Culligan GBE Service manual

CULLIGAN®
Global Electronic (GBE)
Softener & Filter Controller
For Commercial/Industrial Applications
Models from 2008
©2008 Culligan International Company
Cat. No. 01021161
Rev. A 10/16/08
DCO # 010703
Installation,
Operating and
Service
Instructions
Printed in USA

Read this Manual First
Before you operate the Culligan Global Controller, read this manual to become familiar with the device and
its capabilities.
Watch for Special Paragraphs
Please read the special paragraphs in this manual. Examples are shown below.
NOTE A Note provides information or highlights a procedure.
CAUTION
A Caution tells how failing to follow instructions might cause
injury or damage the equipment in some way.
About this Manual
Contents
This manual:
• familiarizes the operator with the equipment
• explains installation and setup procedures
• provides basic programming information
• explains the various modes of operation
• gives specifications and troubleshooting information
TABLE OF CONTENTS ii
i CULLIGAN GLOBAL ELECTRONIC CONTROLLER
This equipment complies with Part 15 of the FCC rules. Any changes or modifications not expressly approved
by the manufacturer could void the user’s authority to operate the equipment. Changes or modifications not
expressly approved by the party responsible for compliance could void the user’s authority to operate
the equipment.
WARNING! Electrical shock hazard! Unplug the unit before removing the cover or accessing any internal control parts.
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 2) this device must accept all interference received including interference that may cause
undesired operation.
CAUTION! To reduce the risk of fire, use only No. 26 AWG or larger telecommunicaitons line cord.
Products manufactured and marketed by Culligan International Company (Culligan) and its affiliates are protected by patents issued or pend-
ing in the United States and other countries. Culligan reserves the right to change the specifications referred to in this literature at any time,
without prior notice. Culligan, AquaSensor, Tripl-Hull, and SoftMinder are trademarks of Culligan International Company or its affiliates.
The product is covered by the following patents:
Softener and/or filter: US 5073255, 5273070, 6457698, 4534867: Israel 095754
Sensor option: US 5699272
Other US and foreign patents pending.

TABLE OF CONTENTS ii
i CULLIGAN GLOBAL ELECTRONIC CONTROLLER
CULLIGAN®
GLOBAL ELECTRONIC (GBE) SOFTENER
& FILTER CONTROLLER
Installation,
Operating and
Service
Instructions
Table of Contents ................Page
Important Safety Information....................................... i
Controller Features..................................................1-2
Operation....................................................................3
Installation ...............................................................4-6
Wiring Schematics.................................................7-17
Circuit Board Layout..............................................7
Transformer ........................................................8-9
Brine Refill Valve .................................................10
Communication Cable .........................................11
Progressive/ Parallel Flow...................................12
Alternating ...........................................................13
Flow Meters .........................................................14
Aqua-Sensor........................................................15
Aux Outputs.........................................................16
Aux Input .............................................................17
Programming.......................................................18-20
Key Pad Operation .............................................19-20
Overview...................................................................21
Commercial Setup....................................................22
First Time Setup..................................................23-27
Customizing the Setup ........................................28-32
Progressive Flow .................................................29
Regeneration .......................................................30
Cycle Times.........................................................31
Regeneration Triggers.........................................32
Installation of Accessories...................................33-45
Aqua-Sensor........................................................33
Beeper Mode .......................................................33
Smart brine Tank Sensor ....................................34
Wireless Remote ............................................35-37
Modem............................................................37-41
Low Meter............................................................41
Progressive Flow ............................................41-42
Brine Reclaim .................................................42-43
Service Phone Number ......................................44
Auxiliary Boards ..................................................46-48
Manual Regeneration ...............................................49
Manual Cycling.........................................................50
System Information .............................................51-52
Error & Alert Codes ..................................................53
Diagnostics / Statistics ........................................54-57
Check Sensors ....................................................55-57
Menu Lockout...........................................................58
Menu Flow Chart.................................................59-62
Appendix A - Meter K-Factors..................................63
Appendix B - Parts & Accessories ..........................64
Appendix C - PLC Output....................................65-68
Appendix D - Control Settings..................................69
Index.........................................................................70

1 CULLIGAN GLOBAL ELECTRONIC CONTROLLER
The Culligan Global Electronic control (GBE) primary function is to
initiate and control the regeneration process via methods that are most
convenient and cost effective for the customer while offering many
operational features and benefits. The controller is designed to operate a
wide range of existing and new softener and filtration valves.
Take control of your system and your productivity
The Culligan Global Electronic Controller (GBE) is an advanced design
engineered to handle regeneration and monitoring of your water
treatment equipment. It offers powerful programming options that
can be used to operate and monitor any softener or filter system. It
also provides sensing capabilities, expanded communications and a
multifunction keypad—all in one simple to use unit.
GBE Controller Features
Advanced Lighted OLED Display
The user is guided through brightly lit graphical menu screens
with clear, multi-line, full text prompts
Membrane Keypad
The keypad uses sealed contacts for programming. No buttons to get dirty
Program Beeper
Emits an audible beep when keys are depressed to help identify
valid (short beep) or invalid (3 short beeps) pushes. Can be
enabled or disabled.
Power Source
Electrical power required is 24 Volt 50/60 Hz AC current. A UL
listed plug-in transformer (120V/24V) is provided.
Time of Day
Displays current time of day in either 12-hour or 24 hour format
Real Time Clock with a 5 Year Battery Back-up
Keeps accurate time even during a power outage. Updates
automatically when the GBE is equipped with optional modem
capability
English or Metric Values
Displays can be set to either English or Metric
Regeneration Interval
Provides the ability to initiate a time clock regeneration based on a number of days (1 to 99) or a specific
day of the week.
Regeneration Start Delay
Allows a user determined number of hours (0-9) to be set for the purpose of increasing the amount of
time between regenerations in a multi unit installation.
Auxiliary Input
Capable of accepting a remote signal from a dry contact device such as an operator push button for the
purpose of initiating a regeneration sequence
Auxiliary Output on Alarm
Capable of sending a signal when an alarm/error is recognized
Expansion Board for Additional Outputs
o Control blocking valves
o Control external solenoids or chemical feeders
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Controller Features
Figure 2
Figure 1

CONTROLLER FEATURES 2
Progressive Flow Trip Point
Allows multiple tank systems operating with flow meters to bring tanks on-line or off-line as facility flow
demands increase or decrease
Multiple Unit Communication
A communication cable interconnects multiple units to operate the controller in the Progressive Flow
mode and prohibits them from regenerating at the same time.
Diagnostics
The user can check the operation of sensors, progressive flow communication, motor positions, or an
optional wireless display
Transformer is UL and CUL Listed
RoHS Compliant
Optional GBE Features
Flow Meter/Sensor Input
Supports various types of Hall effect flow sensors using a programmable “K” factor to initiate a
regeneration sequence
AquaSensor Input
Supports the patented digital Culligan AquaSensor technology used to efficiently initiate and control a
regeneration sequence
Telephone Modem
o Calls in reports on regenerations and alarm conditions
o Automatically updates time and date when calling in
o Automatically checks for and installs and firmware updates when calling in
Wireless Remote Display
Displays the current status of the unit. It can be located up to 200 feet away from the GBE controller
(depending on building and interference). The telephone modem can optionally be installed in the remote
display
Smart Brine Tank Probe
This probe monitors conditions inside the brine tank.
o Predicts when more salt is needed
o Detects the presence of a salt bridge
o Detects eductor line plugging
o Signals brine tank overfilling condition
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Controller Features

Modes of Operation
Time Clock
The controller will initiate a regeneration based upon a time schedule of intervals of days (i.e., every 3 days) or
on a specific day of week schedule (i.e., Mondays, Wednesdays and Saturdays). Because regeneration will
occur at the prescribed schedule regardless of water use, this method is usually the most inefficient method of
water softener operation.
Flow Meter/Sensor
When a flow meter or sensor is connected to the controller circuit board, the controller has the ability to measure
the amount of water treated and initiate a regeneration sequence based upon the gallon capacity of the water
treatment equipment. The controller can delay the regeneration signal until a convenient time of day (known as
a delayed regeneration) or act and initiate the regeneration sequence as soon as the signal is received (known
as immediate regeneration).
When installing an alternating duplex system (one tank on-line, the other in standby), only one flow measuring
device is required to be installed in the common outlet header of the system. Parallel systems (multiple tank sys-
tems, all on-line simultaneously) require one flow device for each mineral tank in the system.
This method is a proven, cost effective means to operate a water softening system.
Aqua-Sensor (Softener use only)
The Aqua-Sensor detects when a softener resin bed has reached its point of exhaustion and, as a result, initiate
a regeneration sequence. This is the most cost-effective method of operation and may be combined with any of
the operational modes previously described.
Progressive Flow
The Progressive Flow mode is used with up to six and as few as two mineral tanks in a system. It allows more
than one tank in a system to either be on-line or off-line depending upon the downstream flow demand. If flow
demand is greater than the flow capability of the tank on-line, another tank can be brought on-line to help satisfy
the excess demand. Once the demand has decreased, the second tank is returned to a standby mode and the
system reverts to just one tank on-line providing treated water.
The progressive flow mode of operation relies on a user programmable set point or Trip Point. The Trip Point
is a unit of flow (gallons or liters) on a per minute basis. Once attained the trip point will cause the second unit
(in multiple resin tank system) to come on-line. Each additional tank in the system will subsequently be brought
on-line as multiples of the trip point are attained. (Example: a 3 tank system with a trip point of 50 gpm will bring
two tanks on-line once the facility flow demands is equal to or greater than the 50 gpm trip point. Should the flow
demand reach 100 gpm or more, the third tank shall be brought on-line.)
Additional tanks shall be returned to stand-by once the facility flow demand is <95% of the trip point for two
tank systems, <95% of 2X the trip point for triplex systems and <95% of 3X the trip point for quad systems, and
remains there for 60 seconds.
Utilizing the progressive flow feature may allow the owner to use smaller units, resulting in the potential for
reduced capital and operation costs.
Differential Pressure (Filters only)
When combined with an optional differential pressure device, the Culligan MVP controller has the ability to
initiate a backwashing sequence when the pressure differential across the media bed reaches a preset amount
(usually 8 to 10 psi).
Operation
Installation 4
3 CULLIGAN GLOBAL ELECTRONIC CONTROLLER

Installation
ELECTRICAL INSTALLATION
CAUTION!
Observe the precautions listed below before electrical installation of your GBE controller.
Failure to do so may cause permanent damage to the controller.
1. Follow the local electrical code requirements.
2. Be sure electrical power is off and disconnected at the source before completing any wiring/cabling
connections.
3. Provide a dedicated 120-volt circuit for the GBE system to ensure maximum electrical protection.
4. DO NOT include the GBE wiring cables in any conduit or raceway containing other 120-volt or higher
circuits.
5. Maintain a distance of at least 10 feet between the GBE controller and any electrical distribution
panels, raceways carrying 300 volts or more, and electrical motors of 1 horsepower or more.
6. Use the cabling provided. Failure to do so may effect performance of the GBE controller adversely.
Note: One transformer is required for each controller in the system. Do not attempt to operate multiple
controllers without a dedicated transformer for each or your system will experience operational
difficulties.
Installation 4
3 CULLIGAN GLOBAL ELECTRONIC CONTROLLER

WIRING PROCEDURES AND DIAGRAMS
Preparation
1. Loosen the screws or latches securing the controller access cover (Figure 3 or 4) on each controller
provided.
2. Using a small screwdriver, loosen all the terminal strip binding screws on the main circuit board that do
not contain wires by turning counterclockwise until the wire clamp has been fully opened (see Figure 5).
Installation
Figure 3
Figure 5
Installation 6
5 CULLIGAN GLOBAL ELECTRONIC CONTROLLER
Figure 4

Installation
Cable Routing
All input and output connections to the circuit board are 24 volt or less.
Although the cables do not have to be run in conduit, it is necessary that long runs of cable be supported or
protected by strapping them to the equipment piping. If conduit will be used to route the shielded cables, three
factors must be considered:
1. DO NOT share the same conduit or raceway with 120 volt or higher circuits.
2. Keep cables at least 6 inches away from 120 volt or higher electrical circuits.
3. GROUND the conduit (if metallic) to a known “earth ground” location.
A series of holes are located on the sides of the controller (see Figure 6 and 7). Strain relief fittings are provided
with the controller enclosure for interconnecting wiring. Install the plastic fittings as needed. Remove the com-
pression 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 to the rubber sleeve and reassemble. This will assure all wiring is secure and assist
in making the tightening of the fitting easier. Insert the plugs provided to block any holes not used for wiring or
other accessories.
Right Side View
Brine Reclaim Solenoid
(optional)
Input Connection
for Flow Sensor
Output Connection
for Remote
Accessories
Input Connection
for Remote
Accessories
24 Volt Power
Input Connection
Brine Reclaim Solenoid
(optional)
Brine Refill Valve
Blocking Solenoid for
Alternating Operation
Left Side View
Figure 6 Figure 7
Installation 6
5 CULLIGAN GLOBAL ELECTRONIC CONTROLLER

GBE Circuit Board Layout–Front
Keypad connector
Battery
CR2032 (Postitive Side Up)
Schematic
OLED Display
Phone line
connection
(optional)
GBE Circuit Board Layout–Back
Figure 8
Motor position cable
Multiple unit jumper
Communication cable (optional)
Flow meter cable
(optional)
Smart Brine Tank cable (optional)
External regeneration
signal connection (optional)
Motor
connection
Programmable outputs (optional)
Blocking valve
connection (optional)
Power cable
from transformer
Aqua-Sensor
cable (optional)
Future use
Do not connect
anything to these.
Data port
Figure 9
Schematic 8
7 CULLIGAN GLOBAL ELECTRONIC CONTROLLER