Crusader Pro User manual

Owner’s Manual
Pro, Deluxe, & Enhanced Systems
2020 Model Year
CrusaderWater.com

Table of Contents
System Features and Benets........................................................................... Page 5
System Components.......................................................................................... Page 6
Your Responsibilities as an Equipment Owner................................................ Page 9
Cleaning and Disinfecting Your System with ProGuard............ Page 10
Recommended Cleaning & Disinfection Schedule.................. Page 11
System Control & Operation........................................................................... Page 12
Understanding How Your System Operates............................... Page 14
Warnings and System Operational Requirements....................................... Page 17
System Installation and Start-up Guidelines & Checklist............................. Page 18
System Programming.................................................................... Page 23
Service Instructions........................................................................ Page 26
Parts & ProGuard Feeder Diagrams.............................................................. Page 29
System Troubleshooting Guidelines............................................................... Page 33
Error Codes....................................................................................................... Page 37
Limited Lifetime Warranty Information.......................................................... Page 39
How Much Money Can Soft Water Save You?............................................ Page 40
Crusader Pro, Deluxe, & Enhanced Systems Owner’s Manual 2020 Page 3

This Product is Made with
Pride in the United States
of America
Each valve is tested and certied by the WQA to NSF/ANSI Standard
61 for material safety and structural integrity and lead free compli-
ance as well as CSA B483.1.
Page 4
CrusaderWater.com
Crusader Pro, Deluxe, & Enhanced Systems Owner’s Manual 2020

Page 5
System Features and Benets
Your newly purchased Crusader Water Quality Management System utilizes robust water
treatment technologies which allow you to enjoy cleaner, softer, and better water.
Efcient
The Crusader System learns your lifestyle and quickly adapts itself to meet your needs to
deliver exceptional water quality while also saving you salt, water, and electricity. The high-
ly sensitive digital ow-meter installed in your system allows it to learn how much water you
use and when you use it so it can adjust reserves and salt consumption to match your water
usage lifestyle while minimizing bacterial growth.
Upgradeable
Designed for the future, your Crusader System is capable of being modularly upgraded as
new technologies are developed to accommodate for rapidly degrading water conditions.
The onboard control center can be updated with the latest software updates & upgrades as
they become available.
Reliable
The Crusader Water Quality Management System is built around Open-platform technology
that has a 40-year legacy of reliable design. It utilizes 21st century composite materials to
ensure reliable and dependable performance.
Safe
Every Crusader System is handcrafted in the USA by skilled artisans in a world-class facility to
provide you with a water treatment system that exceeds industry safety, manufacturing, and
quality control standards to give you peace of mind.
Simple
Advanced manufacturing methods and skillfully crafted computer hardware & software
make a Crusader Water Quality Management System one of the easiest water quality im-
provement systems to own and operate.
Crusader Pro, Deluxe, & Enhanced Systems Owner’s Manual 2020

Page 6
System Components (Pro Model)
Control Valve and Computer
Monolament Pressure Vessel
Top Distributor
Riser Tube
Ion Exchange Resin
Bottom Distributor
The system must be BYPASSED, DEPRES-
SURIZED, and DE-ENERGIZED before
assembling or performing mechanical
repairs
Disassembly, Repair, Replacement,
and/or Reassembly should only be
performed by properly trained service
personnel
Crusader Pro, Deluxe, & Enhanced Systems Owner’s Manual 2020

Page 7
System Components (Deluxe Model)
The system must be BYPASSED, DEPRES-
SURIZED, and DE-ENERGIZED before
assembling or performing mechanical
repairs
Disassembly, Repair, Replacement,
and/or Reassembly should only be
performed by properly trained service
personnel
Control Valve and Computer
Monolament Pressure Vessel
Top Distributor
Riser Tube
Activated Carbon Media Blend
Ion Exchange Resin
Clarifying Media
Bottom Distributor
Gravel Underbedding
Crusader Pro, Deluxe, & Enhanced Systems Owner’s Manual 2020

Page 8
System Components (Enhanced Model)
The system must be BYPASSED, DEPRES-
SURIZED, and DE-ENERGIZED before
assembling or performing mechanical
repairs
Disassembly, Repair, Replacement,
and/or Reassembly should only be
performed by properly trained service
personnel
Control Valve and Computer
Monolament Pressure Vessel
Top Distributor
Riser Tube
ChlorZorb™ Carbon Media Blend
Cation Exchange Resin
Clarifying Media
Bottom Distributor
Gravel Underbedding
Anion Exchange Resin
Crusader Pro, Deluxe, & Enhanced Systems Owner’s Manual 2020

Page 9
Your Responsibilities as an Equipment Owner
Your Crusader Water Quality Management System is manufactured to be efcient and
reliable. To ensure continued performance while keeping your system operating within man-
ufacturer’s specications, the following operating conditions must be ensured by you, the
equipment owner/operator:
Water Pressure Regulator
The inuent water pressure into this water system must be regulated by a code-compliant
pressure-regulating device not to exceed 75 psi.
Power Protection
Power to this system must be supplied by an unswitched 110VAC supply. Surge protection
is mandatory and is to be supplied by you, the equipment owner. The use of a UPS (Uninter-
ruptible Power Supply) is encouraged.
Salt
This water system uses either sodium or potassium salt to clean itself. The brine tank must be
lled with a high quality salt to ensure proper system operation. Consult with your local water
professional to decide on the best salt for your area.
ProGuard
The ProGuard reservoir should be kept full to ensure proper system operation and maximum
efciency. ProGuard works synergistically with the softening media to ensure the very best
water feel and to maximize cleaning power. Check the level of your ProGuard feeder each
time you ll your brine tank with salt.
Periodic Replacement of Media
While built to the highest standards, certain media in your Crusader Water Quality Manage-
ment System will need to be replaced periodically. Replacement intervals vary depending
on your water chemistry and water consumption habits. Consult with your local water spe-
cialist to ensure that you always enjoy the very best water quality.
Crusader Pro, Deluxe, & Enhanced Systems Owner’s Manual 2020

Page 10
ProGuard™
The ProGuard™ feeder incorporated into every Crusader System ensures that you have the
best water quality all year long. This simple dispensing system is specially engineered to work
in all climates to easily introduce ProGuard into your brine tank while the system is waiting to
clean itself.
Your Crusader System will use varying amounts of ProGuard depending on your water con-
sumption habits; it will always try to maximize efciency and performance to provide you
with the water quality that you deserve.
ProGuard is designed to:
•Clean ion-exchange resin without damaging structured matrix media
•Clean all moving parts & create a temporary protective coating
•Create an inhospitable environment for bacteria in the system
•Remove oils and other hydrocarbons from resin
•Clean Activated Carbon Media
•Enhance self-sanitization processes on compatible systems
Always keep your ProGuard reservoir full to ensure proper system performance, longevity, &
efciency.
Crusader Pro, Deluxe, & Enhanced Systems Owner’s Manual 2020

Page 11
Cleaning and Disinfection
Your Crusader Water Quality Management System is probably the hardest working appli-
ance in your home. Over its service life, it will process millions of gallons of water to protect
you from countless amounts of inorganic calcium, magnesium, lead, copper, zinc, iron, man-
ganese, and other contaminants that could be in your water.
In addition to capturing inorganic contaminants, your softener also accumulates sediment,
bacteria, algae, mold, and fungus that can enter the system through safe city water, salt,
or even from the air. These additional contaminants slowly accumulate in your softener and
can even colonize it with a biolm of Heterotrophic Plate Count (HPC) bacteria. These bac-
teria are usually benign, but they can create a food base and safe refuge for potentially
harmful pathogens and seriously compromise the longevity and performance of your system.
While weekly antibacterial rinses and supplementation with ProGuard help minimize bac-
terial growth, your system should also be cleaned and disinfected on a regular schedule to
ensure that it is working to the best of its ability and to protect the safety of your family.
Recommended Cleaning & Disinfection Schedule
This chart shows the recommended monthly cleaning interval.
# PEOPLE IN HOME
WATER
HARDNESS
(grains per
gallon)
123456
112 12 12 12 12 12
512 12 12 12 12 12
10 12 12 12 12 12 12
15 12 12 12 12 12 12
20 12 12 12 12 12 6
25 12 12 12 6 6 6
30 12 12 6 6 6 6
40 12 12 6 6 6 6
Your local dealer can perform the cleaning and disinfection service for you, or you can pur-
chase a comprehensive cleaning and disinfection kit to perform this task yourself.
The system must be BYPASSED, DEPRES-
SURIZED, and DE-ENERGIZED before
assembling or performing mechanical
repairs
Disassembly, Repair, Replacement,
and/or Reassembly should only be
performed by properly trained service
personnel
Crusader Pro, Deluxe, & Enhanced Systems Owner’s Manual 2020

Page 12
System Control & Operation
Your Crusader Water Quality Management system incorporates a highly sophisticated mi-
croprocessor control system, which makes it as efcient and reliable as possible. All system
settings are pre-programmed at the factory and then carefully calibrated by your qualied
in-staller for your specic application and area.
Your Crusader Water Quality Management System incorporates ash EEPROM memory and
an innovative power backup system, which means that your system programming should
never have to be reset, even in the event of an extended power outage. Your system can
also be upgraded with the latest software and hardware revisions as they become availa-
ble. Contact your local authorized dealer for more information.
Normal Operating Mode
In Normal Operating Mode, the display shows the time of day, capacity remaining, and the
system status. Your system continuously monitors the ow meter and makes decisions on
when and how to clean based on its programming prole and observations of your water
usage habits.
Flow Meter
In Service Mode, the display will show the time of day and remaining capacity. The re-
main-ing capacity counts backwards in gallons as water is used. The ow display indicator
can be used to determine if the ow meter is working by opening a faucet downstream of
the system and observing the gallons count down as well as the ow glyph.
Power-Failure Handling
In the event of a power failure, your system’s integrated Snapshot memory system will retain
all programmed data indenitely. The system will maintain the correct time of day during a
period of several hours. In the case of a prolonged power failure, the time of day might not
be maintained; if this happens, the time of day indicator will be ashing when the power
supply is reestablished. This ashing indicator lets you know that the time of day needs to be
reset. All other programming is unaffected.
Critical Software/Hardware Failure
After a critical software or hardware failure, the Error Information icon may illuminate with a
solid or blinking light. Call your local service provider for help.
Crusader Pro, Deluxe, & Enhanced Systems Owner’s Manual 2020

Page 13
Cleaning/Regeneration Mode
Cycle times will vary depending on your water usage habits, the system operational history,
pre-programmed settings, and other environmental factors. In Regeneration Mode the dis-
play shows the current cleaning cycle description and the remaining time for that cycle to
execute. The cleaning sequence is as follows:
System Control & Operation
Tank Fill
Your system calculates the exact amount of
brine solution required to properly clean itself
based on pre-programmed settings, opera-
tional history, your water usage habits, and the
age of the system. Your system is online and in
service at this time.
Percolation
Your system remains online and in service
while the water and salt slowly mix together to
create a perfectly saturated sodium or potas-
sium brine solution.
Brine Draw
Your system will extract brine water from the
brine tank and apply it to the ion exchange
media in the tank. This begins the ion ex-
change process where trapped hardness and
other contaminants are forced off of the ion
exchange resin beads.
Slow Rinse
Once the brine supply is exhausted, your
system will begin slowly rinsing contaminants
through the media bed and out of the tank to
drain.
Backwash
Your system rapidly discharges water upwards
through the media to the drain. This ensures
that trapped sediment & broken media are
ushed out of the tank to minimize pressure
loss & channeling.
Rapid Rinse
A high velocity stream of water is directed
downwards through the multimedia bed to
compact each of the media layers, ush hard
water from the tank, and prepare for returning
itself to service.
Return to Service
The system slowly drives the operating piston
to the home position and gracefully brings
itself back online, ready to work hard for you.
Your system will periodically perform an antibacterial deep cleaning. This cleaning cycle will
occur after a designated period of time (we recommend at least once a week). This clean-
ing cycle will inject ProGuard into your system and possibly even use salt to clean itself, de-
pending on your water usage. If you haven’t used any water during that interval, the system
will not use any salt during the antibacterial cleaning cycle.
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Page 14
Understanding How Your System Operates
Every day, thousands of billions of tons of water evaporate from the earth’s surface.
As the heat of the sun evaporates the water and draws it from the earth’s surface into the
atmosphere, many impurities are left behind. The water vapor eventually cools to form
clouds and then falls back to earth as precipitation.
On its way from the clouds to your faucet, soft rain water dissolves and absorbs a part of al-
most everything is touches.
Falling rain cleans the air as it falls. Unfortunately the impurities that were removed from the
air have not left; they have just been relocated through the water onto the ground. These
gases and other airborne contaminants can cause undesirable tastes, colors, and odors in
water.
Rain falls onto the ground, collecting sediments like rust, sand, and even algae. The water
eventually nds its way to a surface water supply or percolates downward and collects in
an aquifer. As it percolates through the earth, the water can absorb hardness minerals, iron,
heavy metals, radioactivity, organic contaminants, and many other complex elements and
compounds.
Water can also collect numerous harmful man-made chemical impurities during this cycle.
These synthetic chemicals are generally odorless, colorless, and tasteless; and can some-
times be life-threatening. The statement “my parents drank this water for 50 years and it nev-
er hurt them”, is no longer a valid excuse to not be concerned with water quality. There has
been a massive global increase in exposure to chemical waste over the last 50 years.
The scientic and medical community has not had adequate time or budget to study the
long-term health effects of the more than 70,000 harmful chemicals that can be found in use
today.
Approximately 1,000 new synthetic chemical compounds are entering the industrial market-
place each and every year. Precipitation falls upon commercial and municipal dump sites,
toxic waste sites, industrial refuse depots, military test sites, leach elds, mining operations,
farmer’s elds, etc. where it dissolves minute amounts of the toxic chemicals present and
carries them along into water sources.
In 1986, the United States Government estimated that close to two percent of the nation’s
ground water supplies were moderately polluted by sources such as hazardous waste dumps
and leaking landlls.
Industrial wastewater is also a major source of water contamination. Chemicals that are con-
sidered generally acceptable in controlled amounts may react with other elements and/or
chemicals to form new compounds that could be highly carcinogenic.
Chlorine is one of the best-publicized examples. It reacts with organic matter in water and
forms deadly trihalomethanes.
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Page 15
Understanding How Your System Operates
Hard water is one of the major threats facing the American home in the 21st century. Hard
water can coat you, your family, your home, and your appliances with thousands of pounds
of inorganic mineral rock-scale each and every year. Hard water slowly destroys everything
it touches; if left untreated, hard water costs you money, ruins your lifestyle, and can even
lower the value of your home.
No one needs to tell you that you’re living with hard water though. Soap doesn’t lather ea-
si-ly, glasses are cloudy after washing, a ring forms around the bathtub, faucets and shower
heads are crusty, laundering results are poor, and there are many other easily recognizable
signs.
There are several degrees of water hardness. Even moderately hard water can seriously
damage the plumbing system in your home and, in time, cause inconvenient and expensive
problems.
Hard water is a poor cleaner because it is loaded with a variety of impurities. These dissolved
impurities react with certain chemicals found in soap to form a gummy, insoluble curd that
clings stubbornly to everything it touches. The ring around your bathtub is curd. That same
curd causes your hair to become dull and hard to manage.
Soap curd clogs skin pores and prevents your natural oils from properly moisturizing your skin.
This dryness causes itching and can also aggravate skin conditions like psoriasis, eczema,
and acne.
Soap curd is especially noticeable by the scummy lm it forms on dishes, glassware, walls,
and oors. Hardness and other dissolved solids combine to form the residue you see as spots
on glasses, crockery, cutlery, and shower enclosures.
How Water Hardness is Measured
Water hardness is measured in imperial Grains per Gallon (gpg). A grain is the weight of an
average dry grain of wheat, approximately 1/7000th of a pound.
Soft Water 0 - 0.5 gpg
Slightly Hard Water 0.5 - 3.5 gpg
Moderately Hard Water 3.5 - 7.0 gpg
Very Hard Water 7.1 - 10.5 gpg
Extremely Hard Water 10.5 gpg and greater
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Page 16
Water Softening Process
The smallest units that make up chemical compounds and still retain the properties of those
compounds are called molecules. Molecules are made up of atoms or groups of atoms.
Electrically charged atoms are called ions. The charge of a single ion can be either positive
or negative. Ions of metals and minerals are usually positively charged, and are called cat-
ions. Ions such as chlorine, nitrate, phosphate, uoride, and sulfates are negatively charged,
and are called anions.
Certain insoluble materials are made up of large ions forming a skeletal structure contain-ing
oppositely charged ions. These ions can be exchanged with other similar ions in an ion ex-
change.
The rst commercial application of ion exchange was water softening in 1905. Since then, ion
exchange has been the most reliable and cost-effective method of softening and condition-
ing water in homes and industry.
The softening of water by ion exchange relies on the replacement of the calcium and mag-
nesium ions in the water by an equivalent number of sodium ions.
The softening process may be illustrated by the following equation:
R2.Na + Ca(HCO3)2 = R2.Ca+ 2NaHCO3
Sodium Ion Exchange
Resin
Calcium Bicarbonate in
Water
Calcium Ion Exchange
Resin
Sodium Bicarbonate in
Water
Obviously, the system can only exchange a certain amount of hardness and other contami-
nants before becoming exhausted. This is referred to as the capacity of the resin. The capac-
ity of the resin is referred to as grains of calcium carbonate hardness removed per cubic foot
of resin or Milliequivalents per liter. When the capacity has been exhausted, the resin needs
to be regenerated with a solution of sodium chloride (brine) as follows:
R2.Ca + 2NaCl = 2 R.Na + CaCl2
Calcium Ion Exchange
Resin Sodium Chloride Brine Sodium Ion Exchange Resin
Calcium Chloride Wa-
ter
Ion exchange resins used in your Crusader Water Quality Management System are made
without harmful toxic solvents. This media is designed to be physically and chemically strong
while producing water that feels good, tastes great, and works hard for you.
Your Crusader Water Quality Management System can be regenerated with
Potassium Chloride salt if desired.
Crusader Pro, Deluxe, & Enhanced Systems Owner’s Manual 2020

Page 17
Warnings & System Operational Requirements
The Crusader Water Quality Management System incorporates cutting-edge technology to
bring you water that is perfectly soft and free of inorganic minerals.
Your system is designed to address certain impurities in your water through the process of
salt-based ion exchange.
Your system should only be installed on water that is microbiologically safe. To ensure best
performance, and maintain warranty compliance, the following installation re-quirements
should be met:
Minimum Maximum
Water Temperature 30 F 75 F
Water Pressure 30 psi 75 psi
Inuent Water Hardness 0 gpg 100 gpg*
Inuent pH 6.7 8.7
Inuent TDS 10 ppm 1000 ppm*
Pathogenic Bacteria N/A 0 CFU
Chlorine 0 ppm 3 ppm
Chloramine 0 ppm 1 ppm
Ambient Temperature 40 F 120 F
* Inuent water hardness levels above 22gpg and TDS above 500ppm will negatively impact the taste of the water
Do not use with water that is unsafe or of unknown quality.
Test water periodically to verify that the system is performing satisfactorily.
Discard small parts remaining after installation.
Read and follow the information in this manual to minimize the risk of electric
shock or personal injury.
If you are unsure about the installation of your system, contact technical sup-
port, a professional plumber, or certied water specialist.
This system must be installed in compliance with applicable state and local
codes, applicable law, and regulations.
To bypass the system, turn bypass knob on both sides of the valve to bypass
position. When returning to service, put the inlet into service before the outlet.
Crusader Pro, Deluxe, & Enhanced Systems Owner’s Manual 2020

Page 18
System Installation & Startup Guidelines
1. Clear the installation area and carefully sweep the oor where the system will be installed.
2. Test incoming water pressure and make sure it is 30 - 75 psi static. A code-compliant pres-
sure regulator must be installed to protect the system on all municipal water installations.
3. Check to conrm that the water heater has adequate heat expansion protection.
4. Install the system, drain, and brine tank overow according to the manufacturer’s instruc-
tions and prevailing local code.
5. Bypass the system.
6. Run bathtub cold to purge piping of debris and chemical residue from installation.
This will take approximately 5 minutes at 3 gpm.
7. Leave bathtub running and slowly open the inlet valve to the system.
8. Slowly open the outlet valve from the system.
9. Observe ow of water from the bathtub. Water will become a dark brown/black color.
This color is caused by the system disinfectant/preservative as well as dust from shipping
and handling. Allow water to run until clear. Observe water for particles. If resin or other
softening media particles are found in the water, bypass the system and call tech-sup-
port. Leave bathtub running.
10. Enter programming mode:
•Program the system to match the installation conguration and operating condi-
tions.
•Begin a cleaning cycle by pressing and holding the REGEN button for at least 5
seconds.
•Advance the system through each cycle step by pressing the REGEN button.
•Observe the system during each cycle and then progressively advance to the
next until the regeneration terminates.
11. Once the system has been advanced to normal operating mode, observe the ow of
water from the bathtub again for any sign of disinfectant or resin. Allow water to run clear.
Turn bathtub off.
Crusader Pro, Deluxe, & Enhanced Systems Owner’s Manual 2020

Page 
Crusader Pro, Deluxe, & Enhanced Systems Owner’s Manual 2020

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Crusader Pro, Deluxe, & Enhanced Systems Owner’s Manual 2020