Culligan 60K Operation manual

Top Mount (CTM)
Water Softeners
Models from 2020
DCO# 200293 10/21/20
CAT# 01029401 Rev F
© 2020 Culligan International Company

2 Culligan® Top Mount (CTM) Water Softeners 2 Cat. No. 01029401
Contents
Introduction........................................................................ 3
 .................................................................... 6
Installation ......................................................................... 8
Electrical Controller Circuit Board Layout........................ 24
Accessories ..................................................................... 36
Start-Up ........................................................................... 43
Preventative Maintenance............................................... 50
Service............................................................................. 51
Troubleshooting Guide .................................................... 67
Parts List.......................................................................... 84
Limited Warranty ............................................................. 96
Appendix A - Basic Principles ......................................... 97
Appendix B - Hi-Flo 3/3e to CTM Conversion................. 98
Appendix C - Aqua-Sensor Guidelines ........................... 99
Appendix D - Operation Log ......................................... 100
Index.............................................................................. 101
Installation,
Operation, and
Service Instructions
with Parts Lists
Culligan®Top
Mount (CTM)
Water Softeners
Models from 2020

Introduction 3
Cat. No. 01029401
Introduction
Read this Manual First
Before you operate the Culligan® Top Mount (CTM) Water Softeners, read this manual to become familiar with the
device and its capabilities.
The Culligan CTM Water Softeners are tested and certified by WQA against NSF/ANSI/CAN 61
and NSF/ANSI 372. Not certified for Structural Integrity (except for CSA models) or Contaminant
Reduction by WQA.
The Culligan CTM 60K, 90K and 120K Water Softeners are also tested and certified by WQA
against CSA B483.1. Not certified for Contaminant Reduction by WQA.
Models listed by WQA are:
CTM Downflow HWB Capacity Softener (60K, 90K, 120K, 150K, 210K, 300K, 450K, 600K)
CTM Downflow NHWB Capacity Softener (120K, 150K, 210K, 300K, 450K)
CTM Downflow Multi-Tank Capacity Softener (60K, 90K, 120K, 150K, 210K, 300K, 450K, 600K).
The Culligan CTM Water Softeners have been certified by IAPMO R&T against NSF/ANSI
Standard 372, CSA B483.1 and NSF/ANSI/CAN Standard 61 for Material Safety and
Structural Integrity Requirements. Not certified for Contaminant Reductions by IAPMO R&T.
The skid mounted systems have not been tested or certified by IAPMO R&T and WQA.
The Culligan® Top Mount (CTM) 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.

4 Culligan® Top Mount (CTM) Water Softeners 4 Cat. No. 01029401
Safety Instructions and Safety Definitions
Throughout this manual there are paragraphs set off by special headings.
Note
Note is used to emphasize installation, operation or maintenance information which is important,
but does not present any hazard. For example,
NOTE! The clamp and valve will be able to rotate on the tank until pressure is applied.
Caution
Caution is used when failure to follow directions could result in damage to equipment or property. For example,
CAUTION!
Disassembly while under water pressure can result in flooding.
Warning
Warning is used to indicate a hazard which could cause injury or death if ignored. For example,
WARNING!
Electrical shock hazard!
Unplug the unit before removing the timer mechanism or cover plates!
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.
Be sure to check and follow the applicable plumbing codes and ordinances when installing this equipment.
Local codes may prohibit the discharge of sanitizing or descaling solutions to drain.
Use protective clothing and proper face or eye protection equipment when handling chemicals or power tools.

Introduction 5
Cat. No. 01029401
Attention Service Technician:
This publication is written specifically for, and is intended to be used by, trained service and maintenance personnel
who are experienced in the installation, function and repair of Culligan equipment. Untrained individuals who use this
manual assume the risk of any resulting property damage and/or personal injury.
NOTE! Please send any suggestions for improving this manual to [email protected]
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.
CAUTION!
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.
NOTE! 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.
Culligan International Company

6 Culligan® Top Mount (CTM) Water Softeners 6 Cat. No. 01029401
9399 West Higgins Road, Suite 1100
Rosemont, Illinois 60018
1-847-430-2800
www.culligan.com
Specifications for CTM Water Softeners
Culligan commercial water softeners are designed to remove hardness minerals from water. In order to function properly,
some operational parameters must be followed. They include:
An operating water pressure between 50 dynamic psi and 125 psi (345–862 kPa). If water pressure is greater than 80
psi, Culligan recommends following the IAPMO Uniform Plumbing code section 806.2 by installing a Pressure Regulating
Valve before the system. Operating on high pressure for extended periods of time can increase the service frequency of
replacement parts. If water pressure can drop below the minimum water pressure, add a booster pump or operate the
pilot valve using compressed air to maintain a 50 dynamic psi (241 kPa) minimum operating pressure.
NOTE! If an air compressor is used, it must be “oil free” and set
at 10 psi greater than the maximum static water pressure.
1. Operating temperature between 40° and 120°F or 4.4°–49°C.
2. Clear (non-turbid) water supplies (Less than 5 NTU).
3. Voltage of 120V, 50/60 Hz.
Table 1. CTM Flow Specifications.
Softener Model 60K 90K 120K 150K 210K 300K 450K 600K
Service
Continuous Minimum
(gpm) 1.6 2.1 2.8 5 5 6 10 14
Continuous Maximum
(gpm)¹ 20 30 40 45 55 65 76 82
Continuous @ 15 psi
max. pressure loss 51 57 55 59 65 70 76 82
Peak @ 25 psi max.
pressure loss 69 75 73 76 85 95 104 109
Suggested Progressive Flow Trip
Point (gpm)² 20 30 40 45 55 65 76 82
Drain
Backwash/ Fast Rinse
(gpm) 3.5 5 6 8 10 12 20 30
Brine Draw (gpm) 0.53 0.53 1.08 1.08 1.13 1.65 2.07 2.07
Slow Rinse (gpm) 0.93 0.93 1.60 1.60 2.00 2.66 5.34 5.34
Refill (gpm), Standard
[Fast Refill]³ 0.8 0.8 1.25 1.25 1.48
[1.62]
1.78
[2.0]
2.0
[2.75]
2.0
[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 the revised GBE
Programming for Commercial Softeners and Filters (except for HFxN) Manual (P/N 01027295) for more information about
the Progressive Flow mode of operation.
Specifications

Specifications 7
Cat. No. 01029401
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 46).
CTM Dimensions
Table 2. CTM Dimensions (inches)
Model 60K 90K 120K 150K 210K 300K 450K 600K
Overall Depth 19.6 24 24 24 24 24 30 39
Overall Width 43 50 50 52 55 58 69 83
Overall Height (A) 65.5 73.5 84.7 85.4 85.5 94 95.7 102
Plumbing Height (B) 54.1 62.1 73.3 74 74.1 82.6 84.3 90.6
Tank Height (C) 47 55 66.2 67 67 75.5 77.2 83.6
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).
Figure 1. Overview
NOTE! Dimensions for all models
Brine
B
Drain
Outlet
Inlet
Controller can be wall mounted
Drain
4.75”
C
A
11”
19.6”
23.8”
13.3”

8 Culligan® Top Mount (CTM) Water Softeners 8 Cat. No. 01029401
Installation
Materials
With the exception of media containers, open the remaining containers, remove all the components, and inspect
them before starting installation.
The following are necessary components for installing a CTM Softener.
Figure 2. Materials
Eductor Nozzle
Eductor Throat
Flow
Control
Body,
with inserts
Inlet Strainer
Brine Elbow
Assembly
Drain Adapter
Lubricant (Dow Corning 111/Molykote 111, Not Provided)
Brine Tank (Sold Separately)
1/2” Brine Tubing (Not Provided)
Distributor
(Boxed Separately)
Media Tank
(Boxed
Separately)
Flow Meter
(Comes with Valve)
Plumbing Adapter
(Sold Separately)
GBE Controller
w/ bracket mounted
(Boxed separately)
Vacuum
Breaker
Pressure
Relief
Media
(Separate
Packaging,
See Table 3 on
page 10)

Installation 9
Cat. No. 01029401
Locate Softener
1. Select a space that is level and allows a sufficient amount of room above and behind the softener tank(s) for
service access and plumbing supply and drain lines.
2. Floor surface—Choose an area with a smooth, solid and level floor capable of supporting the operating
weight of the softening system
3. Drain facilities—A nearby drain must be capable of handling the water softener discharge flow rates during
the backwash cycle of the regeneration process in addition to the maximum flow rates of other equipment
feeding into the same drain. Refer to page 6for information concerning the backwash flow rate.
Install Distribution System
CAUTION!
Do not attempt to use any distribution part that is damaged. Doing so may create operational problems
and/or create a substantial risk of consequential damage not covered by the product warranty.
Figure 3. Install Distribution System
Rest flat on the bottom
Distributor
Mark flush with tank opening
Media Tank
Remove distributor and cut square on mark
Deburr distributor pipe
Media
Tank

10 Culligan® Top Mount (CTM) Water Softeners 10 Cat. No. 01029401
Loading The Media
Table 3. Loading Quantities.
Model 60K 90K 120K 150K 210K 300K 450K 600K
Cullex (Ft³) 2 3 4 5 7 10 15 20
Cullsan (lbs) 30 40 50 70 100 130 300 400
Freeboard (inches) 19 22 22 23 22 22 19 22
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
for any foreign materials
NOTE! Minimize the amount of water added
until final positioning of the tank with
the control valve mounted
Freeboard
Cullex
Cullsan

Installation 11
Cat. No. 01029401
Attach Tank Adapter (30” and 36” Tanks Only)
Aqua-Sensor Ported Tanks
Fasten the 12 bolts in the sequence indicated below.
Once all of the bolts have been tightened, complete a second pass to ensure all of the bolts are secure.
Figure 5.
Non-Ported Tanks
Figure 6.
NOTE! Replace o-ring included with the valve with the
thicker o-ring provided in the tank adapter kit.
Bolt
Washer
Do not lubricate
o-ring with anything,
but water.
Place o-ring
into the
underside of
the flange.
Do not
lubricate o-ring.
Washer
Lock Nut
Nut
Top of Tank
1
5
9
3
7
11
2
6
10
4
8
12
NOTE! Use the o-ring included with the valve.
Twist the tank adapter onto the tank,
counterclockwise to the thread start.
Twist clockwise, hand-tight, until the
large o-ring provided with the adapter
is fully compressed in the tank.
Position the o-ring above the threads.
Do not lubricate o-ring.

12 Culligan® Top Mount (CTM) Water Softeners 12 Cat. No. 01029401
Mount the Valve
Figure 7.
1. Position large o-ring above
threads. Do not lubricate o-ring.
2. Lubricate small o-ring
3. Attach upper disperser by snapping into the
slots in the tank adapter. Making sure, that
it is secured.
4. Twist the valve onto the tank,
counterclockwise to the thread start.
Twist clockwise, handtight, until the large
o-ring is fully compressed in the tank.
CAUTION!
Do not overtighten. NOTE! Tank may need to be rotated
for preferred positioning.
NOTE! For 24” Aqua-Sensor ported tanks,
replace o-ring included with the
valve with the thicker o-ring
provided with the tank.

Installation 13
Cat. No. 01029401
Plumbing Adapter
Figure 8.
Insert pins into the valve
body and adapter
Lubricate
o-rings
Flow
Meter
Lubricate
o-rings
Coupling
Insert Plumbing
Adapter
1.5” or 2”
Threads
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.

14 Culligan® Top Mount (CTM) Water Softeners 14 Cat. No. 01029401
Install Piping
1. Depending on the type of softener system (such as single, duplex, or triplex) and the installation
parameters, required pipe lengths and piping accessories will vary. See “Specifications” on page 6to aid
the installation. If the layout drawings are not sufficient for your application, consult the Culligan dealer for
specific installation guidelines.
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.
CAUTION!
The media tank must never be subjected to an internal vacuum or it might be damaged.
Drain line suction can be prevented by installing siphon break. Refer to Figure 11 on page 17.
Use of Bypass Valve
Depending on where the particular installation was made, the outside sill cocks may or may not be served by
conditioned water. Ideally, all lines not requiring softened water should be taken off upstream of the softener.
This is not always possible, however, due to the difficulty or expense of rearranging the piping.
Bypass the softener if:
1. The outside lines do not bypass the water softener and the water is to be used for lawn sprinkling
or other outside uses.
2. Water is not used for several days.
3. You wish to inspect or work on the valve or brine system.
4. A water leak from the valve is evident.
Three-Valve Bypass
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!
If the media tank is to remain attached to the control valve, close only the inlet valve, then open
the bypass valve. This will prevent pressure from increasing in the media tank due to warming.

Installation 15
Cat. No. 01029401
Suggested Piping Installation
CAUTION!
Make sure that the plumbing connections to the inlet and outlet are all securely fastened using items,
such as pipe hangers, clamp, etc, to prevent damage to the valve. The plumbing connections should
also allow for 1/4” of movement.
Figure 9. Three-Valve Bypass CTM Single Tank Piping
NOTE! Interconnecting pipe and fittings, bypass valves and isolation valves are not supplied.
Bypass Valve (Normally Closed)
Soft
Water
Hard
Water
Manual
Outlet Valve
Manual
Inlet Valve
Inlet/Outlet
NOTE! Connecting piping must
allow the valve to be
removed without interference.
1/2”
Brine
Line

16 Culligan® Top Mount (CTM) Water Softeners 16 Cat. No. 01029401
Figure 10. CTM Duplex Piping
Outlet Inlet
Soft Water Outlet
Manual Outlet Valve
Hard Water Inlet
Manual Inlet Valve
CTM Controller
Top View
Bypass Valve (Normally Closed)
Brine Tank

Installation 17
Cat. No. 01029401
Drain Line
Proper discharge height and distance of the drain line will be dependent on the pressure supplied to the valve.
Discharge to a nearby floor drain will cause no backpressure, if the drain line needs to run overhead, the maximum
height is 10’ at the minimum supply pressure without decreasing vacuum on the brine line.
Make sure unit is properly located to the drain, refer to “Locate Softener” on page 9.
Figure 11.
WARNING!
Build an anti-siphon or drain line using an air vent.
WARNING!
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
1.5” Drain
Adapter
Min. Standpipe Height
25% of Discharge Height
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
4 cu. ft.
Drain
NOTE! Hard piped drains should include
a union for ease of service.
Air Gap

18 Culligan® Top Mount (CTM) Water Softeners 18 Cat. No. 01029401
Drain Line Flow Control (DLFC) and 1.5” Drain Adapter
Table 4. Drain Line Flow Control
Model 60K 90K 120K 150K 210K 300K 450K 600K
Body/Flow Rate 3.5 gpm 5 gpm* 6 gpm* 8 gpm* 10 gpm* 12 gpm* 20 gpm* 30 gpm*
Inserts
0.4 gpm Black,
0.4 gpm Black,
2.5 gpm Black
Plug,
Plug,
Blue
Plug,
Plug,
Red
Plug,
Plug,
Green
Plug,
Blue,
Blue
Plug,
Red,
Red
Blue,
Blue,
Orange
Orange,
Orange,
Orange
* Please make sure to use the specific Sizing Kit for the correct tank size so all internal components are correct.
Figure 12.
Push in hard on drain adapter until
this corner is flush with the valve.
Insert drain line
flow control in
this orientation.
Lubricate o-ring
Lubricate o-ring
Push down on clip, while
holding the adapter in place.
CAUTION!
Clip was designed to stay attached to the valve.
Do NOT try to detach.

Installation 19
Cat. No. 01029401
Pressure Relief Valve (PRV)
Figure 13.
NOTE! The PRV is set to release at 137 psi.
WARNING!
PRV should be plumbed to a suitable floor drain
independent of the drain line for emergency relief.
CAUTION!
Clip was designed to stay attached
to the valve. Do NOT try to detach.
Lubricate o-ring
Insert fully
into valve
Push in the clip, while
holding the PRV in place.
1” thread

20 Culligan® Top Mount (CTM) Water Softeners 20 Cat. No. 01029401
Eductor Nozzle and Throat Replacement
Table 5. Eductors
Model 60K 90K 120K 150K 210K 300K 450K 600K
Throat Blue #3 Blue #3 Blue #4* Blue #4* Blue #4* Blue #5 Blue #8 Blue #8
Nozzle Black Black Violet* Violet* Red White Blue Beige
*Shipped assembled inside the control standard from factory
Figure 14.
4
CAUTION!
Clip was designed to stay attached to the valve.
Do NOT try to detach.
Pull to release plug and push to secure.
Remove eductor throat and nozzle.
Replace with throat from the Sizing Kit.
Lubricate o-rings.
Insert fully to secure.
Eductor Throat Number Location
Twist off to
access nozzle.
NOTE! Brine draw is optimized when the opening
in the eductor throat is facing down.
Remove with pliers.
See Table 5
for correct
eductor nozzle.