Symmons 7-1000 Installation Manual

7-102, 7-200, 7-400, 7-500, 7-700, 7-900, 7-1000 TempControl 7 Series

Operation & Maintenance Manual Coordinating Model Numbers Speciﬁcation

HTA-100

T-425-( )

BV-( )

SV-( )

TF-( )

WHA-1

High temp audio/visual alarm system

3” bimetal dial thermometer

Volume control shut off valves

Solenoid valve

Tee ﬁttings

Water hammer arrestor

Note: Insert proper model number in parenthesis.

Conﬁgurations (Components Certiﬁed Separately)

A

B

BW

Valve and piping assembly

Valve and piping in cabinet

Valve and piping in cabinet with cold water bypass

TempControl thermostatic mixing valve made from lead free** metal components. Models 102-700 feature serviceable integral check stops. Models 900 & 1000 feature removable check stops with union ells (see table 1

Temperature control range: 70°F - 150°F (21.1°C - 65.6°C)

Approach temperature: 5°F (2.8°C)

follows: “not more than a weighted average of 0.25 percent lead when

Compliance

-ASME A112.18.1/CSA B125.1

-CSA B125.3

-ASSE 1017

-CA 116875 (AB 1953)

-NSF 372

-US S.3874

Warranty

Note:

Valve Model Min. Flow Rate* Min. Flow Rate

pump.

7-102

7-200

7-400

7-500

7-700

7-900

7-1000

0.5 gpm

(1.9 L/min)

0.5 gpm

(1.9 L/min)

0.5 gpm

(1.9 L/min)

0.5 gpm

(1.9 L/min)

0.5 gpm

(1.9 L/min)

0.5 gpm

(1.9 L/min)

0.5 gpm

(1.9 L/min)

0.5 gpm

(1.9 L/min)

5 gpm

(19 L/min)

9 gpm

(34 L/min)

13 gpm

(49 L/min)

13 gpm

(49 L/min)

13 gpm

(49 L/min)

13 gpm

(49 L/min)

5 Years - for commercial installations. Refer to www.symmons.com/warranty for complete warranty information.

Table 1: Flow Rate - gpm (L/min)

5 psi

(34 kPa)

1 gpm

(4 L/min)

7 gpm

(27 L/min)

18 gpm

(68 L/min)

22 gpm

(83 L/min)

25 gpm

(95 L/min)

30 gpm

(114 L/min)

38 gpm

(144 L/min)

10 psi

(69 kPa)

3 gpm

(11 L/min)

12 gpm

(46 L/min)

27 gpm

(102 L/min)

38 gpm

(144 L/min)

43 gpm

(163 L/min)

55 gpm

(209 L/min)

67 gpm

(254 L/min)

Pressure Differential - psi (kPa)

20 psi

(138 kPa)

6 gpm

(23 L/min)

18 gpm

(68 L/min)

37 gpm

(140 L/min)

50 gpm

(190 L/min)

57 gpm

(216 L/min)

76 gpm

(288 L/min)

100 gpm

(379 L/min)

25 psi

(172 kPa)

7 gpm

27 L/min)

21 gpm

(80 L/min)

41 gpm

(155 L/min)

55 gpm

(209 L/min)

62 gpm

(235 L/min)

84 gpm

(318 L/min)

111 gpm

(421 L/min)

30 psi

(207 kPa)

8 gpm

(30 L/min)

23 gpm

(87 L/min)

44 gpm

(167 L/min)

59 gpm

(224 L/min)

66 gpm

(250 L/min)

89 gpm

(337 L/min)

120 gpm

(455 L/min)

45 psi

(310 kPa)

11 gpm

(42 L/min)

27 gpm

(102 L/min)

53 gpm

(201 L/min)

70 gpm

(265 L/min)

77 gpm

(292 L/min)

104 gpm

(394 L/min)

140 gpm

(531 L/min)

1

Symmons Industries, Inc. ■ 31 Brooks Drive ■ Braintree, MA 02184 ■ (800)796-6667 ■ Fax: (800)961-9621

A

H C

7-102, 7-200, 7-400, 7-500, 7-700, 7-900, 7-1000 TempControl 7 Series

Operation & Maintenance Manual Dimensions (7-102)

Model No. Inlet Outlet

Dimension 7-102

TempControl Valve Sizes

7-102 1/2” 1/2”

Measurements

A 4 13/16”, 122 mm

B 9 1/4”, 235 mm

C 2 1/8”, 53 mm

D 3 3/8”, 86 mm

E 5/16”, 8 mm

B

C

D

Note:

1) Dimensions are subject to change without notice.

2

E

Symmons Industries, Inc. ■ 31 Brooks Drive ■ Braintree, MA 02184 ■ (800)796-6667 ■ Fax: (800)961-9621

A

H C

7-102, 7-200, 7-400, 7-500, 7-700, 7-900, 7-1000 TempControl 7 Series

Operation & Maintenance Manual Dimensions (7-200, 7-400, 7-500, 7-700)

Model No. Inlet Outlet

7-200 3/4” 3/4”

TempControl Valve Sizes

B

C

7-400 3/4” 1”

7-500 1” 1 1/4”

7-700 1 1/4” 1 1/2”

Measurements

Dimension 7-200 7-400

A 1/2”, 13 mm 1/2”, 13 mm

B 1 7/8”, 46 mm 1 1/2”, 39 mm

C 8 15/16”, 226 mm 9 3/4”, 251 mm

D 5 15/16”, 150 mm 6 1/2”, 165 mm

E 2”, 51 mm 2 5/8”, 67 mm

F 3 5/16”, 84 mm 4 1/8”, 105 mm

G 1 5/16”, 33 mm 1 1/2”, 38 mm

H 11/16”, 17 mm 3/4”, 19 mm

Dimension 7-500 7-700

Note:

1) Dimensions are subject to change without notice.

3

A 1/2”, 13 mm 1/2”, 13 mm

B 1 15/16”, 49 mm 1 15/16 ”, 49 mm

D

E

C 9 5/8”, 248 mm 9 13/16”, 243 mm

D 7 11/16”, 195 mm 7 11/16”, 195 mm

E 2 15/16”, 75 mm 2 15/16”, 75 mm

F 4 7/8”, 124 mm 4 7/8”, 124 mm

F

G 1 15/16”, 49 mm 1 15/16”, 49 mm

G

H 1 5/16”, 33 mm 1 5/16”, 33 mm

H

Symmons Industries, Inc. ■ 31 Brooks Drive ■ Braintree, MA 02184 ■ (800)796-6667 ■ Fax: (800)961-9621

H C

7-102, 7-200, 7-400, 7-500, 7-700, 7-900, 7-1000 TempControl 7 Series

Operation & Maintenance Manual Dimensions (7-900, 7-1000)

Model No. Inlet Outlet

A B

C

Dimension 7-900 7-1000

D

TempControl Valve Sizes

7-900 1 1/2” 1 1/2”

7-1000 1 1/2” 2”

Measurements

A 7/16”, 11 mm 7/16”, 11 mm

B 1 3/16”, 31 mm 1 3/16”, 31 mm

C 4 9/16”, 116 mm 4 9/16”, 116 mm

D 11 1/6”, 280 mm 11 3/8”, 289 mm

E 11 1/2”, 296 mm 11 1/2”, 296 mm

E F

F 14 1/4”, 365 mm 14 1/4”, 365 mm

G 2 13/16”, 71 mm 2 13/16”, 71 mm

H 3 3/8”, 86 mm 3 3/8”, 86 mm

I 5 7/16”, 138 mm 5 7/16”, 138 mm

J 2 1/16”, 52 mm 2 1/16”, 52 mm

G

H

I

Note:

1) Dimensions are subject to change without notice.

4

J

Symmons Industries, Inc. ■ 31 Brooks Drive ■ Braintree, MA 02184 ■ (800)796-6667 ■ Fax: (800)961-9621

7-102, 7-200, 7-400, 7-500, 7-700, 7-900, 7-1000 TempControl 7 Series

Operation & Maintenance Manual

Parts Breakdown (7-102)

A

Item Description Part No.

A Valve replacement cartridge 7-102NW

B Check stop spindle CSE-35

C O-ring CE-29

D Washer CSE-31

E Check stop cap CSE-26

F Check spring CSE-34

K

G Check assembly CSE-33

Replacement Parts for Model 102

L

B

C

D

E

F

G

H

J

H Gasket (x2) CE-30

I Check stop washer CSE-32

J Check stop body with stop seat CSE-25

K Casing Gasket TT-11-100

L Sleeve o-rings (x3) TT-15-100

I

5

Symmons Industries, Inc. ■ 31 Brooks Drive ■ Braintree, MA 02184 ■ (800)796-6667 ■ Fax: (800)961-9621

7-102, 7-200, 7-400, 7-500, 7-700, 7-900, 7-1000 TempControl 7 Series

Operation & Maintenance Manual Parts Breakdown (7-200, 7-400, 7-500, 7-700)

A

Replacement Parts for Models 200-700

Item Description Part No.

A Valve replacement cartridge 7-( )NW

B

C Cap gasket TT-21-( )

D Casing gasket TT-11-( )

E Check spindle and spring TT-181-( )

F Sleeve o-rings (x3) TT-15-( )

G Check seat TT-26-( )

Notes:

1) Insert proper model number in parenthesis.

2) Item B contains cap gasket, check spring, bonnet assembly and check assembly.

Complete replacement stop

assembly

TT-50AN-( )

B

C

D E

F

G

6

Symmons Industries, Inc. ■ 31 Brooks Drive ■ Braintree, MA 02184 ■ (800)796-6667 ■ Fax: (800)961-9621

7-102, 7-200, 7-400, 7-500, 7-700, 7-900, 7-1000 TempControl 7 Series

Operation & Maintenance Manual Parts Breakdown (7-900, 7-1000)

A

Replacement Parts for Model 900 & 1000

Item Description Part No.

A Valve replacement cartridge 7-( )NW

B Casing gasket TT-11-( )

C Sleeve o-rings (x3) TT-15-( )

D Gasket between stops TT-32A

E Cap gasket TT-21-( )

F Stop spindle TT-22-( )

G

H Check spindle and spring TT-200-( )

Notes:

1) Insert proper model number in parenthesis.

2) Item G contains check body, cap, check spring and check assembly.

Complete replacement stop

body assembly

TT-27-( )

B

C

D

E

F

G

H

7

Symmons Industries, Inc. ■ 31 Brooks Drive ■ Braintree, MA 02184 ■ (800)796-6667 ■ Fax: (800)961-9621

7-102, 7-200, 7-400, 7-500, 7-700, 7-900, 7-1000 TempControl 7 Series

Operation & Maintenance Manual Installation

Technical Assistance and Sizing

CAUTION

When these installation, operation and service

instructions are not followed, TempControl functionality

and service life will be greatly impaired.

All TempControl installations must have a

thermometer and shut off valve in the tempered water

outlet (as shown in diagrams) for proper trouble

shooting service.

Tools Required for Installation

Adjustable wrench

Flat head screwdriver

Phillips head screwdriver

Pipe wrench

For assistance and technical support in sizing and selection of the proper TempControl valve or system, consult the Symmons TempSize™ computer sizing software, your local representative or Symmons Customer Service Department at 1-800-SYMMONS.

TempControl Location

An underlying premise of thermostatic water controller installations is an acknowledgement that thermostatic mixing valves will not operate properly when the hot and cold supplies serving such valves are subjected to pressure disturbances when owing less than full capacity. In a correctly designed mechanical room, the supply pressures are stable and not subject to pressure disturbances. As a result, when a TempControl valve is indicated as being located in the mechanical room, a Hi-Low system will not be recommended.

When the valve’s location is indicated as being outside of the mechanical room, it is assumed that there is a potential for pressure uctuations in the hot and cold supply lines servicing a TempControl valve and a HiLow system will automatically be recommended.

Note: If the system is designed so that the TempControl valve is not subjected to high-low ow demand, even though it is located outside the mechanical room, a single TempControl valve will operate properly.

Safety goggles

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Symmons Industries, Inc. ■ 31 Brooks Drive ■ Braintree, MA 02184 ■ (800)796-6667 ■ Fax: (800)961-9621

Installation Tips

All piping should be thoroughly ushed before TempControl is installed. The TempControl can be installed in any position as long as Hot Water is connected to “H” port and Cold Water is connected to “C” port. Close service stops on TempControl, remove cartridge, (see page 11 for Cartridge Removal & Replacement section), turn on water supply and open stops wide to thoroughly ush piping before putting valve in service. TempControl is set at factory to deliver approximately 100° F.

Diagram 1

Single Valve Installation at or near Hot Water Source

tempered water main hot supply to system

high temperature hot (if required for laundry, etc.)

cold supply

valve

thermometer

TempControl thermostatic water controller

hot

water

tank,

heater,

etc.

valve

Diagram 2

Single Valve Installation with Recirculating

Tempered Water at Hot Water Source

tempered water main hot supply to system

high temperature hot (if required for laundry, etc.)

tempered water return

valve

thermometer

TempControl thermostatic water controller

hot

water

tank,

heater,

etc.

check

thermometer

circulating pump

ball valve

cold supply

check

Diagram 3

Remote HI-LOW System Installation with

Recirculating Tempered Water

tempered water to showers, lavatories, etc.

V1 valve

TMV1

V2 valve

TMV2

check

thermometer

circulating pump

ball valve

hot supply

cold supply

tempered water return to cold inlet of heater

thermometer

check

PRV valve

P1 pressure gauge

P2 pressure gauge

7-102, 7-200, 7-400, 7-500, 7-700, 7-900, 7-1000 TempControl 7 Series

Operation & Maintenance Manual Installation

Piping Diagrams

Diagram 1 INSTALLATION AT OR NEAR THE HOT WATER SOURCE: TempControl must be positioned below the hot water tank or heater, well below the high temperature water line. This procedure creates a heat trap and protects against hot water migrating through the controller.

plumbing system, no water can be added to the system; therefore, the “cold” and “hot” supplies to the TempControl must come from within the system as described below using the ball valve for ne tuning the operation as outlined in (a) and (b).

Diagram 3 REMOTE HI-LOW INSTALLATION WITH RECIRCULATING TEMPERED WATER OR HOT WATER RETURN: TempControl Hi-Low system must have the return line connected exactly as shown (See Diagram 2 notes).

Diagram 2 INSTALLATION WITH RECIRCULATING TEMPERED WATER AT HOT WATER SOURCE: TempControl must have the return line connected exactly as shown. This procedure allows the controller to maintain the set temperature during periods of no draw by (a) allowing the major volume of return water to supply the cold inlet of the TempControl and (b) the minor volume of return water to be reheated and supply the hot inlet of the TempControl. When there is no water draw on the

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Symmons Industries, Inc. ■ 31 Brooks Drive ■ Braintree, MA 02184 ■ (800)796-6667 ■ Fax: (800)961-9621

Remote HI-LOW System Installation with

Recirculating Hot Water

PRV valve

P1 pressure gauge

TMV1

hot supply

hot water return

cold supply

thermometer

V1 valve V2 valve

tempered water to showers, lavatories, etc.

P2 pressure gauge

TMV2

Diagram 4 REMOTE HI-LOW INSTALLATION WITH RECIRCULATING HOT WATER SUPPLY ONLY: TempControl Hi-Low system must be piped as shown.

Diagram 4

7-102, 7-200, 7-400, 7-500, 7-700, 7-900, 7-1000 TempControl 7 Series

Operation & Maintenance Manual Operation & Maintenance

Operation & Adjustment

Cycle valve to full hot (counterclockwise) then cold (clockwise) 3 full times allowing valve to reach full temperature. With approximately 80% of the design intent owing water, turn adjustment bolt to obtain desired setting and lock nut in place. Thermostatic water controllers should be sized according to the ow capacity required from the valve, NOT the pipe size supplied to the valve. For assistance and technical support in sizing and selection of the proper TEMPCONTROL Thermostatic Water Controller, consult the Symmons TEMPSIZE™ computer sizing software, your local representative or Symmons Customer Service Department at 1-800-SYMMONS.

CAUTION: Turning adjustment bolt fully counterclockwise will remove bolt from TempControl. If this occurs simply replace bolt.

For systems piped to Diagram 2:

1. With ball valve closed, set TempControl to desired temperature with water owing from tempered water line.

2. After obtaining desired temperature, stop the water ow.

3. Crack the ball valve open so that a small amount of water is returned to the hot water source. This allows the TempControl to maintain the set temperature during periods of no draw on the system.

4. During no draw, observe the thermometer on the discharge of the TempControl. If the temperature increases above the setting in Step 1, close the ball valve slightly or if temperature decreases, open it slightly.

For systems piped to Diagram 3:

1. Turn off recirculating pump and close ball valve.

2. Shut off (V1).

3. Open 5 showers or equivalent to the full hot position.

4. Set small TempControl valve (TMV2) to the full cold position and note the temperature on thermometer.

5. Shut off valve (V2) and open valve (V1). Set large TempControl valve (TMV1) to desired system

temperature (make sure adjustment screw on PRV

valve is in the full clockwise position).

6. Shut off 2 showers or equivalent (leaving 3 still on) and open valve (V2).

7. Turn PRV adjustment screw counter-clockwise until temperature (T) equals that obtained in step #4.

8. Adjust TempControl valve (TMV2) to desired system temperature and system will be in operational mode.

9. Stop the water ow, after obtaining desired temperature and turn on the recirculating pump.

Crack the ball valve open so that a small amount of

10. water is returned to the hot water source. This allows the TempControl to maintain the set temperature during periods of no draw on the system.

11.

During no draw, observe the thermometer on the

discharge on the TempControl. If the temperature increases above the setting in step #8, close the ball valve slightly or open it if the temperature decreases.

For systems piped to Diagram 4: Follow steps 2 through 9 for systems piped to

Diagram 3. Ignore reference to recirculating pump in step 9 (not applicable to this installation).

Maintenance

The cartridge unit contains the entire valve control mechanism. For non-interrupted service, keep a spare cartridge on hand.

TempControl valve control mechanism must be kept clean and free from deposits and any foreign matter build-up that will be present in many water systems. Inspect within 30 days of initial installation or operation. If inspection determines that your water system causes deposits and foreign matter build-up monthly, then valve should be cleaned monthly as follows: Remove cartridge (see page 11 for Cartridge Removal & Replacement section) and soak in any acceptable de-liming agent (or regular household vinegar). Wash off deposits, be sure piston is moving freely in its sleeve, and replace cartridge. Clean more frequently if your system so demands (do not completely remove piston from cartridge).

The Check Valves in the TempControl are highly important

10

Symmons Industries, Inc. ■ 31 Brooks Drive ■ Braintree, MA 02184 ■ (800)796-6667 ■ Fax: (800)961-9621

7-102, 7-200, 7-400, 7-500, 7-700, 7-900, 7-1000 TempControl 7 Series

Operation & Maintenance Manual

Operation & Maintenance

factors in its proper operation. If chips, dirt or other foreign materials lodge on the seats and prevent the checks from fully seating, there may be a bypass of water into the opposing line, and the TempControl will not operate to its set delivery temperature. A bypass may be detected by feeling the supply line while the TempControl is not operating. If, for example, the cold line feels hot, the cold water check is not seating properly. It should be removed and the check and its seat cleaned.

Cartridge Removal & Replacement

Before removing a used cartridge for cleaning, have new casing gasket and sleeve o-rings on hand.

Shut off supplies at stop checks by turning clockwise. Remove 4 bolts on cartridge bolt ange. With 2 large bladed screwdrivers, pry evenly on two

opposite sides of bolt ange until cartridge is free to be removed by hand. Pull out cartridge with a twisting and turning action, always keeping cartridge on center line.

Leave compensating spring in position at bottom center of valve body.

Clean cartridge as described in maintenance instructions.

Replace sleeve O-rings and grease same. With a twisting and pushing action, replace cartridge

in valve body until bolt ange is rmly against housing gasket.

While holding cartridge in place, replace bolts and tighten. Do not attempt to pull cartridge into position with bolts—it will damage the valve control mechanism.

Open stops and adjust temperature.

Seasonal Use

When a TempControl is used seasonally (schools, campgrounds, golf clubs, etc.) the cartridge must be removed and thoroughly drained of all water to prevent freeze damage. The check stops should also be removed to drain all water from the supply lines and valve body (see “Cartridge Removal & Replacement”). This will prohibit damage caused by freezing water.

11

Symmons Industries, Inc. ■ 31 Brooks Drive ■ Braintree, MA 02184 ■ (800)796-6667 ■ Fax: (800)961-9621

Symmons 7-1000 Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual