Excalibur EWS SD130 User manual

BARRIE • ONTARIO • CANADA TF: 705.733.8900 WWW.EXCALIBURWATER.COM
WATER SOFTENER 1” DUPLEX ALTERNATING
INSTALLATION AND USER GUIDE

1
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) Loading Instructions...................................................................................................................... 4
1.5) Installation Drawing ...................................................................................................................... 5
1.6) Piping and Instrumentation Drawing............................................................................................ 6
1.7) Installation Instructions ................................................................................................................ 7
1.8) Plumbing ....................................................................................................................................... 7
1.9) Brine Line Connection................................................................................................................... 7
1.10) Overflow Line Connection......................................................................................................... 8
1.11) Drain Line .................................................................................................................................. 8
1.12) System Drawing ........................................................................................................................ 9
1.13) Bypass Valve............................................................................................................................10
1.14) Wiring......................................................................................................................................12
1.15) ALT A Control Valve Wiring .....................................................................................................13
2) Programming and Start Up ................................................................................................................. 14
2.1) Regeneration and Error Screens .................................................................................................14
2.2) Button Operation........................................................................................................................14
2.3) User Displays............................................................................................................................... 16
2.4) Setting Time of Day.....................................................................................................................16
2.5) Startup Instructions ....................................................................................................................17
2.6) Configuration Settings ................................................................................................................18
2.7) Installer Display Settings .............................................................................................................19
2.8) OEM Softener System Setup....................................................................................................... 20
2.9) Specifications ..............................................................................................................................24
2.10) Programming Summary ..........................................................................................................25
2.11) Flow Controls and Injectors .................................................................................................... 25
3) Control Valve....................................................................................................................................... 26
3.1) Control Valve Function and Cycles ofOperation..........................................................................26
3.2) Flow Diagrams............................................................................................................................. 27
3.3) Components of Control Valve..................................................................................................... 30

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 705.733.8900 WWW.EXCALIBURWATER.COM
3.4) Motorized Alternating Valve (MAV) ...........................................................................................41
4) Brine Tank Assembly........................................................................................................................... 42
5) Quick Reference Guide ....................................................................................................................... 43
6) Service Instructions............................................................................................................................. 45
6.1) Front Cover Removal ..................................................................................................................45
6.2) PC Board Removal....................................................................................................................... 46
6.3) Drive Bracket Removal................................................................................................................47
6.4) Drive Cap Removal...................................................................................................................... 48
6.5) Spacer Stack Removal ................................................................................................................. 49
6.6) Injector Cap Removal..................................................................................................................50
7) Troubleshooting.................................................................................................................................. 51
7.1) Possible Error Codes ................................................................................................................... 51
7.2) Troubleshooting Procedures....................................................................................................... 52
8) 5 Year Warranty .................................................................................................................................. 56

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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
Excalibur. Installer must program the valve to recommended hardness, Day override and time of
regeneration. Set time of day, read normal operating displays, read power loss and error displays if any.
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 transformers are for dry locations only
•The tank should be on a firm level surface

BARRIE • ONTARIO • CANADA TF: 705.733.8900 WWW.EXCALIBURWATER.COM
1.4) Loading Instructions
Step 1: Check the product upon removal 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.

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

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

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 705.733.8900 WWW.EXCALIBURWATER.COM
1.7) Installation Instructions
1) The softener must be close to drain as much as possible.
2) The salt must be refilled in brine tank with frequency stated by dealer.
3) The water heater’s inlet and outlet must be at least 10ft away from softener.
4) The unit including the drain must be located in a room temperature above 33° F.
5) 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) Plumbing
•The bypass valve must be installed on the control valve.
•The outside tap water must be bypassed from the softener.
•The shutoff valve must be installed at the inlet of unit’s bypass valve.
•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.
1.9) Brine Line Connection
See the brine line size either 1/2” or 3/8” O.D. Polyethylene tube from model specifications. Install the
line from brine tank float to the tee which branches off to both control valves brine elbows.
Brine Elbow
Tee

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 705.733.8900 WWW.EXCALIBURWATER.COM
1.10) 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.
1.11) Drain Line
•The size of the drain must be according to the specifications.
•Leave minimum of 6” gap between flow control fitting and solder joints. The gap less than this
can damage the flow control.
•Use ¾” or 1” tubing 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.
•The strap must be tied at the end to secure the line.

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

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 705.733.8900 WWW.EXCALIBURWATER.COM
1.13) Bypass Valve
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 for normal
operation of a water softener. During the regeneration
cycle this position provides regeneration water to the unit,
while also providing untreated water to the distribution
system
The inlet and outlet handles point to the center of the
bypass. The system is isolated from the water pressure in
the plumbing system. Untreated water is supplied to the
building

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 705.733.8900 WWW.EXCALIBURWATER.COM
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.
The inlet handle points to the center of the bypass valve
and the outlet handle points in the direction of flow, the
water is shut off to the plumbing system. If water is
available on the outlet side of the softener it is an
indication of water bypass around the system (i.e. a
plumbing connection somewhere in the building bypasses
the system).

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 705.733.8900 WWW.EXCALIBURWATER.COM
1.14) Wiring
PORT A
PORT B
MAV
CABLE
INTERCONNECT
CABLE
ALT A
VALVE
ALT B
VALVE
Connect the MAV cable to ALT A control valve’s MAV port.
Connect the interconnect cable between both valves on interconnect ports.
Note: - ALT B unit will be shipped with connected interconnect cable

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 705.733.8900 WWW.EXCALIBURWATER.COM
1.15) ALT A Control Valve Wiring
Use Phillip’s screwdriver to remove the
screw and cover.
Weave the MAV cable and interconnect
cable through the strain relief. Place the
cover over the strain relief and fasten the
screw.

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 705.733.8900 WWW.EXCALIBURWATER.COM
2) PROGRAMMING AND START UP
2.1) Regeneration and Error Screens
2.2) Button Operation
Regen Screen
Displays the time remaining in the current cycle. Pressing REGEN advances to the next
cycle.
Error Screen
Alternated flashing Error and error code every 3 seconds. Clear by
disconnecting the power supply at the PC board and reconnecting,
or press NEXT and REGEN simultaneously for 3 seconds.
Scrolls to the next display.
•Pressing once and releasing will schedule a regeneration at the preset delayed regeneration time.
•Pressing again and releasing will cancel the regeneration.
•Pressing and holding for 3 seconds will initiate an immediate regeneration
•Pressing while in regeneration will advance to the next cycle.
•Pressing in the program levels will go backwards to the previous screen
Change Variable being displayed.
Key sequence to lock and unlock program settings
Holding for 3 seconds initiates a control reset. The software version is displayed and the
piston returns to the home/service position, resynchronizing the valve.
In Alternator Systems when a unit is waiting to initiate the first cycle step of regeneration,
“REGEN Pndg” is displayed.
“STbY” is displayed in Alternator Systems when a valve is in Standby state.
“REGEN Pndg RINSE FILL” is displayed whenever a zero-capacity tank has transferred to an
off-line state and is currently waiting to initiate the second portion of a regeneration
cycle. Viewed only when Delayed Rinse and Fill is set to ON.

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 705.733.8900 WWW.EXCALIBURWATER.COM
Used with valve type 1.0 twin, holding for at least 3 seconds causes a switch in the tank in
Service without cycling the regeneration valve. After tank switch, days remaining and capacity
remaining status is retained for each tank until the next regeneration.

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 705.733.8900 WWW.EXCALIBURWATER.COM
2.3) User Displays
2.4) Setting Time of Day
When the system is operating, one of five displays may be shown.
Pressing NEXT will alternate between the displays shown below.
User 1
Typical user display. Shows volume remaining to regeneration. This
screen will not be viewed if the control is set for time-clock operation.
User 2
Displays number of days to next regeneration.
User 3
Flow Rate.
Displays present flow rate.
User 4
Displays total volume in gallons since last reset. If a meter is not used
this display will be shown but 0 will be displayed.
PRESS ▼FOR 3 SECONDS TO RESET TO 0.
User 5
Shows current time.
Push NEXT until time of day screen is displayed.
Press and hold ▼until SET TIME is displayed and the hour flashes
once. Press ▲or ▼until the correct hour is displayed.
Then press NEXT. The minutes will flash. Press ▲or ▼until the
correct minute is displayed.
Press NEXT to return to the User Displays.
Time of day should only need to be set after power outages lasting
more than 8 hours, if the battery has been depleted and a power
outage occurs, or when daylight saving time begins or ends.
User Display 1
User display-Time of Day

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 705.733.8900 WWW.EXCALIBURWATER.COM
2.5) Startup Instructions
•Plug in transformers of both valves to wall socket.
•Pour some water in brine tank so that water level reaches air check valve.
•One control valve must show status “Standby” and other one must displays the time of day.
•Press and hold “REGEN” button on valve which shows time of day.
•This valve must initiate the immediate regeneration while other valve becomes online showing
time of day. The MAV motor starts turning to change the flowing port.
•Slowly turn the inlet side handle of bypass valve halfway, the air must exit through the drain for
first few minutes.
•When drain water flows steady, turn the inlet side handle of bypass valve fully open. Allow the
backwash cycle to run for at least 3 minutes with full opened inlet.
•Press the “REGEN” button once to advance the regeneration to brine cycle. Confirm the water
suction in brine line by lifting the brine tank cover.
•Press the “REGEN” button again to advance the regeneration to 2nd Backwash cycle.
•When the countdown for 2nd backwash starts, press the REGEN button again to advance the
regeneration to rinse cycle.
•Allow the valve to run rinse cycle for full amount of time.
•When valve automatically advances to fill cycle, check for leaks and then press the REGEN
button to finish the regeneration.
•Fully open the outlet side of the bypass valve, then open the test port downstream of this valve.
•Confirm the “SOFTENING” blinking on display to verify the meter working. Shut off the test port
when water comes clear out of it.
•Now press and hold REGEN button on other valve to start the regeneration.
•Follow the above given sequence for regeneration in backwash cycle, brine cycle, 2nd Backwash
cycle and rinse cycle.
•Check for leaks during fill cycle and let the fill cycle to run for full amount of time so that valve
can fill correct amount of water in brine tank to dissolve salt.

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 705.733.8900 WWW.EXCALIBURWATER.COM
2.6) Configuration Settings
EXIT TO DISPLAY SCREENS
Step 1CS – Press NEXT and ▼simultaneously for 5 seconds and
release. Press NEXT and ▼ simultaneously for 5 seconds and release. If
the screen in Step 2CS does not appear, the lock on the valve is
activated. To unlock, press ▼, NEXT, ▲and REGEN in sequence, then
press NEXT and ▼simultaneously for 5 seconds and release. Press
NEXT and ▼simultaneously for 5 seconds and release.
Step 2CS – Use ▲or ▼to select 1.0 for 1” valve.
Step 3CS – Selecting the use of an outside signal to initiate a
regeneration. Selection only matters if a connection is made to the two
pin connector labeled DP SWITCH located on the printed circuit board.
Select oFF - feature not used. Other options are described below.
on0 – If the dP switch is closed for an accumulative time of 2 minutes a
regeneration will be signaled to the unit.
dEL – If the dP switch is closed for an accumulative time of 2 minutes a
regeneration will occur at the scheduled delayed regeneration time.
HoLd – If the dP switch is closed a regeneration will be prevented from
occurring while there is switch closure.
Press NEXT to go to Step 4CS. Press REGEN to return to previous step.
Step 4CS – Select the first unit as “UNIT A” and second unit as “UNIT B”.
Register units A or B according to the plumbing of MAV and wiring on PC
boards. (See section MAV)
remaining capacity of online unit is less than 10% of total capacity. Press
NEXT to exit OEM Configuration Setup. Press REGEN to return to previous
step.
Step 5CS – Select delay “OFF” for rinse
and fill cycle. The rinse and fill cycles of
regeneration can be delayed until the

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 705.733.8900 WWW.EXCALIBURWATER.COM
2.7) Installer Display Settings
Exit Installer Display Settings
Step 1I - To enter Installer Display press NEXT and ▲simultaneously
for about 5 seconds and release.
Step 2I – Hardness: Set the amount of influent hardness using ▲or
▼. If “oFF” or a number was selected in Step 11S.
Press NEXT to go to step 3I. Press REGEN to exit Installer Display
Settings.
Step 3I – Day Override: When volume capacity is set to “oFF”, sets
the number of days between regenerations. When volume capacity
is set to AUTO or to a volume, sets the maximum number of days
between regenerations. If value set to “oFF”, regeneration initiation
is triggered solely by volume used.
If value is set in days (allowable range from 1 to 28) regeneration
initiation will be called for on that day regardless of actual water
usage. Set Day Override using ▲or ▼:
• number of days between regeneration (1 to 28); or
• “oFF”.
See Setting Options Table for more detail on 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 ▲or ▼. The default time is 2:00. This display
will show “REGEN on 0 GAL” if “on 0” is selected in Set Regeneration
Time Option in OEM Softener System Setup or OEM Filter System
Setup.
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 ▲or ▼. This display will not be shown if “on
0” is selected in Set Regeneration Time Option in OEM Softener
System Setup or OEM Filter System Setup.
Press NEXT to exit Installer Display Settings. Press REGEN to return
to previous step.