HORNE Optitherm Thermostatic Taps

Horne Engineering Ltd
HORNE
Horne OPTITHERM Thermostatic Bib Tap
Type TBT02
INSTALLATION, COMMISSIONING, OPERATING AND MAINTENANCE INSTRUCTIONS
APPROVAL
The Horne OPTITHERM Thermostatic Bib Tap has been independently tested as a Type 3 TMV by
WRc-NSF and approved to the requirements of NHS Model Engineering Specifications D08:
Thermostatic mixing valves (Healthcare premises), to the following designations.
APPLICATION
WASHBASIN
DESIGNATION
HP-WE
HOT & COLD
WATER PRESSURES
1 to 5 BAR
(Hot and cold
pressures do not
need to be equal)
Static Pressure
Max. 10 Bar
WATER
TEMPERATURES
HOT: 52°C - 65°C
COLD: 5°C - 20°C
Differential between
mixed and supply
temperatures: Min. 11°C
Table 1
If the Horne OPTITHERM Thermostatic Bib Tap is operated outwith these conditions it cannot be
guaranteed to operate as a Type 3 TMV.
The Horne OPTITHERM Thermostatic Bib Tap is supplied with WRAS approved integral single
check valves (spring-loaded, resilient trim in-line check valve cartridge with plastic guide and stem)
located in each of the hot and cold water supply inlets.
The Horne OPTITHERM Thermostatic Bib Tap is a tap containing a thermostatic mixing valve
(TMV). All comments made herein regarding TMVs apply equally to thermostatic taps.
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ACCESSORIES:
MULTI-TOOL:
Optitherm Multi Tool (Part
No. 5459) & Screwdriver bit
(Part No. 5632). Available
as part of full toolkit (part
no. 5491).
A
Endcap Gripper
B
Outlet Fitting Tool
C
26mm Ring
Spanner
D
8mm Hex Key
E
12mm Hex Key
F
Screwdriver Bit
THERMAL DISINFECTION ADAPTOR:
As part of Water Quality Compliance
Kit – Part no. 6006. See Section 2.4 & 4.2
FLUSHING ADAPTORS.
Part nos. 5684 (left), & 5492 (right).
The Parts on the right are also contained in
Water Quality Compliance Kit, part no.6006.
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Table of Contents
[1]
1.1
1.2
1.3
1.4
[2]
2.1
2.2
2.3
2.4
2.5
2.6
2.7
[3]
3.1
3.2
3.3
3.4
[4]
4.1
4.2
4.3
4.4
4.5
4.6
4.7
INSTALLATION........................................................................................................ 4
NOTE ON O-RING FITTING ...................................................................................................4
FITTING .............................................................................................................................4
FLUSHING OF PIPEWORK (METHOD 1) .................................................................................5
FLUSHING OF PIPEWORK (METHOD 2) .................................................................................6
COMMISSIONING .................................................................................................... 6
FLUSHING .........................................................................................................................6
TEMPERATURE CHECK (COLD WATER).................................................................................6
TEMPERATURE CHECK (HOT WATER) ..................................................................................6
THERMAL DISINFECTION.....................................................................................................7
TEMPERATURE CHECK (MIXED WATER) ...............................................................................7
MIXED W ATER TEMPERATURE ADJUSTMENT .......................................................................7
COLD W ATER FAILURE TEST ..............................................................................................7
OPERATION............................................................................................................. 8
DUAL LEVER VERSION .......................................................................................................8
SHORT LEVER VERSION .....................................................................................................8
LEVER CLUTCH..................................................................................................................8
POTABLE W ATER SUPPLY ..................................................................................................8
MAINTENANCE ....................................................................................................... 9
IN-SERVICE TESTING .........................................................................................................9
FLUSHING AND THERMAL DISINFECTION ..............................................................................9
CLEANING AND REPLACEMENT OF STRAINERS .....................................................................9
TESTING AND REPLACEMENT OF CHECK VALVES .................................................................9
REPLACEMENT OF THERMOSTATIC CARTRIDGE .................................................................10
REPLACEMENT OF CERAMIC DISC CARTRIDGES.................................................................10
REMOVAL OF TAP FROM SPIGOT FOR W ORKSHOP MAINTENANCE .......................................11
FOLDOUT PAGE – DIAGRAMS ....................................................................................... 12
[5]
5.1
FAULT FINDING CHART ....................................................................................... 13
FAULT FINDING CHART – CONTINUED… .............................................................................14
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[1]
INSTALLATION
The Horne OPTITHERM Thermostatic Bib Tap must be installed in accordance with the Water
Supply (Water Fittings) Regulations 1999.
1.1
NOTE ON O-RING FITTING
Before fitting o-rings care should be taken that they, and the grooves/bores into which they fit are…



Clean
Free from damage (nicks, tears, etc.)
Lubricated lightly with water or a WRAS approved silicone oil.
Failure to do this may result in leaks and considerable damage.
1.2
FITTING
The Horne OPTITHERM Thermostatic Bib Tap is
intended for installation on a vertical panel above a
surgical basin or bath with no tap holes.
1.2.1
Before installation, 2 holes must be bored in the panel
in the configuration shown in the diagram.
A
150mm to 300mm depending on
vessels to be filled. Less than 150mm
will impede access for servicing.
Recommended height 225mm
B
34mm
C
48mm (min 47mm, max 50mm)
D
6mm
Panel
thickness
30mm maximum
► Open out the last (fold out) page of this instruction booklet to see the installation diagrams ►
1.2.2
Install the spigot (5) to the panel. Ensure that the chrome bezel (7) is located around the spigot
first, and that the locating pin in the bezel engages in the small hole bored previously in the panel.
The bezel should be retained between the spigot and the panel. Tighten to the panel using the 1½
BSP bulkhead nut (8) supplied. Put this nut on tightly. If it works loose the tap will not be secure
and the nut may be difficult to tighten later, after the panel has been fixed.
1.2.3
Attach the 10mm compression couplings (22), or optional flexible hoses (9) to the spigot with the
Hot Water Supply connected to the inlet port nearest the lever with the red endcap (i.e. the left
hand side as one faces the basin), and the Cold Water Supply connected to the inlet port nearest
the lever with the blue endcap (i.e. the right hand side as one faces the basin). The note in 1.1
regarding o-ring fitting should be especially heeded here, as any leaks in the hose o-rings may go
undetected for some time and cause considerable damage. Torque couplings or hoses to 5Nm.
1.2.4
At this stage, the screw (6) can be used to attach an electrical earth, if required.
1.2.5
Connect the couplings (or flexible hoses) to the water supply behind the panel, close the ball
valves (13,14) in the spigot and test for leaks. Once this part of the installation is confirmed to be
watertight, and the hot and cold supplies are confirmed to be the right way around (see section
2.2), all further work on the Horne OPTITHERM Thermostatic Bib Tap can be done with the panel
in place.
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1.2.6
If applicable, attach the required extension piece (4) to the spigot using the 4 no. M5 screws (2)
and washers (3) supplied. Ensure that the interconnect nozzles (1) are located correctly with their
o-rings between the spigot (5) and the extension piece (4). See note in 1.1 regarding o-ring fitting.
1.2.7
Offer the main tap body up to the spigot. Locate firmly over the spigot and tighten the retaining
screw (15) from below. In order to get a good fit of the tap onto the spigot it is helpful to push the
tap against the spigot and slightly upwards as the retaining screw is tightened – this ensures that
there is no gap between the spigot and the tap body. Torque the retaining screw to 5Nm (if a
torque wrench is not available, tightening fairly tightly with the 4mm hex key supplied should be
adequate for this purpose).
1.2.8
Do not open the tap yet. Commence with the flushing procedure as detailed in 1.3 below.
1.3
FLUSHING OF PIPEWORK (METHOD 1)
Pipework must be flushed in accordance with
Water Fittings Regulations 1999, schedule 2
G13.1 before connecting the Horne OPTITHERM
Thermostatic Bib Tap.
The most common cause for complaint regarding
the performance of any TMV/thermostatic tap is
traced to dirt or debris in the TMV or check
valves.
1.3.1
DO NOT OPEN either tap lever before flushing
the hot and cold water pipework.
1.3.2
A flushing kit (Horne part no: 5492, or as part of
the Water Quality Complance Kit, part no. 6006)
is available to provide means of flushing the
pipework.
1.3.3
Unscrew the main bottom cover (16) using a
strap wrench.
1.3.4
Remove a strainer/check-valve cartridge (20,21)
using a 12mm hex key or Horne tool no. 23-5459.
1.3.5
Using an 8mm hex key or Horne tool 23-5459,
screw the flushing adaptor (22) into the space
occupied by one of the strainer/check valve
cartridges (20,21).
1.3.6
Ensure that the hose is securely attached to the
flushing adaptor and that the open end of the
hose is also secure - the hot water could scald
badly if the hose ‘whips’ unexpectedly.
1.3.7
Open the ball valve (13,14) using a flat bladed
screwdriver from under the spigot, and allow the
water to flow at full bore into the sink until the
water flows absolutely clean.
1.3.8
Repeat on the other side so that both hot and
cold supplies to the tap are flushed.
Key to diagram above
13
21
23
Hot isolating valve
Strainer/check-valve cartridge
Flushing hose
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14
22
Cold isolating valve
Flushing adaptor
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1.4
FLUSHING OF PIPEWORK (METHOD 2)
Alternatively the pipework can be flushed before fitting the
Optitherm to the spigot using Horne part no.5684.
1.4.1
Connect adapter to spigot with jubilee clip
around the large end.
1.4.2
Tighten the jubilee clip.
1.4.3
Open the valves from under the spigot and
allow water to flow at full bore into the basin
until the water runs absolutely clean.
[2]
COMMISSIONING
The commissioning process comprises sections 2.1 to 2.7 below. The tap cannot be considered
commissioned until these processes are all carried out.
Note that it is NOT possible to commission the Horne OPTITHERM Thermostatic Bib Tap before
the hot water service (boiler) has been commissioned.
2.1
FLUSHING
Before commissioning the Horne OPTITHERM Thermostatic Bib Tap, it is imperative that flushing
of the pipework has been carried out in accordance with section 1.3 or 1.4.
2.2
TEMPERATURE CHECK (COLD WATER)
2.2.1
Open the cold water isolating valve (14) and lever (12), allow the water to run for a while and
ensure that cold water flows from the spout (if hot water comes out, then the supplies are
connected the wrong way around). Ensure that the tap is run for long enough to draw off any
deadleg to be absolutely sure. Getting this right will save frustration later.
2.2.2
To check the temperature of the incoming cold water, open the blue/cold lever (12) only, and
measure the temperature after 30 seconds. This should be within the range on table 1, page 1.
2.2.3
If hot water comes out of the spout when the blue lever is turned, the inlet hoses will have to be
reversed behind the panel. This necessitates removal of the spigot (section 1.1 describes fitting of
the spigot).
2.3
TEMPERATURE CHECK (HOT WATER)
2.3.1
To check the temperature of the incoming hot water, follow the procedure in section 4.3 for
removal of the strainer/check valve cartridge on the hot side only (see also diagram in section 1.3)
2.3.2
Screw the flushing adaptor (22: diagram 2) into the space which was occupied by the hot
strainer/check valve cartridge (20).
2.3.3
Ensure that the hose (23) is securely attached to the flushing adaptor. Take care that the open
end of the hose is also secure and pointing down the drain as the hot water could scald badly.
2.3.4
Carefully open the hot ball valve (13) from under the spigot and measure the temperature of water
that flows out from the tube after 30 seconds; it should be within the range on table 1, page 1.
2.3.5
Re-fit the strainer check-valve cartridge (20) and the bottom cover (16).
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2.4
THERMAL DISINFECTION
2.4.1
Following the hot water temperature check it is recommended that thermal disinfection be carried
out using the Water Quality Compliance Kit (part no.6006) as part of the commissioning procedure.
Instructions for the thermal disinfection procedure are supplied with this kit
2.5
TEMPERATURE CHECK (MIXED WATER)
2.5.1
Check that hot and cold water supplies are at or near to their designated temperatures and
pressures (see sections 2.2 & 2.3 and Table 1 on Page 1 for details).
2.5.2
Open the red (safe hot) lever only and allow water to run through the TMV.
2.5.3
Measure the temperature at the spout. This is the temperature of the mixed water. Ensure that the
mixed water temperature is set appropriately. For healthcare applications, basin taps should
always be set to 41°C.
If necessary, make minor adjustments to the temperature setting as described in Section 2.6
below.
N.B. For TMV3 applications the mixed water at the terminal fitting should never be set to exceed
41°C.
2.6
MIXED W ATER TEMPERATURE ADJUSTMENT
2.6.1
The Horne OPTITHERM Thermostatic Bib Tap is approximately set at the factory to check for
correct function. However temperature must be checked and adjusted on site to ensure correct
installation. For healthcare applications, basin taps should always be set to 41°C.
For other applications, where applicable, the range of temperature adjustment is 35 – 44°C.
2.6.2
It should be noted that the Horne OPTITHERM Thermostatic Bib Tap requires a temperature
differential of at least 11°C to work correctly (ie. the mixed water temperature must be at least
11°C lower than the hot water temperature and 11°C higher than the cold water temperature).
To alter the temperature setting, carry out the following procedure.
2.6.3
Unscrew the main bottom cover (16) using a strap wrench.
2.6.4
Check that hot and cold water supplies are within the designated temperature and pressure ranges
(see sections 2.2 & 2.3)
2.6.5
Open the red/safe-hot lever (11) and allow water to flow until the mixed water temperature has
stabilised. Make sure that the dead leg from the Hot Water Supply to the Horne OPTITHERM
Thermostatic Bib Tap has fully cleared.
2.6.6
Using a 4mm hex key, turn the adjusting screw (19) clockwise as viewed from below † to reduce
the mixed water temperature or anti-clockwise to increase it. Adjustments of not more than half a
turn at a time should be made. The temperature at the outlet should be measured and allowed to
stabilise after each adjustment.
†
Note screwing the adjusting screw inwards towards the cartridge will reduce the set temperature.
Screwing it outwards away from the cartridge will increase the set temperature. The screw has a
conventional right-hand thread.
After making an adjustment, close the red/safe-hot lever (11) for ten seconds then re-open it and
measure the mixed water temperature again. If a further adjustment is required, repeat the
procedure.
2.7
COLD W ATER FAILURE TEST
2.7.1
Close the cold water isolating valve (14) and, after 6 seconds, measure the mixed water
temperature. The flow of mixed water should immediately stop and then a drip or trickle may or
may not be seen. The temperature, measured after 6 seconds, of any water coming from the tap
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should not be more than 3°C above the mixed water set temperature measured in 2.4.1 above. If
no water comes out this is also acceptable.
2.7.2
If the Horne OPTITHERM Thermostatic Bib Tap performs satisfactorily, open the cold water
isolating valve (14) – the Horne OPTITHERM has passed the cold water failure test.
2.7.3
However, if the water coming from the tap is at a temperature of more than 3°C above the mixed
water temperature setting, then the Horne OPTITHERM is not shutting off the hot water supply
properly. The cartridge is likely to be contaminated with dirt or damaged. Replace the cartridge
according to section 4.5.
Note that the Horne OPTITHERM may, in some circumstances, fail the cold water failure test if the
hot supply temperature is not 11°C above the set mixed water temperature. The hot water
temperature can be checked as outlined in section 2.3 above..
[3]
OPERATION
Operation of the Horne OPTITHERM Thermostatic Bib Tap is the same as that of a conventional
tap. Open the red lever to draw hot water at a safe and comfortable temperature (controlled by the
thermostatic mechanism). Open the blue lever to draw fresh, cold water. The user may notice a
slight pulsing of the water stream if both levers are opened. This is normal and is not a cause for
concern. Note that it is not normally necessary to open both levers simultaneously as the water
supplied from the hot lever is at a safe and constant temperature.
3.1
DUAL LEVER VERSION
The dual levers on the Horne OPTITHERM Thermostatic
Bib Tap are a unique feature to prevent the spread of
infection.
The intended mode of operation is that the user should
open (turn-on) the tap using a thumb to push the short
lever (25,26) backwards and downwards.
After washing, the long lever (11,12) should be returned
to the original position with an elbow, thus avoiding recontamination by touching the short lever again.
3.2
SHORT LEVER VERSION
The short levers are pulled forwards to open (turn-on).
And pushed backwards to stop the water flow.
3.3
LEVER CLUTCH
Key to diagram above
11 Long lever (safe-hot)
12 Long lever (cold)
The Horne OPTITHERM is fitted with 25 Short lever (safe-hot)
26 Short lever (cold)
clutches on the levers to prevent
lever breakage in the event of a lever being forced either accidentally or intentionally. Hence if the
tap lever is found to be at an unexpected angle, simply push the lever in the opposite direction,
beyond the normal ‘stop’. One or two clunks should restore the lever to its correct position.
3.4
POTABLE W ATER SUPPLY
When cold water is drawn (via the blue lever) from the Horne OPTITHERM Thermostatic Bib Tap
the water completely bypasses the thermostatic mechanism. Hence, if the cold water supply to the
Horne OPTITHERM Thermostatic Bib Tap is potable, so is the water drawn via the cold lever. NB:
care should be taken to run the tap for at least 20 seconds before drawing water for drinking. This
will ensure satisfactory purging of the spout.
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[4]
MAINTENANCE
Maintenance of all TMVs and thermostatic taps is essential. If a TMV does not operate properly,
there is a risk of someone being scalded. The frequency of maintenance depends upon the
condition of the water passing through the TMV. The remarks in 4.1.3 regarding in-service testing
apply equally to maintenance. Generally, the thermostatic cartridge should be replaced after three
years. The strainer/check-valve cartridges and ceramic disc cartridges should be replaced as
necessary.
4.1
IN-SERVICE TESTING
4.1.1
Periodic testing should be carried out to check whether or not any deterioration has occurred in the
performance of the Horne OPTITHERM Thermostatic Bib Tap.
4.1.2
A COLD WATER FAILURE TEST should be carried out as described in paragraph 2.7 above. If
the water coming from the tap is at a temperature of more than 3°C above the mixed water
temperature setting then the Horne OPTITHERM Thermostatic Bib Tap is due for maintenance.
NOTE: A TMV in need of maintenance can be undetectable in normal use and only become
apparent when a disruption occurs in the hot or cold water supply pressures or temperatures.
4.1.3
The frequency of in-service testing depends upon the condition of the water passing through the
tap. In-service testing must be carried out more frequently in hard water areas than in soft water
areas. As a general guide, in-service testing should be carried out at least every twelve months
and, where the water is hard, the interval may be less than six months. Experience of local
conditions and the in-service testing record will dictate the frequency of in-service testing.
4.2
FLUSHING AND THERMAL DISINFECTION
4.2.1
Horne recommends periodic thermal disinfection in conjunction with high velocity flushing, using
the Water Quality Compliance Kit (part no.6006). See paragraphs 1.3 and 1.4. The periodicity of
this maintenance should be determined in conjunction with the current best practice.
4.3
CLEANING AND REPLACEMENT OF STRAINERS
4.3.1
Close the isolating valves (13,14) at the back underneath the tap spigot; open the levers and allow
the residual water to drain.
4.3.2
Unscrew the main bottom cover (16) using a strap wrench.
4.3.3
Remove the strainer/check-valve cartridges (20,21) using a 12mm hex key or Horne special tool
(part no. 23-5459).
4.3.4
The strainer can be removed from the top of the cartridge and cleaned or replaced as necessary.
4.4
TESTING AND REPLACEMENT OF CHECK VALVES
4.4.1
Close the isolating valves (13,14) at the back underneath the tap spigot; open the levers and allow
the residual water to drain.
4.4.2
Unscrew the main bottom cover (16) using a strap wrench.
4.4.3
Remove a strainer/check-valve cartridge (20,21)
Remove the strainer basket from the top. Inspect the white plastic check valve for signs of obvious
damage. Carefully insert a probe (pen or similar) down the strainer hole to ensure that the check
valve element can move freely. It should spring back into the closed position when released. It
should also be possible to blow through the cartridge from the top to the bottom, but not the other
way around. If the check-valve is not in good condition, the whole strainer/check-valve cartridge
should be replaced.
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4.5
REPLACEMENT OF THERMOSTATIC CARTRIDGE
4.5.1
Close the isolating valves (13,14) at the back underneath the tap spigot; open the levers and allow
the residual water to drain.
4.5.2
Unscrew the main bottom cover (16) using a strap wrench
4.5.3
To remove the thermostatic cartridge, first remove the thermostatic cover (18) using a 12mm hex
key or Horne tool no. 5459. The thermostatic cartridge (17) can then be removed in one of 2 ways.


Screw the Horne cartridge removal tool (part no. 5458) into the cartridge from underneath. This
can then be pulled downwards to remove the thermostatic cartridge.
Use a 4mm hex key to turn the adjusting screw (19) clockwise and remove it from the
thermostatic cover (the adjusting screw has the same thread on it as the cartridge remover
no.5458). This can be used to screw into the cartridge and remove it. Ensure that the
adjusting screw o-ring is in good condition; clean; free from debris and lightly lubricated with
water or WRAS approved silicone oil before re-assembly (see 1.1).
4.5.4
The new cartridge can be inserted into the tap body from below. If the o-rings are dry, they should
be lubricated with some water or WRAS approved silicone oil.
4.5.5
Screw in the new thermostatic cover, again lubricating the o-ring if necessary.
4.5.6
Be sure to adjust the temperature and perform a cold-water failure test after replacing the
cartridge. These processes are detailed in sections 2.4.1; 2.6 & 2.7.
4.6
REPLACEMENT OF CERAMIC DISC CARTRIDGES
4.6.1
The ceramic disc cartridges are reliable and expected to give a very long life provided that the
strainers are maintained in a clean condition. If replacement is necessary a kit should be
purchased from Horne for this purpose (part no. 5489). The kit will comprise…



Endcap removal tool – (part no. 23-5459)
Pair of ceramic disc cartridges (27) – (part
nos. 44-5406 & 44-5407)
Pair of torque control members (31) –
(part no. 23-5410)
4.6.2
Unscrew and remove the
aluminium endcap using the
special Horne tool (no. 5459)
4.6.3
Unscrew and remove the
screw and washer (34,35).
2.5mm hex key needed.
4.6.4
Pull the lever outwards to
remove
4.6.5
Remove the spline adaptor
and torque control member
(30,31). These may come out
as one piece.
4.6.6
Unscrew the actuator sleeve
(28), using a 26mm ring
spanner or Horne tool no.
5459.
4.6.7
Using a 17mm spanner,
unscrew the ceramic disc
cartridge (27). This will be tight.
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 2 no. o-rings (32) (part no. 42-3452)
 4 no. o-rings (33) (part no. 42-5416)
 2 no. M4 screw (35) (part no. 41-5414)
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4.6.8
Fit the replacement cartridge and tighten well. Note that the two cartridges are left and right
handed. The cartridge with the small nicks around the 17mm spanner hex is for the left (hot) side
of the tap. If the o-ring around the cartridge is dry, lubricate it with a little water or WRAS approved
silicone oil.
4.6.9
Fit the new actuator sleeve and o-ring. If using a spanner for this take care not to over-tighten it as
the thread is plastic - only light torque is needed. Horne tool no. 5459 can be used.
4.6.10
Remove the old torque control member (31) from the spline adaptor, and push-fit the new one.
Lubricate this with a little (silicone) oil around the outside before final assembly.
4.6.11
Fit this assembly over the ceramic disc cartridge spline. Note that the spline has 20 teeth and the
torque control member has 7 lobes. This allows 140 possible orientations of the lever. The correct
orientation will have a lobe as near as possible to the vertical position (with the ceramic discs
closed). It may be beneficial to experiment with orientations to ensure that the two levers end up
aligned neatly with each other.
4.6.12
Re-fit the levers, replacing o-rings if necessary. The large o-ring goes on the in-board side and the
two small ones go immediately under the penny washer on the out-board side.
4.6.13
Refit the washer and M4 screw tightly. Then fit the endcap (red on the left, blue on the right). Use
the tool no. 5459 to tighten the endcap. This will prevent unauthorized removal.
4.7
REMOVAL OF TAP FROM SPIGOT FOR W ORKSHOP MAINTENANCE
If desired the tap body can be removed from the spigot for off-site maintenance. Furthermore, a
substitute tap body can be fitted while the original tap is being maintained. The process for this is
as follows.
4.7.1
Close the isolating valves (13,14) at the back underneath the tap spigot; open the levers and allow
the residual water to drain.
4.7.2
Unscrew the main bottom cover (16) using a strap wrench.
4.7.3
Loosen the tap retaining screw (15) until the head is flush or slightly proud of the bottom of the tap
body.
4.7.4
Pull the tap away from the panel horizontally until it is free of the spigot. Pay careful attention not
to drop it as it is rather heavy and may cause damage.
4.7.5
Rotate the tap to allow the residual water to pour out into the sink.
4.7.6
If a replacement tap body is to be fitted, follow the procedure in 1.2.7.
procedures in 2.4.1; 2.6 & 2.7 should be followed for the new tap body.
Key to Diagram on Page 10
27
28
29
30
31
32
33
34
35
Ceramic Disc Cartridge
Actuator Sleeve
Act. Sleeve O-Ring
Spline Adaptor
Torque Control
Member
O-Ring
O-Ring
Washer
M4 Screw
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The commissioning
Key to Diagram on Page 12
1
3
5
7
9
11
13
15
17
19
21
Interconnect Nozzles
Fibre Washers
Spigot
Bezel
Optional Inlet Hose
Long Lever Hot
Hot Isolating Valve
Tap Retaining Screw
Thermostatic Cartridge
Adjusting Screw
Strainer/Check-Valve (C)
L-183 (D9392)
2
4
6
8
10
12
14
16
18
20
36
M4 Screws
Extension Piece
Earth Screw & Washer
Bulkhead Nut
--Long Lever Cold
Cold Isolating Valve
Main Bottom Cover
Thermostatic Cover
Strainer/Check-valve (H)
10mm comp. coupling
Page 11 of 14
Horne Engineering Ltd
FOLDOUT PAGE – DIAGRAMS
Diagram 5
Diagram 6
Issue 2.1 Dec 2012
Diagram 7
L-183 (D9392)
Page 12 of 14
Horne Engineering Ltd
[5]
FAULT FINDING CHART
SYMPTOM
Mixed water
temperature too
high
Mixed water
temperature too
low
Mixed water flow
rate too low.
Mixed water
temp does not
respond to
adjusting screw
Issue 2.1 Dec 2012
POSSIBLE CAUSE
ACTION
REFER
TO
SECTION
Temperature setting too high.
Temperature has been set when hot
water supply temperature was too low
Re-adjust temperature
setting ensuring hot water
supply is at correct
temperature.
2.4.1, 2.6
Hot water supply has migrated into
cold water supply
Inspect/replace cold checkvalve assembly (21)
4.4
Thermostat Element has failed. This
can be checked by carrying out a hot
or cold water failure test.
Replace Thermostatic
cartridge (17) and cover
assembly (18)
2.7 & 4.5
Temperature Setting too low
Re-adjust temperature
setting
2.4.1, 2.6
Hot water supply temperature has
fallen.
Check hot water supply
temperature.
2.3
Cold water has migrated into hot
supply
Inspect/replace hot checkvalve assembly (20)
4.4
Cold valve face requires cleaning
Remove thermostatic cover
(18) and clean up valve face
4.5
Partly blocked strainers
Clean strainers
4.3
Unusually high pressure drop in
supply pipework
Check all valves are full
open.
Check Pressurisation unit.
Check mains supply
-
Extra Demand added to system
Check pipe sizing
-
Thermostatic cartridge is seized
Replace Thermostatic
cartridge (17) and cover
assembly (18)
4.5
Hot and cold inlets reversed
Reverse inlet connections
(9,10). Connect hose from
hot supply to inlet nearest
red endcap
2.2
Hot water supply temperature is too
low
Check hot water supply
-
L-183 (D9392)
Page 13 of 14
Horne Engineering Ltd
5.1
FAULT FINDING CHART – CONTINUED…
Thermostatic cartridge is seized
Replace Thermostatic
cartridge (17) and cover
assembly (18)
4.5
Thermostat element has failed. (This
can be checked by carrying out a hot
or cold water failure test)
Replace Thermostatic
cartridge (17) and cover
assembly (18)
2.7, 4.5
Hot and cold inlets are reversed
Reverse inlet connections
(9,10). Connect hose from
hot supply to inlet nearest
red endcap
2.2
Cold valve face is contaminated with
debris
Remove loose debris from
between Thermostatic
cartridge (17) and cover
assembly (18). Or replace
(17) and (18) if no loose
debris is found.
4.5
Element has failed, or
Slide-Valve seal is damaged, or
Fouling at hot valve seat
Replace Thermostatic
cartridge (17) and cover
assembly (18)
4.5
Re-commission the valve,
closely following the
guidance in Section 2.
2.2 thru’
2.7
If water flowing is less than 11°C
above required mixed water
temperature then the hot water supply
temperature may not be sufficient to
cause thermal shut-off. (N.B. this is
possible with combi boilers).
Repeat test with hot water
temperature at least 11°C
above required mixed water
temp.
2.3, 2.7
Water flow
pulses when
both levers are
opened at once
This can happen when cold water
pressure is low relative to the hot
water pressure. Note that it is not
normally necessary to open both
levers simultaneously as the water
supplied from the hot lever is at a safe
and constant temperature.
This is not a fault condition
and is normal
-
Tap does not
shut-off when
levers are in the
closed position
Possible contamination on
interconnect nozzle (1) o-rings.
Remove o-rings, clean and
re-assemble
-
Mixed water
temp changes
and is not steady
Water at outlet
runs full hot or
full cold
Valve continues
to pass cold
water when hot
supply is isolated
If water flowing is more than 11°C
above required mixed water
temperature then valve may not have
Valve continues
to pass hot water been commissioned with an adequate
when cold supply hot water supply temperature; or the
set temperature may be too high.
is isolated.
NB If this is the case the valve may
not offer scald protection
Issue 2.1 Dec 2012
L-183 (D9392)
Page 14 of 14