Clean Water Systems Greensand 7800 Installation manual

Clean Water Made Easy
www.cleanwaterstore.com
7800 Greensand Filter Installation & Start-Up Guide
Thank you for purchasing a Clean Water System! With proper
installation and a little routine maintenance your system will
be providing iron free water for many years.
GREENSAND MEDIA CONTAINS DUST. USE PAPER MASK
AND VENTILATE TO AVOID BREATHING DUST.
Questions?
Call us toll-free: 1-888-600-5426 or 1-831-462-8500
Email us: [e-mail]
See more information on our website: www.cleanwaterstore.com/resources

Clean Water Made Easy
www.cleanwaterstore.com
Table of Contents
Packing List.................................................................................................................................................... 3
Neutralizer 1.0 cubic foot size .................................................................................................................. 3
Greensand Filter 1.5 cubic foot size.......................................................................................................... 3
Greensand Filter 2.0 cubic foot size.......................................................................................................... 3
Pre-Installation.............................................................................................................................................. 4
Best Practices for Piping & Drain Installation ............................................................................................... 4
How Your Greensand Filter Works ............................................................................................................... 5
Fig 1 - Greensand Filter Tank Water Flow............................................................................................ 5
Fig 2 - Typical Plus Greensand Filter piping installation with ball valve and hose bib after filter....... 5
Assembly and Installation Instructions......................................................................................................... 6
Fig 3 7800 By-Pass and Pipe Connectors.............................................................................................. 9
Troubleshooting the 7800 Greensand Filter............................................................................................... 11

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Packing List
Greensand Filter 0.75 cubic foot size
7800 Backwash Control Valve w/ Bypass Assembly and Pipe connector kit (1”or ¾”)
8” x 44” filter tank with distributor tube
Blue media funnel for adding the Greensand media
8 lbs. Filter gravel
0.75 cubic foot of Greensand media
Greensand Filter 1.0 cubic foot size
7800 Backwash Control Valve w/ Bypass Assembly and Pipe connector kit (1”or ¾”)
9” x 48” filter tank with distributor tube
Blue media funnel for adding the Greensand media
12lbs. Filter gravel
1 cubic foot of Greensand media
Greensand Filter 1.5 cubic foot size
7800 Backwash Control Valve w/ Bypass Assembly and Pipe connector kit (1”or ¾”)
10” x 54” filter tank with distributor tube
Blue media funnel for adding the Greensand media
16lbs. Filter gravel
1.5 cubic foot of Greensand media
Greensand Filter 2.0 cubic foot size
7800 Backwash Control Valve w/ Bypass Assembly and Pipe connector kit (1”or ¾”)
12” x 52” filter tank with distributor tube
Blue media funnel for adding the Greensand media
20lbs. Filter gravel
2.0 cubic foot of Greensand media
Greensand Filter 2.5 cubic foot size
7800 Backwash Control Valve w/ Bypass Assembly and Pipe connector kit (1”or ¾”)
13” x 54” filter tank with distributor tube
Blue media funnel for adding the Greensand media
35 lbs. Filter gravel
2.5 cubic feet of Greensand media

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Greensand Filter 3.0 cubic foot size
7800 Backwash Control Valve w/ Bypass Assembly and Pipe connector kit (1”or ¾”)
14” x 65”filter tank with distributor tube
Blue media funnel for adding the Greensand media
40 lbs. Filter gravel
3 cubic feet of Greensand media
Pre-Installation
1. Review your packing list and make sure you have received all the parts before beginning
installation.
2. If you are going to be turning off the water to the house and you have an electric water heater,
shut off the power to the water heater before beginning installation in case water heater is
accidentally drained.
3. Pick a suitable location for your filter system on a dry level spot where it won’t be exposed to
freezing temperatures. A minimum of 20 PSI is required. Maximum pressure is 90 PSI.
4. Get all of your plumbing parts together before beginning installation. Installation typically takes
3 to 5 hours. However, after installation the Greensand Filter must be allowed to run through a
complete backwash and rinse cycle.
5. After the system is installed and running, your water may be discolored, or full of sediment or
rust, particularly if this is older or corroded piping. This typically clears up over a day or two.
Best Practices for Piping & Drain Installation
1. See typical installation on page 7 (Fig 2). The Greensand filter is installed after the pressure
tank.
2. Make sure to connect the IN pipe to the 7800 inlet and the OUT pipe to the outlet (see Fig 2). As
you face the 7800 control from the front, the water enters on the right and exits on the left.
From the back (see Fig 2) the water enters on the left. The inlet and outlet are attached to the
bypass valve, which is marked with arrows as well.
3. Make sure there is a working gate or ball valve before the 7800 Greensand Filter and also one
after as shown in Fig 2. The pressure gauges are optional and perhaps not necessary but a hose
bib (which is a faucet that you can attach a garden hose to) is strongly recommended after the
Greensand Filter and before the second ball valve. This makes it easy to rinse your new
Greensand Filter on start-up and gives you a place to test the water before it enters your
household plumbing.

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4. If you will be using copper piping, do not sweat the copper pipe directly on to the 7800 control
valve. Avoid heating up the 7800 control valve plastic with the torch.
5. You do not need unions to install your 7800 control valve. If you need to remove it, the 7800
has quick-release couplings that make it easy to put the Greensand filter on by-pass and remove
the filter system from the piping.
6. The drain line tubing (not supplied) is connected to a drain from the drain outlet using flexible
½” ID tubing. Note that the drain can run up above the 7800 control and into a drain, it does not
have to drain down, as the filter backwashes under line pressure from your well pump. Most
plumbing codes require an air-gap connection, so that if your sewer or septic tank backs up, it
cannot cross connect with the drain tubing.
How Your Greensand Filter Works
See Fig 1. In greensand iron filter, the water enters the top of the tank and flows down through the
media and up the distributor tube. Iron and manganese in the water turns to an oxidized particle upon
contact with the media and is trapped in the media. During backwash, the water flow is reversed and
water flows down the distributor tube and up through the media, lifting and expanding the greensand
filter media, and removing all the iron and rust trapped in the filter. After the backwash stage,
potassium permanganate solution is automatically drawn in from the potassium permanganate solution
tank and slowly rinses through the greensand filter for 1 hour, and then the greensand media is
thoroughly rinsed-to-drain. This entire automatic process, called ‘regeneration’ takes about 90 minutes.
Typically the greensand filter is set to regenerate every 3 to 7 days, during the middle of the night when
no water is being used.
Fig 1 - Greensand Filter Tank Water Flow

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Fig 2 - Typical Greensand Filter CWS Plus piping installation with ball valve
and hose bib after the filter

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Fig 3: 7800 from the rear showing the inlet (left) and outlet (right) end-
connector fittings 3/4” or 1” NPT in Noryl plastic. Brass end-connectors are
also available for connecting to copper tubing.
Fig 4 7800 Bypass and Service Positions

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Assembly and Installation Instructions
1. By hand, unscrew the entire 7800 control valve from top of tank if it was shipped screwed on.
Place distributor tube in tank if not already inside. If not already done, make sure the blue cap is
on top of distributor tube, or wrap the top of distributor tube with electrical or duct tape. You
do not want gravel or Greensand to go down the distributor tube.
2. Add the filter gravel that came with your order. You want the gravel to cover the bottom
distributor screen before adding the Greensand media.
3. Next add Greensand media. The tank should be about 2/3rds full of media. Do not fill past
2/3rds, even if there is some media left over
4. Remove cap or tape from top of distributor tube. Be careful not to pull up distributor tube
when removing cap or tape.
5. If possible at this point, fill tank completely with water. This will allow the Greensand Filter
media to settle and eliminate the need of “purging” the air out of the tank later.
6. Attach plastic top screen to the under-side of the 7800 control valve. It is a funnel-shaped
plastic screen that snaps on to the control valve and prevents resin from being backwashed out
to drain during the regeneration cycles.
Plug or tape top of distributor tube
when adding media to prevent media
from entering. Remove when
finished.

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7. Add a small amount of silicone grease or vegetable cooking oil to the tank threads and screw on
7800 control valve carefully. Do not use pipe-joint compound, Teflon tape, or Vaseline or other
petroleum greases to lubricate tank threads.
8. See how the by-pass is connected. Note that Items 2 in Fig 5 below are the pipe connectors and
the other end is what gets attached to the control valve. Items 3 are the red clips that hold the
pipe connectors to the by-pass valve. Your 7800 is usually shipped in the by-pass position, as
in Figure 4.
Fig 5 7800 By-Pass and Pipe Connectors
9. Lubricate the by-pass valve o-rings with some vegetable oil or silicone grease and connect the
bypass assembly to the 7800 control by sliding the bypass valve firmly into the body of the 7800.
Once bypass is in far enough, you will be able to insert the red connector clips.
10. Next lubricate the end-connectors (#2 in Fig 5) with some silicone grease or vegetable cooking
oil and insert them into the bypass valve and then insert the red clips (#3).
11. Note that the 7800 is usually shipped in the bypass position. There is a bypass valve knob on
both the inlet and the outlet (Fig 5). You can easily tell if it is in bypass because the two knobs
will be in line with each other (Fig 4). If the valve is in the Service position (Fig 5) the knobs will
be parallel to each other. Make sure both sides are in the by-pass position.
12. Do NOT remove the red clips in order to put the bypass valve in either bypass or service, it is not
necessary nor desired to remove the red clips on the bypass valve hand knobs (Fig 5, which are
the knobs you will turn to move the bypass valves).
13. Now install your water pipes to the 7800 bypass end connectors. Make sure inlet is installed to
the 'In" pipe connector on the bypass valve and outlet is on the “Out” connector.

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14. Connect some flexible tubing from the drain connection on the 7800 control valve to a suitable
drain such as a septic tank or drain to a sewer. It is OK to run the drain line up and over the
7800 Greensand Filter up to 4 feet above the top of the tank. If the drain line will be more than
20 feet, use larger diameter tubing such as ¾” or 1”. Note that it is desirable to be able to run
the drain line into a bucket in order to test the backwash flow rate in the future. This is why
hard piping the drain line is discouraged, however, if you do use hard PVC piping for the drain
line, and you are able to remove the hard PVC drain piping and attach flexible tubing should you
ever desire for testing purposes, it is OK to use rigid PVC pipe for the drain. Make sure the drain
tubing is firmly clamped to the barbed fitting with a hose clamp to prevent leaks.
Fig 6 7800 Pot Perm Line Installation
15. Loosen the fitting and insert 3/8” diameter tubing into the chlorine side tank connection. Simply
push the tubing into the fitting until it can go no further. The tube should be snug in the fitting.
Hold the tubing in place and then tighten down the fitting to secure it in place. Make sure that it
is secured in place and cannot be easily pulled out.

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Fig 7 7800 Pot Perm Tank Set-Up & Installation
16. First remove the rubber band that comes on the float assembly from the manufacturer. Add
enough clean water to the pot perm solution tank to bring water level about 1” above the felt
pad. Add one 2 or 5-lb jug of potassium permanganate granules to the potassium perm tank by
pouring it directly on top of the white felt pad. Do not pour permanganate down the white
plastic brine well where the black line is attached.
17. See the over-flow barbed fitting on the side of the perm tank. You do not have to connect this
to a drain. If the safety float were to malfunction, there is a small chance that pot perm solution
will drip out of this fitting. If this would cause a big mess where you have installed the
greensand filter, hook some tubing to this and run to a bucket, floor pan or floor drain. Normally
no pot perm solution will leak out of this fitting.
18. Plug your 7800 control valve into an outlet. After being plugged in, the screen may display
“WAITING PLEASE” while it finds the service position. Next you will need to program the system
to work as a Greensand Filter. There are a few settings that must be changed before the system
can be put into service.
PROGRAMMING:
19. Plug in your 7800 control valve to an outlet
20. From the display screen, press and hold the settings button for three seconds to access the
programming menu.
21. Set Time of Day –Use the up and down arrows to select the proper value. Once the proper
value is set, press the Settings button (Enter) to proceed to the next setting. Hitting the Manual
Regen button at any time will take you out of the programming and back to the main menu
22. Set Year - Use the up and down arrows to select the proper value. Once the proper value is set,
press the Settings button (Enter) to proceed to the next setting
23. Set Month - Use the up and down arrows to select the proper value. Once the proper value is
set, press the Settings button (Enter) to proceed to the next setting

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24. Set Day - Use the up and down arrows to select the proper value. Once the proper value is set,
press the Settings button (Enter) to proceed to the next setting
25. Set Regen Days - Set the number of days between backwashes, typically for every 3 days for
moderate to heavy iron. If the iron level is low and water usage is light you can try setting it for
every 4 days, but a setting of every 2 days is recommended by the manufacturer. If your iron is
very high (over 4.0 ppm) and you use a lot of water you can set it to every night. Frequent
backwashing prolongs the life of the media by several years.
26. Gallons On/Off –Select Off to program it to be used as an Iron Filter
27. Regen Time - Set the time of the night that you want the Greensand filter to backwash. The
default time is 2:00 am. Adjust the time by pushing the up or down arrow if you want.
28. Programming Complete –If you need to go back and change anything, simply press and hold
the Settings button to go through the programming menu again.
29. Now you are ready to turn on the water. Turn on the water and leave the Greensand filter on
bypass and check for leaks. Leave the ball valve after the Greensand filter closed, so water is
still off to the house, but connect a garden hose and open up the hose bib after the Greensand
filter and allow the water to run for several minutes. This important step clears out any foreign
material that may be in pipes from the installation. If you do not have a valve and hose bib
installed after the Greensand filter, you will need to turn the water on inside the house to let
the water run. Use a bathtub or laundry sink or other fixture that does not have an aerator
screen.
30. Press and hold the Manual Regen button for three seconds which will start a manual backwash,
watch the display and wait until it starts counting down. Now unplug the power supply and
proceed to step 24.
31. Now you can slowly turn the bypass valve to the service position. You do NOT remove the red
clips on the bypass knobs in order to turn the bypass valves from the bypass to the service
position. First open the Inlet Side of the bypass valve. Second slowly open the Outlet Side of the
bypass until it is in the full service position. The 7800 bypass valve knobs are a little stiff, so you
can use Allen wrench placed in the holes to turn the knobs. Turn the bypass valve knobs in the
correct direction which is counter-clockwise as you face the bypass valve knobs.
32. There should be no Greensand media coming out of the drain line, but the water will be black or
dirty looking. At this point the Greensand filter will be in a backwash cycle. The backwash takes
10 minutes. If the water slows down or stops during the first 10 minutes of backwash, press the
Manual Regen button to move the 7800 control to the next cycle, the Rinse cycle. Then repeat
the backwash and rinse after the rinse cycle is done, by pressing and holding the Manual Regen
button for three seconds again. If you have high water pressure you may need to turn on the
water slowly to the Greensand filter at first to prevent some Greensand fines from coming out

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the backwash. However it is normal for some small amount of fines to come out during the
backwash, although you do not want to see a large amount of media coming out, which would
mean you have very high water pressure, or the drain flow control for the 7800 is missing.
33. If possible verify that the backwash flow rate. You can easily run the drain hose to a bucket and
using a watch verify the flow rate in gallons per minute. For example, if the backwash fills a 5
gallon bucket in 30 seconds, you have 10 gallons per minute or 10 GPM. An adequate
backwash is critical to properly clean the Greensand media and prevent it from cementing
together.
1.0 Cubic Foot Model: 5 GPM recommended
1.5 Cubic Foot Model: 5 GPM recommended
2.0 Cubic Foot Model: 8 GPM recommended
2.5 Cubic Foot Model: 10 GPM recommended
3.0 Cubic Foot Model: 12 GPM recommended
34. The next cycle is the Rinse cycle and this runs for 6 to 8 minutes. After the backwash, the 7800
will automatically advance to the rinse cycle.
35. After the Greensand filter has gone through the backwash and rinse, press and hold the Manual
Regen button for three seconds and repeat the backwash and rinse. This is the same procedure
that needs to be done each time you add Greensand media in the future, that is, the Greensand
media must be thoroughly backwashed and rinsed.

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Maintaining Your Greensand 2510 Filter System
Adding Potassium Permanganate:
Add one 5-lb jug of potassium permanganate every 3 - 4 months. Check the potassium permanganate
solution tank and when you see the mound of potassium permanganate disappear after a few months,
just add another 5-lb jug. In some cases, you won’t see the mound; you might just see solution after a
couple of weeks. This is OK; you still only need to add the potassium permanganate every 3 months in
most cases. If you have it set to regenerate (backwash cycles) every 1 –3 days, you might need to add it
more frequently, perhaps every 2 months.
Troubleshooting the 7800 Greensand Filter
PROBLEM / SYMPTOM
POSSIBLE
CAUSE
SOLUTION
Iron or manganese or sulfur odor in
treated water after Greensand Filter
No permanganate in
solution tank
Not backwashing often
enough
Water being used
when Greensand Filter
is in regeneration.
Permanganate
solution is not being
sucked in during the
regeneration brine
cycle.
Add permanganate powder to tank and
regenerate greensand filter
Set to backwash more frequently.
Backwash twice in one day and re-check
water.
If any water is used during the 90 minute
regeneration cycle, untreated water will
enter household piping. Set time
Greensand Filter regenerates to a time
when no one will be using the water.
Clean brine injector
Clean potassium permanganate tank
Replace permanganate support pad in
permanganate tank
Inadequate backwash flow. Make sure
there that Greensand Filter is backwashing
at the correct backwash flow rate (5 to 10
gallons per minute depending on size of
filter).
Low water pressure. Increase water
pressure to unit by adjusting well pump
pressure switch, or replacing well pump.

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Greensand media
exhausted
Replace Greensand media with new
Greensand.
Strong sulfur odor before and after
Greensand filter
High levels of
hydrogen sulfide gas in
well water
In some cases, the greensand filter may
need a chlorine feed (or ozone, oxygen or
other oxidizer) prior to the filter. Make
sure Greensand filter is working correctly,
and try regenerating it once or twice a day
for one week. If odor persists, replace
Greensand media or add a chlorinator
ahead of the Greensand Filter.
Pink water (permanganate) in
household water
Inadequate backwash
of Greensand Filter
Clogged brine injector
Inadequate rinse time
Too much
permanganate
Make sure Greensand Filter has adequate
backwash at a good pressure and flow rate
Clean or replace injector
Set rinse cycle to longer time
Lower float so that level of permanganate
is lower in permanganate solution tank.
Potassium permanganate tank over-
filling or over-flowing
Clogged brine injector
Clean or replace injector
More Troubleshooting Tips
Potassium Permanganate Not Being Sucked In During Regeneration
Most problems occur when the 7800 is not drawing in the potassium permanganate. Make sure the
injector is drawing in the potassium permanganate:
1. Remove the permanganate solution tank tubing where it enters the 7800 control valve.
2. Turn the regeneration knob clockwise on the timer assembly until a backwash is started. After
it is in a backwash cycle, turn the regeneration knob some more, and it will advance to the next
cycle, which is the Brine Cycle, where it is supposed to suck in the permanganate solution.
3. If is sucking strongly, check the potassium permanganate solution tank float inside the brine well
and make sure there is no rubber bands around it, and that is free of obstructions. In some

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cases it may need to be replaced or cleaned, if there is suction at the control valve, but no
permanganate is being drawn in.
4. If there is NO suction at the control valve port where you removed the permanganate tubing,
then the injector should be cleaned.
5. If the injector has been cleaned and there is still no suction check to make sure there is obstruction
in the backwash line; that the backwash line does not go up and over the greensand filter more
than several feet (which causes pressure loss and the injector not to work correctly); finally check
to make sure there is enough pressure. If possible increase your water pressure to the iron filter
from your well pump and see if a slightly increased pressure makes the injector work. We
recommend a minimum 30 PSI but it does work better if there is 40 to 50 minimum PSI.
System Not Backwashing Adequately
The second main problem that may occur is if you do not have enough backwash flow rate to properly
clean the greensand filter. You can verify the backwash flow rate by running the drain line into a bucket
and timing it when the 7800 is in backwash. A 1.0 or 1.5 cubic foot system should have 5 gallons per
minute and a 2.5 cubic foot system should have 10 gallons per minute of backwash.
Potassium Permanganate Tank with Float

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Permanganate tank not filling with permanganate solution
Potassium permanganate is a powder that is poured on top of the “grid pad” in the pot perm tank.
During the brine fill cycle, water is added to the pot perm tank to make up the pot perm solution
required for the next regeneration.
If your pot perm does not have ½” to 1” of solution above the grid pad, the first to check is to make sure
it is filling the tank:
1. Disconnect the 3/8” black poly line at the pot perm tank or at the control valve.
2. Put the system into a regeneration cycle by holding down the manual regen button. You can
advance to the Brine Fill cycle by turning the regeneration cycle further. Advance to the BF cycle.
3. If it IS filling, remove the safety float and make sure the air check ball is moving free and not
stuck. A stuck float is often the cause of this problem and can be easily fixed. If the float is
defective or older than 5 years, replace float.
4. If it is NOT filling during the Brine Fill (BF) cycle, then make sure there are enough minutes. It
should be set for 12 minutes for standard size Clack pot perm tanks. If you have a larger
commercial size tank, set for 20 minutes.
5. If it is still not filling, the brine valve may need to be cleaned. In the 7800 manual, in the
diagram “Valve Assembly”, disconnect the parts listed and clean them thoroughly.