Installation Instructions

Installation Instructions
Tempcontrol®
Thermostatic Water Controller
INSTALLATION, OPERATION AND SERVICE INSTRUCTIONS
ASSE 1017
All TempControl Installations must have a thermometer
and shut off valve in the tempered water outlet (as shown
in diagrams) for proper trouble shooting service.
IMPORTANT
When these installation, operation and service instructions are not followed, TempControl service life
will be greatly impaired.
SIZING AND TECHNICAL ASSISTANCE
For assistance and technical support in sizing and selection of the
proper TempControl valve or system, consult the Symmons TempSize™
computer sizing software, your local representative or Symmons Customer Service Department at 1-800-SYMMONS.
TEMPCONTROL LOCATION
An underlying premise of thermostatic water controller installations is an
acknowledgement that thermostatic mixing valves will not operate properly when the hot and cold supplies serving such valves are subjected to
pressure disturbances when flowing less than full capacity. In a correctly
designed mechanical room, the supply pressures are stable and not subject to pressure disturbances. As a result, when a TempControl valve is
indicated as being located in the mechanical room, a Hi-Low system will
not be recommended.
When the valve’s location is indicated as being outside of the mechanical room, it is assumed that there is a potential for pressure fluctuations
in the hot and cold supply lines servicing a TempControl valve and a
Hi-Low system will automatically be recommended.
monthly as follows: Remove cartridge and soak in any acceptable deliming agent (or regular household vinegar). Wash off deposits, be sure
piston is moving freely in its sleeve, and replace cartridge. Clean more
frequently if your system so demands (Do not completely remove piston
from cartridge).
The Check Valves in the TempControl are highly important factors in its
proper operation. If chips, dirt or other foreign materials lodge on the Seats
and prevent the checks from fully seating, there may be a by-pass of water
into the opposing line, and the TempControl will not operate to its set delivery temperature. A by-pass may be detected by feeling the supply line
while the TempControl is not operating. If, for example, the cold line feels
hot, the cold water check is not seating properly. It should be removed and
the check and its seat cleaned.
Constant by-passing of hot water will ruin the temperature control
mechanism by keeping it constantly expanded.
The valve will operate most efficiently at controlling a set temperature,
when flowing at its maximum capacity for any given supply pressure.
For example, if supply pressure is 45 psi, the maximum flow rate will be
10 GPM. If it is desired to have a lower flow rate with this 45 psi supply
pressure, reduce volume flow as follows:
Shut off screwdriver supply stops and open volume control shut-off
valve wide…determine maximum desired flow rate and open screwdriver
stops (an equal amount of hot and cold) to obtain the desired flow rate.
Now use volume control shut-off for future operation.
When valve is used at low temperatures (normally below 90 F), always
be sure cold water supply is 10 F lower than set temperature for efficient
operation. In some cases it may be necessary to supply chilled water to
valve.
SEASONAL USE
When a TempControl is used seasonally (schools, campgrounds, golf clubs,
etc.), the cartridge must be removed and thoroughly drained of all water.
The check stops should also be removed to drain all water from the supply
lines and valve body (See “cartridge removal and replacement”). This will
prohibit damage caused by freezing water.
CARTRIDGE REMOVAL AND
REPLACEMENT
Before removing a used cartridge for cleaning, have new casing gasket
and sleeve o-rings on hand.
Shut off supplies at stop checks by turning clockwise.
Note: If the system is designed so that the TempControl valve is not
subjected to hot and cold supply pressure disturbances, even though it
is located outside the mechanical room, a single TempControl valve will
operate properly.
Remove 4 bolts on cartridge bolt flange.
INSTALLATION AND OPERATION
Leave compensating spring in position at bottom center of valve body.
All piping should be thoroughly flushed before TempControl is installed.
The TempControl can be installed in any position as long as Hot Water
is connected to “H” port and Cold Water is connected to “C” port. Close
service stops on TempControl, remove cartridge, (see procedure on bottom of page). Turn on water supply, open stops wide to thoroughly flush
piping before putting valve in service. TempControl is set at factory to
deliver approximately 100 F. Cycle valve to full hot then cold 3 full times
allowing valve to reach full temperature. With approximately 80% of the
design intent flowing water, turn knob to obtain desired setting and lock
setscrew. Thermostatic water controllers should be sized according to
the flow capacity required from the valve, NOT the pipe size supplied to
the valve. For assistance and technical support in sizing and selection of
the proper TEMPCONTROL Thermostatic Water Controller, consult the
Symmons TEMPSIZE™ computer sizing software, your local representative or Symmons Customer Service Department at 1-800-SYMMONS.
MAINTENANCE
The cartridge unit contains the entire valve control mechanism. For noninterrupted service, keep a spare cartridge on hand.
TempControl valve control mechanism must be kept clean and free from
deposits and any foreign matter build-up that will be present in many
water systems. Inspect within 30 days of initial installation or operation. If inspection determines that your water system causes deposits
and foreign matter build-up monthly, then valve should be cleaned
With 2 large bladed screwdrivers, pry evenly on two opposite sides
of bolt flange until cartridge is free to be removed by hand. Pull out
cartridge with a twisting and turning action, always keeping cartridge
on center line.
Clean cartridge as described in maintenance instructions above.
Replace sleeve O-rings and grease same.
With a twisting and pushing action, replace cartridge in valve body until
bolt flange is firmly against housing gasket.
While holding cartridge in place, replace bolts and tighten. Caution: Do
not attempt to pull cartridge into position with bolts—it will damage the
valve control mechanism.
Open stops and adjust temperature.
Diagram 3
Diagram 1
Remote HI-LOW System Installation with
Recirculating Tempered Water
Single Valve Installation at or near Hot Water Source
PRV valve
high temperature hot (if required for laundry, etc.)
tempered water main hot supply to system
valve
hot
water
tank,
heater,
etc.
thermometer
tempered water to showers, lavatories, etc.
P1 pressure gauge
P2 pressure gauge
V1 valve
V2 valve
TMV1
TMV2
thermometer
TempControl thermostatic
water controller
circulating pump
check
hot supply
valve
thermometer
check
cold supply
ball valve
cold supply
tempered water return to cold inlet of heater
Diagram 1 INSTALLATION AT OR NEAR THE HOT WATER SOURCE:
TempControl must be positioned below the hot water tank or heater,
well below the high temperature water line. This procedure creates
a heat trap and protects against hot water by-passing through the
controller, if the checks become fouled with foreign matter and are
prevented from fully seating.
high temperature hot (if required for laundry, etc.)
hot
water
tank,
heater,
etc.
tempered water main hot supply to system
thermometer
TempControl thermostatic
water controller
circulating pump
check
check
thermometer
tempered water return
ball valve
Procedure for setting TempControl Hi-Low System
1. Turn off recirculating pump and close ball valve
2. Shut off (V1).
Diagram 2
Single Valve Installation with Recirculating
Tempered Water at Hot Water Source
valve
Diagram 3 REMOTE HI-LOW INSTALLATION WITH RECIRCULATING
TEMPERED WATER OR HOT WATER RETURN: TempControl Hi-Low
system must have the return line connected exactly as shown (See
Diagram 2 notes).
valve
cold supply
Diagram 2 INSTALLATION WITH RECIRCULATING TEMPERED WATER
AT HOT WATER SOURCE: TempControl must have the return line
connected exactly as shown. This procedure allows the controller
to maintain the set temperature during periods of no draw by (a)
allowing the major volume of return water to supply the cold inlet
of the TempControl and (b) the minor volume of return water to be
reheated and supply the hot inlet of the TempControl. When there is
no water draw on the plumbing system, no water can be added to
the system; therefore, the “cold” and “hot” supplies to the TempControl must come from within the system as described below using
the ball valve for fine tuning the operation as outlined in (a) and (b)
above.
1. With ball valve closed, set TempControl to desired temperature
with water flowing from tempered water line.
3. Open 5 showers or equivalent to the full hot position.
4. Set small TempControl valve (TMV2) to the full cold position and
note the temperature on thermometer.
5. Shut off valve (V2) and open valve (V1). Set large TempControl
valve (TMV1) to desired system temperature (make sure adjustment screw on PRV valve is in the full clockwise position).
6. Shut off 2 showers or equivalent (leaving 3 still on) and open valve (V2).
7. Turn PRV adjustment screw counter-clockwise until temperature
(T) equals that obtained in step #4.
8. Adjust TempControl valve (TMV2) to desired system temperature
and system will be in operational mode.
9. Stop the water flow, after obtaining desired temperature and turn
on the recirculating pump.
10. Crack the ball valve open so that a small amount of water is returned
to the hot water source. This allows the TempControl to maintain the
set temperature during periods of no draw on the system.
11. During no draw, observe the thermometer on the discharge on
the TempControl. If the temperature increases above the setting in
step #8, Close the ball valve slightly or open it if the temperature
decreases.
Diagram 4
Remote HI-LOW System Installation with
Recirculating Hot Water
thermometer
PRV valve
P1 pressure gauge
V1 valve
TMV1
tempered water to showers,
lavatories, etc.
P2 pressure gauge
V2 valve
TMV2
2. After obtaining desired temperature, stop the water flow.
3. Crack the ball valve open so that a small amount of water is
returned to the hot water source. This allows the TempControl
to maintain the set temperature during periods of no draw on
the system.
4. During no draw, observe the thermometer on the discharge
of the TempControl. If the temperature increases above the
setting in Step 1, close the ball valve slightly or if temperature
decreases, open it slightly.
hot supply
hot water return
cold supply
Diagram 4 REMOTE HI-LOW INSTALLATION WITH RECIRCULATING
HOT WATER SUPPLY ONLY: TempControl Hi-Low system must be
piped as shown. Follow steps 2 through 9 from diagram 3. Ignore
reference to recirculating pump in step 9 (not applicable to this
installation).
TEMPCONTROL Repair Parts
Model No.
6-100
6-101
6-101P
6-102
6-102P
Inlets
Outlet
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
INSERT PROPER
MODEL NUMBER
IN PARENTHESIS
CARTRIDGE UNIT 6- (
TT-11-100
TT-16-100
TT-15-100
) NW CARTRIDGE
CASING GASKET
SPRING WITH SPRING SADDLE
SLEEVE O-RINGS (3 REQ’D)
Suffix HC High Capacity
Model specify when
ordering cartridge
Model No.
Inlets
Outlet
6-200
6-400
6-500
6-700
3/4
3/4
1
1-1/4
3/4
1
1-1/4
1-1/2
*TT-22- (
*TT-20- (
TT-21- (
TT-24- (
)
)
)
)
STOP SPINDLE
CAP
CAP GASKET
CHECK SPINDLE & SPRING
CARTRIDGE UNIT
6- (
) NW CARTRIDGE
TT-11- (
*TT-22N- (
*TT-20N- (
*TT-47N- (
TT-21- (
*TT-181- (
TT-26- (
INSERT PROPER
MODEL NUMBER
IN PARENTHESIS
Inlets
Outlet
6-900
6-1000
1-1/2
1-1/2
1-1/2
2
CASING GASKET
STOP SPINDLE
CAP
STOP SPINDLE O-RING
CAP GASKET
CHECK SPINDLE & SPRING
CHECK SEAT
INSERT PROPER
MODEL NUMBER
IN PARENTHESIS
*NO LONGER AVAILABLE
ORDER TT-50AN-( ) CONSISTING OF
TT-22N-( ), TT-20N-( ), TT-47N-( ),
TT-21-( ), TT-181-( ) & TT-17N-( )
Model No.
)
)
)
)
)
)
)
CARTRIDGE UNIT
6- (
) NW CARTRIDGE
TT-11- (
TT-15D- (
TT-16A- (
TT-15- (
TT-22- (
TT-19BC- (
TT-20- (
TT-21- (
TT-31- (
TT-200- (
) GASKET
) O-RING
) S.S. SPRING
) O-RING
) STOP SPINDLE
) GLAND NUT
) CAP, STOP CHECK
) GASKET
) STOP CHECK BODY
) STOP SPINDLE
INSERT PROPER
MODEL NUMBER
IN PARENTHESIS
TROUBLE SHOOTING CHART
For Tempered Water Recirculated Systems:
Problem
Cause
Solution (Follow service instructions)
Thermometer in TempControl outlet rises to
temperature of the heater at start of no draw.
(i.e. sink or showers not running, etc.)
No circulation of tempered water because return line is piped to the hot water source only.
Repipe system to diagram 2 or 3 which allows the discharge of the pump (tempered
water return) to go back to the hot water
source and the cold inlet of the TempControl.
Hot water temperature at sink or shower is
below set point of TempControl.
Same as above
Same as above
Same as above but after a period of draw,
water temperature rises above set point of
controller and then stabilizes to set point.
Same as above
Same as above
Temperature rises 10˚ to 15˚ above set temperature, but not to heater temperature.
Not piped exactly like diagram 2 or 3.
Ball valve open too much.
Check valve must be installed on cold supply
to controller or close ball valve (see diagram 2
or 3 on page 2).
Cannot elevate or decrease tempered water by
turning control handle.
Piston stuck with foreign matter, cause, lack of
preventive maintenance program
Remove cartridge and clean, free piston–
cartridge could be damaged if stuck too
long–replace cartridge.
Temperature drops when draw (sink, shower
etc. running).
Valve was set in no draw mode.
Run showers and sinks and then set valve.
For Tempered Water Non-Recirculated Systems:
Problem
Cause
Solution (Follow service instructions)
By-pass, cold to hot or hot to cold.
Checks not properly seating.
Clean fouled checks, or if damaged, replace
damaged parts.
Initial draw on system running higher than
set temperature, gradually reducing to set
temperature.
Same as above
Same as above
Limited Warranty
Symmons Industries, Inc. warrants to the original user of this product that for
a period of five years from the date of installation of the product, any defective product will be exchanged or reconditioned (at our option) free of charge.
Return the defective product (at your expense) to Symmons Industries, Inc.,
31 Brooks Drive, Braintree, Massachusetts 02184.
There are no other express warranties on this product and ALL WARRANTIES
OF MERCHANTABILITY AND WARRANTIES AS TO FITNESS FOR A PARTICULAR PURPOSE AND ANY OTHER IMPLIED WARRANTIES ARE LIMITED TO A
PERIOD OF FIVE YEARS AFTER INSTALLATION. SYMMONS INDUSTRIES, INC.
EXPRESSLY DISCLAIMS CONTINGENT LIABILITY AND CONSEQUENTIAL
DAMAGE OF EVERY KIND WHATSOEVER. Some states do not allow limitations on
how long an implied warranty lasts or an exclusion may not apply to you. This
warranty gives you specific legal rights, and you may also have other rights which
vary from state to state.
Modification or alteration or improper installation or use will void the warranty
on this product.
Symmons Industries, Inc. ■ 31 Brooks Drive ■ Braintree, MA 02184
(800) 796-6667, (781) 848-2250 ■ Fax (800) 961-9621, (781) 664-1300
Website: www.symmons.com ■ Email: g e t h e l p @ s ymmons.com
©2011 Symmons Industries, Inc. Printed in U.S.A.
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ZV-795
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041911
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