Culligan HE-060 Installation, Operation And Service Instructions Download Page 1

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CULLIGAN

High Efficiency 1.5 Twin

Water Softener

Featuring the

Culligan

Smart Controller™

Models from 2012

Installation,

Operation, and

Service Instructions

with Parts Lists

Cat. No. 01024821

Rev. I 05/09/17

DCO # 017180

Summary of Contents for HE-060

Page 1: ...1 5 Twin Water Softener Featuring the Culligan Smart Controller Models from 2012 2017 Culligan International Com pa ny Installation Operation and Service Instructions with Parts Lists Cat No 01024821...

Page 2: ...ligan Service Agent or similarly qualified per son in order to avoid a hazard WARNING This device complies with Part 15 of the FCC rules subject to the two following conditions 1 This device may not c...

Page 3: ...ts Introduction 1 Basic Principles 2 Performance Specifications 3 Installation 4 Smart Controller Circuit Board Layout 25 Electrical Schematic 26 Installing Accessories 27 Final Startup 33 Preventive...

Page 4: ...Illinois chemical certification our Analytical Laboratory is certified to perform coliform and E coli testing We strive to provide our customers with the testing they need at the lowest possible cost...

Page 5: ...ocal dealer on CPort www cport culligan com under the Technical Service Tab or on the Service Tech App Safe Practices Throughout this manual there are paragraphs set off by special headings Notice Not...

Page 6: ...rapidly upward in reverse direction to the service flow through the resin bed to expand the bed and flush out accumulated dirt sediment and other sources of turbidity Brine Draw The brine solution co...

Page 7: ...s U S units Model No Exchange Capacity kgr Per Tank Service Flow Rate gpm Per Tank Backwash Flow Rate gpm Per Tank Minimum System WxHxD Dimensions in Maximum grains Minimum grains Continuous 15 psi ma...

Page 8: ...ehind the softener tank s for service access and plumbing supply and drain lines Allow a minimum of 24 inches 61 cm above the top of the system NOTE Upon initial installation or in the event the distr...

Page 9: ...d Doing so may create operational problems and or create a substantial risk of consequential damage not covered by the product warranty Figure 1 Install Distribution System Mark flush with tank openin...

Page 10: ...1 Cover the top of the distributor pipe with tape that will prevent media from entering the distributor 2 Use a funnel P N 01029516 in the opening to add 6 of water to protect the distributor Pour Cul...

Page 11: ...e based lubricant 2 Install the inlet disperser to the bottom of the control valve 3 Install the tank adapter o ring above the valve s threads Do not lubricate but can be wetted with water 4 Lower the...

Page 12: ...are threads with either a pipe dope sealant or Teflon tape d Make certain that the fittings are not cross threaded during the assembly process e Do not over tighten fitting or threaded pipe being inse...

Page 13: ...vide an air gap of at least four times the diameter of the drain pipe or conform to local sanitation codes and to permit the observation of drain flow SMART CONTROLLER INTERCONNECTING PIPE SOFT WATER...

Page 14: ...mbled inside the control standard from factory Eductor Nozzle and Throat Replacement Refer to Table 4 Figure 5 and the instructions below when changing the eductor nozzle and throat 1 Remove the educt...

Page 15: ...ll off the drain elbow 3 Remove the backwash flow control located behind the elbow 4 Install the correct drain line flow control 5 Reverse the procedure to reassemble NOTE The number on the flow contr...

Page 16: ...p of the cover into the two holes on top of the frame the cover should be slightly angled See Figure 10 2 Rotate the cover downward inserting the two pins on the side of the cover into the two holes o...

Page 17: ...ial a Softness setting Straight Through Adapter Shipped with each softener is a Culligan straight through adapter which is used to connect the softener to the plumbing system CAUTION Close the inlet s...

Page 18: ...e metal pipe was originally used and is later interrupted by the straight through adapter to maintain proper metallic pipe bonding an approved ground clamp c w not less than 6 copper conductor must be...

Page 19: ...into a sink or open floor drain a loop in the end of the tube will keep it filled with water and will reduce splashing at the beginning of each regeneration NOTE Waste connections or drain outlets sha...

Page 20: ...tank in a convenient location on a smooth surface The brine valve should be at the rear to sim plify removal of the tank cover If multiple softeners will be drawing brine from the same tank connect th...

Page 21: ...the circuit board Mishandling of the circuit board will void the warranty NOTE Observe all state and local electrical codes 1 Remove the electrical enclosure from the control valve First remove the e...

Page 22: ...ntroller 2 4 Open the two ports through the molded recessed area area 4 See Figure 19 Use a sharp object screw driver or knife to push through the plastic 5 Connect the motor cable optical sensor cabl...

Page 23: ...Power pre installed P1025264 Strain Relief Fitting 10 PK 1 2 3 Aqua Sensor SBT replaces 01025274 when used with optional 2 5VAC Power P1025277 Liquid Tight Hole Plug 10 PK 1 2 3 P1025278 Bushing strai...

Page 24: ...ng P N 01025264 See Figure 25 9 Use a small screwdriver to raise the tongue on each metal tab so it is protruding at the top Reinstall the tabs in the housing Tug lightly on the cord to make sure the...

Page 25: ...sure See Figure 21 15 Tighten the nut on the interior side of the port opening on the controller enclosure See Figure 23 16 Connect the Aqua Sensor probe wire harness bushing to the circuit board The...

Page 26: ...al power supplies the GBE boards can be connected to each other using communication cables without paying attention to the polarity of the wiring used on the power supplies DO NOT connect the Aux Outp...

Page 27: ...relays to allow multiple GBE boards to control a shared solenoid valve P N 01016327 COMMUNICATION CABLE RJ11 PHONE MODEM BOARD BASE BOARD RF BOARD AUXILARY BOARD RF BOARD RF BOARD MODEM BOARD MODEM BO...

Page 28: ...prevent leaks 2 Pull the position sensor cable back through the gray rubber bushing 3 Place the enclosure onto the control valve aligning the circuit board edge with the slots on the control valve fr...

Page 29: ...w Keypad connector Battery CR2032 Postitive Side Up Pull protective tab before activating power to activate the battery OLED Display Optional AUX 5 Relay Board Connection Data Port PLC Output RF Board...

Page 30: ...tic GBE Board Modem Board RF Board Auxiliary Board Aqua Sensor Cable from Lead Tank 24V Smart Brine Tank Probe Power Supply Flow Meter from Second Tank Motor from Second Tank Gearbox Position Sensor o...

Page 31: ...nserting it into the port NOTE After installation of the Aqua Sensor probe a complete regeneration is required to set the probe at its proper depth and record the conductivity in the tank Refer to GBE...

Page 32: ...xiliary Outputs Auxiliary Input Figure 35 Auxiliary board input and outputs Aux Output 1 is used to power the 24 VAC drive motor found on all valves When Aux Output 1 is used for this then Aux Output...

Page 33: ...selected on the display this relay is energized holding the normally closed contact open and when the GBE board has power AND there are no errors present the relay is energized Problem Found is not s...

Page 34: ...e sure the RF board is fully seated into all of the sockets Reconnect power 6 Program the remote and main monitor units using the instructions found in the GBE Programming for Commercial Softeners and...

Page 35: ...etween the modem board and the main controller board Make sure that the modem board is fully seated into all four sockets 3 When all connections have been made restore power 4 Connect the modem to the...

Page 36: ...finger pressure and insert the two screws Figure 41 Back of remote board Refer to the GBE Programming for Commercial Softeners and Filters except HF xN Manual P N 01027295 for pro gramming information...

Page 37: ...o the section on manual cycling for information on cycling the control through its positions 9 When in the BACKWASH position slowly rotate the bypass if installed to the soft water position until wate...

Page 38: ...or dry storage is required Dry Storage When enough salt is added to the brine tank so that the salt level is higher than the water level When the proper amount of water is returned to the salt storage...

Page 39: ...Cubic Feet lbs ft Max Load regens Max Load regens Max Load regens 2 6 375 31 3 600 50 900 75 10 375 18 8 600 30 900 45 15 375 12 5 600 20 900 30 3 6 375 20 8 600 33 3 900 50 10 375 12 5 600 20 900 30...

Page 40: ...2 26 4 8 8 26 4 6 6 26 4 5 3 26 4 3 8 26 4 12 14 4 28 8 9 6 28 8 7 2 28 8 5 8 28 8 4 1 28 8 13 15 6 31 2 60 000 10 4 31 2 75 000 7 8 31 2 6 2 31 2 100 000 4 5 31 2 14 11 2 33 6 8 4 33 6 6 7 33 6 4 8 3...

Page 41: ...proper time for refilling the brine tank with water Sanitize the System A water softener in daily use on a potable water supply generally requires no special attention other than keeping the salt tank...

Page 42: ...E controllers have been properly programmed and are active power on All manual isolation valves are open and system by pass valves are closed Clean up the unit and the installation site removing any s...

Page 43: ...ely affect system performance Monitor item for nor mal or unexpected wear Softening Media Every 2 3 years Chlorinated water supplies can break down destroy resin material Resin material may also perfo...

Page 44: ...ee the GBE Programming for Commercial Softeners and Filters except HF xN Manual P N 01027295 for instructions on how to obtain a system data sheet NOTE Refer to the GBE Programming for Commercial Soft...

Page 45: ...oard from the edges and gently rotate it to the back of the enclosure disengage the circuit board from the two support pins on the bottom of the enclosure See Figure 46 Disconnect Flow Meter Disconnec...

Page 46: ...position sensor from the gearbox 5 Remove the motor retainer rod by squeezing the snap release end of the rod See Figure 47 6 Firmly pull the motor straight outward It may be necessary to gently tap o...

Page 47: ...move the compartment plate by removing the compartment plate screw holding it onto the frame 5 Remove the five large Phillips head screws which attach the gearbox to the valve body Gearbox 6 Remove th...

Page 48: ...n re inserting the eductor cap there is an arrow molded into the eductor cap If the cap is installed with the arrow pointing UP then the valve is con figured for Upflow brining If the arrow is pointin...

Page 49: ...down freely approximately 1 2 b Fiberglass rod is rigid If the brine system is functioning properly there will be water in the brine tank but the level should be below the safety valve float and the f...

Page 50: ...regeneration Set circuit board to delayed regeneration See the GBE Programming for Commercial Softeners and Filters except for HFxN Manual 01027295 for programming instructions Incorrect programming S...

Page 51: ...lam shut float rod is rigid Verify that all tubing connections are properly assembled 11 Unit fails to draw brine or chemical Drain line flow control is plugged Clean drain line flow control Plugged e...

Page 52: ...the pin connector at the board or damage to the circuit board Pass SIM Test Ignore this unless you have the Simulator Box P N 01017705 plugged into the board instead of the Aqua Sensor Probe at the t...

Page 53: ...R valves and the Brine Piston are closed BRINE PISTON P6 P1 P4 PR P5 P2 P3 PISTONS P1 Inlet P2 P3 Outlet P4 Backwash P5 Rinse P6 Bypass Brine PR Refill Figure 52 HE 1 5 Twin valve piston locations The...

Page 54: ...to the outlet should be soft if the system is operating properly P1 P2 P3 Raw Water Conditioned Water To Drain To Brine Tank Tank Inlet Tank Outlet Brine Piston P6 P4 P5 PR Hard Water Softened Water...

Page 55: ...drain should be hard P1 P2 P3 Raw Water Bypassed Water To Drain To Brine Tank Tank Inlet Tank Outlet Brine Piston P6 P4 P5 PR Hard Water Softened Water Drain Brine Diluted Brine Figure 54 Down flow r...

Page 56: ...manifold and to the drain 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 P1 P2 P3 Raw Water Bypasse...

Page 57: ...ugh the resin up the manifold and to the drain Hard water is allowed to service during regeneration P1 P2 P3 Raw Water Bypassed Water To Drain To Brine Tank Tank Inlet Tank Outlet Brine Piston P6 P4 P...

Page 58: ...water is allowed to Service during regeneration P1 P2 P3 Raw Water Bypassed Water To Drain To Brine Tank Tank Inlet Tank Outlet Brine Piston P6 P4 P5 PR Hard Water Softened Water Drain Brine Diluted...

Page 59: ...for refill P1 P2 P3 Raw Water Conditioned Water To Drain To Brine Tank Tank Inlet Tank Outlet Brine Piston P6 P4 P5 PR Soft Water to Fill Brine Tank Hard Water Softened Water Drain Brine Diluted Brine...

Page 60: ...sed to the outlet of the control hard water is allowed to service P1 P2 P3 Raw Water Bypass Water To Drain To Brine Tank Tank Inlet Tank Outlet Brine Piston P6 P4 P5 PR Hard Water Softened Water Drain...

Page 61: ...NG GROOVES QUAD RING GROOVE 61 60 STANDARD PISTON 2 EACH 64 O RING GROOVES QUAD RING GROOVE 56 57 64 LARGE PISTON 4 EACH O RING GROOVES 50 49 48 47 46 45 88 87 O RING GROOVES 72 71 70 82 83 39 O RING...

Page 62: ...23550 Connector Plumbing 1 NPT Control 1 40 01020745 Replacement Circuit Board 41 Enclosure w Decal not avail for sale Kit 42 01025650 Electronics Enclosure Kit w o Circuit Board Item Part No Descript...

Page 63: ...792 01011985 40 2 00160702 4 HE 150 18x65 010252442 01019618 70 1 1 00160702 00160710 5 HE 210 21x62 010252452 01019618 80 4 00160702 7 HE 150 18x65 010222573 01019618 80 4 00160702 5 HE 210 21x62 010...

Page 64: ...win Water Softener 60 Cat No 01024821 Aqua Sensor Plug and Probe 1 2 Figure 62 Aqua Sensor probe Item No Part No Description Qty 01025279 Aqua Sensor Probe HE 1 5 1 P1017434 O Ring Plug and Sensor 10e...

Page 65: ...019525 18 x 38 Brine System Complete 01018720 24 x 40 Brine System Complete 1 1 01018716 Tank Repl 18 x 38 1 1 01018718 Tank Repl 24 x 48 2 1 01018717 Cover Repl 18 2 1 01018719 Cover Repl 24 3 1 0101...

Page 66: ...ption Qty 01024638 24 x50 Brine System Complete 0 8 gpm 1 2 Connection 0 8 BLFC includes items 1 8 01024666 Tank Brine 24x50 w Well Cover includes items 1 7 1 Tank 1 2 Cover 1 3 01019623 Salt Plate 24...

Page 67: ...1 01018710 BLFC Elbow 0 45 gpm 01018711 BLFC Elbow 0 8 gpm 2 P1020194 Brine Well Cap 24 Pack 3 P1020196 3 8 Compression Nut 24 Pack 4 P1018871 3 8 Insert 25 Pack 5 P1020191 Retaining Clip 24 Pack 6 P1...

Page 68: ...cement 1 01025113 Circuit Board Remote Soft Filt Italian Replacement 1 01025114 Circuit Board Remote Soft Filt Spanish Replacement 2 01020750 Circuit Board RF GBE 915 MHz North American Version 2 0102...

Page 69: ...NOTE 1 Although the Aqua Sensor device has been used successfully on water with hardness as low as 3 gpg there is an increased risk of missed signal no regeneration when the hardness is less than 6 g...

Page 70: ...27 2 35 8 20 4 7 1 1 5 1 28 7 1 HE 210 11 5 28 0 37 4 21 11 5 1 9 1 6 11 5 The Suggested Progressive Flow Trip Point is simply a suggested flow rate at which point an additional tank will be brought o...

Page 71: ...A thru F are as follows A total gallons since new B current flow rate in gallons per minute 57 2 means 57 2 gallons per minute C Current Status Indicator 0 initialization 1 service 2 prerinse 3 regen...

Page 72: ...ex progressive flow network every 60 seconds the data port on the master unit will send out the following three lines of information CULL A1 B1 C1 D1 E1 1 G1 CULL A2 B2 C2 D2 E2 2 G2 CULL A3 B3 C3 D3...

Page 73: ...l the USB drivers and the Data Port Output Viewer to your local hard drive You will be asked which directory you want to copy these files to You may select any directory Note Previous instructions sho...

Page 74: ...ion can be found by going to Diagnostics Advanced Stats on the GBE Controller Refer to GBE Programming for Commercial Softeners and Filters except for HFxN Manual P N 01027295 for more information Thi...

Page 75: ...44 45 Flow Diagrams 49 Flow Rate Data 66 G Gearbox 43 Gear Motor 42 H Hardness vs Salt Dosage 65 Height of Discharge 15 I Injector Settings 10 Input 68 Installation 4 37 Introduction 1 K Keypad 25 L L...

Page 76: ...72 Culligan High Efficiency 1 5 Twin Water Softener 72 Cat No 01024821 Notes...

Page 77: ...erials and DCO information IT DOES NOT PRINT AS PART OF THE DOCUMENT Let Change By Aprv d DCO Date A New Art Created JS 012612 08 08 11 A1 Revisions JS 012819 11 01 11 B Revisions JS 012828 11 15 11 C...

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