Excalibur Water Systems EWS S25BF User manual

SIMPLEX VALUE WATER SOFTENER
INSTALLATION AND USER GUIDE

1
SOFTENER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 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) Installation Drawing ...................................................................................................................... 3
1.5) System Drawing ............................................................................................................................ 4
1.6) Plumbing Instructions ................................................................................................................... 4
1.7) Brine Line Connection................................................................................................................... 5
1.8) Overflow Line Connection............................................................................................................. 5
1.9) Drain Line ...................................................................................................................................... 5
1.10) Bypass Valve.............................................................................................................................. 6
1.11) Start Up Instructions ................................................................................................................. 7
2) Control Valve Programming.................................................................................................................. 8
2.1) Regeneration Screens ................................................................................................................... 8
2.2) Button Operation.......................................................................................................................... 8
2.3) Setting Time of Day....................................................................................................................... 9
2.4) User Displays................................................................................................................................. 9
2.5) Installer Display Settings .............................................................................................................10
2.6) Softener System Setup................................................................................................................ 11
3) Model Variable Components and Specifications ................................................................................ 12
3.1) Flow Controls and Injectors ........................................................................................................ 12
3.2) Specifications ..............................................................................................................................12
4) Control Valve Cycles............................................................................................................................ 13
5) Components of Control Valve............................................................................................................. 15
5.1) Front Cover and PC Board...........................................................................................................15
5.2) Drive assembly, Piston and Spacer stack ....................................................................................16
5.3) Injector Assembly........................................................................................................................ 17
5.4) Brine Tank Line Flow Control ......................................................................................................18
5.5) Drain Line Flow Control Assembly .............................................................................................. 19
5.6) Outlet Meter Assembly............................................................................................................... 20
5.7) Bypass Valve Components .......................................................................................................... 21
5.8) Installation Fitting Assemblies ....................................................................................................22
6) Brine Tank Assembly........................................................................................................................... 24
7) Troubleshooting.................................................................................................................................. 25
7.1) Possible Error Codes ................................................................................................................... 25
7.2) Troubleshooting Procedures....................................................................................................... 26
8) Quick Reference Guide ....................................................................................................................... 29
9) Warranty ............................................................................................................................................. 31

2
SOFTENER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 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 by
Excalibur. The dealer must guide the installer to change the values according to the hardness, day
override and time of regeneration.
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
black O-Rings but not necessary.
•Do not use pipe dope or other sealant on plastic nuts and caps. Teflon tape must be used only on
NPT threads.
•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 with plug-in transformer (dry locations only).
•The tank should be on a firm level surface

3
SOFTENER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
1.4) Installation Drawing

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
1.5) System Drawing
1.6) Plumbing Instructions
Well Water Installation Municipal Installation
1) The softener must be located at the closest possible location to drain.
2) The water heater’s inlet must be at least 10ft away from softener.
3) The unit including the drain must be located in a room temperature above 33° F.
4) If vacuum occurrence is expected then the vacuum breaker must be installed at the inlet of the
softener.
5) The bypass valve must be installed on the control valve.
6) The outside tap water if possible may be bypassed from the softener.
7) The primer, solder or solder flux must not get on the O-rings while installation.
8) After soldering the lines must be cooled before installing the O-Rings, nuts and caps.
9) If the electrical system is grounded to the plumbing, then a copper strap must be connected
between inlet and outlet as shown in figure above.
10) The plumbing must be done by following the local plumbing codes.
Water
heater
Pressure
Tank
Minimum 10ft
Water
Meter
Minimum 10ft
Brine
Tank
Brine
Tank
Outside
Tap
Outside
Tap
Water
heater
Cold
Cold
Hot
Hot

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
1.7) Brine Line Connection
Install 3/8” O.D. Polyethylene tube according to specification sheet from the brine tank to the control
valve.
1.8) Overflow Line Connection
•Only used where brine tank overflow water spillage can damage flooring or structure.
•Brine tank is equipped with safety float valve which prevents the overflow in case if control
valve fails to control the refill cycle.
•In case if safety float also fails to stop refill then only the water will come through overflow line
connection.
1.9) Drain Line
•The ½” tubing must be used for drain line.
•Leave minimum of 6” gap between flow control fitting and solder joints. The gap less than this
can damage the flow control.
•If the drain line is elevated and then emptied into the drain below the level the of control valve
then 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 drain line must be clamped or strap tied at the end to secure in position.
Tank Brine Line
Connection
Brine Line
Drain Line

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
1.10) Bypass Valve
NORMAL OPERATION
The inlet and outlet handles of bypass valve should be pointing the
direction of flow indicated by the engraved arrows on the control valve.
Water flows through the control valve in normal operation as a water
softener.
BYPASS OPERATION
The inlet and outlet handles point to the center of the bypass valve.
The system is isolated from the water pressure in the plumbing
system. Untreated water is supplied to the house in this position.
DIAGNOSTIC MODE
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.
Untreated water is supplied to the house in this position.
SHUT OFF MODE
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.

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
1.11) Start Up Instructions
•Keep the bypass valve in bypass operation by moving both handles pointing towards the center
of bypass valve. Now the untreated water is being supplied to house. Open the faucet
downstream of the softener 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 6 inches 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 to reach backwash cycle and countdown time begins. Turn the inlet bypass valve
handle halfway into the direction of diagnose operation. Once the steady water flows out of
drain then fully turn both handles of bypass valve into the direction of service operation.
Caution: - If water flow is too rapidly, there will be a loss of resin to drain.
•When the water become clear in drain line then press the regen button to advance the
regeneration to brine cycle. Lift off the brine tank lid to check if water is being drawn from brine
tank and shut off the faucet after confirming the brine draw flow.
•Press REGEN button to advance the regeneration to 2nd backwash cycle. Wait until the
countdown time starts.
•Press REGEN button again to advance the regeneration to rinse cycle with water coming through
the drain. Allow this process for the full amount of time during this cycle.
•The control valve will automatically advance the regeneration to the fill cycle. Allow to fill for the
full amount of time in this cycle. Once finished the control valve will automatically come to the
service position with the time of day being displayed.
•Add the salt to Brine Tank.

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
2) CONTROL VALVE PROGRAMMING
2.1) Regeneration Screens
2.2) Button Operation
Regen Screen
•Displays the time remaining in the current cycle.
•Displays the cycle name and sequence number.
•Pressing REGEN advances to the next cycle.
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 delayed 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.
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.
•Sets time of day
•Save changes and Exit to user display from any programming screen
Regeneration occurs automatically if volume capacity drops below the reserve capacity
automatically predicted by Control Valve or the has control valve reached 14 number of days since
last regeneration.

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
2.3) Setting Time of Day
2.4) User Displays
When the system is operating, one of displays given below may be
shown. Pressing NEXT will alternate between the displays shown below.
User 1
This user display shows the volume capacity remaining.
User 2
Displays current time of the day.
−“SOFTENING” displays when the meter is registering the water.
−“REGEN TODAY” displays when the scheduled regeneration is to
occur at a scheduled time of day.
Push SET CLOCK button.
When hour flashes 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.
Return to User Display 1

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
2.5) 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 (gpg) of hardness using ▲or ▼.
Press NEXT to go to step 3I. Press REGEN to exit Installer Display
Settings.
Step 3I – Day Override: Set “14” the maximum number of days
between regenerations.
Press NEXT to go to step 4I. Press REGEN to return to previous step.
Step 4I – Next scheduled regeneration time (hour): Set the hour of
day for regeneration using ▲or ▼. (Usually 2:00AM or when the
predictable flow is minimum)
Press NEXT to go to step 5I. Press REGEN to return to previous step.
Step 5I – Next scheduled regeneration time (minutes): Set the
minutes of day for regeneration using ▲or ▼.
Press NEXT to exit Installer Display Settings. Press REGEN to return
to previous step.
EXIT INSTALLER DISPLAY SETTINGS

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
2.6) Softener System Setup
Step 1S - 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 – Enter the softening grains capacity given in specification
sheet according to the salt usage.
Step 4S – Enter the pounds of salt usage per regeneration. Press
NEXT to proceed to Step 5S or Press REGEN to return to previous
step.
Step 5S – Select “NORMAL” backwash length. Press NEXT to proceed
to Step 6S.
Step 6S –Set “AUTO” for estimating reserve volume capacity and
total volume capacity automatically.
Step 7S – Set “PoST” Refill location using ▲or ▼to refill the brine
tank immediately after the final rinse.
Press NEXT to go to Step 8S. Press REGEN to return to previous step.

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
3) MODEL VARIABLE COMPONENTS AND SPECIFICATIONS
3.1) Flow Controls and Injectors
Model
Number
Mineral Tank
Brine Tank
Injector
Drain Flow Control
Dia X Height (Inch)
(Inch)
Color
Order #
Flow GPM
Order #
EWS S25BF
8x44
14x14x34 (Length x
Width x Height)
Violet
CLK V30101C
1.7
CLK V3162017
EWS S30BF
9x48
Red
CLK V30101D
2.2
CLK V3162022
EWS S40BF
10x54
White
CLK V30101E
2.7
CLK V3162027
EWS S50BF
10x54
White
CLK V30101E
2.7
CLK V3162027
EWS S60BF
12x52
18x33 (Dia x Height)
Blue
CLK V30101F
3.2
CLK V3162032
3.2) Specifications
* Excalibur Softeners are factory programmed to 10lbs/ft3default settings
Model
Number
Mineral
Tank
Resin
Quantity Grains Capacity Lbs Salt Setting Flow (GPM) Shipping
Weight
Dia X
Height
ft36 lbs Salt/ft310 lbs Salt/ft315 lbs Salt/ft3Continuous Peak LBS
EWS S25BF
8X44
0.83
17,000
5
22,000
8.5
25,000
13
4.2
6.6
70
EWS S30BF
9X48
1.00
20,000
6
27,000
10
30,000
15
5.0
8.0
84
EWS S40BF
10X54
1.33
27,000
8
36,000
13
40,000
20
6.7
10.7
106
EWS S50BF
10X54
1.67
33,000
10
45,000
17
50,000
25
8.4
13.4
124
EWS S60BF
12X52
2.00
40,000
12
54,000
20
60,000
30
10.0
16.0
171
Step 8S – Select “dn” for downflow brine cycle using ▲or ▼. Press
NEXT to go to Step 9S. Press REGEN to return to previous step.
Step 9S –Set “NORMAL” for the regeneration time. Press NEXT to
exit Softener System Setup or Press REGEN to return to previous
step.
EXIT SOFTENER SYSTEM SETUP

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
4) CONTROL VALVE CYCLES
In Service Cycle water flows through the upper basket
and flows down to the bottom distributor. In this
operation hardness of water is removed by resin.
In Backwash Cycle water flows in upflow direction, the
water enters the tank from bottom distributor and
collected by upper basket. This operation lifts the bed
and wash the resin. The water goes out through the
drain line.
Note: -Backwash, Brine and Rinse cycles bypass the
supply water to the demand.

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
In Brine Cycle water flows in downflow direction
which siphon the brine solution from brine tank and
slow rinse water goes to the drain.
In Rinse Cycle water flows rapidly in downflow
direction through the resin to the drain. This cycle
washes the excess sodium from the resin particles.
Fill Cycle (Not Shown): - The water flow same as
Service operation but water also flows to the brine
tank for refilling.

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
5) COMPONENTS OF CONTROL VALVE
5.1) Front Cover and PC Board
Drawing No.
Order No.
Description
Quantity
1
CLK V317501
WS1 Front Cover ASY
1
2
CLK V310701
WS1 Motor
1
3
CLK V310601
WS1 Drive Bracket & Spring Clip
1
4
CLK V310810BOARD
WS1 PCB XMEGA REPL
1
5
CLK V3110
WS1 Drive Reducing Gear 12x36
3
6
CLK V3109
WS1 Drive Gear Cover
1
Not Shown
CLK V3186
WS1 AC ADAPTER 120V-12V
1
CLK V3186EU
WS1 AC ADAPTER 220-240V-12V
CLK V3186UK
WS1 AC ADAPTER 220-240V-12V
CLK V318601
WS1 AC ADAPTER CORD ONLY
AC Adapter
U.S.
Supply Voltage
120 V AC
Supply
60 Hz
Output Voltage
12 V AC
Output Current
500 mA
Battery
Orientation
Battery Fully
Seated
Replacement
battery type 2032

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
5.2) Drive assembly, Piston and Spacer stack
Drawing No.
Order No.
Description
Quantity
1
CLK V3005
WS1 Spacer Stack Assembly
1
2
CLK V3004
Drive Cap ASY
1
3
CLK V3178
WS1 Drive Back Plate
1
4
CLK V3011
WS1 Piston Downflow ASY
1
5
CLK V3174
WS1 Regenerant Piston
1
6
CLK V3135
O-ring 228
1
7
CLK V3180
O-ring 337
1
8
CLK V3105
O-ring 215 (Distributor Tube)
1
Not Shown
CLK V3001
WS1 Body ASY Downflow
1

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
5.3) Injector Assembly
Drawing No.
Order No.
Description
Quantity
1
CLK V3176
INJECTOR CAP
1
2
CLK V3152
O-RING 135
1
3
CLK V317701
INJECTOR SCREEN CAGE
1
4
CLK V30101Z
WS1 INJECTOR ASY Z PLUG
1
5
CLK V30101C
WS1 INJECTOR ASY CVIOLET
For 8” Tank
1
CLK V30101D
WS1 INJECTOR ASY D RED
For 9” Tank
CLK V30101E
WS1 INJECTOR ASY EWHITE
For 10” Tank
CLK V30101F
WS1 INJECTOR ASY F BLUE
For 12” Tank
Not Shown*
CLK V3170
O-RING 011
1
Not Shown*
CLK V3171
O-RING 013
1
* The injector plug and the injector each contain 011 (lower) and 013 (upper) O-ring.

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
5.4) Brine Tank Line Flow Control
Drawing No.
Order No.
Description
Quantity
1
CLK V414401
Elbow 3/8 Liquifit Asy w/RFC
1
2
CLK H4615
Elbow Locking Clip
1
3
CLK H4628
Elbow 3/8” Liquifit
1
4
CLK V3163
0-ring 019
1
5
CLK V316501
WS1 RFC Retainer Asy (0.5 gpm)
1
6
CLK V3182
WS1 RFC
1
Not Shown
CLK V3552
WS1 Brine Elbow Asy w/RFC
Option
Not Shown
CLK H4650
Elbow ½” with nut and insert
Option
#5 - CLK V316501 Retainer Assembly includes #6 - CLK V3182 Refill flow control

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
5.5) Drain Line Flow Control Assembly
Drain Line ¾”
Drawing No.
Order No.
Description
Quantity
1
CLK H4615
Elbow Locking Clip
1
2
CLK PKP10TS8BU
Polytube insert 5/8
Option
3
CLK V3192
WS1 Nut ¾ Drain Elbow
Option
4
CLK V315801
WS1 Drain Elbow ¾ Male
1
CLK V315802
WS1 Drain Elbow ¾ Male No
5
CLK V3163
O-ring 019
1
6
CLK V315901
WS1 DLFC Retainer ASY
1
7
CLK V3162017
WS1 DLFC 1.7 gpm
8” Tank
One DLFC
must
be used if ¾
fitting is used
CLK V3162022
WS1 DLFC 2.2 gpm
9” Tank
CLK V3162027
WS1 DLFC 2.7 gpm
10” Tank
CLK V3162032
WS1 DLFC 3.2 gpm
12” Tank