Excalibur Water Systems Sureflo SFC Series User manual

REVERSE OSMOSIS SFC SERIES
INSTALLATION AND USER GUIDE

BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
1
Reverse Osmosis System Installation
Table of Contents
Introduction............................................................................................................................................................................. 3
MANUAL USER’S GUIDE ...................................................................................................................................................... 3
DISCLAIMER STATEMENT.................................................................................................................................................... 3
PROPRIETARY RIGHTS STATEMENT .................................................................................................................................... 3
Installation .............................................................................................................................................................................. 4
EQUIPMENT SUPPORT ........................................................................................................................................................ 4
GENERAL SAFETY GUIDELINES ............................................................................................................................................ 4
SAFETY PRECAUTIONS......................................................................................................................................................... 5
SAFETY EQUIPMENT............................................................................................................................................................ 5
REQUIRED TOOLS AND PARTS ............................................................................................................................................ 5
EQUIPMENT INSTALLATION GUIDELINES............................................................................................................................ 6
EQUIPMENT INSTALLATION PROCEDURES ......................................................................................................................... 6
ELECTRICAL INSTALLATION ................................................................................................................................................. 7
START UP INSTRUCTIONS........................................................................................................................................................ 8
PROCEDURE ........................................................................................................................................................................ 8
VALVE POSITIONS AND EQUIPMENT STAGE....................................................................................................................... 8
VALVE POSITIONS EFFECT (↑=Increase; ↓=Decrease) .................................................................................................. 8
PIPING AND INSTRUMENTATION (No Clean in Place) ........................................................................................................ 9
.............................................................................................................................................................................................. 14
Series 150 Controller............................................................................................................................................................. 15
DISPLAY AND STATUS INDICATORS................................................................................................................................... 15
System operation.................................................................................................................................................................. 16
GENERAL OPERATION ....................................................................................................................................................... 16
TANK FULL OPERATION..................................................................................................................................................... 16
TANK FULL RESTART.......................................................................................................................................................... 16
TANK FULL OVERRIDE ....................................................................................................................................................... 16
AUTO RESET ...................................................................................................................................................................... 16
ALARM RESET.................................................................................................................................................................... 17
PRETREAT.......................................................................................................................................................................... 17
HIGH TDS / CONDUCTIVITY WARNING/ALARM................................................................................................................ 17
OPERATING HOURS EXCEEDED......................................................................................................................................... 17
I/O EXPANDER................................................................................................................................................................... 17
CONTROLLER LAYOUT........................................................................................................................................................... 18
CONTROLLER SETPOINTS ...................................................................................................................................................... 19
CHANGING/DISPLAYING SETPOINTS................................................................................................................................. 21

BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
2
Reverse Osmosis System Installation
MEMBRANE FLUSH ........................................................................................................................................................... 21
FLUSH MODE..................................................................................................................................................................... 22
.............................................................................................................................................................................................. 22
Flow Rate Specifications ....................................................................................................................................................... 23
sfc unit MODELS/views of critical components .................................................................................................................... 24
.............................................................................................................................................................................................. 27
.............................................................................................................................................................................................. 28
.............................................................................................................................................................................................. 29
Service Instructions............................................................................................................................................................... 31
REGULAR MAINTENANCE.................................................................................................................................................. 31
MEMBRANE DIAGRAM...................................................................................................................................................... 31
MEMBRANE REPLACEMENT.............................................................................................................................................. 32
SEDIMENT FILTER CARTRIDGE REPLACEMENT ................................................................................................................. 32
SHUTDOWN PROCEDURE ................................................................................................................................................. 32
SHORT-TERM SHUTDOWN (MAINTENANCE OR SERVICE)............................................................................................ 32
LONG-TERM SHUTDOWN (21 DAYS - 1 YEAR) .............................................................................................................. 32
Troubleshooting.................................................................................................................................................................... 33
RO Controller .................................................................................................................................................................... 33
SOLENOID VALVE TROUBLESHOOTING............................................................................................................................. 34
BW FLOWMETER INFORMATION...................................................................................................................................... 35
HIGH PRESSURE / BOOSTER PUMP................................................................................................................................... 36
PUMP TROUBLESHOOTING........................................................................................................................................... 37
MULTI-STAGE VERTICAL PUMP......................................................................................................................................... 41
....................................................................................................................................................................................... 41
PUMP TROUBLESHOOTING........................................................................................................................................... 42
SEDIMENT FILTER HOUSING ............................................................................................................................................. 43
Performance and service log ................................................................................................................................................ 45
Warranty ............................................................................................................................................................................... 46

BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
3
Reverse Osmosis System Installation
INTRODUCTION
MANUAL USER’S GUIDE
This manual describes the procedures necessary to install, operate, and maintain your Excalibur Water Systems
Treatment System. Please read this manual carefully before installing and operating your equipment. The
equipment warranty may be voided if installation or operation instructions are not followed correctly.
This manual has been formatted for ease of use, combining the instruction for the entire RO unit into one
manual. Literature supplied with some major components being used on this equipment is provided in the back
of this manual.
DISCLAIMER STATEMENT
The operation and maintenance manual is intended to be used with the information provided in the component
manufacturer’s literature. These manuals should provide complete and accurate information to meet your
operating and/or service requirements based on the information available at the time of publication. However,
Excalibur Water Systems assumes no responsibility for the technical content of the component manufacturer’s
literature.
The information in these manuals may not cover all operating details or variations or provide for all conditions
in connection with installation, operation and maintenance. Should questions arise which are not answered
specifically in this manual, contact the Excalibur Water Systems Service Department.
Excalibur Water Systems reserves the right to make engineering refinements that may not be reflected in these
manuals. The material in these manuals is for informational purposes and is subject to change without notice.
PROPRIETARY RIGHTS STATEMENT
This manual discloses information in which Excalibur Water Systems has proprietary rights. Neither receipt
nor possession of this manual confers or transfers any right to the client, and by its retention hereof, the client
acknowledges that it will not reproduce or cause to be reproduced, in whole or in part, any such information
except by written permission from Excalibur Water Systems. The client shall have the right to use and disclose
to its employees the information contained herein for the purpose of operating and maintaining the Excalibur
Water Systems equipment, and for no other purpose.
In the event the content of this manual is altered or section/items are omitted during a reproduction, in whole or
in part, and instructions or definitions within the reproduction result in personal injury to those who follow the
altered instructions, the burden of responsibility for personal injury falls solely on the party who affects the
reproduction.

BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
4
Reverse Osmosis System Installation
INSTALLATION
EQUIPMENT SUPPORT
Excalibur Water Systems continually strives to provide safe, efficient, trouble-free equipment using the
optimum technology for your application. If problems should develop, our technical support line will be
available to provide assistance. For service, sales, parts, or additional manual copies call your area
representative or the number provided on the bottom of the manual pages.
GENERAL SAFETY GUIDELINES
This equipment operates at high voltage and high pressure, has moving parts and hazardous chemicals that
may cause serious injury or fatality if not operated and maintained according to the procedures outlined in
this manual.
1. No one should use or service this equipment without proper training and supervision. It is the responsibility
of the owner to ensure that this equipment is used properly and safely, strictly following the instructions
contained herein.
2. Always remain alert during the operation of this equipment. Do not get near this equipment if you are
drowsy or impaired in any way.
3. Always wear safety equipment (safety glasses, gloves) for protection while working on the equipment.
4. Refer to Material Safety Data Sheets prior to handling hazardous chemicals.
5. Always operate the equipment at the parameters specified.
6. Never connect the system to piping that has not been approved by Excalibur Water Systems. If there are any
doubts, please call your Excalibur Water Systems local branch.
7. Never remove any components from the unit while under pressure.
8. No one under the age of 18 years of age should operate or be allowed near this equipment.
9. Warning labels have been placed on the equipment to remind the operator of certain hazards. Never remove
these labels. If any warning label is illegible or missing, please contact Excalibur Water Systems for a free
replacement.
10. Proper maintenance assures the equipment will run properly and can lower the risk of injury. Be sure to
follow the instructions on maintenance carefully.
11. Be sure to maintain all equipment, tools and sub-systems used with the equipment.
12. Continuously inspect the system for leaks and damage. Correcting problems as they occur will help prolong
the life of the system.
13. Use Lock-Out and Tag-Out devices when servicing the unit.

BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
5
Reverse Osmosis System Installation
14. This manual should be used as a guidance tool and should not replace common sense. If you are unsure
about a procedure, ask your supervisor. Excalibur Water Systems welcomes any questions you may have
and can arrange to provide on-site training if necessary.
SAFETY PRECAUTIONS
The purpose of this manual is to provide the user with the necessary information to operate this equipment
without undue risk. Failure to follow the instructions laid forth in this manual may put the operators at risk of
injury and possible fatality. Please read this entire manual before beginning any procedure; it should always
remain with the equipment to act as a ready reference guide for anyone who operates this system.
SAFETY EQUIPMENT
Below is a list of equipment and materials that should be kept nearby the equipment.
1. Lock-out and Tag-out devices for servicing and shutdowns.
2. Eyewash/safety shower for any chemical accidents.
3. Safety glasses are always to be worn.
4. Earplugs should be worn when encountering high levels of noise.
5. Gloves that offer protection from the chemicals used herein.
6. Steel toe work boots for protection against heavy equipment and components.
REQUIRED TOOLS AND PARTS
The tools and parts specified in this section are the minimum required to install the RO unit at the site. The use
of other tools and parts may be necessary, depending on the location chosen and other parameters.
Required Tools
Lock-Out/Tag-Out equipment
Safety glasses, gloves, earplugs
Moving equipment
Hammer drill with masonry bit
Pipe cutting, bending, gluing equipment
Required Material
Concrete anchor bolts (size determined by local seismic calculations).
Plumbing and electrical materials as required

BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
6
Reverse Osmosis System Installation
EQUIPMENT INSTALLATION GUIDELINES
1. All lifting and moving procedures must be performed by experienced construction workers using
standard rigging methods.
2. Before beginning any equipment handling procedures, refer to the appropriate sections in the
Occupational Health and Safety Act: “General Industry Standards.” Also, refer to any other
applicable literature and information for cranes, lift trucks, and other equipment used for lifting and
moving.
3. Make sure all equipment used for lifting and moving is properly maintained and is in good repair.
4. Be sure that components being lifted are balanced and will not tip or slip out of the lifting device.
EQUIPMENT INSTALLATION PROCEDURES
1. Locate a level, flat, clean, hard surface, capable of supporting the weight of the RO unit. Refer to the
Equipment Specification Drawing to determine the floor loading requirements and the service access
space requirements for the unit.
NOTE: This area should have a local floor drain to carry away water which will fall to the floor during
operation, testing, and servicing of this equipment.
2. Lay out the area that the RO System will occupy.
3. Move the RO unit to the location laid down in the previous step.
4. Drill holes in the pad through the frame tie down holes.
5. Level the RO unit by installing shim stock under the frame near the frame tie down holes.
6. Install the anchor bolts and secure the frame to the anchor bolts using flat washers, lock washers, and
nuts.
Do not use the RO unit to support external piping. All plumbing runs should be supported per
manufacturers’ recommendations and local codes.
7. Install the feed water plumbing line. The plumbing runs should never be smaller than the actual RO inlet
pipe size and may need to be larger for pipe runs over 50 feet.
NOTE: The plumbing materials should be of non-corroding materials (PVC, SST,Copper etc.) Use of
this material will reduce the tendency to foul the membranes from metal precipitation.
8. Install the reject line directly to an open drain.

BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
7
Reverse Osmosis System Installation
NOTE: As a rule, no valves should be installed in this line. If necessary, install a relief valve set at no greater
than 5 PSIG. The valve should be directed to a visible drain, so relief is clear.
If the reject drain is below the level of the RO unit, install a vacuum breaker valve or open pipe
leg on the reject line. This will prevent siphoning of all water out of the RO unit during
shutdown.
9. A mechanical float switch is provided with each unit. The switch must be disconnected from the Series
150 controller, installed in the storage tank, and rewired to the controller.
The plumbing installation should now be complete. Check the plumbing to ensure all joints are properly
connected and supported.
ELECTRICAL INSTALLATION
The following steps consist of electrical work to be performed by a qualified electrician only.
1. Employ a Lock Out Device and Lock Out Tag on the RO unit main power supply disconnect switch.
2. Run electrical conduit for the high voltage power supply between the Control Panel and the main power
supply.
3. Connect any required wiring between the Controller the product water storage tank level sensing device,
if required.
4. Verify that all electrical connections are secure and wired per the electrical schematic.
5. Remove the Lock-Out / Tag-Out equipment from the main power supply for the RO unit, and energize
the circuit.
Verify that the voltage supplied is correct and matches the Voltage Identification Tag located on the pump
motor

BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
8
Reverse Osmosis System Installation
START UP INSTRUCTIONS
PROCEDURE
The plumbing must be inspected properly before releasing the water pressure into the system. Direct the product
water flow to drain for first hour of operation. Slowly open the supply valve halfway located upstream of the RO.
Connect electrical power to the system. Press the start button and record the pump pressure gauge (Shut off the
system immediately if pump pressure rises more than 150psi), the pump should start after a delay. The TDS
conductivity will be displayed on controller which should decrease gradually. When concentrate flow and
permeate flow stabilizes this means the air has been flushed out of the system. Tune up the concentrate valve and
recirculation valve according to the flow rates given on the performance data sheet or WAVE projection. Check
the pump pressure gauge and membrane pressure gauge. The pressure difference should always be less than 30
psi. After the normal run time of 1 hour permeate (product) flow can diverted to storage tank. The safety float
switch in the storage tank must be lifted by hand and held for 30 seconds. The RO pump should shut off and there
should be no permeate flow. The RO pump should start up again after few seconds of delay once the float switch
is released. After 24 hours of operation the TDS, Permeate Flow, Concentrate Flow, Recirculation Flow, Pump
Pressure and Membrane Pressure must be recorded and confirmed again.
VALVE POSITIONS AND EQUIPMENT STAGE
VALVE POSITIONS EFFECT (↑=Increase; ↓=Decrease)
Valve
Position
Concentrate Valve (Flow Meter)
Fully Open
Recirculation Valve (Flow Meter)
¼ Open
Drain
Fully Open
Water Supply
Fully Open (Slowly)
Storage Tank
Ready for use
Pre-Treatment Equipment
Ready for use
Valve Action Product
Flow
Concentrate
Flow
Recirculation
Flow
Pump
Pressure
Membrane
Pressure
Concentrate
Closes ↑↓↑↑↑
Open ↓↑↓↓↓
Recirculation
Closes ↓↑↓↑↑
Open ↑↓↑↓↓

BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
9
Reverse Osmosis System Installation
PIPING AND INSTRUMENTATION (No Clean in Place)
SFC4

BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
10
Reverse Osmosis System Installation
SFC5

BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
11
Reverse Osmosis System Installation
SFC6

BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
12
Reverse Osmosis System Installation
SFC8

BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
13
Reverse Osmosis System Installation
SFC14

BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
14
Reverse Osmosis System Installation
SFC18

BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
15
Reverse Osmosis System Installation
SERIES 150 CONTROLLER
Reverse Osmosis controls the outputs of pressure pump, inlet solenoid valve and flush valve. Controller senses
the input signal from inlet pressure switch, tank full switch, pre-treat lockout switch and TDS conductivity cell.
The controller functions, switches and TDS calibration can be controlled by switching jumpers on control board.
DISPLAY AND STATUS INDICATORS
LED DISPLAY View system status
ALARM
Flashes when a fault causes a system shutdown. Steady
when setpoint is exceeded but has not shutdown the RO
system
POWER Places controller in operating mode or standby
ALARM
SILENCE/RESET
One press for alarm silence, twice to reset the system
after a shutdown condition
ENTER Confirm Setpoint value
UP ARROW Increase value of Setpoint
DOWN ARROW Decrease value of Setpoint
LEFT ARROW Scroll through Setpoints starting at the first
RIGHT ARROW Scroll through Setpoints starting at the last
Operating Status
Messages
Description
OPERATING
RO unit is in operation.
STANDBY
RO unit is in standby mode.
DELAY 99
RO unit in start delay mode. The number is equal to time (sec) remaining before RO pump starts.
PRETREAT
RO unit shut down due to a pretreat lockout condition.
TANK FULL
RO unit tank is full and has shut down.
TANK FULL 99
RO unit tank is full and has shut down. Blinking number means the tank full high switch has
cleared but the low switch is still active. A steady number indicates both switches cleared, and
delay is now counting down.
MEMB FLUSH 99
Membrane flush initiated. Number is equal to time (min) remaining in flush cycle.
PRESS FAULT
RO unit has shut down due to a pressure fault condition.
Warning Messages
Description
HI TDS / Cond
TDS/Conductivity reading is beyond programmed limit.
OP HOURS
EXCEEDED
Operating hours have exceeded the programmed limit.
TANK LOW
RO unit tank low input is active.
TANK LOW 99
RO unit tank low has cleared, restart delay is now active. Number is equal to time (min) left in
the delay.
The display is a 2-line x 20-character backlit LCD. System
operating status and sensor readings are shown on this display.
Setpoint information is also shown on this display.

BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
16
Reverse Osmosis System Installation
SYSTEM OPERATION
GENERAL OPERATION
The unit has 2 modes of operation, a standby mode and an operating mode. In the standby mode, the unit is
effectively off. All outputs are turned off and the display shows STANDBY. In the operating mode, the unit
operates automatically. All inputs are monitored, and the outputs are controlled accordingly. Pressing the Power
key will toggle the unit from standby to operate or from operate to standby. If power is removed from the unit,
when power is reapplied, the unit will restart in the mode it was in when power was removed.
TANK FULL OPERATION
The unit can be operated with 1 or 2 level switches. With 1 level switch, the switch is connected to the tank full
high input. When this switch has been active for 5 seconds, the unit will shut down on tank full. TANK FULL
will show on the display. When the tank full condition clears, the display will show TANK FULL 99. The number
is the tank full restart time and the unit will restart when this delay times out.
For 2 level switch operation, the upper switch is connected to the tank full high input and the lower switch is
connected to the tank full low input. When both switches are clear, the RO unit will run. The RO unit will continue
to run when the water level rises, and the lower switch becomes active. When the upper switch becomes active,
after the 5 second delay, the RO unit will shut down. TANK FULL will show on the display. When the tank level
drops and the upper-level switch clears, the display will show TANK FULL 99 and the RO unit will remain off.
The number is the tank full restart time, and the number will blink until the lower-level switch clears. When the
lower-level switch clears, the number will remain steady, and the RO will restart when the delay times out.
TANK FULL RESTART
The tank full restart is the delay before the RO unit starts when a tank full condition clears. This delay can be in
minutes or in seconds. The TF Restart Setpoint selects seconds or minutes.
TANK FULL OVERRIDE
A timed tank full override can be initiated when the RO unit is shut down due to a tank full condition. Pressing
the Alarm Silence/Reset key for 3 seconds during a tank full condition will enable the tank full override. The RO
will start and TF OVERRIDE 9 will show on the display. The number is the minutes remaining in the override
timer. When the override times out, the unit will return to the tank full shut down condition.
AUTO RESET
If a pressure fault shut down occurs and the Auto Reset Setpoint is programmed to 0, the unit will remain shut
down until manually reset. If the Auto Reset Setpoint is programmed to a value greater than 0, the unit will
automatically clear the pressure fault and attempt to restart after this delay times out.

BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
17
Reverse Osmosis System Installation
ALARM RESET
When a shutdown occurs that causes the audible alarm to sound, the alarm can be silenced by pressing the Alarm
Silence/Reset key once. The alarm will remain silenced if the Alarm Silence Setpoint is programmed to 0. If the
Alarm Silence Setpoint is programmed to a value greater than 0, the alarm will resound after this delay times out.
Pressing the Alarm Silence/Reset key will silence the alarm and reset this delay.
PRETREAT
If the pretreat input becomes active and stays active for 2 seconds, the unit will shut down in a pretreat lockout
condition. PRETREAT will show on the display and the unit will remain shut down as long as the pretreat input
is active.
HIGH TDS / CONDUCTIVITY WARNING/ALARM
If the TDS / Conductivity reading exceeds the limit programmed the TDS / Cond Limit Setpoint for the delay
programmed in the TDS / Cond Delay Setpoint, the alarm lamp will light and the HI TDS / Cond warning message
will show on the display. This warning will clear when the TDS /Conductivity drops below the Setpoint. If the
TDS / Cond Shutdown Setpoint is programmed to 0, the unit will continue to operate. Otherwise, once a high
TDS / Cond warning occurs, after the time programmed in this setpoint, the RO unit will shut down and the alarm
will sound. The alarm can be cleared by pressing the Alarm Silence/Reset key twice. NOTE: the auto reset
function is not active for this shut down.
OPERATING HOURS EXCEEDED
If the current hours exceed the limit programmed in the Maximum Hours Setpoint, the alarm lamp will light,
and the OP HOURS EXCEEDED warning message will be shown. This warning can be cleared by
programming the current hours to 0 or by increasing the maximum hours limit.
I/O EXPANDER
The I/O Expander board adds 2 relays and 1 switch input. The operation and programming of the 2 relays is
described in the installation section. Consult the manufacturer for more information regarding the I/O Expander
Board

BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
18
Reverse Osmosis System Installation
CONTROLLER LAYOUT

BARRIE ●ONTARIO ●CANADA 705.733.8900 WWW.EXCALIBURWATER.COM
19
Reverse Osmosis System Installation
CONTROLLER SETPOINTS