0162-69 Power Valve Drive & Seal Rebuild Kit

2 Seal Pack

3 Eductor Sleeve w/ O-Rings

3 Brine Piston w/ O-Rings

43 Scotch Yoke Bracket

42 Scotch Yoke

38,39,40,41 Bell Crank & Follower Assembly

44 Screw (2 each)

33 E-Ring

34 Cam

01-0141-79 Drive Motor Kit

36 Motor

39 Bell Crank

38 Nut

41 Follower

40 Roll Pin

35 Roll Pin

32 Switch Bracket

31 Screw (2 each)

66 Culligan Gold Series® Water Softener

Tank Assembly

Item Part No. Description Qty.

1 01-0166-17 Tank Assembly, 9” w/ Fillport, Complete

01-0166-18 Tank Assembly, 10” w/ Fillport, Complete

01-0171-92 Tank Assembly, 12” w/ Fillport, Complete, Less Media

01-0171-94 Tank Assembly, 14” w/ Fillport, Complete, Less Media

01-0163-51 Tank Assembly, 9” w/o Fillport, Complete

01-0163-52 Tank Assembly, 10” w/o Fillport, Complete

01-0163-49 Tank Replacement, 9”, w/ Fillport, Empty

01-0163-50 Tank Replacement, 10”, w/ Fillport, Empty

01-0165-20 Tank Replacement, 12”, w/ Fillport, Empty

01-0165-22 Tank Replacement, 14”, w/ Fillport, Empty

01-0163-47 Tank Replacement, 9”, w/o Fillport, Empty

01-0163-48 Tank Replacement, 10”, w/o Fillport, Empty

2 01-0098-47 Top Strainer - Fine Slot

01-0111-95 Top Strainer - Wide Slot 1

3 01-0090-99 O-Ring, Manifold 1

4 01-0161-76 Outlet Manifold - 9” 1

4 01-0145-39 Outlet Manifold - 10” 1

4 01-0145-40 Outlet Manifold - 12” 1

4 01-0164-29 Outlet Manifold - 14” 1

5 01-0171-34 O-Ring, Plug and Sensor 2

6 01-0151-22 Plug 1

7 01-0187-63 Aqua-Sensor

Probe 1

Parts List 67

16” and 18” Brine Systems

Item Part Number Description

- 01-0187-05 Brine System, 250 lb

- 01-0187-15 Brine System, 375 lb

1 01-0187-09 Replacement Tank, 250 lb

01-0187-16 Replacement Tank, 375 lb

2 01-0187-04 Cover, 250 lb

01--0187-17 Cover, 375 lb

3 01-0187-07 Salt Plate, 250 lb

01-0187-13 Salt Plate, 375 lb

4 01-0187-07 Brine Chamber, 250 lb & 375 lb

5 01-0187-06 Brine Valve

68 Culligan Gold Series® Water Softener

Brine Valve

Item Part Number Description

- 01-0187-06 Brine Valve

1 01-0187-10 BLFC Elbow - 0.45 gpm

01-0187-11 BLFC Elbow - 0.8 gpm

Parts List 69

11” Brine System

Item Part Number Description

- 01-0187-70 Brine System, 156 lb

1 01-0187-69 Replacement Tank, 156 lb

2 01-0189-10 Cover, 156 lb

3 01-0187-64 Salt Plate, 156 lb

4 01-0187-68 Brine Chamber, 156 lb

5 01-0187-06 Brine Valve

70 Culligan Gold Series® Water Softener

24” Brine System

Item Part Number Description

- 01018720 Brine System, 650 lb 1 01-0187-18 Replacement Tank, 650 lb 2 01-0187-19 Cover, 650 lb 3 01-0189-09 Salt Plate, 650 lb 4 01-0187-08 Brine Chamber 5 01-0187-06 Brine Valve

Parts List 71

Culligan Gold Series, Gold 9"", Gold 10"", Gold 12"", Gold 14 Installation & Operation Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual