Laing Thermotech ACT-4 Installation and operating instructions

Installation, Operation
and Maintenance Manual
Laing Thermotech ACT-4 wireless
Potable Hot Water Recirculation Kit

Table of Contents
Introduction and Safety..................................................................................................................2
Introduction..................................................................................................................................2
Safety.............................................................................................................................................2
Safety terminology and symbols........................................................................................... 2
User safety................................................................................................................................ 3
Environmental safety...............................................................................................................4
Product Description........................................................................................................................6
General description.................................................................................................................... 6
Operational specifications......................................................................................................... 6
Installation........................................................................................................................................8
Preinstallation...............................................................................................................................8
Recommended installation........................................................................................................ 9
Install the pump...........................................................................................................................9
Install the valve.......................................................................................................................... 11
Commissioning, Startup, Operation, and Shutdown...............................................................13
Thermostat controlled operation............................................................................................13
Thermostat controlled operation Plus Timer.........................................................................13
Optional Push-Button / Signal Repeater................................................................................ 14
Maintenance..................................................................................................................................16
Valve and pump inspection..................................................................................................... 16
Pairing after pump or valve replacement...............................................................................16
Replace the batteries................................................................................................................16
Return to service after shutdown of two weeks or more......................................................17
Troubleshooting........................................................................................................................... 18
LED codes.................................................................................................................................. 18
Operation troubleshooting......................................................................................................18
Table of Contents
Laing Thermotech ACT-4 wireless Potable Hot Water Recirculation Kit Installation, Operation and Maintenance
Manual
1

Introduction and Safety
Introduction
Purpose of this manual
The purpose of this manual is to provide necessary information for:
• Installation
• Operation
• Maintenance
CAUTION:
Read this manual carefully before installing and using the product. Improper use of the
product can cause personal injury and damage to property, and may void the warranty.
NOTICE:
Save this manual for future reference, and keep it readily available at the location of the
unit.
Safety
WARNING:
• The operator must be aware of safety precautions to prevent physical injury.
• Any pressure-containing device can explode, rupture, or discharge its contents if it is
over-pressurized. Take all necessary measures to avoid over-pressurization.
• Operating, installing, or maintaining the unit in any way that is not covered in this
manual could cause death, serious personal injury, or damage to the equipment. This
includes any modification to the equipment or use of parts not provided by Xylem. If
there is a question regarding the intended use of the equipment, please contact a
Xylem representative before proceeding.
• Do not change the service application without the approval of an authorized Xylem
representative.
CAUTION:
You must observe the instructions contained in this manual. Failure to do so could result
in physical injury, damage, or delays.
Safety terminology and symbols
About safety messages
It is extremely important that you read, understand, and follow the safety messages and
regulations carefully before handling the product. They are published to help prevent
these hazards:
• Personal accidents and health problems
• Damage to the product
• Product malfunction
Introduction and Safety
2 Laing Thermotech ACT-4 wireless Potable Hot Water Recirculation Kit Installation, Operation and Maintenance
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Hazard levels
Hazard level Indication
DANGER:
A hazardous situation which, if not avoided, will result in
death or serious injury
WARNING:
A hazardous situation which, if not avoided, could result
in death or serious injury
CAUTION:
A hazardous situation which, if not avoided, could result
in minor or moderate injury
NOTICE:
• A potential situation which, if not avoided, could
result in undesirable conditions
• A practice not related to personal injury
Hazard categories
Hazard categories can either fall under hazard levels or let specific symbols replace the
ordinary hazard level symbols.
Electrical hazards are indicated by the following specific symbol:
Electrical Hazard:
These are examples of other categories that can occur. They fall under the ordinary
hazard levels and may use complementing symbols:
• Crush hazard
• Cutting hazard
• Arc flash hazard
User safety
General safety rules
These safety rules apply:
• Always keep the work area clean.
• Pay attention to the risks presented by gas and vapors in the work area.
• Avoid all electrical dangers. Pay attention to the risks of electric shock or arc flash
hazards.
• Always bear in mind the risk of drowning, electrical accidents, and burn injuries.
Safety equipment
Use safety equipment according to the company regulations. Use this safety equipment
within the work area:
• Hard hat
• Safety goggles, preferably with side shields
• Protective shoes
• Protective gloves
• Gas mask
• Hearing protection
Introduction and Safety
Laing Thermotech ACT-4 wireless Potable Hot Water Recirculation Kit Installation, Operation and Maintenance
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• First-aid kit
• Safety devices
NOTICE:
Never operate a unit unless safety devices are installed. Also see specific information
about safety devices in other chapters of this manual.
Electrical connections
Electrical connections must be made by certified electricians in compliance with all
international, national, state, and local regulations. For more information about
requirements, see sections dealing specifically with electrical connections.
Precautions before work
Observe these safety precautions before you work with the product or are in connection
with the product:
• Provide a suitable barrier around the work area, for example, a guard rail.
• Make sure that all safety guards are in place and secure.
• Make sure that you have a clear path of retreat.
• Make sure that the product cannot roll or fall over and injure people or damage
property.
• Make sure that the lifting equipment is in good condition.
• Use a lifting harness, a safety line, and a breathing device as required.
• Allow all system and pump components to cool before you handle them.
• Make sure that the product has been thoroughly cleaned.
• Disconnect and lock out power before you service the pump.
• Check the explosion risk before you weld or use electric hand tools.
Wash the skin and eyes
Follow these procedures for chemicals or hazardous fluids that have come into
contact with your eyes or your skin:
Condition Action
Chemicals or hazardous fluids in
eyes 1. Hold your eyelids apart forcibly with your fingers.
2. Rinse the eyes with eyewash or running water for at least 15 minutes.
3. Seek medical attention.
Chemicals or hazardous fluids on
skin 1. Remove contaminated clothing.
2. Wash the skin with soap and water for at least 1 minute.
3. Seek medical attention, if necessary.
Environmental safety
The work area
Always keep the station clean.
Waste and emissions regulations
Observe these safety regulations regarding waste and emissions:
• Appropriately dispose of all waste.
• Handle and dispose of the processed liquid in compliance with applicable
environmental regulations.
• Clean up all spills in accordance with safety and environmental procedures.
• Report all environmental emissions to the appropriate authorities.
WARNING:
Radiation Hazard. Do NOT send the product to Xylem if it has been exposed to any
nuclear radiation.
Introduction and Safety
4 Laing Thermotech ACT-4 wireless Potable Hot Water Recirculation Kit Installation, Operation and Maintenance
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Electrical installation
For electrical installation recycling requirements, consult your local electric utility.
Recycling guidelines
Always follow local laws and regulations regarding recycling.
FCC Statement (United States Only)
This device complies with Part 15 of the FCC Rules. Operation is subject to the following
two conditions:
1. this device may not cause harmful interference and
2. this device must accept any interference received, including interference that may
cause undesired operation.
This equipment has been tested and found to comply with the limits for a Class B digital
device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference in a residential installation. This
equipment generates, uses and can radiate radio frequency energy and, if not installed
and used in accordance with the instructions, may cause harmful interference to radio
communications. However, there is no guarantee that interference will not occur in a
particular installation. If this equipment does cause harmful interference to radio or
television reception, which can be determined by turning the equipment off and on, the
user is encouraged to try to correct the interference by one or more of the following
measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.
• Consult the dealer or an experienced radio/TV technician for help.
Changes or modifications not expressly approved by the manufacturer responsible for
compliance could void the user’s authority to operate the equipment.
Certifications
CSA Certified: NSF/ANSI-372 Compliant
Introduction and Safety
Laing Thermotech ACT-4 wireless Potable Hot Water Recirculation Kit Installation, Operation and Maintenance
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Product Description
General description
The ACT-4 wireless is a potable hot water recirculation kit for use in new and retrofit
domestic hot water systems. The kit helps to:
• Improve comfort through instant hot water
• Save energy
• Conserve water
Parts included in kit
• Pump with a built-in timer
• 6 ft (1.8 m) power cord
• Under-sink mixing valve with transmitter/receiver
• Two 1.5V LR06 AA Batteries
• Valve mounting bracket
• Two screws
• Installation, Operation, and Maintenance Manual (IOM)
Additional parts needed for install
• (2) 3/8" Compression x 1/2" stainless steel flex hoses
• (2) 1/2" x 1/2" stainless steel flex hoses (optional)
• Hand tools including various wrenches and #1 and #2 Phillips Head screwdrivers
• (1) 3/4" Isolation shut-off valve and associated adapters and nipples (optional - if
pump desired to be isolated for maintenance)
Verify the type of 1/2" connection that may be required for the stainless steel flex hoses:
Compression or NPT/IPS.
Operational specifications
Operational limits
Pump and valve
Operating medium Water
Maximum working pressure 145 PSI (10 bar)
Minimum operating differential pressure (Valve) 1.6 PSI (0.11 bar)
Maximum water temperature 203°F (95°C)
Motor 115 V, 1 PH, 60 Hz, 20 Watts input, 0.3 Amps, 4800 RPM
Operating noise level 30 dB
Battery power 1.5 V each
Estimated battery life 2 Years
Maximum operating range 150 ft (45 m)
WARNING:
Do NOT exceed the maximum working pressure of the pump. This information is listed on
the nameplate of the pump.
Product Description
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WARNING:
California Proposition 65 warning! This product contains chemicals known to the state of
California to cause cancer and birth defects or other reproductive harm.
How the system works
The ACT–4 wireless potable hot water recirculation kit features a factory paired pump and
mixing valve that wirelessly communicate temperature data and operational status
between each other. The ACT–4 wireless pump with built-in timer is installed on the
supply side of the hot water source, as presented below. The paired mixing valve is
installed under the sink farthest from the hot water source. A temperature sensor within
the valve detects the water temperature and wirelessly transmits this data to the pump.
The desired water temperature at the mixing valve is set remotely with the thermostat dial
on the pump. When the water temperature sensed at the valve is below the desired
setting, a signal is sent to the ACT–4 wireless pump to begin circulating hot water
throughout the system. The mixing feature of the valve tempers the cold water at the
faucet or tap, providing instant hot water at this location and so satisfying the need for hot
water at all upstream water outlets. When the temperature requirement at the valve has
been satisfied, a signal is sent to turn off the pump. This system prevents continuous
running and saves energy.
For more energy savings, the ACT–4 wireless pump can be set for Timer Operation to run
only during the time periods when hot water is most frequently required.
An optional push-button / signal repeater device is available to provide instant hot water
with a touch of a button. Pressing the push-button will activate the pump and begin
circulating hot water throughout the system, outside of the set Timer Operation, until the
desired temperature is met at the valve. Acting in its secondary function as a signal
repeater, this device will also extend the operational range of the pump and valve and aid
in the transmission of data between the two devices where necessary.
The instant hot water delivery with the ACT–4 wireless potable hot water recirculation kit
saves water and time, while improving comfort, as water does not need to run
continuously while waiting for it to warm up.
1
2
3
4
5
7
6
8
9
10
1. ACT-4 wireless pump
2. Hot water source
3. Hot water
4. Cold water
5. Hot water flex hose
6. cold water flex hose
7. Hot water supply hose
8. Cold water supply hose
9. ACT-4 wireless mixing valve
10. Optional push-button / repeater
Product Description
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Installation
Preinstallation
CAUTION:
All work must be performed by qualified personnel trained in the proper application,
installation, and maintenance of plumbing, steam and electrical equipment or systems in
accordance with all applicable codes and regulations.
The pump and valve as received in this kit are factory paired and wirelessly communicate
water temperature and pump status with each other.
Before installation of the pump and valve, complete the following:
• Shut off water supply.
• Turn off hot water source.
• Drain the lines.
• Allow the system to cool to a safe handling temperature, below 100°F (38°C) and a
zero pressure condition.
Installation
8 Laing Thermotech ACT-4 wireless Potable Hot Water Recirculation Kit Installation, Operation and Maintenance
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Recommended installation
1
2
3
4
5
6
7
8
1. Cold water supply
2. 3/4” NPT isolation valve
3. ACT4 wireless pump
4. 3/4” NPT male adapter, if required
5. 3/4” NPT isolation valve
6. Hot water source
7. Hot water
8. Flexible supply line
Install the pump
1. Remove the motor and timer unit, O-ring, and insert from the pump housing. Set
these items aside.
Installation
Laing Thermotech ACT-4 wireless Potable Hot Water Recirculation Kit Installation, Operation and Maintenance
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1
2
3
1. Pump housing
2. Pump o-ring
3. Pump insert
2. Connect the union end of the pump housing to the 3/4" NPT male inlet of the hot
water source, or male adapter and isolation valve connected to the hot water source.
Make sure that the arrow on the pump housing is properly oriented in the direction of
the supply water flow.
3. Connect flexible supply line to the 3/4” NPT male threads of the pump housing.
Do not twist or excessively bend the hose. Replace the flexible hose with a shorter
length if necessary. Use PTFE tape or pipe compound if necessary.
4. Reattach the motor and timer unit, the insert, and the O-ring to the pump housing.
5. Orient the pump so that the timer is accessible. The timer should never be positioned
in any orientation above the pump housing.
6. Make sure that the screw ring that attaches the motor to the pump is securely hand
tightened. Do not attempt to further rotate the pump timer or the pump may be
damaged.
Over-tightening the pump screw ring can cause damage to the pump. Do not use
pipe compound or plumber's putty on the screw ring.
7. Turn on the water supply to the hot water source and verify that there are no leaks at
any connections.
8. Turn on the faucet/taps or shower farthest from the hot water source until there is a
steady stream of water with no sputter or evidence of air in the lines.
Installation
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9. Plug the pump cord into the wall outlet and start the system. In the event of a
disruption in the power supply, the ACT–4 wireless pump will resume communication
with the paired mixing valve.
10. Open the timer cover. Rotate the dial clockwise until the current time is aligned with
the pointer at the top (12 o'clock position) of the dial.
See Thermostat Controlled Operation PLUS Timer section below.
Install the valve
1. Prepare the installation site, which is the faucet/tap farthest from the hot water source.
2. Close the hot and cold water riser shutoff valves and open the hot and cold water
faucets/taps to relieve the water pressure. Close the water faucets/taps.
In some older homes, the riser shutoff valves may be difficult to shut off completely. If
so, turn off the water at the main water inlet valve to the house.
3. Remove the existing flexible line connections to the hot and cold water faucet/tap
threaded nipples.
Use a bucket to collect any excess drainage.
a) If necessary, replace existing flexible hoses with new stainless steel braided
flexible hoses in the lengths required.
4. Screw on the two existing 1/2” hose connections to the corresponding hot and cold
sides of the valve housing, denoted as “H” and “C” respectively. Grip the valve only by
the brass hex feature during assembly.
Be careful not to kink the existing hose lines while bending, which can prevent
adequate flow and/or cause the valves to break.
a) Inspect the rubber washers in the hose connections to ensure that they are in
reusable condition. If not, replace.
Installation
Laing Thermotech ACT-4 wireless Potable Hot Water Recirculation Kit Installation, Operation and Maintenance
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5. Screw the 3/8" compression end of the purchased flexible hoses to the 3/8"
connections on the valve. Screw the 1/2" ends of these same two hoses to the
underside of the hot and cold water faucet/tap respectively.
a) Make sure to match the hot and cold sides marked on the valve with the
corresponding faucet/tap.
b) Make sure that the hot side connection is attached to the hot water faucet/tap and
the cold water side connection is attached to the cold water faucet/tap
c) Make sure that the hoses are long enough to allow the valve to be positioned as
planned.
6. If desired, fasten the valve to the wall or vanity cabinet using the optional mounting
bracket and screws that are provided in the kit.
7. Open the faucet/tap and hot and cold water riser shutoff valves to purge any air
entrained in the valve or hoses and to insure there are no leaks at any connections.
8. Remove the locking screw from the battery compartment cover on the valve. Insert the
batteries in their proper orientation into the compartment on the valve. Be sure to
match the positive (+) and negative (-) ends of the batteries with the corresponding
polarity symbols on the bottom of the housing. Installing one battery in reverse will
result in improper system operation. Return the locking screw to its proper position
when the batteries have been installed.
CAUTION:
Short circuit hazard. Improper battery installation may cause personal
injury or property damage due to short circuit or battery leakage.
This installation method applies to most situations where faucets/taps are connected to
hot and cold water supply lines with braided flexible hose/shut-off valve arrangements. If
the under-sink arrangement is different, for example the risers are hard copper or plastic,
then other parts not listed here may be required for the installation.
Installation
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Commissioning, Startup, Operation,
and Shutdown
Thermostat controlled operation
The valve and pump are ready to communicate with each other out of the box.
The pump comes with an adjustable temperature feature. This feature is controlled by the
thermostat dial just above the timer housing on the body of the pump and may be set to
activate between 86°F (30°C) and 95°F (35°C). This temperature range represents the
desired water temperature to be sensed at the remotely set under-sink mixing valve.
• Slide the switch on the timer housing to the “ON” position.
In the “ON” position, the pump runs automatically whenever the built-in temperature
sensor in the valve senses the need for hot water at the under-sink valve. In the “OFF”
position, the pump does not operate at any time. In either instance, the LED light on the
thermostat knob will remain steady.
The pump will most likely start running immediately and turn off after a few minutes when
hot water reaches the faucet/tap. The pump continues cycling on and off as required
during the programmed sequence of operation. (Do not be concerned if the pump does
not begin to run immediately after the pump is plugged in, or at times throughout normal
operation. This just means that there is already hot water at the hot water faucet/tap. The
pump turns on automatically when the hot water line cools down.)
Thermostat controlled operation Plus Timer
1
2
3
4
1. Set current time here
2. Pump runs when valve calls for hot water
3. Pump runs only during the desired times when valve calls for hot water
4. Pump does not run
1. Open the timer cover with a small flat head screwdriver. Verify that current time
setting is correct. If not, rotate the dial clockwise until the correct time is aligned with
the pointer at the top (12 o'clock position) of the dial.
Commissioning, Startup, Operation, and Shutdown
Laing Thermotech ACT-4 wireless Potable Hot Water Recirculation Kit Installation, Operation and Maintenance
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2. Automatic Operation: Pull the tabs out on the timer for the desired operating time.
For example, if the desired operating time is 9:00 AM to 11:00 AM, pull out all tabs
from 9 through 11.
1
1. Pull tabs out for desired time
The timer can be set for multiple operating periods of time, in 1/2 hour increments.
3. Slide the switch bar to the clock symbol.
Optional Push-Button / Signal Repeater
The pump and valve as received in this kit are factory paired and wirelessly communicate
water temperature and pump status with each other. An optional push-button device is
available to provide instant hot water regardless of the circulator pump’s timer setting.
This device also works as a signal repeater, extending the operational range between the
pump and valve.
Commissioning, Startup, Operation, and Shutdown
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Push-Button Operation
Follow this procedure when you add the device to your system:
1. Power up the push-button / signal repeater device to be paired by plugging it directly
into the desired outlet.
2. Depress and hold the push-button for five (5) seconds. Pairing mode is indicated by a
rapid series of short flashes.
3. Open the timer cover on the pump and slide the switch from the “ON” position to the
“OFF” position.
4. Wait two (2) seconds and then slide the switch from the “OFF” position to the “ON”
position.
5. Wait two (2) more seconds and slide the switch to the “OFF” position.
6. Wait two (2) seconds and return the switch to the “ON” position.
The LED light in the thermostat knob is on when the device is successfully paired. The
pump is now ready for service. Once the push-button / signal repeater has been paired
with the pump, it can be relocated to a different outlet without having to be re-paired.
The pump is capable of pairing with only two devices: the valve and the optional push-
button / signal repeater.
Signal Repeater Operation
When used as a signal repeater, the device will extend the operational range of the
ecocirc wireless hot water recirculation kit beyond the normally specified distance.
It will aid in the transmission of data between the pump and valve in environments where
building construction or other factors may interfere with ongoing communication.
When used as a signal repeater, the device should be installed at an outlet at an
intermediate location between the pump and valve. Device pairing is not required when
used as a signal repeater.
Commissioning, Startup, Operation, and Shutdown
Laing Thermotech ACT-4 wireless Potable Hot Water Recirculation Kit Installation, Operation and Maintenance
Manual
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Maintenance
Valve and pump inspection
Periodically inspect the valve or pump for signs of leakage or corrosion.
WARNING:
Risk for property damage, serious personal injury or death. You must replace the valve or
pump if corrosion or leakage is found.
Pairing after pump or valve replacement
If either the pump or the valve is replaced, device pairing is required. To pair the devices,
follow this procedure:
1. Power up the valve by inserting the batteries.
If the valve is already in operation, remove and reinsert the batteries. If the valve is
being replaced, remove the batteries from the old valve before pairing the new
replacement with the pump. It is recommended to use a fresh set of batteries in the
new valve being installed.
a) If a push-button / signal repeater device requires pairing, plug it directly into the
desired outlet.
2. Open the timer cover on the pump. Slide the switch from the “ON” position to the
“OFF” position.
3. Wait two (2) seconds and slide the switch from the “OFF” position to the “ON”
position.
4. Wait two (2) seconds and slide the switch to the “OFF” position.
5. Wait two (2) seconds and return the switch to the “ON” position.
When the device is successfully paired, the LED in the thermostat knob is lit. The pump is
now ready for service.
Replace the batteries
The system is designed to provide effective communication between the pump and valve
for approximately two (2) years after system start-up or battery replacement when using
two (2) 1.5 V LR06 alkaline batteries. When using rechargeable batteries, it is
recommended that they have a minimum 2500 mAh capacity.
Do not mix new and old batteries or other makes of batteries, such as alkaline with
lithium-ion. The different attributes can negatively affect the system performance or cause
the batteries to leak fluid, overheat, or explode.
When new batteries are inserted into the valve, the valve will resume communication with
the pump.
CAUTION:
Risk of property damage or personal injury. You must replace the valve if battery leakage
is found.
Maintenance
16 Laing Thermotech ACT-4 wireless Potable Hot Water Recirculation Kit Installation, Operation and Maintenance
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Return to service after shutdown of two weeks or more
You may choose to turn the system off (slide the pump timer switch to the “OFF” position)
as there is no need to maintain hot water in the supply line when no one is home. Before
turning the system back on, follow these instructions:
1. Open the faucets/taps at the sink where the system is installed. Keep them open until
all air is purged and the water flows smoothly.
2. Slide the pump switch back to either the "ON" position or the clock position for Timer
Operation.
Maintenance
Laing Thermotech ACT-4 wireless Potable Hot Water Recirculation Kit Installation, Operation and Maintenance
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Troubleshooting
LED codes
Pump LED sequence code Explanation
No light Pump is off — no power
Steady light on LED Pump is running or on stand-by
One short and one long flash Low input voltage to pump
Two short and one long flash Communication is lost between pump and valve
Three short and one long flash Pump is overheated
Four short and one long flash Pump is overloaded
Five short and one long flash Blocked rotor inside pump
Six short and one long flash Low battery voltage at the valve
Short fast flashes Pump is in pairing mode
Repeater / push-button LED sequence code Explanation
Steady light System is running
Seldom flashes System is running
Short fast flashes Push-button / signal repeater is in pairing mode
Operation troubleshooting
Symptom Cause Remedy
Pump does not turn on Timer slide switch is set to “OFF”
position or timer clock is not
programmed to allow operation.
Set the slide switch to the “ON”
position or program the timer clock.
Water at the valve is already at the set
temperature and does not require
pump operation.
Pump will turn on when the water at
the valve cools. Verify the
temperature setting on the pump.
Outlet has no power Check that there is power at the
outlet. Make sure the outlet that the
pump is plugged into is not
controlled by a wall switch.
GFCI is tripped. Verify the “TEST” and “RESET” of the
GFCI outlet that the pump is plugged
into.
Troubleshooting
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