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Culligan CTM Series User Manual

Culligan CTM Series
102 pages
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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

Table of Contents

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Culligan CTM Series Specifications

General IconGeneral
Power SourceElectric
Voltage120V
TypeCountertop
Dispensing OptionsCold
Filter Life6 months

Summary

Introduction

Read This Manual First

Emphasizes reading the manual before operating the softener for familiarization.

About This Manual

Outlines the manual's content and purpose for operators.

Safe Practices

Details safety guidelines and hazard warnings for installation and operation.

Basic Principles

What Is Hard Water?

Defines hard water and acceptable levels based on calcium and magnesium concentration.

Why Should Hardness Be Removed?

Explains the negative impacts of hard water on equipment and efficiency.

How Does It Work?

Details the ion exchange process using resin to remove hardness minerals.

Resin Saturation, Regeneration, and Control

Explains resin saturation, the regeneration process, frequency, and control methods.

Resin Regeneration Process Steps

Details the four steps of the resin regeneration process: backwash, brine draw, slow rinse, fast rinse.

Performance Specifications

CTM Water Softener Specifications

Lists operational parameters and flow specifications for CTM water softeners.

Installation

Installation Materials and Sizing Kit

Lists necessary components and details the sizing kit for installing a CTM Softener.

Locating the Softener

Provides guidance on selecting a suitable location for the softener unit.

Installing the Distribution System

Details the process of installing the distribution system components.

Loading the Media

Explains the procedure for loading resin and underbedding into the media tank.

Attaching the Tank Adapter

Instructions for attaching tank adapters to both Aqua-Sensor ported and non-ported tanks.

Mounting the Control Valve

Describes how to properly mount the control valve onto the tank adapter.

Plumbing Adapter Installation

Details the installation and connection of the plumbing adapter.

Piping Installation and Bypass Valve Use

Guidelines for installing piping and using the bypass valve for operational purposes.

Suggested Piping Installation Diagrams

Illustrates recommended piping configurations for single-tank systems.

Drain Line Connection

Provides instructions and safety warnings for connecting the drain line.

Drain Line Flow Control and Adapter

Details the installation of the drain line flow control and adapter.

Pressure Relief Valve (PRV) Installation

Instructions for installing the pressure relief valve.

Eductor Nozzle and Throat Replacement

Guides on replacing the eductor nozzle and throat components.

Brine Refill Flow Control Insert Replacement

Instructions for replacing the brine refill flow control insert.

Brine System Installation and Piping

Steps for installing the brine tank and associated piping.

Tubing the Pilot Valve

Details on tubing the pilot valve for water and air operation.

Smart Controller Circuit Board Layout

Circuit Board Front View

Illustrates the front layout of the smart controller circuit board.

Circuit Board Back View

Details the rear layout of the smart controller circuit board and its connections.

Motor and Position Sensor Connections

Details connections for the motor and position sensor on the circuit board.

Wiring Procedures and Diagrams

Wiring Preparation

Steps for preparing the controller enclosure for wiring.

Cable Routing Guidelines

Guidelines for routing cables to the circuit board, maintaining separation.

Power Cord and Transformer Wiring

Instructions for wiring the smart controller power cord and 24V transformer.

Installing Accessories

Multi-Tank Systems - Tubing Ball Valves

Explains tubing ball valves for multi-tank systems to alternate between service and standby.

Multi-Tank Wiring

Wiring diagrams for motorized ball valves in multi-tank configurations.

GBE RS485 Communication Setup

Instructions for setting jumpers for GBE to GBE RS485 communication.

Flow Configurations

Explains progressive, parallel, and alternating flow connection diagrams.

Connecting Multiple Circuit Boards to Power

Guidelines for connecting multiple GBE boards to 24VAC power supplies.

Ported Plumbing Adapter Installation

Details the installation of the ported plumbing adapter.

Gauge and Sample Valve Kit Installation

Instructions for installing the gauge and sample valve kit.

Softening Cartridge Installation

Instructions for mounting and tubing the softening cartridge.

Aqua-Sensor® Installation

Guidelines for installing and positioning the Aqua-Sensor probe.

Auxiliary Outputs

Explains the function and programming of auxiliary outputs for 24VAC devices.

Auxiliary Output 5 Relay Board Installation

Instructions for installing and wiring the auxiliary output 5 relay board.

Modem Installation

Steps for installing the modem into the controller or remote.

Wireless Remote Installation

Guidelines for selecting a location and mounting the wireless remote monitor.

Smart Brine Tank Probe Installation

Information on installing and programming the Smart Brine Tank Probe.

Non-Hardwater Bypass Conversion

Steps to convert the multi-tank system to a non-hardwater bypass.

Final Startup

Pressurizing the Media Tank

Instructions for filling and pressurizing the media tank.

Filling the Salt Storage Container

Guidance on filling the brine tank with salt and understanding terms.

Sanitizing the System

Procedure for sanitizing the water softener system.

Pre-Service Installation Checklist

A checklist to ensure the system is properly installed before use.

Care and Cleaning Recommendations

Precautions for maintaining the appearance and operation of the unit.

Preventative Maintenance

Preventive Maintenance Schedule

Provides a schedule for inspecting system components and reasons for maintenance.

Service and Repair

Analyzing System Problems

Outlines a three-step process for analyzing system problems.

Checking the System

Lists necessary tools and procedures for checking the system's operation.

Depressurizing for Service

Provides a step-by-step procedure to safely depressurize the system for servicing.

CTM Piston Rebuild - Valve Disassembly

Detailed steps for removing and disassembling the control valve for piston rebuild.

Upper Manifold Disassembly

Instructions for disassembling the upper manifold of the control valve.

Removing the Pistons

Steps to remove the pistons from the valve body.

Flow Valve Assemblies

Details the components of large and small flow valve assemblies.

T-Seal Replacement and Assembly

Instructions for replacing T-seals and assembling flow valve components.

Reassembling the Manifold

Steps for reassembling the control valve manifold.

Reassembling the Valve

Steps for reassembling the control valve onto the tank adapter.

Pilot Valve Rebuild - Disassembly

Steps for disassembling the pilot valve for rebuild.

Motor Replacement

Instructions for replacing the motor assembly.

Pilot Spool Replacement

Procedure for replacing the pilot valve spool.

Pilot Valve Reassembly

Steps for reassembling the pilot valve after service.

Troubleshooting

Drain Line Flow Control Issues

Troubleshooting steps for issues with the drain line flow control.

Brine System Analysis

Diagnosing problems related to water levels and rod movement in the brine tank.

Brine Draw/Slow Rinse Times

Table providing brine draw and slow rinse times for various models.

Leak Troubleshooting

Common leak issues: drain, pilot valve, valve core, and hard water leakage into service lines.

Flow and Pressure Issues

Troubleshooting for restricted service flow, brine draw, refill failures, and media to drain.

Pilot Valve and Brine Tank Issues

Addresses pilot valve pressurization, brine tank overfilling, and standby mode problems.

Motorized Ball Valve Operation

Details the operation of motorized ball valves and their positions in different cycles.

Flow Valve Piston Positions

Details piston locations and cycle positions for various valve operations.

CTM Flow Valve Piston Locations

Illustrates piston locations and their cycle positions within the flow valve.

Backwash Piston Cycle Positions

Shows piston positions during the backwash cycle.

Brine Draw/Slow Rinse Piston Positions

Details piston positions during the brine draw and slow rinse cycles.

Fast Rinse Piston Cycle Positions

Shows piston positions during the fast rinse cycle.

Fill Piston Cycle Positions

Details piston positions during the fill cycle.

Aqua-Sensor® Troubleshooting

Recording Important Information

Guides on recording diagnostic data for Aqua-Sensor analysis.

Aqua-Sensor® Data Interpretation

Explains how to interpret Z-ratio, Z-minimum, and Z-increase readings.

CTM Parts List

Replacement Tanks and Media

Lists models, sizes, part numbers for tanks and media.

Sizing Kits

Details the components included in various sizing kits for installation.

Control Valve Assemblies

Exploded view and list of parts for the control valve assembly.

Control Valve Components

Lists various control valve parts, adapters, and accessories.

Valve Rebuild and Replacement Kits

Details O-ring and piston rebuild kits for valve maintenance.

Piston and Valve Core Kits

Lists piston replacement kits, valve core replacement, and pilot valve rebuild kits.

GBE Controller Components

Lists components for the Culligan GBE controller.

Brine System Components

Combines parts lists for different brine system sizes.

3/4" Brine Valve Subassembly

Details parts for the 3/4" brine valve subassembly.

Aqua-Sensor Components

Lists parts for the Aqua-Sensor probe and plug.

Remote Display and Accessories

Lists parts for the remote display and related accessories.

International Remote Display Parts

Lists international versions of remote display parts and accessories.

Appendix A: Hi-Flo 3/3e to CTM Conversion

Retrofit Kit and Adapter Ordering

Guides on ordering retrofit kits and plumbing adapters for conversion.

Appendix B: Aqua-Sensor Guidelines

Aqua-Sensor Application Guidelines

Provides guidelines for applying the Aqua-Sensor based on water parameters.

Hardness vs. Salt Dosage Recommendations

Table correlating water hardness to recommended salt dosage.

Resin Capacity and Salt Dosage

Details resin capacity per inch at different salt dosages.

Operation Log

System Operation Log

Instructions and format for logging system operation data for troubleshooting.

Limited Warranty

Warranty Terms and Conditions

Outlines the warranty period and conditions for the water conditioner.

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