INSTALLATION MANUAL for softeners with standard flow valve Caution: Read All Safety Guides Before You Start To Install Your Softener. Water Softeners u Safety Guides u Unpacking u Where To Install If you have questions when installing, operating or maintaining your softener, and when setting the timer, call this toll--free number... u How To Install u Pressure Testing 1-800-426-9345 SAVE THIS MANUAL Use plastic bag and tie provided, to hang manuals nearby the softener for future reference. Sears, Roebuck and Co., Hoffman Estates, IL 60179 USA PRINTED IN U.S.A. INTRODUCTION This manual gives you the steps needed to install your new Sears Water Softener. To better understand how the water softener is installed, and to know what you will need, please read this entire manual before beginning. After you have installed the water softener, the included Owners Manual tells you how to start, program, operate and maintain it. The owners manual also has the product warranty, and a listing of repair parts available from Sears. Your Sears Water Softener will remove hardness minerals (measured in grains per gallon¼ gpg) and some clear water iron (measured in parts per million¼ ppm) from water. See the specifications, in your owners manual, for the maximum limits of hardness and iron removal. A water softener will not improve other water problems such as acidity, tastes and odors, or iron other than clear water iron. It will not purify contaminated water, or make other unsafe water safe to drink. Sears sells a complete line of water treating equipment to correct various water problems. To be sure you have the proper type and size equipment, you must have your water tested. Your Sears store can give you water test results for hardness, iron and acidity, and tell you what equipment you need. Simply take at least a 4 oz. sample of your water to Sears, and they will test it while you wait. If you need help to get your water tested, or if you have other questions about your water, ask at your Sears store, or call sears Water Line ¼ 1-800-426-9345. 2 TABLE OF CONTENTS PAGE NO. SECTION 1 A. B. C. BEFORE INSTALLING CHECKS AND TESTS 4 5 6 SAFETY GUIDES UNPACKING THE WATER SOFTENER WATER SYSTEM TESTS SECTION 2 A. B. C. D. PLAN YOUR INSTALLATION 7 8-9 10 11 WHERE TO INSTALL THE SOFTENER TOOLS, PIPE AND FITTINGS, OTHER MATERIALS NEEDED TYPICAL SOLDERED COPPER (OR CPVC) IN AND OUT PIPES TYPICAL THREADED IN AND OUT PIPES TO SOFTENER SECTION 3 A. B. C. D. E. F. STEP BY STEP GUIDES TO INSTALL 12-13 14 15 16-17 18 19-20 ASSEMBLE INLET---OUTLET ADAPTORS, OR PLASTIC BYPASS VALVE INSTALLING 3-VALVE BYPASS, OR SINGLE BRASS VALVE LOCATE AND CONNECT WATER SOFTENER CONNECT VALVE AND SALT TANK DRAIN HOSES PRESSURE TEST-- CHECK FOR LEAKS GROUNDING-- CONNECT TO ELECTRICAL POWER RESTART THE WATER HEATER 20 3 SECTION 1 1A. BEFORE INSTALLING CHECKS AND TESTS SAFETY GUIDES s Read all steps, guides and rules carefully before installing and using your new water softener. Follow all steps exactly to correctly install. Failure to follow them could cause personal injury or property damage. Reading this book will also help you to get all of the benefits from your water softener. s Your water softener will remove hardness minerals and " clear water"iron from water, up to the limits shown on the specifications page of your owners manual. It will not remove other types of iron, acids, tastes and odors, etc. It will not purify polluted water or make it safe to drink. s Check with your local public works department for plumbing, electric and sanitation codes. You must follow their guides as you install your softener. s Use only LEAD-FREE SOLDER AND FLUX, as required by Federal and State codes, when installing soldered copper plumbing. s Protect the softener and piping from freezing. Damage from freezing voids the softener warranty. See how to protect from freezing in your owners manual. CAUTIONS PLEASE READ AND COMPLY WITH THE FOLLOWING GUIDES TO PREVENT DAMAGE TO THE SOFTENER OR OTHER PROPERTY, PERSONAL INJURY, OR POSSIBLE FATAL SHOCK. s This softener works on 24 volts only. Be sure to use the transformer included, and plug it into a 120V outlet. s Unplug the transformer right away if the power cable should become damaged or frayed. Make repairs before plugging back into the power outlet. s Always unplug the softener from electrical power before removing outer valve covers. 4 SECTION 1 1B. BEFORE INSTALLING CHECKS AND TESTS UNPACKING THE WATER SOFTENER Use care when handling the softener. DO NOT turn upside-down. DO NOT drop, or set on sharp objects that could make a hole in the bottom. The water softener is heavy and to avoid damage, or personal injury, do not try to lift it or move more than necessary. See page 15, when you are ready to move it into installation position. Directions for unpacking the softener are on the top of the shipping carton. This manual, and the owners manual, were on the small parts cardboard packing piece. You will need the small parts to install the softener. So you don' lose any t parts, keep them on the cardboard piece until you are ready to use them. Remove all other cardboard pieces, foam packings, tapes, etc. from the softener and discard. Check the softener for shipping damage. If you find damage, report it to your Sears store. PARTS DESCRIPTIONS SMALL PARTS MANUALS INLET --- OUTLET* ADAPTOR (2) CLIP (2) BYPASS VALVE* INLET --- OUTLET* NUT (2) WASHER OR* GASKET (2) GROMMET INLET --- OUTLET* TUBE (2) GROUND TUBE CLAMP (2) CLAMP TRANSFORMER GROUNDWIRE, SCREWS AND NUTS TUBE ADAPTOR *PARTS NOT INCLUDED WITH ALL MODELS 5 SECTION 1 1C. BEFORE INSTALLING CHECKS AND TESTS WATER SYSTEM TESTS CHECK YOUR WATER FLOW RATE -- A water flow of at least 3 gallons per minute is needed. A lower flow will keep your softener from working as well as it should. To make an easy check of your flow rate, do the following. You will need a 1 gallon container (can, jar, pail, etc.). Has your water supply had a chemical analysis? Please see page 2. CHECK YOUR WATER PRESSURE -- For your softener to work right, a water pressure of no lower than 20 pounds per square inch (psi) is needed in the house water pipes. The highest pressure allowed in the water pipes is 120 psi. If pressure is over 120 psi, buy and install a pressure reducing valve in the water inlet pipe to the softener. NOTE: If water pressure during the day is 100 psi or more, pressure during the night may go over 120 psi. Adding a pressure reducing valve may reduce the flow. If you have a well water system, look at the pressure gauge to find the water pressure. Call your local water department if you have city water. They will tell you what the water pressure is where you live. 1. Fully open 2 cold water faucets close to the point water enters the house. 2. With both faucets open, fill the gallon container at 1 faucet while looking at a watch or clock to see how many seconds it takes. 3. Empty the container and go to the second faucet (be sure BOTH faucets are still on). Fill the gallon container at the second faucet and see how many seconds it takes. of seconds it took to fill the container at both faucets. system flow rate is good. 4. Turn off both faucets. Now add the number 5. A total of 90 seconds, or less, means the FOR FUTURE REFERENCE, ENTER RESULTS OF YOUR WATER SYSTEM TESTS IN THE " FACTS AND FIGURES TO KEEP"TABLE IN YOUR OWNERS MANUAL. 6 SECTION 2 2A. Think of the following points as you choose a place to put your softener. (see FIG. 1). · Place as close as possible to the pressure tank (well water) or water meter (city water). · Place as close as possible to a water drain such as a floor drain, laundry tub, sump or standpipe. Y ·Connect Y ·Put PLAN YOUR INSTALLATION WHERE TO INSTALL THE SOFTENER the softener in a place water damage is least likely to occur if it develops a leak. Sears or the manufacturer will not repair or pay for water damage. Y ·A to the house main water pipe BEFORE THE WATER HEATER. Temperature of water going through the softener must not be more than 120° (49° Hot water F C). will damage inner softener parts. To reduce the risk of hot water backup, piping between the softener and water heater should be as long as possible. 120V electrical outlet, to plug the transformer into is needed within 10 feet of the softener (the softener has a 10 foot power cable). Be sure the outlet and transformer are in an inside place, to protect from wet weather. So the softener always has electrical power, use a continuously "live" outlet, that cannot be accidentally switched off. installing in an outside location, you must take the steps necessary to assure the softener, installation plumbing, and wiring, are as well protected from the elements, contamination, vandalism, etc., as when installed indoors. the softener out of direct sunlight. The sun' heat can melt plastic parts. s Y ·When · Keep outside faucets on hard water to save soft water and salt. Y ·Do not install in a place where the softener could freeze. Freeze damage voids the warranty by Sears, Roebuck and Co. Y ·Keep FIG. 1 THE PROPER ORDER TO INSTALL WATER TREATING EQUIPMENT (Shows sequence of equipment only -- seldon, if ever, would all items be needed) 7 SECTION 2 2B. You must first decide how to run in and out pipes to the softener. Look at your house main water pipe at the point you will connect the softener. Is the pipe soldered copper, glued plastic, or threaded galvanized or brass? What is the pipe size? What kind of pipe and fittings is it easiest for you to work with, and what tools do you have? Now look at the common plans for in and out piping on pages 10 (soldered copper) and 11 (threaded). Select the drawing best for you and use it as a guide to plan what materials you will need. As you plan your in and out piping, keep in mind the following check list. Then get all the materials you will need before you start. NOTE: Use page 9 to make a plan drawing for your specific installation. Some models may include a plastic bypass valve, an installation kit and a length of drain tubing. 4 In and out pipes to the softener must be at least 3/4 in. size. Some local codes may tell you to use no less than 1 in. pipe size (see Note on pages 10 or 11). You should maintain the same, or larger, pipe size as the water supply pipe, up to the softener inlet and outlet. 4 Use copper, brass, or galvanized pipe and fittings. Some codes may also allow CPVC plastic pipe. 4 Copper and galvanized pipe corrode fast when connected together. Use pipe and fittings of the same material. 4 You can buy adaptors to go from a copper or threaded main water pipe to CPVC in and out pipe. PLAN YOUR INSTALLATION TOOLS, PIPE AND FITTINGS, OTHER MATERIALS NEEDED 4 Sears has kits and bypass valves you can buy to help make installing your softener easier. See pages 10 and 11. 4 ALWAYS install a bypass valve or valves. Either use 3 shut-off valves, or 1 of Sears special valves. Bypass valves let you turn off water to the softener if needed to make repairs, but still have water in the house pipes. 4 Drain tubing (3/8 in. inside diameter) is needed for valve and salt tank drains. See steps 1 and 2 on pages 16 and 17. Some models include a length of drain tubing, or you can buy it at most Sears stores. If a rigid valve drain is needed to comply with plumbing codes, you can buy the parts needed (see page 16) to change the softener to a 1/2 in. copper tubing drain. 4 TOOLS NEEDED:-- Common and cross point (Phillips) screw drivers, slip joint pliers and a tape measure or rule. ALSO¼ ¼ for SOLDERED COPPER -- tubing cutter, propane torch, solid-core LEAD-FREE solder, paste flux, emery cloth, sandpaper or steel wool. ¼ for THREADED PIPE -- hacksaw or pipe cutter, pipe wrenches, pipe threading tool, pipe joint compound approved for use on potable water. ¼ for CPVC PLASTIC -- hacksaw, adjustable wrench, solvent cement approved for use on potable water, primer. 8 SECTION 2 2B. PLAN YOUR INSTALLATION PIPE AND FITTINGS, PLAN DRAWING 9 SECTION 2 2C. PLAN YOUR INSTALLATION TYPICAL SOLDERED COPPER (OR CPVC) IN AND OUT PIPES TO SOFTENER FIG. 2 *NOTE: For 1 in. plumbing connection, buy 2 sweat adaptors (1 in. female thread x 1 in. sweat) and plumb directly to the inlet ---outlet adaptors or bypass valve. Threads on the inlet ---outlet adaptors and bypass valve are 1 in. pipe thread. Do not use the installation kit, Sears Stock No. 42---3441, or the flexible connectors, Sears Stock No. 42---34401. CAUTION: DO ALL SOLDERING BEFORE CONNECTING SWEAT ADAPTOR TO INLET ---OUTLET ADAPTORS OR BYPASS VALVE. SEARS KITS AND VALVES TO MAKE INSTALLING YOUR SOFTENER EASIER 1 BYPASS VALVE (Plastic) Sears Stock No. 42---3437 (included with some models) 2 BYPASS VALVE (Brass) Sears Stock No. 42---3436 One, easy working valve takes the place of 3 separate valves. 3 nut copper tube o-ring INSTALLATION KIT Sears Stock No. 42---3441 (inclu ...