Culligan Gold Series, Gold 9"", Gold 10"", Gold 12"", Gold 14 Installation & Operation Instructions

Cat. No. 01018853

Rev. C 08/20/07

DCO # 10083

Installation,

Operation &

Service Instructions

with Parts List

Culligan Gold Series Water Softener

Models from 2006

™

Attention Culligan Customer:

The installation, service and maintenance of this equipment should be rendered by a qualiﬁed and trained service technician. 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.

Warning! 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.

This system is not intended to be used for treating water that is microbiologically unsafe or of unknown quality without adequate disinfection before or after the system.

Culligan International Company

9399 W. Higgins Road, Suite 1100

Rosemont, Illinois 60018

847.430.2800

www.culligan.com

ii Culligan Gold Series® Water Softener

Service Instructions

Culligan Gold Series Water Softener

Installation,

Operation &

with Parts List

™

Models from 2006

Table of Contents Page

Important Safety Information ..........................................i

Introduction ....................................................................2

Performance Speciﬁcations ...........................................3

Preparation ....................................................................4

Basic Principles

Flow Diagrams ...............................................................8

Controller Features ......................................................13

Operation .....................................................................14

Installation ...................................................................16

Programming ...............................................................23

Statistical Data .............................................................35

Manual Cycling ............................................................40

.............................................................6

Table of Contents Page

Final Start-up ...............................................................41

Care and Maintenance

Recommeded Preventative Maintenance ....................44

Error Codes .................................................................46

Diagnostics Troubleshooting

Service .........................................................................58

Wiring Schematics .......................................................61

Appendix A - Flow Rates & Capacities ........................62

Appendix B - Aqua-Sensor® Application Guidelines ....65

Service Parts ...............................................................66

..................................................................48

................................................43

...........................................................50

Table of Contents 1

Introduction

Read this Manual First

Before you operate the Culligan Gold Series™ Water Softening System, read this manual to become familiar with the device and its capabilities.

Watch for Special Paragraphs

Please read the special paragraphs in this manual. Examples are shown below.

The Culligan Gold Series Water Softeners are tested and certiﬁed by WQA against NSF/ANSI Standard 44 for the effective reduction of hardness (calcium and magnesium) and barium/radium as tested and substantiated by test data.

The Culligan Gold Series Water Softeners are tested and certiﬁed by WQA against NSF/ANSI Standard 61 for material requirements.

For installations in Massachusetts, the Commonwealth of Massachusetts Plumbing Code 248 CMR shall be adhered to. Consult your licensed plumber for installation of the system. This system and its installation must comply with state and local regulations. The use of saddle valves is not permitted.

Safe Practices

Throughout this manual there are paragraphs set off by special headings.

Note: Check and comply with your state and local codes. You must follow these guidelines.

Note: Note is used to emphasize installation, operation or maintenance information which is important, but does not present any

hazard. Example:

Note: 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 water pressure can result in ﬂooding.

Warning! Warning is used to indicate a hazard which could cause injury or death if ignored. Example:

Warning! Electrical shock hazard! Unplug the unit before removing the cover or accessing any internal control parts.

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.

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.

Note: Do not remove or destroy the serial number. It must be referenced on request for warranty repair or replacement.

Products manufactured and marked 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, Flo-Pak and Soft-Minder are trademarks of Culligan International Company or its afﬁliates.

2 Culligan Gold Series® Water Softener

Performance Speciﬁcations

Control Valve 9” Model

1” Reinforced

Thermoplastic

10” Model

1” Reinforced

Thermoplastic

12” Model

1” Reinforced

Thermoplastic

14” Model

1” Reinforced

Thermoplastic

Overall Conditioner Ht 54 in 60 in 58 in 71 in

Media Tank Design Quadra-Hull

Media Tank

9 x 48 in 10 x 54 in 12 x 52 in 14 x 65 in

™

Quadra-Hull Quadra-Hull Quadra-Hull

Dimensions (Dia x Ht)

Salt Storage Tank

16 x 43 in or 18 x 43 in 18 x 43 in 18 x 43 in 24 x 42 in

Dimensions (Dia x Ht)

Exchange Media, Type

Cullex® Media, 1.0 ft

Cullex Media, 1.5 ft

Cullex Media, 2.0 ft

Cullex Media, 3.0 ft

and Quantity

Underbedding, Type and Quantity

Exchange Capacity @ Salt Dosage Per Recharge

Efﬁciency rated

dosage

Freeboard to Media

Freeboard to Underbedding

Cullsan®

Underbedding, 12 lb

19,086 gr @ 4.0 lb 26,301 gr @ 8.0 lb

30,787 gr @ 12.0 lb

4,770 gr/lb

@ 4 lb salt dosage

Cullsan Underbedding,

15 lb

28,629 gr @ 6.0 lb

39,451 gr @ 12.0 lb

46,180 gr @ 18.0 lb

4,770 gr/lb

@ 6 lb salt dosage

Cullsan Underbedding,

20 lb

35,614 gr @ 8.0 lb 51,659 gr @ 16.0 lb 60,523 gr @ 24.0 lb

4,450 gr/lb

@ 8 lb salt dosage

14.5 in 14.5 in 16 in 25 in

44.5 in 47.5 in 46 in 59 in

Cullsan Underbedding,

25 lb

53,540 gr @ 12.0 lb 77,660 gr @ 24.0 lb 90,986 gr @ 36.0 lb

4,460 gr/lb

@ 12 lb salt dosage

Salt Storage Capacity 250 lb or 375 lb 375 lb 375 lb 600 lb

Rated Service Flow @

9.0 gpm @ 14 psi 9.4 gpm @ 15 psi 10.0 gpm @ 15 psi 10.6 gpm @ 15 psi

Pressure Drop

Total Hardness,

75 gpg 99 gpg 99 gpg 99 gpg

Maximum

Total Iron, Maximum 5 ppm 5 ppm 5 ppm 5 ppm

Hardness to Iron Ratio,

8 gpg to 1 ppm 8 gpg to 1 ppm 8 gpg to 1 ppm 8 gpg to 1 ppm

Minimum

Operating Pressure 20-125 psi 20-125 psi 20-125 psi 20-125 psi

Operating Pressure

20-90 psi 20-90 psi 20-90 psi 20-90 psi

(Canada)

Operating Temperature 33-120°F 33-120°F 33-120°F 33-120°F

Electrical

24V/60 Hz 24V/60 Hz 24V/60 Hz 24V/60 Hz

Requirements

Electrical Power

3 Watts/35 Watts 3 Watts/35 Watts 3 Watts/35 Watts 3 Watts/35 Watts

Consumption, Min/Max

Drain Flow, Maximum

Recharge Time, Average

Recharge

1.6 gpm 1.6 gpm 2.6 gpm 6.6 gpm

68 min 57 min 52 min 55 min

Water

Consumption, Average

35 gal 46 gal 51 gal 176 gal

1 The efﬁciency rated dosage is only valid at the stated salt dosage and is efﬁciency rated according to NSF/ANSI 44. 2 Measured from top of media to top surface of tank threads. (backwashed and drained). 3 Measured from top of underbedding to top surface of tank threads. 4 Backwash at 120 psi (830 kPa). 5 10 minute backwash, 4 lb 9” model, 6 lb. 10” model, 7 lb. 12” model or 12 lb. 14” model salt dosage.

Performance Speciﬁcations 3

Preparation

Component Description

The water conditioner is shipped from the factory in a minimum of four cartons. Remove all components from their cartons and inspect them before starting installation.

Control Valve Assembly - Includes the regeneration control valve and the Accusoft contain additional installation hardware, and the conditioner Owner’s Guide.

Media Tank - Includes Quadra-Hull™ media tank complete with Cullex® ion exchange resin, underbedding and outlet manifold (12” and 14” tanks are shipped without media).

Salt Storage Tank Assembly - Includes salt storage container with support plate and Dubl-Safe™ brine reﬁll valve and chamber.

Bypass Valve - Includes the molded bypass valve, the interconnecting couplings, and the assembly pins.

Tools and Materials

The following tools and supplies will be needed, depending on installation method. Observe all applicable codes.

Note: Check and comply with your state and local codes. You must follow these guidelines.

Plus Controller. Small parts packages will

All Installations

• Safety glasses

• Phillips screwdrivers, small and medium tip.

• Gauge assembly (PN 00-3044-50 or equivalent)

• Silicone lubricant (PN 00-4715-07 or equivalent) - DO NOT USE PETROLEUM-BASED LUBRICANTS

• A bucket, preferably light-colored

• Towels

Special Tools

• Torch, solder and ﬂux for sweat copper connections

• Use only lead-free solder and ﬂux for all sweat-solder connections, as required by state and local codes.

• Threading tools, pipe wrenches and thread sealer for threaded connections.

• Saw, solvent and cement for plastic pipe connections.

Materials

• Brine line, 3/8” (PN 01-0098-19 or equivalent) or 1/2” (P/N 00-9018-00 or equivalent)

• Drain line, 1/2” (PN 00-3030-82, gray, semi-ﬂexible; or PN 00-3319-46, black, semi-rigid; or equivalent)

• Thread sealing tape

• Pressure reducing valve (if pressure exceeds 125 psi [860 kPa], PN 00-4909-00 or equivalent)

• Pipe and ﬁttings suited to the type of installation

• Water softener salt (rock, solar or pellet salt formulated speciﬁcally for water softeners)

Application

Water quality - Verify that raw water hardness and iron are within limits. Note the hardness for setting the salt dosage and

recharge frequency.

Iron is a common water problem. The chemical/physical nature of iron found in natural water supplies is exhibited in four general types:

1. Dissolved Iron - Also called ferrous or “clear water” iron. Up to 5 ppm of this type of iron can be removed from the water by the same ion exchange principle that removes the hardness elements, calcium and magnesium. Dissolved iron is soluble in water and is detected by taking a sample of the water to be treated in a clear glass. The water in the glass is initially clear, but on standing exposed to the air, it may gradually turn cloudy or colored as it oxidizes.

4 Culligan Gold Series® Water Softener

2. Particulate Iron - Also called ferric or colloidal iron. This type of iron is an undissolved particle of iron. A softener will remove larger particles, but they may not be washed out in regeneration effectively and will eventually foul the ion exchange resin. A ﬁltering treatment will be required to remove this type of iron.

3. Organic Bound Iron - This type of iron is strongly attached to an organic compound in the water. The ion exchange process alone cannot break this attachment and the softener will not remove this type of iron.

4. Bacterial Iron - This type of iron is protected inside a bacteria cell. Like the organic bound iron, it is not removed by a water softener.

When using a softener to remove both hardness and up to 5 ppm of dissolved iron it is important that it regenerates more frequently than ordinarily would be calculated for hardness removal alone. Although many factors and formulas have been used to determine this frequency, it is recommended that the softener be regenerated when it has reached 50 - 75% of the calculated hardness alone capacity. This will minimize the potential for bed fouling (iron removal claims have not been veriﬁed by the Water Quality Association or Underwriters Laboratories).

If you are operating a water softener on clear water iron, regular resin bed cleaning is needed to keep the bed from coating with iron. Even when operating a softener on water with less than the maximum of dissolved iron, regular cleanings should be performed. Clean every six months or more often if iron appears in your conditioned water supply. Use resin bed cleaning compounds carefully following the directions on the container. Hardness sample kits are available through your local Culligan dealer.

Caution! Do not use where the water is microbiologically unsafe or with water of unknown quality without adequate disinfection before or after the unit.

Pressure - If pressure exceeds 125 psi (860 kPa), install a pressure reducing valve (see materials checklist). On private water systems, make sure the minimum pressure (the pressure at which the pump starts) is greater than 20 psi (140 kPa). Adjust the pressure switch if necessary.

Caution! The use of a pressure reducing valve may limit the ﬂow of water in the household.

Temperature - Do not install the unit where it might freeze, or next to a water heater or furnace or in direct sunlight. Outdoor

installation is not recommended and voids the warranty. Use the Culligan Outdoor Gold Series softener for outdoor installations. The Culligan Outdoor Gold Series softener has been certiﬁed by Underwriter’s Laboratories for outdoor installation. If installing in an outside location, you must take the steps necessary to assure the softener, installation plumbing, wiring, etc. are as well protected from the elements (sunlight, rain, wind, heat, cold), contamination, vandalism, etc. as when installed indoors.

Location

Space requirements - Allow 6-12 inches (15-30 cm) behind the unit for plumbing and drain lines and 4 feet (1.3 meters) above

for service access and ﬁlling the salt container.

Floor surface - Choose an area with solid, level ﬂoor free of bumps or irregularities. Bumps, cracks, stones and other irregularities can cause the salt storage tank bottom to crack when ﬁlled with salt and water.

Drain facilities - Choose a nearby drain that can handle the rated drain ﬂow (ﬂoor drain, sink or stand pipe). Refer to the Drain Line Chart, Table 3 (page 21), for maximum drain line length.

Note: Most codes require an anti-siphon device or airgap. Observe all local plumbing codes and drain restrictions. The system and installation must comply with all state and local laws and regulations.

Electrical facilities - A 10-foot cord and wall mount plug-in transformer are provided. The customer should provide a receptacle, preferably one not controlled by a switch that can be turned off accidentally. Observe local electrical codes.

Note: P.N. 01012956 and P.N. 01018133 plug-in transformer are rated for indoor installations only. P.N. 01015972 plug-in transformer is rated for indoor/outdoor installations. (Non-Aqua-Sensor®)

Note: The softener works on 24 volt - 60 Hz power only. Be sure to use the included transformer. Be sure the electrical outlet and transformer are in an inside location to protect from moisture. Properly ground to conform with all governing codes and ordinances.

Preparation 5

Basic Principles

Brine Tank Cover

Brine Tank

Salt Plate

Brine Valve

Brine Chamber

Terms

Brine - A solution of water and salt used to regenerate the resin.

Distributor - A pipe with slits that allows the water to enter and leave inside the media tank.

Media - The underbedding and resin the media tank holds.

Regenerate - A process where the resin once exhausted of its softening capabilities is revitalized to soften again.

Resin - The actual material that softens hard water, shaped like little beads.

Underbedding - A gravel mixture that keeps the resin from entering the distributors.

Brine Tank - Figure 1

Refer to section “Filling the Salt Storage Container”, page 21 for proper Brine Tank usage.

Media Tank - Figure 2

The letters underneath the component’s description refer to the values listed on Appendix A, Table 2

- Media Volumes and Freeboard.

6 Culligan Gold Series® Water Softener

What is Hard Water?

Water is said to be hard when it carries too high a concentration of calcium and magnesium. Acceptable water hardness levels will vary depending on the application.

How Does it Work?

The components of dissolved minerals are called ions. They carry either a positive or negative charge. Hardness ions of minerals dissolved in water carry a positive charge. These positively charged ions (cations) are attracted to a synthetic softening material called ion exchange resin.

The heart of the softening system, therefore, is a deep bed of resin which draws calcium and magnesium ions, as well as ferrous iron, from the water as it passes through the resin bed.

Can the Resin Draw Out Hardness Ions Indeﬁnitely?

No. During normal operation, the resin becomes saturated with positive ions and functions less efﬁciently. When hardness leakage occurs, the resin should be regenerated to restore its efﬁciency.

How Do You Regenerate Resin?

You regenerate a resin bed by removing the mineral ions through a process called “ion exchange”. This regeneration process occurs in four steps and takes approximately 50 to 70 minutes. Each of the following steps are graphically depicted on pages 8 - 12.

1. 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.

2. 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.

3. 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.

4. 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.

How Often Must You Regenerate?

Frequency must be determined for each installation based on the amount of water usage, its degree of hardness and the amount of resin through which it ﬂows. In some cases it is necessary to utilize a resin cleaner when the raw water contains iron. Contact your local Culligan dealer for more information.

How Do You Control the Regeneration Process?

The regeneration process for the water softener is controlled automatically either on a predetermined time, volume, or external signal basis through the use of the Culligan Accusoft Plus controller with optional Aqua-Sensor® or ﬂow sensor. The regeneration process can also be initiated manually by the operator as required.

Basic Principles 7

Flow Diagrams

Service

Refer to Figure 3

Raw water is allowed in the inlet to the top of the tank. The water is run through the resin up the manifold to the outlet. The water to the outlet should be soft if the system is operating properly.

Figure 3

8 Culligan Gold Series® Water Softener

Backwash

Refer to Figure 4

Raw water is directed down the center of the manifold, up through the resin, out the top of the tank to drain. The water to drain should be hard.

Figure 4

Flow Diagrams 9

Regenerant Draw

Refer to Figure 5

Raw water is directed from the inlet through the nozzle and into the throat. A vacuum is created and concentrated brine is educted (drawn). The raw water and concentrated brine combine, enter the mineral tank, and pass through the resin, up the manifold and to the drain. Once all of the brine has been educted and the brine valve seats, the unit goes into slow rinse. Hard water is allowed to service during regeneration.

Figure 5

10 Culligan Gold Series® Water Softener

Slow Rinse

Refer to Figure 6

Raw water is directed from the inlet through the nozzle and into the throat. A vacuum is created but the brine valve has seated, so no brine is educted. The raw water enters the mineral tank, passes through the resin, up the manifold and to the drain. Hard water is allowed to service during regeneration.

Figure 6

Flow Diagrams 11

Fast Rinse/Reﬁll

Refer to Figure 7

Raw water is directed from the inlet, through the eductor and inlet to the top of tank, down the resin, up the manifold, out to drain and brine line until the correct amount of water is in the brine tank. Hard water is allowed to service during regeneration.

Figure 7

12 Culligan Gold Series® Water Softener

FAST

RINSE

& REFILL

Controller Features

The Culligan Gold Series™ control’s primary function is to initiate and control the regeneration process via methods that are most convenient and cost effective for the customer while offering many operation features and beneﬁts.

Features

• Power Source

Electrical power required for the control is 24-VAC 50/60 Hz. A plug-in

transformer (120v/24v) is provided

• Battery Backup

Battery backup is available as an optional ﬁeld add-on. The battery backup

will maintain the time of day for a minimum of 4 weeks using a 3.6V 1/2AAlithium type battery as supplied by Culligan (PN 01013839).

• EEPROM

Saves programmed and statistical functions.

• Lock/Unlock

Allows the control to be easily locked out from inadvertent program changes or

abuse. This feature can be disabled if desired.

• Time of Day

Displays current time in either 12 hour (AM/PM) or 24 hour format.

• Regeneration Interval

Provides an ability to initiate a time clock back-up operated system on a

number of days (range from 1 to 99 days).

• Program Beeper

Emits an audible beep when key pads are depressed to help identify valid

(short beep) or invalid (3 short beeps) key pad touches. Can be enabled or disabled as desired.

Figure 8

Controller Features 13

Operation

Modes of Operation

Water Meter Mode

In water meter mode, the controller keeps track of the quantity of water that has ﬂowed through the resin bed. Based on the inﬂuent water hardness and the hardness capacity of the resin bed, a service life expectancy in the quantity of softened water is calculated and programmed into the control. When the set point is reached, regeneration is triggered. In delay regeneration mode, if the predict mode is turned on, the average daily water usage will be compared to the remaining capacity at the regeneration delay time to predict if another day’s water usage can occur before requiring regeneration. If enough capacity is not present then the regeneration will occur at that time. If the predict mode is not selected, the regeneration will start at time of regeneration. If time clock backup is set and the capacity has not been exhausted, the softener will regenerate when days since last regeneration equal time clock back up. In immediate mode the regeneration starts when the capacity is exhausted.

Aqua-Sensor® Mode

The Aqua-Sensor is a conductivity probe that senses when a hardness front passes through the resin bed. It functions independently of the inﬂuent water hardness so therefore, is useful in conditions when the inﬂuent water hardness varies throughout the year. It provides for the most efﬁcient mode of operation. In addition to sensing when a resin bed is exhausted, it can also be used to determine when the brine solution is rinsed from the resin bed during the Brine Draw / Slow Rinse cycle triggering the control to move to fast rinse. This patented feature provides water savings by optimizing the amount of rinse water required to completely rinse out the resin bed.

Time Clock Backup Mode

This setting is used as a backup feature for either the meter or Aqua-Sensor modes of regeneration. It provides regeneration when a set period of time has elapsed. If the meter or Aqua-Sensor does not trigger regeneration prior to the time clock backup value, the time clock backup will trigger the regeneration.

Manual Regeneration

Pressing and holding the regen button for 3 seconds will initiate regeneration. The beeper is to give one beep at the start of manual regeneration (cam starts to turn). In delay mode, pressing and releasing the regen button will light the regen icon for regeneration to occur at the set delay time. Pressing and releasing the regen button again will turn off the regen icon. This function is active in the Service mode and Diagnostic mode. In the diagnostic mode, toggling the “Up” key will advance to the next valve position while the regeneration is in process until home is reached. The information will not be updated if the last cycle of regeneration does not automatically complete (The “Up” key is pressed to cycle the control to the next position).

Predict Mode

The Predict Mode is used in the ﬂow meter mode to determine the optimum regeneration point. Before the regeneration starts, the control will compare the remaining capacity value with the average daily water use. If the average daily water usage is less than the remaining capacity, the controller will wait 24 more hours before regeneration. If the remaining capacity is less than the average daily water usage, the control will initiate regeneration. This works in delay mode only. At any time, if the total capacity value is reached, the control will initiate an immediate regeneration (Unless “delay” is set in the hidden menu; in this case, the control will always wait until the time of regeneration to regenerate).

14 Culligan Gold Series® Water Softener

Efﬁciency Mode

Water softeners historically use an optimum time range to control the Regeneration cycle steps with a minimum and maximum time required to perform each step dependent on the salt being used, the hardness total and iron level. Culligan typically uses the maximum time range to ensure effective Regeneration. However, if the iron content of the water to be softened is zero, and the hardness level is less than 20 gpg, Culligan has developed a new set of regeneration times geared to reducing salt and water usage. These times are deﬁned under a new operating mode coined “Efﬁciency Mode” (Not available if DIP switches #6 or #9 are on). When in Efﬁciency mode, the control will reﬁll for a higher salt dosage once every 10 regenerations according to tank size as shown in the following table.

Tank Sizes Salt Dosages (lbs)

9 x 48 10

10 x 54 15

12 x 52 20

14 x 65 30

Pre-Rinse Mode

The Pre-rinse mode is used in the Time Clock, Flow Meter, and Aqua Sensor® softener modes, as well as in Flow Meter Filter mode, to pre-rinse the softener resin bed or ﬁlter media DIP switch 9 must be set to “on”. The pre-rinse in ﬂow meter mode will occur after the control has sensed that no water has ﬂowed through the control for a period of X hours (can be set through the programming menu). When the control is in this mode, once the X amount of hours have elapsed the control will cycle to the fast rinse position for the pre-set length of minutes and then return to the home or service position. For Time Clock or Aqua Sensor modes the pre-rinse will occur at a ﬁxed time then return to the home or service position.

Note: Be sure to set the brine safety level ﬂoat to the proper position when using this mode since the reﬁll step also occurs in the fast rinse position. failure to do so will result in a higher salt dosage than anticipated.

Operation 15

Installation

Note: Read this section entirely before starting the installation. Follow all applicable plumbing and electrical codes.

With the exception of media containers, open the remaining containers, remove all the components, and inspect them before starting installation.

Placement

Refer to ﬁgure 9 for system placement.

• Set the media tank on a solid, level surface near water, drain and electrical facilities.

• Set the brine system on a ﬂat, smooth, solid surface as near the media tank as possible.

Tank Assembly

Before the unit can be connected to the plumbing the manifold distributors must be assembled and the underbedding and resin must be loaded into the tank for 12” and 14” tanks.

Caution! Do not lay the tank down unless a suitable lifting device is available. Personal injury and damage to the unit can result if dropped.

Position the Mineral Tank(s)

Determine the location for the mineral tanks(s) prior to loading, since they will be difﬁcult to move after the underbedding and gravel are loaded.

16 Culligan Gold Series® Water Softener

Figure 9

Loading the Tank (12” and 14” Tanks)

Small Aqua-Sensor

Plug

1. Position the tank so that the Culligan® logo is in the front.

2. Remove the inlet strainer.

3. Install the outlet manifold into the tank (Figure 10).

4. Cover the tops of the manifolds with a clean rag.

5. Using a large-mouth funnel, load the Culligan underbedding through the top of the tank.

Caution! DO NOT allow the outlet manifold to move when loading the media. The manifold must remain vertical to ensure a good seal at the gasket. Rap the tank near the bottom with a rubber mallet to level the sand.

6. Aqua-Sensor® Installation (optional device)

A. Measure the sensor cable

length as shown in Figure 10 and Table 1 (the Aqua-Sensor cord is set at the factory for a 9” tank).

B. Loosen the small Aqua-Sensor

Plug, a needle-nose pliers works best.

C. Moisten the cable sheath and

slide the cable grip up or down to the proper cable length.

D. Tighten the small Aqua-Sensor

plug so that the ﬁtting cannot

Dimension “X” is the exposed length the Aqua-

Sensor

cord (cord length from the Aqua-Sensor plug to the circuit board connector). You can then verify the Aqua-Sensor probe is inserted to the proper depth by conﬁrming dimension “X” is at the corrected length.

Tank Model X Y

9” Quadra-Hull™ Tank 34 1/2” 40”

10” Quadra-Hull Tank 30 1/2” 44”

12” Quadra-Hull Tank 32 1/2” 42”

14” Quadra-Hull Tank 22 1/2” 52”

Table 1

slide along the cable.

Note: There must be no kinks or bends in the cable.

E. Insert the probe and cable through the Aqua-Sensor port.

7. Load the tank with the Cullex® ion exchange resin. Leveling is not required. Remove the funnel.

8. Install the inlet strainer making sure to thread the strainer until it bottoms out on the tank thread. Failure to install the strainer correctly can cause the control to leak.

Figure 10

Figure 11

Installation 17

Mount the Control Valve

Valve - Adapter O-ring

Tank Adapter

Adapter - Tank O-ring

Tank Clamp

See Figure 12 for a visual on mounting the control valve to the tank.

• Assemble the o-rings, located in the parts pack, to the tank adapter.

• The valve adapter o-ring sits on the ﬁrst step on the adapter. See Figure 13.

Note: Do not push the top o-ring down to the ﬂange surface on the adapter.

Note: The larger of the two o-rings in the parts part goes between the adapter and the valve, do not stretch the smaller

o-ring onto the top of the tank adapter.

• Lubricate only the top o-ring on the tank adapter, and the outlet manifold o-ring with silicone lubricant.

• Screw the adapter into the tank until the adapter bottoms out on the tank ﬂange.

Note: The adapter only needs to be tightened hand-tight to the tank ﬂange.

• Align the manifold with the center opening in the valve, and press the valve onto the adapter ﬁrmly.

Note: Make sure to push the valve straight down onto the manifold. If the valve is cocked, it may cause the o-ring to slip off the manifold.

• Assemble the tank clamp to the control, and tighten the clamp screw.

Note: The clamp and valve will be able to rotate on the tank until pressure is applied.

Figure 13

Figure 12

18 Culligan Gold Series® Water Softener

Flow Control Eductor Nozzle

Listed below is the recommended eductor nozzle to be used at various salt dosages.

Refer to Figure 14 for a visual on changing the eductor nozzle and the backwash ﬂow control.

Table 2 - Flow Restrictors

Unit Backwash Flow Nozzle Throat Brine Reﬁll Flow

9” 2.0 gpm (#2 Brown) Blue* Light Brown* 0.45 gpm

10” 2.0 gpm (#2 Brown) Beige Light Brown 0.45 gpm

12” 3.5 gpm (#3 Green) Beige Light Brown 0.8 gpm

14” 5.5 gpm (Black) Green Blue 0.8 gpm

* Standard from factory

Eductor Nozzle Replacement:

• Remove the three screws on the eductor cap and remove the cap.

• Remove the eductor assembly.

• Remove the eductor screen from the assembly

• Remove the blue nozzle and replace it with the beige nozzle. Make sure to put the o-ring on the correct nozzle.

• Reverse the procedure to reassemble. To prevent leaks, ensure that the gasket is in the proper position.

Backwash Flow Control Replacement:

• Remove the drain clip and pull the drain elbow straight off.

• Remove the backwash ﬂow control located behind the elbow.

• Install the correct backwash ﬂow control.

Note: The number on the ﬂow control should face into the valve body.

• Reverse the procedure to reassemble.

Note: Dip switch #5 is to be in the “off” position for 9” and 10” Tanks (0.45 gpm reﬁll ﬂow control). Dip switch 5 is to be in the “on” position for 12” and 14” tanks (0.80 gpm brine reﬁll ﬂow control).

Plumbing Connections

Shipped with each softener is a Culligan® bypass valve, which is used to connect the softener to the plumbing system. The bypass allows the softener to be isolated from the water service line if service is necessary while still providing water to the home. The bypass valve can be directly plumbed into the system, or can be connected with the following optional sweat connection kits.

• P/N 01010783 1” Sweat Copper Adapter Kit

• P/N 01016564 3/4” Sweat Copper Adapter Kit

• P/N 01016565 3/4” Elbow Sweat Copper Adapter Kit

Caution! Close the inlet supply line and relieve system pressure before cutting into the plumbing! Flooding could result if not done!

Caution! When making sweat connections, use care to keep heat away from the plastic nuts used to connect the plumbing to the bypass. Damage to these components may result otherwise.

Installation 19

Bypass Valve Installation

About 1-1/4”

A screwdriver shank may be used in the slot as a lever for extra turning force if needed.

Bypass

Assembly Pin

Brine Connection

Coupling or Meter Body

Coupling

Assembly Pin

The bypass valve connects directly to the control valve with a pair of couplings and two assembly pins (Figure

15). Lubricate all o-rings on the couplings with silicone lubricant.

On Soft-Minder® meter controls, the meter replaces the coupling on the outlet side of the control. The meter body ﬁts in the same space as the coupling between the control valve and the bypass. Make sure that the arrow on the ﬂow meter is pointing in the direction of ﬂow (Figure 15).

Note: If the ground from the electrical panel or breaker box to the water meter or underground copper pipe is tied to the copper water lines and these lines are cut during installation of the bypass valve, an approved grounding strap must be used between the two lines that have been cut in order to maintain continuity. The length of the grounding strap will depend upon the number of units being installed. In all cases where metal pipe was originally used and is later interrupted by the bypass valve to maintain proper metallic pipe bonding, an approved ground clamp c/w not less than #6 copper conductor must be used for continuity. Check your local electrical code for the correct clamp and cable size.

To bypass, turn the blue knob clockwise (see directional arrow on end of knob) until the knob stops as shown. DO NOT OVERTIGHTEN! (Figure 16a).

To return to service, turn the blue knob counter-clockwise (see directional arrow on the end of knob) until the knob stops as shown. DO NOT OVERTIGHTEN! (Figure 16b)

Figure 15

Figure 16a

Drain Line Connection

Refer to Table 3, under the applicable tank size for drain line length and height limitations.

• Remove 1/2” pipe clamp from the small parts pack included with the control.

• Route a length of 1/2” drain line from the drain elbow to the drain.

• Fasten the drain line to the elbow with the clamp.

• Secure the drain line to prevent its movement during regeneration. When discharging into a sink, or open ﬂoor drain, a loop in the end of the tube will keep it ﬁlled with water and will reduce splashing at the beginning of each regeneration.

Note: Waste connections or drain outlets shall be designed and constructed to provide for connection to the sanitary waste system through an air gap of 2 pipe diameters or 1 inch, whichever is larger.

Note: Observe all plumbing codes. Most codes require an anti-siphon device or air gap at the discharge point. The system and installation must comply with state and local laws and regulations.

20 Culligan Gold Series® Water Softener

Figure 16b

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Culligan Gold Series, Gold 9"", Gold 10"", Gold 12"", Gold 14 Installation & Operation Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual