ENCON Therma-Flow PLUS Installation, Operation And Maintenance Manual Download Page 39 | Manualshive

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4 MAINTENANCE AND REPAIR

Therma-Flow

®

PLUS

IOM 09900002

Revision C 08/15/21

© 2021, Encon Safety Products, Inc.

4-20

Figure 4-13. Upper Section with Alarms and Flow Switch

Bonnet Nut

Shuttle Assembly

"O" Ring

Spring

PTFE Sleeve

Magnet

Disc

Retainer Ring "B"

Retainer Ring "A"

Figure 4-14. Flow Switch — Exploded View

Unit Body

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Summary of Contents for Therma-Flow PLUS

Page 1: ...Installation Operation and Maintenance Manual 09900002 Revision C 08 15 2021 Copyright 2021 Encon Safety Products Inc All rights reserved ...

Page 2: ... inspection by Encon personnel of the warranty claim However in no event shall ENCON be liable under this Warranty unless ENCON is provided an opportunity to inspect such material or workmanship and at its option allowed to repair or replace such material or workmanship No warranty is given in connection with any portion of the Equipment which is altered or rebuilt without ENCON s express written ...

Page 3: ...RMATION Contact Encon Safety Products Encon for inquiries customer service or suggestions Toll Free USA and Canada 1 800 AT ENCON 1 800 283 6266 Web Site http www enconsafety com Email customerservice enconsafety com Address Encon Safety Products 6825 West Sam Houston Pkwy N Houston Texas 77041 USA ...

Page 4: ... 3 2 3 4 Testing the Shower 3 3 3 5 Therma Flow Plus Inspection Report 3 4 4 MAINTENANCE AND REPAIR 4 1 4 1 Scheduling Maintenance 4 1 4 2 Removing and Replacing ABS Covers to Access Components 4 1 4 3 Relieving Fluid and Pressure from the System for Plumbing Repairs 4 3 4 4 Dismantling and Reassembling the Eyewash and Drench Hose 4 3 4 5 Ball Valves 4 5 4 5 1 Eyewash Ball Valve 4 6 4 5 2 Shower B...

Page 5: ...15 21 2021 Encon Safety Products Inc 5 TROUBLESHOOTING 5 1 5 1 High Water Temperature 5 1 5 2 Freezing 5 1 5 3 Electrical 5 2 5 4 Alarms 5 3 6 SPARE PARTS 6 1 6 1 Shower Parts 6 1 6 2 Alarm Parts 6 3 6 3 Cover Assemblies 6 5 6 4 Accessory Parts 6 5 ...

Page 6: ...t Information on page iii 1 2 About Therma Flow Plus Therma Flow Plus is a freeze protected emergency shower and eyewash that meets or exceeds the American National Standards Institute Standard Z358 1 for emergency shower and eyewash equipment The shower and eyewash station is enclosed in an insulated fibre reinforced plastic FRP building Key features of Therma Flow Plus include 20 GPM 75 7 LPM sh...

Page 7: ...porting 2 5 psi load Ensure the location has enough space to fit the unit Ensure the placement of the unit is such that the area meets the latest American National Standards Institute Standard Z358 1 for emergency shower and eyewash equipment Water Supply Your facility must have an uninterrupted supply of potable water with an 1 or 1 NPT inlet to the unit The water supply pressure must be 30 PSI 2...

Page 8: ...2 2 WARNING Never alter or modify the certified construction of Therma Flow Plus or its components or bypass any safety features 121 92 cm 132 08 cm THERMOSTAT 259 08 cm Figure 2 1 Therma Flow Plus Shower and Eyewash ...

Page 9: ...ift carefully insert the forklift prongs between the wooden skid runners and lift the building off of the wooden pallet 3 Place the building at the desired location for installation Set the unit on a pad structural grate or other suitable surface Carefully and slowly remove the forklift prongs 4 Bolt the unit down using U clamps steel grate or bolts concrete through the pad eyes 2 4 Connecting the...

Page 10: ...iner with a clean out valve in the supply line Ensure the strainer drain connection is free flowing and freeze protected if necessary 3 It is recommended that you include an isolation valve on the supply pipe in an accessible position to shut off the water supply during maintenance The isolation valve should have locking mechanisms to prevent unauthorized shutoff and should be labelled accordingly...

Page 11: ...2 INSTALLATION 2 5 Therma Flow PLUS IOM 09900002 Revision C 08 15 21 2021 Encon Safety Products Inc Figure 2 2 Underground Extension With and Without Flow Switch Figure 2 3 Typical Light Fixture ...

Page 12: ... supply 2 It is highly recommended you install a circuit breaker at the electrical power source for the incoming supply 3 Insert the electrical power supply wires into the junction box and connect them to the positive negative and neutral ground wires Refer to the typical electrical schematics Figure 2 4 or 2 5 on pages 2 7 and 2 8 to make the proper connections 4 Secure the electrical power suppl...

Page 13: ...5 21 2021 Encon Safety Products Inc 2 INSTALLATION 2 7 Figure 2 4 Electrical Schematic Typical Therma Flow Shower with Flow Switch Alarm and Enclosure Heater 120 Volt System Note Options may vary please refer to Electrical Schematic for your model ...

Page 14: ...STALLATION 2 8 Figure 2 5 Electrical Schematic Typical Galvanized Shower with MAP Switch Alarm and Enclosure Heater 120 Volt System Note Options may vary please refer to Electrical Schematic for your model ...

Page 15: ...losed and there is enough resistance to prevent the wind from opening them To adjust the door spring tension 1 Insert a tension rod or 1 8 spring steel in the tension hole of the double acting hinge 2 Tighten the spring tension so that you can remove the tension pin 3 Using the tension rod or drill bit rotate the hinge in the direction of the arrow as shown in Figure 2 6 When you get the desired t...

Page 16: ...e alarms if applicable If applicable notify the control room personnel that the alarms will operate due to testing For more information see 4 9 Alarms optional on page 4 14 To actuate and stop the eyewash water flow 1 To start the water flow push down on the push plate or foot pedal if applicable 2 To stop the water flow and alarms if applicable pull the push plate to its original position CAUTION...

Page 17: ...nformation see 4 4 Dismantling and Reassembling the Eyewash and Drench Hose on page 4 3 2 If applicable ensure the alarms operate as designed 3 Stop the water flow by pulling the push plate to its original position 4 Ensure the eyewash completely drains The three way self draining eyewash requires 30 to 90 seconds to completely drain Dripping from the bottom port at this time is normal 5 Reinstall...

Page 18: ...ure the water is clear b Ensure the pattern of water spray is a minimum 20 508 mm diameter pattern from the shower head and 60 1524 mm at standing level If the test fails you may need to remove the shower head to remove an obstruction 2 If applicable ensure the alarms operate as designed 3 Stop the water flow and alarms if applicable by pushing up on the pull rod to its original position 4 Inspect...

Page 19: ...S q Adjustment q Replacement HEAT TRACE INDICATOR LIGHT q On q Off if applicable FREEZE SCALD PROTECTION VALVES q Leaking F P Valve S P Valve OK NO II OPERATIONAL INSPECTION SHOWER VOLUME Min 20 gpm 75 7 lpm SHOWER PATTERN TEST 20 diameter pattern 60 from standing level SHOWER VELOCITY NONINJURIOUS TO USER q Too High q OK EYEWASH VOLUME Min 0 4 gpm 1 5 lpm EYEWASH PATTERN TEST EYEWASH VELOCITY NON...

Page 20: ...t you can easily remove them to access the components for repairs The covers are held together by closure strips compressed at the flange area of the cover The closure strips are adjustable and can be opened using a blade screw driver and reinstalled by using pliers to compress them The compo nents that pass through the removable covers are sealed with synthetic rubber seals grommets that keep out...

Page 21: ...TICAL Figure 4 1 Therma Flow Plus ABS Cover Assembly To inspect the covers 1 Inspect the ABS covers and ensure they are not cracked and intact to maintain thermal integrity of the unit 2 Inspect the closure strips and seals and ensure they are tight 3 Make sure all grommets that seal the protrusions are in place and secure Dead air space is essential to keep the unit freeze protected ...

Page 22: ...nch Hose A Complete the following procedure to access the heat trace cable if applicable and ball valves To dismantle the eyewash and drench hose 1 Switch off the electrical power supply 2 Relieve fluid and pressure from the system as described in 4 3 Relieving Fluid and Pressure from the System for Plumbing Repairs on page 4 3 3 Eyewash Remove the eyewash yoke by holding it at the wye and turning...

Page 23: ...eat trace cable to valve and pipe Be careful do not cut the outer jacket of the heat trace cable b Pull the heat trace cable over the end of the elbow and lay cable away from pipe c The valve can now be removed for inspection and repair as required For more information see 4 5 Ball Valves on page 4 5 To re assemble the eyewash and drench hose 1 Replace the heat trace cable in reverse order of remo...

Page 24: ... leaking To maintain the ball valves 1 If applicable remove the covers insulation and heat trace cable as described in 4 2 Removing and Replacing ABS Covers to Access Components on page 4 1 2 Adjust the packing gland by tightening the packing gland and or repack the valve as required 3 Should the valve leak by the seals remove it from the pipe and disassemble the valve as described in 4 5 1 Eyewas...

Page 25: ...ther pipe wrench to unscrew and remove the eyewash ball valve 9 Install the new eyewash ball valve in reverse order of removal Use pipe sealant Pipe sealant is recommended for metal to metal thread ball valve to pipe 10 Test the valve operation by assuring the valve push plate is at 12 o clock when the valve is off and when the valve is completely open the valve push plate is at 3 o clock 11 Test ...

Page 26: ...tension sleeve 12 Place the 9 push plate over the 5 valve extension and secure by attaching the 10 bolt through the 9 push plate into the 5 valve extension 13 Replace the existing black seal strip to the covers 14 Test the valve operation by assuring the valve push plate is at 12 o clock when the valve is off and when the valve is completely open the valve push plate is at 3 o clock Ensure machine...

Page 27: ...ipe wrench to unscrew and remove the shower ball valve 8 Install the new shower ball valve in reverse order of removal Use pipe sealant Pipe sealant is recommended for metal to metal thread ball valve to pipe 9 Test to ensure the valve opens and closes properly and does not leak before putting Therma Flow Plus into service To repair the shower ball valve 1 Remove the ball valve by completing step ...

Page 28: ...valves The freeze protection valve prevents rupture damage during freezing temperatures It must be in a vertical position in order to drain the shower The scald protection valve prevents the water from getting too hot This valve will operate in any position Discharge from the freeze protection valve and scald protection valve should be directed to waste without restrictions The temperature control...

Page 29: ...hing 00002305 F P Valve 00011020 S P Valve 00011021 Bushing 00002305 Grommet 00014517 NOTE LOCATE ON LEFT SIDE OF FOUNTAIN Drain Tube 00008500 Figure 4 5 Freeze and Scald Protection Valves 4 6 1 Testing and Cleaning Freeze and Scald Protection Valves It is recommended that at least once every year the freeze and scald protection valves are uninstalled tested and cleaned NOTE LOCATE ON RIGHT SIDE O...

Page 30: ... freeze protection valve in warm water 70 F 21 1 C 80 F 26 7 C for 10 to 15 minutes 8 Remove the valve from the warm water and attempt to force compressed air 60 PSI 414 kPa through the inlet of the valve No passage of air ensures the valve seat is closed and the valve is functioning properly 9 With air connected to the valve submerge the valve in a warm water bath to check for leakage If bubbles ...

Page 31: ...o the valve submerge the valve in a cold water bath to check for leakage If bubbles appear repeat the cleaning process Steps 6 through 8 and retest the valve in the water bath 10 If the valve leaks after being cleaned two 2 times replace the valve in reverse order of removal 11 Open the water supply 12 Switch on the electrical power supply to Therma Flow Plus 4 7 Heat Trace Cable if applicable The...

Page 32: ...d 65 F 18 3 C temperature range the thermostat may need to be replaced You need a continuity tester for the following procedure You need a continuity tester and a cold and hot water supply for the following quick test If a warm or cold water supply is not available remove and test the thermostat in the subsequent procedure Figure 4 6 Thermostat Assembly To perform a quick test on the thermostat 1 ...

Page 33: ...and disconnecting the union from the thermostat coupling 6 Remove the upper vertical ABS cover see Figures 4 1 and 4 5 7 Use a 7 8 wrench to remove the thermostat 8 Test the thermostat by doing the following a Immerse the thermostat in a cold below 45 F 7 2 C water bath and test for continuity The continuity tester should show the contacts as closed b Immerse the thermostat in hot 65 to 70 F 18 3 ...

Page 34: ...s with a piezo annunciator audible alarm Alarm Flasher To stop the alarms you need to close the shower eyewash and drench hose valves However units equipped with a piezo annunciator audible alarm has an alarm silence button to stop audible alarm but not visual alarms Figure 4 7 Wiring Diagram Piezo Annunciator Audible Alarm with Reset Button ...

Page 35: ...it to operate the alarm SHOWER or DRENCH HOSE MAP SWITCH EYEWASH MAP SWITCH REPAIR PARTS KIT REPAIR PARTS KIT 01052326 01052324 1 Magnet 00013324 1 Magnet 00013324 2 Magnet Cap 00013007 2 Magnet Cap 00013007 3 Switch 00013325 3 Switch 00013325 4 Bracket 00014707 4 Bracket 00014715 Figure 4 8 MAP Switch Repair Parts Kit If the MAP switch does not operate the alarm or shut off the alarm when it is r...

Page 36: ...00013501 Unilet 00014444 Magnet 00013324 Switch 00013325 Magnet Cap 00013007 Actuator Arm for reference not included in MAP Switch assembly Bracket 00014707 Figure 4 9 Shower MAP Switch Assembly Cover 00013448 Bracket 00014715 Magnet Cap 00013007 Gasket 00013474 Magnet 00013324 Unilet 00013800 Switch 00013325 Push Plate for reference not included in MAP Switch assembly Figure 4 10 Eyewash MAP Swit...

Page 37: ...itch off the electrical power supply to Therma Flow Plus 2 Remove the screws and switch box cover 3 Make note of the wiring and disconnect the wires to the switch 4 Remove the defective switch and install the new switch using silicone or acceptable caulking and in reverse order of removal 5 Ensure the switch and the magnet on the actuator are aligned and there is no more than a one inch gap betwee...

Page 38: ...witch is an optional alarm actuating device When flow is detected 2 0 gpm 7 6 lpm or more the alarm circuit is closed or opened to operate a local and or remote alarm see Figure 4 12 The fluid flow pushes the magnet up to engage the switch Replace the flow switch if it fails the test in the following procedure ...

Page 39: ... Revision C 08 15 21 2021 Encon Safety Products Inc 4 20 Figure 4 13 Upper Section with Alarms and Flow Switch Bonnet Nut Shuttle Assembly O Ring Spring PTFE Sleeve Magnet Disc Retainer Ring B Retainer Ring A Figure 4 14 Flow Switch Exploded View Unit Body ...

Page 40: ...ng A for complete shuttle disassembly and remove ring B to disassemble the disc only see Figure 4 13 to thoroughly clean the assembly 6 Remove the unilet cover where the flow switch wire connections are made by turning the cover counter clock wise to access the wire connections 7 Make note of the wire connections and disconnect the flow switch wires see Figure 2 4 Electrical Schematic on page 2 7 ...

Page 41: ...aintenance WARNING Do not steam clean the enclosure as severe structural and cosmetic damage will occur The enclosure surface can be cleaned using acetone however avoid contact with the graphics and the plexiglas windows acetone will dissolve graphic decals and glaze plexiglas Use soft soap and water to clean the graphics and windows When repairs to the enclosure are required consult with a local ...

Page 42: ...the enclosure However if replacement is necessary contact Encon Safety Products see Contact Information on page iii to order the part To replace a window 1 Using a Phillips screw driver remove the screws from the window frame 2 Remove the window frame and the window 3 Install the new window in reverse order of removal 4 10 3 Enclosure Heater optional Heater equipped units have a factory set non ad...

Page 43: ...er starts when the temperature goes below the thermostat setting WARNING Always disconnect the heater from the electrical power source before performing any service or maintenance To maintain the heater 1 Keep the heater clean especially the heating elements Ensure the heater is off and cool to the touch then remove dust lint and accumulation of other material 2 Never allow the heater to operate w...

Page 44: ...et 5 Remove the thermostat and replace it with the new thermostat 6 Wire the new thermostat in reverse order of removal 7 Switch the electrical power on and test the thermostat by checking if the heater starts when the temperature goes below the thermostat setting Enclosure Heater Contactor The heater contactor is in the junction box located inside the enclosure see Figure 4 16 When the thermostat...

Page 45: ...nction box located inside the enclosure 3 Make note of the wire connections and disconnect the wires 4 Remove the defective contactor and install the new contactor in reverse order of removal 5 Switch on the electrical power supply to Therma Flow Plus 6 Test the contactor by checking if the heater starts and shuts off when the temperature goes below and above the thermostat setting 80 F 26 7 C App...

Page 46: ...ed at fluid temperatures of 40 F 4 4 C and above To test the freeze protection valve see 4 6 1 Testing and Cleaning Freeze and Scald Protection Valves on page 4 10 Eyewash only freezing Trapped water in the eyewash due to The 3 way self draining valve is plugged and needs to be cleared The eyewash covers were replaced too quickly not allowing water to drain back to atmosphere wait 30 to 90 seconds...

Page 47: ...n Ensure the heat trace cable is operating See 4 7 Heat Trace Cable on page 4 12 The thermostat is incorrectly wired or thermostat failure See 4 8 Thermostat on page 4 13 If fluid is evident on the insulation Fix the leak 5 3 Electrical Component Solution Circuitbreaker supplied by others tripping Check the ground fault interrupter and reset it if necessary Circuit breaker trip is typically a resu...

Page 48: ...Activated Proximity Switch MAP Switch on page 4 16 Alarm light does not operate Check bulb in alarm light If the light bulb is good check continuity of the alarm circuit according to the wiring diagram refer to Figure 2 4 on page 2 7 Audible Alarm does not operate Check for debris in MAP switch or flow switch see first item above Shavings rocks and objects can prevent switches form closing the ala...

Page 49: ...5 BALL VALVE REPAIR KIT 1 SHOWER INCLUDES O RINGS AND BALL VALVE SEATS 00011053 ACTUATOR ARM WITH WELD BLOCK 01110152 NUT FOR SHOWER ACTUATOR ARM 00011201 PULL ROD ASSEMBLY SHOWER INCLUDES PULL ROD AND ACTUATOR ARM 35052460M PULL ROD WITH DECAL FASTENER 01052003 SHOWER HEAD 20 GPM 75 7 LPM REGULATOR INCLUDED 01054005 SHOWER HEAD 30 GPM 113 5 LPM REGULATOR INCLUDED 01054003 BALL VALVE SELF DRAINING...

Page 50: ...REW PUSH PLATE 01052544 BALL VALVE REPAIR KIT EYEWASH OR DRENCH HOSE INCLUDES O RINGS AND BALL VALVE SEATS 00011052 CAP COVER 01110500 EYEWASH YOKE WITH POP OFF COVERS 01052123 NUT FOR EYEWASH BALL VALVE EXTENSION 00011206 PUSH PLATE SST WITH WELD BLOCK 01052016 DRENCH HOSE ASSEMBLY 01090020 DRAIN TUBE EYEWASH OR DRENCH HOSE 00008500 NIP PLASTIC x 2 EYEWASH OR DRENCH HOSE 00008504 SCREW SELF LOCKI...

Page 51: ...M FLASHER 120 VOLT 00013575 ALARM FLASHER 240 VOLT 00013662 ALARM HORN 120 VOLT 00014460 ALARM HORN 240 VOLT 00014462 FLOW SWITCH BONNET 1 00014683 FLOW SWITCH 00014685 GROMMET FLOW SWITCH BONNET 00014536 GROMMET FLOW SWITCH INLET 00014555 MAGNET CAP FOR MAP SWITCH 00013007 MAGNET ONLY FOR MAP SWITCH 00013324 MAGNET SWITCH FOR MAP SWITCH 00013319 SWITCH ONLY FOR MAP SWITCH 00013325 TILT BRACKET SH...

Page 52: ...O RING FOR FLOW SWITCH BONNET 00014677 PIEZO ANNUNCIATOR AUDIO 120 VOLT 2 EACH 00014482 PIEZO ANNUNCIATOR AUDIO 240 VOLT 2 EACH 00014486 RELAY SOCKET FOR FLOW SWITCH OR MAP SWITCH 120 240 VOLTS 00014638 RELAY FOR ALARM 120 VOLT 5 AMP 00013393 RELAY FOR ALARM 240 VOLT 3 AMP 00013252 RELAY USED FOR EXTRA HEAT TRACE CABLE 120 VOLT 10 AMP 00014620 RELAY USED FOR EXTRA HEAT TRACE CABLE 240 VOLT 10 AMP ...

Page 53: ...LET 01110677 EYEWASH RIGHT SIDE FREEZE VALVE SIDE TOP CENTER OUTLET 01110680 LOWER VERTICAL LEFT SIDE 01110527 LOWER VERTICAL RIGHT SIDE 01110528 UPPER VERTICAL LEFT SIDE THERMOSTAT 01110659 UPPER VERTICAL RIGHT SIDE 01110658 6 4 Accessory Parts NOMENCLATURE PART NO BALL VALVE 3 WAY 1 UNDERGROUND EXTENSION SHUTOFF 00011097 BULB 120 VOLT HEAT TRACE INDICATOR 00014538 BULB 240 VOLT HEAT TRACE INDICA...

Page 54: ...EA LIGHT 00013582 GLOBE CLEAR AREA LIGHT INTERIOR LIGHT 00013460 GLOBE GREEN AREA LIGHT 00013571 GLOBE RED ALARM LIGHT 00014606 LIGHT GUARD 00013612 GROMMET COVER SHOWER HEAD 00014554 GROMMET 1 I D FOR BALL VALVE EXTENSION SHOWER 00013644 GROMMET FOR DRAIN TUBE EYEWASH OR DRENCH HOSE 00013676 GROMMET EYEWASH YOKE TOP CENTER OUTLET LOCATION 00013676 GROMMET FOR BALL VALVE EXTENSION EYEWASH OR DRENC...

Page 55: ...MMET FREEZE SCALD PROTECTION VALVES 00014517 GROMMET HEAT TRACE CABLE UNILET 00013644 GROMMET THERMOSTAT 00014519 GROMMET SOLID WATER INLET 00014525 INSULATION 2 50 8 mm IPS x 12 7 mm THK 620 ARMAFLEX 00013545 INSULATION 1 34 93 mm ID x 19 05 mm THK 00014504 INSULATION 1 38 1 mm IPS x 12 7 mm THK 01360177 FOAM TAPE 00013727 ...

Page 56: ...s known to the State of California to cause birth defects or other reproductive harm For more information go to www P65Warnings ca gov 6825 W Sam Houston Pkwy N Houston Texas 77041 1 800 AT ENCON 1 800 283 6266 customerservice enconsafety com http www enconsafety com ...

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