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		High temp audio/visual alarm system	TempControl thermostatic mixing valve made from lead
T-425-( )		3” bimetal dial thermometer	free** metal components. Models 102-700 feature
			serviceable integral check stops. Models 900 & 1000
BV-(	)	Volume control shut off valves	feature removable check stops with union ells (see table 1
SV-(	)	Solenoid valve	Temperature control range:
			70°F - 150°F (21.1°C - 65.6°C)
TF-(	)	Tee fittings	Approach temperature: 5°F (2.8°C)
WHA-1		Water hammer arrestor
			follows: “not more than a weighted average of 0.25 percent lead when

Note:

Compliance

Insert proper model number in parenthesis.

-ASME A112.18.1/CSA B125.1

Configurations

(Components Certified Separately)

-CSA B125.3

-ASSE 1017

A

Valve and piping assembly

-CA 116875 (AB 1953)

B

Valve and piping in cabinet

-NSF 372

BW

Valve and piping in cabinet with cold

-US S.3874

Warranty

water bypass

5 Years - for commercial installations.

Note:

Refer to www.symmons.com/warranty for complete

warranty information.

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

Pressure Differential - psi (kPa)

Valve Model

Min. Flow Rate*

Min. Flow Rate

5 psi

10 psi

20 psi

25 psi

30 psi

45 psi

(34 kPa)

(69 kPa)

(138 kPa)

(172 kPa)

(207 kPa)

(310 kPa)

7-102

0.5 gpm

0.5 gpm

1 gpm

3 gpm

6 gpm

7 gpm

8 gpm

11 gpm

(1.9 L/min)

(1.9 L/min)

(4 L/min)

(11 L/min)

(23 L/min)

27 L/min)

(30 L/min)

(42 L/min)

7-200

0.5 gpm

5 gpm

7 gpm

12 gpm

18 gpm

21 gpm

23 gpm

27 gpm

(1.9 L/min)

(19 L/min)

(27 L/min)

(46 L/min)

(68 L/min)

(80 L/min)

(87 L/min)

(102 L/min)

7-400

0.5 gpm

9 gpm

18 gpm

27 gpm

37 gpm

41 gpm

44 gpm

53 gpm

(1.9 L/min)

(34 L/min)

(68 L/min)

(102 L/min)

(140 L/min)

(155 L/min)

(167 L/min)

(201 L/min)

7-500

0.5 gpm

13 gpm

22 gpm

38 gpm

50 gpm

55 gpm

59 gpm

70 gpm

(1.9 L/min)

(49 L/min)

(83 L/min)

(144 L/min)

(190 L/min)

(209 L/min)

(224 L/min)

(265 L/min)

7-700

0.5 gpm

13 gpm

25 gpm

43 gpm

57 gpm

62 gpm

66 gpm

77 gpm

(1.9 L/min)

(49 L/min)

(95 L/min)

(163 L/min)

(216 L/min)

(235 L/min)

(250 L/min)

(292 L/min)

7-900

0.5 gpm

13 gpm

30 gpm

55 gpm

76 gpm

84 gpm

89 gpm

104 gpm

(1.9 L/min)

(49 L/min)

(114 L/min)

(209 L/min)

(288 L/min)

(318 L/min)

(337 L/min)

(394 L/min)

7-1000

0.5 gpm

13 gpm

38 gpm

67 gpm

100 gpm

111 gpm

120 gpm

140 gpm

(1.9 L/min)

(49 L/min)

(144 L/min)

(254 L/min)

(379 L/min)

(421 L/min)

(455 L/min)

(531 L/min)

pump.

1

Symmons Industries, Inc. 31 Brooks Drive Braintree, MA 02184 [phone] Fax: [phone]

©2014 Symmons Industries, Inc. www.symmons.com [e-mail]

ZV-3008 REV D 01/06/14

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

Operation & Maintenance Manual

Dimensions (7-102)

	A
H	C

B

TempControl Valve Sizes

Model No.	Inlet		Outlet
7-102	1/2”		1/2”
	Measurements
Dimension		7-102
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

C

D

E

Note:

1) Dimensions are subject to change without notice.

	2	Symmons Industries, Inc. ■ 31 Brooks Drive ■ Braintree, MA 02184 ■ [phone] ■ Fax: [phone]
		©2014 Symmons Industries, Inc.■ www.symmons.com ■ [e-mail] ■ ZV-3008 REV D 01/06/14

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)

	A			TempControl Valve Sizes
			Model No.	Inlet		Outlet
	B		7-200	3/4”		3/4”
			7-400	3/4”		1”
H	C		7-500	1”		1 1/4”
		C	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
			A	1/2”, 13 mm		1/2”, 13 mm
	D		B	1 15/16”, 49 mm		1 15/16 ”, 49 mm
			C	9 5/8”, 248 mm		9 13/16”, 243 mm
	E		D	7 11/16”,	195 mm	7 11/16”, 195 mm
			E	2 15/16”, 75 mm		2 15/16”, 75 mm
		F	F	4 7/8”, 124 mm		4 7/8”, 124 mm
	G		G	1 15/16”, 49 mm		1 15/16”, 49 mm
			H	1 5/16”,	33 mm	1 5/16”, 33 mm

H

Note:

1) Dimensions are subject to change without notice.

	3	Symmons Industries, Inc. ■ 31 Brooks Drive ■ Braintree, MA 02184 ■ [phone] ■ Fax: [phone]
		©2014 Symmons Industries, Inc.■ www.symmons.com ■ [e-mail] ■ ZV-3008 REV D 01/06/14

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)

	A	B
H	C	C

D

E

F

G

TempControl Valve Sizes

Model No.		Inlet			Outlet
7-900		1 1/2”			1 1/2”
7-1000		1 1/2”			2”
		Measurements
Dimension		7-900			7-1000
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
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

H I

J

Note:

1) Dimensions are subject to change without notice.

	4	Symmons Industries, Inc. ■ 31 Brooks Drive ■ Braintree, MA 02184 ■ [phone] ■ Fax: [phone]
		©2014 Symmons Industries, Inc.■ www.symmons.com ■ [e-mail] ■ ZV-3008 REV D 01/06/14

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

K

L

B

C

D

E

F

G

H

I

J

Replacement Parts for Model 102

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
G	Check assembly	CSE-33
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

	5	Symmons Industries, Inc. ■ 31 Brooks Drive ■ Braintree, MA 02184 ■ [phone] ■ Fax: [phone]
		©2014 Symmons Industries, Inc.■ www.symmons.com ■ [e-mail] ■ ZV-3008 REV D 01/06/14

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	Complete replacement stop	TT-50AN-( )
		assembly
	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.

B C

D

E

F

G

	6	Symmons Industries, Inc. ■ 31 Brooks Drive ■ Braintree, MA 02184 ■ [phone] ■ Fax: [phone]
		©2014 Symmons Industries, Inc.■ www.symmons.com ■ [e-mail] ■ ZV-3008 REV D 01/06/14

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	Complete replacement stop	TT-27-(	)
		body assembly
	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.

B

C D

E

F

G

H

	7	Symmons Industries, Inc. ■ 31 Brooks Drive ■ Braintree, MA 02184 ■ [phone] ■ Fax: [phone]
		©2014 Symmons Industries, Inc.■ www.symmons.com ■ [e-mail] ■ ZV-3008 REV D 01/06/14

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

Operation & Maintenance Manual

Installation

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

Safety goggles

Technical Assistance and Sizing

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 flowing 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 fluctuations 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 flow demand, even though it is located outside the mechanical room, a single TempControl valve will operate properly.

Installation Tips

All piping should be thoroughly flushed 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 flush piping before putting valve in service. TempControl is set at factory to deliver approximately 100° F.

	8	Symmons Industries, Inc. ■ 31 Brooks Drive ■ Braintree, MA 02184 ■ [phone] ■ Fax: [phone]
		©2014 Symmons Industries, Inc.■ www.symmons.com ■ [e-mail] ■ ZV-3008 REV D 01/06/14

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

Single Valve Installation at or near Hot Water Source

		high temperature hot (if required for laundry, etc.)
		tempered water main hot supply to system
	hot	valve
	water	thermometer
	tank,	TempControl thermostatic
	heater,
		water controller
	etc.
		valve
		cold supply

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.

Diagram 2

Single Valve Installation with Recirculating

Tempered Water at Hot Water Source

	high temperature hot (if required for laundry, etc.)
	tempered water main hot supply to system
	valve
hot	thermometer
water
		TempControl thermostatic
tank,
heater,		water controller
etc.
			circulating pump
	check	check	thermometer

	tempered water return
ball valve	valve
	cold supply

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

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 fine tuning the operation as outlined in (a) and (b).

Diagram 3

Remote HI-LOW System Installation with

Recirculating Tempered Water

PRV valve	thermometer	tempered water to showers, lavatories, etc.
P1 pressure gauge		P2 pressure gauge
V1 valve		V2 valve
TMV1		TMV2
		circulating pump
		check	thermometer
hot supply		check
cold supply		ball valve

tempered water return to cold inlet of heater

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 4

Remote HI-LOW System Installation with

Recirculating Hot Water

	thermometer
	PRV valve	tempered water to showers,
	P1 pressure gauge
		lavatories, etc.
		P2 pressure gauge
	V1 valve	V2 valve
	TMV1	TMV2

hot supply

hot water return

cold supply

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

	9	Symmons Industries, Inc. ■ 31 Brooks Drive ■ Braintree, MA 02184 ■ [phone] ■ Fax: [phone]
		©2014 Symmons Industries, Inc.■ www.symmons.com ■ [e-mail] ■ ZV-3008 REV D 01/06/14

	7-102, 7-200, 7-400, 7-500, 7-700, 7-900, 7-1000
	TempControl 7 Series
	Operation & Maintenance Manual
	Operation & Maintenance
	Operation & Adjustment						temperature (make sure adjustment screw on PRV
							valve is in the full clockwise position).
	Cycle valve to full hot (counterclockwise) then cold					6. Shut off 2 showers or equivalent (leaving 3 still on) and open
							valve (V2).
	(clockwise) 3 full times allowing valve to reach full
						7. Turn PRV adjustment screw counter-clockwise until
	temperature. With approximately 80% of the design
	intent flowing water, turn adjustment bolt to obtain						temperature (T) equals that obtained in step #4.
	desired setting and lock nut in place. Thermostatic					8. Adjust TempControl valve (TMV2) to desired system
	water controllers should be sized according to the flow						temperature and system will be in operational mode.
	capacity required from the valve, NOT the pipe size sup-					9. Stop the water flow, after obtaining desired tempera-
	plied to the valve. For assistance and technical support						ture and turn on the recirculating pump.
	in sizing and selection of the proper TEMPCONTROL					10. Crack the ball valve open so that a small amount of
	Thermostatic Water Controller, consult the Symmons
							water is returned to the hot water source. This allows
	TEMPSIZE™ computer sizing software, your local repre-
							the TempControl to maintain the set temperature
	sentative or Symmons Customer Service Department at						during periods of no draw on the system.
	1-800-SYMMONS.					11. During no draw, observe the thermometer on the
			CAUTION: Turning adjustment bolt fully counter-				discharge on the TempControl. If the temperature
							increases above the setting in step #8, close the ball
			clockwise will remove bolt from TempControl. If
							valve slightly or open it if the temperature decreases.
			this occurs simply replace bolt.
							For systems piped to Diagram 4:
		For systems piped to Diagram 2:
							Follow steps 2 through 9 for systems piped to
		1. With ball valve closed, set TempControl to desired					Diagram 3. Ignore reference to recirculating pump in
							step 9 (not applicable to this installation).
			temperature with water flowing from tempered water
			line.
		2. After obtaining desired temperature, stop the water					Maintenance
			flow.
		3. Crack the ball valve open so that a small amount of					The cartridge unit contains the entire valve control
			water is returned to the hot water source. This allows
							mechanism. For non-interrupted service, keep a spare
			the TempControl to maintain the set temperature
			during periods of no draw on the system.				cartridge on hand.
		4. During no draw, observe the thermometer on the					TempControl valve control mechanism must be kept
			discharge of the TempControl. If the temperature				clean and free from deposits and any foreign matter
			increases above the setting in Step 1, close the ball
							build-up that will be present in many water systems.
			valve slightly or if temperature decreases, open it
							Inspect within 30 days of initial installation or opera-
			slightly.
							tion. If inspection determines that your water system
	For systems piped to Diagram 3:						causes deposits and foreign matter build-up month-
							ly, then valve should be cleaned monthly as follows:
	1. Turn off recirculating pump and close ball valve.
							Remove cartridge (see page 11 for Cartridge Removal
	2. Shut off (V1).						& Replacement section) and soak in any acceptable
	3. Open 5 showers or equivalent to the full hot position.						de-liming agent (or regular household vinegar). Wash off
							deposits, be sure piston is moving freely in its sleeve,
	4. Set small TempControl valve (TMV2) to the full cold
							and replace cartridge. Clean more frequently if your
			position and note the temperature on thermometer.				system so demands (do not completely remove piston
	5. Shut off valve (V2) and open valve (V1). Set large
							from cartridge).
			TempControl valve (TMV1) to desired system				The Check Valves in the TempControl are highly important
10			Symmons Industries, Inc. ■ 31 Brooks Drive ■ Braintree, MA 02184 ■ [phone] ■ Fax: [phone]
			©2014 Symmons Industries, Inc.■ www.symmons.com ■ [e-mail] ■ ZV-3008 REV D 01/06/14

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 flange.

With 2 large bladed screwdrivers, pry evenly on two opposite sides of bolt flange 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 flange is firmly 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 ■ [phone] ■ Fax: [phone]
		©2014 Symmons Industries, Inc.■ www.symmons.com ■ [e-mail] ■ ZV-3008 REV D 01/06/14