US Water Systems FSF-150 User manual

US Water Systems Fusion
Superfilters
Chemsorb, Calcite,
Carbon, Bone Char and
Katalox-Light
REVISION # 1.2
REVISION DATE October 23, 2014
1. Read all instructions carefully before operation.
2. Avoid pinched o-rings during installation by applying (provided with install kit) NSF
certified lubricant to all seals.
3. This system is not intended for treating water that is microbiologically unsafe or of
unknown quality without adequate disinfection before or after the system.
US Water Systems
1209 Country Club Road
Indianapolis, IN 46234
1-800-608-8792
WWW.USWATERSYSTEMS.COM
Owners Manual

2
Safety Guide
 Check and comply with your provincial /
state and local codes. You must follow
these guidelines.
 Use care when handling the filter tank. Do
not turn upside down, drop, drag or set on
sharp protrusions.
 The system works on 12 volt-60 Hz electri-
cal power only. Be sure to use only the in-
cluded transformer.
 Transformer must be plugged into an in-
door 120 volt, grounded outlet only.
 WARNING: This system is not intend-
ed for treating water that is microbiologi-
cally unsafe or of unknown quality without
adequate disinfection before or after the
system.
For your safety, the information in this manual must be followed to minimize the risk of elec-
tric shock, property damage or personal injury.
Be sure to check the entire unit for any shipping damage or missing parts. Also note damage
to the shipping cartons. Contact US Water Systems at 1-800-608-8792 for all damage and
loss claims. A damage claim must be made within 24 hours of receipt of the unit or the claim
may not be honored.
Small parts, needed to install the softener, are in a parts bag. To avoid loss of the small
parts, keep them in the parts bag until you are ready to use them.
Unpacking / Inspection
PAGE
Unpacking / Inspection 2
Safety Guide 2
Proper Installation 3
Specification 4
Before Starting Installation 6
Sizing Requirements 6
Filter Preparation 8
Installation Instructions 11
System Start Up 15
Programming Instructions 16
About The System 17
Maintenance 18
Main Repair Parts 19
Trouble Shooting 26
Pressure Gauge Installation Drawing 27
Warranty 28
Table of Contents

3
Proper Installation
This water filter system must be properly installed and located in accordance with the
Installation Instructions before it is used.
 Do not install or store where it will not be
exposed to temperatures below freezing or
exposed to any type of weather. Water
freezing in the system will break it. Do not
attempt to treat water over 100°F.
 Do not install in direct sunlight. Excessive
sun or heat may cause distortion or other
damage to non-metallic parts.
 Properly ground to conform with all gov-
erning codes and ordinances.
 Use only lead-free solder and flux for all
sweat-solder connections, as required by
state and federal codes.
 Maximum allowable inlet water pressure is
125 psi. If daytime pressure is over 80 psi,
night time pressure may exceed the maxi-
mum. Use a pressure reducing valve to
reduce the flow if necessary.
 WARNING: Discard all unused parts and
packaging material after installation. Small
parts remaining after the installation could
be a choke hazard.
Overall
System
Inlet-Outlet
Connection
Height
C
Tank
BA
Model Tank Size ABC
FSF-150 10” X 54” 60.25” 57.25” 10”
FSF-200 12” X 52” 58.25” 55.25” 12”
FSF-250 13” X 54” 60.25” 57.25” 13”
FSF-300 14” x 65” 72.25” 68.25” 14”
FSF-400 16” x 65” 72.25” 68.25” 16”
FSF-500 18” x 65” 72.25” 68.25” 16”

4
Specifications

5
Specifications
 Continuous operation at flow rates greater than the ser-
vice flow rate may affect capacity and efficiency perfor-
mance.
 The manufacturer reserves the right to make product
improvements which may deviate from the specifications
and descriptions stated herein, without obligation to
change previously manufactured products or to note the
change.
 Peak flow rates are intended for intermittent use only and
are for residential application only
 At the stated service flow rates, the pressure drop
through these devices will not exceed 15 psig

6
Before Starting Installation
Tools, Pipe, and Fittings, Other Materials
 Pliers
 Screwdriver
 Teflon tape
 Razor knife
 Two adjustable wrenches
 Additional tools may be required if modifi-
cation to home plumbing is required.
 Plastic inlet and outlet fittings are included
with the filter. To maintain full valve flow,
3/4” or 1” pipes to and from the filter fittings
are recommended. It is important to main-
tain the same, or larger, pipe size as the
water supply pipe, up to the softener inlet
and outlet.
 Use copper, brass, or PEX pipe and fit-
tings.
 Some codes may also allow PVC plastic
pipe.
 ALWAYS install the included bypass valve,
or 3 shut-off valves. Bypass valves let you
turn off water to the filter for repairs if
needed, but still have water in the house
pipes.
 5/8” OD drain line is needed for the valve
drain.
Sizing Requirements
Water Pressure
The water system must have a pump large enough to deliver the recommended backwash
rate with a minimum pressure at the inlet of the filter of 30 psi. If the existing system cannot
do this, it must be upgraded to do so. Whenever possible, the water system should be ad-
justed to deliver at least 30 psi for even more satisfactory results.
Backwash Flow Rates
The most important criteria in sizing a filter is the capacity of the pump. The water must pass
through the filter media at the proper service flow rate. The filter must also be backwashed
at a flow rate sufficient to dislodge and remove the captured particles. Failure to provide
sufficient water will cause a build-up of particles in the filter media, impairing its ability. In
order for your filter to backwash and rinse properly, your pump must be capable of providing
the backwash flow rates indicated on page 4 & 5.

7
 Place the filter tank as close as possible to
the pressure tank (well system) or water
meter (city water).
 Place the filter tank as close as possible to
a floor drain, or other acceptable drain
point (laundry tub, sump, standpipe, etc.).
 Connect the filter to the main water supply
pipe BEFORE the water heater. DO NOT
RUN HOT WATER THROUGH THE FIL-
TER. Temperature of water passing
through the filter must be less than 100
deg. F.
 Do not install the filter in a place where it
could freeze. Damage caused by freez-
ing is not covered by the warranty.
 Put the filter in a place water damage is
least likely to occur if a leak develops. The
manufacturer will not repair or pay for wa-
ter damage.
 A 120 volt electric outlet, to plug the includ-
ed transformer into, is needed within 6 feet
of the filter. The transformer has an at-
tached 6 foot power cable. Be sure the
electric outlet and transformer are in an
inside location, to protect from wet
weather.
 If installing in an outside location, you must
take the steps necessary to assure the fil-
ter, installation plumbing, wiring, etc., are
as well protected from the elements, con-
tamination, vandalism, etc., as when in-
stalled indoors.
 Keep the filter out of direct sunlight.
The sun’s heat may soften and distort
plastic parts.
Where To Install The Filter

8
Filter Preparation
Fusion Backwashing Filter Tank Installation Instructions
WATER PRESSURE: A minimum of 20 pounds of water pressure is required for regeneration valve to oper-
ate effectively.
ELECTRICAL FACILITIES: An uninterrupted alternating current (A/C) supply is required. Note: Other volt-
ages are available. Please make sure your voltage supply is compatible with your unit before installation.
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.
LOCATION OF FUSION NLT TANK AND DRAIN: The Infusion tank should be located close to a drain to
prevent air breaks and back flow.
CAUTION: Water pressure is not to exceed 80 psi, water temperature is not to exceed 110°F (43°C), and
the unit cannot be subjected to freezing conditions.
Media Installation
1) Remove the tank from carton.
2) Verify the riser tube is centered in the bottom center of the tank. A flashlight may be
necessary. The distributor tube will be flush with the top of the tank when it is cen-
tered.

9
Filter Preparation
3) Place a piece of duct tape over the riser tube so no media enters the riser while filling.
4) Use the Blue Funnel provided, to pour the gravel and media into the tank. Pour the grav-
el into the tank first, then the media. Pour the gravel and media evenly around the hole to
ensure it is well distributed in the tank and pour slow enough, to keep from plugging the
hole. A helper may be needed to hold the funnel during the filling process. It is recom-
mended that a dust mask and safety goggles be worn to prevent possible injury. A shop
vacuum can be used to capture dust during the filling procedure. Pour all the gravel and all
the media shipped with the unit into the tank. US Water does not send extra/unused me-
dia.
5) When media is installed move tank side to side to settle the media. Remove the funnel
and tape from the distributor tube.

10
Filter Preparation
6) Lubricate the distributor O-ring and the tank O-ring on the bottom of the control valve.
Then install the upper basket on the bottom of the valve by lining up the tabs then turning
the basket clockwise to lock it in place. Place the upper basket over the distributor tube
and push the valve on the tank. Thread the valve on the tank by turning it clockwise. Be
sure not to cross-thread the valve on the tank. Tighten the valve hand tight, then snug it
further by tapping it with the palm of the hand. DO NOT use tools to tighten the valve or
damage could occur.

11
Installation Instructions
1. If your hot water tank is electric, turn off the power to it to avoid damage to the element in
the tank.
2. If you have a private well, turn the power off to the pump and then shut off the main water
shut off valve. If you have municipal water, simply shut off the main valve. Go to the fau-
cet, (preferably on the lowest floor of the house) turn on the cold water until all pressure is
relieved and the flow of water stops.
3. Locate the filter tank close to a drain where the system will be installed. The surface
should be clean and level.
4. Connect the inlet and outlet of the filter using appropriate fittings. Perform all plumbing
according to local plumbing codes. Pressure gauges should be added in some applica-
tions. There is a drawing on page 27 that shows gauge location.
 ON COPPER PLUMBING SYSTEMS BE SURE TO INSTALL A GROUNDING
WIRE BETWEEN THE INLET AND OUTLET PIPING TO MAINTAIN GROUNDING
WHEN APPLICABLE.
Any solder joints being soldered near the valve must be done before connecting any piping
to the valve. Always leave at least 6" (152 mm) between the control valve and joints being
soldered when soldering pipes that are connected to the valve. Failure to do this could
cause damage to the valve.
The Fusion Backwashing Filter is equipped with 1” removable connectors. It is recommend-
ed that these connectors are installed in the plumbing fitting using Teflon tape then lubricate
the o-ring on the connector. Remove the red clips and push the connectors into the bypass
valve once they are tight in the plumbing fitting. The red clips can then be re-installed to se-
cure the connectors in the bypass valve.
The inlet and outlet can be identified on the bypass valve. There are arrows stamped in the
bypass valve showing flow (See page 18 diagram). The arrow pointing toward the valve is
the inlet and the arrow pointing away from the valve is the outlet.
All piping should be secured to prevent stress on the bypass valve and connectors.

12
Hose barb fitting for drain line.
Be sure to use a hose clamp to
secure the line.
5. Connect the drain hose to the filter valve and secure it with a hose clamp. Run the drain
hose to the nearest laundry tub or floor drain. This can be ran overhead or down along the
floor. Drain hose should be a minimum of 1/2”. If running the drain line more than 20 ft
overhead, it is recommended to increase the hose size to 3/4”. A DIRECT CONNECTION
INTO A WASTE DRAIN IS NOT RECOMMENDED. A PHYSICAL AIR GAP OF AT LEAST
1.5” SHOULD BE USED TO AVOID BACTERIA AND WASTEWATER TRAVELING BACK
THROUGH THE DRAIN LINE INTO THE FILTER.
Be sure to secure the drain line. The softener will drain with force and it should be
secured to prevent a leak. Hose clamps should be used to secure the drain line at the
connection points.
Installation Instructions

13
Installation Instructions
6. Using the Allen Key (included), place the unit in the bypass position (See page 18 for by-
pass valve handle placement). Slowly turn on the main water supply. At the nearest cold
treated water tap nearby remove the faucet screen, open the faucet and let water run a few
minutes or until the system is free of any air or foreign material resulting from the plumbing
work.
7. Make sure there are no leaks in the plumbing system before proceeding. Close the water
tap when water runs clean.
8. Proceed to start up instructions.
Note: The unit is not ready for service until you complete the start-up instructions.

14
Filter Installation

15
System Start-Up
1. Plug the valve into an approved power source.
2. When power is supplied to the control, the screen will display “INITIALIZING WAIT
PLEASE” while it finds the service position.
3. Start an Immediate Manual Regeneration. The valve will immediately start moving to the
BACKWASH position.
4. Partially open the inlet on the bypass valve slowly and allow water to enter the unit. Allow
all air to escape from the unit before turning the water on fully then allow water to run to
drain for 3-4 minutes or until all media fines are washed out of the softener indicated by
clear water in the drain hose.
KATALOX SYSTEMS SHOULD BE BACKWASHED FOR A MINIMUM OF 1 HOUR. IN
SOME CASES ADDITIONAL RINSING MAY BE NEEDED. For Katalox filters, when the
valve is in the backwash position, unplug the power cord for the valve. This will keep the
unit in the backwash cycle. Allow the system to backwash for 1 hour, then plug the power
cord back in and go to step 5. All other media types can use the general backwash in Step
4.
5. Press any button to advance to the RINSE position. Slowly open the bypass inlet valve
during the rinse cycle until it is fully opened. Check the drain line flow. Allow the water to
run for 3-4 minutes or until the water is clear.
6. The valve will automatically advance to the SERVICE position after the RINSE cycle is
complete. Open the outlet valve on the bypass, then open the nearest treated water fau-
cet and allow the water to run until clear, close the tap and replace the faucet screen.
7. Program time, date, and number of days between regenerations into controller using the
following Programming Instructions
Start-up Instructions
Key Pad Configuration
SET-
TINGS
This function is to enter the basic set up
information required at the time of installa-
tion.
MANUAL
REGEN
This function is to initiate an immediate or
delayed manual regeneration.
DOWN /
UP
Increase or decrease the value of the set-
tings while in the programming mode.
DELAYED REGENERATION
Press and release the MANUAL REGEN.
Button to set a delayed regeneration that will
occur at the regeneration time. The main dis-
play page will show DELAYED REGEN ON.
To cancel press and release the MANUAL
REGEN. Button. The main display page will
show DELAYED REGEN OFF.
IMMEDIATE REGENERATION
To start an immediate regeneration (or step
valve through each position), press and hold
the MANUAL REGEN. Button for 3 seconds
(until beeps). The valve will start an immedi-
ate regeneration. Press any key to skip to
the next cycle.
Manual Regeneration (Step / Cycle Valve)

16
Backwash Frequency
Programming Instructions
TIME OF DAY, YEAR, MONTH, DAY,
Time of day is for normal operation of system and the scheduling of the re-
generation time. The date is used in a diagnostic function to track the last
time the system regenerated.
REGEN DAYS
This value is the number of days between regenerations or back washes to
clean the filters.
GALLONS
Default value is OFF. This should not be changed.
REGEN TIME
This setting determines the time of day to perform a scheduled regenera-
tion. The normal regen time for a filter is 12:00 AM.
Settings
Press SETINGS key (3 SECONDS / BEEP)
VALVE MODE
B.W. FILTER
TIME OF DAY
12:01 PM
YEAR
2012
MONTH
AUGUST
DAY
21
REGEN DAYS
3 DAYS
GALLONS
OFF
REGEN TIME
12:00 AM
PROGRAMMING
COMPLETE
Contact US Water Systems at 1-800-608-8792 to help with the backwash frequency setting.
This can be adjusted by the home owner to suite their individual needs with frequencies
available from 1 – 99 days.

17
Control Operation During A Power Failure
In the event of a power failure, the valve will keep track of the time and day for 48 hours.
The programmed settings are stored in a non-volatile memory and will not be lost during a
power failure. If power fails while the unit is in regeneration, the valve will finish regenera-
tion from the point it is at once power is restored. If the valve misses a scheduled regenera-
tion due to a power failure, it will queue a regeneration at the next regeneration time once
power is restored.
Main Display
About The System
Periodically the filter will require a back wash to clean the trapped particles and unpack the
filter bed to restore the system flow rates. The table below explains the regeneration steps.
Regeneration Process
Step Name
Description
#1 Back Wash
Fresh water is introduced to the bottom of the tank flowing upwards expanding
the filter media to rinse out any dirt or small particles to the drain and to un-
compact the bed to restore full service flow rates.
#2 Rinse
Fresh water is introduced from the top of the tank flowing down through the
filter bed rinsing any unfiltered water to the drain.
The main display page will pause on the Date and Time page for 5 seconds. Then it will
continually scroll through all of the system diagnostic display pages. Depending on the
Valve Type some pages will not be displayed. To manually scroll through the diagnostics,
press the down or up key. To reset the TOTAL REGENS, TOTAL GALLONS OVER RUN
TOTAL, or PEAK flow rates, press and hold the MENU until the value changes to zero.
PARAMETER DESCRIPTION
JULY/17/2012
8:30 PM
TOTAL 1,500 GAL
REMAIN 1,200 GAL
LAST REGEN
9/24/12
TOTAL REGENS
10
TOTAL GALLONS
001590 GAL
TOTAL 4 DAYS
REMAIN 3 DAYS
OVER RUN TOTAL
0000 GAL
CURRENT 1.5 GPM
PEAK 6.5 GPM
DELAYED REGEN
OFF
REGEN TIME
12:00 AM
VALVE MODE
B.W. FILTER
The current setting for regeneration time.
The current setting of the valve mode.
The total number of regenerations.
The total amount of gallons treated by the system.
The total amount of water that has exceeded the system capacity over the last 4
regenerations. When remaining goes to zero, the gallons used will be added to over run total.
The current flow rate and the peak flow rate since the last regeneration.
Advises whether a delayed regeneration has been scheduled manually or automatically.
Month, Day, Year, Time
The number of days remaining before regeneration. This option is only in filter mode.
The total amount is the system capacity when fully regenerated. The remaining is the
capacity left in the system.
The date of the last regeneration.

18
Automatic Raw Water Bypass During Regeneration
The regeneration cycle can last 30 minutes after which filtered water service will be restored.
During regeneration, un-filtered water is automatically bypassed for use in the household.
Hot water should be used as little as possible during this time to prevent un-filtered water
from filling the water heater. This is why automatic regeneration is set for sometime during
the night and manual regenerations should be performed when little or no water will be used
in the household.
Normal regeneration time is 2:00 AM.
New Sounds
You may notice new sounds as your filter operates. The regeneration cycle lasts up to 30
minutes. During this time, you may hear water running intermittently to the drain.
Manual Bypass
In the case of emergency you can isolate your water filter from the water supply using the
bypass valve located at the back of the control. In normal operation the bypass is open with
the on/off knobs in line with the inlet and outlet pipes.
To isolate the filter, simply rotate the knobs clockwise (as indicated by the word BYPASS
and arrow) until they lock. You can use your water related fixtures and appliances as the wa-
ter supply is bypassing the filter. However, the water you use will be hard. To resume water
service, open bypass valve by rotating the knobs counterclockwise.
Maintenance
Maintenance of your new water filter requires very little time or effort but it is essential. Reg-
ular maintenance will ensure many years of efficient and trouble-free operation.
1. Periodically make sure your pump is performing satisfactorily to ensure sufficient water is
available for backwashing the filter.
2. Periodically test your raw and filtered water to ensure conditions are still the same for
your original settings and that the unit is working they way it is intended to. Water testing
is often the best way to determine when the filter media will require replacement.
3. Periodically check that the drain line is clear and free from any obstructions.

19
Main Repair Parts
Replacement Part Number Part Description DWG # Quantity
60010052 POWER TRANSFORMER 120V-12V A 1
60010002 BYPASS / METER B 1
10010063 485 UP DOWN FLOW FILTER VALVE C 1
60010048 TOP CONE D 1
25020041 844 TANK (75) E 1
25020042 948 TANK (100) E 1
25020043 1054 TANK (150) E 1
25010058 1252 TANK (200) E 1
25030007 1465 TANK (300) E 1
50010005 DISTRIBUTOR 1X54 F 1
REPLACEMENT PARTS - FILTER
Replacing Drain Line Flow Control (DLFC)
1. Remove the red clip that secures the drain line elbow.
2. Remove the BLFC washer from the elbow fitting.
3. Reassemble using the reverse procedure.

20
Filter Exploded View