Cat. No. 01019924 Rev.
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.
Installation and Operation Instructions with Parts List Culligan® Iron-Cleer® Plus Water Filters Models from 2007 Table of Contents Page Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Settings . . . . .
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Introduction This system and its installation must comply with state and local regulations. The System is ONLY to be supplied with cold water. The Culligan® Iron-Cleer® water filter has been tested and certified by WQA against S-200 for the effective reduction of iron up to 1,400 gallons for 10” units and 2,000 gallons for 12” units. For installations in Massachusetts, the Commonwealth of Massachusetts plumbing code 248 CMR shall be adhered to.
Specifications Culligan® Iron-Cleer® Plus Water Filters 10” Iron-Cleer 12” Iron-Cleer 1” reinforced thermoplastic 1” reinforced thermoplastic Electro-mechanical Electro-mechanical 67” 65” 2 ea. 10” x 54” tanks 2 ea. 12” x 52” tanks 1.0 cu. ft. birm 1.5 cu. ft. birm 35 lbs. 35 lbs. Cullsan U 25 lbs. 25 lbs. Capacity 1400 gallons 2000 gallons 21” 18” Max. Clear Water (Soluble) Iron 10 ppm 10 ppm Max. Hydrogen Sulfide 5.0 ppm 5.
Preparation Component Description The Iron-Cleer® water filter is shipped from the factory in nine(9) cartons. Remove all components from their cartons and inspect them before starting installation. Control Valve Assembly - Regeneration control valve, small parts package contains installation hardware and consumer literature, including the warranty policy. Media Tank - Two (2) fiberglass tanks complete with fittings.
Bypass Valves Provide a manual bypass to permit water flow to service in the event the water conditioner must be removed or disconnected. Cul-Flo-Valv® Bypass - 1” control The Cul-Flo-Valv bypass connects directly to the control valve bracket. 01016464 Cul-Flo-Valv Bypass 1-1/4” NPT 01010783 Copper Adapter Kit 1” Sweat 01016564 Copper Adapter Kit 3/4” Sweat 01016565 Copper Adapter Elbow Kit 3/4” Sweat Operation Solenoid Valve Shuttle Valve Step 1.
Timer Operation A timer controls the air recharge cycle and how frequently it occurs. The timer simultaneously energizes the air pump and the solenoid valve. After a preset amount of time, the timer shuts off the air pump and de-energizes the solenoid valve. Solenoid Valve Operation The solenoid valve is a three-way valve having ports that connect to the air pump, shuttle valve and the atmosphere.
Operating Conditions The concentration limits listed below reflect the maximum individual limit that each contaminant was tested for separately without any interference of other contaminants in the influent water. In reality, however, we know that these contaminants may be present in combination which may limit the filter’s ability to remove these contaminants in higher concentrations.
Pre-Installation Check List ___ Water Pressure: A minimum of 20 psi at a predetermined flow rate is required to backwash the filter properly, with a maximum of 60 psi to be used. If pressure exceeds 60 psi a pressure reducing valve must be installed ahead of the Iron-Cleer® System. ___ Actual Influent Flow Rate: (Water, available from well pump, service inlet, etc.) The actual pumping rate must exceed the backwash rate (drain flow) for the model of filter selected at a minimum of 20 psi.
Installation Placement Refer to figure 1. • Set the media tank on a solid, level surface near water, drain and electrical facilities. • Set the aeration tank on a flat, smooth, solid structure as near the media tank as possible. Filter Tank Filling It is possible to fill the tank in the plant. If filled at the plant, the tank must remain upright to prevent disturbing the layers. However, because of its weight and handling difficulty, it is advisable to perform this on-site. Proceed as follows: 1.
Install Backwash Flow Control Washer Drain Clip Refer to figure 4 1. Locate the thin black flow control washer and the plastic flow control spacer from the small parts pack. 2. Remove the drain elbow retaining clip and drain elbow from the filter control valve. 3. Remove the rubber backwash flow control washer and discard it. 4. Install the thin black flow control washer into the filter control valve with the molded numbers facing the control valve. Install the plastic flow control spacer.
To bypass, turn the blue knob clockwise (see directional arrow on end of knob) until the knob stops as shown. DO NOT OVERTIGHTEN! (Figure 6a). 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 6b) About 1-1/4” A screwdriver shank may be used in the slot as a lever for extra turning force if needed.
Aeration Tank Installation Aeration Head Assembly Quick Install 1. Insert the white disperser into the bottom of the aeration head. Twist it clockwise to lock it into position. Note: The small hole in the white disperser must be in the position shown after it is locked into position. Hole in disperser must be in this position when locked 2. Insert the small grey rigid tube into the white disperser and up into the aeration head.
8. Lightly lubricate the o-ring on the plastic elbow check valve with silicone lubricant and then assemble it to the inlet port on the bypass valve as shown. Note: The inlet of the plastic elbow check valve must face down when installed. Note: No extra external check valve is required. Note: Tighten the plastic nuts by hand only. Plastic elbow fitting Must Face Down 9. Assemble the 1” threaded fittings using the fittings, nuts, O-rings, and split rings provided.
Aeration Tank – Bypass Valve Operation Normal Operation “Treated” Water Exits Supply Water Enters Diagnostic Mode Supply Water Exits Supply Water Enters Bypass Operation Supply Water Exits Supply Water Enters Shut-Off Mode No Water Exits Supply Water is Shut Off From The House and The Valve Installation 13
Settings Your Culligan® Iron-Cleer® Plus Water Filter is designed to perform efficiently on a wide range of water supplies. Before the unit can be recharged and put into service, several settings must be made. Backwash Step Backwash expands and loosens the media bed, and flushes away accumulated particulate matter. The backwash interval is preset at the factory for 10 minutes, which is adequate for most water supplies.
Programming Switch Definitions The circuit board is shipped with all DIPswitches in the off position. Prior to programming the controller some DIPswitches 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: Note: DIPswitch #2 must be set to the “ON” Position for filter operation.
Display Regeneration Key Program Program Key Regen Information Information Key Press Regen once to begin regeneration tonight. Or hold for immediate regeneration. Toggle Up Toggle Down Setting Time Of Day 1. Press Program until 'tod' is displayed. 2. Use arrow keys to adjust minutes. 3. Press Regen once then adjust hours. 4. Continue to press Program to exit menu & save. Display Back-lit LCD display. Program Key Depress to enter and move through the programming steps.
Programming Menus In the programming mode all keys are active. Repeatedly pressing the “Program” key until the desired programm option is displayed enters the standard programming mode. The value is then set by using the “Up” and “Down” keys to increase or decrease the value. Pressing the “Program” key, after value selection, saves the programmed value to EEPROM (unless otherwise specified; some settings are temporarily stored before they are saved).
Settings Display Range Limits Default Comments Cycle 1 time (Backwash) 1 to 99 minutes 10 minutes Cycle 2 time (Pause) 1 to 150 minutes 2 minutes Calculated only with dip # 4 off; add 10 minutes to calculation for A/S mode. Cycle 3 time (Fast Rinse) 1 to 40 minutes 10 minutes Fast Rinse/Refill on Gold. Calculated value for Gold with dip # 4 off. Filter Media Life Toggle (Y or N) N Enable/disable the filter media life feature (filter Operation ONLY).
Display Icons The display is to be backlit and have the icons as shown below.
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.
• 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.
Total Capacity Set Point (Max Capacity) – This setting is used to program a value that corresponds to the maximum gallons that can be expected from a unit before media needs to be replaced (or scheduled service check is required). This setting will only appear if a flow meter is connected to the circuit board. The display will show the “Regen” icon and “Maxcap” for two seconds and then display the “Regen” and “Gallons” or “Liters” icons (depending on DIPswitch # 7 setting) and the setting numbers to adjust.
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.
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.
Accessed by pressing the “Information” key once, then the “Down” key repeatedly Service Statistics Display Range Limits Comments Flow Rate 0 to 999.0 Same as above Capacity Remaining 0 – 999,999 Remaining gallons (liters) until batch capacity is reached Filter Media Life Remaining 0 – 999,999 -ONLY active in filter mode with ‘Life’ option set to ‘Y’.
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. • Flow Rate (standard information) - This display will only show if the flow meter is attached to the control.
• 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.
Manual Cycling text 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.
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.
Before Leaving The Installation Site • Explain the operation of the filter to the customer. Make sure the customer knows that there will be new sounds associated with the recharging of the unit. • Sign and date the corresponding performance data sheet in the Owners Guide. 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. Check the correct tank size.
Preventative Maintenance Recommended Preventative Maintenance The Culligan Iron Cleer water filter has been designed to provide a good, consistent service life. Because of the nature of problem water, we recommend that the local Culligan dealer provide regular maintenance/service contracts for the proper operation of your systems. The water filter service begins with a multi point inspection of your water filter system in an effort to uncover any and all problems that may exist.
Error Codes & 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.
Examples of enhanced error codes Error Code Desplay Comments Err 1 • In regeneration • While advancing to backwash cycle Err 2 • In regeneration • While in brine rinse cycle Err 3 • In service • While in home position ErrP 3H • In Pre-Rinse cycle • While advancing to home position Err 3 • In regeneration • While in fast rinse/refill cycle Err 4 • In service • While seeking home position (initializing) Display Alert Code Description Mode of Detection Comments CHANGE MEDIA Filter mode; total gallo
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).
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.
Troubleshooting Guide Complaint Problem Cause Solution Iron bleedthrough or staining. A. 1. Plugged drain line flow control 1. Clean or replace drain line flow control 2. Insufficient water supply from well. 2. Check for minimum specified flow and pressure requirements of filter system. 3. Plugged aeration tank inlet diffuser or pick-up tube. 3. (Generally will only plug with the presence of iron bacteria.
Complaint Problem Cause Solution Iron bleedthrough or staining. Cont. F. Regeneration during service flow demand. 1. Time of day set incorrectly. 1. Reset timer. G. Raw water bleeding through filter. 1. Internal control valve leak. 1a. Assure all adapter base o-ring seals are in place 1b. Replace seals, spacer and piston assemblies. Water leaking from relief valve. A. Dirt lodged under seat of valve. B. Faulty or defective relief valve 1.
Complaint Problem Cause Water is running to drain continuously. A. Control valve is 1. Electrical service to control(s) has stuck in regeneration been interrupted. cycle. 2. Faulty circuit board. Solution 1. Assure continuous electrical service is available. (check plug, breaker, fuse, etc.) 2. Replace circuit board.. 3. Faulty drive motor. 3. Replace drive motor. 4. Foreign material lodged in piston. 4. Disassemble and clean control valve, replace seals, spacers and piston assemblies. 1.
Circuit Board Troubleshooting 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.
Service Warning! Disconnect all electrical power to the unit before servicing. Bypass the unit and relieve system pressure before attempting repair. Familiarize yourself with the replacement procedures and component parts thoroughly before attempting any 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.
Refer to Figure 16 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.
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.
Wiring Diagram Iron Cleer Relay Base Ground Green Compressor Black 3 2 White 4 1 5 8 6 7 Black Solenoid Valve Green Black Black White Rear View Circuit Board Switch Assembly Motor and power wires are not polarity ensitive. Motor Brown Red Yellow Battery Power 24V OPT 2.
8 44 Culligan® Iron-Cleer® Plus Water Filters 57 52 2 3 4 5 1 17 56 25 23 9 10 15 Chamfered Side Face In 22 55 53 24 54 18 19 20 16 49 63 67 48 68 51 50 44 37 31 32 34 30 43 33 29 59 42 47 46 36 21 45 Parts List Control
Item No. Part No. — 01-0174-95 Control Valve Assembly - Gold Series 1 01-0139-76 Control Valve Body ‡2 01-0130-83 Seal Pack Assembly ‡3 01-0012-58 Eductor Sleeve Filter ‡* P0-4479-86 O-Ring, Eductor Sleeve, Small ORing (25/Kit) ‡* P0-3084-07 O-Ring, Eductor Sleeve, Large ORing (25/Kit) 4 00-4464-75 Plug P0-3316-36 Backwash Restrictor, 3.5 GPM (10/Kit) 00-4010-31 Backwash Restrictor, 5.5 GPM A0-7080-08 Backwash Restrictor, 10.
Conditioner Tank Item Part No.
Compressor Item No. Description Qty. *16 Piston Cup 1 **17 Connecting Rod/Eccentric Bearing Assem.
Aeration 2 8 5 1 6 8&5 4 10 & 11 8 7 3 Item No. Part No.
