Excalibur EWS S1590 User manual

BARRIE • ONTARIO • CANADA TF: 705.733.8900 WWW.EXCALIBURWATER.COM
WATER SOFTENER 1.5” SIMPLEX
INSTALLATION AND USER GUIDE

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 705.733.8900 WWW.EXCALIBURWATER.COM
TABLE OF CONTENTS
1) Installation ............................................................................................................................................ 3
1.1) Pre-installation instructions.......................................................................................................... 3
1.2) General Installation and Service Warnings................................................................................... 3
1.3) Site Requirements......................................................................................................................... 3
1.4) Installation Drawing ...................................................................................................................... 4
1.5) Piping and Instrumentation Drawing............................................................................................ 5
1.6) System Drawing ............................................................................................................................ 6
1.7) Plumbing ....................................................................................................................................... 6
1.8) Brine Line Connection ................................................................................................................... 6
1.9) Overflow Line Connection............................................................................................................. 7
1.10) Drain Line .................................................................................................................................. 7
1.11) 3-Way Bypass Valve .................................................................................................................. 7
1.12) Loading Instructions.................................................................................................................. 9
1.13) Start Up Instructions ............................................................................................................... 10
2) Programming ...................................................................................................................................... 11
2.1) Regeneration and Error Screens .................................................................................................11
2.2) Button Operation........................................................................................................................11
2.3) User Displays............................................................................................................................... 12
2.4) Setting Time of Day ..................................................................................................................... 13
2.5) Configuration Settings ................................................................................................................13
2.6) Installer Display Settings .............................................................................................................14
2.7) OEM Softener System Setup....................................................................................................... 15
2.8) Diagnostics ..................................................................................................................................17
3) Model Variable Programming and Components ................................................................................ 19
3.1) Programming ..............................................................................................................................19
3.2) Flow Controls and Injectors ........................................................................................................19
3.3) Specifications ..............................................................................................................................20
4) Control Valve....................................................................................................................................... 21
4.1) Control Valve Specifications........................................................................................................... 21
4.2) Control Valve Drawing ................................................................................................................23
4.3) Flow Diagrams............................................................................................................................. 24
4.4) Components of Control Valve..................................................................................................... 27

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 705.733.8900 WWW.EXCALIBURWATER.COM
5) Brine Tank Assembly........................................................................................................................... 32
6) Quick Reference Guide ....................................................................................................................... 33
7) Service Instructions............................................................................................................................. 35
7.1) Front Cover Removal ..................................................................................................................35
7.2) PC Board Removal....................................................................................................................... 36
7.3) Drive Bracket Removal................................................................................................................37
7.4) Drive Cap Removal...................................................................................................................... 38
7.5) Piston Removal ...........................................................................................................................39
7.6) Stack Assembly Removal.............................................................................................................40
7.7) Injector Cap Removal..................................................................................................................41
8) Troubleshooting.................................................................................................................................. 42
8.1) Possible Error Codes ................................................................................................................... 42
8.2) Troubleshooting Procedures.......................................................................................................43
9) 5 Year Warranty .................................................................................................................................. 47

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

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 705.733.8900 WWW.EXCALIBURWATER.COM
1.4) Installation Drawing

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 705.733.8900 WWW.EXCALIBURWATER.COM
1.5) Piping and Instrumentation Drawing

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 705.733.8900 WWW.EXCALIBURWATER.COM
1.6) System Drawing
1.7) Plumbing
•The 3-way bypass valves must be installed.
•The softener must be close to drain as much as possible.
•The primer, solder or solder flux must not get on the O-rings.
•After soldering the lines must be cooled before installing the O-Rings, nuts and caps.
•If the electrical system is grounded to the plumbing than copper strap must be connected
between inlet and outlet as shown in figure above.
•The plumbing must be done by following the local plumbing codes.
•The unit including the drain must be located in a room temperature above 40° F.
•Never let the vacuum occur in tank this may cause implosion and leakage. If vacuum occurrence
is expected than vacuum breaker must be installed in line.
1.8) Brine Line Connection
Install the 1/2” or 3/4” O.D. Polyethylene tube according to specification sheet from the brine tank to
the control valve.

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 705.733.8900 WWW.EXCALIBURWATER.COM
1.9) Overflow Line Connection
The overflow drain line is used where overflow of the brine tank can damage the floor finishing or
structure. The brine tank line is equipped with safety float valve which prevents the overflow so, the
overflow line is only used in case is overflow float valve fails. The overflow line will transfer fluid from
brine tank to the drain hence prevents the spillage.
1.10) Drain Line
•Leave minimum of 6” gap between flow control fitting and solder joints. The gap less than this
can damage the flow control.
•Use ¾”, 1” or 1.25” tubing or pipe for drain line according to the specifications.
•If the drain line is elevated and then emptied into the drain below the level the of control valve
the 7” loop should make at the end of drain line.
•The air gap between the drain and the end of the drain line must be twice the diameter of the
tube or pipe
•The strap must be tied at the end to secure the line.
1.11) 3-Way Bypass Valve
The shut off valves must be installed at inlet and outlet of control valve. The bypass pipe including the
ball valve must also be installed to bypass the hard water to supply.

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 705.733.8900 WWW.EXCALIBURWATER.COM
Normal Position: - Fully close the bypass valve and fully open
both valves at inlet and outlet of the control valve. The supply
water (untreated) enters in and treated water exits.
Bypass Position: - The inlet and outlet valves at the control
valve must be fully closed but the bypass valve must be fully
open. The supply water enters and bypass the control valve
and exits untreated as supply water.
Diagnostic Position: - The outlet valve must be fully closed but
bypass valve and inlet valve must be fully open. The untreated
water will be supplied but in this position technician will be
able to draw a brine and perform other tests.
Shut Off Position: - All three valves must be at fully closed
position. The water supply is shut down means there will be
no flow at the outlet.
NORMAL POSITION
BYPASS POSITION
DIAGNOSTIC POSITION
SHUT OFF POSITION
Open
Open
Open
Open
Close
Close
Close
Close
Close
Close
Open
Open

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 705.733.8900 WWW.EXCALIBURWATER.COM
1.12) Loading Instructions
Step 1: Check the product upon arrival and remove from box packaging checking for any shipping
damage or shortages that must be reported to Excalibur Water Systems immediately for confirmation.
Step 2: Insert distributor(s) inside of media mineral tank(s) so it is positioned properly in the bottom
centre groove. If not already sized properly cut the top of the distributor pipe ½ - ¾” above top of tank
opening and clean off and excess PVC materials with grit cloth.
Step 3: Plug the top inlet opening of the distributor (Hub & Lateral) or bottom stack with a clean cloth,
rag, or tape to prevent any gravel or resin from entering into the distributor tube.
Step 4: Load the gravel under bedding onto the mineral tank using a funnel or some sort of loading
devise. If multiple layers of gravel with different sizes being utilized always load the largest gravel size in
diameter to the smallest last.
Step 5: Load the water softening cation exchange resin also by the use of a funnel or some sort of
loading device until all resin is inside of mineral tank. If loading a duplex system that has two tanks
divide the resin and gravel up equally when loading.
Step 6: Remove top opening cover of the distributor carefully not to move or disturb the distributor
tube not allowing any debris or materials to get inside of the now loaded softener(s).
Step 7: Thread on control valves onto top opening tanks be sure to check and verify that the O-ring on
the bottom base of the control valve is present and properly lubricated with silicone. Tighten control
valve(s) clockwise until you have reached the end of the thread and have secured a water tight seal. (If
control valves that utilize quick connect collars thread the collars the same into the tanks then attach
control valves).
Step 8: Precede now with the unit(s) in their proper installation locations to run piping and materials for
all inlet, outlet, and drain connections properly with isolation valves and test ports for future water
tests. Also unions should be included in installation materials for easy future servicing of the control
valves when necessary on all inlet, outlet, and drain lines.