CTM2 Softener Manual
CTM2 Softener Manual
0
Water Softeners
CTM 2.0
Water Softeners
Contents
Introduction......................................................................... 3 Troubleshooting Guide..................................................... 63
Specifications..................................................................... 6 Parts List.......................................................................... 77
Installation.......................................................................... 8 Limited Warranty.............................................................. 90
Electrical Controller Circuit Board Layout......................... 24 Appendix A - Basic Principles.......................................... 91
Accessories...................................................................... 33 Appendix B - Aqua-Sensor Guidelines............................ 92
Start-Up............................................................................ 40 Appendix C - Operation Log............................................ 93
Preventative Maintenance................................................ 47 Index................................................................................. 94
Service............................................................................. 48
The Culligan CTM 2.0 Water Softeners are certified by IAPMO R&T against NSF/ANSI
372 and NSF/ANSI/CAN 61 for Material Safety Requirements. Not certified for Structural
Integrity (except for CSA models) or Contaminant reduction by IAPMO R&T.
The Culligan CTM 2.0 Ported 60K, 90K, 120K and all CTM 2.0 Non-Ported Water Softeners
are also certified to CSA B483.1. Not certified for Contaminant Reductions by IAPMO R&T.
Models listed by IAPMO R&T are:
CTM 2.0 Downflow HWB Ported Capacity Softener (60K, 90K, 120K, 150K, 210K, 300K, 450K, 600K)
CTM 2.0 Downflow HWB Non-Ported Capacity Softener (60K, 90K, 120K, 150K, 210K, 300K, 450K, 600K)
CTM 2.0 Downflow NHWB Ported Capacity Softener (60K, 90K, 120K, 150K, 210K, 300K, 450K, 600K)
CTM 2.0 Downflow NHWB Non-Ported Capacity Softener (60K, 90K, 120K, 150K, 210K, 300K, 450K, 600K).
The skid mounted systems have not been tested or certified by WQA and IAPMO R&T.
The CTM 2.0 Water Softeners are designed to meet the needs of applications for high quality water. This manual
contains important information about the unit, including information needed for installation, operating, and
maintenance procedures. A troubleshooting section provides a guide for quick and accurate problem solving.
In order for the water treatment system to continue to provide high quality water, you must develop a thorough
understanding of the system and its operation. Review this manual before making any attempt to install, operate,
or service the system. Installation or maintenance done on this system by an untrained service person can cause
major damage to equipment or property damage.
Licensed plumbers know that standard industry procedures include only to hand tighten or use strap
wrenches on plastic parts. Plastic piping systems must be installed, operated and maintained in accordance
with accepted standards and procedures. Not adhering to the recommended service/maintenance can cause
damage to equipment or property damage.
This manual is based on information available at the time it was finalized, approved, and published.
Continuing design refinement could cause changes that may not be included in this publication.
Your local independently 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 individuals 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.
NOTE! This manual can be obtained from your local dealer, on CPort (www.cport.culligan.com)
under the Technical Service Tab or on the Service Tech App.
Note
NOTE! “Note!” is used to emphasize installation, operation or maintenance
information which is important, but does not present any hazard.
Caution
CAUTION!
“Caution” is used when failure to follow directions could result in damage to equipment or property.
Warning
WARNING!
“Warning” is used to indicate a hazard which could cause injury or death if ignored.
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 which cannot be built into
the equipment. These MUST be supplied by the personnel installing, operating, or maintaining the system.
WARNING!
Electrical shock hazard! Prior to servicing equipment, disconnect power supply
to prevent electrical shock.
WARNING!
If incorrectly installed, operated, or maintained, this product can cause severe injury. Those who
install, operate, or maintain this product should be trained in its proper use, warned of its dangers,
and should read the entire manual before attempting to install, operate, or maintain this product.
Failure to comply with any warning or caution that results in any damage will void the warranty.
CAUTION!
This product is not to be used by children or persons with reduced physical, sensory or mental
capabilities, or lack of experience or knowledge, unless they have been given supervision or
instruction. Children should be instructed not to play with this appliance.
CAUTION!
If the power cord from the power supply to the unit looks or becomes damaged, the cord and
power supply should be replaced by a Culligan Service Agent or similarly qualified person in
order to avoid a hazard.
CAUTION!
To reduce the risk of fire, use only No. 26 AWG or larger telecommunications line cord.
NOTE! This system is not intended for use with water that is microbiologically unsafe
or of unknown quality without adequate disinfection either before or after the system.
Check with your public works department for applicable local plumbing and sanitation
codes. Follow local codes if they differ from the standards used in this manual.
To ensure proper and efficient operation of this Culligan product to your full satisfaction,
carefully follow the instructions in this manual.
Products manufactured and marketed by Culligan International Company (Culligan) and its affiliates are protected
by patents issued or pending 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, Aqua-Sensor, Tripl-Hull, and
SoftMinder are trademarks of Culligan International Company or its affiliates.
Softener Model 60K 90K 120K 150K 210K 300K 450K 600K
Minimum Flow Rate
(gpm) 1.6 2.1 2.8 5 5 6 10 14
Maximum Continuous
Flow (gpm)¹ 20 30 40 45 55 65 76 82
Service
Continuous @ 15 psi
pressure loss 51 57 55 59 65 70 76 82
Brine Draw (gpm) 0.53 0.53 1.08 1.08 1.13 1.65 2.07 2.07
Drain
Slow Rinse (gpm) 0.93 0.93 1.60 1.60 2.00 2.66 5.34 5.34
Refill (gpm), Standard 1.48 1.78 2.0 2.0
[Fast Refill]³ 0.8 0.8 1.25 1.25
[1.62] [2.0] [2.75] [2.75]
¹Maximum softening performance (minimized hardness leakage) can be achieved using this service flow rate.
²The Suggested Progressive Flow Trip Point is simply a suggested flow rate at which point an additional tank will be
brought on line if facility flow demand meets this rate. The Culligan GBE Controller will not remove a tank brought
on line by attaining the Trip Point unless the flow is under the Trip Point amount for a 30-second period. In the event
additional units are not brought on line or off line when desired, simply adjust the programmed Trip Point. Refer to GBE
Programming document for more information about the Progressive Flow mode of operation.
³Refill flow rates based on 60 psi inlet/influent pressure and eductor combinations specified per Table 5 on page 20 and
brine refill flow control inserts specified on page 21. The use of the standard or fast refill brine refill flow control insert
options will change the brine refill times (see Table 8 on page 43).
NOTE! Overall dimensions assume systems include an optional, standard size brine tank.
NOTE! Allow a minimum of 12" above the overall system height for access into the top of tank(s).
Inlet
4.75”
Outlet
11”
A
Drain 19.6”
Brine 13.3”
23.8”
Eductor
Nozzle
Drain Adapter
Flow Flow Meter
Control (Comes with Valve)
Body,
Brine Elbow with inserts
Assembly
Vacuum
Pressure Breaker
Relief
Inlet Strainer
Media Tank
(Boxed
Separately)
Distributor
(Boxed Separately)
Media
Brine Tank (Sold Separately)
1/2” Brine Tubing (Not Provided)
(Separate
Packaging,
See Table 3 on
page 10)
Media Tank
Distributor
Deburr distributor pipe
Media
Tank
NOTE! Do NOT attempt to load the media without having the tank in its final position.
Moving the tank once the media has been loaded will be difficult at best.
Figure 4.
1. Cover the top of the distributor pipe with tape that will
prevent media from entering the distributor.
2. Use a funnel (P/N 01029516) in the
opening to add 6” of water to protect the
distributor. Pour Cullsan per Table 3, level
before adding resin.
3. Pour bags of Cullex per Table 3.
4. Clean tank threads, remove tape and check Freeboard
for any foreign materials
Cullex
Cullsan
8 9
Place o-ring
into the 4 3
underside of
the flange.
Do not
lubricate o-ring.
10 7
Washer
Top of Tank
Lock Nut 6 11
2
Nut
Non-Ported Tanks
Figure 6.
Figure 7.
Lubricate
o-rings
Flow
Meter
Coupling
1.5” or 2”
Lubricate Insert Plumbing Threads
o-rings Adapter
CAUTION!
All soldering must be done on any
connections requiring soldering prior to
connecting the main control valve. The
main control valve will be damaged if it is
connected at the time of soldering.
NOTE! The use of unions and inlet and outlet isolation valves is REQUIRED to facilitate the
servicing of the system. It is also recommended a full flow by-pass line be provided.
2. Follow good plumbing practices for installation. These include:
a. Check threads and make certain that they are clean and free of foreign matter.
b. Fittings must be free of cracks or chips.
c. Prepare threads with either a pipe dope sealant or Teflon tape.
d. Make certain that the fittings are not cross threaded during the assembly process.
e. Do not over-tighten fitting or threaded pipe being inserted into a cast or forged part.
To bypass, close the inlet and outlet valves, and open the bypass valve. Reverse the process to get softened water once again.
Be sure to close the bypass valve completely to avoid mixing hard water with softened water. (See Figure 9)
CAUTION!
Never connect two dissimilar metals (such as copper and steel) together. The use of dielectric unions or
schedule 80 PVC or PVC plastic to break the connection is highly recommended in order to reduce the
risk of galvanic reaction and subsequent corrosion.
Soft Hard
Water Water
Manual
Manual Inlet Valve
Outlet Valve
1/2”
Brine
Line Inlet/Outlet
NOTE! Interconnecting pipe and fittings, bypass valves and isolation valves are not supplied.
Outlet Inlet
Top View
GBE Controller
Brine Tank
Figure 11.
1.5” Drain
Adapter
CAUTION!
Securely fasten and support drain piping to
prevent damage to the valve and allow for
1/4” of movement during regeneration.
Siphon
Break
Min.
Diameter
1.5”
required
for models
larger than Drain
4 cu. ft.
WARNING!
Build an anti-siphon or drain line using an air vent. Do not make a direct connection to the drain.
Provide an air gap, that conforms to state and local sanitation codes and to permit the observation
of drain flow
Figure 12.
Lubricate
o-ring
Lubricate o-ring
CAUTION!
Clip was designed to stay attached to the valve.
Do NOT try to detach.
Lubricate o-ring
CAUTION!
Clip was designed to stay attached to the valve.
Do NOT try to detach.
WARNING!
PRV should be plumbed to a suitable floor drain independent of the drain line for emergency relief.
WARNING!
If the PRV has released or been opened because of high pressure, it should be replaced and the source
of the high pressure corrected.
Figure 14.
CAUTION!
Clip was designed to stay attached to the valve.
Do NOT try to detach.
4
Eductor Throat
Number Location
Lubricate o-rings.
Insert fully to
secure.
Figure 15.
CAUTION!
Clip was designed to stay attached to the valve.
Do NOT try to detach.
Twist to remove/attach
brine elbow screen.
Remove/Insert brine refill
control from/into brine elbow.
Brine Piping
The softeners can be used with a variety of brine systems. Please refer to Table 6 on page 41 for sizing parameters.
Position the salt storage tank in a convenient location on a smooth surface.
Brine Chamber
Cut 1/2” tubing (not supplied) sufficient
to reach control using brine fitting.
NOTE! Culligan recommends routing the
overflow to a floor drain to prevent
damage to the facility.
Brine Valve
1. Pull Brine
Valve Clip
If connecting multiple softeners to the same brine tank, use the tee provided in a Duplex Kit 01040950 or Triplex Kit 01040951.
NOTE! At least 30 dynamic psi dynamic pressure must be maintained for the pilot valve to hold the proper
piston position. If the unit falls below this amount, even during the regeneration cycle of another unit,
the system will not operate as expected.
Figure 17. Inlet/Outlet Tubing
Stem
Elbows
Insert with
1/4” plug for
air operation
Connect to
Insert a 1/4” plug Air Supply
for air operation
144”
8.75”
144”
4”
Culligan® CTM 2.0 Water Softeners 01035702 Electrical Controller Circuit Board Layout 24
Valve Side Mount (Optional, P/N 01029171)
Culligan® CTM 2.0 Water Softeners 01035702 Electrical Controller Circuit Board Layout 25
Wiring Procedures and Diagrams
Preparation
1. Loosen the screws securing the controller access cover (see Figure 21) on each controller provided.
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 six (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 openings are located on the sides of the Smart Controller enclosure (see Figure 22). 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 to the rubber sleeve and
reassemble. This will assure all wiring is secure and assist in making the tightening of the fitting easier. Leave the plugs, already
installed, to block any holes not used for wiring or other accessories.
Figure 21.
Figure 22.
Figure 23. 01021015
Cord Grip for 24V Power Cord
Power Cord,
Flow Meter
Cable, Motor
and Position
Sensor Cable
Culligan® CTM 2.0 Water Softeners 01035702 Electrical Controller Circuit Board Layout 26
Wiring the Smart Controller Power Cord and 24V Transformer
The Smart Controller is powered by a 24 VAC and 2.1 Amps (50 VA) transformer (P/N 01014897, 60 Hz). If there are
multiple controls in the system being installed, each controller will require its own transformer. It is recommended that
each transformer be plugged into a dedicated 120V circuit.
NOTE! The 2.5 V cord is only necessary when using an Aqua-Sensor.
CAUTION!
DO NOT PLUG THE TRANSFORMER INTO THE WALL UNTIL ALL WIRING IS COMPLETED.
CAUTION!
Connecting 24 V to the 2.5 V connection on the circuit board will damage the circuit board.
CAUTION!
To eliminate the possibility of polarity issues, carefully follow the wiring details shown in Figure 26.
Culligan® CTM 2.0 Water Softeners 01035702 Electrical Controller Circuit Board Layout 27
Smart Controller Circuit Board Layout—Front
Figure 27. Smart Controller circuit board layout, front view.
OLED Display
Keypad connector
AUX INPUT AUX OUT1 AUX OUT2 AUX OUT3 AUX OUT4 Power Cable
(from transformer)
Auxiliary Input Programmable External 24VAC Blocking
Outputs (Optional) Valve Output (Optional)
Culligan® CTM 2.0 Water Softeners 01035702 Electrical Controller Circuit Board Layout 28
Circuit Board - Motor and Position Sensor
Figure 29.
POSITION DC
MOTOR
J22
AQUA SENSOR
RS485 FLOW
METER
BRINE
TANK
2.5v 24v
AUX INPUT AUX OUT1 AUX OUT2 AUX OUT3 AUX OUT4
Culligan® CTM 2.0 Water Softeners 01035702 Electrical Controller Circuit Board Layout 29
IMPORTANT—Setting the Jumpers for GBE to GBE RS485 Communication
For GBE controls to communicate via RS485 properly, the first and last Figure 30.
units must have the jumpers set to pins 1 and 2 on terminal J22 (see
Figure 30 at right). All middle units should have the jumpers on pins 2 Jumper location for
and 3 (see Figure 30). first and last units
1 2 3 (end units).
Jumper location
Progressive Flow or Parallel Flow for middle units.
Jumper
Location
To RS 485 Comm
Port on GBE
Circuit Board, #1 To RS 485 Comm Port on
GBE Circuit Board, #2 Connect
NOTE! Communication cable is Included in the Add Jumper (from Triplex Kit)
Duplex Kit 01040950 (quantity: 1 cable) & for connecting to another cable.
Triplex Kit 01040951 (quantity: 2 cables).
Connect to
additional cable
Culligan® CTM 2.0 Water Softeners 01035702 Electrical Controller Circuit Board Layout 30
Connecting Multiple Circuit Boards to 24VAC Power Supplies
In progressive flow systems, each GBE circuit board requires electrical power. Because the GBE circuit boards are
electrically connected to each other via the communication cable, it is very important to use care in properly wiring
these systems to electrical power. Failure to do so can result in, at a minimum, damaging the GBE circuit boards.
Culligan STRONGLY RECOMMENDS that every GBE circuit board be provided with its own individual
power transformer as shown in Figure 34.
When using individual power supplies, the GBE boards can be connected to each other using communication cables
without paying attention to the polarity of the wiring used on the power supplies. DO NOT connect the Aux-Outputs
of multiple GBE boards to the same electrical load (for example, a “load” can be the coils of a relay or a solenoid
valve). If you need the Aux Outputs of multiple GBE boards to run the same load; it is required that you use isolation
relays as shown on page 32.
Figure 34. Correct connections for multiple GBE boards to individual 24VAC power supplies.
CORRECT
THREE INDIVIDUAL TRANSFORMERS
NO NEED TO MATCH POLARITY
P/N 01016327
COMMUNICATION CABLE
Culligan® CTM 2.0 Water Softeners 01035702 Electrical Controller Circuit Board Layout 31
Figure 35. Use of isolation relays to allow multiple GBE boards to control a shared solenoid valve.
CORRECT
FOUR INDIVIDUAL TRANSFORMERS
NO NEED TO MATCH POLARITY
SOLENOID
VALVE
Figure 36. Not recommended connections for multiple GBE boards to shared 24VAC.
NOT RECOMMENDED
POLARITY IS THE SAME
ON ALL UNITS
WARNING!
This configuration, while correct, should be avoided, since any single polarity change will cause
immediate failure of GBE boards and/or transformers.
Culligan® CTM 2.0 Water Softeners 01035702 Electrical Controller Circuit Board Layout 32
Accessories
Ported Plumbing Adapter
The ported plumbing adapter is installed onto the valve the same way as the standard plumbing adapter.
See page 13 for instructions.
Figure 37. .
CAUTION!
Do not over tighten fittings in the port
adapter. Over tightening can damage
the ports causing them to leak.
1.5” or 2” Threads
Figure 38.
Connect to the
bottom of the
GBE controller.
Connect to
the gauge kit.
Softener Model 60K 90K 120K 150K 210K 300K 450K 600K
Recommended “A” 37.5” 42.6” 54.4” 52.5” 52.5” 62.1” 55.0” 54.8”
NOTE! Measurement to the bottom of the probe allows for a 30% reserve capacity.
Figure 41. Aqua-Sensor® probe positioning.
Small
1” minimum from bottom
Aqua-Sensor®
of probe to gravel bed.
Plug
Gravel Underbedding
Auxiliary Input
Auxiliary Outputs
AUX 1 AUX 4
OUTPUT OUTPUT
AUX 2 AUX 3
OUTPUT OUTPUT
Aux 1, 2, and 3 are programmable to operate solenoids, relays and other control devices, based on electrical parameters
described above. Aux Output 4 is powered during all cycles except service, and unpowered during service.
For example, Figure 44 shows how the timing would work if an auxiliary output is set to NORMALLY OFF. The cycle
position is set to BACKWASH, the delay minutes setting is greater than zero, and ON minutes is greater than zero.
EXAMPLE
Culligan CTM 2.0 WaterGALLONS:
® 1500
Softeners 01035702 Accessories 36
ON SECONDS: 10
OFF MINUTES: 15 @ 1500 gallons, on seconds is activated by GALLONS
Auxiliary Output 5 Relay Board (P/N 01022238)
The GBE board offers support for the Auxiliary Output 5 Relay board (P/N 01022238).
To use the relay board, install it onto the back of the GBE board.
Refer to GBE Programming document for programming information. .
Figure 45. Example of customer wiring to the GBE Alarm Signal Output.
Relay Board
Plug in here
RELAY
In this example, the circuit is wired
to the Common (Com) Terminal and
Up to 250VAC Normally Closed (NC) Terminal, which
Supply 5A Inductive means that when the light is ON an
10A Resistive error has occurred, and when the light
Lamp or Buzzer is OFF the circuit is operating normally.
This mode of operation occurs when the relay board is plugged into the GBE board chlorinator socket. When Error Status
is selected on the display, this relay is energized holding the normally closed contact open, and when the GBE board has
power AND there are no errors present the relay is energized. (“Problem Found” is not showing on the Home screen). The
relay is in the de-energized state when the GBE is either powered OFF or when there is an error present on the GBE board.
On a multiple-tank softener system, such as a twin-alternating, or progressive flow network, the Alarm Signal Output
Relay board must be installed on each Smart Controller that the user wants monitored for errors.
Tee
Cable
Jumper
Cables
Figure 48.
5. Make sure all the coupling o-rings are fully inserted into the core.
6. Screw manifold back onto the valve body. Be careful not to pinch any of the o-rings
7. Screw the cover onto the manifold. (16 screws)
8. Reconnect the tubing (see page 23).
1. If you are cycling the valve before installation the best method is using an air compressor with minimum
50 dynamic psi able to connect to ¼” tubing. If only water pressure is available, you don’t want to have
the whole system pressurized, only the pilot and pistons should have pressure during the cycling.
2. Using a Phillips screwdriver, remove the four screws and the enclosure, then loosen the four screws on the Pilot
Drive Motor Bracket and set it aside.
3. Connect the ¼” tubing to the inlet fitting of the pilot valve and open the air supply with it regulated to min.
of 50 dynamic psi.
4. Advance the positions by hand turning the Pilot Drive Gear counterclockwise for at least three complete
revolutions.
5. Some popping noises are likely as you advance the indicator wheel as the pistons break loose and then
air exhausts from the drain port.
6. Disconnect the tubing, reassemble components, re-tighten the screws, and make preparations to fully
pressurize the system.
2. The pilot valve located on top of the CTM 2.0 valve body should be in home position (position 1) indicated by
the 1 in the window facing the front of the control. If it is not in home position, follow the instructions on manual
cycling in the GBE Programming document.
3. When the water has reached the fillport, replace the plug and allow the system to pressurize. After filling the
tank, cycle the pilot valve several times to start purging the air on both sides of the pistons. Once the air has all been
purged, only water, and not air will be discharged to the drain.
4. Check the system and piping for leaks. If leaks occur, close the inlet valve to depressurize the system
and make the needed repairs before going onto the next step.
5. With the system fully pressurized without leaks the GBE controller can be fully programmed following
the instructions provided in the GBE Programming document.
Key for 3/4” Brine Valve Chart and 1” Brine Valve Chart
Dry Storage
Wet Storage
Do Not Use This Size
Resin Volume
2.0 3.0 4.0 5.0 7.0
(ft³)
Refill Insert
Size (GPM)
2.0 [180] 2.0 [180] 2.0 [180] 2.0 [180] 2.0 [180]
[Molded
Identifier]
Refill (GPM),
Standard 0.8 0.8 1.25 1.25 1.48
[Fast Refill]
Resin Tank
12.0 14.0 16.0 18.0 21.0
Diameter (in.)
lb/
Refill Minutes Dos. Cap. lb/ft³ Dos. Cap. lb/ft³ Dos. Cap. lb/ft³ Dos. Cap. lb/ft³ Dos. Cap.
ft³
22 13.5 95
23 14.1 99
24 14.7 103
Installation Wrap Up
Table 1 on page 6, provides the expected flow rates to the drain during the various steps of the regeneration process.
Figure 49. Dry storage. Figure 50. Wet storage.
BRINE
LEVEL
BRINE
LEVEL
CAUTION!
Hazard from toxic fumes! Chlorine bleach and common iron control chemicals may generate toxic fumes
when mixed. Do not use this procedure if the softener salt contains iron control additives.
Check List
√ The media tank(s) has been properly loaded with gravel and media.
√ The drain line has been properly installed.
√ All option kits have been properly installed.
√ The system has been properly piped and tubed.
√ Each media tank has been backwashed manually.
√ The GBE controller(s) have been correctly and completely wired, including differential pressure switches if equipped.
√ All GBE controllers have been properly programmed and are active (power on).
√ All manual isolation valves are open and system by-pass valves are closed.
√ Clean up the unit and the installation site, removing any soldering
or pipe threading residues from the equipment with a damp towel.
√ Explain the operation of the system to the customer.
√ Advise the customer to check and replenish the salt supply regularly.
Table 9.
Although it may be possible to solve a specific problem simply by changing a component, analyzing the entire system can
reveal additional problems which would otherwise require extra service calls. Changing parts is not the same as service.
2. Manually cycle the pilot valve to backwash position #2 (Main Menu > DIAGNOSTICS > MANUAL
CYCLING). Refer to GBE Programming document for programming information.
3. Allow water to flow to the drain until this system is no longer under pressure.
4. Disconnect electrical connection to the controller.
5. Proceed with servicing the CTM 2.0 System.
We suggest the use of “a mild cleaning solvent”. We suggest the following brands or their equivalents:
Cleaning Solvent: Simple Green --- water soluble for removing corrosion and dirt.
Dow Corning #111, silicone grease, must be used in order to maintain the unit’s NSF certifications.
32 26
31
13 12 11
30
27
24
29
28
25
2. Separate the plumbing at the unions, if necessary to remove the plumbing adapter from the valve.
3. Disconnect the tubing from the pilot valve at the inlet and drain ports on the valve.
4. Disconnect the wiring and remove the GBE controller by removing the two mounting screws, if using a front
or side mount bracket.
5. Remove the tank adapter clamp by loosening the bolts on both sides and lift the valve body from the tank
using the pry points (see Figure 67 on page 57)
6. Remove 16 #3 screws from the top manifold, including the two under the enclosure, then remove the top
manifold by prying at the pry points. (see Figure 53)
Figure 53.
Remove manifold
couplers using the pry points.
Figure 55.
Remove non-hardwater
bypass plug (if applicable)
Bottom
Figure 57.
Figure 59.
#3 screws
SS Insert
Small Flow Valve Assembly (3)
#2 screws
Lubricate o-rings
CAUTION!
Do NOT lubricate T-Seals!
Load all pistons (8) in from the top and push to lower into the fully
seated position. Flip the valve body onto its top (flow valves up)
Figure 61.
CAUTION!
Do NOT lubricate T-Seals! Instead,
lightly lubricate the t-seal valve bore.
Replace
#3 screws
Replace
#2 screws Washer Replace T-Seal Upper Flow
Valve
1. Push all the valves down into the fully seated position. Use the screws provided in the replacement kit. Do
not reuse old screws. Start each screw then flip the core onto it’s side, hold back pressure on the top of the
valve. “Hand tighten” the screws.
2. Move all valves into the upper position.
Figure 66.
CAUTION!
Do not overtighten the screws. It will not prevent a
leak, but it could likely loosen the embedded insert.
1. Lubricate
T-Seal
Flow Port
CAUTION!
Do not rock the valve core onto the tank adapter, just place
it straight down. Rocking may cause damage to the o-rings.
4. Replace Clamp.
9. Re-pressurize unit (page 40). Check for leaks around the Top Manifold, Clamp and to the drain.
10. Reassemble the GBE Controller and wiring after checking the valve body for leaks. Pilot Valve Rebuild
(Kit P/N 01041070)
Figure 70.
4. Remove enclosure
5. Remove o-ring
Motor Bracket
Remove
#2 Screws
Figure 72.
NOTE! Make sure to that the position indicator dial is centered between the position sensor.
Figure 74.
Figure 75.
Enclosure #2 Screws
6. If no leaks,
replace
enclosure and
tighten with
3. Connect tubing #2 screws.
(page 23) through
the enclosure.
4. Re-pressurize unit
(page 40) 2. Reconnect
5. Cycle valve, while checking electrical
the pilot valve for leaks connections,
if removed,
making sure to
route through
the enclosure
1. Replace clamp
and tighten the
four #2 screws
CAUTION!
Ensure the o-ring is in place when replacing the enclosure.
lb/ft³ 4 5 6 7 8 9 10 11 12 13 14 15
Model min min min min min min min min min min min min
60K 21 23 25 26 28 30 31 33 34 36 38 39
90K 36 39 41 43 46 48 51 53 56 58 60 63
120K 25 27 28 30 31 33 35 36 38 39 41 42
150K 34 36 38 40 42 44 46 48 50 52 54 56
210K 28 29 31 33 35 37 39 40 42 44 46 48
300K 42 45 48 50 53 55 58 61 63 66 68 71
450K 36 39 42 45 48 51 55 58 61 64 67 70
600K 50 55 59 63 67 71 75 80 84 88 92 96
Check to see if the leak is at the drain Pilot spool o-rings damaged.
port on the valve manifold.
Check to see if the leak is at the pilot Pilot spool shaft o-rings damaged.
spool shaft and/or inner pilot spool body.
Leak around the Outside of the Check drain holes. See the Check Procedures and Causes for
Valve Core. (See Figure 76 on page 69) “Leak at the Pilot Valve”.
High Flow to Drain Check position dial on pilot. If not in Position #1, manually cycle the
During Service. pilot drive assembly to Position #1. If the
flow stops, check the pilot drive assembly.
Use a test kit and check the hardness Use a test kit and check the hardness of
of the water at the drain. the water at the drain. If soft then fast rinse
drain piston #5 is open. If the water tests
hard then backwash drain piston #4 is open.
Check the feed water pressure. Water pressure is less than
minimum pressure.
Hard Water Leakage Into the Inspect the bypass piston. If no flow from the tubing the pilot strainer
Service Lines. is probably plugged.
CAUTION!
• T-Seal may be dirty, worn or loose.
Make certain that
the water pressure • Seat may be eroded.
is relieved from
the system before • Upper piston o-ring may be torn.
disassembling the Build-up on the inside of the valve cavity
control valve. may be preventing the piston assembly
from seating.
Check Bypass Valve(s)
Restricted or No Service Flow. Either Service Inlet piston or Service Flow should be the same for both positions
Outlet piston are not opening fully. To but if not:
determine which one, turn the pilot to
Service Outlet piston #2 is not
position #2. Observe the flow to the
opening properly.
drain. Cycle the pilot to position #4 and
compare the flow of water in position If backwash (position #2) is higher,
#4 to the flow in position #2. Return the then Service Inlet piston #4 is not
pilot to position #1. responding properly.
Potentially clogged distributors Failed distributors.
or compacted media bed.
Contamination of resin bed.
Check water level in brine tank. Failure to Refill properly. Check “Check
Procedures and Cause for Failure to Refill.”
Verify the pilot is in the #3 (brine If the pilot is not in the proper position
draw) position. for the brine draw/slow rinse cycle, the
system will not draw brine. Check the
pilot drive assembly.
Verify there is a vacuum If there is a vacuum, the brine valve should
on the brine line. have 20 - 27 in. Hg. No vacuum indicates:
Inspect brine refill elbow assembly. Plugged brine refill elbow assembly
Check piston stuck or plugged
Plugged brine refill elbow filter.
Check correct function of brine valve Not working properly.
inside the brine tank.
Check feed water pressure is always Low feed water pressure to the pilot valve
above 30 dynamic psi. will prevent proper setting of the pistons.
Media to Drain. High flow of water to drain. Check/replace drain line flow
control washer(s).
Air in system. Brine valve did not air check, allowing air
into media tank.
Replace Brine Valve, if necessary
Air from source other than water softener.
Eliminate source.
Fails to Refill Properly. Feed water pressure must be above 30 Low pilot valve pressure will prevent the #7
dynamic psi. piston from opening properly.
T-Seal on Piston 7 needs replacement. Replace T-Seal.
Eductor Nozzle Plugged. Clean Eductor Nozzle.
Clean refill restrictor.
Figure 76.
NOTE! Position 6 places the valve in Standby for a Multi-tank system by closing piston #1.
Tank
Inlet
8
Feed Drain
1 4
3
2 6 5
Service
COLOR KEY
RED = Hard Water GREEN = Waste Water
Outlet
YELLOW = Brine Water GRAY = Piston
Tank
Inlet
8
Feed Drain
1 4
2 6
5
Service
COLOR KEY
RED = Hard Water GREEN = Waste Water
Brine Tank Tank BLUE = Soft Water BROWN = Drain Water
Tank
Inlet
8
Feed Drain
1 4
3
2 6 5
Service
COLOR KEY
RED = Hard Water GREEN = Waste Water
Outlet
YELLOW = Brine Water GRAY = Piston
Tank
Inlet
8
Feed Drain
1 4
3
2 6 5
Service
COLOR KEY
RED = Hard Water GREEN = Waste Water
Outlet
YELLOW = Brine Water GRAY = Piston
Tank
Inlet
8
Feed Drain
1 4
3
6
2 5
Service
COLOR KEY
RED = Hard Water GREEN = Waste Water
Outlet
YELLOW = Brine Water GRAY = Piston
¹The flanged tank adapter kit (P/N 01030828) required to mount the valve to these tanks is sold separately.
²Each Cullex (P/N 00156001) bag is 1 cubic foot.
Drain Adapter
Kit Component 60K 90K 120K 150K 210K 300K 450K 600K
01040940 01040941 01037836 01037838 01037840 01040942 01040943 01037844
35
35
34
8
1
2 3 35
9 7
10 4
10a
6
11
22
5
6
17
12
2
19
38
34
35
35
21
36
39
14
16
18
13
15
33
32
30
28 31
29
27
36 NOTE:
Items cannot be
purchased separately
2
5 2
3 6
3 5
1 6
4
1
4
1
18
Item Qty. Part No. Description
A — 01033059 Brine Valve (3/4”), Replacement
B — 01033062‡ Brine Valve (3/4”) Rebuild Kit
1 1 A 3/4” PVC Riser Pipe
2 1 A Body, Threaded
3 1 A, B O-Ring
4 1 A, B Seat Washer Bottom (Clear)
5 1 A, B Lower Retainer
6 1 A High Flow Air Check Ball
7 1 A 484 Cage, Long
16 8 1 A Brine Valve Cone
9 1 A, B Upper Seal Retainer
15 10 1 A, B Seat Washer Top (Orange)
14 11 1 A Cap, Threaded
12 1 A Basket Diffuser
13 1 A Bell Float with Locking Nipple
1 13 14 1 A 3/8” Compression Nut
15 1 A Float Collet
16 2 A Float Rod Guide
Coupling, Socket x FIPT Schedule
17 1 A
80 3/4”
18 1 A 3/4” NPT PVC Elbow
Male Tubing Adapter, 1/2 T x 1/2
— 1 00303041**
NPTE (included with brine valve)
12
PVC Bushing Sch 80, 3/4” x 1/2”
— 1 00229200**
Threaded (included with brine valve)
6
5
4
17 3
For a period of THREE YEARS The entire metered model conditioner, including internal parts.
The control valve internal parts. The brine valve and its component
parts. Culligan-designed accessories limited to the flow meter,
vacuum breaker, pressure relief valve, plumbing adapter, GBE
board, pilot valve and Aqua-Sensor Probe.
For a period of FIVE YEARS The control valve body, excluding internal parts.
The salt storage container internal components.
The fiberglass wound container(s), if so equipped*.
The salt storage container(s), if so equipped.
*The tank must be protected by a vacuum breaker device as described in the unit’s operating manual. Damage to the
tank caused by vacuum is not covered by this warranty. The unit must be used in operating conditions that conform
to Culligan’s recommended design guidelines. This warranty will not apply if the unit has been modified, repaired or
altered by someone not authorized by Culligan.
If a part described above is found defective within the specified period, you should notify your independently operated
Culligan dealer and arrange a time during normal business hours for the dealer to inspect the water conditioner on your
premises. Any part found defective within the terms of this warranty will be repaired or replaced by the dealer. You pay only
freight from our factory and local dealer charges.
We are not responsible for damage caused by accident, fire, flood, freezing, Act of God, misuse, misapplication, neglect,
oxidizing agents (such as chlorine, ozone, chloramines and other related components), alteration, installation or operation
contrary to our printed instructions, or by the use of accessories or components which do not meet Culligan specifications.
Refer to the specifications section in the Installation and Operating manual for application parameters.
Our product performance specifications are furnished with each water conditioning unit. TO THE EXTENT PERMITTED
BY LAW, CULLIGAN DISCLAIMS ALL IMPLIED WARRANTIES, INCLUDING WITHOUT LIMITATION WARRANTIES
OF MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE; TO THE EXTENT REQUIRED BY LAW,
ANY SUCH IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE ONE-YEAR PERIOD SPECIFIED ABOVE
FOR THE ENTIRE CONDITIONER. As a manufacturer, we do not know the characteristics of your water supply or
the purpose for which you are purchasing this product. The quality of water supplies may vary seasonally or over a
period of time, and your water usage rate may vary as well. Water characteristics can also differ considerably if this
product is moved to a new location. For these reasons, we assume no liability for the determination of the proper
equipment necessary to meet your requirements, and we do not authorize others to assume such obligations for
us. Further, we assume no liability and extend no warranties, express or implied, for the use of this product with a
nontaxable water source or a water source which does not meet the conditions for use described in the installation
and operation manual(s) that accompany the equipment. OUR OBLIGATIONS UNDER THIS WARRANTY ARE
LIMITED TO THE REPAIR OR REPLACEMENT OF THE FAILED PARTS OF THE WATER CONDITIONER, AND WE
ASSUME NO LIABILITY WHATSOEVER FOR DIRECT, INDIRECT, INCIDENTAL, CONSEQUENTIAL, SPECIAL,
GENERAL, OR OTHER DAMAGES.
Some states do not allow the exclusion of implied warranties or limitations on how long an implied warranty lasts, so the
above limitation may not apply to you. Similarly, some states do not allow the exclusion of incidental or consequential
damages, so the above limitation or exclusion may not apply to you. This warranty gives you specific legal rights, and you
may also have other rights which vary from state to state. Consult your telephone directory for your local independently
operated Culligan dealer, or write Culligan International Company for warranty and service information.
Backwash
During the backwash step, raw water flows rapidly upward (in reverse direction to the service flow) through the resin bed
to expand the bed and flush out accumulated dirt, sediment and other sources of turbidity.
Brine Draw
The brine solution consisting of water and salt is drawn from a brine storage tank and allowed to flow slowly down through
the resin bed. The brine solution removes the calcium and magnesium ions from the resin. This cycle can also be split into
three “sub-cycles” which allow for the cost saving feature of brine reclaim.
Slow Rinse
Brine draw is then followed by a raw water slow rinse. This rinse step will slowly remove most of the remaining brine,
exchanged calcium and magnesium ions from the resin. This cycle can also be split into three “sub-titles” which allow for
the cost saving feature of brine reclaim.
Fast Rinse
Slow rinse is followed by a raw water flush, a very rapid down flow of raw water which removes the last traces of brine,
and settles the resin bed.
Resin Bed Depth and Estimated Capacity per Inch at Various Salt Dosages (Downflow)
Table 20. Resin Bed Depth and Estimated Capacity per Inch at Various Salt Dosages (Downflow)*
Grains Capacity per Grains Capacity per Grains Reserve Grains Reserve
Resin Depth of
Model inch (15 lb/ft³ salt inch (6 lb/ft³ salt Capacity@15 lb/ft³ Capacity@ 6 lb/ft³
Qty Resin (in.)
dosage) dosage) salt dosage salt dosage
60K 2 22.5 2667 1778 16002 10668
90K 3 25.8 3488 2326 20928 13956
120K 4 34.4 3488 2326 20928 13956
150K 5 34.0 4412 2941 26472 17646
210K 7 35.0 6000 4000 36000 24000
* 300K, 450K and 600K models were not designed to be used with an Aqua-Sensor.
NOTE! Although the Aqua-Sensor device has been used successfully on water with hardness as low as 3 gpg,
there is an increased risk of missed signal (no regeneration) when the hardness is less than 6 gpg.
NOTE! For each tank diameter, there is a specific volume of resin in the space between the cell pairs. The
capacity of that resin is influenced by hardness and salt dosage. Any combination of flow rate and
hardness that causes the hardness front to pass through that volume of resin in less than 6 minutes
will result in the sensor failing to detect the need to regenerate. In general, the volume of resin between
the cell pairs on commercial units will permit a proper signal at or below the continuous flow rating
when raw water hardness is less than 50 gpg. At higher hardness levels, it may be necessary to reduce
the flow rate to assure adequate sensor signal duration.
NOTE! If precipitated or bound iron is present it must be removed before the softener.
NOTE! Manganese can deposit on the sensor electrodes, particularly on the upper pair, causing missed
signals (no regeneration). Periodic cleaning may be needed to maintain satisfactory performance.
NOTE! Adequate signal strength has been demonstrated at ratios as high as 14, but signal strength diminishes
with decreasing TDS to hardness index.
NOTE! Amount shown is based on the distance between the referencing cell pairs. Reserve capacity at salt
dosages less than 15 lb per cubic foot are shown for reference purposes only and may not provide
adequate representation of actual capacity per inch of bed depth for operational purposes.