Checking Hot Water Shut-Off
Allow full hot and cold water to flow through the valve for
one minute. Shut off the cold water stop and check valve
only. The hot water should be reduced to a negligible
amount.
Failure to do so will indicate:
a. The hot water supply is not 20°F above the required
maximum temperature setting.
b. The plunger is sticking and requires cleaning or
replacement.
Inspection and Cleaning Valve
Shut off the hot and cold water supply to the controller.
Remove bonnet #19. To replace pusher O-ring #18,
remove pusher #21 from bonnet #19 and replace O-ring.
Reassemble in reverse order.
With the bonnet assembly off the valve, remove thermostat
#22 and check and clean (see fig. A). Unscrew bottom plug
#14 and remove valve spring #13 and plunger #12 (see fig.
C). If the assembly does not slide out, remove the plunger
with liner #11 and gently tap plunger until it becomes free.
Clean and polish the liner and plunger with very fine emery
cloth until plunger moves freely in the liner.
With the liner out of the valve, replace liner O-ring #10.
If the piston or liner is nicked or shows signs of excessive
wear, it should be replaced.
Resetting the Mixing Valve
After repairing or cleaning the mixing valve, a “reset” may
need to occur when setting the mixing valve. In order to
reset the mixing valve, turn off the recirculation pump,
create demand on the valve that is more than the rated
minimum flow of the mixing valve and insert the 5/32 allen
key in the set screw. Turn the set clockwise until you feel
and hear the set screw click a couple of times. At this point,
start turning the set screw counter clockwise until desired
outlet temperature is reached.
Temperature Adjustment
Valves are normally factory set for a maximum 110°F outlet
temperature, or that stamped on the label. If it is desired to
change this setting, proceed as follows:
While allowing water to flow through the controller:
1. Remove screw #1.
2. With a 5/32 allen key, turn adjusting screw #2
counterclockwise to increase temperature or clockwise
to decrease temperature.
3. When temperature is correct, replace screw #1.
If outlet temperature desired is 15°F or more higher
than that stamped on the label, contact the factory or a
representative for a special thermostat.
CAUTION:
The liner and plunger cannot be dropped.
Please handle carefully. The liner must be inserted correctly.
Carefully examining the outside of the liner will reveal a very
small difference in diameter between the upper half and the
lower half. On reassembly, the smaller diameter must be
inserted first through bottom plug opening.
Performance
The Model 803 water temperature controller is carefully
assembled and tested at the factory to mix hot and cold
water to any desired temperature within range. The
temperature of the hot water should be at least 20°F higher
than the maximum valve setting. The major safety features
are:
1. Failure of cold water supply causes the hot water ports
to reduce hot water flow.
2. Failure of hot water supply causes the cold water ports
to reduce cold water flow.
3. Failure of the thermostat allows both ports to reduce
flow of hot and cold water.
At each inlet of the controller is a union end stop and check
valve with removable strainer. Stop and check valves
prevent water from bypassing between the hot and cold
water supply lines. These valves should be fully open when
in operation.
Maximum Inlet Conditions
Pressure: 125 psi
Temperature: 200°F
Maintenance
The controller should be checked periodically and, if
needed, cleaned as outlined in “INSPECTION and
CLEANING VALVE.” To test for proper setting and operation
- proceed as follows:
1. Turn on full hot and cold water to the valve. The mixing
valve should deliver water at the outlet temperature
stamped on the label. Standard setting is 110°F. If the
outlet temperature is different than that shown on the
label, readjust valve according to “TEMPERATURE
ADJUSTMENT” procedure on page 2.
2. If after adjusting the outlet temperature the water stays
below the set temperature, see “CHECKING COLD
WATER SHUT-OFF.” If the temperature stays above the
set temperature, see “CHECKING HOT WATER SHUT-
OFF.”
Checking Cold Water Shut-Off
Turn on full hot and cold water supply to the valve, then
shut off the hot water stop and check valve only. Cold water
should flow through the controller momentarily then be
reduced to a negligible amount.
Failure to do so indicates that:
a. Plunger is sticking and requires cleaning or
replacement.
b. Spring #13 has lost its strength and should be replaced.
Lack of water flow can be normal on the first test if the
temperature of the cold water is below 75°F. A quick
test is to momentarily turn on the hot water to warm the
thermostat. If flow then starts, the thermostat is good; failure
to obtain flow when first starting, or when valve is cold, is a
normal reaction.
