Cat. No. 01-8822-22 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.
Service Manual CULLIGAN® MARK 100 AUTOMATIC WATER CONDITIONER MODELS FROM 2000 Table of Contents Page Introduction ............................................................... 2 Specifications ........................................................... 3 Familiarization ........................................................... 4 Programming ............................................................ 10 Manual Cycling ........................................................ 12 Service Check .........
Introduction The Culligan® Mark 100 water softeners are tested and validated by WQA against ANSI/NSF Standard 44 for the effective reduction of calcium and magnesium, along with Barium and Radium 226/228*. SAFE PRACTICES Throughout this manual there are paragraphs set off by special headings. NOTICE: Notice is used to emphasize installation, operation or maintenance information which is important, but does not present any hazard.
Specifications Culligan® Mark 100 Water Conditioners with Time Clock, Aqua-Sensor® Device or Soft-Minder® Meter Control Valve Overall Conditioner Height Media Tank Dimensions (Dia x Ht) Salt Storage Tank Dimensions (Dia x Ht) Exchange Media, Type and Quantity Underbedding, Type and Quantity Exchange Capacity @ Salt Dosage Per Recharge1 Freeboard to Media2 Freeboard to Underbedding3 Salt Storage Capacity Rated Service Flow @ Pressure Drop Total Hardness, Maximum Total Iron, Maximum Hardness to Iron Ratio,
Familiarization Control The Culligan® Mark 100 water softener uses the same power valve control as in our Culligan Mark 89/812 models. It can be programmed as either a time clock, Aqua-Sensor® sensing device or Soft-Minder® meter model. Each model has its own programming parameters which can be set to control the operation and regeneration of the system. These functions are outlined in Table 1. TABLE 1 Function 1. Time of Day 2. Time of Regen. 3. Not Used 4. Salt Dosage 5. Backwash Time 6.
Programming Switches The circuit board will require the proper setting of the dip switches in order to function properly. Figure 1 shows the dip switches. Switch 1 - Sets the unit in the Run or Test mode. Switch 2 - Sets the unit for Filter or Softener. Switch 3 - Sets the flow meter K factor for the 3/4" or 1-1/4" flow meter. Switch 4 - Sets the control for 9” or 12” diameter tanks. Switch 5 - Sets the unit for the standard or accelerated Refill cycle.
A qua-Sensor Operation The Aqua-Sensor models contain a feature which can automatically detect when the brine solution has been rinsed through the Cullex media. This feature will advance the control to the next position when it senses that the brine has been rinsed out prior to the time set in the brine rinse option. The Brine/Rinse time can be manually raised or lowered in the microprocessor.
Display Blanking As shipped from the factory, the display of the board will turn off if there has been no keypad activity for a 1 minute period. To have the display constantly lit, press the STATUS button until the number 10 icon is lit. Next, press the UP arrow. A “d” for disable will appear in the display. To have the display blank again , press the UP arrow. An “E” will appear in the display .
8 CULLIGAN® MARK 100 WATER SOFTENER TABLE 3A - CAPACITY, 9” AQUA-SENSOR® SENSING DEVICE (GALLONS) “A” DIMENSION HARDNESS SALT 160 LB 250 LB 375 LB DOSAGE INCH(CM) INCH(CM) INCH(CM) 1-5 6-10 11-15 16-20 21-25 26-30 31-35 36-40 41-45 46-50 51-55 56-60 61-65 66-70 71-75 8 14-3/4 (37.5) 9-1/4 (23.5) 7-1/2 (19.1) TOTAL CAPACITY CAPACITY TO SIGNAL 4,900 2,450 1,633 1,225 3,537 1,949 1,179 1,004 12 21-3/4 (55.2) 15-3/4 (40.0) 11-3/8 (26.
TABLE 4A - CAPACITY, 12” TIME CLOCK AND AQUA-SENSOR® SENSING DEVICE (GALLONS) “A” DIMENSION HARDNESS SALT 160 LB 250 LB 375 LB DOSAGE INCH(CM) INCH(CM) INCH(CM) 1-5 6-10 11-15 16-20 21-25 26-30 31-35 36-40 41-45 46-50 51-60 61-70 71-80 81-90 91-99 12 21-3/4 (56.2) 15-3/4 (40.0) 11-3/8 (28.9) TOTAL CAPACITY CAPACITY TO SIGNAL 6,740 3,370 2,247 1,685 1,348 1,123 4,542 2,271 1,514 1,136 908 757 18 N/A 24-1/2 (62.2) 17-1/4 (43.
Programming The display will initially power up flashing "12:00 PM". After 1 minute the motor will energize and cycle the control, without stopping, to the home position. This is required to ensure that the control is in the home position. FIGURE 3 - Circuit Board Display The timer uses four buttons: 1. 2. 3. 4. STATUS: UP ARROW: DOWN ARROW: REGEN.: Advance timer through display options. Increase the setting. Decrease the setting. Initiate a manual regeneration.
5. 6. 7. 8. Press status again, this displays the Backwash Time in minutes. The setting can be adjusted between 5 and 40 minutes by using the up and down arrows. A number “5” will appear at the bottom of the display while in this mode. Press ▲ to increase or ▼ to decrease Press status again to display the Brine/Rinse Time in minutes. The settings can be adjusted using the up and down arrows (37-85 min for 9”, 35-89 min for 12”).
Manual Cycling The Culligan® microprocessor can be indexed through the various regeneration stages. For all steps, the cycle numbers do not appear, or change, until the motor stops. 1. Press the status button to move past steps 1-10 until the display is blank. Push the up arrow. The number “11” icon will light up. An "H" will appear in the display. The control is in the HOME position. Pressing the regen button once will light the 'REGEN' icon. 2. Press the regen button one more time.
Service Check The service check mode allows one to view the instantaneous flow rate, the days since the last regeneration, the total number of regenerations, the regenerations in the past fourteen days, and the gallons remaining. To enter the service check mode, follow these steps: 1. Press the status key to move past steps 1-10 until the display is blank. 2. Push the down arrow. The number '12' will appear only when the Soft-Minder® meter is connected. The display reads the gallons per minute flow rate.
Board Diagnostics Board Diagnostic To enter the board test mode, flip all of the dip switches to the ON position. All the segments of the board will light until either a key is depressed, an option is changed or a CAM micro switch changes position. Pressing one of the keys, closing a micro switch or turning OFF a dip switch will cause a different segment to light as outlined in Table 5. A balanced signal should be applied to the Aqua-Sensor® pin connector.
Parts Replacement Guide 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™ circuit board, refer to the parts list and proceed as follows: 1. Remove the timer cover be removing the two screws located in the front of the cover. 2.
Refer to Figure 5 for assembly and disassembly of the various valve components listed below. Drive Motor Assembly 1. 2. 3. 4. 5. 6. 7. 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. Using a 1/4" hex driver, remove the bolt above the eductor piston assembly.
Seal Pack Assembly Follow the instructions for the replacing drive motor assembly through step 7, then continue as follows: 1. 2. 3. With the drive motor and backplate set aside, firmly pull the seal pack assembly from the valve body. Lightly lubricate the o-rings of the replacement seal pack with silicone grease. Reverse the procedure for reassembly. NOTICE: Use only silicone grease; petroleum-based lubricants will cause the degradation of the rubber components.
Eductor Assembly Refer to Figure 7 and the following instructions for replacement of the eductor: 1. Remove the three screws and the eductor plate 2. Remove the eductor screen by lifting it from the eductor body. 3. Remove the eductor body by grasping one of the projections with the pliers and gently pulling upward. 4. Reverse the procedure to reassemble. Be certain that the replacement eductor body contains the correct eductor nozzle.
Troubleshooting Guide PROBLEM 1. Unit has blank display. 2. Softener fails to automatically initiate a regeneration. CAUSE A. Display is set to blank after 1 minute of no activity. i. Refer to the 'Programming' section to disable the display blanking B. Unit has no power. i. Verify that unit is connected to a constant power source. (Not an outlet on a switch) C. Defective plug-in transformer. i. Replace plug-in transformer. A. Electrical service to the unit has been disrupted. i.
PROBLEM 4. Phone Icon 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 softeners. 6. Loss of water pressure. CAUSE SOLUTION A. Jammed seal pack or brine piston. i. Replace the seal pack or brine piston as outlined in the 'Parts Replacement Guide' section. B. Defective cam microswitches. i. Replace cam microswitches. C. Defective motor. i.
PROBLEM 7. Loss of mineral to drain. 8. Mineral to service. 9. Water in storage tank up to float. 10. Excessive water in salt storage tank. (Water above brine valve float) CAUSE SOLUTION A. Improper drain line flow control. i. Ensure that the control has the proper drain line flow control. (See Table 7) B. Air in water system. i. Ensure that system has proper air eliminator control. A. Control connected to tank backwards. i. Verify that control is properly mounted to the tank.
PROBLEM 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. CAUSE SOLUTION A. Drain line flow control is plugged. i. Clean drain line flow control. B. Plugged eductor system. i. Clean or replace eductor screen and nozzle. C. Line pressure too low. i. Increase line pressure to a minimum of 20 psi (140 kPa). D. Internal control leak. i. Replace seal pack and/or eductor sleeve/piston assembly. E.
Wiring Diagram WIRING DIAGRAM 23
“A” Dimension Charts/Refill Rates The “A” dimension is the distance from the top of the filter screen of the brine valve chamber to the bottom edge of the lower float when the stem is in the fully raised position. Refer to Table 8 for the correct “A” dimension (secondary shutoff) for the salt dosages on the water softener models. Adjust the “A” dimension as follows (Figure 8). • • • • Lift the brine valve from the brine chamber. Find the correct “A” dimension from Table 8.
TABLE 8 - Brine Valve "A" Dimension REFILL TIME (MIN) BRINE TANK “A” DIMENSION POUND STANDARD FAST 160 LB 250 LB 375 LB SALT (0.45 gpm) (0.80 gpm) (13") (16") (18") 3 2.23 1.30 6 5-1/4 4-1/2 4 3.08 1.73 7-3/4 6-5/8 5-1/2 5 3.83 2.17 9-1/2 8 6-1/2 6 4.62 2.63 11-1/4 9-3/8 7-1/2 7 5.38 3.03 13 10-7/8 8-1/2 8 6.15 3.47 14-3/4 12-1/4 9-1/2 9 6.92 3.90 16-1/2 13-5/8 10-1/2 10 7.70 4.32 18-1/4 15 11-1/2 11 8.47 4.75 20 16-3/8 12-1/2 12 9.23 5.
CULLIGAN® MARK 100, 9” WATER CONDITIONER Fast Back Rinse Fast Rinse Min. Back Wash B/W Rinse Rate Rinse Rate PresVac. Wash Sec./ Restric- Rate Sec./ Rate Sec./ sure Ht. gpm Gal. tor No. gpm Gal. gpm Gal. Eductor psi 4 in. 0.22 273 20 Min. Max. 25 33 19" 2.0 30 2 0.32 Avg. 188 Avg. 2.0 30 Blue HEIGHT OF DRAIN DISCHARGE ABOVE FLOOR 1 ft. 2 ft. 3 ft. 27 17 7 4 ft. 5 ft. 6 ft. 7 ft. 8 ft. Extra Brine 9 ft. 10 ft. Line 0.9 1.
CULLIGAN® MARK 100,12” WATER CONDITIONER Fast Back Rinse Fast Rinse Min. Back Wash B/W Rinse Rate Rinse Rate PresVac. Wash Sec./ Restric- Rate Sec./ Rate Sec./ sure Ht. gpm Gal. tor No. gpm Gal. gpm Gal. Eductor psi 4 in. 0.42 142 20 5 Min. Max. 25 18 19" 3.5 17 3 0.75 Avg. 80 Avg. 3.5 17 Beige HEIGHT OF DRAIN DISCHARGE ABOVE FLOOR 1 ft. 2 ft. 3 ft. 4 ft. 5 ft. 6 ft. 7 ft. 8 ft. 12 Extra Brine 9 ft. 10 ft. Line 0.9 1.
Flow Charts 28 CULLIGAN® MARK 100 WATER SOFTENER TANK INLET EDUCTOR TANK OUTLET DRAIN BRINE TANK OR SOLUTION TANK CONDITIONED WATER OUT RAW WATER IN SERVICE
TANK INLET EDUCTOR TANK OUTLET DRAIN BRINE TANK OR SOLUTION TANK BYPASSED WATER OUT RAW WATER IN FLOW CHARTS 29 BACKWASH
30 CULLIGAN® MARK 100 WATER SOFTENER TANK INLET EDUCTOR TANK OUTLET DRAIN BRINE TANK OR SOLUTION TANK BYPASSED WATER OUT RAW WATER IN REGENERANT DRAW
TANK INLET EDUCTOR TANK OUTLET DRAIN BRINE TANK OR SOLUTION TANK BYPASSED WATER OUT RAW WATER IN FLOW CHARTS 31 SLOW RINSE
32 CULLIGAN® MARK 100 WATER SOFTENER TANK INLET EDUCTOR TANK OUTLET DRAIN BRINE TANK OR SOLUTION TANK BYPASSED WATER OUT RAW WATER IN RAPID RINSE & REFILL
