Culligan Mark 100 User manual

CULLIGAN®
MARK 100
AUTOMATIC
WATER CONDITIONER
MODELS FROM 2000
©2000CulliganInternationalCompany
Cat. No. 01-8822-22
Rev. A 04-25-00
DCO#992590
Service
Manual
Printed in USA

WARNING-Priortoservicingequipment,disconnectpower
supplytoprevent electricalshock.
IF THIS EQUIPMENT IS TO BE USED IN THE TREATMENT
OF DRINKING WATER, THE WATER MUST BE MICROBIO-
LOGICALLY SAFE.
Attention Culligan Customer:
The installation, service and maintenance of this equipment should be
rendered by a qualified and trained service technician.Your local indepen-
dently operated Culligan dealer employs trained service and maintenance
personnel who are experienced in the installation, function and repair of
Culligan equipment. This publication is written specifically for these indi-
viduals and is intended for their use.
We encourage Culligan users to learn about Culligan products, but we
believe that product knowledge is best obtained by consulting with your
Culligan dealer. Untrained individuals who use this manual assume the
risk of any resulting property damage or personal injury.
WARNING-Ifincorrectlyinstalled,operatedormaintained,this
productcancausesevereinjury. Thosewho install,operate,or
maintainthisproductshouldbe trainedinitsproper use,warnedofits
dangers,andshouldreadtheentiremanualbeforeattemptingto
install,operateormaintainthis product.

Table of Contents Page
Introduction ............................................................... 2
Specifications ........................................................... 3
Familiarization........................................................... 4
Programming............................................................10
ManualCycling ........................................................12
ServiceCheck ..........................................................13
BoradDiagnostics....................................................14
PartsReplacementGuide ........................................15
TroubleshootingGuide..............................................19
WiringDiagram ........................................................23
DimensionCharts/RefillRates ..................................24
FlowRate and DrainLine Charts ..............................26
FlowCharts..............................................................28
Service
Manual
CULLIGAN®
MARK 100
AUTOMATIC
WATER CONDITIONER
MODELS FROM 2000

2CULLIGAN®MARK100 WATERSOFTENER
Introduction
SAFEPRACTICES
Throughout this manual there are paragraphs set off by special headings.
NOTICE: Notice is used to emphasize installation, operation or maintenance information which is important, but
does not present any hazard.
Example: NOTICE: The nipple must extend no more than 1 inch above the cover plate.
CAUTION: Caution is used when failure to follow directions could result in damage to equipment or
property. Example:
CAUTION:Disassembly while under waterpressure can result inflooding.
WARNING: Warning is used to indicate a hazard which could cause injury or death if ignored. Example:
WARNING! ELECTRICALSHOCKHAZARD!UNPLUGTHEUNITBEFORE
REMOVINGTHECOVERORACCESSINGANYINTERNALCONTROLPARTS.
SERIAL NUMBERS
The control valve serial number is located on the back of the timer case.
The media tank serial number is located on the top surface of the tank.
NOTICE: Do not remove or destroy the serial number. It must be referenced on request for warranty repair or
replacement.
This publication is based on information available when approved for printing. Continuing design refinement
could cause changes that may not be included in this publication.
* Verified using hardness surrogate perANSI/NSF Standard 44.
The Culligan®Mark 100 water softeners are tested and validated by WQAagainstANSI/NSF
Standard 44 for the effective reduction of calcium and magnesium, along with Barium and
Radium226/228*.

SPECIFICATIONS 3
Specifications
Culligan®Mark100WaterConditionerswithTimeClock,Aqua-Sensor®DeviceorSoft-Minder®Meter
1 Capacities and corresponding salt dosages pertain to low hardness waters. Capacities given are per recharge
2 Measured from top of media to top of inlet fitting (backwashed and drained).
3 Measured from top of underbedding to top of inlet fitting.
4 Backwash at 120 psi (830 kPa).
5 10 minute backwash, 7 lb (3.2 kg) 9” model or 13 lb (5.9 kg) 12” model salt dosage at 30 psi (204 kPa).
9” Model 12” Model
ControlValve 5-cycle, Reinforced Thermoplastic 5-cycle, Reinforced Thermoplastic
Overall Conditioner Height 51 in 51 in
1 295 mm 1 295 mm
Media Tank Dimensions (Dia x Ht) 9 x 45 in 12 x 45 in
229 x 1 143 mm 305 x 1 143 mm
Salt StorageTank Dimensions (Dia x Ht) 16 x 43 in 18 x 43 in
406 x 1 092 mm 457 x 1 092 mm
18 x 43 in
457 x 1092 mm
Exchange Media, Type and Quantity Cullex®Media, 0.86 ft3Cullex®Media, 1.4 ft3
Cullex®Media, 24.5 L Cullex®Media, 40 L
Underbedding, Type and Quantity Cullsan®Underbedding, 12 lb Cullsan®Underbedding, 30 lb
Cullsan®Underbedding, 5.4 kg Cullsan®Underbedding, 14 kg
Exchange Capacity 17,500 gr @ 4.0 lb 24,100 gr @ 6.0 lb
@ Salt Dosage Per Recharge11 133 g @ 1.8 kg 1 560 g @ 2.7 kg
23,900 gr @ 8.0 lb 34,500 gr @ 12.0 lb
1 547 g @ 3.6 kg 2 234 g @ 5.4 kg
26,600 gr @ 12.0 lb 41,900 gr @ 18.0 lb
1 722 g @ 5.4 kg 2 713 g @ 8.1 kg
Freeboard to Media216.6-17.6 in 17.5-18.5 in
420-447 mm 444-470 mm
Freeboard to Underbedding339.2 in 38.5 in
996 mm 978 mm
Salt Storage Capacity 250 lb or 375 lb 375 lb
114 kg or 170 kg 170 kg
Rated Service Flow @ Pressure Drop 7.5 gpm @ 15 psi 7.5 gpm @ 15 psi
30 Lpm @ 102 kPa 31 Lpm @ 102 kPa
Total Hardness, Maximum 75 gpg 99 gpg
1 283 mg/L 1 692 mg/L
Total Iron, Maximum 5 ppm 5 ppm
5mg/L 5 mg/L
Hardness to Iron Ratio, Minimum 8 gpg to 1 ppm 8 gpg to 1 ppm
140 mg/L to 1 mg/L 140 mg/L to 1 mg/L
Operating Pressure 20-125 psi 20-125 psi
140-860 kPa 140-860 kPa
Operating Temperature 33-120°F 33-120°F
1-50°C 1-50°C
ElectricalRequirements 120V/60 Hz 120V/60 Hz
Electrical Power Consumption, Min/Max 3 Watts/35 Watts 3 Watts/35 Watts
Drain Flow, Maximum42.0 gpm 3.5 gpm
8 Lpm 14 Lpm
RechargeTime,Average580 min 85 min
RechargeWater Consumption,Average 45gal 86gal
170 L 325 L

Familiarization
4CULLIGANMARK 100WATERSOFTENER
Control
The Culligan®Mark 100 water softener uses the same power valve control as in our Culligan Mark 89/812 models. It can
be programmed as either a time clock,Aqua-Sensor®sensing device or Soft-Minder®meter model. Each model has its
own programming parameters which can be set to control the operation and regeneration of the system. These functions
are outlined inTable 1.
Aqua-Sensor
Time Soft-Minder Sensing
Function Clock Meter Device
1. Time of Day YES YES YES
2. Time of Regen. YES YES YES
3. Not Used NO NO NO
4. Salt Dosage YES YES YES
5. Backwash Time YES YES YES
6. Brine Rinse Time YES YES YES
7. Hardness Level NO YES NO
8. Gallons Capacity / Regen. Interval YES YES NO
8A. Forced Regeneration Interval NO YES* YES*
9. Lock/Unlock display YES YES YES
10. Blanking Feature YES YES YES
TABLE1
During the programming stage, the user will be prompted to enter the appropriate parameter. Refer to the programming
section for further information.
Circuit Board
TheAccuSoft™microprocessor circuit board controls every function of the Culligan Mark 100 water softener. This board
has several unique features which allow it to perform a variety of functions. Familiarization of the board is essential for
a thorough understanding of the softener.
The AccuSoft™circuit board has a set of default
settings that the microprocessor will reset to when-
ever any dip switches are flipped, or if a meter or
Aqua-Sensor cable is attached or removed while the
power is on the the control. Table 2 is a list of the
default microprocessor settings.
TABLE2
1 Time of Day 12:00 A.M.
2 Time of Regeneration 2:00 A.M.
3 Chlorination (Not Used) 10 min.
4 Salt Dosage 10 lb., 9”
16 lb., 12”
5 Backwash Time
6 Brine Rinse 71 min., 9”
59 min., 12”
7 Hardness
8 Regeneration Interval 3 days
9 Display Blanking Enabled
10 Display Lock Out Disabled
10 min.
20 GPG
It is reccomended to always disconnect the power
from the circuit board prior to replacing anAqua-
Sensor probe or Meter cable so that the programmed
settings are not lost.
* When dip switch #10 is in the ON position

FAMILIARIZATION 5
FIGURE 2
Programming Switches
The circuit board will require the proper setting of the dip switches in order to function properly. Figure 1 shows the dip switches.
Switch 1 - Sets the unit in the Run or Test mode.
Switch 2 - Sets the unit for Filter or Softener.
Switch 3 - Sets the flow meter K factor for the 3/4" or 1-1/4" flow meter.
Switch 4 - Sets the control for 9” or 12” diameter tanks.
Switch 5 - Sets the unit for the standard or accelerated Refill cycle.
NOTICE: For an accelerated Refill cycle, the refill flow control in the brine refill assembly must be changed to PN 00-4016-23.
Switch 6 - Sets the unit for immediate or delayed regeneration.
Switch 7 - Sets the unit to measure in liters and French or German hardness, or in gallons and the conventional gpg hardness.
Switch 8 - Sets the unit to display time with a 24 or 12 hour clock.
Switch 9 - Sets the unit for either French or German hardness degrees when switch #7 is in the ON position.
Switch 10 - When turned ON, the microprocessor will force a regeneration based on the setting 8A in the menu.
Auxiliary Connections
Refer to Figure 2 for all circuit board connections.
Power terminals are located along the lower section
ofthe circuit board. The connection marked 'POWER'
is for the transformer connector, and the motor con-
nection is marked 'MOTOR'. The connection for the
cam switch harness, marked 'CAM', is located in the
upper right corner near the dip switches. The Aqua-
Sensor sensing device connection is located in the
lower center of the board, just above the power con-
nectors, while the Soft-Minder connection is located
in the upper left side of the board. Just below the
meter connection is a connection marked 'BATT',
which is for the optional battery back-up. All termi-
nals are clearly marked to ease installation.
Dip Switch
1
2
3
4
5
6
7
8
9
10
Function
Run or Test Mode
Filter or Softener
Flow Meter K Factor (3/4" or 1-1/4")
9"-12" Tank Settings
Standard vs.Accelerated Refill
Delay vs. Immediate Regeneration
English vs. Metric Settings
12or 24 Hour Clock
German or French Hardness Degrees
TimeClockBackup
Default(OFF) Position
Run Mode
Softener
3/4" Flow Meter
9"Tank
StandardRefill
Delayed Regeneration
English Settings
12HourClock
German(When #7is ON)
No Forced Regeneration
FIGURE 1

6CULLIGANMARK 100WATERSOFTENER
Aqua-SensorOperation
The Aqua-Sensormodels contain a feature which can automatically detect when the brine solution has been
rinsed through the Cullexmedia. This feature will advance the control to the next position when it senses that
the brine has been rinsed out prior to the time set in the brine rinse option. The Brine/Rinse time can be manually
raised or lowered in the microprocessor.
Tables 3A and 4A show the total capacity of the Aqua-Sensorunit at various salt dosages, along with the
average capacity used prior to a signal calling for a regeneration.
To view the length of the last Brine/Rinse cycle, press the STATUS button until the display is blank. Press the
down arrow until the number 15 is illuminated. See the Service Check section for more information.
Soft-MinderOperation
The microprocessor automatically calculates the gallons of water which can be treated based on the salt dosage,
the water hardness, and the tank size. Numeric enunciator 8 will display the GALLONS TO SIGNAL for regenera-
tion (the portion of the capacity which is held in reserve is not displayed).
NOTICE: Changes to the salt dosage, or water hardness will not immediately update the GALLONS TO
SIGNAL setting. The control will recalculate the setting upon completion of a regeneration cycle.
As an option GALLONS TO SIGNAL for regeneration can be set to directly override the calculation through
numeric enunciator 8. The gallon value can be raised or lowered to meet the needs of your specific application.
The control must be cycled through a complete regeneration before the gallon override setting is stored by the
microprocessor.
NOTICE: Changing the capacity will affect the reserve capacity. An INCREASE in the gallons capacity will
DECREASE the reserve capacity. A DECREASE in the gallons capacity will INCREASE the reserve capacity.
Refer to Tables 3B and 4B to determine the units total capacity based on salt dosage and the hardness level.
The gallons remaining can be viewed by pressing the STATUS button until the display is blank. Press the down
arrow until the number 15 is illuminated. The value in the display must be multiplied by 10 to determine the
actual gallons remaining before the unit calls for a regeneration. The unit will initiate an immediate regeneration if
dip switch 6 in the ON position. See the Service Check section for more information.
Regeneration
There are several conditions that will cause the control to trip a regeneration. The 'REGEN' enunciator will light
when the control has signaled for a regeneration. The 'REGEN' enunciator will flash while the control is in
regeneration.
The following are conditions that will call for regeneration:
1. When the Aqua-Sensor®probe senses the hardness in the Cullex®media.
2. When the Soft-Minder®meter has recorded the passage of a predetermined number of gallons.
3. When the time clock has counted past the set number of days.
4. At the preset time, when the number of days without a regeneration is equal to the days set in menu #8A.
5. At the preset time, when the 'REGEN.’ button is depressed once. 'REGEN.' will light.
6. Immediately, when the ‘REGEN.” buttonis depressedtwice. 'REGEN.' will light and blink.
7. Immediately, if power to the unit has been off for more than 3 hours.
If dip switch 6 is in the ON position the unit will begin a regeneration immediately for instances 1 and 2. With dip
switch 6 in the OFF position, the regeneration will not begin until the preset regeneration time.

Display Blanking
As shipped from the factory, the display of the board will turn off if there has been no keypad activity for a 1 minute
period. To have the display constantly lit, press the STATUS button until the number 10 icon is lit. Next, press the
UParrow.A“d” for disable will appear in the display. To have the display blank again , press the UParrow. An “E”
will appear in the display .
Display Lockout
The Culligan®Mark 100 control is equipped with a new feature which will allow you to protect the programmed
settings from tampering by unauthorized individuals. When the lockout feature is activated, the only parameter
which can be adjusted is the Time-of-Day.
Toactivate the lockout feature, press the STATUS buttonuntil thenumber 9 icon is illuminated.A“U”for unlock will
bedisplayed. Press theUPand DOWN arrows simultaneously.A“L” for lock willappear along with an iconof a lock.
All program parameters, except time of day, are now frozen at their current settings. To disable this feature, press the
UPand DOWN arrows simultaneously.
Power Loss
The AccuSoft®circuit board is equipped with a Hi-Cap Capacitor and EEPROM memory chip. The capacitor is
capable of maintaining the time, for at least one day, in the event of a power outage. The EEPROM ensures that the
individual programming parameters of the softener are not lost.
If the power outage lasts long enough to drain the Hi-Cap Capacitor, the control will flash "12:00 PM" when
power is returned to the control. The unit will continue to keep time from the moment power is restored, and will
initiate a full regeneration at the preset regeneration time. The time of day will need to be reset in order to return
the regeneration to its preset time.
Failure Mode
The Culligan Mark 100 control is equipped to detect a motor or piston which is locked in a frozen position. The
AccuSoft™circuit board will apply power to the motor for 30 seconds. If there is no change in the motor homing or
position switch, the control will power down for 90 seconds. The circuit board will repeat this procedure two more
times in an attempt to remove the obstruction. If no movement has been detected, the control will permanently
power down and a phone icon will appear in the display. The phone indicates that a service call is required to fix the
control. To return to the service mode, turn off the power to the unit for 1 full minute and remove the obstruction to
the motor or piston.
FAMILIARIZATION 7

TABLE3A-CAPACITY,9”AQUA-SENSOR®SENSINGDEVICE(GALLONS)
8
12
SALT
DOSAGE 160 LB INCH(CM) 250 LB INCH(CM) 375 LB INCH(CM)
“A” DIMENSION
14-3/4
(37.5)
21-3/4
(55.2)
9-1/4
(23.5)
15-3/4
(40.0)
7-1/2
(19.1)
11-3/8
(26.9)
4,900
3,537
5,420
3,656
1-5
2,450
1,949
2,710
1,828
6-10
1,633
1,179
1,807
1,219
11-15
1,225
1,004
1,355
914
16-20
980
707
1,084
731
21-25
817
590
903
609
26-30
774
522
31-35
678
457
36-40
602
406
41-45
542
366
46-50
493
332
51-55 56-60 61-65 66-70 71-75
HARDNESS
TOTAL CAPACITY
CAPACITY TO SIGNAL
TOTAL CAPACITY
CAPACITY TO SIGNAL
TABLE3B-CAPACITY,9”SOFT-MINDER®METER(GALLONS)
4
8
12
SALT
DOSAGE 160 LB INCH(CM) 250 LB INCH(CM) 375 LB INCH(CM)
“A” DIMENSION
7-3/4
(19.7)
14-3/4
(37.5)
21-3/4
(55.2)
4-5/8
(11.7)
9-1/4
(23.5)
15-3/4
(40.0)
3-1/4
(8.9)
7-1/2
(19.1)
11-3/8
(26.9)
3,220
2,596
4,900
3,314
5,420
3,656
1-5
1,610
1,298
2,450
1,657
2,710
1,828
6-10
1,073
849
1,633
1,084
1,807
1,195
11-15
805
637
1,225
813
1,355
896
16-20
644
495
980
631
1,084
696
21-25
537
412
817
526
903
580
26-30
700
442
774
987
31-35
613
387
678
426
36-40
544
333
602
367
41-45
490
300
542
331
46-50
445
267
493
294
51-55
452
270
56-60
417
246
61-65
387
229
66-70
361
209
71-75
HARDNESS
TOTAL CAPACITY
CAPACITY TO SIGNAL
TOTAL CAPACITY
CAPACITY TO SIGNAL
TOTAL CAPACITY
CAPACITY TO SIGNAL
700
505
613
442
544
393
490
354
445
322
452
305
417
281
387
261
301
244
8CULLIGAN®MARK100 WATERSOFTENER