Lawler 802 SEA Basic Instruction Manual

Model 802 SEA Basic
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Installation &
Maintenance Manual
M 802 E
PAT. NO. 5,203,496.
PAT. NO. 5,323,960.
NOTICE!
Thermostatic Water Controllers will not work satisfactorily if improperly installed.
Read these instructions carefully before installing and follow directions as outlined.
Checking Cold Water Shut-Off
Turn on full hot and cold water supply to the valve
and let it run for one minute. Then shut off the hot
water stop and check valve only. Cold water should
ow through the controller momentarily then be re-
duced to a negligible amount.
Failure to do so indicates that:
a. Plunger is sticking and requires cleaning or
replacement.
at the outlet temperature stamped on the label.
Standard setting is 110 ° F. If the outlet temperature
is different than that shown on the label, readjust
valve according to “TEMPERATURE ADJUST-
MENT” procedure on page 2.
2. If after adjusting the outlet temperature the wa-
ter stays below the set temperature, see “CHECK-
ING COLD WATER SHUT-OFF.” If the tem-
perature stays above the set temperature, see
“CHECKING HOT WATER SHUT-OFF.”
Caution: When maintaining and adjusting the
mixing valve, all xtures should be isolated from
use. Lawler Manufacturing Co., Inc. recommends
that you work safely at all times and in a manner
consistent with the OSHA Lock/Tagout standard,
29 CFR 1910.147 and other applicable standards.
WARNING: Opening of the actuator may result in
electrical shock.
General Description
The Model 802 water temperature controller is care-
fully assembled and tested at the factory to mix hot
and cold water to any desired temperature within
range. The temperature of the hot water should be
at least 20 °F higher than the maximum valve setting.
The major safety features are:
1. Failure of cold water supply causes the hot water
ports to reduce hot water ow.
2. Failure of hot water supply causes the cold water
ports to reduce cold water ow.
3. Failure of the thermostat allows both ports to
reduce ow of hot and cold water.
At each inlet of the controller is a union end stop and
check valve with removable strainer. Stop and check
valves are to prevent water from bypassing between
hot and cold water supply lines. These valves should
be fully open when in operation.
Maximum Inlet Conditions
Pressure: 125 psi
Temperature: 200°F
Maintenance
The controller should be checked periodically and,
if needed, cleaned as outlined in “INSPECTING and
CLEANING VALVE.” To test for proper setting and
operation - proceed as follows:
1. Turn on full hot and cold water supply to the
valve. The mixing valve should deliver water
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CAPACITIES – MODEL 802
Pressure Drop PSI 5 10 20 30 45 60 80
Valve Number Capacity
802-GPM 28 39 54 66 80 91 103
802-LPM 106 148 208 247 303 341 388

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1. Place a 3/8″wooden dowel
rod into center of thermo-
stat then place in 85° F
water. Make a reference
mark on the rod as shown
in g. A.
2. Now insert thermostat into
hot water that is at least
20°F higher than the set
temperature stamped on
label.
3. The rod should move out
of the thermostat approxi-
mately 1/8″. If the rod shows
no movement or can be
pushed inward, a new ther-
mostat is required.
Figure A
Checking Cold Water Shut-Off (Cont.)
b. Spring #13 has lost its strength and should
be replaced.
Note: Lack of water ow can be normal on the rst
test if the temperature of the cold water is
below 75°F. A quick test is to momentarily
turn on the hot water to warm the thermostat.
If ow then starts, the thermostat is good;
failure to obtain ow when rst starting, or
when valve is cold, is a normal reaction.
Checking Hot Water Shut-Off
Allow full hot and cold water to ow through the
valve for one minute. Shut off the cold water stop
and check valve only. The hot water should be
reduced to a negligible amount.
Failure to do so will indicate:
a. The hot water supply is not 20 ° F above the
required maximum temperature setting.
b. The plunger is sticking and requires cleaning
or replacement.
Inspection and Cleaning Valve
Shut off the hot and cold water supply to the controller.
Remove bonnet #19. To replace pusher O-ring #18,
remove pusher #21 from bonnet #19 and replace
O-ring. Reassemble in reverse order.
With the bonnet assembly off the valve, remove
thermostat #22 and check and clean (see g. A).
Unscrew bottom plug #14 and remove valve spring
#13 and plunger #12 (see g. C). If the assembly
does not slide out, remove the plunger with liner #11
and gently tap plunger until it becomes free. Clean
and polish the liner and plunger with very ne em-
ery cloth until the plunger moves freely in the liner.
With the liner out of the valve, replace liner O-ring #10.
Note: If the piston or liner is nicked or shows signs
of excessive wear, it should be replaced.
Caution: The liner and plunger cannot be dropped
please handle carefully. The liner must be in-
serted correctly. Carefully examining the outside
of the liner will reveal a very small difference in
diameter between the upper half and the lower
half. On reassembly, the smaller diameter must
be inserted rst through bottom plug opening.
Temperature Adjustment
Valves are normally factory set for a maximum 110°F outlet tem-
perature, or that stamped on the label. If it is desired to change
this setting, proceed as follows:
1. Insert key and turn to set mode. (Power light should illuminate)
2. Turn off recirculation pump. (Flow light should illuminate)
3. If ow light is not illuminated, create sufcient demand on the
system.
4. To increase set temperature, press actuator switch up for
3-5 seconds. Wait for a response from temperature indicator.
Repeat until the desired set temperature is reached. (Note:
Both power light and ow light must be illuminated to permit
temperature adjustment.)
5. To decrease set temperature, press actuator switch down for
3-5 seconds. Wait for a response from temperature indicator.
Repeat until the desired set temperature is reached. (Note:
The set point must have a 20°F temperature differential
between hot and cold inlet temperatures and is limited to a
range of 90-120°F).
6. Once the desired set point is reached and stabilized, turn
the key to operate mode and remove key.
Note: If outlet temperature desired is 15°F or more higher than that
stamped on the label, contact the factory or a representative
for a special thermostat.
REFERENCE 
MARKS
THERMOSTAT
Warning: This product contains chemicals known to the
State of California to cause cancer and birth defects or
other reproductive harm.
(Installer: California law requires that this warning be
given to the consumer.)
For more information: www.oehha.org/prop65
1
19
18
21
Figure B

See Fig. B
8
7
See Fig. C
42
10
13
14
41
35 34 33
32
31
30
29
28
27
26
25
24
22
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Model 802 Repair Parts
Figure C
Item Description Part No.
1 Actuator —
7 Bonnet Gasket
8 Dome —
10 Liner O-Ring
11 Liner
12 Plunger
12a Piston Liner Assembly Figure C
13 Valve Spring —
14 Bottom Plug —
18 Pusher O-Ring
19 Bonnet
21 Pusher
22 Thermostat
23 Body Screw (NS)
24 Liner Gasket, Upper
25 Valve Body —
26 Tailpiece —
27 Union Nut
28 Stop & Check Stem
29 S & C Stem O-Ring
30 S & C Bonnet —
31 Strainer —
32 S & C Spring —
33 Shutoff Disc Assembly —
34 S & C Body —
35 Seat O-Ring —
36 Pushrod —
37 Spring Retainer —
38 Relief Spring —
39 Acorn Nut
40 Nameplate (NS) —
41 Liner Gasket, Lower —
42 S & C Gasket —
(NS) - Not Shown
12a Only available in Assembly
Repair Kits and Assemblies
Item Description Contains Part No.
1 Complete Repair Kit 7-10-12a-13-18-22-24-31-32-35 79978-01
2 Piston and Liner Assy. 11-12a 71945-16
3 Stop and Check Repair Kit 28-29-31-32-33-35 79908-02
4 Thermostat Repair Kit 7-22 72911-11
5 O-Ring and Gasket Kit 7-10-18-24-29-35-41-42 79830-02
Kit H
11
12
36
37
39
38
1
19
18
21
Figure B

GUARANTEE
We guarantee the Lawler Mixing Valve to be free from
defects in workmanship and material, and for a pe-
riod of one year from date of purchase, will replace
any parts found by us to be defective. We will not be
held responsible, however, for any labor incidental
to, or for any damages caused by defective mate-
rial. Each mixing valve is thoroughly inspected and
tested under actual conditions at our factory.
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Figure 1
Figure 2
Setting The Mixing Valve To The System
Typical Installation
Install the mixing valve below the hot water tank or
heater. If this is not possible, pipe in a heat trap as
shown in Figure 1 with an approximate 2′drop.
Connect a tempered water return line as shown in
Figure 1. This allows ow through both ports of the
mixing valve during periods of no draw.
If a dual temperature system is used, a separate re-
circulating loop and pump are required to return high
temperature hot water to the water heater. See Figure 2.
Install an aquastat at the tempered water return pump.
Install the water heater per manufacturer’s instructions.
1. After installations be sure to ush the system
thoroughly.
2. Make sure the hot water supply is heated to normal
design temperature.
3. Close and tag all xtures to ensure they are not
used during this procedure.
4. Turn off the recirculating pump.
5. Create a draw on the system greater than the
minimum ow rating of the mixing valve. All open
xtures must be tagged to ensure they are not
tampered with or used during this procedure.
6. Allow water to ow through the mixing valve until
the water temperature is stable. If necessary,
readjust the mixing valve in accordance with the
TEMPERATURE ADJUSTMENT section of the
installation manual.
7. Once the temperature is set, start the recirculating
pump and allow the system to reach set tempera-
ture.
8. Measure the water temperature at the return pump
and adjust the aquastat to shut off the pump should
the return water exceed the set point by 2 de-
grees F. Set the low limit switch to restart the
return pump when return water drops 5 degrees
F below the set temperature.
9. If adjustment of the diverting valve is necessary,
rotate the adjustment stem 1/16" of a turn.
10. Shut off all xtures and ensure there is no draw
on the system. The cold inlet to the mixing valve
should be warm.
11. Allow the system to run in this condition for at least
30 minutes.
12. In some cases, an increase in water temperature
may occur during a no draw period. If this occurs,
slowly close the balancing valve until the water
temperature is back to the original set temperature.
Typical Installation
When used in a dual temperature
recirculating system
Typical Installation
When used in a single temperature
recirculating system
M 805 Single Temp System
Water
Heater
Storage
Tank
Check Valve (TYP.)
To Low Temperature
Fixtures
Model 805
CW
Balancing Valve (TYP.)
Recirculating Pump
A
B
C
D
Aquastat
TS
Heat Trap
27" Drop
M 805 Duel Temp System
Water
Heater
Storage
Tank
Check Valve (TYP.)
To Low Temperature
Fixtures
To High Temperature
Fixtures
Model 805
CW
Balancing Valve (TYP.)
Recirculating Pumps
A
B
CAquastat
TS
D
E
Heat Trap
27" Drop