Excalibur CHLOR-A-SOFT User manual

Page 1
Installation and Operation Manual
CHLOR-A-SOFT With Coconut Shell
Carbon
220 Bayview Avenue Unit #18
Barrie, Ontario L4N 4Y8
www.excaliburwater.com
Water Softener

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Table of Contents
Installation ......................................................................................................................... 3
Bypass Valve ...................................................................................................................... 6
Start-up Instructions ...........................................................................................................7
General Operation...............................................................................................................8
User Displays/Settings ....................................................................................................... 10
Installer Displays/Settings.................................................................................................. 12
Drawing and Part Numbers ................................................................................................ 13
Front Cover and Drive Assembly......................................................................................... 14
Drive cap Assembly, Down flow Piston, Regenerant Piston and Spacer Stack Assembly ........... 15
Injector Cap, Injector Screen, Injector, Plug and O-ring ....................................................... 16
Refill and Refill Port Plug.................................................................................................... 17
Drain Line – ¾” ................................................................................................................ 18
Drain Line – 1”.................................................................................................................. 19
Water Meter & Meter Plug.................................................................................................. 20
Installation Fitting Assemblies ............................................................................................ 21
Bypass Valve .................................................................................................................... 22
WS1 Wrench (order No. V3193) ......................................................................................... 23
Service Instructions........................................................................................................... 24
Troubleshooting................................................................................................................ 29
Warranty.......................................................................................................................... 31

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Installation
GENERAL INSTALLATION & SERVICE WARNINGS
The control valve, fittings and/or bypass are designed to accommodate minor plumbing
misalignments but are not designed to support the weight of a system or the plumbing.
Do not use Vaseline, oils, other hydrocarbon lubricants or spray silicone anywhere. A silicone
lubricant may be used on black o-rings but is not necessary. Avoid any type of lubricants,
including silicone, on red or clear lip seals.
Do not use pipe dope or other sealants on threads. Teflon tape must be used on the
threads of the 1” NPT elbow or the ¼” NPT connection and on the threads for the drain line
connection. Teflon tape is not necessary on the nut connections or caps because o-ring seals are
used. The nuts and caps are designed to be unscrewed or tightened by hand or with the special
plastic Service Wrench, #V3193. If necessary pliers can be used to unscrew the nut or cap. Do
not use a pipe wrench to tighten or loosen nuts or caps. Do not place screwdriver in slots
on caps and/or tap with a hammer.
SITE REQUIREMENTS:
•Water pressure, 20-125 psi •Current draw is 0.25 ampers
•Water temperature (to 30C) or (40 to 100F) •A 15-foot power cord is furnished
•The tank should be on a firm, level surface •The plug-in transformer is for dry locations only
•Electrical: Use a 115/120v, 60Hz uninterrupted
outlet
•Batteries are not used
1. The distance between the drain and the water conditioner should be as short as possible.
All plumbing should be done in accordance with local plumbing codes. NOTE: Maximum
head 15 10’ or 3 meters.
2. Since salt must be periodically added to the brine tank, it should be located where it is
easily accessible.
3. Do not install any water conditioner with less than 10 feet of piping between its outlet
and the inlet of a water heater.
4. Do not locate unit where it or its connections (including the drain and overflow lines) will
ever be subjected to room temperatures under 34F.

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5. The use of resin cleaners in an unvented enclosure is not recommended.
6. INLET/OUTLET PLUMBING: Connect to supply line downstream of outdoor spigots.
Install an inlet shutoff valve and plumb to the unit’s bypass valve inlet located at the
right rear as you face the unit. There are a variety of installation fittings available. They
are listed under Installation Fitting Assemblies. When assembling the installation
fitting package (Inlet and Outlet), connect the fitting to the plumbing system first and
then attach the nut, slit ring and o-ring. Heat from soldering or solvent cements may
damage the nut, split ring or o-ring. Solder joints should be cool and solvent cements
should be set before installing the nut, split ring and o-ring. Avoid getting solder flux,
primer and solvent cement on any part of the o-rings, split rings, bypass valve or control
valve. If the building’s electrical system is grounded to the plumbing, install a copper
grounding strap from the inlet to the outlet pipe. Plumbing must be done in
accordance with all applicable local codes.
7. DRAIN LINE: First, be sure that the drain can handle the backwash rate of the system.
Solder joints near the drain must be done prior to connecting the drain line flow control
fitting. Leave at least 6” between the drain line flow control fittings and solder joints.
Failure to do this could cause interior damage to the flow control. Install a 1/2” I.D.
flexible plastic tube to the Drain Line Assembly or discard the tubing nut and use the ¾”
NPT fitting for rigid pipe. If the backwash rate is greater than 7 gpm, use a ¾” drain line.
Where the drain line is elevated but empties into a drain below the level of the control
valve, form a 7” loop at the discharge end of the line so that the bottom of the loop is
level with the drain connection on the control valve. This will provide an adequate anti-
siphon trap. Where the drain empties into an overhead sewer line, a sink-type trap must
be used. Run drain tube to its discharge point in accordance with plumbing codes. Pay
special attention to codes for air gaps and anti-siphon devices
8. BRINE TANK CONNECTION: Install a 3/8” O.D. polyethylene tube from the Refill
Elbow to the Brine Valve in the brine tank.
9. OVERLOW LINE CONNECTION:
AN OVERFLOW DRAIN LINE RECOMMENDED WHERE A BRINE OVERFLOW COULD
DAMAGE FURNISHINGS OR THE BUILDING STRUCTURE.
Your softener may be equipped with a brine tank safety float which greatly reduces the
chance of an accidental brine overflow. In the event of a malfunction, however, an
OVERFLOW LINE CONNECTION will direct the “overflow” to the drain instead of spilling
on the floor where it could cause considerable damage. This fitting should be on the side
of the cabinet or the brine tank. To connect overflow fitting, locate hole in side of brine
tank. Insert overflow fitting into tank and tighten with plastic thumb nut and gasket from
the inside. Attach a length of 1/2” I.D. tubing (not supplied) to fitting and run to drain.
Do not elevate overflow line higher than 3” below bottom of overflow fitting. Do not “tie”
this tube into the drain line of the control valve. Overflow line must be a direct, separate
line from overflow fitting to drain, sewer, or tub. Allow an air gap as per the drain line
instructions.
IMPORTANT: Never insert a drain line directly into a drain, sewer line, or trap.
Always allow an air gap between the drain line and the wastewater to prevent the
possibility of sewage being back-siphoned into the conditioner.
10. SERIAL NUMBER: Record the serial number on the installer’s and customer’s records.
Bypass Valve
The bypass valve is typically used to isolate the control valve from the plumbing system’s
water pressure in order to perform control valve repairs or maintenance. The WS1 bypass

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valve is particularly unique in the water treatment industry due to its versatility and state of
the art design features. The 1” full flow bypass valve incorporates four positions including a
diagnostic position that allows service personnel to work on a pressurized system while still
providing untreated bypass water to the facility or residence. It’s completely non-metallic, all
plastic design allows for easy access and serviceability without the need for tools.
The bypass body and rotors are glass filled Noryl and the nuts and caps are glass filled
polypropylene. All seals are self-lubricating EPDM to help prevent seizing after long periods of
non-use. Internal o-rings can easily be replaced if service is required.
The bypass consists of two interchangeable plug valves that are operated independently by
red arrow shaped handles. The handles identify the flow direction of the water. The plug
valves enable the bypass valve to operate in four positions.
1. Normal Operation Position: 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 during normal operation and this position also allows the control valve
to isolate the media bed during the regeneration cycle. (see Figure 1)
2. Bypass Position: The inlet and outlet handles point to the centre of the bypass, the
control valve is isolated from the water pressure contained in the plumbing system.
Untreated water is supplied to the plumbing system. (see Figure 2)
3. Diagnostic Position: The inlet handle points in the direction of flow and the outlet
handle points to the centre 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. (see Figure 3)
4. Shut Off Position: The inlet handle points to the centre of the bypass valve and the
outlet points to the direction of flow, the water is shut off to the plumbing system. If
water is available on the outlet side of the softener it is an indication of water bypass
around the system (i.e. a plumbing connection somewhere in the building bypasses
the system). (see Figure 4)

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Start-up Instructions
•After installation is completed and checked for leaks, rotate the bypass handles to the
bypass position (see bypass valve diagram page).
•Fully open a cold water faucet.
•Allow water to run until clear to rid pipes of debris, which may have occurred during
installation.
•The system is now ready for testing:
1. With the bypass valve in the bypass position, manually pour enough water into
the brine tank to reach the top of the air check valve.
2. Press and hold the REGEN button for three seconds until the drive motor starts.
Wait until the motor stops and the display reads “Backwash”. The backwash time
will begin to count down.
3. Open the inlet handle of the bypass valve very slightly allowing water to fill the
tank slowly in order to expel air. CAUTION: If water flows too rapidly, there will
be a loss of media out of the drain.
4. When the water is flowing steadily to the drain without the presence of air, press
the REGEN button to advance the control to the brine position. The brine time
will begin to count down.
5. Fully open the inlet bypass valve handle (bypass is now in the diagnostic position)
Check to verify that water is being drawn from the brine tank
There should be a slow flow to the drain
Allow three minutes for the media bed to settle
6. Press the REGEN button again to advance the control to the next position and
allow water to run for 2-3 minutes. Control will transfer and the display will read
backwash or rinse depending on the program used. If backwash is displayed
press the REGEN button to advance the control to the rinse position. Allow water
to run to drain until clear.
7. Press the REGEN button to advance the control to where the display reads fill.
This will allow water to run into the brine tank and prepare it for the next
regeneration. Allow the brine tank to fill automatically.
8. While the brine tank is filling, load it with water softener salt.
9. SANTIZE! For each cubic foot of resin, add two ounces of 6% household chlorine
bleach to the water in the brine tank brine well. Press and hold the REGEN and
DOWN buttons simultaneously for three seconds to begin regeneration. Allow the
system to complete the regeneration automatically. The system will now be
sanitized and producing soft water. Be sure to check for local codes, which may
also specify sanitization methods.

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General Operation
PLEASE NOTE: For complete instructions refer to manual. Hand tighten nuts only.
GENERAL OPERATION
When the system is operating
one of two displays will be
shown: time of day will be one
choice, gallons of treated water
available or days until the next
regeneration will be the other choice.
Pressing NEXT will toggle
between the two choices.
TO SET TIME OF DAY
In the event of a prolonged
power outage, time of day
flashes, indicating that this
needs to be reset. All other
information will be stored in
memory no matter how long
the power outage, Please
complete the steps as shown to
the right. To access this mode,
press “SET CLOCK”.
1. Accessed by pressin
g
SET
CLOCK
2. Adjust hours with UP and
DOWN arrows. AM/PM
toggles at 12.
3. Press NEXT.
4. Adjust minutes with up
and down arrows.
5. Press “NEXT” to complete
and return to normal
operation
ADJUST HARDNESS,
DAYS BETWEEN
REGENERATIONS,
OR TIME OF
REGENERATION
For initial set-up or to make
adjustments, please complete
the steps as shown to the right.
Access this mode by pressing
“NEXT” and “” simultaneously.
Note: Hardness display shows
“-NA-“ if used as a filter. If
other displays do not appear
refer to manual.
1. Accessed by pressing
“SET CLOCK”.
2. Adjust hardness using
up and down arrows.
3.Press “NEXT”
4. Adjust days between
regenerations using up
and down arrows.
5. Press “NEXT”
6. Adjust time of
regeneration hours with
up and down arrows,
AM/PM toggles at 12.
7. Press “NEXT”
8. Adjust time of
regeneration minutes
with up and down
arrows.
9. Press “NEXT to
complete and return to
normal operation.

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MANUAL REGENERATION
NOTE: For softeners, if brine tank does not
contain salt, fill with salt and wait at least 2 hours
before regeneration.
If you need to initiate a manual regeneration,
either immediately, or tonight at the
preprogrammed time (typically 2 a.m.). complete
The following steps.
For Immediate Regeneration:
Press and hold REGEN
until valve motor starts (typically 3 seconds)
For Regeneration Tonight:
Press and release “REGEN”(notice that flashing “REGEN)
TODAY” appears).
If the display shows “E1,” “E2” or” E3” (for error), call
a service technician
To shut off water to the system, please position arrow handles as shown in the bypass operation
diagram below. If your valve doesn’t look like the diagram below, contact your service technician
for instructions on how to shut off water.
NOTES:
Installation Date:
Injector color
Installed:_________________
Drain Control
Size installed: _____________
Hardness (gpg):__________
Water Pressure:__________
Salt setting:_____________
Iron (ppm):_____________
Manganese (ppm):_______
TDS (ppm):_____________
pH:___________________

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User Displays/Settings
General Operation
When the system is operating one of two displays will be shown.
Pressing NEXT will alternate between the displays.
One of the displays is always the current time of day (to the nearest hour).
The second display is the days remaining until the next regeneration. If the
days remaining are equal to one, regeneration will occur at the next preset
regeneration time. The user can scroll between displays as desired.
If the system has called for a regeneration that will occur at the preset time of
regeneration, the words REGEN TODAY will appear on the display.
When water is being treated (i.e. water flowing through
The system) the word Softening or Filtering flashes on the display
If a water meter is installed.
Regeneration Mode
Typically a system is set to regenerate at a time of low water usage. An example
of a time with low water usage is when a household is asleep. If there is a demand
for water when the system is regenerating, untreated water will be used.
When the system begins to regenerate, the display will change to include information about the step of the
regeneration process and the time remaining for that step to be completed. The system runs through the
steps automatically and will reset itself to provide treated water when the regeneration has been completed.
Manual Regeneration
Sometimes there is need to regenerate the system, sooner than when the system
calls for it, to as a manual regeneration. There may be a period of heavy water
usage because of guests or a heavy laundry day.
To initiate a manual regeneration at the preset delayed regeneration time, when the regeneration time
option is set to “NORMAL” or “NORMAL + on 0”, press and release “REGEN”. The words “REGEN TODAY”
will flash on the display to indicate that the system will regenerate at the preset delayed time. If you
pressed the “REGEN” button in error, pressing the button again will cancel the request. Note: If the
regeneration time option is set to “on 0” there is not set delayed regeneration time so “REGEN TODAY” will
not activate if “REGEN” button is pressed.
To initiate a manual regeneration immediately, press and hold the “REGEN” button for three seconds. The
system will begin to regenerate immediately. The request cannot be cancelled.
Note: For softeners, if brine tank does not contain salt, fill with salt and wait at least two
hours before regenerating.

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Set Time of Day
The user can also set time of day. Time of day should only need to
be set after extended power outages or when daylight saving time
begins or ends. If an extended power outage occurs, the time of day
will flash on and off which indicates the time of day should be reset.
STEP 1U – Press SET CLOCK
STEP 2U – Current time: Set the clock to the closest hour by using
UP and DOWN button. AM/PM toggles after 12. Press NEXT to go to
step 3U.
STEP 3U – Current Time (minutes): Set the minutes of the day
using UP or DOWN buttons. Press NEXT to exit SET CLOCK. Press
REGEN to return to previous step.
Power Loss
If the power goes out for less than two hours, the system will automatically reset itself. If an extended
power outage occurs, the time of day will flash on and off which indicates the time of day should be reset.
The system will remember the rest.
Error Message
If the word “ERROR” and a number are alternately flashing on the display contact the OEM for help. This
indicates that the valve was not able to function properly.

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Installers Displays/Settings
STEP 1I – Press NEXT and UP simultaneously for 3 seconds.
STEP 2I – Hardness: Set the amount of hardness in grains of hardness as
calcium carbonate per gallon using the DOWN or UP buttons. The default is 20
with value ranges from 1 to 150 in 1 grain increments. Note the grains per gallon
can be increased if soluble iron needs to be reduced. This display will show “-NA-
“if “FILTER” is selected in Step 2F or if “AUTO” is not selected in Step 6S. Press
NEXT to go to step 3I. Press REGEN to exit Installer Displays/Settings.
STEP 3I – Day Override: When gallon capacity is set to off, sets the number of
days between regenerations. When gallon capacity is set to AUTO or to a
number, sets the maximum number of days between regenerations. If value set
to “OFF” regeneration initiation is based solely on gallons used. If value is set as
a number (allowable range from 1 to28) a regeneration initiation will be called
for on that day even if sufficient number of gallons were not used to call for
regeneration. Set Day Override using down or up buttons:
•Number of days between regeneration (1 to 28); or
•“OFF”.
See table 12 for more detail on softener setup and Table 13 for more detail on
filter 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 down or up buttons. AM/PM toggles after 12. The default time is 2:00 a.m.
This display will show “REGEN on 0 GAL” if”on0” is selected in Step 7F. 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 down or up buttons. This display will not be shown if “on 0” is
selected in Step 9S or Step 7F. Press NEXT to exit Installer Displays/Settings.
Press REGEN to return to previous step.
To initiate a manual regeneration immediately, press and hold the “REGEN”
button for three seconds. The system will begin to regenerate immediately. The
control valve may be stepped through the various regeneration cycles by
pressing the “REGEN” button.

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Drawings and
Part Numbers

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Front Cover and Drive Assembly
Drawing
No.
Order No. Description Quantity
1 CLK V3175TC01 WS1TC Front Cover ASY 1
2 CLK V310701 WS1 Motor 1
3 CLK V310601 WS1 Drive Bracket & Spring Clip 1
4 CLK V3108TC WS1TC PC Board 1
5 CLK V3110 WS1 Drive Gear 12 x 36 3
6 CLK V3109 WS1 Drive Gear Cover 1
CLK V3002TC WS1TC Drive ASY *
Not Shown CLK V3186 WS1 Transformer 110V-12V 1
* Drawing number parts 2 through 6 may be purchased as a complete assembly, part
CLK V3002TC.

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Drawing No. Order No. Description Quantity
1 CLK V3005 WS1 Spacer Stack Assembly 1
2 CLK V3004 Drive Cap ASY 1
3 CLK V3135 O-ring 228 1
4 CLK V3011 WS1 Piston Downflow ASY 1
5 CLK V3174 WS1 Regernerant Piston 1
6 CLK V3180 O-ring 337 1

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Injector Cap, Injector Screen, Injector, Plug and O-Ring
Drawing No. Order No. Description Quantity
1 CLK V3176 Injector Cap 1
2 CLK V3152 O-Ring 135 1
3 CLK V3177 Injector Screen 1
4 CLK V30101Z WS1 Injector ASY Z Plug 1
CLK V30101A WS1 Injector ASY A BLACK
CLK V30101B WS1 Injector ASY B BROWN
CLK V30101C WS1 Injector ASY C VIOLET
CLK V30101D WS1 Injector ASY D RED
CLK V30101E WS1 Injector ASY E WHITE
5 CLK V30101F WS1 Injector ASY F BLUE 1
CLK V30101G WS1 Injector ASY G YELLOW
CLK V30101H WS1 Injector ASY H GREEN
CLK V30101I WS1 Injector ASY I ORANGE
CLK V30101J WS1 Injector ASY J LIGHT BLUE
CLK V30101K WS1 Injector ASY LIGHT GREEN
Not Shown CLK V3170 O-ring 011 *
Not Shown CLK V3171 O-ring 013 *
* The Injector plug and the injector each contain one 011 (lower) and 013 (upper) o-ring.
NOTE: For down flow, injector is located in the down hole and injector plug in the up hole. For a
filter that only backwashes, injector plugs are located in both holes, and regenerant piston must
be removed.

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Refill and Refill Port Plug
Drawing
No.
Order No. Description Quantity
1 CLK V319501 WS1 Refill Port Plug ASY. This part is required for backwash only
systems
2 CLK H4615 Elbow Locking Clip 1
3 CLK JCPP6 Polytube insert 3/8 1
4 CLK JCPG6PBLK Nut 3/8 1
5 CLK H4613 Elbow Cap 3/8 1
6 CLK V3163 O-ring 019 1
7 CLK V316501* WS1 RFC Retainer Asy. 1
8 CLK V3182 WS1 RFC 1
Not
Shown
CLK H4650 Elbow ½" with nut and
insert
Option
* Assembly includes WS1 RFC

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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 CLKV3192 WS1 Nut ¾" Male Asy. Option
4 CLK V315801 WS1 Drain Elbow ¾ Male
Asy.
1
5 CLK V3163 O-ring 019 1
6 CLK V315901 WS1 DLFC Retainer Asy. 1
CLK V3162007 WS1 DLFC 0.7 gpm for ¾"
CLK V3162010 WS1 DLFC 1.0 gpm for ¾"
CLK V3162013 WS1 DLFC 1.3 gpm for ¾"
CLK V3162017 WS1 DLFC 1.7 gpm for ¾" One
CLK V3162022 WS1 DLFC 2.2 gpm for ¾" DLFC
CLK V3162027 WS1 DLFC 2.7 gpm for ¾" must be
7 CLK V3162032 WS1 DLFC 3.2 gpm for ¾" used if
CLK V3162042 WS1 DLFC 4.2 gpm for ¾" ¾"
CLK V3162053 WS1 DLFC 5.3 gpm for ¾" fitting is
CLK V3162065 WS1 DLFC 6.5 gpm for ¾" used
CLK V3162075 WS1 DLFC 7.5 gpm for ¾"
CLK V3162090 WS1 DLFC 9.0 gpm for ¾"
CLK V3162100 WS1 DLFC 10.0 gpm for
¾"

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Drain Line – 1"
Drawing
No.
Order No. Description Quantity
1 CLK H4615 Elbow Locking Clip 1
2 CLK V300802 WS1 Drain FTG 1 Straight 1
3* CLK V3166 WS1 Drain FTG Body 1 1
4* CLK V3167 WS1 Drain FTG Adapter 1 1
5* CLK V3163 O-ring 019 1
6* CLK V3150 WS1 Split Ring 1
7* CLK V3150 WS1 Nut 1" QC 1
8* CLK V3105 O-ring 215 1
CLK V3190090 WS1 DLFC 9.0 gpm for 1
CLK V3190100 WS1 DLFC 10.0 gpm for 1 One
CLK V3190110 WS1 DLFC 11.0 gpm for 1 DLFC
9 CLK V3190130 WS1 DLFC 13.0 gpm for 1 must be
CLK V3190150 WS1 DLFC 15.0 gpm for 1 used if
CLK V3190170 WS1 DLFC 17.0 gpm for 1 1" fitting
CLK V3190200 WS1 DLFC 20.0 gpm for 1 is used
CLK V3190250 WS1 DLFC 25.0 gpm for 1
* Can be ordered as a set order number CLK V300802, description: WD Drain FTG 1 Straight