BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM ULTIMATE SERIES WATER SOFTENER INSTALLATION AND USER GUIDE
1 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM TABLE OF CONTENTS 1) Installation ............................................................................................................................................ 2 1.1) Pre-installation instructions.......................................................................................................... 2 1.2) General Installation and Service Warnings ................................................................................... 2 1.3) Site Requirements......................................................................................................................... 2 1.4) Installation Drawing ...................................................................................................................... 3 1.5) System Drawing ............................................................................................................................ 4 1.6) Plumbing Instructions ................................................................................................................... 4 1.7) Brine Line Connection................................................................................................................... 5 1.8) Overflow Line Connection............................................................................................................. 5 1.9) Drain Line ...................................................................................................................................... 6 1.10) Bypass Valve.............................................................................................................................. 7 1.11) Start Up Instructions ................................................................................................................. 9 2) Control Valve Programming................................................................................................................ 10 2.1) Regeneration Screens ................................................................................................................. 10 2.2) Button Operation ........................................................................................................................ 10 2.3) Setting Time of Day ..................................................................................................................... 10 2.4) User Displays............................................................................................................................... 11 2.5) Installer Display Settings ............................................................................................................. 12 2.6) Configuration Settings ................................................................................................................ 13 2.7) Softener System Setup................................................................................................................ 14 3) Model Specifications and Components .............................................................................................. 16 3.1) Flow Controls and Injectors ........................................................................................................ 16 3.2) Specifications .............................................................................................................................. 16 4) Control Valve Cycles............................................................................................................................ 17 5) Components of Control Valve............................................................................................................. 19 5.1) Front Cover and PC Board........................................................................................................... 19 5.2) Drive assembly, Piston and Spacer stack .................................................................................... 20 5.3) Injector Assembly........................................................................................................................ 21 5.4) Brine Tank Line Flow Control ...................................................................................................... 22 5.5) Drain Line Flow Control Assembly .............................................................................................. 23 5.6) Outlet Meter Assembly............................................................................................................... 24 5.7) Bypass Valve Components .......................................................................................................... 25 5.8) Installation Fitting Assemblies .................................................................................................... 26 6) Brine Tank Assembly ........................................................................................................................... 28 7) Troubleshooting.................................................................................................................................. 29 7.1) Possible Error Codes ................................................................................................................... 29 7.2) Troubleshooting Procedures....................................................................................................... 30 8) Quick Reference Guide ....................................................................................................................... 33 9) Warranty ............................................................................................................................................. 35
2 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 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 by Excalibur. The dealer must guide the installer to change the values according to the hardness, day override and time of regeneration. 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 black O-Rings but not necessary. • Do not use pipe dope or other sealant on plastic nuts and caps. Teflon tape must be used only on NPT threads. • 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 with plug-in transformer (dry locations only). • The tank should be on a firm level surface
3 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM 1.4) Installation Drawing
4 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM 1.5) System Drawing 1.6) Plumbing Instructions Well Water Installation Municipal Installation 1) The softener must be located at the closest possible location to drain. 2) The water heater’s inlet must be at least 10ft away from softener. 3) The unit including the drain must be located in a room temperature above 33° F. 4) If vacuum occurrence is expected then the vacuum breaker must be installed at the inlet of the softener. 5) The bypass valve must be installed on the control valve. 6) The outside tap water if possible may be bypassed from the softener. 7) The primer, solder or solder flux must not get on the O-rings while installation. 8) After soldering the lines must be cooled before installing the O-Rings, nuts and caps. 9) If the electrical system is grounded to the plumbing, then a copper strap must be connected between inlet and outlet as shown in figure above. 10) The plumbing must be done by following the local plumbing codes. Water heater Pressure Tank Minimum 10ft Water Meter Minimum 10ft Brine Tank Brine Tank Outside Tap Outside Tap Water heater Cold Cold Hot Hot
5 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM 1.7) Brine Line Connection Install 3/8” O.D. Polyethylene tube according to specification sheet from the brine tank to the control valve. 1.8) Overflow Line Connection • Only used where brine tank overflow water spillage can damage flooring or structure. • Brine tank is equipped with safety float valve which prevents the overflow in case if control valve fails to control the refill cycle. • In case if safety float also fails to stop refill then only the water will come through overflow line connection. Tank Brine Line Connection Brine Line Drain Line
6 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM 1.9) Drain Line • The ½” tubing must be used for drain line. • Leave minimum of 6” gap between flow control fitting and solder joints. The gap less than this can damage the flow control. • If the drain line is elevated and then emptied into the drain below the level the of control valve then 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 drain line must be clamped or strap tied at the end to secure in position.
7 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM 1.10) Bypass Valve NORMAL OPERATION The inlet and outlet handles of bypass valve should be pointing the direction of flow indicated by the engraved arrows on the control valve. Water flows through the control valve in normal operation as a water softener. BYPASS OPERATION The inlet and outlet handles point to the center of the bypass valve. The system is isolated from the water pressure in the plumbing system. Untreated water is supplied to the house in this position.
8 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM DIAGNOSTIC MODE 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. Untreated water is supplied to the house in this position. SHUT OFF MODE 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.
9 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM 1.11) Start Up Instructions • Keep the bypass valve in bypass operation by moving both handles pointing towards the center of bypass valve. Now the untreated water is being supplied to house. Open the faucet downstream of the softener until water comes clear out of it. The initial water can be dirty because of installation debris. Now inspect the leaks in plumbing. • Manually add approximate 6 inches of water to brine tank so that level reaches air check valve. • Press and hold the “REGEN” button down for 5 seconds to start manual regeneration. The drive motor will start to reach backwash cycle and countdown time begins. Turn the inlet bypass valve handle halfway into the direction of diagnose operation. Once the steady water flows out of drain then fully turn both handles of bypass valve into the direction of service operation. Caution: - If water flow is too rapidly, there will be a loss of resin to drain. • When the water become clear in drain line then press the regen button to advance the regeneration to brine cycle. Lift off the brine tank lid to check if water is being drawn from brine tank and shut off the faucet after confirming the brine draw flow. • Press REGEN button to advance the regeneration to 2nd backwash cycle. Wait until the countdown time starts. • Press REGEN button again to advance the regeneration to rinse cycle with water coming through the drain. Allow this process for the full amount of time during this cycle. • The control valve will automatically advance the regeneration to the fill cycle. Allow to fill for the full amount of time in this cycle. Once finished the control valve will automatically come to the service position with the time of day being displayed. • Add the salt to Brine Tank.
10 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM 2) CONTROL VALVE PROGRAMMING 2.1) Regeneration Screens 2.2) Button Operation 2.3) Setting Time of Day Regen Screen • Displays the time remaining in the current cycle. • Displays the cycle name and sequence number. • Pressing REGEN advances to the next cycle. 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 delayed 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. 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. Step 1: - Push NEXT until time of day screen is displayed. Press and hold ▼ until SET TIME is displayed and the hour flashes once. Step 2: - Press ▲ or ▼ until the correct hour is displayed. Then press NEXT button. Step 3: - 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 if: - • power outage lasts more than 8 hours with good battery • battery is depleted and power outage occurs • when daylight saving time begins or ends. Regeneration occurs automatically if volume capacity drops below the reserve capacity automatically predicted by Control Valve or the has control valve reached 14 number of days since last regeneration.
11 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM 2.4) 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: - Shows volume remaining to next regeneration. User 2: - Displays the number of days to next regeneration as per time clock. User 3: - Displays the current flow rate. User 4: - Displays the total volume used. User 5: - Shows current time of day. Press NEXT to return to User Display 1 Return to User Display 1
12 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM 2.5) 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 (gpg) of hardness using ▲ or ▼. Press NEXT to go to step 3I. Press REGEN to exit Installer Display Settings. Step 3I – Day Override: Set “14” the maximum number of days between regenerations. Press NEXT to go to step 4I. Press REGEN to return to previous step. Step 4I – Next scheduled regeneration time (hour): Set the hour of day for regeneration using ▲ or ▼. (Usually 2:00AM or when the predictable flow is minimum) Press NEXT to go to step 5I. Press REGEN to return to previous step. Step 5I – Next scheduled 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. EXIT INSTALLER DISPLAY SETTINGS
13 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM 2.6) Configuration Settings Step 1CS: - Press NEXT and ▼ simultaneously for 5 seconds and release. Again press NEXT and ▼ simultaneously for 5 seconds. Step 2CS: - Use to select “1.0” for 1in valve. Note: - Do not select “1.0t” Step 3CS: - Select “dPoFF” for softeners when no outside signal is used for regeneration. Press NEXT to proceed to step 3CS or press REGEN to go back to previous step. Step 4CS: - Select “oFF” for standard softeners and when no motorized alternating valves are used. Press NEXT to exit Configuration settings. Exit Configuration Settings
14 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM 2.7) Softener System Setup Step 1S: - Press NEXT and ▼ simultaneously for 5 seconds and release. Step 2S: - Choose “SOFTENING” using ▲ or ▼. Press NEXT to go to step 3S. Step 3S: - Choose “dn” for downflow brining direction. Press NEXT to go to step 4S or press REGEN to go back to previous step. Step 4S: - Set “PoST” refill location to initiate refill cycle immediately after rinse cycle. Step 5S: - Select “6 min” duration for first backwash cycle. Press NEXT to go to step 6S or press REGEN to go back to previous step. Step 6S: - Select “60 min” duration for brine cycle. Press NEXT to go to step 7S or press REGEN to go back to previous step. Step 7S: - Select “4 min” for the 2nd backwash cycle. Press NEXT to proceed to step 8S or press REGEN to return to previous step.
15 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM EXIT SOFTENER SYSTEM SETUP Step 8S: - Select “4 min” for the rinse cycle. Press NEXT to proceed to step 9S or press REGEN to return to previous step. Step 9S: - Select the salt dosage as per the performance data given. Step 10S: - Set System Grains Capacity. Refer the performance table given. Step 11S: - Set “AUto” for automatic volume capacity and reserve capacity calculations. Step 12S: - Set “NORMAL” regeneration time so that regeneration should occur only at preset time. Step 13S: - Set relay operation “oFF”. Press NEXT to exit softener system setup or press REGEN to return to previous step.
16 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM 3) MODEL SPECIFICATIONS AND COMPONENTS 3.1) Flow Controls and Injectors Model1 Number Mineral Tank Brine Tank Injector Drain Flow Control Dia X Height (Inch) (Inch) Color Order # Flow GPM Order # EWS SUS24BF 9x48 18x33 (Dia x Height) Red CLK V30101D 1.3 CLK V3162013 EWS SUS34BF 10x54 White CLK V30101E 1.7 CLK V3162017 EWS SUS54BF 12x52 Blue CLK V30101F 2.2 CLK V3162022 3.2) Specifications * Excalibur Softeners are factory programmed to 10lbs/ft3 default settings 1 S is only included in superior models and the given model numbers are for Ultimate superior softeners Model1 Number Mineral Tank Resin Quantity Grains Capacity Lbs Salt Setting Flow (GPM) Shipping Weight Dia X Height ft3 6 lbs Salt/ft3 10 lbs Salt/ft3 15 lbs Salt/ft3 Continuous Peak LBS EWS SUS24BF 9x48 1.0 20,000 6.0 27,000 10.0 30,000 15.0 4.0 6.4 74 EWS SUS34BF 10x54 1.5 30,000 9.0 40,500 15.0 45,000 22.5 5.7 9.0 95 EWS SUS54BF 12x52 2.0 40,000 12.0 54,000 20.0 60,000 30.0 9.0 14.4 161
17 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM 4) CONTROL VALVE CYCLES In Service Cycle water flows through the upper basket and flows down to the bottom distributor. In this operation hardness of water is removed by resin. In Backwash Cycle water flows in upflow direction, the water enters the tank from bottom distributor and collected by upper basket. This operation lifts the bed and wash the resin. The water goes out through the drain line. Note: - Backwash, Brine and Rinse cycles bypass the supply water to the demand.
18 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM In Brine Cycle water flows in downflow direction which siphon the brine solution from brine tank and slow rinse water goes to the drain. In Rinse Cycle water flows rapidly in downflow direction through the resin to the drain. This cycle washes the excess sodium from the resin particles. Fill Cycle (Not Shown): - The water flow same as Service operation but water also flows to the brine tank for refilling.
19 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM 5) COMPONENTS OF CONTROL VALVE 5.1) Front Cover and PC Board Drawing No. Order No. Description Quantity 1 CLK V3175EE01 WS1EE FRONT COVER ASSEMBLY 1 2 CLK V310701 WS1 MOTOR 1 3 CLK V310601 WS1 DRIVE BRACKET & SPRING CLIP 1 4 CLK V3408EE04BOARD WS1THRU/2 EE PCB 5 DIGIT REPL 1 5 CLK V3110 WS1 DRIVE GEAR 12X36 3 6 CLK V3109 WS1 DRIVE GEAR COVER 1 Not Shown CLK V3186 WS1 AC ADAPTER 120V-12V 1 CLK V318601 WS1 AC ADAPTER CORD ONLY Not Shown CLK V3178 WS1 Drive Back Plate 1 AC Adapter U.S. Supply Voltage 120 V AC Supply Frequency 60 Hz Output Voltage 12 V AC Output Current 500 mA Battery fully seated Correct battery orientation 3 Volt lithium coin cell type 2032
20 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM 5.2) Drive assembly, Piston and Spacer stack Drawing No. Order No. Description Quantity 1 CLK V3005 WS1 Spacer Stack Assembly 1 2 CLK V3004 Drive Cap ASY 1 3 CLK V3178 WS1 Drive Back Plate 1 4 CLK V3011 WS1 Piston Downflow ASY 1 5 CLK V3174 WS1 Regenerant Piston 1 6 CLK V3135 O-ring 228 1 7 CLK V3180 O-ring 337 1 8 CLK V3105 O-ring 215 (Distributor Tube) 1 Not Shown CLK V3001 WS1 Body ASYDownflow 1
21 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM 5.3) Injector Assembly Drawing No. Order No. Description Quantity 1 CLK V3176 INJECTOR CAP 1 2 CLK V3152 O-RING 135 1 3 CLK V317701 INJECTOR SCREEN CAGE 1 4 CLK V30101Z WS1 INJECTOR ASY ZPLUG 1 5 CLK V30101D WS1 INJECTOR ASY DRED For 9” Tank 1 CLK V30101E WS1 INJECTOR ASY EWHITE For 10” Tank CLK V30101F WS1 INJECTOR ASY F BLUE For 12” Tank Not Shown* CLK V3170 O-RING 011 1 Not Shown* CLK V3171 O-RING 013 1 * The injector plug and the injector each contain 011 (lower) and 013 (upper) O-ring.
22 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM 5.4) Brine Tank Line Flow Control Drawing No. Order No. Description Quantity 1 CLK V414401 Elbow 3/8 Liquifit Asy w/RFC 1 2 CLK H4615 Elbow Locking Clip 1 3 CLK H4628 Elbow 3/8” Liquifit 1 4 CLK V3163 0-ring 019 1 5 CLK V316501 WS1 RFC Retainer Asy (0.5 gpm) 1 6 CLK V3182 WS1 RFC 1 Not Shown CLK V3552 WS1 Brine Elbow Asy w/RFC Option Not Shown CLK H4650 Elbow ½” with nut and insert Option #5 - CLK V316501 Retainer Assembly includes #6 - CLK V3182 Refill flow control
23 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM 5.5) Drain Line Flow Control Assembly Drain Line ¾” Drawing No. Order No. Description Quantity 1 CLK H4615 Elbow Locking Clip 1 2 CLK PKP100TS8BULK Polytube insert 5/8 Option 3 CLK V3192 WS1 Nut ¾ Drain Elbow Option 4 CLK V315801 WS1 Drain Elbow ¾ Male 1 CLK V315802 WS1 Drain Elbow ¾ Male No 5 CLK V3163 O-ring 019 1 6 CLK V315901 WS1 DLFC Retainer ASY 1 7 CLK V3162013 WS1 DLFC 1.3 gpm 9” Tank One DLFC must be used if ¾ fitting is used CLK V3162017 WS1 DLFC 1.7 gpm 10” Tank CLK V3162022 WS1 DLFC 2.2 gpm 12” Tank
24 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM 5.6) Outlet Meter Assembly Drawing No. Order No. Description Quantity 1 CLK V3151 WS1 Nut 1” QC 1 2 CLK V3003* WS1 Meter ASY 1 3 CLK V311801 WS1 Turbine ASY 1 4 CLK V3105 O-ring 215 1 * CLK V3003 includes CLK V311801 and CLK V3105 NOTE: - THIS WATER METER SHOULD NOT BE USED AS THE PRIMARY MONITORING DEVICE FOR CRITICAL OR HEALTH EFFECT APPLICATIONS.
25 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM 5.7) Bypass Valve Components CLK V3006 WS1 Bypass Valve Assembly Drawing No. Order No. Description Quantity 1 CLK V3151 WS1 Nut 1” Quick Connect 2 2 CLK V3150 WS1 Split Ring 2 3 CLK V3105 O-Ring 215 2 4 CLK V3145 WS1 Bypass 1” Rotor 2 5 CLK V3146 WS1 Bypass Cap 2 6 CLK V3147 WS1 Bypass Handle 2 7 CLK V3148 WS1 Bypass Rotor Seal 2 8 CLK V3152 O-ring 135 2 9 CLK V3155 O-ring 112 2 10 CLK V3156 O-ring 214 2 *Bypass Valve Vertical Adapter not shown in drawing CLK V319101 WS1 Bypass Vertical Asy Adapter Order No. Description Qty CLK V3151 WS1 Nut 1” Quick Connect 2 CLK V3150 WS1 Split Ring 2 CLK V3105 O-Ring 215 2 CLK V3191 WS1 Bypass Vertical 2
26 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM 5.8) Installation Fitting Assemblies CLK V3007 WS1 Fitting 1” PVC Male NPT Elbow Assembly Drawing No. Order No. Description Quantity 1 CLK V3151 WS1 NUT 1” QUICK CONNECT 2 2 CLK V3150 WS1 SPLIT RING 2 3 CLK V3105 O-RING 215 2 4 CLK V3149 WS1 FITTING 1 PVC MALE NPT 2 CLK V300702LF WS1 Fitting 1” Brass Sweat Assembly LF Drawing No. Order No. Description Qty 1 CLK V3151 WS1 NUT 1” QUICK CONNECT 2 2 CLK V3150 WS1 SPLIT RING 2 3 CLK V3105 O-RING 215 2 4 CLK V3188LF WS1FITTING1 BRASSSWEATASSEMBLYLF 2 Do not install in California. CLK V300703LF WS1 Fitting ¾” Brass Sweat Assembly LF Drawing No. Order No. Description Quantity 1 CLK V3151 WS1 NUT 1” QUICK CONNECT 2 2 CLK V3150 WS1 SPLIT RING 2 3 CLK V3105 O-RING 215 2 4 CLK V318801LF WS1 FITTING ¾ BRASS SWEAT LF 2 Do not install in California. CLK V300704 WS1 Fitting 1” Plastic Male NPT Assembly Drawing No. Order No. Description Quantity 1 CLK V3151 WS1 NUT 1” QUICK CONNECT 2 2 CLK V3150 WS1 SPLIT RING 2 3 CLK V3105 O-RING 215 2 4 CLK V3164 WS1 FITTING 1" PLASTIC MALE NPT 2 CLK V300701 WS1 Fitting ¾” & 1” PVC Solvent 90o Assembly Drawing No. Order No. Description Quantity 1 CLK V3151 WS1 NUT 1” QUICK CONNECT 2 2 CLK V3150 WS1 SPLIT RING 2 3 CLK V3105 O-RING 215 2 4 CLK V3189 WS1 FITTING ¾ & 1 PVC SOLVENT 90 2 * Water Softener is CSA certified for use with this assembly * Water Softener is CSA certified for use with this assembly
27 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM CLK V300705 WS1 Fitting 1-1/4” Plastic Male NPT Assembly Drawing No. Order No. Description Quantity 1 CLK V3151 WS1 NUT 1” QUICK CONNECT 2 2 CLK V3150 WS1 SPLIT RING 2 3 CLK V3105 O-RING 215 2 4 CLK V3317 WS1 FITTING 1-¼" PLASTIC MALE NPT 2 CLK V300709LF WS1 Fitting 1-1/4” & 1-1/2” Brass Sweat Assembly LF Drawing No. Order No. Description Quantity 1 CLK V3151 WS1 NUT 1” QUICK CONNECT 2 2 CLK V3150 WS1 SPLIT RING 2 3 CLK V3105 O-RING 215 2 4 CLK V3375LF WS1 FITTING1-1/4"& 1-1/2" BRASS 2 CLK V300712LF WS1 Fitting 3/4” Brass SharkBite Assembly LF Drawing No. Order No. Description Quantity 1 CLK V3151 WS1 NUT 1” QUICK CONNECT 2 2 CLK V3150 WS1 SPLIT RING 2 3 CLK V3105 O-RING 215 2 4 CLK V3628LF WS1 FTG 3/4 BRASS SHARKBITE LF 2 CLK V300713LF WS1 Fitting 1” Brass SharkBite Assembly LF Drawing No. Order No. Description Quantity 1 CLK V3151 WS1 NUT 1” QUICK CONNECT 2 2 CLK V3150 WS1 SPLIT RING 2 3 CLK V3105 O-RING 215 2 4 CLK V3629LF WS1 FTG 1” BRASS SHARKBITE LF 2 CLK V300715 WS1 FTG ¾ JG QC 90 Assembly Drawing No. Order No. Description Quantity 1 CLK V3151 WS1 NUT 1 QC 2 2 CLK V3150 WS1 SPLIT RING 2 3 CLK V3105 O-RING 215 2 4 CLK V3790 WS1 ELBOW 3/4 QC W/STEM 2 CLK V300717 WS1 FTG 1” JG QC Assembly Drawing No. Order No. Description Quantity 1 CLK V3105 O-RING 215 2 2 CLK V3150 WS1 SPLIT RING 2 3 CLK V3151 WS1 NUT 1 QC 2 4 CLK V4045 WS1 FTG 1 INCH QC 2 * Water Softener is CSA certified for use with this assembly * Water Softener is CSA certified for use with this assembly * Water Softener is CSA certified for use with this assembly * Water Softener is CSA certified for use with this assembly * Water Softener is CSA certified for use with this assembly
28 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM 6) BRINE TANK ASSEMBLY *Item#1 is a full assembly, contains Item#2,3,4 & 5 SAFETY FLOAT BRINE ELBOW Item No. Part No. Description Qty. 1 CLK H4628 Quick Connect Elbow 1 2 CLK CV3163 O-Ring 019 1 3 CLK CH4615 Elbow locking clip 1 BRINE TANK ASSEMBLY Item No. Part No. Description Size Qty. 1* CLK BT1833C Black 18”X33” Brine Tank Assembly 18”x33” 1 CLK BT1434AC Almond 14”X14”X34” Brine Tank Assembly 14”x14”x34” CLK BT1434BC Black 14”X14”X34” Brine Tank Assembly 14”x14”x34” 2 CLK BT1833 Brine Tank Empty with Cover Ø18”x33” 1 CLK BT1434AS Brine Tank Almond Empty with Cover 14”x14”X34” CLK BT1434BS Brine Tank Black Empty with Cover 3 CLK H107202 Salt Grid Platform with legs Ø18”x33” 1 CLK H106902 14”X14” 4 CLK H470028 Float Brine Valve Assembly (Ø18”x33”) & (14”x14”x34”) 1 5 CLK H1018 2 Piece Overflow Set (Ø18”x33”) & (14”x14”x34”) 1 1 2 3
29 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM 7) TROUBLESHOOTING 7.1) Possible Error Codes Possible Errors Code Description E1 Control unable to sense motor movement Err-1001 Err-101 E2 Control Valve motor ran too short Err-1002 Err-102 E3 Control Valve motor ran too long and unable to find next cycle Err-1003 Err-103 Err-1004 Control Valve ran too long and timed out Err-104 Err-1006 MAV/NHWB motor ran too long Err-106 Err-1007 MAV/NHWB motor ran too short and stalled Err-107 If the word “Error” and number flashes alternatively. Refer to the table given above and
30 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM 7.2) Troubleshooting Procedures Problem Possible Cause Solution 1. No Display on PC Board a. No power at electric outlet a. Repair outlet or use working outlet b. Control valve Power Adapter not plugged into outlet or power cord end not connected to PC board connection b. Plug Power Adapter into outlet orconnect power cord end to PC Board connection c. Improper power supply c. Verify proper voltage is being delivered to PC Board d. Defective Power Adapter d. Replace Power Adapter e. Defective PC Board e. Replace PC Board 2. PC Board does not display correct time of day a. Power Adapter plugged into electricoutlet controlled by light switch a. Use uninterrupted outlet b. Tripped breaker switch and/or b. Reset breaker switch and/ or GFI switch c. Power outage c. Reset time of day. If PC Board has battery back up present the battery may be depleted. See Front Cover and Drive Assembly drawing for instructions. d. Defective PC Board d. Replace PC Board 3. Display does not indicate that water is flowing. Refer to user instructions for how the display indicates water is flowing a. Bypass valve in bypass position a. Turn bypass handles to place bypass in service position b. Meter is not connected to meter connection on PC Board b. Connect meter to three pin connection labeled METER on PC Board c. Restricted/ stalled meter turbine c. Remove meter and check for rotation or foreign material d. Meter wire not installed securely into three pin connector d. Verify meter cable wires are installed securely into three pin connector labeled METER e. Defective meter e. Replace meter f. Defective PC Board f. Replace PC Board 4. Time of day flashes on and off a. Power outage a. Reset time of day. If PC Board has battery back up present the battery may be depleted. See Front Cover and Drive Assembly drawing for instructions. 5. Control valve does not regenerate when the REGEN button is depressed and held. a. Broken drive gear or drive cap assembly a. Replace drive gear or drive cap assembly b. Broken Piston Rod b. Replace piston rod c. Defective PC Board c. Defective PC Board 6. Control valve does not regenerate automatically but does when the REGEN button is depressed and held. a. Bypass valve in bypass position a. Turn bypass handles to place bypass in service position b. Meter is not connected to meter connection on PC Board b. Connect meter to three pin connection labeled METER on PC Board c. Restricted/ stalled meter turbine c. Remove meter and check for rotation or foreign material d. Incorrect programming d. Check for programming error e. Meter wire not installed securely into three pin connector e. Verify meter cable wires are installed securely into three pin connector labeled METER f. Defective meter f. Replace meter g. Defective PC Board g. Replace PC Board
31 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM Problem Possible Cause Solution 7. Hard water is being delivered a. Bypass valve is open or faulty a. Fully close bypass valve or replace b. Media is exhausted due to high water usage b. Check program settings or diagnostics for abnormal water usage c. Meter not registering c. Remove meter and check for rotation or foreign material d. Water quality fluctuation d. Test water and adjust program values accordingly e. No regenerant or low level of regenerant in regenerant tank e. Add proper regenerant to tank f. Control fails to draw in f. Refer to Trouble Shooting Guide number 12 g. Insufficient regenerant level in regenerant tank g. Check refill setting in programming. Check refill flow control for restrictions ordebris and clean or replace h. Damaged seal/stack assembly h. Replace seal/stack assembly i. Control valve body type and piston type mix matched i. Verify proper control valve body type and piston type match j. Fouled media bed j. Replace media bed 8. Control valve uses too much regenerant a. Improper refill setting a. Check refill setting b. Improper program settings b. Check program setting to make sure they are specific to the water quality andapplication needs c. Control valve regenerates frequently c. Check for leaking fixtures that may be exhausting capacity or system is undersized 9. Residual regenerant being delivered to service a. Low water pressure a. Check incoming water pressure – water pressure must remain at minimum of 25 psi b. Incorrect injector size b. Replace injector with correct size for the application c. Restricted drain line c. Check drain line for restrictions or debris and clean 10. Excessive water in regenerant tank a. Improper program settings a. Check refill setting b. Plugged injector b. Remove injector and clean or replace c. Drive cap assembly not h d l c. Re-tighten the drive cap assembly d. Damaged seal/ stack assembly d. Replace seal/ stack e. Restricted or kinked drain line e. Check drain line for restrictions or debris and or un-kink drain line f. Plugged backwash flow controller f. Remove backwash flow controller and clean or replace g. Missing refill flow controller g. Replace refill flow controller 11. Control valve fails to draw in regenerant a. Injector is plugged a. Remove injector and clean or replace b. Faulty regenerant piston b. Replace regenerant piston c. Regenerant line connection leak c. Inspect regenerant line for air leak d. Drain line restriction or debris cause excess back pressure d. Inspect drain line and clean to correct restriction e. Drain line too long or too high e. Shorten length and or height f. Low water pressure f. Check incoming water pressure – water pressure must remain at minimum of 25 psi 12. Water running to drain a. Power outage during regeneration a. Upon power being restored control will finish the remaining regeneration time. Reset time of day. b. Damaged seal/ stack assembly b. Replace seal/ stack assembly c. Piston assembly failure c. Replace piston assembly d. Drive cap assembly not tightened in properly d. Re-tighten the drive cap assembly
32 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM Problem Possible Cause Solution 13. E1, Err – 1001, Err – 101 = Control unable to sense motor movement a. Motor not inserted full to engage pinion, motor wires broken or disconnected a. Disconnect power, make sure motor is fully engaged, check for broken wires, make sure two pin connector on motor is connected to the two pin connection on the PC Board labeled MOTOR. Press NEXT and REGEN buttons for 3 seconds to resynchronize software with piston position or disconnect power supply from PC Board for 5 seconds and then reconnect. b. PC Board not properly snapped into drive bracket b. Properly snap PC Board into drive bracket and then Press NEXT and REGEN buttons for 3 seconds to resynchronize software with piston position or disconnect power supply from PC Board for 5 seconds and then reconnect. c. Missing reduction gears c. Replace missing gears 14. E2, Err – 1002, Err – 102 = Control valve motor ran too short and was unable to find the next cycle position and stalled a. Foreign material is lodged in control valve a. Open up control valve and pull out piston assembly and seal/ stack assembly for inspection. Press NEXT and REGEN buttons for 3 seconds to resynchronize software with piston position or disconnect power supply from PC Board for 5 seconds and then reconnect. b. Mechanical binding b. Check piston and seal/ stack assembly, check reduction gears, check drive bracket and main drive gear interface. Press NEXT and REGEN buttons for 3 seconds to resynchronize software with piston position or disconnect power supply from PC Board for 5 seconds and then reconnect. c. Main drive gear too tight c. Loosen main drive gear. Press NEXT and REGEN buttons for 3 seconds to resynchronize software with piston position or disconnect power supply from PC Board for 5 seconds and then reconnect. d. Improper voltage being delivered to PC Board d. Verify that proper voltage is being supplied. Press NEXT and REGEN buttons for 3 seconds to resynchronize software with piston position or disconnect power supply from PC Board for 5 seconds and then reconnect. 15. E3, Err – 1003, Err – 103 = Control valve motor ran too long and was unable to find the next cycle position a. Motor failure during a regeneration a. Check motor connections then Press NEXT and REGEN buttons for 3 seconds to resynchronize software with piston position or disconnect power supply from PC Board for 5 seconds and then reconnect. b. Foreign matter built up on piston and stack assemblies creating friction and drag enough to time out motor b. Replace piston and stack assemblies. Press NEXT and REGEN buttons for 3 seconds to resynchronize software with piston position or disconnect power supply from PC Board for 5 seconds and then reconnect. c. Drive bracket not snapped in properly and out enough that reduction gears and drive gear do not interface c. Snap drive bracket in properly then Press NEXT and REGEN buttons for 3 seconds to resynchronize software with piston position or disconnect power supply from PC Board for 5 seconds and then reconnect. 16. Err – 1004, Err – 104 = Control valve motor ran too long and timed out trying to reach home position a. Drive bracket not snapped in properly and out enough that reduction gears and drive gear do not interface a. Snap drive bracket in properly then Press NEXT and REGEN buttons for 3 seconds to resynchronize software with piston position or disconnect power supply from PC Board for 5 seconds and then reconnect.
33 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM 8) QUICK REFERENCE GUIDE Manual Regeneration Immediate Regeneration: - Press and hold “REGEN” button for more than 3 seconds. Press “REGEN” button to advance the unit to next cycle in regeneration. Delayed Regeneration: - Press and release “REGEN” button once the “REGEN TODAY” will be flashing on screen. Now the regeneration will occur tonight at preset time. The delayed regeneration can be cancelled by pressing “REGEN” button again. This error screen and error number will toggle. Contact Service Technician or Excalibur to report the error code. The bypass valve handles must be turned towards the center as shown above The bypass valve handle must be in the direction of flow and engraved arrows on control valve. Set Time of Day • Press ▼ button until the time of day is displayed • Press and hold ▼ button release when hour flashes. • Hours will flash press up and down buttons to adjust hours to current hour of day. Then press “NEXT” button. • By pressing up and down buttons adjust minutes. Then press “NEXT” button. • The time is set and the valve display will return to normal display.
34 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM Installer Settings Step # Value Description 2I Hardness Water hardness grains per gallon 3I 14 Maximum number of day between regenerations 4I 2:00 (Default) Minimum water usage hour of the day 5I 2:00 (Default) Regeneration starting minute of the hour Softener System Setup Step # Value Description 2S Softening Configured as softener 3S dn Downflow brining direction 4S POST Refill cycle starts right after rinse cycle 5S 6 Backwash cycle Duration 6S 60 Brine cycle Duration 7S 4 2nd Backwash cycle Duration 8S 4 Rinse cycle Duration 9S lbs salt Salt usage per regeneration (See performance table) 10S Grains Capacity Total grain capacity (See performance table) 11S Auto Automatic volume and reserve capacity estimation 12S NORMAL Regeneration occurs only at preset time 13S oFF No relay working Configuration Settings Step# Value Description 2CS 1.0 1in Control Valve 3CS dPoFF No outside regeneration signal used 4CS oFF No MAV installed
35 SOFTENER INSTALLATION AND USER GUIDE BARRIE • ONTARIO • CANADA 705.733.8900 WWW.EXCALIBURWATER.COM 9) WARRANTY Ultimate Superior 12 Year Warranty Ultimate Premium 20 Year Warranty Thank you for your purchase of our ULTIMATE SERIES WATER SOFTENER. For proof of purchase, please retain your Invoice/Sales Order Copy. Warranty ~ Offered Excalibur Water Systems warranties its products to be free from defect in materials and workmanship to the original owner from the date on the proof of purchase as described below. Warranty ~ Working Procedures If during the suitable warranty period, a part is defective, then Excalibur Water Systems will repair or replace that part at no charge to the original owner, with the exception of charges for nominal shipping, service and/or installation. Warranty ~ Coverage Outlined Excalibur Water Systems guarantees, to the original owner, a period of 12 or 20 years, the CONTROL BODY to be free of defects in materials and workmanship and to perform its proper functions. To the original owner, a period of 12 or lifetime 20 years, the ELECTRONIC CONTROL VALVE as well as all parts to be free of defects in materials and workmanship and to perform their normal functions. To the original owner, the SALT TANK and the MINERAL TANKS will not rust, corrode, leak, burst or in any other form fail to perform their proper functions for a LIFETIME period of 20 YEARS. Warranty ~ Service In the event you require service, Excalibur Water Systems Dealer will provide all necessary service and installation for your ULTIMATE SERIES Water Softener. To obtain warranty service within 30 days of discovery of the defect, notification must be given to Excalibur Water Systems. General Provisions The above warranties are effective provided the ULTIMATE SERIES WATER SOFTENER is operated at water pressures not exceeding 125psi and at water temperatures not exceeding 120°F; also provided that the water softener is not subject to abuse, misuse, alteration, neglect, freezing, accident or negligence; and provided further that the water softener is not damaged as the result of any unusual force of nature such as, but not limited to flood, hurricane, tornado or earthquake. Excalibur Water Systems is excused if failure to perform its warranty obligations is the result of strikes, government regulation, materials shortages or other circumstances beyond its control. THERE ARE NO WARRANTIES ON THE WATER SOFTENER BEYOND THOSE SPECIFICALLY DESCRIBED ABOVE. ALL IMPLIED WARRANTIES, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE, ARE DISCLAIMED TO THE EXTENT THEY MIGHT EXTEND BEYOND THE ABOVE PERIODS. THE SOLE OBLIGATION OF EXCALIBUR WATER SYSTEMS UNDER THESE WARRANTIES IS TO REPLACE OR REPAIR THE COMPONENT OR PART PROVES TO BE DFEFECTIVE WITHIN THE SPECIFIED TIME PERIOD AND EXCALIBUR WATER SYSTEMS IS NOT LIABLE FOR CONSEQUENTIAL OR INDIDENTAL DAMAGES. NO DEALER, AGENT, REPRESENTATIVE OR OTHER PERSON IS AUTHORIZED TO EXTEND OR EXPAND THE WARRANTIES EXPRESSED ABOVE. Certain provinces or states do not allow limitations on how long an implied warranty lasts or exclusions or limitations of incidental or consequential damage, therefore limitations and exclusions in this warranty may not apply to you. This warranty extends you specific legal rights as you may have other rights which vary from province to province or state to state. Excalibur Water Systems is a manufacturer of water treatment products. 142 Commerce Park Drive Barrie, Ontario Canada
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