Installation Instructions and User Guide
Contents
1. PRESTEX DOMESTIC VALVE SOLUTIONS Installation Instructions and User Guide 15mm amp 22mm In Line Thermostatic Mixing Valve TMV2 Model P404 Model P404 indd 1 D 13 2 09 15 02 45 IMPORTANT INTRODUCTION NOTES The valves covered by these instructions have been tested and certified as being in compliance with BS EN 1111 1999 and BS EN 1287 1999 Valves operating outside the requirements of these standards are not covered by the TMV2 Scheme and are not guaranteed to operate as Type 2 valves The installer should be aware of his duty of care and responsibility in ensuring that compliance with regulations is maintained The valve is not guaranteed to function correctly to the TMV2 specification unless it is installed and used in accordance with these instructions Regular servicing is essential to ensure continued safe operation of this thermostatic mixing valve The recommended service interval is no greater than 12 months This Prestex Model P404 in line thermostatic mixing valve available in 15mm and 22mm sizes is intended to be fitted into applications where the reliable control of hot water temperature is necessary to prevent scalding In the event of cold water supply failure the product will shut off the hot water supply Water Regulations The Prestex Model P404 mixing valve must be installed in accordance with the regulations of the local water company and the Water Supply Water Fittings Regulation2. APPLICATION The Prestex Model P404 thermostatic mixing valve has been independently tested by WRc NSF against the requirements of BS EN 1287 Low Pressure LP and BS EN 1111 High Pressure HP and certified as complying with the requirements of the TMV2 Scheme and is suitable for use in the designations shown in the table below Valves approved for designation for use HP only If a water supply is fed by gravity then the supply pressure should be verified to ensure the conditions of use are appropriate for the valve Application Pressure Maximum set mixed water temperature Shower HP and LP 41 C Wash basin HP and LP 41 C Bidet HP and LP 38 C Bath Tub HP 44 C The above temperatures are recommended by the Thermostatic Mixing Valve manufacturers Association as relevant settings for the varying applications shown This is the maximum commissioning temperature but valves may exceed this by 2 C in use The range of available temperature adjustment is 35 C to 48 C but 46 C is the maximum recommended mixed water temperature from a bath tap The maximum temperature takes account of the allowable temperature tolerances inherent in thermostatic mixing valves and temperature losses in metal baths 46 C is not a safe bathing temperature for adults or children The British Burns Association recommends 37 C to 37 5 C as a comfortable bathing temperature for children In premises covere
3. may be necessary to replace the thermal element a PROTECTIVE CAP AND FIXING SCREW SELEMENT AND ASSEMBLY MAIN SPRING AND FLOW a GUIDE Bede Ae 2i J Aonnes Exploded view of TMV assembly TMV3 Model P404 indd 7 SPARES In order to ensure that the Prestex Model P404 thermostatic mixing valve continues to provide satisfactory service only GENUINE Pegler spare parts must be used Spare part order Description code 1 854453 Protective cap complete with screw 854447 Hexagon key 854454 4 854449 15mm Tailpiece 854450 22mm Strainer kit 5 854451 15mm Angle valve 854452 22mm strainer kit 854456 15mm Sealing washer 854457 22mm 7 854455 15mm Wafer Strainer 817012 22mm 13 2 09 15 02 47 PL Pegler Yorkshire Our brands terrien EATING SOLUTIONS YORKS RKSHIRE SOLDER RING SOLUTIONS Tectite PUSH FIT SOLUTIONS XPress PRESS FIT SOLUTIONS ENDEX ND FEED SOLUTIONS KUTERLITE PLUMBING SOLUTIONS PRESTEX DOMESTIC VALVE SOLUTIONS PEGLER COMMERCIAL VALVE SOLUTIONS ipea UTILITY TAP AND MIXER SOLUTIONS Also available from Pegler Yorkshire francis H LUXURY TAP SOL TMV3 Model P404 indd 8 Aalberts Industries Al UK Sales Free Phone 0800 156 0010 Free Fax 0808 156 1011 Email uk sal
4. the valve particularly at the hot inlet The formation of the scale may adversely affect the performance of the valve which will be detected during the in service testing If this occurs it will be necessary to remove the valve for de scaling and servicing 13 2 09 15 02 47 TO SERVICE THE VALVE e Isolate the hot and cold supply e Remove the valve to a clean working area Remove the protective cap Unscrew the headwork of the valve Carefully remove the element and valve assembly and put to one side e Remove the main spring and flow guide and carefully put to one side e Inspect the components for contamination or damage e Clean or replace as necessary e Remove the two o rings e Clean the valve body and headwork using a propriety de scaler e Thoroughly rinse the body and headwork in clean water e Carefully fit new o rings from the service kit taking care to ensure they are not damaged and are correctly located e Lubricate the o rings with the lubricant provided e Re fit the flow guide and spring lubricating the flow guide around the greatest diameter with the lubricant provided e Lubricate the shuttle valve with the lubricant provided e Re fit the shuttle valve and element assembly e Re fit the headwork ensuring correct tightening e Re fit the assembled valve and perform the comissioning sequence e If after cleaning the valve and replacing the o ring seals the valve does not function correctly it
5. Service Tests should be RECORDED and should preferably be the same as that used at installation Note If there is a residual flow during the commissioning or the annual verification cold water supply isolation test then this is acceptable providing the temperature of the water seeping from the valve is no more than 2 C above the designated maximum mixed water outlet temperature setting of the valve Any higher temperatures should occur only briefly Temperature readings should be taken at the normal flow rate after allowing the system to stabilise The sensing part of the thermometer probe must be fully submerged in the water that is to be tested Any TMV that has been adjusted or serviced must be re commissioned and re tested in accordance with the manufacturer s instructions In the absence of any other instruction or guidance it is recommended that In Service Tests are carried out once every 12 months as a minimum If the temperature is outside of the expected range it will be necessary to remove and clean the valve in accordance with the following instructions TMV Cleaning and Servicing Instructions Most domestic water supplies contain calcium which will separate out when the water is heated in a system The degree and speed of scaling may vary depending on factors such as water flow rates system design the hardness of the water and the temperature to which the water is heated Deposits of scale may over time form in
6. d by the Care Standards Act 2000 the maximum mixed water outlet temperature is 43 C 13 2 09 15 02 46 COMMISSIONING The valve must be commissioned under normal site system conditions and after establishing supply conditions with the hot and cold water supplies open leave the system running to allow temperatures and pressures to stabilise and be checked Prior to commencing commissioning the following checks should be carried out e The designation of the thermostatic mixing valve matches the application e The supply pressures and temperatures are within the operating range of the valve e Isolating valves and strainers are provided If all these conditions are met proceed to set the temperature as described below The Prestex thermostatic mixing valve is supplied factory set at 43 C but the valve may be simply adjusted after installation The mixed water temperature at the terminal fitting must never exceed 46 C When the valve has been installed with the correct conditions of use it is advised that the valve is subjected to exercise prior to the commissioning at the application temperature Operate the valve from full cold to full hot at least three times With the valve at the full cold position bring the valve to the correct application temperature by turning the spanner clockwise If the valve overshoots this temperature return the valve to the full cold condition and reset it to the correct temperatur
7. e 0 2 C Do not set a valve on a lowered temperature as this will not provide consistent operation When the valve is set to the required temperature for the application carry out 5 cold water isolation tests to further exercise the valve TMV3 Model P404 indd 5 e Set the mixed water temperature to the required value It is advisable to use a calibrated digital thermometer for checking the inlet and outlet temperatures e Remove the plastic protective cap on top of the valve with a suitable tool e using a close fitting spanner reduce the mixed outlet temperature by turning clockwise e increase the mixed water outlet temperature by turning counterclockwise e Measure and record the temperature of the hot and cold water supplies at the inlets to the valve e Measure and record the temperature of the water discharging from the valve at the greatest draw off flow rate e In the absence of other temperatures being specified those detailed in Table 2 are the desired settings Once the required mixed outlet temperature has been achieved isolate the cold water supply and monitor and record the mixed water temperature including the maximum and final temperatures achieved The mixed water temperature should never exceed 46 C Re fit the cap Record all the equipment used during commissioning 13 2 09 15 02 47 MAINTENANCE The Prestex Model P404 thermostatic mixing valve will provide satisfactory se
8. e complete with union nuts and compression nuts and olives e Locate the sealing gaskets insert them into the union nuts against the faces of the tailpieces and screw the union nuts onto the valve until a tight seal has been made e Remove the compression nuts and olives from the tailpieces Locate the inlet filter screens and insert them into the bore of the tailpieces up to the shoulder e Assemble the valve to the pipework and ensure the hot and cold water pipes have full penetration into the tailpiece e Tighten the compression nuts ensuring that the end of the pipe remains in contact with the filter element 13 2 09 15 02 46 Exploded view of tailpiece assembly u The Prestex Model P404UA mixing valve is optionally provided with angled assemblies in lieu of the tailpiece arrangement shown above This allows the connections of the hot and cold water supplies to be parallel to the mixed water outlet for ease of piping layouts The assemblies comprise an integral full bore ball valve and in line strainer in an angled housing When this arrangement is used the requirements for isolation valves and Y strainers previously mentioned are regarded as fulfilled Exploded view of angled valve assembly PRESSURE TAKE OFF POINT PLUG Hp ooo FILTER MESH UNION NUT SEALY VALVEN N a HANDLE FOR ISOLATING BALL ISOLATION VALVE TMV3 Model P404 indd 4
9. es pegleryorkshire co uk Export Tel 44 0 1302 855 656 Fax 44 0 1302 730 513 Email export pegleryorkshire co uk Technical Help Free Phone 0800 156 0050 Free Fax 0808 156 1012 Email tech help pegleryorkshire co uk Brochure Hotline Free Phone 0800 156 0020 Free Fax 0808 156 1011 Email info pegleryorkshire co uk www pegleryorkshire co uk Pegler Limited St Catherine s Avenue Doncaster South Yorkshire DN4 8DF England Registered Company No 01194543 Place of Registration England Yorkshire Limited Haigh Park Road Stourton Leeds West Yorkshire LS10 1RT England Registered Company No 00401507 Place of Registration England All brand names and logo styles are registered trademarks Maintaining a policy of continual product development Pegler Yorkshire reserves the right to change specifications design and materials of products listed in this leaflet without prior notice 13 2 09 15 02 49
10. rrect location of the mixing valve is important to ensure that it is accessible for commissioning and servicing e The valve body is clearly marked with C for Cold and a blue indicator and H for Hot and a red indicator pmp The valve must be correctly connected to the respective supplies e The use of sealing compounds must be avoided since they may intrude into the water supply and impair the valve performance e The valve must be so installed that it is readily accessible for commissioning and maintenance when being installed in accordance with TMV2 TMV3 Model P404 indd 3 e The valve must be installed with isolation valves on both the hot and cold water systems as close as possible to the valve so as to allow the valve to be commissioned and tested correctly e The valve is supplied with integral strainers on the hot and cold water supplies therefore inline strainers should not be required e The valve is fitted with integral listed non return valve cartridges which command the water supply therefore the thermostatic valve is protected against cross flow due to unbalanced line pressures as required by the Water Supply Water Fittings Regulations 1999 Assembly Procedure e Unpack the main valve assembly remove the three plastic protection caps and check that the bores are free of debris and the end sealing faces are clean e Unpack the two tailpieces and confirm they ar
11. rvice and a high level of protection provided it is maintained and subjected to In Service Testing Approximately 6 8 weeks after commissioning the following tests should be undertaken e Temperature of the hot and cold water supplies RECORD e Temperature of the mixed water temperature at the greatest draw off flow rate RECORD If the mixed water temperature has significantly changed from that measured at installation e g gt 1 C RECORD the change and before making any adjustments to the valve confirm that e Strainer elements in the hot and cold water supplies are clean and undamaged e Non return valves are clean and operating correctly e Isolation valves are operating correctly and are set in the fully open position If the mixed water temperature is acceptable the following additional observations should be made Isolate the cold water supply and RECORD the maximum temperature achieved After 5 seconds if water is still flowing RECORD the final temperature e If there is no significant change to the set outlet temperature 2 C or less deviation from the original setting and the fail safe shut off is functioning then the valve is working correctly and no further service work is required e If the maximum mixed water temperature exceeds the previous test results by more than 2 C then the need for service work on the valve is indicated TMV3 Model P404 indd 6 e The equipment used in these In
12. s 1999 Approvals This product is certified under the BuildCert TMV2 scheme and has been independently tested by an approved testing laboratory WRc NSF and is a Water Regulations Advisory Scheme WRAS approved product and listed in the Water Fittings and Materials Directory TMV3 Model P404 indd 2 Installation Separate isolation valves must be installed on the hot and cold water inlet supplies To ensure proper performance of the thermostatic mixing valve the isolating valves should preferably be full bore and always be fully open during operation The mixing valve is supplied with filter elements but it is advisable to additionally install Y strainers on the hot and cold water supplies The isolating valves and strainers should be installed as close as practicable to the location of the mixing valve and should always be in an accessible location Before installation the hot and cold water supply systems must be thoroughly flushed to remove any dirt debris that may have accumulated Failure to do so may adversely affect the performance of the mixing valve CONDITIONS OF NORMAL USE Table 1 Operating Range High Pressure Low Pressure Maximum static pressure bar 10 10 Hot amp cold flow pressure bar 1 0to5 0 1 to1 Hot supply temperature C 55 to 65 55 to 65 Cold supply temperature C lt 25 lt 25 Minimum hot inlet to mixed outlet temperature differential 10 C Note Valves opera
13. ting outside these conditions can not be guaranteed by the Scheme to operate as Type 2 valves The highest flow rates will be achieved under balanced pressure conditions but the pressure at the valve inlets must be within a ratio of 5 1 under flow conditions and the size and layout of pipework and fittings must take this into account 13 2 09 15 02 45 FITTING Before installation the system operating conditions of inlet pressures hot water temperature and hot and cold water flow rates should be determined and confirmed to be within the expected conditions of normal use shown in the table below BS1287 BSEN1111 Maximum static pressure bar 10 0 10 0 Supply pressure hot and cold bar 0 1 1 0 1 0 5 0 Hot supply C 55 65 55 65 Cold supply C Maximum 25 Maximum 25 Mixed water temperature Maximum 46 Maximum 46 Valves must operate in either a high pressure setting or a low pressure setting These valves are not capable of operation with for instance hot water supply in one pressure range and cold water supply in the other pressure range In these conditions it is necessary to either boost one pressure or reduce the other so that both supplies are within a common pressure range If your water supply cannot meet these conditions then the valve cannot be guaranteed to operate as a Type 2 valve Operating pressures above 5 0 Bar will require the installation of a pressure reducing valve Co
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