Cat. No. 01882311 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 MEDALLIST SERIES™ AUTOMATIC WATER CONDITIONER MODELS FROM 2002 Table of Contents Page Introduction................................................................. 2 Specifications............................................................. 3 Familiarization............................................................ 4 Settings...................................................................... 7 Programming.............................................................
Introduction The Culligan Medallist Series™ Water Softeners are tested and validated by WQA and certified by UL against ANSI/NSF Standard 44 for the effective reduction of calcium and magnesium along with Barium and Radium 226/228*. Because the ability of the unit to remove Barium and Radium is based upon reducing hardness to less than 1 gpg, effective hardness reduction should be periodically verified. Hardness sample kits are available through your local Culligan Dealer.
Specifications CULLIGAN MEDALLIST SERIES WATER CONDITIONER WITH TIMECLOCK OR SOFT MINDER METER 8" MODEL 303 MODEL Control Valve Type 5-cycle Reinforced 5-cycle Reinforced Thermoplastic Thermoplastic Overall Conditioner Height 51 in 49 in 1,295 mm 1,245 mm Media Tank Dimensions (Dia. x Ht.) 8 x 44 in 10 x 40 in 203 x 1,118 mm 254 x 1,016 mm Salt Storage Tank Dimensions 16 x 43 in 18 x 43 in (Dia. x Ht.
Familiarization CONTROL The Culligan Medallist Series™ 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 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 Time of Day Time of Regen. Salt Dosage Backwash Time Brine Rinse Time Gallons Capacity/Regen. Interval Forced Regen.
FIG. 1 SOFT-MINDER® OPERATION The Soft-Minder meter utilizes a turbine impeller to accurately monitor the customer's water usage. After a predetermined amount of water has passed through the system, the microprocessor will signal a regeneration. The "REG" enunciator will light at this point. The unit will perform a standard regeneration cycle at the preset time, unless the programming option "dip2" is changed from "DEL" to "Id".
If "dip2" is set to "Id", the unit will begin a regeneration immediately for instances 1 and 2. With "dip2" set to "del", 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 12:00 AM and regeneration will occur at delayed time.
Settings The mircoprocessor can be set in two distinct operation modes, Soft-Minder® meter or Timeclock. As shipped from the factory, the control is set for 8" Timeclock operation. CAPACITY AND SALT SETTINGS As mentioned previously, the softener will regenerate once the amount of water equal to the treated water volume set point has passed through the turbine for meter models or after a fixed time interval for timeclock models.
TABLE 4 - SALT DOSAGE Capacity 160 lb. Brine Tank 250 lb. Brine Tank 375 lb. Brine Tank "A" Dimension "A" Dimension "A" Dimension Salt Capacity Secondary (Only) Secondary Primary Secondary Primary Dosage 8" ft3 30 ft3 45 ft3 in. (cm) in. (cm) in. (cm) in. (cm) in. (cm) 4 18,300 X X 7-3/4 19.7 6-5/8 16.8 4-5/8 11.7 5-1/2 14.0 3-1/2 8.9 5 20,000 20,000 20,000 9-1/2 24.1 8 20.3 6 15.2 6-1/2 16.5 4-1/2 11.4 6 22,000 22,500 23,500 11-1/4 28.6 9-3/8 23.8 7-3/8 18.
Example - Timeclock: Softener Model Medallist 2 Capacity @ 9 lb. Salt Dosage: 25,100 Grains Compensated Water Hardness: 19 Grains Per Gallon Estimated Daily Water Usage: 300 Gallons Per Day Softener Capacity Treated Water Volume Set Point = Compensated Hardness Softening Capacity Divide by Compensated Hardness Result is total number of gallons of soft water per regeneration Subtract daily Water Usage (needed as a reserve to ensure continuous soft water until regeneration occurs).
BRINE VALVE "A" DIMENSION The brine valve contains a float-actuated safety shut-off device to prevent overflow of the brine tank in the unlikely case of an electrical or mechanical failure during the brine tank refill cycle. It is recommended that the brine valve float be used as intended, that is, as a secondary, safety shut off. Remember, the timer mechanism provides the primary refill shut-off. To use the float as a safety shut-off, refer to Table 4 for the salt dosage and brine tank size being used.
Programming Make sure the inlet water supply is turned off, then supply power to the timer. The display will power up flashing "12:00 PM" and 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. The timer uses four buttons: FIG. 3 - Circuit Board Display 1. 2. 3. 4. STATUS: PLUS SIGN "+": MINUS SIGN "-": REGEN.: Advance timer through display options. Increase the setting. Decrease the setting.
OFF seconds and then show the current status. Toggle between “OFF” (Timeclock backup is off) and “ON” (Timeclock backup is on) with the “+” or “-” key. Note: Changing this setting will not change any of the programmed values and will load the default Timeclock Backup value of 3 days. Programming step 7 will be activated when this is set to On. Note: This option will only be available when the flowmeter is plugged into the control 5 English or Metric Press the “STATUS” key.
Step 3 – Programming Salt Dosage Press the “Status” key after programming regeneration time. The display will blink “SLtP” if set to English or “SLtG” if set to Metric for 3 seconds and then display the salt dosage. Adjust the setting with the “+” or “-” key (3-24 lbs.)(1-10 kgs.) Note: This option will not show if the control is set to Filter mode. Step 4 – Programming Backwash Time Press the “Status” key after programming salt dosage.
Exiting Program Mode From Step 6 (or step 7 if it is active) press the “Status” key. The display will go blank. Press the “Status” key again to exit programming. Note: The control will exit the programming mode if no key press activity takes place within one minute. Locking the Programmed Menu Press and hold the “+” key for 3 seconds while in the service mode. The display will show the status of the lock feature. (“LoC” or “unL”) Adjust with the “+” or “-“ key.
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. 2. 3. 4. Press the status button to move past the programming steps until the display is blank. From blank display press the “+” key. An "H" will appear in the display. The control is in the HOME position. REG Press and hold the regen button. The 'REGEN' icon will blink, and the motor will advance the control.
Service Check The service mode allows one to view the instantaneous flow rate, the gallons remaining before the softener signals for regeneration, the number of regenerations in the past 14 days, the total number of regenerations the control has cycled through and the number of days since the last regeneration. To enter the service check mode, follow these steps: 1. From the Blank display: 2. Press “-” key. The display will blink “FLO” for 3 seconds and then display the gallons per minute flow rate.
Board Diagnostics To enter the circuit board test mode, follow the procedure listed below: Service or Test Mode Press and hold the “STATUS” key until “dIP 1” appears in the display. “dIP 1” will blink for 3 seconds and then the display will show the status of this option (SEr or tES). Toggle the feature with the “+” or “-” key. Note: Pressing “STATUS” after changing option to test mode will place the control in test mode. After testing is complete press and hold “STATUS” for 3 seconds to exit.
18 6. Press the “-” key. A “3” will appear on the display for 3 seconds. 7. Press the “REG” key. A “4” will appear on the display for 3 seconds. 8. A signal from the flow meter will cause the phone icon to flash. If a flow meter is connected to the circuit board, the bar will be displayed in steps 3-7. 9. Hold the status key for 3 seconds to return to the time of day. The motor will automatically energize to the home position. Note: The control will not “TIME OUT” when in the test mode.
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. Lift up the front cover of the control. 2. Remove all connected wire leads from the board.
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 replacing the 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 CAUSE SOLUTION 1. Unit has blank A. Unit has no power A. Verify that unit is connected to a display. constant power source. (Not an outlet on a switch) B. Defective plug-in transformer B. Replace plug-in transformer 2. Softener fails to A. Electrical service to the unit has been A. automatically initiate disrupted. a regeneration. B. Soft-Minder® meter not properly B. recording total gallons used.
PROBLEM CAUSE SOLUTION I. Salt bridge I. Break up salt bridge in brine tank. Do not try to break the salt bridge by pounding on the outside of the brine tank 6. Loss of water pressure A. Inadequate mineral in media tank. A. B. Control and/or resin bed plugged with B. debris or iron build-up. C. Inlet manifold plugged. C. D. Control plugged with foreign material D. broken loose from recent plumbing work. See problem 7 & 8.
PROBLEM CAUSE SOLUTION 13. Unit uses an A. Incorrect programming A. Refer to the 'Programming' section and excessive amount of verify all settings. salt or chemical B. Excessive water in storage tank B. Refer to problems 9 & 10. 14. Continuous flow to A. Internal seal pack leak. A. drain. B. Seal pack or brine piston jammed B. in position. C. Power failure while unit was in C. regeneration. Replace seal pack as outlined in the 'Parts Replacement Guide' section.
Wiring Diagram Old Schematic Models Purchased Before 3/1/2002 Current Schematic Models Purchased After 3/1/2002 26 CULLIGAN MEDALLIST SERIES™
SALT STORAGE ELEVATION For each foot the salt storage tank is lowered below the floor on which the softener stands, it is necessary to deduct 8 feet of drain line from the allowable length shown on the chart. For each foot the salt storage tank is elevated above the floor on which the softener stands, the height of drain discharge can be raised 2 inches, or the total length of the drain line can be increased 4 feet.
28 CULLIGAN MEDALLIST SERIES Fast HEIGHT OF DRAIN DISCHARGE ABOVE FLOOR Back Rinse Fast Rinse Min. Back Wash B/W Rinse Rate Rinse Rate Pres- Extra sure Brine Vac. Wash Sec./ Restric- Rate Sec./ Rate Sec./ Ht. gpm Gal. tor No. gpm Gal. gpm Gal. Eductor psi 4 in. 1 ft. 2 ft. 3 ft. 4 ft. 5 ft. 6 ft. 7 ft. 8 ft. 9 ft. 10 ft. Line 0.42 142 20 5 0.9 Min. Max. 25 18 12 1.0 30 44 38 28 18 1.
Flow Charts FLOW CHARTS 29
30 CULLIGAN MEDALLIST SERIES™
FLOW CHARTS 31
32 CULLIGAN MEDALLIST SERIES™
FLOW CHARTS 33
Control Valve Parts List 34 CULLIGAN MEDALLIST SERIES™
CONDITIONER TANK PARTS LIST 35 01014042 00449865 01013083 01013606 P0447986 P0308407 P0448750 P0447987 P0443291 P0303192 P0-3031-93 00446835 P0331634 P0331635 P0447387 P0308438 P0308437 00401248 00446038 00446039 P0445269 00445797 00401022 P0448687 01005130 00448128 P0444914 00448126 01004689 P0318383 01014036 01882288 P0448686 — 1 ‡ 2 ‡ 3 ‡ * ‡ * ‡ * ‡ * 4 5 6 7 8 9 ‡ 10 ‡ 11 ‡ 12 ‡ 13 14 ‡ 15 16 17 18 19 ‡ 20 21 22 23 24 25 26 Control Valve Assembly - Medallist Control Valve Seal Pack Assembly E
Conditioner Tank Parts List Item 1 ‡2 3 ‡4 5 * Part No.
Salt Storage Tank Parts List Item — — — — — † 1 2 — — — — 3 — — Part No. 00441390 00441886 01004875 00441887 01004876 01004870 00303993 01014942 00401042 00303980 01014943 00304010 00441391 00303975 Description Brine System, 160 lb. Replacement Brine System, 250 lb. Replacement Brine System, 250 lb. Replacement Less Salt Plate Brine System, 375 lb. Replacement Brine System, 375 lb. Replacement Less Salt Plate Gold Band Cover with Band, 250 lb. Cover 250 lb. Less Gold Band Cover with Band, 160 lb.
Brine Valve Parts List Item Part No. — 00441888 — 00401141 1 00303193 2 00303192 3 00440796 ‡4 00308407 ‡5 00401622 6 00340014 7 00440795 ‡8 00332528 9 00223435 10 00304703 11 00304718 12 00444873 13 00332072 14 00444664 ‡15 00444496 16 00447392 17 00447781 ‡18 00304804 19 00541821 00541834 20 01004901 00-4413-92 21 00-3046-06 * 00-4463-88 * 00-4463-89 Description Brine Valve Assembly Brine Valve Assy., Brine Tank, 160 lb.
Materials & description: 8-1/2 x 11, 40 page book, saddle stitched, three hole punched - Prints black ink on 20# white LET CHANGE A DCO 1610 B DCO 2882 C DCO 3594 D DCO 4625 BY APRVD TPD JB SMP MW LR JS LR JS DATE 10/19/00 9/7/01 06/05/02 09/17/02 This page contains materials and DCO information.
