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Culligan CTM Series User Manual
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CULLIGAN
®
Culligan Top Mount (CTM)
Water Softeners
Models from 2016
©2016 Culligan International Com
pa
ny
Installation,
Operation, and
Service Instructions
with Parts Lists
Cat. No. 01029401
Rev. C 09/18/17
DCO # 017553
2
Table of Contents
Table of Contents
3
Safe Practices
5
Caution and Warning
5
Introduction
5
What Is Hard Water?
6
Why Should Hardness be Removed?
6
How Do You Regenerate Resin?
6
Basic Principles
6
Specifications for CTM Water Softeners
7
CTM Flow Specifications
7
Performance Specifications
7
CTM Dimensions
8
Overview
8
Materials
9
Sizing Kit
9
Installation
9
Locate Softener
10
Install Distribution System
10
Loading the Media
11
Loading Quantities
11
Attach Tank Adapter (30” and 36” Tanks Only)
12
Aqua-Sensor Ported Tanks
12
Non-Ported Tanks
12
Mount the Valve
13
Plumbing Adapter
14
Install Piping
15
Use of Bypass Valve
15
Three-Valve Bypass
15
Suggested Piping Installation
16
Three-Valve Bypass CTM Single Tank Piping
16
Top View
17
CTM Duplex Alternating Piping
17
Drain Line
18
60K Drain Assembly
19
90K and Larger Drain Assembly
19
Drain Line Flow Control
19
Drain Line Flow Control (DLFC) and 1.5” Drain Adapter
19
Pressure Relief Valve (PRV)
20
Eductor Nozzle and Throat Replacement
21
Eductors
21
Replacing the Brine Refill Flow Control Insert
22
Brine Refill Flow Control
22
Brine Elbow Assembly
22
Brine System Installation
23
Brine Piping
23
Brine Connection Tubing
23
18X38 and 24X40 Brine Systems
23
Tubing Pilot Valve
24
Inlet/Outlet Tubing
24
Mounting the Controller
25
Valve Front Mount (Provided in Sizing Kit)
25
Controller Valve Front Mounted
25
Wall Mount (Single Unit - P/N 01030100, Multi-Unit - P/N 01030101)
26
Valve Side Mount (Optional, P/N 01029171)
26
Controller Valve Side Mounted
26
Wiring Procedures and Diagrams
27
Cable Routing
27
Transformer and Smart Controller Circuit Board
28
24 V Power Connection
28
Wiring the Smart Controller Power Cord and 24V Transformer
28
Smart Controller Circuit Board Layout–Front
29
Smart Controller Circuit Board Layout–Back
29
Smart Controller Circuit Board Layout, Rear View
29
Smart Controller Circuit Board Layout
29
Circuit Board - Motor and Position Sensor
30
Multi-Tank Systems
31
Tubing Ball Valves for Multi-Tank Systems
31
Installing Accessories
31
Tubing to Ball Valve #2 (Ports 1, 2, 3)
32
Motorized Ball Valves, Wall Mounted Controller
33
Motorized Ball Valves, Valve Mounted Controller
33
Wiring for Multi-Tank Systems
33
Setting the Jumpers for GBE to GBE RS485 Communication
34
Progressive, Parallel or Alternating Flow
34
Duplex Connections
34
Parallel Cable for Smart Controller
34
Connecting Multiple Circuit Boards to 24VAC Power Supplies
35
Ported Plumbing Adapter
37
Gauge and Sample Valve Kit (P/N 01029507)
37
Softening Cartridge with Cartridge Adapter (P/N 01029504)
38
Mounting to Bracket
38
Tubing
38
Aqua-Sensor
39
Auxiliary Outputs (P/N 01020748)
40
Auxiliary Board Activation Timing
40
Auxiliary Output 5 Relay Board (P/N 01022238)
41
Example of Customer Wiring to the GBE Alarm Signal Output
41
Modem
42
Installing the Modem (P/N 01020747)
42
Installing the Landline Modem on the Smart Controller Board
42
Back of GBE Board
42
Installing the Modem in the Remote
43
Back of Remote Board
43
Smart Brine Tank Probe (P/N 01027289)
44
RF Board (Note Orientation)
44
Wireless Remote Monitor
44
Installing the Wireless Remote (P/N 01020553)
44
Non-Hardwater Bypass Conversion
45
Pressurize the Media Tank
47
Fill the Salt Storage Container
47
Final Startup
47
CTM Brinemaker Data
48
Key for Table 8 on the Next Two Pages
48
Initial Backwash of the System
51
Installation Wrap up
51
Creating Brine
51
Care and Cleaning
52
Before Leaving the Installation Site
52
Check List
52
Sanitize the System
52
Suggested Preventive Maintenance Inspection Schedule
53
Preventative Maintenance
53
Analyze the System
54
Check the System
54
Procedure for Depressurizing the CTM System for Service
54
Service and Repair
54
CTM Piston Rebuild
55
Valve Removal and Disassembly
55
Upper Manifold Dissembly
56
Removing the Pistons
57
T-Seal Replacement and Assembly
60
For All 5 Large Pistons
60
For All 3 Small Pistons
60
For All 8 Pistons
60
Reassemble Manifold
61
Reassemble Valve
62
Pilot Valve Rebuild (Kit P/N 01029583)
64
Pilot Valve Disassembly
64
Motor Replacement
65
Pilot Spool Replacement
66
Pilot Valve Reassembly
67
Drain Line Flow Control—Service
68
Brine System Analysis
68
CTM Complete Brine Draw/Slow Rinse Times
68
Troubleshooting
68
General Troubleshooting
69
CTM Refill Piston (#7) Vent Port Location
73
CTM Motor Cover Drain Hole Location
73
Aqua-Sensor Troubleshooting
74
Recording Important Information
74
Ball Valve Positions
75
Ball Valve Ports (Multi-Tank Softeners Only)
75
Ball Valve to Pilot Valve Flow Paths
75
Motorized Ball Valve Operation
75
Flow Diagrams
76
CTM Flow Valve Piston Locations
76
Piston Cycle Positions
76
Piston Locations
76
Service
77
Piston Cycle Positions, Service
77
Backwash
78
Piston Cycle Positions, Backwash
78
Piston Cycle Positions, Brine Draw/Slow Rinse
79
Brine Draw/Slow Rinse
79
Fast Rinse
80
Piston Cycle Positions, Fast Rinse
80
Refill
81
Piston Cycle Positions, Fill
81
Replacement Softener Tanks and Media
82
Sizing Kits, Downflow
82
CTM Parts List
82
Sizing Kit, 60K Softeners
83
Sizing Kit, 90K, 120K, 150K and 210K Softeners
83
Sizing Kit, 300K Softeners
84
Sizing Kit, 450K and 600K Softeners
84
Valve Body and Adapter
85
Control Valve
85
Valve Top Manifold
86
Valve Service Rebuild Kits
88
CTM Valve O-Ring Kit
88
CTM Piston Rebuild Kit
88
CTM Piston Replacement Kit
89
CTM Valve Core Replacement
89
Pilot Valve Rebuild Kits
89
Culligan GBE Controller for CTM
90
18”X38” and 24”X40” Brine Systems
91
24" and 30" Brine Systems
92
39” and 42” Brine Systems
92
3/4” Brine Valve Subassembly
93
Aqua-Sensor Plug and Probe
94
Remote Display and Accessories
95
Remote Display
95
International Parts
96
Appendix A Hi-Flo 3/3E to CTM Conversion
97
Aqua-Sensor Application Guidelines
98
Hardness Vs. Salt Dosage
98
Resin Bed Depth/Estimated Capacity Per Inch at Various Salt Dosages
98
Appendix B Aqua-Sensor Guidelines
98
Operation Log
99
Limited Warranty
100
Index
101
4
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Culligan CTM Series Specifications
General
Power Source
Electric
Voltage
120V
Type
Countertop
Dispensing Options
Cold
Filter Life
6 months
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