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Before beginning repairs read and understand Section 3.1 and follow the steps in Section 3.2
to decommission the Therm-O-Mix Station. The Station should be tested after all repairs are
completed.
1.
Label each hose going to the V4 Control Valve to ensure proper orientation during
re-assembly.
2.
Using a 9/16” wrench disconnect the 3 hose connections on the V4 Control Valve.
*Note: two orifice plates will drop out of the upper and lower hose connections.
3.
Unthread the V4 Control Valve from the V1 Valve Mixing Tee assembly using a 1-1/8”
wrench.
4.
Place V4 Control Valve stainless steel sensor into a water bath at 98F or above for five
minutes.
5.
Using a compressed air nozzle, blow air into the upper angled hose fitting. (See Appendix #8)
If air can be felt coming from the center hose fitting, the V4 Control Valve has failed and must
be replaced. If not, continue to the next step.
6. Place V4 Control Valve stainless steel sensor into a water bath at 85F or below for five
minutes.
7.
Using a compressed air nozzle, blow air into the lower straight hose fitting. (See Appendix #8)
If air can be felt coming from the center hose fitting, the V4 Control Valve has failed and must
be replaced. If not, continue to the next step.
8.
If the V4 Control Valve is working correctly, thread the valve back into the 3/8 NPT port. Use
teflon tape or equal pipe thread sealant on all NPT threads.
9.
The 2 outside connections on the V4 Control Valve require orifice plates to be installed. Place
an orifice plate in the female end of the hose and carefully thread the hose on to the proper
male fitting. *Note: the middle connection of the V4 Valve does not receive an orifice plate.
1.
Label each hose going to the V4 Valve to ensure proper orientation during re-assembly.
2.
Using a 9/16” wrench disconnect the 3 hose connections on the V4 Valve.
3.
Unthread the V4 Valve from the V1 Valve Mixing Tee assembly using a 1-1/8” wrench.
4.
Thread the replacement V4 Valve into the 3/8 NPT port. Use teflon tape or equal pipe thread
sealant on all NPT threads.
5.
The 2 outside connections on the V4 Valve require orifice plates to be installed. Place an
orifice plate in the female end of the hose and carefully thread the hose on to the proper male
fitting. *Note: the middle connection of the V4 Valve does not receive an orifice plate.
6. Thread fitting until hand tight. Use a 9/16” wrench to tighten the swivel nut 1 full revolution
to crush the orifice plate. Now turn swivel nut 1 to 1-1/2 hex flats or 60 to 90 to complete
tightening the hose.
*Use a second 1/2” wrench as a backup wrench to prevent hose from twisting.
Section 4.4: V4 Control Valve Replacement Instructions
V4 Control Valve Test
V4 Control Valve Replacement
10. Thread fitting until hand tight. Use a 9/16” wrench to tighten the swivel nut 1 full
revolution to crush the orifice plate. Now turn swivel nut 1 to 1-1/2 hex flats or 60 to 90
to complete tightening the hose.
*Use a second 1/2” wrench as a backup wrench to prevent hose from twisting.
