Apricus tempermate Service manual

APRICUS
TEMPERMATE
OWNERS AND
INSTALLATION
MANUAL
Note: This manual must be left with a responsible person
after installation and remain on site.

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IMPORTANT
It is a NSW requirement and may be a requirement in other states that a Warm Water System must
be registered by the owner of the building with the local council or regulatory authority.
Notice to Victorian Customers from the Victorian Plumbing Industry Commission.
This warm water system must be installed by a licensed person as required by the Victorian Building
Act 1993. Only a licensed person will give you a Compliance Certificate, showing that the work
complies with all the relevant Standards. Only a licensed person will have insurance protecting their
workmanship for 6 years. Make sure you use a licensed person to install this water heater and ask
for your Compliance Certificate.
Notification of Apricus Tempermate Warm Water Installation
The following Apricus Warm Water System(s) and UV Sterilisation System(s) have been installed.
Warm Water System:
UV Sterilisation System:
Date: System Owner:
Address:
Contact Person: Phone Number:
Installer: Phone Number:
The system will be ready for commissioning on or around the / /
Please arrange to contact the owner or installer to organise a suitable date for the system to be commissioned.
A service contract has been sold to the system owner and includes:
Routine maintenance
UV maintenance
Microbial water testing

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Contents
IMPORTANT................................................................................................................................. 3
GENERAL ..................................................................................................................................... 6
BENEFITS OF WARM WATER SYSTEMS ............................................................................................... 6
SAFETY.................................................................................................................................................6
TECHNICAL DATA ......................................................................................................................... 7
WARM WATER COMPONENTS............................................................................................................ 8
DIMENSIONS .......................................................................................................................................9
OPERATION ............................................................................................................................... 10
HYDRAULIC CHARACTERISTICS..........................................................................................................11
SYSTEM SIZING..................................................................................................................................12
INSTALLATION ........................................................................................................................... 13
INSTALLATION STANDARDS ..............................................................................................................13
LOCATION..........................................................................................................................................13
SYSTEM PARAMETERS.......................................................................................................................13
WATER PRESSURE ............................................................................................................................. 14
PLUMBING ........................................................................................................................................15
PLUMBING DIAGRAM .......................................................................................................................16
COMMISSIONING THE TMV ..............................................................................................................17
ADJUSTING THE VALVE TEMPERATURE ............................................................................................18
SYSTEM RECIRCULATION COMMISSIONING .....................................................................................19
TMV FAULT FINDING.................................................................................................................. 20
MAINTENANCE AND WATER TESTING REQUIREMENTS ............................................................... 21
MONTHLY TEMPERATURE CHECK.....................................................................................................21
MAINTENANCE OF WARM WATER SYSTEM................................................................................. 22
YEARLY SERVICE ................................................................................................................................ 22
5 YEAR SERVICE.................................................................................................................................23
MAINTENANCE STICKER....................................................................................................................23
SPARE PARTS.....................................................................................................................................24
MICROBIAL WATER TESTING ...................................................................................................... 25
PROCEDURES FOR SAMPLING FOR MICROBIOLOGICAL TESTING.....................................................25
LEGIONELLA TESTING ................................................................................................................. 26
LEGIONELLA DETECTION................................................................................................................... 28
THERMAL DISINFECTION ............................................................................................................ 29

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UV DISINFECTION....................................................................................................................... 31
UV SYSTEM BYPASS LINE................................................................................................................... 31
OPTIONAL COMPONENTS FOR UV....................................................................................................32
MAINTENANCE CHECK LOG ........................................................................................................ 33
WATER QUALITY TEST LOG......................................................................................................... 34
COMMISSIONING REPORT.......................................................................................................... 35
SERVICE REPORT ........................................................................................................................ 39
WARM WATER UNIT WARRANTY ............................................................................................... 43

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GENERAL
This warm water system is designed for the purpose of providing potable water. Its use in an
application other than this may shorten its life.
The Apricus Tempermate Warm Water System provides water at a safe and usable temperature in a
situation where the control of the temperature of the water discharging from an outlet is of the
utmost Importance i.e. within hospitals, schools, aged care facilities, etc. This type of system is
intended mainly for use in applications with set temperature between 43-50°C. The valve is designed
to prevent the flow of water discharging from the mixed water outlet in the event of the failure of
either hot or cold supply.
The Apricus Tempermate utilises one or more Caleffi 2522TM series high performance thermostatic
mixing valves that have been specifically designed and manufactured to meet the requirements of:
“AS 4032.1 Thermostatic Mixing Valves-Materials, Design and Performance requirements”. This
particular series of valves can be used with high temperature water in solar applications.
If this warm water system is to be used where an uninterrupted warm water supply is required, you
should ensure that the warm water system is designed in such a way that you have back up
redundancy. We recommend you seek advice from your plumber or specifier about your needs with
regards to building redundancy into your warm water system.
BENEFITS OF WARM WATER SYSTEMS
Centralised mixing valves provide several benefits over point of use;
•Reduces the installation cost of multiple valves, as well as reducing the cost and
inconvenience of having to service multiple units
•Maintenance can be managed from one central location, usually at the hot water plant room
•Reduced interruption of water supply through improved maintenance scheduling
•Improved aesthetics from requiring mixing valves under cabinets, in walls etc
•Energy savings are achieved with warm water systems by reducing the circulation
temperature, thereby reducing the heat loss through pipes.
SAFETY
The Apricus Tempermate can give stable operation provided it is installed, commissioned and
maintained as per the recommendations outlined in this manual. This unit cannot be considered as
an alternative to adequate duty of care during its use and operation.

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TECHNICAL DATA
Temperature adjustment range: 30 –50°C
Factory pre-set temperature: 41°C
Set temperature: must be commissioned on site to achieve desired temperature
Temperature control: ±2°C
Cold inlet temperature supply (min –max): 5°C –30°C
Hot inlet temperature supply (min –max): 55°C –100°C
Maximum working pressure (static): 1400 kPa
Working pressure range (dynamic): 20 –500 kPa
Maximum unbalanced dynamic supply (hot/cold or cold/hot): 6 : 1
Minimum temperature differential between hot water inlet
and mixed water outlet to ensure shut off function: 10°C
Minimum temperature differential between mixed water outlet
and cold water inlet to ensure stable operation: 5°C
Minimum flow rate for stable operation:
AT80 Model 4 l/min
AT160 Model 8 l/min
AT240 Model 12 l/min
AT320 Model 16 l/min

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WARM WATER COMPONENTS

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DIMENSIONS

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OPERATION
The Apricus Tempermate warm water system is a centralised warm water plant which allows warm
water to be circulated around a building.
The system utilises a thermostatic mixing valve(s) which mixes hot and cold water in such a way as to
maintain the set temperature of the mixed water at the outlet. The TMV thermostatic element is
fully immersed into the mixed water. It then contracts or expands causing movement of the piston,
closing either the hot or cold inlets, regulating the flow rates entering the valve. If there are
variations of temperature or pressure at the inlets, the internal element automatically reacts
attempting to restore the original temperature setting.
The Apricus Tempermate Warm Water Unit may have one, two, three or four TMV’s depending
upon the unit selected. On models with more than one TMV, the valves are manifolded in parallel
and operate independently of each other to supply warm water to a common outlet.
Draw-off Mode
When a warm water outlet is opened, hot and cold water flows through the thermostatic mixing
valves, and to the opened warm water outlets.
Recirculation Mode
When no warm water is being drawn from the system, the warm water circulates through the unit
and continues to keep the water at the set temperature.
The returning water splits at the cold water inlet with a proportion returning to the TMV’s cold
inlets, and the remaining proportion returning to the TMV’s hot inlets. The proportion returning to
the hot inlets does so by flowing back up the cold water inlet pipe to the cold water supply line and
on to the boiler where it is reheated and returned to the TMVs via the hot water pipe.
THERMAL SHUT OFF
In the event of a failure of the hot or cold supply, the piston will shut off, stopping water discharging
from the mixed water outlet. The TMVs require a minimum temperature differential from hot inlet
to mixed water outlet of 10°C to ensure the correct operation of the thermal shut off feature.

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HYDRAULIC CHARACTERISTICS
MODEL
MINIMUM
FLOW
MAX NOMINAL
FLOW
MAX RATED
FLOW
CONNECTIONS
AT80
4
60
80
25 INLET / 32 OUTLET
AT160
8
120
160
32 INLET / 40 OUTLET
AT240
12
180
240
40 INLET / 50 OUTLET
AT320
16
240
320
40 INLET / 50 OUTLET
The system must be sized taking into account the current legislation with regard to the nominal flow
rate of each outlet. The reference is AS/NZS 3500.1.
Note that the Apricus Tempermate systems should be sized on maximum nominal flows. Pipe
dimensions are based on velocities of 1.5m/s and the valves not exceeding the recommended
maximum differential pressure of 150kPa. The warm water system may exceed nominal flow rates
up to the maximum flows as shown in the table for short periods, but these flows should not be used
for system sizing purposes.

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SYSTEM SIZING
TYPICAL RATES OF FLOW
(Informative)
Typical flow rates of hot water demand at the outlet of fixtures are as follows
Bath.......................................................................................................................... 0.3 L/s
Shower ..................................................................................................................... 0.1 L/s
Handbasin ................................................................................................................ 0.1 L/s
Kitchen Sink.............................................................................................................. 0.2 L/s
Washing Machine .................................................................................................... 0.2 L/s
Laundry Trough........................................................................................................ 0.2 L/s
These values are for calculation purposes and are not necessarily the minimum that may be supplied
(see AS/NZS 3500.1).
Sizing Example
25 x 2 bedroom apartments
1 x shower, 1 x basin, 1 x bath (warm water fixtures only)
= (6 + 6 + 18) = 30l/m x 25 apt
= 750 x 20% diversified flow
= 150 l/min
SELECT APRICUS TEMPERMATE ‘AT240’ WITH MAX NOMINAL FLOW OF 180L/M
Please note that the above calculation is a quick sizing guide only. Flow rates and loading units to
work out actual diversified flow are dependent on the type of application, ie hotel, apartments,
commercial premises, aged care facility etc, and should be calculated by an experienced designer or
engineer.

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INSTALLATION
The information below indicates the minimum requirements, particularly for health care
installations, as set out by various advisory codes and AS/NZS standards and have been designed to
incorporate information as required by state health care publications and AS/NZS 3666:2002.
INSTALLATION STANDARDS
The Apricus Tempermate must be installed by a licensed plumber or, where applicable, a
licenced plumber who has undertaken T.A.F.E. training in Thermostatic Mixing Valves.
The installer has a duty of care to ensure that all aspects of the installation comply with
AS/NZS 3500 current regulations and legislation.
The Apricus Tempermate should be installed using the appropriate Standard, Code of
Practice and legislation applicable to each state and following the details in this manual.
LOCATION
The warm water unit is suitable for both indoor and outdoor installation. The warm water unit
should be installed in close proximity to the water heating plant.
The cold water supply to the warm water unit and to the water heating plant must be supplied from
the same source in order for the system recirculation to operate correctly.
Clearance must be allowed for servicing of the thermostatic mixing valves. The unit must be secured
to a solid wall and be accessible without the use of a ladder / scaffold.
It is recommended the warm water unit be installed at ground or floor level. Note; all local
authorities have regulations about locating plumbing equipment into roof spaces.
Where damage to property can occur in the event of the warm water system leaking, the warm
water system must be installed over a safe tray. Installation and use of a safe tray must comply with
AS/NZS 3500.4 and all local codes and regulatory authority requirements.
SYSTEM PARAMETERS
Prior to the installation of the Apricus Tempermate, the system must be checked to ensure that the
system operating conditions fall within the recommended operating range of the unit, i.e. verify
supply temperatures, supply pressures, risk assessments, etc.
The supply system into which the Apricus Tempermate is to be installed must be thoroughly flushed
and cleaned to remove any debris which may accumulate during the installation. Failure to remove
any debris will affect the performance and the manufacturer’s warranty on the product.

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In areas that are subject to high levels of aggressive water, provision must be made to treat the
water prior to it entering the unit.
The connecting hot and cold water supplies must be connected to the unit strictly in accordance
with the indications on the inlet pipes. The inlets are clearly marked with green arrows for cold, red
arrows for hot and yellow arrows for the warm inlet and outlets.
To ensure that the performance of the Apricus Tempermate is maintained (in the event of cold
water failure), the temperature of the hot water supply at the point of entry to the unit must be a
minimum of 10°C higher than the set mixed water discharge temperature.
WATER PRESSURE
This warm water system is not suitable for use on gravity fed tank supply systems. If a tank supply is
used, a booster pump must be installed to supply cold water to the water heating plant and warm
water unit.
Check the cold water supply pressure to the warm water system, the pressure should NOT exceed
500kPa static (under AS3500.1 Section 3.3.4; maximum pressure within buildings).
Where one or both the incoming supply pressures are excessive, a Caleffi pressure reducing valve
should be fitted to reduce the pressure(s) to within the limits as shown in the specification.
Check the pressure gauges installed in the hot and cold manifold of the warm water system, the
pressure difference must NOT exceed 150kPa.

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PLUMBING
CONNECTIONS
Check the connections between the Warm Water System and hot water plant closely for correct
connection using the plumbing diagrams provided.
The following points are of particular importance:
1. A non-return valve must be installed with the Warm Water System between the cold water
take off to the Warm Water System and the inlet to the water heating plant.
2. The HOT water building return line (if fitted) is connected after the non-return valve i.e.
between the non return valve and the inlet to the water heating plant.
3. The cold water supply is common to the Warm Water System and the water heating plant to
ensure balanced pressure across the system.
4. NO other cold water take offs have been made after the isolating/non-return valve in the
common cold water supply to the Warm Water System and the water heating plant.
ISOLATION & NOT RETURN VALVES
Check isolation valves and non-return valves (where required) have been fitted at:
1. The common cold water supply to the Warm Water System and water heating plant.
2. On both sides of the warm water ring main circulator(s).
3. At the inlet and outlet of each water heater (if applicable)
COLD / HOT WATER
Using a digital thermometer check the cold water supply temperature, the temperature must be
within 5 to 30°C for the Warm Water System to operate reliably.
Using a digital thermometer check the hot water temperature at the water heating plant, the
temperature must be between 55 and 100°C for the Warm Water System to operate correctly.

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PLUMBING DIAGRAM
Check valve between the cold water take off to the WW System and the inlet to the heater
The HOT water return line connected after the check
Cold supply is common to the WW System and the heater to ensure balanced pressure across the system. No check valve on this line
WW System as close to heater as possible
No take-offs after WW system allowed

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COMMISSIONING THE TMV
Upon completion of the installation, the valve should be tested and commissioned in accordance
with AS 4032.3 as per the procedure outlined below or as specified by the local authority. Use the
“Commissioning Report” form at the back of this manual.
The following instructions should be read and understood prior to commissioning the Caleffi
2522TM series valve. If, under any circumstances, there are aspects of the installation/system which
do not comply with our requirements or the specifications as laid down, the valve must not be put
into service until the installation/system does comply.
1. Ensure that the system is thoroughly clean and free from debris prior to commissioning the
thermostatic mixing valve.
2. We recommend that the commissioning of temperatures are carried out using a suitably
calibrated and accurate digital thermometer. The valve is commissioned by measuring the
mixed water temperature at the outlet.
3. In accordance with the requirements of AS/NZS 3500, all new water installations shall deliver
hot water at the outlet of the sanitary fixtures used primarily for personal hygiene purposes
at a temperature not exceeding:
a) 45°C for general Health applications;
b) 43.5°C advisable for childhood centres, primary and secondary schools and nursing
homes or similar facilities for aged, sick or disabled persons and
c) 50°C in all other classes of buildings
4. The temperature at the outlet of each valve must be set taking into consideration any
fluctuations which may occur within the system due to simultaneous demand.
5. Once the supply temperatures are stabilised and the normal operating conditions are
established, the valve can be commissioned.
6. Turn OFF the warm water ring main circulator(s) and close the isolation valve on at least one
(1) side of the circulator(s).
7. Close the hot and cold isolation valves on all TMV’S (if applicable) except the one which is to
be adjusted.
8. Open the warm water outlet nearest to the Warm Water System so that a flow rate of
approximately 8 litres per minute is achieved.
9. We suggest that the following sequence is followed when commissioning the valve.
a) Set the mixed water discharge temperature to the required temperature.
b) Measure and record the temperature of the water discharging from the warm water
outlet and ensure the required blend temperature is achieved.
c) Measure and record the temperature of hot and cold water supplies at the
connections to the valve.
d) Measure and record the temperature at the TMV test point in the warm water unit
for the appropriate valve.
e) Create a higher flow rate that corresponds to maximum design flows by opening
additional outlets. Measure and record the temperature at the TMV test point for
the appropriate valve.

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f) Perform the thermal shut-off test. Isolate the cold water supply to the Caleffi valve
and monitor the mixed water temperature. The outlet flow should quickly cease
flowing. TIP: to perform the thermal shut off test on each TMV individually without interrupting the warm
water supply to the system; close the inlet and mixed outlet isolating valves, then connect a hose to the mixed
outlet test point and run to a bucket. The discharge can now be checked with water flowing to the bucket.
g) Measure and record the maximum mixed water temperature. The temperature
should not exceed that allowed by the applicable standard or code of practice for
each state.
h) Restore the cold water supply to the valve and measure and record the outlet
temperature after the mixed water temperature has stabilised. The final
temperature found during this test should not exceed the permitted values +2°C.
i) Once the desired temperature has been reached, the adjustment spindle can be
locked in position using the locking nut supplied with the valve and replace the cap
to prevent tampering by unauthorised persons.
10. Isolate the adjusted valve and repeat steps a - i for each valve in the warm water unit
(AT160, AT240 & AT320 models only).
11. When each valve is completed open all cold and hot TMV isolation valves. Open sufficient
taps to meet the minimum flow rate required for the model (refer to minimum flow rate
table under Hydraulic Characteristics).
12. Measure and record the temperature at the nearest and furthest warm water outlets.
13. Note: If the final measured temperature with all valves operating at the nearest outlet is
higher than the required temperature, then it is necessary to repeat steps 6 to 10.
ADJUSTING THE VALVE TEMPERATURE
Remove the cap
Fit temperature adjustment cap
Temperature adjustment
Lock spindle with locking nut

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SYSTEM RECIRCULATION COMMISSIONING
1. Turn the warm water ring main pumps on and set to the highest speed.
2. Allow time for the system to stabilise. Note: The amount of time will depend on the length
of the ring main and the volume of water in it.
3. Monitor the return temperature on the digital thermometer inserted in the cold water inlet
connection of the Warm Water temperature.
Note: During recirculation i.e. when water is not being drawn, the Apricus Tempermate
Warm Water System requires a flow rate of at least 4 litres per minute per valve and a
temperature differential between the outlet and return of at least 3°C to maintain the
system temperature accurately.
Depending on the plumbing design it may be necessary to adjust the pump speed to achieve the
required temperature drop provided the flow rate can be maintained at 4 litres per minute per valve.
4. Once the system has stabilised with a flow rate of at least 4 litres per minute per valve and
the difference between the outlet and return temperatures is at least 3°C, record the return
temperature and pump circulator speed in the “Commissioning Report”form.
5. Close and lock the Warm Water Unit and hand over the keys to the system owner.
6. Provide a copy of the completed commissioning form to the system owner.

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TMV FAULT FINDING