Well since you're starting from scratch.
What kind of fertilizer are you using?
What's the fertilizer's N-P-K ratio?
What's the breakdown for the type of nitrogen it's using? Is there urea? What's the percentage of ammonia? What's the percentage of nitrate?
What kinds of micro-nutrients are present in the fertilizer. It should be listed on the bottle of the fertilizer.
How's the humidity of your growing area?
What kind of light is it receiving?
How big is the pot relative to the root mass?
How is the plant oriented? Is it propped upright? If so, please place it as horizontally as you can. This will save you the problem of crown rot. The plant will also tend to naturally want to lean anyways.
What's the temperature range of your growing area?
Here's a link to someone else's Flickr page. It has a series of photos of Phalaenopsis in the wild. I highly recommend looking at them:
Phalaenopsis in situ - Flickr: Search
Why a terra-cotta pot? Why not a clear plastic pot?
What was the problem with mounting them? What was the advantage/disadvantage of growing it this way for you?
And yes, softened water is not good for orchids in general.
If the salt content builds up, expect the roots to shrivel up and die.
Water softener does not remove chlorine as was stated.