Clean Water Systems Pro-OX 7800 Installation manual

Clean Water Made Easy
www.cleanwaterstore.com
7800 Carbon 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 chlorine free water for many years.
CARBON 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: [email protected]
See more information on our website: www.cleanwaterstore.com/resources

Clean Water Made Easy
www.cleanwaterstore.com
Table of Contents
Packing List ................................................................................................................................................3
Carbon Filter 1.0 cubic foot size.............................................................................................................3
Carbon Filter 1.5 cubic foot size.............................................................................................................3
Carbon Filter 2.0 cubic foot size.............................................................................................................3
Carbon Filter 2.5 cubic foot size ............................................................................................................3
Pre-Installation .......................................................................................................................................... 4
Best Practices for Piping & Drain Installation .............................................................................................4
How Your Carbon Filter Works ..................................................................................................................5
Fig 1 - Carbon Filter Tank Water Flow ...............................................................................................5
Fig 2 - Typical Carbon Filter 7800 piping installation with ball valve and hose bib after the filter ......6
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. ........7
Fig 4 7800 Bypass and Service Positions ...........................................................................................7
Assembly and Installation Instructions ......................................................................................................8
Fig 5: 7800 By-Pass and Pipe Connectors ...........................................................................................9
Initial Programming: ................................................................................................................................ 10
Troubleshooting the 7800 Carbon Filter .................................................................................................. 12

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Packing List
Carbon 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 Carbon media
12lbs. Filter gravel
1 cubic foot of Carbon media
Carbon 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 Carbon media
16 lbs. Filter gravel
1.5 cubic foot of Carbon media
Carbon 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 Carbon media
20lbs. Filter gravel
2.0 cubic foot of Carbon media
Carbon 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 Carbon media
35lbs. Filter gravel
2.5 cubic foot of Carbon media

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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 Carbon 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 Carbon 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 3) 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 Carbon 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
Carbon Filter and before the second ball valve. This makes it easy to rinse your new Carbon
Filter on start-up and gives you a place to test the water before it enters your household
plumbing.
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. If have copper pipe before the Carbon Filter and it is too difficult to change out, you may still
experience some copper staining of fixtures and have a copper residual in the water because
this section of pipe will still have acidic water flowing through it. We recommend PEX or PVC
pipe up to the Carbon Filter and then copper after it, if you have copper plumbing.

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6. 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 Carbon filter on by-pass and remove the
filter system from the piping.
7. 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 Carbon Filter Works
See Fig 1 below. In your Carbon Filter the water enters the top of the tank (red arrows) and flows down
through the media and up the distributor tube (blue arrows). The downflow type Carbon Filter
removes sediment and can be backwashed, which cleans and re-classifies the Carbon, preventing
channeling. During backwash the flow of water is reversed and water flows down the distributor tube
and up through the media, lifting and expanding the Carbon media. During the backwash the Carbon is
cleaned by the action of the water flowing through it.
Fig 1 - Carbon Filter Tank Water Flow

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Fig 2 - Typical Carbon Filter 7800 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 Carbon 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 Carbon media.
3. Next add Carbon media. The tank will be about 2/3rds full of media. Do not fill past 2/3rds,
even if there is some 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 Carbon 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 assembly 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. 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 (see 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 Carbon 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.
15. Plug your 7800 control valve into an outlet. After being plugged in, the screen may display
“WAITING PLEASE” while it finds the service position. By default, the control valve will be set to
work like a Water Softener, but that’s not correct for this application. So, next you will need to
program the system to work as a Carbon Filter. There are a few settings that must be changed
before the system can be put into service.
Initial Programming:
16. Plug in your 7800 control valve to an outlet
17. From the display screen, press and hold the settings button for three seconds to access the
programming menu.
18. 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
19. 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
20. 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
21. 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
22. Set Regen Days - Set the number of days between backwashes. The recommended setting for a
Carbon filter is every 7 days. If you are having some problems with bleed-through of chlorine (or
whatever else it is that is being filtered out) after the carbon filter has been online for a few
days, you may want to change it to 2 or 3 days.
23. Gallons On/Off –Select Off to program it to be used as an Carbon Filter
24. Regen Time - Set the time of the night that you want the Carbon filter to backwash. The default
time is 2:00 am. Adjust the time by pushing the up or down arrow if you want.

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25. 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.
Starting the Initial Backwash
26. Now you are ready to turn on the water. Turn on the water and leave the Carbon filter on
bypass and check for leaks. Leave the ball valve after the Carbon filter closed, so water is still off
to the house, but connect a garden hose and open up the hose bib after the Carbon 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 Carbon 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.
27. 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 28.
28. 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.
29. There should be no Carbon media coming out of the drain line, but the water will be black or
dirty looking. At this point the Carbon 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 Carbon filter at first to prevent some Carbon fines from coming out 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.
30. 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 Carbon 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: 7 GPM recommended

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2.5 Cubic Foot Model: 10 GPM recommended
31. 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.
32. After the Carbon 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 Carbon media in the future, that is, the Carbon media
must be thoroughly backwashed and rinsed.
Troubleshooting the 7800 Carbon Filter
One problem that may occur is if you do not have enough backwash flow rate to properly clean the
Carbon filter. You can verify the backwash flow rate by running the drain line into a bucket and timing it
when the 7800 is in Cycle 1 or 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.
In some cases, the 7800 may not be programmed correctly. See the 7800 service manual for instructions
on how to access the master programming.
How To Remove Media From Control Head
Sometimes, when doing the Initial Backwash, the media gets lifted up into the control head. You can tell
this happened because you will have little or no flow, either going out to drain while in the backwash
positon, or when in the service positon.
To remove media from a control head, do the following:
1) Put the Inlet Bypass in the Closed position.
2) From the Service Mode, initiate a manual regeneration, by pressing and holding the regen button
(button on far left).
3) The valve will advance to the BW (backwash) position, and start counting down. Press the Regen
button again, and wait for the valve to advance and stop at the Rapid Rinse (RR) position.
4) With the valve in the RR position, open and close the Inlet Bypass valve several times. After the third
or fourth time, leave it in the open position and check the drain line- do you have a good solid flow?
90% of the time, the answer is yes, but sometimes, even after opening and closing the valve many times,
you still don’t have good flow… But, in either case (good or no flow), continue…
5) With the Inlet Valve OFF, Advance the valve back to Service position again, and again press and hold
the Regen button, we are putting the valve back to the Backwash position.

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6) Open the Inlet valve just enough so you can hear the water passing thru the valve- you should notice
a corresponding slow flow out of the drain line. After a minute, if there are no air bubbles present, open
the valve about another quarter inch- again, you should see a corresponding increase in the flow… And
you will continue until the valve is full open.
IMPORTANT:
Any time that you are in the Backwash or Rapid Rinse position, you may need to unplug the power- this
will hold the valve in its current position, so it doesn’t ‘time out’ and go to the next position. When you
plug the valve back in, after a minute it will return to where it was when you unplugged it (i.e. 2:32
remaining in BW). Understand, it is not possible to jam media into the head while in Rapid Rinse, or
Service, just in the Backwash, when the flow direction is reversed.
What you are trying to accomplish, after you have pushed the media back in to the tank in the Rapid
Rinse position, is to get the Inlet valve all the way open in the Backwash position, without it jamming
media back in the head, and this is the part where you have to go slow, open up the Inlet valve a little
bit at a time and let it run for a few minutes- this is why you may have to unplug it- and then, once you
have done that, finally, do one more backwash, starting with the Inlet valve open, just as it will be when
it does it automatically at night. Once it does that successfully, you are done.