Culligan Aquasential Select Plus Iron-OX5 Installation, Operation And Service Instructions Download

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Culligan Aquasential Select Plus & Select Series Iron-OX5 & Sulfur-OX3 Water Filters 01040683

Dip Switch Definitions

The circuit board is shipped with all DIP switches in the off position. Prior to programming the controller some DIP

switches 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. The definitions and purpose are as follows:

NOTE!

DIP switch #3, #4, and #7 MUST be set to the “ON” position for the Iron-OX5 and Sulfur-OX3 filters.

All other switches are set to “OFF.”

Switch #

Abbreviation

Definition

Purpose

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.

D / I

Delayed / Immediate

Off - Reconditioning Cycle will occur at

Delayed Time of Day upon a controller

receiving a valid reconditioning cycle

initiation signal.
On - Reconditioning Cycle shall occur

immediately upon a controller receiving a valid

reconditioning initiation signal, regardless of the

time of day.

SO / FI

Softener / Filter

Off - The unit shall be operated as a softener.

On -The unit shall function as a filter but

utilize program logic to time the air draw

cycle to recharge the air head.

- / TCB

Time Clock Back-up Disabled /

Enabled

Off - The time clock backup option is not enabled.

On - Allows the user to program the time

clock function of the control to initiate the

reconditioning cycle on a fixed interval. This

setting MUST be on for the Sulfur-OX3 filter.

E / M

English / Metric

Off - The unit will function in standard

English dimensions.
On - The unit will function in standard

metric dimensions.

12 / 24

12 Hour Clock / 24 Hour Clock

Off - All time keeping functions shall be

based on an AM/PM basis. The 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.

.75” / 1”

3/4” / 1” Control

Off - 3/4” Medallist Control Valve

On - 1” Medallist Plus Control Valve

S / F

Standard Refill / Fast Refill

Not applicable for filter applications.

Summary of Contents for Aquasential Select Plus Iron-OX5

Page 1: ...DCO 210369 11 04 2021 CAT 01040683 Rev B 2021 Culligan International Company Aquasential Select Plus Iron OX5 Sulfur OX3 Water Filters Models from 2021 ...

Page 2: ...k 26 Start Up 28 Preventative Maintenance 31 Service 33 Troubleshooting Guide 37 Circuit Board Troubleshooting 40 Flow Diagram 44 Wiring Diagram 48 Parts List 49 Appendix A Application Iron OX5 55 Appendix B Application Sulfur OX3 56 Appendix C Outdoor Installation 57 Index 59 Installation Operation and Service Instructions with Parts Lists Aquasential Select Plus Iron OX5 Sulfur OX3 Water Filters...

Page 3: ...ntiated by test data In order for the water treatment system to continue to provide high quality water you must develop a thorough understanding of the system and its operation Review this manual before making any attempt to install operate or service the system Installation or maintenance done on this system by an untrained service person can cause major damage to equipment or property damage Lic...

Page 4: ... to cover all possible conditions and situations that may occur It must be understood that common sense caution and careful attention are conditions which cannot be built into the equipment These MUST be supplied by the personnel installing operating or maintaining the system Products manufactured and marketed by Culligan International Company Culligan and its affiliates are protected by patents i...

Page 5: ...mply with any warning or caution that results in any damage will void the warranty WARNING Use protective clothing and proper face or eye protection equipment when handling chemicals or power tools CAUTION This product is not to be used by children or persons with reduced physical sensory or mental capabilities or lack of experience or knowledge unless they have been given supervision or instructi...

Page 6: ...w Pressure Drop Clean Bed Normal 4 gpm 5 psi 4 gpm 2 9 psi Maximum 6 gpm 9 psi 6 gpm 9 psi Operating Pressure 20 60 psi 20 60 psi Operating Temperature 33 120 F 1 48 C 33 120 F 1 48 C Electrical Requirements 24 Volts 60 Hz 24 Volts 50 60 Hz Power Consumption Continuous Maximum 3 Watts 10 Watts 3 Watts 10 Watts Drain Flow 5 5 gpm 5 5 gpm Reconditioning Time Backwash 15 minutes 15 minutes Air Draw 4...

Page 7: ...atalytic Carbon and 20 lbs of Cullsan underbedding to be used in this system The Iron OX5 system includes one cubic foot of Birm 50 lbs of G 50 media and 25 lbs of Cullsan U underbedding Note Only 35 lbs of G 50 is used in this system Install Kit Small parts pack including inlet check valve air line check valve air line strainer the required no refill eductor sleeve backwash flow control and insta...

Page 8: ...rements 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 Floor Surface Choose an area with solid level floor free of bumps or irregularities Drain Facilities Choose a nearby drain that can handle the rated drain flow floor drain sink or stand pipe NOTE Most codes require an anti siphon device or air gap for the drain line Observ...

Page 9: ...nts are illustrated in Figure 2 r o d e p i r t S e l b a c d e b b i r d e p i r t s n o N h t o o m s r o e l b a c 1 n i P 2 n i P ta 40 C 1120 TDC POWER PRODUCTS CO LTD 01 PN 01040206 INPUT 100 240V 50 60Hz 1 2A Max CAUTION RISK OF ELECTRIC SHOCK DRY LOCATION USE ONLY TO REDUCE THE RISK OF FIRE OR ELECTRIC SHOCK DO NOT INTERCONNECT OUTPUT TERMINATIONS POWER SUPPLY MADE IN CHINA E231682 VI OUTP...

Page 10: ...ed See Table 1 7 Load the Birm media See Table 1 8 Remove the funnel 9 Using a hose top off the tank with water to bring the water level to within a few inches of the top opening and add 2 ounces of 6 liquid chlorine bleach to the tank for sanitization 10 Install the inlet strainer making sure to thread the strainer until it bottoms out on the tank thread Failure to install the strainer correctly ...

Page 11: ...underbedding through the top of the tank See Table 2 6 Load the tank with Cullar S media Leveling is required See Table 2 7 Remove the funnel 8 Using a hose top off the tank with water to bring the water level to within a few inches of the top opening and add 2 ounces of 6 liquid chlorine bleach to the tank for sanitization 9 Install the inlet strainer making sure to thread the strainer until it b...

Page 12: ...et strainer must be threaded all the way down against the outlet manifold or the tank adapter won t fit properly 4 Screw the adapter into the tank until the adapter bottoms out on the tank flange The adapter only needs to be hand tightened to the tank flange The adapter must be tight plastic against plastic with no gap to prevent the tank o ring from escaping 5 Align the manifold with the center o...

Page 13: ...ound 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 ca...

Page 14: ... arrow on end of knob until the knob stops as shown Figure 7 DO NOT OVERTIGHTEN To return to service turn the blue knob counter clockwise until the knob stops as shown Figure 8 See directional arrow on the end of knob DO NOT OVERTIGHTEN To Bypass About 3 8 Figure 7 About 1 1 4 A screwdriver shank may be used in the slot as a lever for extra turning force if needed Figure 8 ...

Page 15: ...ltered water will be available to the household throughout the remainder of the installation process Set the Cul Flo Valve Bypass in the bypass position by screwing the stem all the way in against the body 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 con nec tions remove all plastic and ...

Page 16: ...010783 Select Plus 1 Copper Tube Straight 1 Set P1009856 Select Plus Select 3 4 and 1 Copper Plumbing Adapters Gasket 25 ea P10vv18758 Select Plus 1 Plastic PVC Threaded MNPT Straight 5 Sets P1018757 Select Plus 1 Plastic PVC Threaded MNPT 90 Elbow 5 Sets MS030226 Select Plus 1 John Guest CTS Straight 1 Fitting MS030225 Select Plus 1 John Guest CTS 90 Elbow 1 Fitting MS030451 Select Plus 1 Boshart...

Page 17: ...d by the local plumbing code The system and installation must comply with state and local laws and regulations Figure 10 Table 3 Maximum Allowable Drain Line Length Height of Discharge Above Floor Level Operating 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 f...

Page 18: ...quasential Select Plus Iron OX5 or Sulfur OX3 Green Beige P1024333 10 ea Backwash Flow Control Refer to Figure 10 on page 17 and the following instructions for replacement of the drain line flow control 1 Remove the drain elbow retaining clip from the valve body 2 Pull the drain elbow from the valve body 3 Remove the flow control from the valve body and replace with a new flow restrictor NOTE The ...

Page 19: ... OX3 should be set up for Timeclock operation Circuit Board All terminals are clearly marked to ease installation Build A 3107 1 2 3 4 5 6 7 8 R T DE IM SO FI TCB E M 12 24 75 1 SL FA ON DIP SWITCHES 1 2 3 4 5 6 7 8 ON OPTIONAL BATTERY CONNECTION FLOW METER CONNECTION BACKSIDE OF CIRCUIT BOARD WIRE HARNESS CONNECTION MICROSWITCHES AND MOTOR POWER POWER CONNECTION MOUNTING HOLES ...

Page 20: ...ld provide an electrical outlet that is not controlled by a switch that can be turned off accidentally Observe local electrical codes NOTE The filter works on 24 volt 60 Hz electrical power only P N 01041743 20 ft plug in power supply is rated for indoor installations only P N 01031263 30 ft optional power cord for longer runs to an indoor outlet Figure 12 20 foot AC Power Supply 01041743 ...

Page 21: ...ed power up the control The display will power up flashing 12 00 PM and the motor will energize and cycle the control without stopping This is required to ensure that the control is in the home position The timer uses four buttons Figure 13 Keypad Advance timer through display options Initiate a reconditioning cycle Decrease the setting Increase the setting ...

Page 22: ...conditioning Cycle shall occur immediately upon a controller receiving a valid reconditioning initiation signal regardless of the time of day 3 SO FI Softener Filter Off The unit shall be operated as a softener On The unit shall function as a filter but utilize program logic to time the air draw cycle to recharge the air head 4 TCB Time Clock Back up Disabled Enabled Off The time clock backup opti...

Page 23: ...meter is connected to circuit board Hidden Programming Menu Accessed from service mode by holding the key for 5 seconds Delay Immediate Toggle Delay or Immediate Delay Locks in a regen signal after a 3 hour or more power outage regen can be set to go immediate or delay until the tor Only accessible from service mode time of day display by pressing and holding for 5 seconds not in programming menu ...

Page 24: ...n possibly be decreased Hydrogen Sulfide Removal Applications 0 3 3 0 ppm Hydrogen Sulfide Recommended every 3rd Day Frequency of backwash may need to be increased for high water usage If water usage is low frequency of backwash can possibly be decreased NOTE Settings based on average pressure 50psi and 500 gallon capacity between reconditioning cycles Gallons Capacity The Aquasential Iron OX5 and...

Page 25: ...wn in the 3rd digit from the right The center bar of the digit will light solid and the LEDs will turn off when the motor output is on The cycle time remaining will be displayed in the two right most end digits If a flow meter is attached the phone icon will show solid and flash if the control is getting a flow signal form the flow meter Figure 15 1 While in the service mode press the Status key u...

Page 26: ...ng is complete cycle 3 times out automatically Number of days since last Reconditioning Cycles 0 to 99 Days counter is to be updated at 12 00 AM ONLY when dip 2 is on AND dip 4 is off Otherwise update at whatever TOR is set for After a valid reconditioning is complete cycle 3 times out automatically the counter is to be reset to 0 Number of Reconditioning Cycles Life of the Unit 0 to 9 999 Counter...

Page 27: ... Days This display will show the number of reconditioning cycles that have occurred in the last 14 days The display will first show 14dY for two seconds and then display the number of valid reconditioning cycles that have occurred Number of Days since Last Reconditioning Cycle This display shows the number of days that have elapsed since the last reconditioning cycle The display will show dAYS for...

Page 28: ...eck for leaks on the suction line as it pressurizes 13 When the drain runs clear cycle the control back to H Home position complete the installation and cleanup 14 Initiate an immediate reconditioning cycle before leaving the installation site to establish a proper head of air in the filter tank CAUTION If a sudden rush of water enters the filter some of the media could be forced into the control ...

Page 29: ... precautions 1 Do not place heavy objects on top of the filter 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 Culligan recommends Simple Green or an equivalent cleaner 3 Protect the filter and drain line from freezing temperatures 4 Reset the time if required after any interruption of electrica...

Page 30: ...onditioning cycle at 12 00 AM In the delay mode REG indicator will light at 12 00 AM and reconditioning cycle will occur at programmed delayed time Display Lockout The Culligan Aquasential Select Plus control is equipped with a feature which will allow you to protect the programmed settings from tampering by unauthorized individuals When the lockout feature is activated the only parameters which c...

Page 31: ...maintenance items to be inspected at a minimum of once a year or more frequently depending on the untreated water quality Test Water Feed Product Hardness Iron pH Level Alkalinity TDS Other Comments Bypass Valve Bypass in Service or Bypass Condition of bypass valve Operation OK Control Valve Condition of Seal Pack Condition of Motor Condition of Flow Control Condition of Switches Condition of Inle...

Page 32: ... to be inspected at a minimum of once a year or more frequently depending on the untreated water quality Test Water Feed Product Hardness Hydrogen Sulfide Iron pH Level Alkalinity TDS Comments Bypass Valve Bypass in Service or Bypass Condition of bypass valve Operation OK Control Valve Condition of Seal Pack Condition of Motor Condition of Flow Control Condition of Switches Condition of Inlet Chec...

Page 33: ... CAUTION Electrical static discharges may cause damage Do not touch any surfaces of the circuit board Hold only by the edges Mishandling will void the warranty CAUTION The wire connectors must be connected to the circuit board properly 1 Lift up the front cover of the control 2 Remove all connected wire leads from the board 3 Remove the circuit board from the retaining clips on the front cover 4 T...

Page 34: ...ke 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 When attaching the yoke support plate be certain to push up on the plate until the two mounting screws bottom in the U shaped channels of the support plate 1 Remove the drive motor cam switches by removing the one screw holding the switches to the motor 2 Remove the E rin...

Page 35: ... With the drive motor and backplate 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 ...

Page 36: ...he 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 Table 6 Eductor Selection Model Nozzle Color Nozzle with O Ring P N 10 Aquasential Select Plus Ir...

Page 37: ...e greater than limits established by the manufacturer 1 It is not uncommon for local water conditions to change 1 Consult manufacturer D Inadequate aeration 1 Loss of air through inlet check valve 1a Check installation position of check valve Consult Installation and Operation Manual for proper position 1b Check for foreign material in seat of check valve clean or replace as required 2 Loss of air...

Page 38: ...p system 1 Repair or replace well pump system 2 Water flow is restricted by supply piping and or water treatment equipment 2a Eliminate restrictions in supply piping to water treatment equipment such as iron bacteria plugging the upper diffuser assembly etc 2b Install larger water treatment system to provide less pressure drop Loss of media through drain line A New filter media was loaded dry in f...

Page 39: ...ilter System to protect the distribution piping Periodic Sanitization Procedure If the system develops off tastes and odors and requires sanitization follow the procedure below to educt 3 ounces of a 6 household bleach solution into the system Bypass the system and relieve water pressure by manually cycling the system into the backwash cycle When flow to drain has stopped and it is certain the sys...

Page 40: ...mal Display Error Description Mode of Detection Clearing Error Alarm Motor Failure to Start No switch changes If the valve fails to reach the desired state within 70 seconds of driving the motor The control will attempt to start the motor 3 times for 70 seconds each time with a 60 second off period between each attempt Press and hold STATUS key for 10 seconds Motor Failure to Stop unexpected switc...

Page 41: ...ting 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 reappeared yet Let s start with what to check when you come upon a circuit board problem 1 Are the switches aligned too closely to the cam There should be a small but obvious gap between the switches and the cam so that a wobbling cam d...

Page 42: ...s only used to step down the voltage it is not used for protection or filtering the power source Test Mode In this mode the control can be put through a performance test to verify the operation of the board components Moving dip 1 from service to test mode enters the test mode the motor output should turn off if it was on upon entering test mode When entering test mode all program settings and sta...

Page 43: ...to show P when Position switch closed Close Position Switch Display to Blank when open Open Position Switch Flow Meter Display to show Phone icon when flow meter is connected Connect Flow Meter Display to blink Phone icon when flow meter is sending pulses Spin Flow Meter Chlorinator Display to show Colon icon when chlorinator is connected Connect Chlorinator Display to blink Colon icon when chlori...

Page 44: ...e water is run through the filter media then up the manifold to the outlet to service The water to the service should be free of iron if the system is operating properly Figure 19 COLOR KEY RED Raw Water ORANGE Diluted Brine YELLOW Concentrated Brine PURPLE Piston BLUE Treated Water GRAY Water To Drain TANK INLET TANK OUTLET EDUCTOR EDUCTOR TANK OUTLET TANK INLET AIR SUCTION LINE Diluted Air Air W...

Page 45: ...trol valve to drain The water to drain may be discolored for several minutes due to the volume of precipitated iron being removed from the filter tank and media Unfiltered water is available to service during backwash Figure 20 COLOR KEY RED Raw Water ORANGE Diluted Brine YELLOW Concentrated Brine PURPLE Piston BLUE Treated Water GRAY Water To Drain TANK INLET TANK OUTLET EDUCTOR EDUCTOR TANK OUTL...

Page 46: ...al tank and displaces the water in the tank to recharge the air head Water moves up the manifold and to the drain Once the air draw cycle is complete the unit cycles to fast rinse Unfiltered water is allowed to service during Air Draw Figure 21 COLOR KEY RED Raw Water ORANGE Diluted Brine YELLOW Concentrated Brine PURPLE Piston BLUE Treated Water GRAY Water To Drain TANK INLET TANK OUTLET EDUCTOR ...

Page 47: ...d within the filter tank and the filter media is rinsed prior to the system returning to the service cycle Unfiltered water is available to service during Fast Rinse NOTE No water should flow continuously from the air line during fast rinse if the no refill eductor sleeve was installed Figure 22 COLOR KEY RED Raw Water ORANGE Diluted Brine YELLOW Concentrated Brine PURPLE Piston BLUE Treated Water...

Page 48: ...ct Series Iron OX5 Sulfur OX3 Water Filters 01040683 Wiring Diagram 48 Wiring Diagram Figure 23 YEL RED BRN BRN CIRCUIT BOARD GEARMOTOR BLK BLK POWER CORD 24 VOLT AC FROM POWER TRANSFORMER MOTOR POSITION SWITCH TOP MOTOR HOME SWITCH BOTTOM ...

Page 49: ...s List 49 Culligan Aquasential Select Plus Select Series Iron OX5 Sulfur OX3 Water Filters 01040683 Parts List Aquasential Select Plus OX 1 Control Figure 24 1 Control Valve 8 6 10 9 39 12 5 4 7 62 3 61 11 ...

Page 50: ...n Aquasential Select Plus Select Series Iron OX5 Sulfur OX3 Water Filters 01040683 Parts List 50 Figure 25 1 Control Valve 15 14 16 18 13 1B 21 22 23 24 2 36 31 30 28 32 34 26 20 17 19 64 33 35 43 40 60 58 59 ...

Page 51: ...Aquasential Select Plus Select Series Iron OX5 Sulfur OX3 Water Filters 01040683 Figure 26 1 Control Valve 57 51B 55 53 54 56 52B 83 72B 72B 67B 70 70 Select Plus 1 Bypass Valve Select Plus 1 Tank Adapter 82B 71B 85 68 69 81 ...

Page 52: ... 18 00448126 Plug Body Rear 1 EA 19 P0448128 Clip Body Rear 10 EA PK 20 P1040222 Drain Elbow Assembly Barbed with O ring 10 EA PK 21 P1001257 Repl Eductor Sleeve Sulfur Cleer OX Includes Items 22 23 and 24 10 EA PK 22 P0447986 O ring Eductor Sleeve Small 25 EA PK 23 P0308407 O ring Eductor Sleeve Large 25 EA PK 24 P0448750 Screen Eductor Sleeve 10 EA PK 26 P1040214 Drain Line Flow Control 5 5 GPM ...

Page 53: ...4 Rotary Includes Items 68 and 71B 1 EA 68 01018755 Rebuild Kit 1 1 1 4 Rotary Bypass Includes Item 69 1 EA 69 P1016467 O Ring Bypass Valve 50 EA PK 70 P1009075 Retaining Pin 1 Bypass valve 10 EA PK 71B 01014033 Coupling Kit for 1 Bypass Includes couplings 2 O rings 4 Pins 2 1 Kit 72B P1009099 O ring 1 Couplings Meters 50 EA PK 81 01034517 Inlet Check Valve 1 EA 82B 01011188 Meter Kit 1 w wire har...

Page 54: ...m 1 0 ft bag 1 BAG Filter Media Sulfur OX3 P N Description Qty UM 00160702 Mineral Cullsan 20 lb bag 1 BAG 01034911 Mineral Cullar S Catalytic Carbon 1 BAG Filter Tank Item P N Description 1 01040431 Tank Assembly QH 10 x 54 Complete Gray Outdoor 01040418 Replacement Tank Fiberglass 10 x 54 Complete Gray 2 01014539 Outlet manifold 10 x 54 P1009099 O ring outlet manifold for 1 control 50 PK 3 P1011...

Page 55: ...ccomplished by water entering the filter tank being immediately exposed to an airhead at the top of the filter tank to begin the oxidation process The filter media acts as a catalyst to help complete the oxidation reaction and retain the precipitated iron Periodic reconditioning purges the accumulated iron particles from the filter tank and re classifies the media bed After the backwash cycle the ...

Page 56: ...ilter tank and the filter media is rinsed prior to the system returning to the service cycle 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 Although the system is designed and tested to operate at a maximum pressure of 60 psi it is not expected that the system should be exposed to such ...

Page 57: ...secured so the system can t be knocked over The customer should provide a GFCI electrical outlet suitable for outdoor use that is NOT controlled by a switch that can be turned off accidentally For outdoor installation only use an outdoor rated power supply Power supply MUST be mounted on the wall at least 1 foot above ground level See Figure 28 Properly ground to conform with all governing codes a...

Page 58: ...ower supply to select to complete the installation Power Supply and Cable 1 Connect the power cable from the control valve to the power transformer where shown 2 Insert the two prong cable connection into the transformer and tighten the water proof nut 3 The power supply plug can now safely be connected to the power receptacle Enlarged Area Figure 29 Rear Port Markings Close up View Attach the str...

Page 59: ...de 40 F Fast Rinse 47 Filter Valve 1 49 Floor Surface 8 Flow Diagram 44 Function Timeout 27 H Hidden Programming 23 I Initiating Regeneration Cycle 24 Inlet Check Valve 13 Introduction 3 Iron 55 L Lockout 30 M Manual Cycling 25 Materials 7 Media 10 11 Media Tank 8 N Number of Conditioning Cycle 27 O Operating Conditions 55 P Parts List 52 Parts Select Plus 1 Control 52 Power Loss 30 Pressure 55 56...

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