Fusion, Fusion Hybrid and Prelude Water Softener Service Manual
Contents
1. The hardness level should be set 5 GPG above the actual water feed hardness The hardness level from the original feed water test will either be expressed in GPG grains per gallon or ppm mg L parts per million milligrams per liter If the reading is in ppm mg L then divide that value by 17 1 to get GPG This system only allows hardness inputs in GPG 8 Reserve Selection Display Code RS Press the Extra Cycle button Use this display to set the Safety Factor Use this display to select the type of reserve to be used in your system This setting is identified by RS in the upper left hand corner of the screen The reserve selection parameter is only available if the control type has been set to one of the metered options There are two possible settings SF Safety Factor Fixed Reserve Capacity 9 Safety Factor Display Code SF Press the Extra Cycle button Use this display to set the Safety Factor This setting specifies what percentage of the system capacity will be held as a reserve Since this value is expressed as a percentage any change to the unit capacity or feed water hardness that changes the calculated system capacity will result in a corresponding change to the reserve volume This option setting is identified by SF in the upper left hand corner of the screen Use the Up and Down buttons to adjust the value from 0 to 50 as needed Add 10 for each member in the home up to 50 80 Ran2. S Water Systems com Fusion Fusion Hybrid and Prelude Water Softener Service Manual IMPORTANT Fill in Pertinent Information on Page 3 for Future Reference l e Hits 2 gt I ne gt 1 IMPORTANT PLEASE READ The information specifications and illustrations in this manual are based on the latest information available at the time of printing The manufacturer reserves the right to make changes at any time without notice This manual is intended as a guide for service of the valve only System installation requires information from a number of suppliers not known at the time of manufacture This product should be installed by a plumbing professional This unit is designed to be installed on potable water systems only This product must be installed in compliance with all state and municipal plumbing and electrical codes Permits may be required at the time of installation If daytime operating pressure exceeds 80 psi nighttime pressures may exceed pressure limits A pressure reducing valve must be installed Do not install the unit where temperatures may drop below 32 F 0 C or above 125 F 52 C Do not place the unit in direct sunlight Black units will absorb radiant heat increasing internal temperatures Do not strike the valve or any of the components Warranty of this product extends to manufacturing defects Misapplication of this product may result in failure to pr
3. supply Irrigation and outside water spigots should be plumbed in prior to the softener If this cannot be done it is recommended that the softener be in the bypass position during irrigation or watering from a spigot Grass and other plants do not like soft water and damage to the lawn or landscaping can occur 2 Check the distributor tube in each tank and make sure they are secured to the tank if the system is using Vortech tanks If the system is using standard tanks the distributor will be loose in the tank with a lower basket on the tube For standard tanks make sure the distributor is centered in the tank There is an indentation that will center the distributor The top of the distributor tube will be flush with the tank when it is installed properly 3 Now place a piece of duct tape over the distributor tube to prevent media from entering the tube during the fill process 4 Place the supplied funnel in the tank with the distributor tube in the middle It is recommended that a helper hold the funnel during the fill process A face shield or eye protection should be used during the fill procedure to prevent an injury E A 5 If gravel was shipped with the unit standard tank large units pour the gravel in first Pour the resin in the tank next The tank should be 60 80 full when the media is installed Use all the resin that was shipped with the unit 6 During cold weather it is recommended that the installer warm
4. Clean injector and screen C Timer not cycling C Replace timer D Foreign material in brine valve D Replace brine valve seat and clean valve E Foreign material in brine E Clean brine line flow control line flow control Troubleshooting Problem Cause Correction 8 Softener fails to draw brine A Drain line flow control A Clean drain line flow control is plugged B Injector is plugged B Clean injector C Injector screen plugged D Line pressure is too low D Increase line pressure to 20 P S I E Internal control leak E Change seals spacers and piston assembly F Service adapter did not cycle F Check drive motor and switches 9 Control cycles continuously A Misadjusted broken or A Determine if switch or timer is faulty shorted switch and replace it or replace complete power head 10 Drain flows continuously A Valve is not programming cor A Check control program and rectly positioning of control Replace power head assembly if not positioning properly B Foreign material in control B Remove power head assembly and inspect bore Remove foreign material and check control in various regeneration positions ee C Internal control leak C Replace seals and piston assembly Control Dimensions NOTES
5. creen D Insufficient water flowing into D Check brine tank fill time and clean brine tank brine line flow control if plugged E Hot water tank hardness E Repeated flushings of the hot water tank is required F Leak at distributor tube F Make sure distributor tube is not cracked Check O ring and tube G Internal valve leak G Replace seals and spacers and or piston 3 Unit used too much salt A Improper salt setting A Check salt usage and salt setting B Excessive water in brine tank B See problem 7 4 Loss of water pressure A Iron buildup in line to water A Clean line to water conditioner conditioner B Iron buildup in water condi B Clean control and add mineral cleaner tioner to mineral bed Increase frequency of regeneration C Inlet of control plugged due C Remove piston and clean control to foreign material broken loose from pipes by recent work done on plumbing system 5 Loss of mineral through drain line A Air in water system A Assure that well system has proper air eliminator control Check for dry well condition B Improperly sized drain line B Check for proper drain rate flow control 6 Iron in conditioned water A Fouled mineral bed A Check backwash brine draw and brine tank fill Increase frequency of regeneration Increase backwash 7 Excessive water in brine A Plugged drain line flow control A Clean flow control tank B Plugged injector system B
6. e upper left hand Corner of the screen RE Inn A Uu 6 Press the Extra Cycle button Use this display to set the Current Day of the Week This option setting is identified by CD in the upper left hand corner of the screen 7 Press the Extra Cycle button to end User Programming Mode DIAGNOSTIC PROGRAMMING MODE Diagnostic Programming Mode Options Abbreviation FR Flow Rate Displays the current outlet flow rate PF Peak Flow Displays the highest flow Rate rate measured since the last regeneration HR Hours in Displays the total hours that the Service unit has been in service VU Volume Used Displays the total volume of water treated by the unit RC Reserve Displays the system s reserve Capacity capacity calculated from the system capacity feedwater hardness and safety factor SV Software Displays the software version Version installed on the controller NOTE Some items may not be shown depending on timer configuration The timer will exit Diagnostic Mode after 60 seconds if no buttons are pressed Press the Extra Cycle button to exit Diagnostic Mode at any time Diagnostic Programming Mode Steps 1 Press the Up and Extra Cycle buttons for five seconds while in service 2 Use this display to view the current Flow Rate This option setting is identified by FR in the upper left hand corner of the 9 Cj 3 Press the Up button Use this display to view the Peak Flow Rate since the last regen
7. eration cycle This option setting is identified by PF in the upper left hand corner of the screen gt Bb 4 Press the Up button Use this display to view the Hours in Service since the last regeneration cycle This option setting is identified by HR in the upper left hand corner of the screen HR 5 Press the Up button Use this display to view the Volume Used since the last regeneration cycle This option setting is identified by VU in the upper left hand corner of the screen Vl LJ E x1000 6 Press the Up button Use this display to view the Reserve Capacity This option setting is identified by RC in the upper left hand corner of the screen RC 3nn o CUU 7 Press the Up button Use this display to view the Software Version This option setting is identified by SV in the upper left hand corner of the screen gt ef Press the Extra Cycle button to end Diagnostic Programming Mode Troubleshooting 1 Water conditioner fails to A Electrical service to unit A Assure permanent electrical service regenerate has been interrupted check fuse plug pull chain or switch B Control is defective B Replace Control C Power failure C Reset time of day 2 Hard water A By pass valve is open A Close by pass valve B No salt is in brine tank B Add salt to brine tank and maintain salt level above water level C Injector screen plugged C Clean injector s
8. esets all parameters to the system default values except the volume remaining in meter immediate or meter delayed systems and days since regeneration in the time clock system Master Reset Hold the Extra Cycle button while powering up the unit This resets all of the parameters in the unit Check and verify the choices selected in Master Programming Mode THE HIGHLIGHTED VALUES ARE THE SELECTIONS THAT SHOULD BE MADE SOME PARAMETERS WILL REFER TO THE SETTINGS CHART FOR VALUES 1 Display Format Display Code DF This ts the first screen that appears when entering Master Programming Mode The Display Format setting specifies the unit of measure that will be used for volume and how the control will display the Time of Day This option setting is identified by DF in the upper left hand corner of the screen There are three possible settings Display Format Setting Unit of Volume Time Display GAL U S Gallons 12 Hour AM PM 2 Valve Type Display Code VT Press the Extra Cycle button Use this display to set the Valve Type The Valve Type setting specifies the type of cycle that the valve follows during regeneration Note that some valve types require that the valve be built with specific subcomponents Ensure the valve is configured properly before changing the Valve Type setting This option setting is identified by VT in the upper left hand corner of the screen There are 5 possible settings VT 3 Control Type Displa
9. g Mode Options Abbreviation Parameter Day Override The timer s day override setting RT Regeneration The time of day that the system Time will regenerate meter delayed timeclock and day of week systems Feed Water The hardness of the inlet water Hardness used to calculate system capacity for metered systems RC or SF Reserve Capacity The fixed reserve capacity Current Day The current day of week NOTE Some items may not be shown depending on timer configuration The timer will discard any changes and exit User Mode if any button is not pressed for sixty seconds User Programming Mode Steps 1 Press the Up and Down buttons for five seconds while in service and the time of day is NOT set to 12 01 PM 2 Use this display to adjust the Day Override This option setting is identified by DO in the upper left hand corner of the screen LJ LIA gt ap m LJ 3 Press the Extra Cycle button Use this display to adjust the Regeneration Time This option setting is identified by RT in the upper left hand corner of the screen 7 200 4 Press the Extra Cycle button Use this display to adjust the Feed Water Hardness This option setting is identified by H in the upper left hand corner of the screen Wael Range 1 199 hardness 5 Press the Extra Cycle button Use this display to adjust the Fixed Reserve Capacity This option setting is identified by RC or SF in th
10. ge 0 5096 10 Fixed Reserve Capacity Display Code RC Press the Extra Cycle button Use this display to set the Reserve Capacity This setting specifies a fixed volume that will be held as a reserve The reserve capacity cannot be set to a value greater than one half of the calculated system capacity The reserve capacity is a fixed volume and does not change if the unit capacity or feed water hardness is changed This option setting is identified by RC in the upper left hand corner of the screen Use the Up and Down buttons to adjust the value as needed RE f1 M J Range 0 half the calculated capacity WILL NOT BE DISPLAYED WHEN USING SF SAFETY FACTOR 11 Day Override Display Code DO Press the Extra Cycle button Use this display to set the Day Override This setting specifies the maximum number of days between regeneration cycles If the system is set to a timer type control the day override setting determines how often the system will regenerate A metered system will regenerate regardless of usage if the days since last regeneration cycle equal the day override setting Setting the day override value to OFF disables this function This option setting is identified by DO in the upper left hand corner of the screen Use the Up and Down buttons to adjust the value as needed nn HIU al Range Off 99 days This will most likely be set at 14 days unless you take vacations lasting more than two weeks Mo
11. grains of hardness when configuring a softener system and in the desired volume capacity when configuring a filter system This option setting is identified by C in the upper left hand corner of the screen The Unit Capacity parameter is only available if the control type has been set to one of the metered options Use the Up and Down buttons to adjust the value as needed 49g Range 1 999 900 gallons 100 9 999 000 Liters Use the following chart to determine your capacity setting LowSaltSetings Medium Salt Settings High Salt Settings Setting mins mins Setting mins 26 000 15 000 18 000 24 000 com Tm 35 000 20 000 25 000 30 000 10 cm OP ot em ot mme om 53 000 30 000 37 000 10 45 000 14 Om oe t mm m mq ou 70 000 40 000 50 000 16 60 000 20 Grain 88 000 50 000 10 63 000 18 75 000 25 Grain 105 000 60 000 12 75 000 20 90 000 30 Grain 140 000 80 000 16 100 000 28 120 000 Grain 7 Feed Water Hardness Display Code H Press the Extra Cycle button Use this display to set the feed water hardness Enter the feed water hardness in grains per unit volume for softener systems or 1 for filter systems This option setting is identified by H in the upper left hand corner of the screen The feed water hardness parameter is only available if the control type has been set to one of the metered options Use the Up and Down buttons to adjust the value as needed 30 Range 1 199 hardness
12. low Indicator Service Icon x1000 Indicator Extra Cycle Up Button Button 1 When in the service mode the service icon will be illuminated If a delayed regeneration is initiated the service icon will blink The flow indicator icon will blink when water is being used When setting the time of day and delayed regeneration time be sure the clock is in the correct 12 hour time cycle When you are in the PM time cycle the PM icon will be illuminated If it is not illuminated the clock is in the AM time cycle 4 When the display is in the service mode it will flash from the time of day to the remaining capacity before regeneration in gallons 5 When water is being used and the flow icon is blinking water drip on right hand side of display the remaining capacity value will decrease for each gallon used The service icon will be illuminated during programming or regeneration The extra cycle button serves as an enter return button when programming The up and down arrows allow value changes in each parameter programming mode Once the value is reached the extra cycle button can be pushed to save the value and move to the next parameter 8 The extra cycle button also initiates immediate or delayed regenerations Pushing and releasing it immediately triggers a delayed regeneration will regenerate at the time specified under RT in the programming mode The service icon will blink when a delayed regeneration is initiated Pushing and h
13. mage the unit j hh hh e af 4 hh 12 Solder joints near the drain must be done before connecting the Drain Line Flow Control fitting DLFC Leave at least 6 152 mm between the DLFC and solder joints when soldering pipes that are connected on the DLFC Failure to do this could cause interior damage to DLFC 13 Use only Teflon tape on the drain fitting threads Two wrenches or channel locks may be needed to tighten the barbed fitting or hard plumbing fitting if tubing is not used Be sure not to over tighten this fitting 14 Once the fittings are installed and tight push the 5 8 drain line on the barb and secure it using a hose clamp This tube should be attached to a sanitary drain An air gap fitting should be installed on the drain pipe where this tube will be connected check local codes If this is being conveyed to a floor drain sink or sump pump be sure to maintain a proper air gap Typically a 1 air gap is sufficient 15 Be sure the floor under the salt storage tank is clean and level Any debris can cause a leak when the tank is weighted down with salt and brine solution 16 Connect the supplied 3 8 tubing to both brine connections 17 At the control valve place the nut over the tube install the brass sleeve in the tube Install the cone screen in brass insert Install the plastic flange over the tube Install the tube in the control valve and tighten the nut by turning it clockwise Tighten it hand
14. ns to adjust the value as needed Press the Extra Cycle button to accept the current setting and move to the next parameter BD Brine Draw 60 Mins RR Rapid Rinse 10 Mins Brine Fill see chart RR af Range 0 199 minutes TED mum D This setting is determined by the chart used for the capacity setting Input the number of minutes that corresponds to the capacity setting that was chose previously LewSaltSetings Medium Salt Settings High Salt Settings Setting mins mins Setting mins 26 000 15 000 18 000 24 000 com Tm em 35 000 20 000 25 000 30 000 10 com om t mm me 53 000 30 000 37 000 10 45 000 14 com om t mm m mm eom 70 000 40 000 50 000 16 60 000 20 Grain 88 000 50 000 10 63 000 18 75 000 25 Grain 105 000 60 000 12 75 000 20 90 000 30 Grain 140 000 80 000 16 100 000 28 120 000 Grain 14 Flow Meter Type Display Code FM Press the Extra Cycle button Use this display to set the type of flow meter connected to the control This option setting is identified by FM in the upper left hand corner of the screen Use the Up and Down buttons to select one of the 7 available settings GEn 7 t l THE 9500 VALVE WILL USE t1 5 FOR THIS SETTING 15 End of Master Programming Mode Press the Extra Cycle button to save all settings and exit Master Programming Mode USER PROGRAMMING MODE User Programmin
15. olding the extra cycle button for 5 seconds will initiate an immediate regeneration The service icon will blink and the valve will move to the first regeneration position and begin the process 9 Ifthe error icon is illuminated there is a problem with the unit and a service technician should be contacted 10 The x1000 icon will illuminate when values are multiplied by 1000 capacity setting 11 The system will hold the values for up to 48 hours after a power outage Outages exceeding 48 hours should have the programming values revisited It is a good idea to write down the programming parameters values so they are available if a reprogramming is required General and Commercial Installation Checklist WATER PRESSURE A minimum of 25 pounds of water pressure is required for regeneration valve to operate effectively ELECTRICAL FACILITIES A continuous 115 volt 60 Hertz current supply is required Make certain the current supply is always energized and cannot be turned off with another switch EXISTING PLUMBING Condition of existing plumbing should be free from lime and iron buildup Piping that is built up heavily with lime and or iron should be replaced If piping is clogged with iron a separate iron filter unit should be installed ahead of the water softener LOCATION OF SOFTENER AND DRAIN The softener should be located close to a drain Programming Setting the Time of Day 1 Press and hold either the Up or Down buttons until
16. operly condition water or damage to product A prefilter should be used on installations in which free solids are present In some applications local municipalities treat water with Chloramines High Chloramine levels may damage valve components Correct and constant voltage must be supplied to the control valve to maintain proper function Job Specification Sheet Job Number Model Number Water Test Capacity Per Unit Mineral Tank Size Diameter Height Brine Tank Size amp Salt Setting per Regeneration 9000 9100 9500 Control Valve Specifications 1 Type of Timer A 82 minute available regeneration time 1 15 RPM B 164 minute available regeneration time 1 30 RPM 2 Type of Meter Mechanical Valves Gallon Settings Meter Standard Range Extended Range 3 4 125 2 125 625 10 625 1 310 5 270 1 150 26 350 1 1 2 625 10 625 3 125 53 125 3 Timer Gallon Setting Gallons 4 Regeneration Program Setting A Backwash Minutes B Brine and Slow Rinse Minutes C Rapid Rinse Minutes D Brine Tank Refill Minutes 5 Drain Line Flow Control gpm 6 Brine Refill Rate gpm 7 Injector Size General and Commercial Installation Instructions 1 Place the softener tank where you want to install the unit NOTE Be sure the tank is level and on a firm base The tank base black plastic is a floating base that can be adjusted to meet uneven floors The softener should be located close to the incoming water
17. s pointer should be pointing to bypass on the valve When the bypass valve is in the bypass position the handle will bisect the plumbing connections Turn on the main water supply Open a cold soft water tap nearby and let water run a few minutes or until the system is free of foreign material usually solder resulting from the installation Close the water tap when water runs clean 2 Slowly place the bypass In Service position and let water flow into the mineral tank Open the bypass in small increments until it is fully open When water flow stops slowly open a cold water tap nearby and let water run until air is purged from the unit Preferably a garden spigot or bath tube Then close tap once the water runs clear and there is no air in the system The bypass valve pointer should be pointing toward service and the handle should be in line with the plumbing connections Electrical 28 Make all electrical connections according to codes Plug the valve into an approved power source 29 The valve position will be displayed on the control panel If the unit is in the regeneration process the cycle will be shown on the screen When the system is in the service position it will display the time of day and flash to the amount of gallons that are remaining before a regeneration of the tank in service is required TIMER FEATURES Parameter Data PM Display Display Indicator Error Information Icon Fe INNY F
18. st households will eclipse the gallon capacity prior to the override engaging However if you are gone for two weeks it is a good idea to set this at 10 days so it regenerates and is fresh when you return Water standing in the system for longer than 14 days can become stagnant 12 Regeneration Time Press the Extra Cycle button Use this display to set the Regeneration Time This setting specifies the time of day the control will initiate a delayed manually queued or day override triggered regeneration This option setting is identified by RT in the upper left hand corner of the screen Use the Up and Down buttons to adjust the value as needed 7 200 This should be set to a time that is about 2 hours after everyone is sleeping in the home 13 Regeneration Cycle Step Times Press the Extra Cycle button Use this display to set the Regeneration Cycle Step Times The different regeneration cycles are listed in sequence based on the valve type selected for the system and are identified by an abbreviation in the upper left hand corner of the screen The abbreviations used are listed below If the system has been configured with the OTHER valve type the regeneration cycles will be identified as R1 R2 R3 R4 R5 and R6 Each cycle step time can be set from 0 to 199 minutes Setting a cycle step time to O will cause the control to skip that step during regeneration but keeps the following steps available Use the Up and Down butto
19. the programming icon replaces the service icon and the parameter display reads DO 2 Adjust the displayed time with the Up and Down buttons 3 When the desired time is set press the Extra Cycle button to resume normal operation The unit will also return to normal operation after 5 seconds if no buttons are pressed LL Queuing a Regeneration 1 Press the Extra Cycle button and release The service icon will flash to indicate that regeneration is queued 2 Tocancel a queued regeneration press the Extra Cycle button and release Regenerating Immediately Press and hold the Extra Cycle button for five seconds Entering Master Programming Mode Set the Time Of Day display to 12 01 P M Press the Extra Cycle button to exit Setting Time of Day mode Then press and hold the Up and Down buttons together until the programming icon replaces the service icon and the Display Format screen appears Exiting Master Programming Mode Press the Extra Cycle button to accept the displayed settings and cycle to the next parameter Press the Extra Cycle button at the last parameter to save all settings and return to normal operation The control will automatically disregard any programming changes and return to normal operation if it is left in Master Programming mode for 5 minutes without any keypad input Resets Soft Reset Press and hold the Extra Cycle and Down buttons for 25 seconds while in normal Service mode This r
20. the valve to room temperature before operating 7 Perform all plumbing according to local plumbing codes including the drain Use a 1 2 minimum pipe tube size for the drain Use a 3 4 drain line for backwash flow rates that exceed 7 gpm or length that exceeds 20 6 m 8 The distributor tube must be flush with the top of the tank Cut if necessary Remove the duct tape Lubricate the tube and nylon seal ring on the tank Use only non aerosol food grade silicone lubricant 9 Lubricate the distributor o ring seal and tank o ring seal on the control valve Install the upper basket by pushing in the slotted holes and turn it clockwise until it locks in place 10 Place the control valve on the tank Place the valve over the distributor tube through the bottom of the upper basket Slide the valve down and thread the valve on the tank by turning it clockwise Once the valve is hand tight turn it an additional 1 4 turn to snug it to the tank 11 Attach the plumbing according to local codes The inlet and outlet pipes will attach to the 1 female threads on bypass valve The bypass valve will be labeled with arrows The inlet port will have an arrow pointing toward the unit and the outlet will have an arrow pointing away from the unit If soldering is necessary it is recommended that solder joints closer than 6 to the unit be completed prior to screwing the pipes into the bypass Excessive heat close to the bypass valve can da
21. tight then snug it an additional 1 4 to 1 2 turn 3 F 18 Remove the white cap from the white tube in the brine tank Place the other end of the tube through the hole in the side of the bine tank 19 Remove the nut from the brine safety valve BE CAREFUL not to drop the nut and sleeves 2 in the brine tube 9 20 Place the nut over the tube Be sure the brass insert is in the tube 21 Now place the black split ring on the tube with the coned side facing the nut be 22 Now place the white ring on the tube with the shoulder touching the black split ring 23 Insert the tube in the brine safety valve elbow and tighten the nut by turning it clock wise Tighten the nut hand tight and snug it an additional 1 4 to turn Place the white cap back on the white tube 24 There is a barb fitting on the side of the brine tank This is used as an overflow and only is used if the brine tank overfills This barb is for 5 8 tubing If you elect to use tubing for this elbow run it to a floor drain or sump pump 25 Place 3 6 bags of salt in the salt tank The salt tank is full when the salt level is 1 below the white tube in the brine tank Pour in 5 gallons of water The salt should be used then refilled It is not a good practice to top off the salt weekly It is better to use it all then refill it 26 Place the unit in the Bypass position There is a pointer on the bypass valve handle Thi
22. y Code CT Press the Extra Cycle button Use this display to set the Control Type This specifies how the control determines when to trigger regeneration For details on how the various options function refer to the Timer Operation section of this service manual This option setting is identified by CT in the upper left hand corner of the screen There are four possible settings Meter Delayed Fd Meter Immediate Fl Time Clock tc Day of Week dAY 4 Number of Tanks Display Code NT Press the Extra Cycle button Use this display to set the Number of Tanks in your system This option setting is identified by NT in the upper left hand corner of the screen There are two possible settings Single Tank System 1 Two Tank System 2 5 Tank in Service Display Code TS Press the Extra Cycle button Use this display to set whether tank one or tank two is in service This option setting is identified by TS in the upper left hand corner of the screen This parameter is only available if the number of tanks has been set to 2 There are two possible settings Tank One in Service U1 Tank Two in Service U2 TS Il NO CHANGES NECESSARY ON THIS PARAMATER 6 Unit Capacity Display Code C Press the Extra Cycle button Use this display to set the Unit Capacity This setting specifies the treatment capacity of the system media Enter the capacity of the media bed in
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