Excalibur EWS SD15 Series User manual

BARRIE • ONTARIO • CANADA TF: 877.733.8999 WWW.EXCALIBURWATER.COM
WATER SOFTENER 1.5”DUPLEX
INSTALLATION AND USER GUIDE

1
SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 877.733.8999 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) System Drawing ............................................................................................................................7
1.8) Plumbing .......................................................................................................................................7
1.9) Brine Line Connection...................................................................................................................7
1.10) Overflow Line Connection.........................................................................................................8
1.11) Drain Line ..................................................................................................................................8
1.12) 3-Way Bypass Valve ..................................................................................................................8
1.13) Wiring......................................................................................................................................10
1.14) ALT A Control Valve Wiring.....................................................................................................11
2) Programming and Startup................................................................................................................... 12
2.1) Regeneration and Error Screens.................................................................................................12
2.2) Button Operation........................................................................................................................12
2.3) User Displays...............................................................................................................................13
2.4) Setting Time of Day.....................................................................................................................14
2.5) Startup Instructions ....................................................................................................................15
2.6) Configuration Settings ................................................................................................................16
2.7) Installer Display Settings.............................................................................................................17
2.8) OEM Softener System Setup.......................................................................................................18
2.9) Diagnostics..................................................................................................................................20
3) Model Variable Programming and Components ................................................................................ 22
3.1) Programming ..............................................................................................................................22
3.2) Flow Controls and Injectors ........................................................................................................22
4) Control Valve....................................................................................................................................... 23
4.1) Specifications ..............................................................................................................................23
4.2) Flow Diagrams.............................................................................................................................24
4.3) Components of Control Valve.....................................................................................................27

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 877.733.8999 WWW.EXCALIBURWATER.COM
5) Brine Tank Assembly........................................................................................................................... 33
6) Quick Reference Guide ....................................................................................................................... 34
7) Service Instructions............................................................................................................................. 36
7.1) Front Cover Removal ..................................................................................................................36
7.2) PC Board Removal.......................................................................................................................37
7.3) Drive Bracket Removal................................................................................................................38
7.4) Drive Cap Removal......................................................................................................................39
7.5) Piston Removal ...........................................................................................................................40
7.6) Stack Assembly Removal.............................................................................................................41
7.7) Injector Cap Removal..................................................................................................................42
8) Troubleshooting.................................................................................................................................. 43
8.1) Troubleshooting Procedures.......................................................................................................43
8.2) Possible Error Codes ...................................................................................................................46
9) 5 Year Warranty.................................................................................................................................. 47

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 877.733.8999 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 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: 877.733.8999 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: 877.733.8999 WWW.EXCALIBURWATER.COM
1.5) Installation Drawing

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 877.733.8999 WWW.EXCALIBURWATER.COM
1.6) Piping and Instrumentation Drawing

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 877.733.8999 WWW.EXCALIBURWATER.COM
1.7) System Drawing
1.8) Plumbing
•The 3-way bypass valves must be installed.
•The softener system 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 water heater’s inlet and outlet must be at least 10ft away from softener.
•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.
1.9) 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: 877.733.8999 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”, 1” or 1.25” 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.
1.12) 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 demand outlet.

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 877.733.8999 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: 877.733.8999 WWW.EXCALIBURWATER.COM
1.13) Wiring
PORT B
PORT A
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: 877.733.8999 WWW.EXCALIBURWATER.COM
1.14) 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: 877.733.8999 WWW.EXCALIBURWATER.COM
2) PROGRAMMING AND STARTUP
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.
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: 877.733.8999 WWW.EXCALIBURWATER.COM
2.3) User Displays
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.

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 877.733.8999 WWW.EXCALIBURWATER.COM
2.4) Setting Time of Day
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. If a power outage lasting more than 8 hours occurs,
the time of day will flash on and off which indicates the time of day
should be reset. If a power outage lasts less than 8 hours and the time of
day flashes on and off, the time of day should be reset and the battery
replaced.
Exit Setting Time of Day

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 877.733.8999 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 valve handle halfway, the air must exit through the drain for first few
minutes.
•When drain water flows steady, turn the inlet valve handle to 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 valve, then open the test port downstream of softener.
•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.
•Now close the 3-way bypass valve.

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 877.733.8999 WWW.EXCALIBURWATER.COM
2.6) Configuration Settings
Step 5CS –Select “ALT” when control valve act as an alternator following
using ▲or ▼buttons. Then press NEXT button.
Choose the ALT unit A or B
“ALT A” must be the unit in which MAV wire is connected and outlet is
connected to A port of the MAV.
“ALT B” must be the unit in which outlet is connected to B port of the
MAV.
Step 6CS - Select “off” the delay for fill
and rinse cycle. All regeneration cycles
will be done at once. This option is only
in ALT A.
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 1.5 for 1.5” valve. Press NEXT to go to
Step 3CS. Press REGEN to exit Configuration Settings.
Step 4CS –Select dP oFF –outside regeneration signal feature not used,
by using ▲or ▼buttons.
Press NEXT to go to Step 4CS. Press REGEN to return to previous step.
Step 3CS –Use ▲or ▼to select “1.5” meter size.
Press NEXT to go to Step 4CS. Press REGEN to return to previous step.

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 877.733.8999 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
▼.
Press NEXT to go to step 3I. Press REGEN to exit Installer Display
Settings.
Step 3I –Day Override: Set “14”maximum number of days between
regenerations. Set Day Override using ▲or ▼:
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.
Press NEXT to go to step 5I. Press REGEN to return to previous step.
Step 6CS –Fill Units, LBS should be selected. MIN (minutes) should
be selected only for model# EWS SD15450. Press NEXT to exit OEM
Configuration Setup. Press REGEN to return to previous step.
Step 5I –Next Regeneration Time (minutes): Set the minutes of day
for regeneration using ▲or ▼.
Press NEXT to exit Installer Display Settings. Press REGEN to return
to previous step.

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 877.733.8999 WWW.EXCALIBURWATER.COM
2.8) OEM Softener System Setup
Step 1S - Press NEXT and ▼simultaneously for 5 seconds and
release. If screen in Step 2S does not appear, the lock on valve
programming has been activated.
Step 2S –Choose SOFTENING using ▲or ▼. Press NEXT to go to
Step 3S. Press REGEN to exit OEM Softener System Setup.
Step 3S –Choose “dn” Downflow Brining Direction using ▲or ▼.
This screen is not viewed when Step 2S is set to Filtering. Press NEXT
to go to Step 4S. Press REGEN to return to previous step.
Step 4S –Set Post Refill location using ▲or ▼:
“PoST” to refill the brine tank after the final rinse; or
Press NEXT to go to Step 5S. Press REGEN to return to previous step.
Step 5S –Select the time for the first backwash cycle using ▲or ▼
buttons. Press NEXT to go to Step 6S. Press REGEN to return to
previous step.
Step 6S –Select the time the brine cycle using ▲or ▼.
NOTE: The display will flash between cycle number and time, and
brine direction (dn).
Press NEXT to go to Step 7S. Press REGEN to return to previous step.

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SOFTENER INSTALLATION AND USER GUIDE
BARRIE • ONTARIO • CANADA TF: 877.733.8999 WWW.EXCALIBURWATER.COM
Step 7S –Select the time for second backwash cycle using ▲or ▼
buttons.
Press NEXT to go to Step 8S. Press REGEN to return to previous step.
Step 8S –Select the time for rinse cycle using ▲or ▼.
Press NEXT to go to Step 9S. Press REGEN to return to previous step.
Step 9S –Select the pounds for the fifth cycle using ▲or ▼. According
to the specifications of the softener model.
Press NEXT to go to Step 10S. Press REGEN to return to previous step.
Step 10S –Set System Capacity using ▲or ▼. The System Capacity
setting should be based on the volume of resin and LBS of salt fill set in
Step 9S. Press NEXT to go to Step 11S. Press REGEN to return to
previous step.
For reference see page#24
Step 11S –Set “AUTO” Volume Capacity using ▲or ▼. The capacity
will be automatically calculated and reserve capacity will be
automatically estimated.
Press NEXT to go to Step 12S. Press REGEN to return to previous step.
Step 12S –Set Regeneration Time “on0” Options using ▲or ▼buttons
the regeneration will occur immediately when the volume capacity
reaches 0 (zero).
Press NEXT to go to Step 13S. Press REGEN to return to previous step.
oFF
On 0
Step 13S –Set Relay Operation “OFF”
using ▲or ▼. The choices are:
Steps 14S and 15S will not be shown.
Press NEXT to go to Step 14S. Press
REGEN to return to previous step.