Culligan Gold Series Installation & Operation Instructions
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Culligan Gold Series Installation & Operation Instructions

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See also: Service Manual , Owner's Manual
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
© 2007 Culligan International Company

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Summary of Contents for Culligan Gold Series

  • Page 1: Service Instructions

    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 © 2007 Culligan International Company...
  • Page 2 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.

  • Page 3: Table Of Contents

    Installation, Operation & Service Instructions with Parts List Culligan Gold Series ™ Water Softener Models from 2006 Table of Contents Page Table of Contents Page Important Safety Information ..........i Final Start-up ...............41 Introduction ..............2 Care and Maintenance ..........43 Performance Specifications ...........3 Recommeded Preventative Maintenance ....44...

  • Page 4: Introduction

    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.

  • Page 5: Performance Specifications

    Performance Specifications Control Valve 9” Model 10” Model 12” Model 14” Model 1” Reinforced 1” Reinforced 1” Reinforced 1” Reinforced Thermoplastic Thermoplastic Thermoplastic Thermoplastic Overall Conditioner Ht 54 in 60 in 58 in 71 in Media Tank Design Quadra-Hull Quadra-Hull Quadra-Hull Quadra-Hull ™...

  • Page 6: Preparation

    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. Culligan Gold Series ®...
  • Page 7 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.

  • Page 8: Basic Principles

    The letters underneath the component’s description page 21 for proper Brine Tank usage. refer to the values listed on Appendix A, Table 2 - Media Volumes and Freeboard. Brine Tank Cover Brine Valve Brine Tank Brine Chamber Salt Plate Culligan Gold Series ® Water Softener...
  • Page 9 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 ®...

  • Page 10: Flow Diagrams

    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 Culligan Gold Series ® Water Softener...
  • Page 11 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...
  • Page 12 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 Culligan Gold Series ® Water Softener...
  • Page 13 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.
  • Page 14 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. FAST RINSE & REFILL Figure 7 Culligan Gold Series ® Water Softener...

  • Page 15: Controller Features

    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 1/2AA- lithium type battery as supplied by Culligan (PN 01013839). • EEPROM Saves programmed and statistical functions.

  • Page 16: Operation

    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). Culligan Gold Series ® Water Softener...

  • Page 17: Efficiency Mode

    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.

  • Page 18: Installation

    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. Figure 9 Culligan Gold Series ® Water Softener...
  • Page 19 Install the outlet manifold into the tank (Figure 10). Cover the tops of the manifolds with a clean rag. 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.
  • Page 20 Note: The clamp and valve will be able to rotate on the tank until pressure is applied. Figure 13 Valve - Adapter O-ring Tank Clamp Tank Adapter Adapter - Tank O-ring Tank Clamp Figure 12 Culligan Gold Series ® Water Softener...

  • Page 21: Plumbing Connections

    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 ®...

  • Page 22: Bypass Valve Installation

    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. Culligan Gold Series ® Water Softener...
  • Page 23 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.

  • Page 24: Electrical Connection

    Caution! Failure to connect power to the correct terminals will damage the circuit board! 2.5 VAC 24 VAC Aqua- Power Sensor Power Power to circuit board, 2.5 VAC for Aqua-Sensor installation Aqua-Sensor Wiring Figure 20 Figure 21 Culligan Gold Series ® Water Softener...

  • Page 25: Programming

    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.
  • Page 26 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. Table 6 Culligan Gold Series ® Water Softener...
  • Page 27 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.
  • Page 28 Toggle Y or N 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 Culligan Gold Series ® Water Softener...
  • Page 29 Outputs Settings Display Range Limits Default Comments DOSAGE Salt Dosage 3 – 64 Lbs Calculated based Only active if dip # 4 is off (N/A in Filter mode); If on tank size this is changed, then the appropriate outputs get 1.5 –...
  • Page 30 The time can be adjusted in 30 minute increments by pressing the “Up” or “Down” keys. Time Flashing Pressing the “Program” key will save the setting and move to the next programming step. Culligan Gold Series ® Water Softener...
  • Page 31 • Day(s) of Week Regeneration - In the time clock mode only (Meter or Aqua-Sensor ® 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”...
  • Page 32 “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. Culligan Gold Series ® Water Softener...
  • Page 33 • 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”...
  • Page 34 “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. Culligan Gold Series ® Water Softener...
  • Page 35 • 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”...
  • Page 36 “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: Culligan Gold Series ®...
  • Page 37 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.
  • Page 38 [Indicates the increase of the Z Ratio above the Z Minimum during a service cycle] 07.5 Impedance ratio percent increase only active with A/S; number only applies while in service, NOT regeneration; updates every 30 seconds like Z ratio. Culligan Gold Series ® Water Softener...
  • Page 39 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.
  • Page 40 Z-Increase Percent (impedance ratio increase) - Durring service, this number Z INCR % 07.5% 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. Culligan Gold Series ® Water Softener...

  • Page 41: Manual Cycling

    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.

  • Page 42: Final Start-Up

    • 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 ™...
  • Page 43 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. •...

  • Page 44: Care And Cleaning

    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. Protect the conditioner and drain line from freezing temperatures. Reset the time, if required, after any interruption of electrical power to keep the unit on its normal schedule. Culligan Gold Series ® Water Softener...

  • Page 45: Recommended Preventative Maintenance

    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.
  • Page 46 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.

  • Page 47: Error Codes And Alerts

    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.
  • Page 48 ‘regen’ button for 10 seconds while ‘Life setpoint. total gallons reaches this remaining’ statistic is displayed; resets total MEDIA number, the alert is triggered. gallons and total regens information. Table 9 Culligan Gold Series ® Water Softener...

  • Page 49: Diagnostics

    Diagnostics 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).
  • Page 50 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. Culligan Gold Series ®...

  • Page 51: Troubleshooting

    Troubleshooting Troubleshooting Guide Problem or Symptom Cause Solution Unit has blank Unit has no power. Verify that unit is connected to a constant display. power source (Not an outlet on a switch). Defective plug-in transformer. Replace plug-in transformer. Softener fails Electrical service to the unit has been Verify that unit is connected to a constant to automatically...
  • Page 52 Low water pressure lengthens brine draw B. Increase line pressure to a minimum of 20 psi time. (210 kPa). C. Too much brine in the storage tank. C. Refer to problems 9 & 10. Culligan Gold Series ® Water Softener...
  • Page 53 Circuit Board Test Verify there is 2.5 VAC power supply at the Culligan Gold Series™ circuit board for the Aqua-Sensor®. Record program, DIP switch settings and statistical information (last slow rinse, Z ratio, Z minute and Z increase %) before beginning this procedure.
  • Page 54 Visual inspection Look for discoloration (brown film or blue spots) on electrode fins. If discolored, try cleaning the probe (Sofner-Gard chemical or white vinegar). The fins can be lightly scrubbed with a soft toothbrush. Culligan Gold Series ® Water Softener...
  • Page 55 Testing Set the chamber in a stand so that it is vertical. 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 Unplug the control and place the softener control into the test mode (Set Dip switch 1 to the ON) position Connect the sensor to the control circuit board Plug the control in again (in test mode)
  • Page 56 Check eductor nozzle and screen for plugging or Check Resin fouling Check brine refill function. Short salting could cause reduced capacity Test circuit board & probe Check seal pack for internal leak Check Resin Culligan Gold Series ® Water Softener...
  • Page 57 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: 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”...

  • Page 58: Service

    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. Figure 22 Culligan Gold Series ® Water Softener...
  • Page 59 Refer to Figure 23 for assembly and disassembly of the various valve components listed below. Drive Motor Assembly Remove the drive motor cam switches by removing the one screw holding the switches to the motor Remove the E-ring holding the drive motor cam to the camshaft with a flat tip screwdriver. Lift the cam off the shaft.
  • Page 60 Figure 24 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. Culligan Gold Series ® Water Softener...

  • Page 61: Wiring Schematics

    Wiring Schematic Switch Assembly Motor and power wires are not polarity ensitive. Motor Brown Yellow Battery Power 24V OPT 2.5V (Sensor) Sensor Meter Rear View Circuit Board Wiring Schematic...
  • Page 62 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 Culligan Gold Series ® Water Softener...
  • Page 63 Table 5 - Capacities Gold 9” x 48” NaCl “A” Dimension Hard- Salt Brine Refill Time Total Capacity to Total Capacity to ness Dosage Rinse Capacity Signal Capacity Signal Grains lbs. Time Min. Sec. Min. 4567 4567 3197 4202 3654 3654 2558 3362...
  • Page 64 2582 1807 2066 1446 2252 1576 1801 1261 15 1/2 2032 1422 1626 1138 16 1/2 1690 1183 1352 18 3/8 1465 1026 1172 20 1/2 1282 1025 22 1/2 1137 1018 25 3/4 Culligan Gold Series ® Water Softener...

  • Page 65: Appendix B - Aqua-Sensor

    Appendix B Aqua-Sensor Application Guidelines ® Parameter Value Hardness (gpg as CaCO 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 CaCO...

  • Page 66: Parts List

    Parts List Control Culligan Gold Series ® Water Softener...
  • Page 67 Parts List...

  • Page 68: Service Parts

    Brine Piston w/ O-Rings Scotch Yoke Bracket Scotch Yoke 38,39,40,41 Bell Crank & Follower Assembly Screw (2 each) E-Ring 01-0141-79 Drive Motor Kit Motor Bell Crank Follower Roll Pin Roll Pin Switch Bracket Screw (2 each) Culligan Gold Series ® Water Softener...
  • Page 69 Tank Assembly Item Part No. Description Qty. 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”...
  • Page 70 01-0187-16 Replacement Tank, 375 lb 01-0187-04 Cover, 250 lb 01--0187-17 Cover, 375 lb 01-0187-07 Salt Plate, 250 lb 01-0187-13 Salt Plate, 375 lb 01-0187-07 Brine Chamber, 250 lb & 375 lb 01-0187-06 Brine Valve Culligan Gold Series ® Water Softener...
  • Page 71 Brine Valve Item Part Number Description 01-0187-06 Brine Valve 01-0187-10 BLFC Elbow - 0.45 gpm 01-0187-11 BLFC Elbow - 0.8 gpm Parts List...
  • Page 72 11” Brine System Item Part Number Description 01-0187-70 Brine System, 156 lb 01-0187-69 Replacement Tank, 156 lb 01-0189-10 Cover, 156 lb 01-0187-64 Salt Plate, 156 lb 01-0187-68 Brine Chamber, 156 lb 01-0187-06 Brine Valve Culligan Gold Series ® Water Softener...
  • Page 73 24” Brine System Item Part Number Description 01018720 Brine System, 650 lb 01-0187-18 Replacement Tank, 650 lb 01-0187-19 Cover, 650 lb 01-0189-09 Salt Plate, 650 lb 01-0187-08 Brine Chamber 01-0187-06 Brine Valve Parts List...

This manual is also suitable for:

Gold 9"Gold 10"Gold 12"Gold 14"

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