Installation and Maintenance Instructions Caremix ® Thermostatic Taps High performance TMV3 approved sequentially controlled thermostatic taps for healthcare applications Reliance Water Controls ® Worcester Road, Evesham, Worcestershire, WR11 4RA, UK Tel: +44 (0)1386 712400 Fax: +44 (0)1386 712401 www.rwc.co.uk Reliance Water Controls ® reserves the right to make changes to the product which may affect the accuracy of information contained in this leaflet. ZINS100001_003_02/12 Caremix ® S3 Caremix ® T3 Caremix ® H3 Other product's available from Reliance: Thermostatic Mixing Valves Thermostatic Showers Timeflow Controls Electronic Controls Pressure Reducing Valves Heating Products Expansion Vessels Water Meters Underfloor Heating Controls
Transcript
Installation and Maintenance Instructions
Caremix® Thermostatic Taps
High performance TMV3 approved sequentially controlled thermostatic taps for healthcare applications
Reliance Water Controls®Worcester Road, Evesham, Worcestershire,
Reliance Water Controls® reserves the right to make changes to the product which may affect the accuracy of information contained in this leaflet.
ZINS100001_003_02/12
Caremix® S3
Caremix® T3
Caremix® H3
Other product's available from Reliance:
Thermostatic Mixing Valves
Thermostatic Showers
Timeflow Controls
Electronic Controls
Pressure Reducing Valves
Heating Products
Expansion Vessels
Water Meters
Underfloor Heating Controls
1 General Information
2 Specifications
3 General Installation Guidance
3.1 Caremix® S3
3.2 Caremix® T3
3.3 Caremix® H3
4 Commissioning and in Service Tests
5 Servicing the Caremix® Taps
6 Cleaning
7 Spares‑
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Contents Section 7- Spares for Caremix® H3
ZNOB100001Standard handle
ZNOB100002Extended lever handle
INDC 100 006Indices stating‘Caremix ® H3’
SKIT 100 008TMV3 approvedthermostaticcartridge
ZBST100001Flow straightener& housing
COVR 100 001Chrome covers
SKIT 100 003Check valve, strainer
& �ow regulator
INDC 100 008End cover indices
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2
The Caremix® range of TMV3 thermostatic taps are designed for use in high risk environments such as hospitals or nursing homes to protect vulnerable people from the danger of scalding.
There are 3 version of the Caremix® taps available:
All of the taps use the same one piece sequential thermostatic cartridge and are supplied complete with isolators, flow regulators, check valves and strainers.
This installation and maintenance manual has been prepared to provide as much information as possible to aid the plumber in the initial instal-lation and to provide details of ongoing maintenance requirements and spare parts for the facilities manager.
Section 1 - General InformationSection 7- Spares for Caremix® T3
SKIT 100 003Check valve, strainer
& flow regulator
INDC 100 008End cover indices
ZNOB100002Extended lever handle
ZNOB100001Standard handle
INDC 100 007Indices stating‘Caremix ® T3’
SKIT 100 008TMV3 approvedthermostaticcartridge
ZBST100001Flow straightener& housing
COVR 100 001Chrome covers
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Hot temperature supply range: 50-85ºCRecommended hot supply temperature: 55-60ºCCold temperature supply range: 5-25ºCMaximum static pressure: 10.0 barMaximum working pressure: 6.0 barMinimum working pressure: 0.1 barPermitted supply pressure variation: 10:1Factory set temperature: 38ºC (+/- 2ºC)Minimum temperature differential : 10ºC(between hot supply and the outlet temperature)Flow rate (regulated): 6lpm
Approved ApplicationsCode Operating
PressureApplication Recommended
TemperatureMaximum
Temperature
HP-W High Pressure Washbasin 41ºC 43ºC
LP-W Low Pressure Washbasin 41ºC 43ºC
For wash hand basins it is assumed washing will be under running water
This installation guide is provided to give instruction on the best installation practices that should be observed to ensure the correct functioning of the Reliance Caremix® taps. Failure to comply with these instructions will result in the warranty becoming null and void.
In all cases before installing the taps it is imperative to ensure that the sys-tem conditions i.e. pressures, temperatures and flow rates are within the limits stated in the specifications section.
Prior to installing the taps please ensure that the pipework is flushed out and is free from any system debris, i.e. sealant, PTFE tape, flux, solder or any other material that could become trapped in the strainers or check valves. Failure to do this may result in very poor flow performance and/or damage to the taps. As thermostatic taps contain temperature sensitive components soldering on or near the taps must be avoided.
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Section 3 - General Installation Guidance
The Caremix® range of thermostatic taps are chrome plated to a very high standard in addition to this a special PVD coating is applied afterwards to increase the taps resistance to fading and scratches.
As with any chrome plated sanitary tap product it is important to make sure that corrosive cleaning agents are not used on the tap body.
A solution of warm soapy water will generally be strong enough to clean the tap if use on a regular basis.
Section 6 - Cleaning
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The Caremix® S3 is a monobloc, sequentially controlled TMV3 approved thermostatic tap. It is supplied with combination valves incorporating isolation, flow regulation, check valves and strainers; these must be fitted to the hot and cold inlet tails of the tap.
Section 3.1 - Installing the Caremix® S3 Tap
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Using a spanner or deep socket on the brass headwork turn the cartridge in a counter clockwise fashion until it reaches the end of its threads and then pull it out of the tap body.
A new cartridge can now be installed, the handle refitted and the tap re-commissioned as laid out in the commissioning section.
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Installing the tap
The Caremix® S3 is suitable for fixing to basins, sinks and other sanitary fixtures like countertops or surfaces that are strong enough to carry the weight of the tap.
Assemble the threaded fixing rod into position and fit the gasket to the bottom of the tap.
Assemble the 2 copper tailpieces into the base of the tap and tighten them with a suitably sized spanner on the flats near the threads. Do not grip the copper tails to tighten them in as the soft copper may twist or crimp.
Ensure that the hole through the surface that the tap will be fixed to is at least 35mm in diameter and that the thickness of the surface is a maximum of 80mm and is clean and free from any sharp edges or burrs then install the tap into the basin or countertop as shown. Ensure that the surface is suitably strong to accept the weight of the tap.
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With the tap in the off position and using a suitable jeweller’s type screwdriver or similar tool carefully remove the indices from the centre of the tap handle to gain access to the Allen screw that holds the handle onto the cartridge.
Using a 4mm Allen key remove the handle retaining screw
Lift the handle out of position this will expose the top of the thermostatic cartridge.
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Secure the tap in position using the washers, backplates and fixing nut supplied.
Install the 15mm compression type combination isolating valve/strainer/flow regulator/check valve to the end of the copper tails, taking care to observe the direction of flow arrows.
Note: to comply with current water regulations single check valves must be installed to prevent cross contamination. If the supplied combination valves are not used then alternative arrangements to prevent backflow must be made.
Connect the water supply lines to the inlets of the combination valves.
Commission the tap as laid out in the commissioning section before putting it into service.
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Servicing the Thermostatic Cartridge on Caremix® S3, T3 and H3
If you are servicing the Caremix® T3 or H3 first unscrew the chrome cover plates on the hot and cold water supplies to reveal the integral isolation valves
Isolate the hot and cold water inlets by using either the integral ball type isolating valves (H3, T3).
Isolate the hot and cold water inlets by using the combination type isolating valve (S3)
The Caremix® T3 is a wall mounted, sequentially controlled TMV3 approved thermostatic tap. It is supplied with integral isolating valves, flow regulation, check valves and strainers as part of the design of the tap.
Section 3.2 - Installing the Caremix® T3 Tap
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Caremix® S3
The Caremix® S3 is supplied with combination valves incorporating isolation, flow regulation, check valves and strainers, which are fitted to the hot and cold inlet tails of the tap.
To service the strainers, check valves or flow regulators first isolate the valve.
To clean the strainer and flow regulator assembly remove the access cover nut and pull the strainer and flow regulator out of position, rinse under clean water and re-install.
To replace the check valve remove the triangular circlip and pry the check valve out of position, this will destroy the check valve but a new one can then be inserted and the triangular clip replaced.
Check Valve
Strainer & Flow RegulatorIsolating Ball Valve
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Installing the tap
The Caremix® T3 is suitable for fixing to an IPS panel or similar surfaces that are strong enough to carry the weight of the tap, and which have a void behind to conceal the pipework.
Draw a horizontal level line at the height above the basin or other fixture that you wish the tap to be centred on, ensure that there is enough clearance under the intended centreline of the tap for patients and carers to get their hands and possibly arms underneath.
Make a vertical mark in the position where the centre of the spout should end up.
Make a vertical mark 100mm on either side of the centre mark.
Erase the centre mark
Drill a minimum 32mm hole through the panel or substrate on the centre point of each of the remaining 2 marks. This will leave you with 2 minimum 32mm diameter holes 200mm apart centre to centre.
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Using a needle nosed pair of pliers or other suitable tool remove the one piece structure which houses the strainer, flow regulator and check valves so they can be rinsed under clean cold running water.
Exploded drawing of the one piece structure
Repeat these steps on the hot inlet elbow.
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Slide the chrome cover plates over the legs of the tap.
Fit the backplates in position ensuring that the o ring rubber seal is facing away from you so that when installed it will make a seal against the wall or panel.
Mount the tap to the wall by inserting the hot and cold threaded sections through the 2 previously drilled hole
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Using a fine “Jewellers” type screwdriver or other appropriate tool pry the coverplate off the end of the elbow on the cold inlet.
This will expose an end plug with an 12mm Allen screw type socket. Remove the plug by turning counter clockwise.
Remove the washer; this will expose the strainer/flow, check valve regulator assembly.
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Secure the tap in position by using the washers, and fixing nuts supplied. If the wall or panel is 10mm or less in thickness then use the brass spacer rings supplied to secure the tap in addition to the backnut and washer.
Connect the water supply lines to the hot and cold inlets of the tap using a standard 15mm compression fitting, swivel connector or some other suitable approved pipe connector (not supplied)
After commissioning the tap as laid out in the commissioning section carefully thread the chrome cover plates onto the backplates to cover the isolating valves.
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Servicing the check valves, strainers, and flow regulators:
Caremix® H3 and T3
Unscrew the chrome cover plates on the hot and cold water supplies to reveal the integral isolation valves
Isolate the hot and cold water inlets using these ball type isolating valves.
Section 5 - Servicing the Caremix® Taps
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The Caremix® H3 is a 2 hole deck mounted, sequentially controlled TMV3 approved thermostatic tap. It is supplied with integral isolating valves, flow regulation, check valves and strainers as part of the design of the tap.
Section 3.3 - Installing the Caremix® H3 Tap
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Testing frequency
In the absence of any other instruction or guidance on the means of determining the appropriate frequency of in-service testing, the following procedure may be used 6 to 8 weeks after commissioning carry out the tests detailed in “In-Service Testing”
12 to 15 weeks after commissioning carry out the tests detailed in “In-Service Testing” If no significant changes (+/- 2°C) in mixed water temperatures are recorded between commissioning and 6 to 8 week testing, or between commissioning and 12-15 week testing the next in-service test can be deferred to 24 to 28 weeks after commissioning.
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Installing the tap
The Caremix® H3 is suitable for fixing to basins, sinks and other sanitary fixtures or to countertops or other surfaces that are strong enough to carry the weight of the tap.
Basin or Sink Installation
Slide the chrome cover plates over the legs of the tap.
Fit the backplates in position ensuring that the o ring rubber seal is facing away from you so that when installed it will make a seal against the Basin, Sinkwall or panel.
If the tap is to be installed on a sink or other sanitary fixture then you should ensure that the holes are on 200mm centres and at least 32mm in diameter and that the thickness of the surface is a maximum of 30mm and is clean and free from any sharp edges or burrs then install the tap as shown. Ensure that the surface is suitably strong to accept the weight of the tap.
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In Service Testing
The purpose of in-service tests is to regularly monitor and record the performance of the thermostatic taps. Deterioration in performance can indicate the need for service work on the valve and/or the water supplies. Procedure
Using the same measuring equipment or equipment to the same specification as used in the commissioning of the valve, carry out the following sequence:
If the mixed water temperature has changed +/- 2°C from the previous test results then this could indicate that the tap requires servicing.
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Secure the tap in position by using the washers, and fixing nuts supplied. If the basin or sink is 10mm or less in thickness then use the brass spacer rings supplied to secure the tap in addition to the backnut and washer.
Connect the water supply lines to the hot and cold inlets of the tap using a standard 15mm compression fitting, swivel connector or some other suitable approved pipe connector (not supplied)
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Commissioning
Since the installed supply conditions are likely to be different from those applied in the laboratory tests it is appropriate, at commissioning, to carry out some simple checks and tests on each tap to provide a performance reference point for future in-service tests.
In all cases the following must be checked to ensure the correct performance of the thermostatic tap:
the designation of the thermostatic tap matches the intended •applicationthe supply pressures and temperatures are within the range of •operating pressures and temperatures for the designation of the valvethe supply temperatures are within the range permitted for the tap and •by guidance information on the prevention of legionella etc.
It is important to record the testing done during the commissioning and also to record the temperature of the hot and cold water supplies and the temperature of the mixed water at the full hot setting.
Once the correct outlet temperature has been achieved the valves internal mechanism should be exercised at least 3 times by alternately shutting off the hot and cold supplies while the tap is set in the full hot position. This will cause the piston inside the cartridge to travel its full stroke and ensure that it is moving freely so the valve can operate correctly.
Test 1. – With the tap in the full hot position and both hot and cold suplies turned fully on and at system temperatures isolate the cold supply to the thermostatic tap. The flow should reduce to a drip within a few seconds. Restore the cold supply and check that the set temperature has not altered.
Test 2. – Repeat the test for the hot supply
Record the testing done during the commissioning and also record the temperature of the hot and cold water supplies and the temperature of the mixed water at the full hot setting
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Countertop Installation
If the tap is to be installed in a counter top or other suitable surface adopt the following procedure
Draw a horizontal line behind the basin or other fixture that you wish the tap to be centred on, ensure that there is enough clearance behind the fixture to mount the tap. Make a mark in the position where the centre of the spout should end up
Make a mark 100mm on either side of the centre mark.
Erase the centre mark
Drill a minimum 32mm minimum hole through the countertop on the centre point of each of the remaining 2 marks. This will leave you with 2 minimum 32mm diameter holes 200mm apart centre to centre.
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Once the temperature is set remove the handle without changing the spindle position and re-fit the maximum temperature stop cam tight against the brass stop.
Loosely fit the handle and shut off the tap.
Re-fit the Allen screw and indices to the handle of the tap making sure that the handle is in the desired position when shut off.
Note: Changing the maximum set temperature will change the amount of rotation of the handle. Increasing the temperature will mean extra rotation whilst decreasing will result in less rotation.
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Slide the chrome cover plates over the legs of the tap.
Fit the backplates in position ensuring that the o ring rubber seal is facing away from you so that when installed it will make a seal against the countertop.
Mount the tap to the counter top by inserting the hot and cold threaded sections through the 2 previously drilled holes
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Remove the maximum temperature cam (upper) and loosely refit the handle.
Turn the tap on and check the temperature of the water with a handheld digital thermometer, continue to move the handle until the desired maximum temperature is achieved
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Secure the tap in position by first using the washers, and fixing nuts supplied. If the countertop is 10mm or less in thickness then use the brass spacer rings supplied to secure the tap in addition to the backnut and washer.
Connect the water supply lines to the hot and cold inlets of the tap using a standard 15mm compression fitting, swivel connector or some other suitable approved pipe connector (not supplied)
After commissioning the tap as laid out in the commissioning section carefully thread the chrome cover plates onto the backplates to cover the isolating valves.
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Setting the outlet temperature
The Caremix® thermostatic taps are supplied factory set at a ,maximum of 38°C +/- 2°C to alter this temperature adopt the following procedure.
With the tap in the off position and using a suitable jeweller’s type screwdriver or similar tool carefully remove the indices from the centre of the tap handle to gain access to the Allen screw that holds the handle onto the cartridge.
Using a 4mm Allen key remove the handle retaining screw
Lift the handle out of position this will expose the top of the thermostatic cartridge. You should now be able to see 2 stainless steel cams. One cam (lower) will be up against the brass stop while the other, the maximum temperature cam (upper) will be in approximately mid position.
