Excalibur Water Systems EWS S12530 User manual

BARRIE • ONTARIO • CANADA TF: 877.733.8999 WWW.EXCALIBURWATER.COM
WATER SOFTENER 1.25” SIMPLEX
INSTALLATION AND USER GUIDE

1
SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 877.733.8999 WWW.EXCALIBURWATER.COM
TABLE OF CONTENTS
1) Installation ............................................................................................................................................ 2
1.1) Pre-installation instructions.......................................................................................................... 2
1.2) General Installation and Service Warnings................................................................................... 2
1.3) Site Requirements......................................................................................................................... 2
1.4) Loading Instructions...................................................................................................................... 3
1.5) Installation Drawing ...................................................................................................................... 4
1.6) Piping and Instrumentation Drawing............................................................................................ 5
1.7) System Drawing ............................................................................................................................ 6
1.8) Plumbing ....................................................................................................................................... 7
1.9) Brine Line Connection ................................................................................................................... 7
1.10) Overflow Line Connection......................................................................................................... 8
1.11) Drain Line .................................................................................................................................. 8
1.12) Bypass Valve.............................................................................................................................. 9
1.13) Start Up Instructions ............................................................................................................... 11
2) Programming ...................................................................................................................................... 12
2.1) Regeneration and Error Screens ................................................................................................. 12
2.2) Button Operation........................................................................................................................12
2.3) User Displays............................................................................................................................... 13
2.4) Setting Time of Day ..................................................................................................................... 14
2.5) Configuration Settings ................................................................................................................14
2.6) Installer Display Settings .............................................................................................................16
2.7) Softener System Setup................................................................................................................ 17
2.8) Diagnostics ..................................................................................................................................21
3) Model Variable Programming and Components ................................................................................ 23
3.1) Programming ..............................................................................................................................23
3.2) Flow Controls and Injectors ........................................................................................................23
3.3) Specifications ..............................................................................................................................24
4) Control Valve....................................................................................................................................... 25
4.1) Control Valve Function and Cycles ofOperation..........................................................................25
4.2) Flow Diagrams............................................................................................................................. 26
4.3) Components of Control Valve.....................................................................................................29
5) Brine Tank Assembly........................................................................................................................... 40
6) Quick Reference Guide ....................................................................................................................... 41
7) Troubleshooting Procedure ................................................................................................................ 43
8) 5 Year Warranty .................................................................................................................................. 47

2
SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 877.733.8999 WWW.EXCALIBURWATER.COM
1) INSTALLATION
1.1) Pre-installation instructions
The cycle times, sequence of cycles, salt dose refill time and exchange capacity are preset to default by
Excalibur. Installer must program the valve to recommended hardness, Day override and time of
regeneration. Set time of day, read normal operating displays, read power loss and error displays if any.
WATER TEST
Hardness gpg
Iron ppm
pH number
*Nitrates ppm
Manganese ppm
Sulphur yes/no
Total Dissolved Solids
1.2) General Installation and Service Warnings
•The softener is designed so that it can be installed easily with minor plumbing changes on
previous plumbing.
•The piping must be clamped properly and the weight of the plumbing must not be on the
softener.
•Do not use any kind of lubricant including silicone. A silicone based lubricant can be only used on
O- Rings but not necessary.
•The nuts and caps can be fastened and unfastened by hand or the plastic service wrench. Do not
use pipe wrench to tighten the caps and nuts.
1.3) Site Requirements
•Water Pressure: - 40-110 psi
•Water Temperature: - 40-110°F (4.4-43°C)
•Electrical- 115/120 V, 60Hz Uninterrupted Outlet
•Current required is 0.5 Amperes
•The plug-in transformer is for dry locations only
•The tank should be on a firm level surface

BARRIE • ONTARIO • CANADA TF: 877.733.8999 WWW.EXCALIBURWATER.COM
1.4) Loading Instructions
Step 1: Check the product upon removal and remove from box packaging checking for any shipping
damage or shortages that must be reported to Excalibur Water Systems immediately for confirmation.
Step 2: Insert distributor(s) inside of media mineral tank(s) so it is positioned properly in the bottom
centre groove. If not already sized properly cut the top of the distributor pipe ½ - ¾” above top of tank
opening and clean off and excess PVC materials with grit cloth.
Step 3: Plug the top inlet opening of the distributor (Hub & Lateral) or bottom stack with a clean cloth,
rag, or tape to prevent any gravel or resin from entering into the distributor tube.
Step 4: Load the gravel under bedding onto the mineral tank using a funnel or some sort of loading
devise. If multiple layers of gravel with different sizes being utilized always load the largest gravel size in
diameter to the smallest last.
Step 5: Load the water softening cation exchange resin also by the use of a funnel or some sort of
loading device until all resin is inside of mineral tank. If loading a duplex system that has two tanks
divide the resin and gravel up equally when loading.
Step 6: Remove top opening cover of the distributor carefully not to move or disturb the distributor
tube not allowing any debris or materials to get inside of the now loaded softener(s).
Step 7: Thread on control valves onto top opening tanks be sure to check and verify that the O-ring on
the bottom base of the control valve is present and properly lubricated with silicone. Tighten control
valve(s) clockwise until you have reached the end of the thread and have secured a water tight seal. (If
control valves that utilize quick connect collars thread the collars the same into the tanks then attach
control valves).
Step 8: Precede now with the unit(s) in their proper installation locations to run piping and materials for
all inlet, outlet, and drain connections properly with isolation valves and test ports for future water
tests. Also, unions should be included in installation materials for easy future servicing of the control
valves when necessary on all inlet, outlet, and drain lines.

4
SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 877.733.8999 WWW.EXCALIBURWATER.COM
1.5) Installation Drawing

5
SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 877.733.8999 WWW.EXCALIBURWATER.COM
1.6) Piping and Instrumentation Drawing

6
SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 877.733.8999 WWW.EXCALIBURWATER.COM
1.7) System Drawing

7
SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 877.733.8999 WWW.EXCALIBURWATER.COM
Well Water Installation Municipal Installation
1) The softener must be close to drain as much as possible.
2) The salt must be refilled in brine tank with frequency stated by dealer.
3) The water heater’s inlet and outlet must be at least 10ft away from softener.
4) The unit including the drain must be located in a room temperature above 33° F.
5) Never let the vacuum occur in tank this may cause implosion and leakage. If vacuum occurrence
is expected than vacuum breaker must be installed in line.
1.8) Plumbing
•The bypass valve must be installed on the control valve.
•The outside tap water must be bypassed from the softener.
•The shutoff valve must be installed at the inlet of unit’s bypass valve.
•The primer, solder or solder flux must not get on the O-rings.
•After soldering the lines must be cooled before installing the O-Rings, nuts and caps.
•If the electrical system is grounded to the plumbing than copper strap must be connected
between inlet and outlet as shown in figure above.
•The plumbing must be done by following the local plumbing codes.
1.9) Brine Line Connection
Install the 1/2” or 3/8” O.D. Polyethylene tube according to specification sheet from the brine tank to
the control valve.

8
SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 877.733.8999 WWW.EXCALIBURWATER.COM
1.10) Overflow Line Connection
The overflow drain line is used where overflow of the brine tank can damage the floor finishing or
structure. The brine tank line is equipped with safety float valve which prevents the overflow so, the
overflow line is only used in case is overflow float valve fails. The overflow line will transfer fluid from
brine tank to the drain hence prevents the spillage.
1.11) Drain Line
•The size of the drain must be according to the specifications.
•Leave minimum of 6” gap between flow control fitting and solder joints. The gap less than this
can damage the flow control.
•Use ¾” or 1” tubing for drain line according to the specifications.
•If the drain line is elevated and then emptied into the drain below the level the of control valve
the 7” loop should make at the end of drain line.
•The air gap between the drain and the end of the drain line must be twice the diameter of the
tube.
•The strap must be tied at the end to secure the line.

9
SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 877.733.8999 WWW.EXCALIBURWATER.COM
1.12) Bypass Valve
The inlet and outlet handles point in the direction of flow
indicated by the engraved arrows on the control valve.
Water flows through the control valve for normal
operation of a water softener. During the regeneration
cycle this position provides regeneration water to the unit,
while also providing untreated water to the distribution
system
The inlet and outlet handles point to the center of the
bypass. The system is isolated from the water pressure in
the plumbing system. Untreated water is supplied to the
building

10
SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 877.733.8999 WWW.EXCALIBURWATER.COM
The inlet handle points in the direction of flow and the
outlet handle points to the center of bypass valve, system
water pressure is allowed to the control valve and the
plumbing system while not allowing water to exit from the
control valve to the plumbing.
The inlet handle points to the center of the bypass valve
and the outlet handle points in the direction of flow, the
water is shut off to the plumbing system. If water is
available on the outlet side of the softener it is an
indication of water bypass around the system (i.e. a
plumbing connection somewhere in the building bypasses
the system).

11
SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 877.733.8999 WWW.EXCALIBURWATER.COM
1.13) Start Up Instructions
•Keep the bypass valve in bypass operation by moving both the handles into the center direction
of the bypass valve. Now the untreated water is being supplied to house. Open the faucet until
water comes clear out of it. The initial water can be dirty because of installation debris. Now
inspect the leaks in plumbing.
•Manually add approximate 5 gallons of water to brine tank so that level reaches air check valve.
Press and hold the “REGEN” button down for 5 seconds to start manual regeneration. The drive
motor will start the backwash cycle and countdown time begins. Turn the inlet bypass valve
handles halfway into the direction of service operation. Once the steady water flows out of
drain then fully open the bypass valve into the direction of service operation.
•When the water become clear in drain line then press the regen button to advance the
regeneration in brine cycle. Fully open the faucet and check if water is being drawn from brine
tank. Allow this cycle to run for 3 minutes.
•Press REGEN button to advance the regeneration to rinse cycle. The water will come through the
drain. Allow this process until water coming through the drain becomes clear.
•Add salt to the tank and allow ample time to dissolve it in water to become brine solution.

12
SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 877.733.8999 WWW.EXCALIBURWATER.COM
2) PROGRAMMING
2.1) Regeneration and Error Screens
2.2) Button Operation
Regen Screen
Displays the time remaining in the current cycle. Pressing REGEN advances to the next
cycle.
Error Screen
Alternated flashing Error and error code every 3 seconds.
Clear by disconnecting the power supply at the PC board and
reconnecting, or press NEXT and REGEN simultaneously for 3
seconds.
Scrolls to the next display.
•Pressing once and releasing will schedule a regeneration at the preset delayed regeneration time.
•Pressing again and releasing will cancel the regeneration.
•Pressing and holding for 3 seconds will initiate an immediate regeneration
•Pressing while in regeneration will advance to the next cycle.
•Pressing in the program levels will go backwards to the previous screen
Change Variable being displayed.
Key sequence to lock and unlock program settings
Holding for 3 seconds initiates a control reset. The software version is displayed and the
piston returns to the home/service position, resynchronizing the valve.

13
SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 877.733.8999 WWW.EXCALIBURWATER.COM
2.3) User Displays
When the system is operating, one of five displays may be shown.
Pressing NEXT will alternate between the displays shown below.
User 1
Typical user display. Shows volume remaining to regeneration. This
screen will not be viewed if the control is set for time-clock operation.
User 2
Displays number of days to next regeneration.
User 3
Flow Rate.
Displays present flow rate.
User 4
Displays total volume in gallons since last reset. If a meter is not used
this display will be shown but 0 will be displayed.
PRESS ▼FOR 3 SECONDS TO RESET TO 0.
User 5
Shows current time.

14
SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 877.733.8999 WWW.EXCALIBURWATER.COM
2.4) Setting Time of Day
2.5) Configuration Settings
Push NEXT until time of day screen is displayed. Press and hold ▼
until SET TIME is displayed and the hour flashes once. Press ▲or
▼until the correct hour is displayed.
Then press NEXT. The minutes will flash. Press ▲or ▼until the
correct minute is displayed.
Press NEXT to return to the User Displays. Time of day should only
need to be set after power outages lasting more than 8 hours, if
the battery has been depleted and a power outage occurs, or
when daylight saving time begins or ends. If a power outage lasting
more than 8 hours occurs, the time of day will flash on and off
which indicates the time of day should be reset. If a power outage
lasts less than 8 hours and the time of day flashes on and off, the
time of day should be reset and the battery replaced.
Step 1CS – Press NEXT and ▼simultaneously for 5 seconds and
release. Press NEXT and ▼ simultaneously for 5 seconds and release. If
the screen in Step 2CS does not appear, the lock on the valve is
activated. To unlock, press ▼, NEXT, ▲and REGEN in sequence, then
press NEXT and ▼simultaneously for 5 seconds and release. Press
NEXT and ▼simultaneously for 5 seconds and release.
Step 2CS – Use ▲or ▼to select 1.25 for 1.25” valve.
1.25

15
SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 877.733.8999 WWW.EXCALIBURWATER.COM
Step 4CS – Select OFF when none of below given features are used.
Note: - This display will not appear if 1.0t was selected in Step
2CS. Allows selection of one of the following using ▲or ▼:
• the Control Valve to have no hard water bypass;
• the Control Valve to act as an alternator;
• the Control Valve to have a separate source during the regeneration cycle; or
• the Control Valve to operate with the System Controller.
EXIT TO DISPLAY SCREENS
Step 3CS – Selecting the use of an outside signal to initiate a
regeneration. Selection only matters if a connection is made to the two
pin connector labeled DP SWITCH located on the printed circuit board.
Select oFF - feature not used. Other options are described below.
on0 – If the dP switch is closed for an accumulative time of 2 minutes a
regeneration will be signaled to the unit.
dEL – If the dP switch is closed for an accumulative time of 2 minutes a
regeneration will occur at the scheduled delayed regeneration time.
HoLd – If the dP switch is closed a regeneration will be prevented from
occurring while there is switch closure.
Press NEXT to go to Step 4CS. Press REGEN to return to previous step.

16
SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 877.733.8999 WWW.EXCALIBURWATER.COM
2.6) Installer Display Settings
Exit Installer Display Settings
Step 1I - To enter Installer Display press NEXT and ▲simultaneously
for about 5 seconds and release.
Step 2I – Hardness: Set the amount of infl uent hardness using ▲or
▼. If “oFF” or a number was selected in Step 11S.
Press NEXT to go to step 3I. Press REGEN to exit Installer Display
Settings.
Step 3I – Day Override: When volume capacity is set to “oFF”, sets
the number of days between regenerations. When volume capacity
is set to AUTO or to a volume, sets the maximum number of days
between regenerations. If value set to “oFF”, regeneration initiation
is triggered solely by volume used.
If value is set in days (allowable range from 1 to 28) regeneration
initiation will be called for on that day regardless of actual water
usage. Set Day Override using ▲or ▼:
• number of days between regeneration (1 to 28); or
• “oFF”.
See Setting Options Table for more detail on setup.
Press NEXT to go to step 4I. Press REGEN to return to previous step.
Step 4I – Next Regeneration Time (hour): Set the hour of day for
regeneration using ▲or ▼. The default time is 2:00. This display
will show “REGEN on 0 GAL” if “on 0” is selected in Set Regeneration
Time Option in OEM Softener System Setup or OEM Filter System
Setup.
Press NEXT to go to step 5I. Press REGEN to return to previous step.
Step 5I – Next Regeneration Time (minutes): Set the minutes of day
for regeneration using ▲or ▼. This display will not be shown if “on
0” is selected in Set Regeneration Time Option in OEM Softener
System Setup or OEM Filter System Setup.
Press NEXT to exit Installer Display Settings. Press REGEN to return
to previous step.

17
SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 877.733.8999 WWW.EXCALIBURWATER.COM
2.7) Softener System Setup
Step 1S - Press NEXT and ▼simultaneously for 5 seconds and
release. If screen in Step 2S does not appear, the lock on valve
programming has been activated. To unlock press ▼, NEXT, ▲,
REGEN in sequence, then press NEXT and ▼simultaneously for 5
seconds and release.
Step 2S – Choose SOFTENING using ▲or ▼. Press NEXT to go to
Step 3S. Press REGEN to exit OEM Softener System Setup.
Step 3S – Choose Downflow Brining Direction using ▲or ▼. This
screen is not viewed when Step 2S is set to Filtering. Press NEXT to
go to Step 4S. Press REGEN to return to previous step.
Step 4S – Set Refill location using ▲or ▼:
• “PoST” to refill the brine tank after the final rinse; or
• “PrE” to refill the brine tank four hours before the regeneration
time set.
This screen is not viewed when Step 2S is set to Filtering.
Press NEXT to go to Step 5S. Press REGEN to return to previous step.
Step 5S – Select the time for the first cycle using ▲or ▼. Press
NEXT to go to Step 6S. Press REGEN to return to previous step.

18
SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 877.733.8999 WWW.EXCALIBURWATER.COM
Step 6S – Select the time for the second cycle using ▲or ▼.
NOTE: The display will flash between cycle number and time, and
brine direction (UP or dn).
Press NEXT to go to Step 7S. Press REGEN to return to previous step.
Step 7S – Select the time for the third cycle using ▲or ▼.
Press NEXT to go to Step 8S. Press REGEN to return to previous step.
Step 8S – Select the time for the fourth cycle using ▲or ▼.
Press NEXT to go to Step 9S. Press REGEN to return to previous step.
Step 9S – Select the pounds for the fifth cycle using ▲or ▼.
Press NEXT to go to Step 10S. Press REGEN to return to previous
step.
Step 10S – Set System Capacity using ▲or ▼. The System Capacity
setting should be based on the volume of resin and LBS of salt fill set
in Step 9S. Press NEXT to go to Step 11S. Press REGEN to return to
previous step.

19
SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 877.733.8999 WWW.EXCALIBURWATER.COM
Step 11S – Set Volume Capacity using ▲or ▼. If value is set to:
• “AUTO” capacity will be automatically calculated and reserve
capacity will be automatically estimated;
• “oFF” regeneration will be triggered solely by the day override
setting (see Installer Display/Settings Step 4I);
• a number, regeneration will be triggered by the value specified (in
Gallons).
If “oFF” or a volume is used, the hardness display will not be allowed
to be set in Installer Display Settings Step 2I. See Setting Options Table
for more detail. Press NEXT to go to Step 12S. Press REGEN to return
to previous step.
Step 12S – Set Regeneration Time Options using ▲or ▼. If value is
set to:
• “NORMAL” means regeneration will occur at the preset time;
• “on 0” means regeneration will occur immediately when the volume
capacity reaches 0 (zero); or
• “NORMAL + on 0” means regeneration will occur at one of the
following:
— the preset time when the volume capacity falls below the reserve
or the specified number of days between regenerations is reached
whichever comes first; or
— immediately after 10 minutes of no water usage when the volume
capacity reaches 0 (zero).
This step will not appear if Step 11S is set to oFF.
Press NEXT to go to Step 13S. Press REGEN to return to previous step.
Step 13S – Set Relay Operation using ▲or ▼. The choices are:
• Time on: Relay activates after a set time at the beginning of a
regeneration and then deactivates after a set period of time. The start
of regeneration is defined as the first backwash cycle or Dn brine
cycle, whichever comes first.
• Gallons softening on: Relay activates after a set number of gallons
have been used while in service and then deactivates after the meter
stops registering flow and the set time period has expired.
• Gallons Softening Regen on: Relay activates after a set number of
gallons have been used while in service, or during regeneration, and
then deactivates after the meter stops registering flow and the set
time period has expired.
•ERROR: Relay closes whenever the valve enters error mode, and
immediately deactivates when error mode is exited. If set to ERROR,
Steps 14S and 15S will not be shown.
• Off: If set to Off, Steps 14S and 15S will not be shown.
Press NEXT to go to Step 14S. Press REGEN to return to previous step.
oFF