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Fusion, Fusion Hybrid and Prelude Water Softener

Service Manual

IMPORTANT: Fill in Pertinent Information on Page 3 for Future Reference

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Summary of Contents for Fusion

Page 1: ...Fusion Fusion Hybrid and Prelude Water Softener Service Manual IMPORTANT Fill in Pertinent Information on Page 3 for Future Reference ...

Page 2: ...t 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 not place the unit in direct sunlight Black units will absorb radiant heat increasing internal temperatures Do not strike the valve or any of the c...

Page 3: ...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 ...

Page 4: ...ion or watering from a spigot Grass and other plants do not like soft 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 distribut...

Page 5: ...rge 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 the resin 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 t...

Page 6: ...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 ...

Page 7: ...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 ...

Page 8: ...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 screwi...

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Page 10: ...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 s...

Page 11: ... 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 nut by turning it clockwise Tighten it hand tight then snug it an additional to turn ...

Page 12: ...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 ...

Page 13: ...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 ...

Page 14: ...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 ...

Page 15: ...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 to turn Place the white cap back on the white tube ...

Page 16: ...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 Ope...

Page 17: ...system The bypass valve pointer should be 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 ...

Page 18: ... 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 a...

Page 19: ...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 ...

Page 20: ...ke 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...

Page 21: ...Cycle button at the last parameter to save all settings and return to normal operation The control will automatically disregard any programming changes and return to normal operation if it is left in Master Programming mode for 5 minutes without any keypad input Resets Soft Reset Press and hold the Extra Cycle and Down buttons for 25 seconds while in normal Service mode This resets all parameters ...

Page 22: ...ter UFbd Upflow Brine First 8500 TwinFlo 100 Othr Other 3 Control Type Display Code CT Press the Extra Cycle button Use this display to set the Control Type This specifies how the control determines when to trigger regeneration For details on how the various options function refer to the Timer Operation section of this service manual This option setting is identified by CT in the upper left hand c...

Page 23: ... desired volume capacity when configuring a filter system This option setting is identified by C in the upper left hand corner of the screen The Unit Capacity parameter is only available if the control type has been set to one of the metered options Use the Up and Down buttons to adjust the value as needed Range 1 999 900 gallons 100 9 999 000 Liters Use the following chart to determine your capac...

Page 24: ...serve Selection Display Code RS Press the Extra Cycle button Use this display to set the Safety Factor Use this display to select the type of reserve to be used in your system This setting is identified by RS in the upper left hand corner of the screen The reserve selection parameter is only available if the control type has been set to one of the metered options There are two possible settings SF...

Page 25: ...generate regardless of usage if the days since last regeneration cycle equal the day override setting Setting the day override value to OFF disables this function This option setting is identified by DO in the upper left hand corner of the screen Use the Up and Down buttons to adjust the value as needed Range Off 99 days This will most likely be set at 14 days unless you take vacations lasting mor...

Page 26: ...ns to adjust the value as needed Press the Extra Cycle button to accept the current setting and move to the next parameter Abbreviation Cycle Step BW Backwash 10 Mins BD Brine Draw 60 Mins RR Rapid Rinse 10 Mins BF Brine Fill see chart Range 0 199 minutes This setting is determined by the chart used for the capacity setting Input the number of minutes that corresponds to the capacity setting that ...

Page 27: ...g Mode USER PROGRAMMING MODE User Programming Mode Options Abbreviation Parameter Description DO Day Override The timer s day override setting RT Regeneration Time The time of day that the system will regenerate meter delayed timeclock and day of week systems H Feed Water Hardness The hardness of the inlet water used to calculate system capacity for metered systems RC or SF Reserve Capacity The fi...

Page 28: ...fied by H in the upper left hand corner of the screen Range 1 199 hardness 5 Press the Extra Cycle button Use this display to adjust the Fixed Reserve Capacity This option setting is identified by RC or SF in the upper left hand Corner of the screen 6 Press the Extra Cycle button Use this display to set the Current Day of the Week This option setting is identified by CD in the upper left hand corn...

Page 29: ...xit Diagnostic Mode at any time Diagnostic Programming Mode Steps 1 Press the Up and Extra Cycle buttons for five seconds while in service 2 Use this display to view the current Flow Rate This option setting is identified by FR in the upper left hand corner of the screen 3 Press the Up button Use this display to view the Peak Flow Rate since the last regeneration cycle This option setting is ident...

Page 30: ... the Up button Use this display to view the Software Version This option setting is identified by SV in the upper left hand corner of the screen Press the Extra Cycle button to end Diagnostic Programming Mode ...

Page 31: ...g B Excessive water in brine tank B See problem 7 4 Loss of water pressure A Iron buildup in line to water conditioner A Clean line to water conditioner B Iron buildup in water condi tioner B Clean control and add mineral cleaner to mineral bed Increase frequency of regeneration C Inlet of control plugged due to foreign material broken loose from pipes by recent work done on plumbing system C Remo...

Page 32: ...cycle F Check drive motor and switches 9 Control cycles continuously A Misadjusted broken or shorted switch A Determine if switch or timer is faulty and replace it or replace complete power head 10 Drain flows continuously A Valve is not programming cor rectly A Check control program and positioning of control Replace power head assembly if not positioning properly B Foreign material in control B ...

Page 33: ...Control Dimensions ...

Page 34: ...NOTES ...

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