Culligan Premier Series Installation, Operation And Service Instructions Download

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Flow Device K-Factor Data

Cat. No. 01024000

Appendix C Flow Device K-Factor Data

Meter Type

Installation Fitting

Type/Material

Pipe Size

NPT

Flow Range

(GPM)

K-Factor

Gallons

K-Factor

Liters

Culligan

Part No.

Shaded = Obsolete

Culligan

Turbine, PVC, NPT

0.5"

21.1

01021033

Tubine, PVC, NPT

0.75"

21.1

01021259

Tee, Stainless Steel, NPT

1.5”

0.75 - 75

28.5

7.5

01027900

2.0”

1.5 - 180

15.2

4.0

01027901

3.0”

3.5 - 400

6.4

1.7

01027902

Clack

Tee, Stainless Steel, NPT

1.5"

0.75 - 75

9.8

01020408

Replaced by 01027900

Tee, Stainless Steel, NPT

2.0"

1.5 - 150

5.3

01020409

Replaced by 01027901

Tee, Stainless Steel, NPT

3.0"

3.5 - 350

2.1

01021978

Replaced by 01027902

GE/

Autotrol

Turbine, Noryl, Union, NPT

1.0"

0.25 - 40

16.4

01018887

Turbine, Noryl, Union, SS, NPT

1.5"

5 - 250

01018954

Turbine, Noryl/SS, Union, NPT

Turbine, Noryl/PVC, Union, Soc

2.0"

5 - 250

01018891

01018892

Fleck

Hi-Flo 22 integral plastic

1.5"

0.5 - 60

20.6

01019670

Tee, Brass, NPT

1.5"

1.5 - 75

1.1

—

Tee, Brass, NPT

2.0"

3 - 150

0.5

—

Tee, Brass, NPT

3.0"

7 - 300

0.67

0.2

—

SeaMetrics

Saddle Clamp, Brass

Tee, Brass, NPT

Sweat, Copper

3.0"

6.6 - 440.6

2.9

01009751

01009752

01009753

Sweat, Copper

4.0”

11.74 - 783.2

6.5

1.7

01009756

GF/Signet

Paddlewheel

Blue Nut

Tee, Sch. 80, PVC, NPT

1.25"

1.2 - 77

177.2

46.8

D1018838

1.5"

1.6 - 106

117.9

31.1

D1018839

2.0"

2.7 - 179

66.7

17.6

D1018840

2.5"

3.8 - 256

11.4

D1018841

3.0"

6.0 - 401

26.7

7.1

D1018842

4.0"

10.5 - 701

D1018843

Saddle, Sch. 80, PVC

2.5"

3.9 - 256

11.4

D1018834

3.0"

6.0 - 401

36.7

9.7

D1018835

4.0"

10.5 - 701

D1018836

6.0"

16.7 - 1595

8.3

2.2

D1018837

Tee, Copper Sweat

1.0"

0.7 - 48

256.4

67.7

D1018822

1.25"

1.1 - 75

176.4

46.6

D1018823

1.5"

1.6 - 107

115.7

30.6

D1018824

2.0"

2.8 - 187

63.4

16.8

D1018825

Tee, Galvanized Steel,

Sch. 40, NPT

1.0"

0.7 - 44

213

56.3

D1018826

1.25"

1.2 - 80

127.7

33.7

D1018827

1.5"

1.7 - 110

94.4

24.9

D1018828

2.0"

2.8 - 184

58.4

15.4

D1018829

Saddle, Sch. 40, Iron

2.5"

4.5 - 298

37.6

9.9

D1018830

3.0"

6.9 - 460

23.2

6.1

D1018831

4.0"

11.9 - 793

13.3

3.5

D1018832

6.0"

27 - 1800

7.2

1.9

D1018833

Brazolet, Brass

2.5"

4.0 - 264

37.6

9.9

D1018814

3.0"

6.2 - 411

24.3

6.4

D1018815

4.0"

10.8 - 716

13.9

3.7

D1018816

6.0"

25 - 1624

7.52

D1018817

Weldolet, Carbon Steel

2.5"

4.0 - 264

37.6

9.9

D1018818

3.0"

6.2 - 411

24.3

6.4

D1018819

4.0"

10.8 - 716

13.9

3.7

D1018820

6.0"

25 - 1624

7.52

D1018821

Summary of Contents for Premier Series

Page 1: ...tomatic Deionizer Water Treatment Systems Models from 2012 Firmware Version 206LT30 2014 Culligan International Com pa ny Installation Operation and Service Instructions with Parts List Cat No 01024000 Rev G 09 23 14 DCO 014570 ...

Page 2: ...r instruction WARNING This device complies with Part 15 of the FCC rules subject to the two following conditions 1 This device may not cause harmful interference and 2 This device must accept all interference received including interference that may cause undesired operation This equipment complies with Part 15 of the FCC rules Any changes or modifications not expressly approved by the manufacture...

Page 3: ... Programming 29 Navigating the Menus and Keypad 30 First Time Setup 32 System Setup 34 Adding and Programming Accessories 36 Regeneration 37 Cycle Times 39 Service and Maintenance 41 Diagnostics 42 Errors and Alert Codes 45 Operating Checklist 46 Troubleshooting 47 Preventive Maintenance 48 Regeneration Flow Diagrams 51 Premier Series Automatic Deionizer Parts 66 Premier Auto DI Menu Overview 73 A...

Page 4: ...ii Culligan Premier Series Automatic Deionizer ii Cat No 01024000 This page intentionally left blank ...

Page 5: ...ning Warning is used to indicate a hazard which could cause injury or death if ignored For example WARNING Electrical shock hazard Unplug the unit before removing the timer mechanism or cover plates The CAUTION and WARNING paragraphs are not meant to cover all possible conditions and situations that may occur It must be understood that common sense caution and careful attention are conditions whic...

Page 6: ... Display The user is guided through brightly lit graphical menu screens with clear multi line full text prompts See Figure 1 Membrane Keypad The keypad uses sealed contacts for programming No buttons to get dirty See Figure 1 Power Source Electrical power required is 120 Volt 60 Hz AC current See page 27 to convert the unit to 220 VAC 50 60 Hz operation Time of Day Displays current time of day in ...

Page 7: ...ditions Automatically updates time and date when calling in Alarm Relay PCB Operation An alarm relay printed circuit board P N 01022238 can be in stalled onto the GBE board If the DIGBE is powered on and there are no errors present then the relay is energized When an error condition exists the relay is de energized Auxiliary Input optional Capable of accepting a remote signal from a dry contact de...

Page 8: ...oda 55 Gallon Drum Heaters Optional Recommended Heat belts with thermostat controls specially designed for plastic 55 gallon drums are available as optional equipment The heat belts wrap around the lower portion of the drum They have a patented grounded heating element The heating element is laminated between two layers of 20 mil fiberglass reinforced silicone rubber They also have an adjustable t...

Page 9: ...ate CO3 Silicate SiO3 Sulfate SO4 Carbon dioxide CO2 Silica SiO2 Hydroxide OH H2O CATION ANION Figure 2 Overview of deionization process The raw water enters the top of the first column and flows down through the resin The cationic part of the dissolved minerals in the raw water is exchanged for hydrogen H as the water passes through the cation resin The water then flows out the bottom of the firs...

Page 10: ... 10 000 ohms to 200 000 ohms range The quality of water capable of being produced by the deionizer is directly related to the amount of sodium leakage from the Cation column and the Type of Anion Resin being used The lower the sodium leakage the higher the quality produced Example 1 0 ppm sodium leakage will provide 400 000 ohms from a Strong Base Anion Resin but 200 000 ohms from a Weak Base Anio...

Page 11: ...l The pH will drop below 7 0 as the Chlorides start to come through to service The Chloride leakage can be determined by monitoring the pH of the product water The graph depicts the normal performance curve for a two bed deionizer Notice that the quality will increase slightly just before the end of the run The water quality will then drop until the pre determined set point is reached then regener...

Page 12: ...water Sodium Chloride mg l TDS mg l as CaCO3 Conductivity µS cm Resistivity ohms TDS grains gal as CaCO3 0 024 0 020 0 050 20 000 000 0 0011 0 026 0 022 0 055 18 000 000 0 0012 0 033 0 028 0 07 14 000 000 0 0016 0 039 0 033 0 08 12 000 000 0 0019 0 047 0 04 0 1 10 000 000 0 0023 0 094 0 08 0 2 5 000 000 0 0047 0 235 0 20 0 5 2 000 000 0 0116 0 47 0 40 1 0 1 000 000 0 0233 0 63 0 53 1 3 750 000 0 0...

Page 13: ...60 Anion GPM 5 7 8 15 20 25 Freeboard Cation Anion Inches 25 20 21 21 20 16 13 10 21 17 18 14 mm 635 508 533 533 508 406 330 254 533 432 457 355 Temperature Min Max F 45 100 C 7 38 Inlet Water Pressure Min Max PSI 40 60 kPa 345 691 Air Clean dry compressed air is required PSI 100 minimum 85 SCFM 8 10 m3 hr 13 6 17 Power 120 VAC 60 Hz 1 pH 15 A see page 27 for 240 VAC operation Space Required W x D...

Page 14: ... Anion GPM 5 7 8 15 20 25 Freeboard Cation Anion Inches 20 25 21 25 16 23 10 16 17 24 14 25 mm 566 707 481 707 453 651 283 453 481 679 396 707 Temperature Min Max F 45 100 C 7 38 Inlet Water Pressure Min Max PSI 40 60 kPa 345 691 Air Clean dry compressed air is required PSI 100 minimum 85 SCFM 8 10 m3 hr 13 6 17 Power 120 VAC 60 Hz 1 pH 15 A see page 27 for 240 VAC operation Space Required W x D x...

Page 15: ...rom freezing weather conditions Temperatures at and below freezing will cause damage to tanks valves and plumbing Water expands when it freezes and can cause the tanks and plumbing to burst Protect the system from high temperatures in excess of 100 F Some of the components used in the manufacture of the system will not withstand high temperatures Do not connect the system down stream of a hot wate...

Page 16: ...nion 2 Upper and Lower Distribution System 1 Culligan DI Controller with Quality Monitor 1 Harness Assembly Mounted on Frame 1 Strong Acid Cation Exchanger Resin 1 Strong Base Type 2 Anion Exchanger Resin or Weak Base Anion Resin 1 Gravel Underbedding 2 Air Operated Chemical Feed Pumps The standard TDS cell is assembled in the main piping Chemical can be drawn directly out of 55 gallon drums if de...

Page 17: ...cations for dimen sions 3 Locate the harness assembly and unbox it and set it upright in front of the tanks roughly centering between tanks Locate the two 2 lower distribution pipes These connect to the harness assembly and the bottom of each tank 4 Connect the tubing from the manifold block to the valves Match the valve numbers on the tubing as shown in Figure 7 on page 16 5 Load the resin and gr...

Page 18: ...r proper connections WARNING Air pressure must not exceed the maximum 100 psi Table 2 Deionizer resin and gravel quantities Model Cation Resin Quantity ft3 Anion Resin Quantity ft3 Gravel per Tank Quantity lbs QS 21 5 6 100 2 bags QW 21 6 5 100 2 bags QS 24 9 9 150 3 bags QW 24 9 8 150 3 bags QS 30 14 15 250 5 bags QW 30 15 13 250 5 bags QS 36 21 22 300 6 bags QW 36 22 19 300 6 bags QS 42 26 29 40...

Page 19: ...ve Sequence Chart Cycle Cation Anion Diaphragm Valve C1 C2 C3 C4 C5 A1 A2 A3 A4 A5 A6 Service O O O Cation Backwash O O Acid Draw O Cation Rinse O Pre Cation Fast Rinse O O Cation Fast Rinse O O Anion Backwash O O O Caustic Draw O O Anion Rinse O O Pre Anion Fast Rinse O O O Anion Fast Rinse O O O Quality Purge O O O O Error Recirc Pump O O NOTE O designates an open valve All diaphragm valves A6 a...

Page 20: ...P RP Solenoid Valve NC NC NC NC NC NC NC NC NC NC NC NC NC NC Service E E E Cation Backwash E E Acid Draw E E Cation Rinse E Pre Cation Fast Rinse E E Cation Fast Rinse E E Anion Backwash E E E Caustic Draw E E E Anion Rinse E E Pre Anion Fast Rinse E E E Anion Fast Rinse E E E Quality Purge E E E E Error Recirc Pump Relay E NOTE E designates solenoid is energized All solenoid valves NC Pneumatic ...

Page 21: ...ed height for the drain lines is eight 8 feet above the top of the unit When using a recirculation pump installation of a check valve on the inlet of the DI is required to prevent deionized water acid or caustic from being fed into the incoming lines The recirculation pump comes with a flow control check valve hose and all necessary fittings to install the unit as shown in Figure 8 and Figure 9 OP...

Page 22: ...er Follow the local electrical code requirements Be sure electrical power is off and disconnected at the source before completing any wiring cabling connections Provide a dedicated 120 Volt circuit for the Smart Controller system to ensure maximum electrical protection DO NOT include the Smart Controller wiring cables in any conduit or raceway containing other 120 Volt or higher circuits Maintain ...

Page 23: ...ure 10 Strain relief fittings are provided with the controller enclosure for interconnecting wiring Install the plastic fittings as needed Remove the compression nut and rubber sleeve from each fitting Prior to connection of the cable wires to the circuit board slide the compression nut and sleeve over the cable for the wiring connections When wiring is completed apply a small amount of silicone t...

Page 24: ...nnect switch as indicated on the unit wiring schematic diagram see Figure 13 on page 27 3 Plug in the power cable to dedicated 120V power source For alternate voltages see Figure 13 on page 27 4 Turn power to control box to the On position I on O off The display should light up Complete the controller programming before perform ing the initial system startup see Deionizer Controller Programming on...

Page 25: ... regener ation of the Premier Deionizer are 20o Baume 32 by Weight Hydrochloric Acid HCl Recommended Grade Food Grade Minimum Grade Required Technical Grade 50 Liquid Sodium Hydroxide NaOH or Caustic Soda Recommended Grade Mercury Cell Grade Minimum Grade Required Rayon Grade Set up the chemical containers properly near the deionizer as shown in Figure 8 on page 17 Follow all chemical han dling pr...

Page 26: ...ust the air regulator located at the chemical feed pump in a clockwise position to the fully closed position Open the regulator adjustment valve in a counterclockwise position to increase the pump flow rate The flow rate for the acid feed for the corresponding model numbers is shown in Table 5 on page 64 and Table 6 on page 65 NOTE REFER TO THE CHEMICAL PUMPS MANUAL COPY ATTACHED IN THE ADDENDUM S...

Page 27: ...tart Let cation column go through the Backwash Cycle This is a good time to re check the backwash flow rate previously set and for any resin loss to drain 2 The cation will advance to the Acid Draw Cycle The system will start feeding the acid Check flow rates and concentrations as specified above Let the system run the total 30 minutes of the Acid Draw 3 Manually advance the system through the cyc...

Page 28: ...ing mode the master system should go into service and the slave sys tem should go into standby mode See Twin Alternating Mode for Multi System Setup on page 34 If the master or the slave ever loses communication with each other the controller displays the error message Lost Comm Both systems will change from alternating mode to single mode and continue to operate as if each system were a single sy...

Page 29: ...ystem will switch to the REGENERATION mode 3 While in SERVICE mode if the time is currently equal to Time of Regen and the REGEN INTERVAL user spec ified value is not zero and the number of days since the last regen is equal to or greater than the REGEN inter val value then the system shall enter the REGENERATION mode 4 When in service mode if the user requests a manual regeneration via the contro...

Page 30: ...ut Back POWER 24VAC Alarm Relay Board optional Optional Modem Connection Data Port PLC Output Flow Meter Cable optional J22 Connection Jumper RS485 Connection Communication Cable JLO Connection MT Board TDS Probe 24v Figure 12 Smart Controller circuit board layout rear view Keypad connector Battery CR2032 Postitive Side Up Pull protective tab before activating power to activate the battery OLED Di...

Page 31: ...1 Install all black leads from items 13 and 14 solenoid valves onto item 9 screw leads on panel to any terminal as they are all common 2 Install all white leads from items 13 and 14 onto items 5 and 6 in the locations shown 3 Install black lead wire from item 14 locations A6 AP C5 and CP onto item 17 4 Install the five pin connector end from item 7 into item 2 with the black wire located in gnd lo...

Page 32: ...C1 C2 C3 C4 C5 CP To 1 Figure 14 PLC connections All wires are white unless otherwise noted Item No Part No Description Quantity 1 01025814 Transformer 120 208 240VAC 24VAC 20VA 1 2 01024074 DI GBE PCB 1 3 01021263 Disconnect Switch 1 4 01023673 Power Supply PLC 24V DC 1 3A 1 5 01025188 CPU PLC 6 Outputs 1 6 01023675 Output Module PLC 8 Outputs 1 7 01024109 Cable TTL 1 10 01022143 PCB MT 1 11 0102...

Page 33: ...g mode and display the home screen Any setting that was changed prior to the controller timing out will revert to its original value Press to save the setting Program Input Acceptance Press to select a value to make it changeable or to change and press again to accept a selected setting value You must press prior to programming mode timeout Menu Lockout It is possible to lock the keypad of the Pre...

Page 34: ...ton selects the highlighted option opens a new screen or accepts a changed setting CANCEL or EXIT button returns to the previous screen or cancels a changed setting NOTE Hold down the or button to quickly scroll through the setting without repeatedly pressing the button Basic Menu Operation SERVICE JAN 01 13 9 00A 10 0GPM 161PPM 1 This is the home screen Press or or to display the main menu 1 INFO...

Page 35: ... indicates that the value may be changed by pressing the or button SET MONTH FEB 7 Press to select a new value The screen displays the new setting value next to the cursor 8 Press to select the next available value You may press or to scroll through all available options for this setting SET MONTH FEB 9 Press to accept the selected screen value The screen displays the value no longer preceded by t...

Page 36: ...ng First Time Setup Other Values Use the procedure on page 30 to change the values of other Premier Series Automatic Deionizer Controller settings After changing the setting press to accept the displayed screen value Screen Display Range Changing the Setting SET MONTH JAN Jan Dec Press to change the month The screen displays the selected year SET DAY 1 1 31 Press to change the day The screen displ...

Page 37: ...t Time Setup SERVICE FEB 01 13 12 11P 10 0GPM 161PPM 4 When the setup is complete the screen displays the home screen Note the new date selected during the setup 1 INFORMATION 2 MANUAL REGEN 3 SET DATE TIME 4 ADV SETUP 5 Press to display the main menu ...

Page 38: ...vice settings to SLAVE1 NOTE PFLOW UPDATE works only in one direction SLAVE1 deionizer settings can NOT be applied to the MASTER deionizer NOTE Only one system set should ever be in service at any given time Regeneration Trigger Setup MINIMUM CAPACITY 1000 Gals 7 This setting is used to trigger a regeneration of the deionizer based on the capaci ty remaining default 1000 gallons This setting requi...

Page 39: ...menu Use the procedure on page 30 to change the date and time settings After changing the setting press to accept the displayed screen value Date and Time Settings Setting Range Unit of Measure Default SET MONTH JAN DEC JAN SET DAY 1 31 1 SET YEAR 2009 2040 2012 CLOCK TYPE 12 or 24 HR 12 HR SET HOUR 12PM 12AM or 00 00 23 59 AM PM unless 24 hour clock was selected 12PM or 00 01 SET MINUTES 0 59 1 D...

Page 40: ...ger a regeneration To change the value press and or and The screen displays the next TDS setting TDS ALARM NOTE If the TDS drops below the limit before MIN CAPACITY GALS is reached a PURGE will occur If quality does not rise above the limit a regeneration will be triggered If MIN CAPACITY is set to zero the unit will trigger a regeneration immediately upon falling below the limit TDS ALARM 200 PPM...

Page 41: ...u screen press to 4 ADV SETUP 3 Press The screen displays the Advanced Setup menu 1 SYSTEM SETUP 2 REGEN SETUP 3 CYCLE TIMES 4 AUXOUT SETUP 4 Press and to select REGEN SETUP REGEN INTERVAL 0 DAYS 5 The first regeneration setting is the interval in days between each system regen eration Press and or to change the setting 0 14 days 6 Press The screen displays the Time of Regen setting TIME OF REGEN ...

Page 42: ...ME 4 ADV SETUP 2 Press and to select the manual regeneration command MANUAL REGEN REGEN NOW 3 Press to select REGEN NOW This is the only available selection 4 Press to confirm the command and return to the main menu The system be gins regeneration REGENERATING FEB 01 13 12 11P 10 0GPM 161PPM 5 Press until the deionizer controller displays the home screen The system status is now REGENERATING which...

Page 43: ...o select CYCLE TIMES BACKWASH CAT 10 MINUTES 5 The first cycle times setting determines the duration of the cation backwash cycle Press and or to change the setting 0 99 minutes 6 Press The screen displays the cation slow rinse setting SLOW RINSE CAT 60 MINUTES 7 Change the acid draw times and other cycle times settings as needed see below Cycle Times Settings See Regeneration Time Cycles on page ...

Page 44: ...SLOW RINSE ANI 60 MINUTES 0 99 Minutes default 60 This cycle allows water to flow down through the resin rinsing away the excess caustic and remaining anions Press and or then to change the setting PRE FR ANI 2 MINUTES 0 99 Minutes default 2 The duration of the rinse preceding the anion fast rinse Press and or then to change the setting FAST RINSE ANI 20 MINUTES 0 99 Minutes default 20 The duratio...

Page 45: ...isplays the days elapsed since the most recent system regeneration Press and to display the next setting Press to see the previous setting TOTAL GALLONS SINCE NEW 1 0 GALS 7 The screen displays the total gallons that have flowed through the system since the system was installed Press and to display the next setting Press to see the previous setting WATER QUALITY OK 8 The screen displays the water ...

Page 46: ...s to select 1 MANUAL CONTROL BACKWASH CAT MINUTES LEFT 6 NEXT CYCLE 4 If the system is regenerating the first screen displayed is the remaining minutes for cation backwash BACKWASH CAT 5 Press The screen displays a prompt to view the next cycle SLOW RINSE CAT MINUTES LEFT 30 END REGEN NOW 6 The next diagnostic screen displays the current state of the deionizer tank in ser vice such as SLOW RINSE C...

Page 47: ...t 6 DIAGNOSTICS the diagnostics informa tion and settings 1 MANUAL CONTROL 2 CHECK INPUTS 3 TEST PHONELIN 4 TEST PROGFLOW 3 Press to select 2 CHECK INPUTS CHECK INPUTS SW1 OP 4 The screen displays the open or closed state of auxiliary switch SW1 and SW2 if a duplex alternating system OP means that water quality meets the minimum requirements so the switch is open CL indicates water quality that do...

Page 48: ...ROGFLOW 3 Press to select 4 TEST PROGFLOW PROGRESSIVE TEST Rx 0027 Tx 0027 4 The screen displays the communication status shown on the master system be tween the master and slave systems Both numbers should be increasing in value for the transmitter and receiver to verify that communication is working Press any key to view the next diagnostic screen Refer to step 5 for the slave system screen disp...

Page 49: ...ill display the home screen Error Reason for Error Comment Clearing Error Message Min Capacity Err Water quality has dropped below spec ified target levels and has not returned after a quality rinse attempt The total number of gallons treated since the pre vious regeneration is less than the spec ified minimum capacity value Check the supply of deionization chemicals Recovery Mode Press Any Key To...

Page 50: ...d rinse cycles psi 14 Record time when anion backwash starts 15 Record flow rate to drain during anion backwash gpm 16 Record inlet pressure during anion backwash psi 17 Record time at start of caustic draw 18 Record rate of flow to drain at start of caustic draw gpm 19 Take a sample of the drain effluent 5 minutes after the start of caustic draw a Keep the sample and label it 5ANI b Record the sp...

Page 51: ... up anion resin Low Capacity 1 Change in supply Increase in TDS reduces gallonage throughput 2 Increase in water usage 1 Get updated water analysis and recalculate gallons between regenerations 2 Re evaluate actual water usage using a water meter Will Not Draw Chemical Acid or Caustic 1 Rate set valves in chemical line closed 2 Caustic soda too cold will not flow through tubing 3 Solenoid Coil bur...

Page 52: ...ays adequate even at maximum plant loads Drain moisture from the air inlet regulator filter every 30 days 3 Rubber parts in valves a Replace regenerant chemical lines on a yearly basis b Replace diaphragms and other rubber parts as needed 4 Resin Inspection should be completed annually a Freeboard space top of tank down to top of resin An increase in freeboard means resin loss Loss may be due to n...

Page 53: ...t may also be noticed and gurgling sounds from inside the tank this is normal 3 Allow the Anion to continue through regeneration When rinse is complete advance the system to service Reconnect the acid draw hose to the cation feed pump and reconnect the caustic draw hose to the anion feed pump 4 Initiate a normal regeneration Monitor the acid and caustic to insure proper amounts of chemical are use...

Page 54: ... by dissolving 3 75 lbs of salt and 7 oz of 50 liquid caustic soda in 5 gal lons of water 2 Connect tubing from the salt caustic solution to the anion feed pump 3 Initiate a manual regeneration of the anion column Allow the Anion to complete the regeneration through the rinse cycle then advance the control to the service position 4 Reconnect the normal caustic drawtube to the eductor and then rege...

Page 55: ...ved as the water flows down through the anion resin The deionized water is col lected at the bottom of the anion tank and flows out to process through the Failsafe Valve A2 C1 C4 A5 C2 A3 A1 A2 A4 C3 A6 C5 CP AP PR TO SERVICE Figure 15 Service cycle The optional recirculation pump is operational during the Service Cycle If water is not being drawn from the system the pump will re circulate the wat...

Page 56: ...h the dis tributors and up through the cation bed providing for at least 50 percent expansion of the resin The water then flows out through the top collector to drain through the Backwash Cation Outlet Valve C4 and the Backwash Flow Control C1 C4 A5 C2 A3 A1 A2 A4 C3 A6 C5 CP AP PR TO DRAIN Figure 16 Backwash cation cycle The Backwash time is usually ten minutes It takes approximately six of those...

Page 57: ...xit the Cation Column and flow through to Drain C3 This drain water is acidic low pH and must be neutralized prior to sending it to the city sewage system C1 C4 A5 C2 A3 A1 A2 A4 C3 A6 C5 CP AP PR 2 ACID PUMP ON ACID SUPPLY TO NEUTRALIZATION TANK HYDROCHLORIC ACID Figure 17 Acid draw cycle The percentage of the acid can be adjusted with use of the adjustment knobs on the air regulating valve see F...

Page 58: ...ve C2 remains closed The Drain Valve C3 remains open Feed water flows through the pressure regulator PR and is directed to flow down through the resin rinsing away the excess acid and remaining cations This water takes the same path as in the previous cycle C1 C4 A5 C2 A3 A1 A2 A4 C3 A6 C5 CP AP PR 2 TO NEUTRALIZATION TANK Figure 18 Slow Rinse Cation cycle ...

Page 59: ... The Pre Cation Fast Rinse step rinses the cation solution that has settled in the piping The Cation Backwash Inlet Valve C1 Cation fast rinse valve C5 remains open C1 C4 A5 C2 A3 A1 A2 A4 C3 A6 C5 CP AP PR 2 TO NEUTRALIZATION TANK Figure 19 Pre cation fast rinse cycle ...

Page 60: ...P PR 2 TO NEUTRALIZATION TANK Figure 20 Fast rinse cation cycle The rinse is complete when the pH of the water exiting to drain is between 2 5 and 3 0 and the Hardness is 0 grains Samples can be taken at the test cock just below the Rinse Outlet Valve This test cock can also be used to tell when the acid breaks through the bottom of the resin bed When Rinse is complete the Cation Column returns to...

Page 61: ...utors and up through the anion bed providing for at least 50 percent expansion of the resin The water then flows out through the top collector to drain through the Backwash Anion Outlet Valve and the Backwash Flow Control C1 C4 A5 C2 A3 A1 A2 A4 C3 A6 C5 CP AP PR 2 TO DRAIN Figure 21 Backwash anion cycle The Backwash time is usually ten minutes It takes approximately six of those minutes before th...

Page 62: ...n This drain water is caustic high pH and must be neutralized prior to sending it to the city sewage system C1 C4 A5 C2 A3 A1 A2 A4 C3 A6 C5 CP AP PR 2 CAUSTIC SUPPLY CAUSTIC PUMP ON TO NEUTRALIZATION TANK SODIUM HYDROXIDE Figure 22 Caustic draw cycle The percentage of the caustic can be adjusted with use of the adjustment knobs on the air regulating valve Samples of the diluted acid are taken at ...

Page 63: ...xide The Anion Inlet Valve A3 and the Rinse Outlet Valve A4 remain open allowing water to flow down through the resin rinsing away the excess caustic and remaining anions This water takes the same path as in the previous cycle C1 C4 A5 C2 A3 A1 A2 A4 C3 A6 C5 CP AP PR 2 TO NEUTRALIZATION TANK Figure 23 Slow rinse anion cycle ...

Page 64: ...e step allows the anion to rinse at full flow rate clearing out the caustic that has settled in the piping The Cation Backwash Inlet Valve C1 Backwash Inlet valve A1 and Anion fast rinse valve A6 remain open C1 C4 A5 C2 A3 A1 A2 A4 C3 A6 C5 CP AP PR 2 TO NEUTRALIZATION TANK Figure 24 Pre fast rinse anion cycle ...

Page 65: ...e regeneration process is complete this will establish the quality level considered poor C1 C4 A5 C2 A3 A1 A2 A4 C3 A6 C5 CP AP PR 2 TO NEUTRALIZATION TANK Figure 25 Fast rinse anion cycle The rinse is complete when the pH of the water exiting to drain is between 6 8 and 8 1 and the quality starts increasing Samples can be taken at the test cock just below the Rinse Outlet Valve This test cock can...

Page 66: ...own through the resin and out the bottom of the column as decationized water and into the Anion Column The decationized water flows down through Anion Resin and out the bottom of the column through the Sensor Cell and out to drain through the Anion Fast Rinse Valve A6 and to service through the Service Valve A2 The water running to drain should be low quality deion ized water C1 C4 A5 C2 A3 A1 A2 ...

Page 67: ...nizers with 30 Hydrochloric Acid and diluting it to 6 and 50 Sodium Hydroxide diluted to 4 Table 4 Deionizer Model Cation Resin Qty Acid Flow Rate gpm Gallons of 30 HCL Required Acid Draw Time mins Anion Resin Qty Caustic Flow Rate gpm Gallons of 50 Caustic Required Caustic Draw Time mins QS 21 5 ft3 0 35 10 5 30 6 ft3 08 5 6 70 QW 21 6 ft3 0 35 12 6 36 5 ft3 08 4 7 59 QS 24 9 ft3 0 70 18 9 27 9 f...

Page 68: ... Flow Control 45 2 0 90 0 3 6 162 0 5 5 247 5 7 0 315 0 10 5 472 5 15 0 675 0 Pre Fast Rinse 2 10 0 20 0 10 0 20 0 15 0 30 0 15 0 30 0 20 0 40 0 20 0 40 0 Fast Rinse 20 10 0 200 0 10 0 200 0 15 0 300 0 15 0 300 0 20 0 400 0 20 0 400 0 ANION Backwash Flow Control 10 5 0 50 0 7 0 70 0 8 0 80 0 15 0 150 0 20 0 200 0 25 0 250 0 NaOH Draw Caustic Flow 60 0 1 6 0 0 2 12 0 0 3 18 0 0 4 24 0 0 5 30 0 0 6 ...

Page 69: ... 90 0 3 6 162 0 5 5 247 5 7 0 315 0 10 5 472 5 15 0 675 0 Pre Fast Rinse 2 10 0 20 0 10 0 20 0 15 0 30 0 15 0 30 0 20 0 40 0 20 0 40 0 Fast Rinse 20 10 0 200 0 10 0 200 0 15 0 300 0 15 0 300 0 20 0 400 0 20 0 400 0 ANION Backwash Flow Control 10 5 0 50 0 7 0 70 0 8 0 80 0 15 0 150 0 20 0 200 0 25 0 250 0 NaOH Draw Caustic Flow 60 0 1 6 0 0 2 12 0 0 3 18 0 0 4 24 0 0 5 30 0 0 6 36 0 NaOH Draw Water...

Page 70: ...er Series Automatic Deionizer 66 Cat No 01024000 Premier Series Automatic Deionizer Parts 21 36 Premier Series Automatic Deionizer Assembly A A Q H F G P I J S Figure 27 21 36 Premier Series automatic deionizer assembly ...

Page 71: ...Premier Series Automatic Deionizer Parts 67 Cat No 01024000 21 36 Diaphragm Valve P Q E E E E E P B R K D C L E N M T B Figure 28 21 36 Diaphragm valve ...

Page 72: ...8 Culligan Premier Series Automatic Deionizer 68 Cat No 01024000 42 48 Premier Series Automatic Deionizer Assembly I J A A Q H F G P S D K C L Figure 29 42 48 Premier Series automatic deionizer assembly ...

Page 73: ...Premier Series Automatic Deionizer Parts 69 Cat No 01024000 42 48 Diaphragm Valve Q E E E E E E N R B B T M Figure 30 42 48 Diaphragm valve ...

Page 74: ...2446 01022446 01022446 J Hub Latteral 01023917 01023917 01022459 01023967 01023879 01023879 K Flow Control Backwash Cation 01022461 01023892 01023989 01027529 L Flow Control Backwash Anion 01023924 01023985 01022462 01023986 01024029 01023892 M Flow Control Rinse Cation 01023957 01023987 01023988 01025812 01025813 01023986 N Flow Control Rinse Anion 01023957 01023980 01023924 01025811 01022462 010...

Page 75: ...rrow is pointing toward the solenoid 1 Figure 31 Solenoid manifold assembly Item No Part No Description 01023880 Solenoid Manifold Assembly DI 1 DI Solenoid Assembly Replacement 3 Way Normally Closed Stainless Steel 2 01024330 DI Solenoid Assembly Replacement normally closed for air manifold 3 01025096 Air Regulator 1 4 NOTE Use Teflon tape for all threaded connections ...

Page 76: ...or Levernut 5 Conductor 1 18 01018403 Cord Grip Liquid Tight 170 450 ID 14 19 01020498 Membrane Keypad Oval w Connector 1 21 01021173 Terminal Block End Block 2 22 01024192 Enclosure GBE Large 1 23 01021261 SHAFT DISCONNECT SWITCH 1 Item No Part No Description Qty 24 01021262 Switch Disconnect Door Handle 1 25 01022147 SCREW MACH 10 32X3 8 18 8SS PHIL PAN HD 6 26 SCREW MACH 6 32X1 2 PAN HD SLT 2 2...

Page 77: ...Premier Auto DI Menu Overview 73 Cat No 01024000 Premier Auto DI Menu Overview FWR LT30 MON DD YEAR FWR LT30 MON DD YEAR ...

Page 78: ... Cat No 01024000 1 AUXOUT 6 2 AUXOUT 7 3 AUXOUT 8 AUX 6 CYCLE SERVICE AUX 6 ON DELAY 0 AUX 6 ON TIME 0 AUX 7 ON DELAY 0 AUX 7 ON TIME 0 2 AUXOUT 7 AUX 7 CYCLE SERVICE AUX 8 ON DELAY 0 AUX 8 ON TIME 0 AUX 8 CYCLE SERVICE 3 AUXOUT 8 00000000 18552518958 ...

Page 79: ... 783 1267 6 7 67 3 21 1 0 18 75 13876 7 67 3 21 1 7 67 352 2 6 7 0 187 6 7 5 0 187 6 7 1 7 3UHVV 2 1 552 5 0 187 6 7 1 5 1 12 6 2 5 16 7 0 187 6 7 1 7 35 5 7 0 187 6 7 1 7 67 5 16 7 0 187 6 7 1 7 6 1 0 187 6 7 1 7 867 5 0 187 6 7 1 7 6 2 5 16 1 0 187 6 7 1 7 3UHVV 0 5 WR YLHZ QH W F FOH VWDWXV 35 5 1 0 187 6 7 1 7 67 5 16 1 0 187 6 7 1 7 21 5 1 6 59 0 18 75 13876 7 67 3 21 1 7 67 352 2 13876 7 67 ...

Page 80: ...wo de ionizer system consists of two systems two flow meters and two switch inputs See Figure 33 7 21 7 21 1 21 1 21 5 5 8 7 21 3803 83 1 7 83 287 7 0 9 9 2 21752 5 35 6685 6 7 9 9 9 9 0 9 9 9 9 5 5 8 7 21 3803 9 9 2 21752 5 35 6685 6 7 9 9 9 9 21752 21752 20 Figure 33 Duplex deionizer configuration with recirculation kit NOTE Use 14 GA Wire Recirculation Pump and Internal Recirculation High Volta...

Page 81: ...ic concentrations NEVER inhale fumes given off by hydrochloric acid and provide adequate ventilation where the acid is being used Hydrochloric acid will dissolve many metals and cements It will not react with glass some rubber and most plastics All contact with body or clothing should be avoid ed Safety goggles or face shield should be used If hydrochloric acid does contact the body or clothing th...

Page 82: ...NG AND FACE SHIELD OR SAFETY GOGGLES Caustic soda is a strong alkali which can cause serious burns on contact with skin or eyes Caustic dust and mist represent a hazard to the respiratory tract All contact with body or clothing should be avoided If caustic soda does contact the body or clothing the affected clothing should be removed and washed with large quantities of cold water Caustic destroys ...

Page 83: ...al 9 14 85 Gal 5 166 Gal 10 16 5 Gal 5 74 Gal 11 18 15 Gal 6 314 Gal 12 19 8 Gal 6 888 Gal 13 21 45 Gal 7 462 Gal 14 23 1 Gal 8 036 Gal 15 24 75 Gal 8 61 Gal 16 26 4 Gal 9 184 Gal 17 28 05 Gal 9 758 Gal 18 29 7 Gal 10 332 Gal 19 31 35 Gal 10 906 Gal 20 33 Gal 11 48 Gal 50 gallon drum 1 1 65 GALLON 15 gallon carboy 1 375 GALLON NOTE Measurements are to be made prior to and after regeneration Measur...

Page 84: ...___________ Measurement of Inches from Container Opening Down to Regenerant Noted prior to each regeneration Inches Day Start of Full Regenerant Acid Caustic Container Entry Made By 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 27 28 29 30 31 The availability and usage of acid and caustic soda during regeneration is one of the most important factors affecting the Deionizer s...

Page 85: ...addle Clamp Brass Tee Brass NPT Sweat Copper 3 0 6 6 440 6 11 2 9 01009751 01009752 01009753 Sweat Copper 4 0 11 74 783 2 6 5 1 7 01009756 GF Signet Paddlewheel Blue Nut Tee Sch 80 PVC NPT 1 25 1 2 77 177 2 46 8 D1018838 1 5 1 6 106 117 9 31 1 D1018839 2 0 2 7 179 66 7 17 6 D1018840 2 5 3 8 256 43 11 4 D1018841 3 0 6 0 401 26 7 7 1 D1018842 4 0 10 5 701 15 4 D1018843 Saddle Sch 80 PVC 2 5 3 9 256 ...

Page 86: ...ecirculation Pump and Internal Recirculation High Voltage Side Relay DI Recirculation Installation and Start Up 1 Refer to Figure 8 on page 17 for set up and installation of the recirculation piping 2 Refer to Figure 13 on page 27 to install the relay that controls the pump in the control box 3 Install the pressure switch onto the air manifold refer to Figure 7 on page 16 4 To operate the recirc p...

Page 87: ...inlet water pressure Set the air pressure on the manifold to slightly less than that of the inlet water pressure 10 Increase the pressure setting on the pressure switch by turning the body clockwise until the pump turns on 11 Increase the manifold air pressure back to 10 15 above the inlet water pressure and the pump should now return to the running state 12 You can now return water pressure to th...

Page 88: ...e Format The format of the status message is CULL aaa aa bbb bb cccccc dddddd eeeeeeee ffffffff g h mmddyyhhmm Example CULL 000005 1 000000 0 0021094 0000000 0021094 0000000 0 2 0104101618 aaa aa flow rate tank1 bbb bb flow rate tank2 cccccc gal since regen tank1 dddddd gal since regen tank2 eeeeeeee total gal since new tank1 ffffffff total gal since new tank2 g tank1 status 1 2 3 or 4 1 service 2...

Page 89: ...0000 0021094 0000000 0 2 0104101618 AUX 00000 AUX 00000 AUX 00000 AUX 00000 AUX 00000 AUX 00000 AUX 00000 AUX 00000 AUX 00000 AUX 00000 AUX 00000 CULL 000005 1 000000 0 0021099 0000000 0021099 0000000 0 2 0104101619 AUX 00000 AUX 00000 AUX 00000 AUX 00000 AUX 00000 AUX 00000 Figure 35 Data from DIGBE debug port ...

Page 90: ...ription Front Panel Figure 36 Conductivity meter 1 Liquid Crystal Display 2 Switch for selecting Alarm Mode OFF Alarm Disabled AUTO Automatic alarm based on set point value ON Alarm always active 3 MEAS push button to set instrument to measurement mode 4 SET push button to display and set the set point value 5 SET trimmer pot to adjust set point value 6 CAL calibration trimmer pot 7 LED indicator ...

Page 91: ... quality monitor uses the same probe that comes pre installed in the Premier AutoDI system It is necessary however to cut off the connector on the ends of the probe wiring remove the wire insulation from the last 0 1 of each of the 4 colored wires and then attach those wires to the screw terminals identified as 1 COM in Figure 36 5 Use the Smart Controller menu to set up the sensor for the system ...

Page 92: ...ernal Quality Monitor Operation 1 Turn on the control and adjust the set point to 20 uS cm 50 000 ohms 2 Make sure the 5 jumper has been removed from the rear of the monitor 3 Turn the OFF AUTO ON switch to the AUTO position 4 Immerse the probe in the solution to be monitored and press the MEAS button if necessary The LCD will show the uS cm value of the liquid The LED indicator will light up Gree...

Page 93: ... to each circuit board at the location shown below in the drawing For duplex alternating meter connection please refer to page 76 See Appendix C Flow Device K Factor Data on page 81 optional 2535 2536 Signet Black Shield Red Black Green Red Paddle Wheel optional Seametrics Green Red Black White SINGLE OR PROGRESSIVE Bare Red Green Black Red Black Wht Clear 2 Autrol Turbine Meter optional Black Whi...

Page 94: ... value does not need to be set Press and or and to change the setting and return to the Accessories menu See Appendix C Flow Device K Factor Data on page 81 for more information SERVICE FEB 01 13 12 11P 10 0GPM 161PPM 7 Press until the deionizer controller displays the home screen External Flow Meter Set Point Adjustment 1 Turn on the Power and press the SET button the display will show the defaul...

Page 95: ...and the controller board Make sure that the modem board is fully seated into all four sockets 4 When all connections have been made restore power to the circuit board Installing a Modem on the Deionizer Circuit Board Open the controller cover and locate the modem connection on the back of the board see Figure 40 Insert the line modem board part number 01020307 into the socket on the back of the bo...

Page 96: ...phone number Refer to your phone service provider to verify how to dial an outside phone line DEALER ID 00000000 0 9 for 8 digits 7 The screen displays the Culligan Dealer I D number To change the value press and or Press when finished add ing changing a digit TIME TO CALL 23 HOURS 0 23 8 The screen displays the time duration until the next attempt to communicate using the modem Press and or to ch...

Page 97: ...ncorrect value for the hours it is likely that the time zone setting on the control is incorrect SERVICE FEB 01 13 12 11P 10 0GPM 161PPM 1 From the default home screen press to display the main menu 3 SET DATE TIME 4 ADV SETUP 5 ACCESSORIES 6 DIAGNOSTICS 2 From the main menu screen press to 6 DIAGNOSTICS 3 Press The screen displays the Diagnostics menu 1 MANUAL CONTROL 2 CHECK INPUTS 3 TEST PHONEL...

Page 98: ...n valve on the neutralization holding tank The ON TIME setting specifies the number of minutes the valve will remain open enough time to completely empty the tank When using external 24VAC or 120VAC solenoid valves connect one wire to either the Aux6 Aux7 or Aux8 output as shown in Figure 13 on page 27 Connect the other wire to Terminal Block 9 or Terminal Block 17 Time Total Tank Volume On Time t...

Page 99: ...7 The AUX 6 ON DELAY setting is time delay to open the drain valve in the waste neutralization tank Press and or to change the setting 0 120 minutes 8 Press The screen displays the AUX 6 ON TIME setting AUX 6 ON TIME 1 MINUTES 9 The AUX 6 ON TIME setting is the time interval that the waste neutralization drain will be kept open Press and or to change the time interval 0 120 10 Press and to change ...

Page 100: ... 43 Installation 11 17 82 Introduction 1 K Keypad 26 30 K Factor Data 81 L Locating the Equipment 13 Lockout Menu 29 M Maintenance 41 48 Manual Control 42 Manual Regeneration 38 Menu 29 30 35 73 Meter 4 86 89 90 Min Capacity Err 45 Modem 91 92 93 Motor Control 42 Muriatic Acid 77 O OLED Display 26 Operating 11 46 Operation 24 Organics 50 P Parts 66 Performance Characteristics 6 pH 7 Pin Connection...

Page 101: ...Notes 97 Cat No 01024000 Notes ...

Page 102: ...98 Culligan Premier Series Automatic Deionizer 98 Cat No 01024000 ...

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