Excalibur Water Systems FILTERMAX ZENTEC User manual

BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
FILTERMAX ZENTEC FILTER
INSTALLATION AND USER GUIDE

1
FILTER 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) Drain Line ...................................................................................................................................... 5
1.8) Bypass Valve.................................................................................................................................. 6
1.9) Start Up Instructions ..................................................................................................................... 8
2) Control Valve Programming.................................................................................................................. 9
2.1) Regeneration Screens ................................................................................................................... 9
2.2) Button Operation.......................................................................................................................... 9
2.3) Manual Regeneration ................................................................................................................... 9
2.4) Setting Time of Day.....................................................................................................................10
2.5) User Displays............................................................................................................................... 10
2.6) Installer Display Settings .............................................................................................................11
2.7) Installer Display Settings (Weekly)..............................................................................................12
2.8) System Setup...............................................................................................................................14
3) Model Variable Components and Specifications................................................................................ 14
4) Control Valve Cycles............................................................................................................................ 15
5) Components of Control Valve............................................................................................................. 17
5.1) Front Cover and PC Board...........................................................................................................17
5.2) Drive assembly, Piston and Spacer stack ....................................................................................18
5.3) Injector Assembly........................................................................................................................ 19
5.4) Brine Tank Port ........................................................................................................................... 20
5.5) Drain Line Flow Control Assembly .............................................................................................. 21
5.6) Outlet Meter Port .......................................................................................................................22
5.7) Bypass Valve Components .......................................................................................................... 23
5.8) Installation Fitting Assemblies .................................................................................................... 24
6) Troubleshooting.................................................................................................................................. 26
6.1) Troubleshooting Procedures.......................................................................................................26
6.2) Possible Error Codes ................................................................................................................... 28
7) Quick Reference Guide ....................................................................................................................... 29
8) Warranty ............................................................................................................................................. 31

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FILTER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
1) INSTALLATION
Pre-installation instructions
The cycle times, sequence of cycles and days between regeneration are preset by Excalibur Water
Systems.
WATER TEST
Hardness _________________gpg
Iron _________________ppm
Ph _________________number
Nitrates _________________ppm
Manganese _________________ppm
Sulphur _________________yes/no
Total Dissolved Solids _________________
General Installation and Service Warnings
•The filter 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 filter.
•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.
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

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FILTER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
Installation Drawing

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FILTER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
System Drawing
Plumbing Instructions
Well Water Installation Municipal Installation
1) The filter must be located at the closest possible location to drain.
2) The water heater’s inlet must be at least 10ft away from filter.
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
filter.
5) The bypass valve must be installed on the control valve.
6) The outside tap water if possible may be bypassed from the filter.
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
10ft
Water
Meter
Outside
Tap
Outside
Tap
Water
heater
Cold
Cold
Hot
Hot
10ft

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FILTER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
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.

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FILTER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
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 filter.
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. Unfiltered
water is supplied to the house in this position.

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FILTER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
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. Unfiltered
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 Filter, it is
an indication of water bypass around the system.

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FILTER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
Start Up Instructions
•Keep the bypass valve in bypass operation by moving both handles pointing towards the center
of bypass valve. Now the unfiltered water is being supplied to house. Open the faucet
downstream of the filter until water comes clear out of it. The initial water can be dirty because
of installation debris. Now inspect the leaks in plumbing.
•Press and hold the “UP” and “DOWN” buttons simultaneously for 3 seconds to start immediate
manual regeneration. The drive motor will start to reach backwash cycle and countdown time
begins (C1--). 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 media to drain.
•When the water becomes clear in drain line then press the “UP” or “DOWN” button to advance
the regeneration to rinse cycle (C4--). Allow this process for the full amount of time during the
cycle.
•Once regeneration is finished the control valve will automatically come to the service position
with the time of day or days to next regeneration being displayed.

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FILTER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
2) CONTROL VALVE PROGRAMMING
Regeneration Screens
Button Operation
Manual Regeneration
•Displays the cycle sequence number.
•Displays the time remaining in the current cycle.
Regeneration Tonight: - Press ▲and ▼buttons once
and release to schedule a regeneration for preset time.
The arrow will point the word REGEN which indicates the
regeneration is expected tonight.
Press ▲and ▼buttons again to cancel the scheduled
regeneration for tonight.
Immediate Regeneration: - Press ▲and ▼buttons and
hold for 3 seconds until the control valve motor starts.
•Change Variable being displayed.
•Scroll to the next display
•Advance the regeneration to next cycle
•Sets time of day
•Proceed to next step in settings
•Save changes and Exit to user display from any programming screen
REGEN
ARROW
•Exit programming without saving
•Initiate medium reset

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FILTER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
Setting Time of Day
User Displays
When the system is operating, one of displays given below may be
shown. Pressing ▲or ▼will alternate between the displays shown
below.
User 1
This user display shows the time of the day.
User 2
Displays the days until the next regeneration.
“REGEN” arrow is displayed when the regeneration is supposed to
occur at a scheduled time of day.
Step #1: - Push “SET” button and hold for 3 seconds.
Step #2: - When hour flashes press ▲or ▼until the correct hour is
displayed. Then press “SET” to proceed to next step.
Step #3: - The minutes will flash. Press ▲or ▼until the correct
minute is displayed. Press “SET” 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.
Note: -Timekeeping is 12 hour with 60Hz frequency and 24 hour
with 50Hz
Return to User Display 1

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FILTER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
Installer Display Settings
Weekly Installer Display day codes: -
Display
Day of Week
day 1
d1
Sunday
day 2
d2
Monday
day 3
d3
Tuesday
day 4
d4
Wednesday
day 5
d5
Thursday
day 6
d6
Friday
day 7
d7
Saturday
Step #1: - Press and hold “SET” and ▼buttons for 3 seconds.
Step #2: - When hour flashes press ▲or ▼until the correct hour is
displayed. Then press “SET” to proceed to next step.
Step #3: - The minutes will flash. Press ▲or ▼until the correct
minutes for hour is displayed. Press “SET” to proceed to next step.
Step #4: - Set the number of days between regenerations using ▲or
▼buttons. Press “SET” button to exit Installer display settings.
EXIT INSTALLER DISPLAY SETTINGS

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FILTER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
Installer Display Settings (Weekly)
Step 1I7: - Press “SET” and ▲buttons simultaneously for seconds
and release.
Step 2I7: - Set the regeneration time hour using ▲or ▼buttons.
Press SET to proceed to step 3I7.
Step 3I7: - Set the regeneration time minutes using ▲or ▼
buttons. Press SET to proceed to step 4I7.
Step 4I7: - Set the current day of the week by using ▲or ▼
buttons. Refer to the table on previous page. Press SET to go to
step 5I7.
Step 5I7: - Sunday (d1) regeneration: - Use ▲or ▼buttons to
point the arrow on “REGEN” then Regeneration will occur on
Sunday. Press SET to go to step 6I7.
Step 6I7: - Monday (d2) regeneration: - Use ▲or ▼buttons to
point the REGEN arrow for regeneration on every Monday. Press
SET to go to 7I7.

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FILTER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
Step 7I7: - Tuesday (d3) regeneration: - Use ▲or ▼button to
point the REGEN arrow then regeneration will occur every
Tuesday.
Step 8I7: - Wednesday (d4) regeneration: - Use ▲or ▼button to
point the REGEN arrow then regeneration will occur every
Wednesday. Press SET to proceed to step 9I7.
Step 9I7: - Thursday (d5) regeneration: - Use ▲or ▼button to
point the REGEN arrow then regeneration will occur every
Thursday. Press SET to proceed to step 10I7.
Step 10I7: - Friday (d6) regeneration: - Use ▲or ▼button to point
the REGEN arrow then regeneration will occur every Friday. Press
SET to go to step 11I7.
Step 11I7: - Saturday (d7) regeneration: - Use ▲or ▼button to
point the arrow on “REGEN” then Regeneration will occur on
Saturday. Press SET to go to Exit Installer Display Settings (Weekly).
EXIT INSTALLER DISPLAY SETTINGS

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FILTER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
System Setup
3) MODEL VARIABLE COMPONENTS AND SPECIFICATIONS
Model1
Number
Mineral
Tank
Media Flow (GPM) Drain Flow Control
Shipping
Weight
Dia X Height
ft3
Continuous
Peak
Flow (GPM)
Order #
LBS
EWS BTZH05
8X44
0.5
3.0
6.0
4.2
CLK V3162042
80
EWS BTZH1
9X48
1.0
4.0
8.0
5.3
CLK V3162053
140
EWS BTZH1.5
10X54
1.5
5.0
10.0
6.5
CLK V3162065
200
1: Include “S” as EWS BTSZH_ for Superior models and Include “P” as EWS BTPZH_ for Premium models
Step 1SS: - Press and hold “SET” and ▲buttons simultaneously
for 3 seconds and release. Again, press and hold “SET” and ▲
buttons simultaneously for 3 seconds and release.
Step 2SS: - Press ▲or ▼buttons to select program “P 8”. Press
“SET” button to proceed to step 3SS.
Step 3SS: - Use ▲or ▼buttons to select “99” number of days
between regeneration. Note: - For weekly 7 days regeneration
specific scheduled regeneration for each day is required.
Step 4SS: - Use ▲or ▼buttons to switch between immediate
regeneration and scheduled regeneration.
When “Regen Time” arrow is not displayed then regeneration will
occur immediately and when “Regen Time” arrow is displayed the
regeneration will occur at scheduled time of day when DP switch
closes.

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FILTER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
4) CONTROL VALVE CYCLES
Service Cycle
In Service Cycle water flows through the upper basket and
flows down to the bottom distributor. In this operation water
is filtered downward through Media.
C1 Cycle
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 Media. The
water goes out through the drain line.

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FILTER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
Note: -Backwash and Rinse cycles bypass the supply water to the demand.
C4 Cycle
In Rinse Cycle water flows rapidly in downflow direction through
the Media to the drain. This cycle pack the media bed and washes
the media particles in downflow direction.
Service Cycle
After the end of rinse of cycle the control valve automatically
returns to the service operation.

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FILTER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
5) COMPONENTS OF CONTROL VALVE
Front Cover and PC Board
Drawing No.
Order No.
Description
Quantity
1
CLK V3175TC01
WS1TC FRONT COVER ASY
1
2
CLK V310701
WS1 MOTOR ASY
1
3
CLK 310601
WS1 DRIVE BRACKET & SPRING CLIP
1
4
CLK V3818TC
WS1TC PC BOARD 4-DIGIT
1
5
CLK V3110
WS1 DRIVE REDUCING GEAR 12 X 36
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 EU
CLK V3186UK
WS1 AC ADAPTER 220-240V-12V UK
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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FILTER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
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 V3135
O-ring 228
1
6
CLK V3180
O-ring 337
1
7
CLK V3105
O-ring 215 (Distributor Tube)
1
Not Shown
CLK V3001
WS1 Body ASY Downflow
1

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FILTER INSTALLATION AND USER GUIDE
BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
Injector Assembly
Drawing No.
Order No.
Description
Quantity
1
CLK V3176
INJECTOR CAP
1
2
CLK V3152
O-RING 135
1
3
CLK V30101Z
WS1 INJECTOR ASY Z PLUG
1
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.