US Water Systems Fusion User manual

Fusion, Fusion Hybrid and Prelude Water Softener
Service Manual
IMPORTANT: Fill in Pertinent Information on Page 3 for Future Reference

IMPORTANT PLEASE READ:
The information, specifications and illustrations in this manual are based on the latest information available at the
time of printing. The manufacturer reserves the right to make changes at any time without notice.
This manual is intended as a guide for service of thevalve only. System installation requires information from a number of
suppliers not known at the time of manufacture. This product should be installed by a plumbing professional.
This unit is designedto be installed on potable watersystems only.
This product must be installed in compliance with all state and municipal plumbing and electrical codes. Permits may
be required at the time of installation.
If daytime operating pressure exceeds 80 psi, nighttime pressures may exceed pressure limits. A pressure reducing valve
must be installed.
Do not install the unit where temperatures may drop below 32°F(0°C) or above 125°F (52°C).
Do notplacethe unit in direct sunlight. Black units will absorb radiant heat increasing internal temperatures.
Do not strike the valve or any of the components.
Warranty of this product extends to manufacturing defects. Misapplication of this product may result in failure to
properly condition water, or damage to product.
A prefilter should beused on installations in which free solids are present.
In some applications localmunicipalities treat water with Chloramines. High Chloramine levelsmay damage valve components.
Correct and constant voltage must be supplied to the control valve to maintain proper function.

Job Specification Sheet
Job Number: ________________
Model Number: ______________
Water Test: _________________
Capacity Per Unit: ____________
Mineral Tank Size: _________ Diameter:___________Height:
Brine Tank Size & Salt Setting per Regeneration:_______
9000/9100/9500 Control Valve Specifications:
1.
Type of Timer:
A. 82 minute available regeneration time, 1/15 RPM
B. 164 minute available regeneration time, 1/30 RPM
2.
Type of Meter:
Mechanical Valves (Gallon Settings)
Meter Standard Range
Extended Range
3/4” 125 - 2,125
625 - 10,625
1” 310 - 5,270
1,150 - 26,350
1-1/2” 625 - 10,625
3,125 - 53,125
3.
Timer Gallon Setting:
Gallons
4.
Regeneration Program Setting:
A. Backwash:___________________ Minutes
B. Brine and Slow Rinse: _________ Minutes
C. Rapid Rinse: _________________ Minutes
D. Brine Tank Refill: ______________ Minutes
5. Drain Line Flow Control: __________ gpm
6. Brine Refill Rate:__________________ gpm
7. Injector Size:____________________

General and Commercial Installation Instructions
1. Placethe softener tank where you want to install the unit. NOTE: Be sure the tank is level and on afirm
base. The tank base (black plastic) is a floating base that can be adjusted to meetuneven floors. The
softener should be located close to the incoming water supply. Irrigation and outside water spigots should
beplumbed inprior to the softener. If this cannotbe doneit is recommendedthat the softenerbe in the
bypass position during irrigation or wateringfrom a spigot. Grass and other plants donot likesoft water
and damage to the lawn or landscaping can occur.
2. Check the distributor tube in each tank and make sure they are secured to the tank if the system is using
Vortech tanks. If the system is using standard tanks, the distributor will be loose in the tank with a lower
basket on the tube. For standard tanks make sure the distributor is centered in the tank. There is an
indentation that will center the distributor. The top of the distributor tube will be flush with the tank when it
is installed properly.
3. Now place a piece of duct tape over the distributor tube to prevent media from entering the tube during the
fill process.

4. Place the supplied funnel in the tank with the distributor tube in the middle. It is recommended that a helper
hold the funnel during the fill process. A face shield or eye protectionshould be used during the fill
procedure to preventaninjury.
5. If gravel was shipped with theunit(standard tank large units), pour the gravel in first. Pour the resin in the
tank next. The tank should be 60-80% full when the media is installed. Use all theresin that was shipped
with the unit.
6. During cold weather it is recommended that the installer warm the valve to room temperature
before operating.
7. Perform all plumbing according to local plumbing codes including the drain. —Use a 1/2” minimum
pipe/tube size for the drain. —Use a 3/4” drain line for backwash flow rates that exceed 7 gpm or length
that exceeds 20’ (6 m).

8. The distributor tube must be flush with the top of the tank. Cut if necessary. Remove the duct tape.
Lubricate the tube and nylon seal ring on the tank. Use only non-aerosol food grade silicone
lubricant.

9. Lubricate the distributor o-ring seal and tank o-ring seal on the control valve. Install the upper basket
by pushing in the slotted holes and turn it clockwise until it locks in place.

10.Place the control valve on the tank. Place the valve over the distributor tube through the bottom of
the upper basket. Slide the valve down and thread the valve on the tank by turning it clockwise.
Once the valve is hand tight turn it an additional ¼ turn to snug it to the tank.
11.Attach the plumbing according to local codes.
The inlet and outlet pipes will attach to the 1” female threads on bypass valve. The bypass
valve will be labeled with arrows. The inlet port will have an arrow pointing toward the unit
and the outlet will have an arrow pointing away from the unit. If soldering is necessary it is
recommended that solder joints closer than 6” to the unit be completed prior to screwing the
pipes into the bypass. Excessive heat close to the bypass valve can damage the unit.

12.Solder joints near the drain must be done before connecting the Drain Line Flow Control fitting
(DLFC). Leave at least 6” (152 mm) between the DLFC and solder joints when soldering pipes that
are connected on the DLFC. Failure to do this could cause interior damage to DLFC.
13.Use only Teflon tape on the drain fitting threads. Two wrenches or channel locks may be needed to tighten
the barbed fitting or hard plumbing fitting if tubing is not used. Be sure not to over tighten this fitting.
14. Once the fittings are installed and tight, push the 5/8” drain line on the barb and secure it using a hose
clamp. This tube should be attached to a sanitary drain. An air gap fitting should be installed on the drain
pipe where this tube will be connected (check local codes). If this is being conveyed to a floor drain, sink
or sump pump be sure to maintain a proper air gap. Typically a 1” air gap is sufficient.
15.Be sure the floor under the salt storage tank is clean and level. Any debris can cause a leak when the tank
is weighted down with salt and brine solution.

16.Connect the supplied 3/8” tubing to both brine connections.
17.At the control valve place the nut over the tube, install the brass sleeve in the tube. Install the cone screen
in brass insert. Install the plastic flange over the tube. Install the tube in the control valve and tighten the
nutby turning it clockwise. Tighten it hand tight then snug it an additional ¼ to ½ turn.

18.Remove the white cap from the white tube in the brine tank. Place the other end of the tube through the hole
in the side of the bine tank.

19.Remove the nut from the brine safety valve. BE CAREFUL, not to drop the nut and sleeves (2) in the brine
tube.
20.Place the nut over the tube. Be sure the brass insert is in the tube.

21.Now place the black split ring on the tube with the coned side facing the nut.
22.Now place the white ring on the tube with the shoulder touching the black split ring.

23.Insert the tube in the brine safety valve elbow and tighten the nut by turning it clock wise. Tighten the nut
hand tight and snug it an additional ¼ to ½ turn. Place the white cap back on the white tube.

24.There is a barb fitting on the side of the brine tank. This is used as an overflow and only is used if the brine
tank overfills. This barb is for 5/8” tubing. If you elect to use tubing for this elbow, run it to a floor drain or
sump pump.
25.Place 3-6 bags of salt in the salt tank. The salt tank is full when the salt level is 1” below the white
tube in the brine tank. Pour in 5 gallons of water. The salt should be used then refilled. It is not a
good practice to top off the salt weekly. It is better to use it all then refill it.
26.Place the unit in the Bypass position. There is a pointer on the bypass valve handle. This pointer should be
pointing to “bypass” on the valve. When the bypass valve is in the bypass position the handle will bisect
the plumbing connections.
—Turn on the main water supply.
—Open a cold soft water tap nearbyand let water runa few minutes or until the system is free of foreign
material (usually solder) resulting from the installation. Close the water tap when water runsclean.

27.Slowly place thebypass In Service position and let water flow into the mineral tank. Open the bypass in
small incrementsuntil it is fullyopen. When water flowstops, slowly open a cold water tap nearby and
let water run until air is purged from the unit. Preferably a garden spigot or bath tube. Then close tap
once the water runs clear and there is no air in the system. The bypass valve pointer shouldbe pointing
toward “service” and the handle should be in line with the plumbing connections.
Electrical
28. Make all electrical connections according to codes. Plug the valve into an approved power source.
29. The valve position will be displayed on the control panel. If the unit is in the regeneration process the cycle
will be shown on the screen. When the system is in the service position it will display the time of dayand
flash to the amount of gallons that are remaining before a regeneration of the tank inservice is required.

TIMER FEATURES
1. When in the service mode the service icon will be illuminated. If a delayed regeneration is initiated the
service icon will blink.
2. The flow indicator icon will blink when water is being used.
3. When setting the time of day and delayed regeneration time, be sure the clock is in the correct 12 hour
time cycle. When you are in the PM time cycle the PM icon will be illuminated. If it is not illuminated
the clock is in the AM time cycle.
4. When the display is in the service mode it will flash from the time of day to the remaining capacity
before regeneration (in gallons).
5. When water is being used and the flow icon is blinking (water drip on right hand side of display) the
remaining capacity value will decrease for each gallon used.
6. The service icon will be illuminated during programming or regeneration.
7. The extra cycle button serves as an enter/return button when programming. The up and down arrows
allow value changes in each parameter programming mode. Once the value is reached the extra cycle
button can be pushed to save the value and move to the next parameter.
8. The extra cycle button also initiates immediate or delayed regenerations. Pushing and releasing it
immediately triggers a delayed regeneration (will regenerate at the time specified under RT in the
programming mode). The service icon will blink when a delayed regeneration is initiated. Pushing and
holding the extra cycle button for 5 seconds will initiate an immediate regeneration. The service icon
will blink and the valve will move to the first regeneration position and begin the process.
Parameter Data PM
Display Display Indicator
Error/
Information
Icon
S e r v i c e
Icon
Flow Indicator
x1000 Indicator
Extra Cycle
Button
Up
Button
Dow n
Button

9. If the error icon is illuminated there is a problem with the unit and a service technician should be
contacted.
10. The x1000 icon will illuminate when values are multiplied by 1000 (capacity setting).
11. The system will hold the values for up to 48 hours after a power outage. Outages exceeding 48 hours
should have the programming values revisited. It is a good idea to write down the programming
parameters/values so they are available if a reprogramming is required.

General and Commercial Installation Checklist
WATER PRESSURE: A minimum of 25 pounds of water pressure is required for regeneration valve to
operate effectively.
ELECTRICAL FACILITIES: A continuous 115 volt, 60 Hertz current supply is required. Make certain the
current supply is always energized and cannot be turned off with another switch.
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. If piping is clogged with iron, a separate
iron filter unit should be installed ahead of the water softener.
LOCATION OF SOFTENER AND DRAIN: The softener should be located close to a
drain.