US Water Systems Fusion User manual

Owners Manual
US Water Systems Corporate Office
1209 Country Club Road
Indianapolis, IN 46234
[e-mail]
www.uswatersystems.com
1-800-608-8792
Visit us online at
www.uswatersystems.com
REVISION # 1.1
REVISION DATE June 27, 2017
US Water Systems 1” Fusion NLT Water
Softener

2
Safety Guide
For general safety, the information in this manual must be followed to minimize the risk of
electric shock, property damage or personal injury.
 Check and comply with the provincial /
state and local codes. These guidelines
must be followed.
 Use care when handling the softener 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.
 Use 99.8% pure Solar Salt. Extra-coarse
grade or crystals are best but pellets will
work too.
 Potassium Chloride my be used in lieu of
Sodium Chloride but be sure no one in the
household has a medical problem that
could be aggravated by a potassium in-
take.
 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.
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 they are ready to be used.
Unpacking / Inspection
PAGE
Unpacking / Inspection 2
Safety Guide 2
Proper Installation 3
Specification 4
Before Starting Installation 4
Tank Preparation 6
Installation Instructions 8
Programming 19
Manual Regeneration Steps 21
System Start Up 22
Maintenance 23
Main Repair Parts 24
Warranty 28
Table of Contents
Installation, Operation and Maintenance Manual

3
Proper Installation
Installation, Operation and Maintenance Manual
This water softening system must be properly installed and located in accordance with the
Installation Instructions before it is used or the warranty will be void.
 Do not install or store where it will 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. Exces-
sive 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 pressure.
 Softener resins may degrade in the pres-
ence of chlorine or chloramines above 2
ppm. If you have chlorine or chloramines
in excess of this amount, you may experi-
ence reduced life of the resin. In these
conditions, you may wish to consider pur-
chasing a whole house carbon filter soften-
er system with a chlorine reducing media.
Contact US Water Systems for Chlorine
and Chloramine removal equipment.
 WARNING: Discard all unused parts
and packaging material after installation.
Small parts remaining after the installation
could be a choke hazard.

4
Specifications
Installation, Operation and Maintenance Manual
Before Starting Installation
Tools, Pipe, and Fittings, Other Materials
 Channel Locks
 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 softener. To maintain full valve
flow, 1” pipes to and from the softener fit-
tings are recommended. You should 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 softener for repairs if
needed, but still have water in the house
pipes.
 5/8” OD drain line is needed for the valve
drain.
 A length of 5/8” OD drain line tubing is
needed for the brine tank over flow fitting
(optional).
 Extra Course Grade or Crystal water sof-
tener
 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 service pressure
drop through these devices should not exceed 15 psig

5
How the Softener Works
The principle behind water softening is simple chemistry. A water softener contains resin
beads which hold electrically charged ions. When hard water passes through the softener,
calcium and magnesium ions are attracted to the charged resin beads. The result is remov-
al of calcium and magnesium ions which produces soft water.
This system is controlled with simple, user-friendly electronics displayed on a LCD screen.
The main page displays the current time and the remaining gallons in meter mode or the re-
maining days in calendar clock mode. The system will also scroll through other pertinent
information.
Installation, Operation and Maintenance Manual
Where To Install The Softener
 Place the softener as close as possible to
the pressure tank (well system) or water
meter (city water).
 Place the softener as close as possible to
a floor drain, or other acceptable drain
point (laundry tub, sump, standpipe, etc.).
 Connect the softener to the main water
supply pipe BEFORE the water heater.
DO NOT RUN HOT WATER THROUGH
THE SOFTENER. Temperature of water
passing through the softener must be less
than 100 deg. F.
 Outside faucets and irrigation systems
should be supplied with hard water prior to
the water softener.
 Do not install the softener in a place where
it could freeze. Damage caused by freez-
ing is not covered by the warranty.
 Put the softener in a place water damage
is least likely to occur if a leak develops.
The manufacturer will not repair or pay for
water damage.
 A 120 volt electric outlet is needed within 6
feet of the softener. The transformer has
an attached 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 sof-
tener, installation plumbing, wiring, etc. are
protected from the elements and contami-
nation sources.
 Keep the softener out of direct sunlight.
The sun’s heat may soften and distort
plastic parts.

6
1. Remove the tank from carton.
2. Verify the distributor tube is centered
in the bottom of the tank. A flashlight
may be necessary. There is a small
indentation in the bottom of the tank
that will allow the distributor tube to
drop in place. The top of the distribu-
tor tube will be flush with the top of the
tank when it is installed correctly.
Fusion NLT Softener Tank Preparation
WATER PRESSURE: A minimum of 30 pounds of water pressure is required for regeneration valve to
operate effectively.
ELECTRICAL FACILITIES: An uninterrupted alternating current (A/C) supply is required. Note: Other
voltages are available. Please make sure the voltage supply is compatible with the unit before instal-
lation.
EXISTING PLUMBING: Condition of existing plumbing should be free from lime and iron buildup. Pip-
ing that is built up heavily with lime and/or iron should be replaced.
LOCATION OF FUSION TANK AND DRAIN: The Fusion tank should be located close to a drain to pre-
vent air breaks and back flow.
BY-PASS VALVES: Always provide for the installation of a by-pass valve if unit is not equipped with
one.
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.
Installation, Operation and Maintenance Manual

7
3. Place a piece of duct tape over the distributor tube so no gravel or media enters the
opening while filling.
4. Use the Blue Funnel provided, to pour the RESIN in the tank. Pour resin evenly around
the hole to ensure it is well distributed in the tank. Pour it slow enough, to prevent the
funnel from plugging. A helper may be needed to hold the funnel during the filling pro-
cess. It is recommended that a dust mask and safety goggles be worn to prevent possi-
ble injury. A shop vacuum can be held in the area to help control the dust created by the
filling process. Pour all the resin that was shipped in the tank. US Water Systems
DOES NOT ship extra resin.
5. When the resin is installed move tank side to side to settle the media. Remove the fun-
nel and tape from the distributor tube. It is a good practice to fill the tank with water and
allow the media to saturate.
Installation, Operation and Maintenance Manual

8
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 on the pipe connection side of the valve.
DO NOT use tools to tighten the valve or damage could occur.
Installation, Operation and Maintenance Manual

9
7. Lubricate the O-rings on the bypass valve and 1” threaded connectors. Remove the red
clips and install the bypass on the control valve. Re-install the red clips once the bypass
is in place. Put the bypass valves in the bypass position (picture shows “Service Posi-
tion”, see page 18 for valve position)
8. Apply Teflon tape to the 1” connectors. Remove the red clips from the previously in-
stalled bypass and install the 1” connectors in the bypass valve. Re-install the red clips
for the 1” connectors.
Installation, Operation and Maintenance Manual

10
Note: As the picture shows, connect the inlet and outlet according to
the arrow direction which can be seen from the top view of the control
valve.
The installation of 1“ integrated bypass valve：
If the 1” integrated bypass is used instead of a three manual valve, the instal-
lation method is shown in the picture below.
Installation, Operation and Maintenance Manual

11
9. Install the Fusion system close to the water source. BE SURE to install the Fusion sys-
tem directly after the well pressure tank. It is a good practice to add a sediment filter pri-
or to the Fusion system between the pressure tank and the Fusion tank. Outside spigots
or irrigation should be plumbed in prior to the Fusion system. Shut off the main water
supply and relieve the pressure on the plumbing system.
10.Install the inlet plumbing on the inlet side of the control valve and the outlet plumbing on
the outlet of the control valve. The inlet and outlet can be identified by the arrows on the
control valve. The arrow pointing toward the control valve is the inlet. The arrow point-
ing away from the control valve is the outlet. (Optional flexible connectors shown utilize
rubber washer seals and do not require Teflon tape).
NOTE: The Fusion system is equipped with a bypass valve. If a 3 valve bypass in the
plumbing system is in place or preferred, the supplied bypass is not required.
Installation, Operation and Maintenance Manual

12
11.Install the drain line on the 3/4” threaded elbow. This can be a 3/4” solid pipe conveyed
to a floor drain, sink drain or stand pipe or the hose barb fitting can be used to install 1/2”
drain tubing. An air gap should be established if the local code requires it. Drain line
larger than 3/4” is acceptable. The system will drain with pressure, so the drain line can
be ran vertically for up to 5’. If the drain line is ran vertically then along the wall horizon-
tally, make sure the horizontal pipe/tubing has a drop to the final drain point (1” drop per
10’ of linear run). The system should be plumbed with the least amount of back pressure
on the drain line.
12.The drain elbow can be removed by removing the red clip and pulling the elbow out of
the valve. This will make it easer to connect the plumbing fitting used. BE CAREFUL
not to cross thread the fitting on the elbow. There is a small thread tolerance for this fit-
ting to help reduce the potential for a leak so it can be cross threaded easily.
NOTE: It may be necessary to install a 3/4” drain line on a linear stretch of drain line
that exceeds 15’.
Installation, Operation and Maintenance Manual

13
Installation, Operation and Maintenance Manual
13. Connect the brine line to the control valve by removing the nut on the brine elbow on
the control valve and sliding it on the brine line. Then install the line stiffener in the
brine line. There is a brass stiffener pre-installed in the line.
14. Push the brine line in the elbow fitting on the control valve until it stops. Then push
the nut down on the fitting and tighten it hand tight. Use channel locks to tighten the
nut an additional 1/2 turn.
Installation Instructions

14
Installation, Operation and Maintenance Manual
15. Connect the brine line to the control valve by pushing it over the hose barb and in-
stalling a clamp to hold it in place.
16. Now connect the brine line to the brine tank safety float assembly. Remove the brine
tank lid and the brine well cap. Then push the brine line through the brine tank and
brine well.
Installation Instructions

15
Installation, Operation and Maintenance Manual
17. Slide the nut and sleeves over the brine line. Be sure to install the sleeves properly
(see pictures below).
Installation Instructions

16
Installation, Operation and Maintenance Manual
Installation Instructions

17
Installation, Operation and Maintenance Manual
18. Be sure brass stiffener is in the brine tubing, then push the tubing in the elbow. Now
tighten the nut by hand. Be sure not to cross thread it. Now tighten it an additional
full turn with pliers or channel locks.
Installation Instructions
1. When the two knobs on the bypass valve are parallel, the inlet and outlet
are open, this state of operation is “Service”；
2. Rotate each of the two knobs in clockwise and counterclockwise respec-
tively, when the knobs on the bypass is in one line, the inlet and outlet are
both closed, this state of operation is “By-pass”.

18
Programming Levels
There are 3 levels to the valve program. Master options and Factory options are typically adjusted at the facto-
ry. These options link the PCB function with the type of control valve and should not be tampered with. Ad-
vanced options are used to configure the unit when the valve is assembled to the tank so that it can function as
the proper size and intended system operation. Settings are the final options chosen when the unit is installed
to a specific location.
Button Configuration
Key Pad Configuration
MENU This function is to enter the basic set up information required at the time of installation.
SET This function is to accept the values if changed and advance to the next page in the menu.
+ / - These buttons are used to increase or decrease the value of the settings while in the pro-
gramming mode.
The main display page shows the Date, Time Of Day and Days To Remaining and Total Capacity. The display
will alternate between the main page and the dealer information page.
PROGRAM LEVEL USER ACCESS
USER SETTINGS(I) These settings are programmed when the unit is installed. The settings should only be adjusted
by a qualified person.
MAIN MENU (II) These settings are programmed when the unit is installed. The settings should only be adjusted
by a qualified person.
ADVANCED MENU (II)
These settings are programmed by the factory and should be adjusted when the valve is assem-
bled into a unit or system. It contains important settings so the valve will operate properly for the
type of system it is intended for. The settings should only be changed by qualified person.
HISTORY MENU (IV) This menu contains key diagnostics for trouble shooting the system.
FACTORY MENU (V) These settings are programmed by the factory. The settings are important for the operation of the
valve that should only be changed by a qualified person.
Date & Time:
20-Dec-2015 12:12AM
Days To Regen: 01
+
-
MENU
SET
Installation, Operation and Maintenance Manual
Flow Rate: 00.00GPM
20-Dec-2015 12:12AM
Remain: 01000GAL
Capacity: 01500GAL
US Water Systems
Indianapolis, IN
1-800-608-8792

19
Programming
Main Menu
To get to the “Main Menu”, press the Menu button to get to the “User Menu”.
Use the Down arrow to go to “Main Menu” then press and hold the Set button for 5 seconds. This will take the
valve to the “Main Menu”.
Press MENU key.
Press + or - to change menu option. Press SET to enter.
Press + or - to change value. Press SET to accept.
Installation, Operation and Maintenance Manual
 Date & Time Setting
 Hardness
 Manual Regen.
 Dealer Information
 Main Menu
=====Main Menu=====
 Regen. Time Setting
 Regen. Days Setting
 Advanced Menu
Main Menu
Use the “UP or DOWN” arrows to move the cursor over
“Regen. Time Setting” and press the “Set” button.
Use the UP or DOWN” arrows to change the Time to 2:00 AM or a
least 1 hour after water usage has stopped for the day. Once the
hour value is adjusted, press the “Set” button, then set the minute
value, press the “Set” button again, then set the 12 cycle (AM or PM)
and press the “Set” button to save the value then press the “Menu”
button to confirm the change and return to the “Main Menu”.
Use the “UP or DOWN” arrows to move the cursor over
“Salt Mode Setting” and press the “Set” button.
=====Main Menu=====
 Regen. Time Setting
 System Capacity
 Salt Mode Setting
 Brine Pre-Fill Set
 Advanced Menu
=====Regen. Time=====
2:00 AM
Press [ ] To Cancel ,
Press [ ] To Confirm
=====Main Menu=====
 Regen. Time Setting
 Regen. System Capacity
 Salt Mode Setting
 Brine Pre-fill Set
 Advanced Menu

20
Programming
Installation, Operation and Maintenance Manual
Use the “UP or DOWN” to change the “Mode”. The system is factory set on
“Economy Mode”. This is the mode that is used for city/municipal water
sources. If there is high hardness levels or if the softener is used to remove iron
or other contaminants, the “Standard Mode” should be used. If there are high
levels of several contaminants, the “High Capacity Mode” should be used. Once
the selection is made, press the “Set” button to save it and then press the “Menu”
button to confirm the setting and return to the “Main Menu”. All other settings are
factory adjusted and do not need attention.
Press the “Menu” button again and return to the “User Menu”.
User Settings
Use the “UP or DOWN” arrows to move the cursor over
“Date & Time Setting” and press the “Set” button.
Use the UP or DOWN” arrows to change the day of the month value
then press the “Set” button to save it and move to the month. Once the
month is entered, press the “Set” button to save it and move to the
year. Once the year is entered, press the “Set” button to save it and
move to the hour. Once the hour is entered press the “Set” button to
save it and move to the minutes. Once the minutes are entered, press
the “Set” button to save it and move to the 12 hour cycle selection.
Once AM or PM have been entered, press the “Set” button to save it.
Then press the “Menu” button to confirm all the settings.
Use the “UP or DOWN” arrows to move the cursor over
“Hardness” and press the “Set” button.
Use the “UP or DOWN” arrows to set the hardness level to 5 GPG
above the hardness level for the feed water. If you have iron, take the
iron reading in ppm or mg/L and multiply it by 4 and add that value to
the hardness level plus the 5 GPG cushion. Press the “Set” button to
save it. Press the “Menu” button to return to the main screen.
====Date and Time====
01 - Jan-2016 06:13 PM
Press [ ] To Cancel,
Press [ ] To Confirm!
=====Salt Mode=====
 Economy Mode
 Standard Mode
 High Capacity Mode
 Date & Time Setting
 Hardness
 Manual Regen.
 Dealer Information
 Main Menu
 Date & Time Setting
 Hardness
 Manual Regen.
 Dealer Information
 Main Menu
 Date & Time Setting
 Hardness
 Manual Regen.
 Dealer Information
 Main Menu
====Hardness====
15 GPG
Press [ ] To Cancel,
Press [ ] To Confirm!