Excalibur Water Systems CHLOROSOFT SERIES User manual

CHLOROSOFT SERIES
ELECTRONIC METERED
WATER SOFTENER/FILTER
Installation Manual
220 Bayview Avenue Unit #18
Barrie, Ontario Canada
L4N 4Y8
www.excaliburwater.com

EXCALIBUR CHLOROSOFT
WATER SOFTENER/FILTER
INSTALLATION MANUAL
GENERAL WATER SOFTENER/FILTER
INSTALLATION PROCEDURES
The Water Softener/Filter control valve, fittings and/or bypass Water
Softener/Filter valve are designed to accommodate minor plumbing
misalignments that may occur during the Water Softener/Filter
installation. Do Not use Vaseline, oils or other hydrocarbon lubricants
when installing your Chlorosoft Water Softener/Filter or spray silicone
anywhere. A silicone lubricant may be used when installing your
Chlorosoft Water Softener/Filter on black o-rings but is not necessary.
Avoid any type of lubricants including silicone when installing your
Chlorosoft Water Softener/Filter on red or clear lip seals.
Do not use pipe dope or other sealants on the Water Softener/Filter
threads. Teflon tape must be used on the Water Softener/Filter
threads such as the 1 inch NPT elbow, the ¼ inch NPT connection,
and the Water Softener/Filter drain line connection. The nuts and
caps of the Chlorosoft Water Softener/Filter are designed to be
unscrewed or tightened by hand or with the special plastic Water
Softener/Filter service wrench part number V3193. If necessary,
pliers can be used to unscrew the Chlorosoft Water Softener/Filter

nut or cap. No not use a pipe wrench to tighten or loosen the
Chlorosoft Water Softener/Filter nuts or caps. Do not place
screwdriver in slots on caps and/or tap with a hammer as this could
damage the Chlorosoft Water Softener/Filter
WATER SOFTENER/FILTER/FILTER INSTALLATION
SITE REQUIRMENTS
•Water pressure 20 – 125
psi
•Current draw is 0.25 amps
•Water temperature 5 to
30°C or 40 to 100°F
•A 15 foot power cord is
furnished
•The Water Softener/Filter
tank should be on a firm
level surface
•The plug-in transformer is
for dry location only
•Electrical use of 115/120
volt 60 Hz uninterrupted
outlet
•Batteries are not used
1. The distance between the Chlorosoft Water Softener/Filter
and the water drain should be as short as possible. When
installing your Chlorosoft Water Softener/Filter all plumbing
must be done in accordance with local plumbing codes. The
Water Softener/Filter must not have a piping header that
exceeds 3 meters (10 feet).
2. Since Water Softener/Filter salt must be used periodically
and be added to the Water Softener/Filter, the brine tank
should be located where it is easily accessible.

3. Do not install your Chlorosoft Water Softener/Filter with less
than 10 feet of piping between your Water Softener/Filter
and it’s electrical outlet and the inlet of the water heater.
4. Do not locate the Chlorosoft Water Softener/Filter where it’s
connections including the Water Softener/Filter drain and
overflow plumbing will be in a room with a room temperature
under 2°C or 34°F.
5. The use of resin cleaner in your Chlorosoft Water
Softener/Filter in an unvented enclosure is not
recommended.
6. The Water Softener/Filter inlet/outlet plumbing will be
installed downstream of outdoor spigots. Install an inlet
shutoff valve and plumbing to the Water Softener/Filter
bypass valve located at the right rear as you face the Water
Softener/Filter. There are a variety of Water Softener/Filter
installation fittings available. They are listed under Water
Softener/Filter installation fitting assemblies. When
assembling the Water Softener/Filter installation fitting
package (inlet and outlet) connect the fitting to the plumbing
system first and attach the Water Softener/Filter nut, split
ring and o-ring. Heat from soldering or solvent cements may
damage the Water Softener/Filter nut, split ring or o-ring.
Solder joints should be cool and solvent cements should be
set before installing the Water Softener/Filter nut, split ring
and o-ring. Avoid getting solder flux, primer and solvent
cement on any part of the Water Softener/Filter o rings, split
rings, bypass valve or control valve. If the building electrical
system is grounded to the plumbing system, install a copper
grounding strap from the inlet to the outlet plumbing.
7. WATER SOFTENER/FILTER DRAIN LINE
First, be sure that the Water Softener/Filter drain line can
handle the flow rate of the Water Softener/Filter. Solder joints
near the drain line must be done prior to connecting the Water
Softener/Filter drain line flow control fitting. Leave at least 6
inched between the Water Softener/Filter drain line flow control

fittings and solder joints. Failure to do this could cause interior
damage to the Water Softener/Filter flow control. Install a ½ inch
inside diameter flexible plastic tube to the Water Softener/Filter
drain line assembly or discard the tubing nut and the 3/4 inch NPT
fitting for rigid pipe. If the Water Softener/Filter backwash flowrate
is greater than 7 gallons per minute, use a ¾ inch Water
Softener/Filter drain line. Where the Water Softener/Filter drain
line is elevated but empties into a water drain below the level of
the Water Softener/Filter control valve, form a 7 inch loop at the
discharge end of pipe so that the bottom of the loop is level with
the drain connection of the Water Softener/Filter control valve.
This will provide an adequate anti-siphon trap. Where the drain
empties into an overhead sewer pipe, a sink-type trap must be
used. Run a drain tube to its discharge point in accordance with
local plumbing codes. Pay special attention to plumbing codes for
air gaps and anti-siphon devices.
8. WATER SOFTENER/FILTER BRINE TANK CONNECTION
Install a 3/8 inch outside diameter polyethylene tubing from the
Water Softener/Filter refill elbow to the brine valve in the Water
Softener/Filter brine tank.
9. WATER SOFTENER/FILTER OVERLOW DRAIN TUBING
CONNECTION
A Water Softener/Filter overflow drain tubing is recommended
where a Water Softener/Filter brine tank overflow could
damage furnishings or the building structure. Your Chlorosoft
Water Softener/Filter will be equipped with a brine tank safety
float which greatly reduces the chance of an accidental brine
overflow. In the event of a Water Softener/Filter malfunction,
an overflow tubing connection will direct the overflow to the
drain instead of spilling on the floor where it could cause
considerable damage. This fitting should be on the side of the
Water Softener/Filter cabinet of brine tank. To connect the
Water Softener/Filter overflow fitting, locate a hole inside of the
brine tank. Insert the Water Softener/Filter overflow fitting into
the brine tank and tighten with plastic nut and gasket from the
inside. Attach a length of ½ inch inside diameter tubing (not

supplied) to fitting and run tubing to drain. Do not elevate the
Water Softener/Filter overflow tube higher than 3 inches below
bottom of overflow fitting. Do not “tie” this overflow tube into the
drain tube of the Water Softener/Filter control valve. Overflow
tube must be a direct, separate line from fitting to drain.
IMPORTANT:
Never insert a drain line directly into a drain, sewer line or
ptrap. Always allow an air gap between the drain line of the
waste water to prevent the possibility of sewage being back-
siphoned in the Water Softener/Filter.
10. WATER SOFTENER/FILTER SERIAL NUMBER
Record the Water Softener/Filter serial number on the
installer’s records and consumer’s sales invoice.
11. WATER SOFTENER/FILTER BYPASS VALVE
The Water Softener/Filter bypass valve is typically used to
isolate the Water Softener/Filter control valve from the
plumbing system, water pressure in order to perform Water
Softener/Filter control valve repairs or maintenance. The
bypass valve is particularly unique due to its versatility and
design features. The 1 inch Water Softener/Filter full flow
bypass valve incorporates four positions including a
diagnostic position that allows to work on a pressure system
while still providing untreated bypass valve water to the
residence. The bypass valve is completely non-metallic, all
composite design. The Water Softener/Filter bypass valve
consists of two interchangeable plug valves that are
operated independently by red arrow shaped handles. The
handles identify the water flow direction of the water. The
plug valves enable the bypass valve to operate in four
positions.
A) NORMAL OPERATION POSITION
The inlet and outlet handles point in the direction of water
flow of the Water Softener/Filter indicated by the engraved

arrows on the bypass valve. Water flows through the bypass
valve during normal operation and this position also allows
the bypass valve to isolate the Water Softener/Filter resin
bed during the regeneration cycle.
B) BYPASS POSITION
The inlet and outlet handles point to the centre of the bypass
valve. The bypass valve is isolated from the water pressure
contained in the plumbing system. Untreated water is
supplied to the plumbing system
C) DIAGNOSTIC POSITION
The inlet handle points in the direction of water flow and
outlet handle points to the centre of the bypass valve.
System water pressure is allowed to flow to the Water
Softener/Filter control valve and the plumbing system while

not allowing water to exit from the control valve to the
plumbing system.
D) SHUTOFF POSITION
The inlet handles points to the centre of the bypass valve
and the outlet points to the direction of flow. The water is
shut off to the plumbing system. If water is available on the
outlet side of the Water Softener/Filter, it is an indication of
water bypass around the system.
WATER SOFTENER/FILTER STARTUP INSTRUCTIONS
•After Water Softener/Filter installation is completed and
checked for leaks, rotate the bypass valve handles to the
bypass position.

•Fully open a cold water tap to release air pressure from
plumbing system. Allow water to run until the plumbing system
is rid of debris, which may have occurred during installation.
THE WATER SOFTNER/FILTER IS NOW READY FOR
TESTING
1. With the bypass valve in the bypass position, manually pour
5 gallons of water into the Water Softener/Filter brine tank.
2. Press and hold the Water Softener/Filter regeneration button
for three seconds until the motor drive starts. Wait until the
motor stops and the display reads “Backwash”. The
backwash time will begin to count down.
3. Open the inlet handle of the bypass valve very slowly
allowing water to fill the Water Softener/Filter slowly to expel
air. If water flows too rapidly, there will be a loss of media
out of the drain.
4. When the Water Softener/Filter is flowing steadily to drain
without the presence of air, press the Water Softener/Filter
regeneration button to advance the Water Softener/Filter
control valve to the brine position. The brine time will begin
to countdown.
5. Fully open the inlet of the Water Softener/Filter bypass valve
(bypass is no in the diagnostic position). Check to verify that
water is being drawn from the brine tank. There should be a
slow flow to the drain. Allow three minutes for the media bed
to settle.
6. Press the Water Softener/Filter regeneration button to
advance the Water Softener/Filter control valve to where the
display reads fill. This will allow water to run into the brine
tank and prepare it for the next regeneration. Allow the brine
to fill automatically.

7. While the Water Softener/Filter brine tank is filling, load two
20kg bags of Water Softener/Filter salt.
WATER SOFTENER/FILTER PROGRAMMING SETTINGS
Step I:Press next and up simultaneously for 3 seconds.
Step II: Set hardness in grains per gallon using the up and down
buttons. The default is 15 with a valve range of 1 to 150
in 1 grain increments. The display will show NA if filter is
selected. Add 5 gains of hardness for every one part of
iron, then press next to go to Step III.
Step III: Day override when gallon is set to off sets the number of
days between regenerations when gallon capacity is set
to auto or to a number sets the maximum number of days
between regenerations. If valve set to off regeneration
initiation is based solely on gallons used. If valve is set
as a number allowable range 1 to 28 days. A
regeneration initiation will be called for on that day even if
sufficient number of gallons were not used to call for
regeneration. Set day override using down or up buttons.
Step IV: Press next regeneration time (hour). Set the hour of the
day for regeneration using down or up buttons. AM/PM
toggles after 12. The default time is 2:00AM.
To initiate a manual regeneration immediately, press and hold the
regen button for three seconds. The system will begin to regenerate
immediately. The Water Softener/Filter control valve may be stepped
through the various regeneration cycles pressing the regen button.

Table 15
Troubleshooting Procedures
Problem Possible Cause Solution
a. Transformer unplugged a. Connect power
1. Timer does not display time
of day
b. No electric power at outlet b. Repair outlet or use working outlet
c. Defective transformer c. Replace transformer
d. Defective PC board d. Replace PC board
a. Switched outlet a. Use uninterrupted outlet
2. Timer does not display
correct
b. Power outage b. Reset time of day
time of day c. Defective PC board c. Replace PC board
a. Bypass valve in bypass position a. Put bypass valve in service position
3. No softening/filtering display b. Meter connection disconnected b. Connect meter to PC board
when water is flowing c. Restricted/stalled meter turbine c. Remove meter and check for rotation or foreign
material
d. Defective meter d. Replace meter
e. Defective PC board e. Replace PC board
a. Power outages a. Reset control valve to correct time of
day
b. Time of day not set correctly b. Reset to correct time of day
4. Control valve regenerates c. Time of regeneration incorrect c. Reset regeneration time
at wrong time of day d. Control valve set at "on 0"
(immediate regeneration)
d. Check control valve set-up procedure
regeneration time option
e. Control valve set at NORMAL
+ on 0
e. Check control valve set-up procedure
regeneration time option
a. Control valve has just been
serviced
a. Press NEXT and REGEN for 3
seconds or unplugged power source
jack (black wire) and plug back in to
reset control valve
5. ERROR followed by code
number
b. Foreign matter lodged in control
valve
b. Check piston and spacer stack
assembly for foreign matter
Error Code 1001 – Unable to
Recognize start of regeneration
c. High drive forces on piston c. Replace piston(s) and spacer stack
assembly
Error Code 1002 – Unexpected
stall
Error 1003 – Motor ran to long,
timed out trying to reach next
cycle
d. Control valve piston not in home
position
d. Press NEXT and REGEN for 3
seconds or unplug power source
jack (black wire) and plug back in to
reset control valve
position
Error Code 1004 – Motor ran to
long, timed out trying to reach
home position
e. Motor not inserted fully to
engage pinion, motor wires
broken or disconnected, motor
failure
e. Check motor and wiring. Replace
motor if necessary
f. Drive gear label dirty or
damaged, missing or broken gear
f. Replace or clean drive gear
If other Error Codes display
contact the factory
g. Drive bracket incorrectly aligned
to back plate
g. Reset drive bracket properly
h. PC board is damaged or defective h. Replace PC board
i. PC board incorrectly aligned to
drive bracket
i. Ensure PC board is correctly snapped
on to drive bracket

Problem Possible Cause Solution
a. Motor not operating a. Replace motor
b. No electric power at outlet b. Repair outlet or use working outlet
6. Control valve stalled in c. Defective transformer c. Replace transformer
regeneration d. Defective PC board d. Replace PC board
e. Broken drive gear or drive cap
assembly
e. Replace drive gear or drive cap
assembly
f. Broken piston retainer f. Replace drove cap assembly
g. Broken main regenerant piston g. Replace main regenerant piston
a. Transformer unplugged a. Connect transformer
7. Control valve does not b. No electric power at outlet b. Repair outlet or use working outlet
regenerate automatically
when
REGEN button is depressed
c. Broken drive gear or drive cap
assembly
c. Replace drive gear or drive cap
assembly
and held d. Defective PC board d. Replace PC board
8. Control valve does not
a. By-pass valve in bypass
position
a. Put bypass valve in normal
operation position
regenerate automatically b. Meter connection disconnected b. Connect meter to PC board
But does when REGEN
Button is depressed
c. Restricted/stalled meter turbine c. Remove meter and check for
rotation or foreign matter
d. Defective meter d. Replace meter
e. Defective PC board e. Replace PC board
f. Set-up error f. Check control valve set-up
procedure
9. Time of day flashes on and
off
a. Power has been out more than
two hours, the transformer
was
unplugged and then plugged
back into the wall outlet, the
transformer plug was
unplugged and then plugged
back into the board or the
NEXT and REGEN buttons
Were pressed to reset the
valve.
a. Reset the time of day