Apollo Precision Tools Valves 4S-100 User's Manual
Contents
1. FIGURE 3 1 2 45 103 WSS NO FLOW CONDITION oc NX e 100 PSIG No Flow Condition FIGURE 4 40 10 T2 Top Entry No Flow Condition FIGURE 5 Double Check Detector Assembly DCDA The DCDA device consists of a mainline DCV and a by pass assembly consisting of an approved DCV assembly and water meter Each device is equipped with test cocks for periodic field testing and is normally supplied with inlet and outlet shut off valves For information on operation installation trouble shooting amp testing refer to Installation Instruction Booklet 1476700 furnished with each DCDA unit For maintenance instructions see pages 4 6 For parts list see pages 21 24 S oo lil TROUBLE SHOOTING GUIDE CAUSE CORRECTIVE ACTION Check valve fails to hold 1 psid E completely Shut off valve not closed a Close 2 shut off valve or inspect for possible Check valve fouled with through leakage debris Check poppet stem not Inspect and clean seat disc and seat moving freely in guide Inspect for debris or IV MAINTENANCE INSTRUCTIONS 1 2 40 103 A Disassembly Check Valves 1 Close 2 shut off valve then close 1 shut off valve 2 Bleed pressur2. N N N N gt 4 W679000 Contact Factory 060310 WW 10 05 W671805 7B10401 K350600 K350500 W706200 W709400 W378905 K350200 7B10431 N A N A N A N A K337000 7010310 Q453019 179700 K340600 7825701 K341200 K350100 D256600 3256 00 K300800 L463705 L522806 PART NO 4 W682400 Contact Factory 7080310 W710005 W673105 7B10401 K350600 K350500 W706200 W709400 W738905 K350200 7B10431 C186705 D261000 K379106 K350400 K337000 7010310 Q453319 B180100 K340600 7825701 N A N A 325 400 D257300 K300800 5 N A 6 8 10 DCDA ITEM NO N N S N S 8 9 10 10 11 12 13 14 15 16 20 21 22 23 24 25 N S N S DESCRIPTION Gate Valve OS amp Y Body 1st Check Body 2nd Check Ball Valve 1st Chk Poppet Ass y 2nd Chk Poppet Ass y By Pass Shut Off Valve Tee 3 4 NPT Coupling Water Meter Water Meter in Cubic Feet Water Meter in Gallons Coupling 3 4 3 4 DCV Elbow 3 4 NPT By Pass Shut Off Valve Nipple 3 4 NPT Ball Valve Cap Cap Bolt Nipple 3 4 NPT Nipple 3 4 x 5 1 2 Lg Nipple 3 4 NPT Test Cock Elbow 3 4 90 Cap O Ring 6 12 8 amp 10 QTY 24 DCDA Parts List QUANTITY N N zech 1 6 W682500 Contact Factory Contact Factory 7080410 W706605 W674205 7B10401 K351100 K350
3. BP 1 gt I 2 VENT HOSE CONNECTED IN LEGEND PROCEDURE STEPS 7 10 ONLY HYDRAULIC HOSE pq BY PASS VALVE TC TEST COCK DUPLEX GAUGE OR TWO BOURDON TUBE GAUGES FIGURE 6 E I amp E III I WWIR II IIIQI IIIICI I IZMI II IKIK NI I I 1 OC KMK lt E RU ZUI I III IIIIIIIIO II II IIII IO I IIIII lt I III IIOIIITGI 2 NI I IIG I G oiI I I IIIIIIIIIII ICINcMM WZI H vYOEII KIQII lt II SI sss METHOD 2 NOTE Test set up is illustrated in Figure 7 for 1 2 through 2 and Figure 8 for 2 1 2 through 10 EQUIPMENT REQUIRED Differential pressure gauge type test kit such as Conbraco Model No 40 200 TKU or 40 200 TK5U NOTE For all testing the gauge and open ends of hoses not being used must be held at the same level as the assembly being tested TEST NO 1 Purpose To determine the static pressure drop across check valve No 1 Requirement The static Pressure drop across check valve No 1 shall be at least 1 psid PROCEDURE 1 To eliminate foreign material flush all four test cocks one at a time 2 Open test valves No 1 and No 2 on the gauge and close test valve No 3 Attach high side hose to test cock No 2 3 Bleed all air from hose and gauge by slowly opening test cock No 2 Then slowly close test valve No 2 4 Close the outlet shut off val
4. THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY IMPLIED WARRANTY OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE OR OTHER WARRANTY OF QUALITY WHETHER EXPRESSED OR IMPLIED EXCEPT THE WARRANTY OF TITLE AND AGAINST PATENT INFRINGEMENT Correction of non conformities in the manner and for the period of time provided above shall constitute fulfillment of all liabilities of Conbraco to our initial purchaser with respect to the goods whether based on contract negligence strict tort or otherwise It is the intention of Conbraco Industries Inc that no warranty of any kind whether express or implied shall pass through our initial purchaser to any other person or corporation LIMITATION OF LIABILITY Conbraco Industries Inc SHALL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL OR CONSEQUENTIAL DAMAGES SUCH AS BUT NOT LIMITED TO DAMAGES OR LOSS OF OTHER PROPERTY OR EQUIPMENT LOSS OF PROFITS OR REVENUE COST OF CAPITAL COST OF PURCHASED OR REPLACEMENTS GOODS OR CLAIMS OF CUSTOMERS OF OUR INITIAL PURCHASER AND ALL OTHERS SET FORTH HEREIN ARE EXCLUSIVE AND THE LIABILITY OF CONBRACO WITH RESPECT TO SAME SHALL NOT EXCEPT AS EXPRESSLY PROVIDED HEREIN EXCEED THE PRICE OF THE GOODS UPON WHICH SUCH LIABILITY IS BASED RO Southern Midwestern Region Southern Marketing Group AVC Mechanical Sales Inc Armstrong Weatherly Associates Apollo Valves Manufactured by Conbraco Industries Inc SERVI
5. A 170000 K 336200 D 250300 D 249900 B 175000 D 250000 78 257 01 L 486400 D 227400 40 004 5 40 004 2 40 004 6 40 004 8 40 200 TKU 3 Valve 40 200 TK5U 5 Valve 1 8 NPT plub needed for units without top mounted test cocks 1 4 NPT plug needed for units without top mounted test cocks PART NO 1 1 4 1 1 2 2 Consult Factory F 311505 K301900 A 170100 K 336700 D 250800 D 250900 B 175000 D 251000 78 258 01 486600 D 256500 40 007 A5 40 007 A2 40 007 A6 40 007 A8 Parts Listing 3 4 2 Bronze Top Entry 40 100 T SERIES TOP ENTRY DOUBLE CHECK VALVE ASSEMBLY ITEM NO DESCRIPTION QUANTITY PART NO 3 4 amp 1 1 1 4 1 1 2 2 1 Body 1 Consult Consult Factory Factory 2 Cap 2 F 3108 05 F 3115 05 3 Spring 2 A 1700 00 A 1701 00 4 Poppet 2 K 3362 00 K 3367 00 5 Seat Disc 2 D 2503 00 D 2508 00 6 Seat Retainer 2 D 2499 00 D 2509 00 7 Screw 2 B 1750 00 B 1750 00 8 Cap O Ring 2 D 2500 00 D 2510 00 9 Test Cock 3 78 257 01 78 258 01 10 Check Seat 2 L 4864 00 L 4866 00 11 Check O Ring 2 D 2274 00 D 2565 00 Repair Kits Major Repair Kit 4 2 5 2 6 2 7 2 8 2 10 2 11 2 n s packet lube 40 004 A5 40 007 A5 Check Valve Repair Kit 4 5 6 7 8 10 11 n s packet lube 40 004 A2 40 007 A2 Rubber Repair Kit 5 2 8 2 11 2 n s packet lube 40 004 A6 40 007 A6 Replaceable Seat Kit 10 2 11 2 n s packet lube 40 004 A8 40 007
6. Double Check Valve DCV device consists of two independently acting spring loaded check valves Two resilient seated shut off valves and four test cocks complete the assembly Each check is designed to maintain a minimum of 1 psi across the valve during normal operation If at any time the pressure downstream of the device increases above the supply pressure both check valves will close to prevent any backflow from occurring The various styles and sizes of Double Check Valves are illustrated in figures 1 2 3 4 and 5 II INSTALLATION a The DCV must be installed in an accessible location to facilitate periodic field testing and maintenance b Flush all upstream piping thoroughly to remove foreign matter prior to installing the device c The device should be installed horizontally for ease of maintenance and testing A clearance between the lower most portion of the device and flood grade or floor should be provided for ease of maintenance d When shut off valves are provided separately they should be installed with a test cock on the upstream side of the inlet shut off valve e After installing the assembly and with downstream or 2 shut off valve closed pressurize the device and bleed air through test cock 4 Then open 2 shut off valve 99 PSIG 100 PSIG 98 PSIG FIGURE 1 1 2 40 103 FIGURE 2 40 10X A2 Y Pattern
7. METHOD 1 Duplex Gauge NOTE Test set up is illustrated in Figure 5 for 1 2 through 2 and Figure 6 for 2 1 2 through 10 EQUIPMENT REQUIRED Conbraco double check backflow preventer test kit NOTE All connections must be free from leaks in order to achieve accurate readings during testing TEST NO 1 Purpose To test check valve 1 for tightness against reverse flow Requirement The valve shall permit no through leakage in a direction reverse normal flow under all conditions of a pressure differential PROCEDURE 1 Bleed water through all four test cocks to flush any foreign material 2 Connect the high side hose to test cock 2 Connect the low side hose to test cock 83 3 Open test cocks 2 and 3 Bleed both hoses making sure to bleed the low side last 4 Close 2 shut off valve then close 1 shut off valve 6 To remove the seat disc remove the retaining plate nut On the 8 amp 10 units remove the retaining plate bolts and retaining plate remove disc WARNING The check valve spring is held in compression by the stem nut on top This nut should not be removed unless the spring requires replacement B Assembly Check Valves 1 Install seat disc in holder and secure with retaining plate and retaining nut or bolts as applicable NOTE Due to the symmetry of the disc the old disc may be turned over to obtain an effective seal 2 Install the check valve assembly
8. 12 3747 For Representatives And Distributors In Your International Area Please Contact The Closest Conbraco Industries International Office e www apollovalves com Printed in USA COPYRIGHT 1 08 BP 5M BFMM4001
9. 3 7000 086 774 1490 763 262 4740 402 573 7371 Midwest Spec Ohio North Pennsylvania West West Virginia West glsalesOmwspec com 330 538 0406 330 538 0410 Elmco and Associates California North kkleinen elmcoassoc com 916 383 0110 916 383 0181 Spec Management Group California South Irrigation Hawaii All Products msmarch4 cox net 949 481 4225 949 487 0990 Cisco Speciality Products Inc California South ciscoemail aol com 714 921 9228 714 921 0442 2 Marshall Rodeno Associated CO WY MT ID SE UT NV NE NM EI Paso TX trodeno marshallrodeno com 303 575 6701 303 575 6706 Braley Gray amp Associates Oregon SW Washington Western Idaho Sales braleygray com 503 249 6972 503 288 4464 Braley Gray Washington Alaska Washington info braleygray com 206 405 4370 206 405 4390 Southwestern Industrial Sales Co Arizona Nevada SW eduardop sw ind com 480 458 5838 480 458 5843 Jack Prust Sales California North Irrigation jack jpsales com 530 878 2922 530 878 2341 Active Sales Northwest Inc Conbraco Industries Canada Oregon WA Western Idaho Irrigation 160 Pennsylvania Ave Unit 3 Concord Ontario L4K 4A9 skactive aol com conbraco canada conbraco com 541 726 0320 905 761 6161 541 726 1148 Urell Inc Massachusetts New England States conbraco urell com 617 923 9500 617 926 9414 2 McMahon Marketing Inc New York Upstate New York West Sales mcmahonmarketing com 518 792 3350 518 792 3351 5 Continuous Sales Corporation New York E
10. 500 W706200 W709400 K350400 W738905 K350100 7B10431 K350900 7010410 Q453719 B180000 K341200 K350900 K350900 7825701 K350100 PART NO 6 W682600 Contact Factory Contact Factory 7080410 W708505 W674605 7B10401 K351100 K350500 W706200 W709400 K350400 W738905 K350100 7B10431 K352700 7010410 Q454519 B169000 K341200 K350900 K350900 7825701 K350100 10 W685900 Contact Factory Contact Factory 7080410 W711305 W685705 7B10401 K351100 K350500 W706200 W709400 K350400 W738905 K350100 7B10431 K356000 7010410 Q457419 B188100 K341200 K350900 K355900 7825701 K350100 1 um Conbraco Industries Statement of Warranty amp Limitation of Liability Conbraco Industries Inc warrants to its initial purchaser only that its products which are delivered to this initial purchaser will be of the kind described in the order or price list and will be free of defects in workmanship or material for a period of two years from the date of delivery to you our initial purchaser Should any failure to conform to this warranty appear within two years after the date of the initial delivery to our initial purchaser Conbraco will upon written notification thereof and substantiation that the goods have been stored installed maintained and operated in accordance with Conbraco s recommendations and standard industry practice correct such defects by suitable repair or replacements at Conbraco s own expense
11. 7 00 70 803 10 40 009 02 40 009 03 40 009 04 4 W 6824 00 W 6743 00 6Q 20A 01 K 3406 00 70 103 01 Q 4534 19 D 2573 00 L 4640 05 G 3242 00 D 2561 00 C 1756 00 E 2204 00 D 2572 00 F 3001 05 A 1744 00 A 1744 00 E 2202 05 C 1589 05 D 2574 00 Q 4533 19 B 1801 00 70 803 10 40 00A 02 40 00A 03 40 00A 04 6 8 10 DCV DCV Parts List ITEM NO DESCRIPTION QUANTITY PART NO 6 8 10 1 Shut Off Valve OS amp Y 2 W 6825 00 W 6826 00 W 6859 00 1 Shut Off Valve NRS 2 W 6744 00 W 6827 00 W 6858 00 1 Shut Off Valve Ball 2 6Q 20C 01 6Q 20E 01 N A 2 Brass Nipple 1 K 3412 40 K 3412 00 K 3412 00 3 Test Cock 1 70 104 10 70 104 10 70 104 10 6A Stud 2 N A N A B 2036 00 7 Body 1 Consult Factory Consult Factory Consult Factory Body 1 Consult Factory Consult Factory Consult Factory 10 C V Seat O Ring 2 D 2576 00 D 2589 00 D 2588 00 11 Seat 2 L 4644 05 L 4653 05 L 4759 05 12 C V Stem 2 G 3246 00 G 3273 00 G 3305 00 13 C V Stem O Ring 2 D 2578 00 D 2587 00 D 2587 00 14 Retainer Nut Bolt C 1760 00 B 1754 00 B 1754 00 15 Retainer Washer 2 E 2205 00 E 2208 00 E 2229 00 16 C V Seat Disc 2 D 2575 00 D 2586 00 D 2649 00 17 Seat Disc Holder 2 F 3002 05 F 3008 05 F 3019 05 18 1st Check Spring 1 A 1746 00 A 1748 00 A 1779 00 19 2nd Check Spring 1 A 1746 00 A 1748 00 A 1779 00 20 Spring Retainer 2 E 2203 05 E 2207 05 E 2228 05 21 Jam Nut 2 C 1706 00 C 1763 00 C 1763 00 22 Cap O Ring 2 D 2577 00
12. A8 Accessories Double Check Valve Test Kit 40 200 TKU 3 Valve 40 200 TK5U 5 Valve Parts Listing 2 1 2 10 Ductile Iron 2 1 2 3 4 DCV ITEM NO N 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Repair Kits DESCRIPTION Shut Off Valve OS amp Y Shut Off Valve NRS Shut Off Valve Ball Brass Nipple Test Cock Body C V Seat O Ring C V Seat C V Stem C V Stem O Ring Retainer Nut Retainer Washer C V Seat Disc Seat Disc Holder 1st Check Spring 2nd Check Spring Spring Retainer Jam Nut Cap O Ring C V Cap Cap Bolt Test Cock 1st Check Valve Repair Kit 12 13 14 15 16 17 18 20 21 22 n s packet lube Seat Repair Kit 10 11 22 n s packet lube Rubber Repair Kit 2 each 10 13 16 22 n s packet lube QUANTITY N 3 M D A A a DCV Parts List 2 1 2 W 6789 00 W 6785 00 6Q 209 01 K 3406 00 70 103 01 Q 4526 19 D 2576 00 L 4637 05 G 3239 06 D 2561 00 C 1756 00 E 2199 00 D 2560 00 F 3000 05 1741 00 1741 00 2198 05 1589 05 D 2566 00 Q 4530 19 B 1797 00 70 803 10 40 009 02 40 009 03 40 009 04 PART NO 3 W 6790 00 W 6786 00 6Q 200 01 K 3406 00 70 103 01 Q 4527 19 D 2567 00 L 4637 05 G 3239 00 D 2561 00 C 1756 00 E 2199 00 D 2560 00 F 3000 05 A 1741 00 A 1741 00 E 2198 05 C 1589 05 D 2566 00 Q 4530 19 B 179
13. BFMM4001 Apollo vaves MAINTENANCE MANUAL COVERING MODELS 40 300 Series 1 2 4S 100 Series 1 2 ONLY 40 100 Series 3 4 2 40 100 T Series 3 4 2 40 100 Series 2 1 2 10 40 600 Series 3 10 704 841 6000 704 841 6020 www conbraco com TABLE OF CONTENTS Double Check Valve Backflow Preventer 1 2 10 amp Double Check Detector Assembly 3 10 Section Page Description and Operation 2 3 hzcicuo P 2 Trouble Shooting G ide va e bade oss 4 Maintenance Instructions 1 2 40 103 4 Maintenance Instructions 1 2 45 103 5 Maintenance Instructions 3 4 2 5 Maintenance Instructions 2 1 2 10 _ 6 Testing Procedure 1 2 10 6 11 Faris Gisting 402000 1027 of tives tau 12 Parts Listing 45 103 1 9 19 Parts Listing 40 100 9 4 2 2 02 2000 14 17 Parts Listing 2 1 72 10 18 21 Parts Listing 3 10 DCDA 22 25 lucas Rd CR D RS oes 26 Double Check Backflow Preventer I DESCRIPTION AND OPERATION The
14. CE AND SALES DEPARTMENT P 0 Box 247 Matthews NC 28106 Phone 704 641 6000 Fax 704 841 6020 MS TN West AR Bowie Cty TX Oklahoma Texas North Texas South Louisiana E Mail Address SMG49 bellsouth net valvesales avalve com Sales armstrong weatherly com Phone 901 547 0042 214 201 0100 713 692 5566 Fax 5 8 Lynch amp Associates Florida Sales blynchandassociates com 813 792 5060 813 792 5213 Spotswood Associates Georgia Alabama dlewis spotswoodassociates com 770 447 1227 770 263 6899 3 Pro Marketing Inc North Carolina South Carolina Tennessee East Sales promarketinginc net 864 578 4334 864 578 4889 Mid South Marketing Inc Virginia Maryland Washington D C WV East midsouth aol com 804 213 3801 804 213 3802 901 547 0035 214 201 0104 713 692 6021 HEBCO Inc Kansas Missouri West kewinelvr aol com 913 491 0797 913 491 5126 New Tech Marketing ILAWI East IN North MI Upper Peninsula IA River Counties ntm012 mcleodusa net 630 378 4300 630 378 0343 New Tech Marketing Eastern Missouri Southern Illinois ntm112 aol com 618 394 0329 618 394 0427 Whitfill McCarthy LLC Kentucky Indiana South Ohio South whitfill win net 502 459 4545 502 459 9944 V E Sales Co Inc Fourmation Sales Willco Inc Michigan Except Upper Peninsula Minnesota North amp South Dakota Wisconsin West Nebraska lowa Except River Counties tomv vesalesinc com dean fourmationsales com bill willcoinc com 586 774 7760 763 262 4700 402 57
15. D 2588 00 D 2651 00 23 C V Cap 2 Q 4537 19 Q 4545 19 Q 4574 19 24 Cap Bolt e B 1800 00 B 1690 00 B 1881 00 25 Test Cock 3 70 804 10 70 804 10 70 804 10 N S Seat Bolt 12 N A N A B184900 6 QTY 2 8 amp 10 QTY 8 mee 6 QTY 12 8 amp 10 QTY 24 Repair Kits Check Valve Repair Kit 40 00C 02 40 00E 02 40 00G 02 12 13 14 15 16 17 18 20 21 22 n s packet lube Seat Repair Kit_ 40 00C 03 40 00E 03 40 00G 03 10 11 22 n s packet lube Rubber Repair Kit 40 00C 04 40 005 04 40 00 3 04 2 each 10 13 16 22 n s packet lube 3 4 Notes 1 Use P N W 7062 00 for meter in cubic feet register Use P N W 7094 00 for meter in gallons register ITEM NO N S N S O CON O 11 12 13 N S 15 16 17 18 22 23 24 25 N S N S N S N S N S N S N S kk DESCRIPTION Gate Valve OS amp Y DCDA Body Test Cock 1st Chk Poppet Ass y 2nd Chk Poppet Ass y By Pass Shut Off Valve Tee Reducing Coupling Water Meter Water Meter in Cubic Feet Water Meter in Gallons 3 4 DCV Elbow Street By Pass Shut Off Valve Swivel Nut Washer Meter Coupling 3 4 Coupling Nipple Close Test Cock Cap Cap Bolt Nipple Test Cock Nipple 3 4 x 3 Lg Elbow 3 4 90 Cap O Ring Seat O Ring Plug 1 2 Check Valve Seat Meter to DCV Adapter 3 QTY 3 4 1 3 QTY 2 4 OTY 4 DCDA Parts List QUANTITY G N FNM
16. ast New Jersey North csc07Gaol com 516 575 6800 516 349 8411 Layden Company Pennsylvania East Delaware New Jersey South joejr laydencompany com 610 363 6657 877 529 3361 Keith Engle amp Associates OEM accounts keith engle verizon net 610 827 9560 610 827 9561 905 761 6666 Barclay Sales Ltd British Columbia bbarclay barclaysales com 604 945 1010 604 945 3030 Dynamic Agencies Ltd Saskatchewan doug dynamicage sasktel net 306 343 1901 306 343 1901 Tom Beggs Agencies Ltd Manitoba NW Ontario TBA MB SYMPATICO CA 204 953 1900 204 774 6915 Task Controls Inc Ontario infotoronto taskcontrols com 416 291 3004 416 754 3481 E Agences J Pierre Sylvain Inc Quebec agencespsylvain golden net 450 655 9588 450 641 2737 5 Kern Industries Ltd Alberta North kernind telusplanet net 780 451 2056 780 454 6687 e CE 9 gt Kern Industries Calgary Ltd J Levandier Sales Inc Alberta South Nova Scotia New Brunswick Prince Edward Island and kerncalgary telus net 403 730 7791 403 239 8179 Newfoundland jlssales istar ca 506 858 1615 506 858 1084 Key to the North Sales Agency Inc Ontario North hmehes keytothenorth ca 705 524 6714 705 566 0148 Steam and Industrial Equipment Ottawa sie sie ca 1 800 363 8482 514 457 7111 Rafael Rodriguez Barril Inc Puerto Rico rauli rrbarril com 787 982 1550 787 982 1570 Conbraco International Limited Manchester England Sales conbraco co uk 44 161 212 3745 44 161 2
17. e from the assembly by opening 2 3 and 4 test cock CAUTION Caps are spring loaded and should be removed carefully to avoid personal injury 3 Unscrew cap using hex head provided 4 Remove spring and poppet assembly from the body 5 Remove the seat disc from the poppet 1 deposit on poppet stem or guide Inspection All parts should be carefully inspected for any damage or excessive wear and thoroughly rinsed in clean water prior to reassembly Replace worn parts as necessary Assembly Check Valve Poppet Install new disc in poppet NOTE Due to symmetry of the disc the old disc may be turned over to obtain an effective seal D Assembly Check Valve 1 Install the poppet assembly into the body 2 3 Apply a thin coat of FDA approved lubricant Install the spring onto the poppet on cap O Ring Guide cap over spring and poppet stem and tighten cap INNEN V MAINTENANCE INSTRUCTIONS 1 2 45 103 Disassembly 1 Close inlet and outlet shut off valves 2 Bleed pressure from the assembly by opening 2 3 and 4 test cock 3 Unscrew and remove bronze cap 4 Remove stainless steel spacer using lifting tab 5 Remove first check module by pulling outward with fingers a small screwdriver may aid removal Be sure test cock 2 is open so as to prevent hydraulic lock Generally the first check o ring will remain in the bore 6 Remove second ch
18. eck assembly by sliding the assembly out of its bore a small screwdriver placed in the groove provided will aid removal Be sure test cock 4 is open as to prevent hydraulic lock VI MAINTENANCE INSTRUCTIONS 3 4 2 A Disassembly Check Valves 1 Close 2 shut off valve then close 1 shut off valve 2 Bleed pressure from the assembly by opening 2 3 and 4 test cock CAUTION Caps are spring loaded and should be removed carefully to avoid personal injury 3 Unscrew cap using hex head provided 4 Remove spring and poppet assembly from the body B Disassembly Check Valve Poppet CAUTION Do not use pliers or other tools which may damage or scratch the plastic stem Inspection 1 All parts should be carefully inspected for any damage or excessive wear and thoroughly rinsed in clean water prior to reassembly 2 Replace all worn parts as necessary NOTE Check valve modules are not user serviceable In the event of check failure replacement modules are sold individually Assembly 1 Replace check modules second check first then first check Make sure first check o ring is installed Tip push o ring to the bottom of the bore before installing check module Press check module into bore A thin coat of FDA approved lubricant on o ring will aid insertion 2 Replace stainless steel spacer 3 Apply a thin coat of FDA approved lubricant on cap o ring Replace Cap 1 Holding the poppet ass
19. embly in one hand remove screw and retaining washer 2 Remove the seat disc 3 All parts should be carefully inspected for any damage or excessive wear and thoroughly rinsed in clean water prior to reassembly Replace worn parts as necessary Assembly Check Valve Poppet Install new disc in poppet and secure with washer and screw Assembly Check Valve Place and center the poppet assembly in the body gt Install the spring onto the poppet Apply a thin coat of FDA approved lubricant on cap O Ring 5 Guide cap over spring and poppet stem and tighten cap S NN VII MAINTENANCE INSTRUCTIONS 2 1 2 10 A Disassembly Check Valves 1 Close 2 shut off valve then close 1 shut off valve 2 Bleed pressure from the assembly by opening 2 3 and 4 test cock 3 Remove cover bolts and cover NOTE The spring load on the cover will be removed when the cover bolts are backed off approximately 3 8 4 Remove the complete check assembly straight out of the valve body being careful not to damage the seat ring 5 The check valve seat is threaded into the body and may be removed at this time if necessary The seat is bolted into the body on the 10 unit Vill TESTING PROCEDURES NOTE It is important that the DCV device be tested periodically in compliance with local codes but at least once a year or more as service conditions warrant
20. epaired or bypassed before testing continues If the water recedes from the test cock opening then move the gauge to a point level with the centerline of the check seat area and record the gauge reading as the static pressure differential across check No 2 HEN S INLET SHUT OFF VALVE OUTLET SHUT OFF VALVE FLUW R VALVE NO 2 TC 1 CHECK VALVE NO 1 NOT SHOWN 1 1 2 SIZE Ol gt Ten INLET SHUT OFF CHECK 1 OUTLET SHUT OFF VALVE CHECK 2 YALVE 3 4 2 SIZE EN FLOW IE 2 TC NO 3 TC 4 VENT HOSE TV NO 1 TV NO 2 OPEN TO ATMOSPHERE FOR ALL TESTS HGH SIDE Par CONNECT TO LOW SDE 2 FOR TEST NO 1 HOLD OPEN END AT SAME NO 3 FOR TEST NO 2 3 LEVEL AS GAUGE DURING LA LEGEND TV TEST VALVE TC TEST COCK FIGURE 7 INLET SHUT OFF VALVE QUTLET SHUT OFF VALVE TC ND 1 2 1 2 10 SIZE li gt FLOW N0 2 CHECK NO 2 CHECK 0 1 VENT HOSE NO 1 TV NO 2 OPEN ATMOSPHERE FOR ALL TESTS HGH SIDE CONNECT X LOW SDE NO 2 FOR TEST NO 1 TC NO 3 FOR TEST 2 3 im e TESTING LEGEND GAUGE TV TEST VALVE TC TEST COCK FIGURE 8 M Parts Listing 1 2 Bronze 40 300 Series Double Check Backflow Preventer ITEM NO DESCRIPTION Body Cap Spring Poppet Seat D
21. erential cannot be maintained the check valve is reported as leaking MI amp IOI Q HI II I II IsIBI QZQK I Bl8 BI I zIII IKCIK IIIIIII II I W IOI I I T lt I AI I IwI I AIIIIAIIAIAI IAIIASI lt AII TEST NO 2 Purpose To test check valve 2 for tightness against reverse flow Requirement The valve shall permit no through leakage direction reverse to normal flow under all conditions of a pressure differential INLET SHUT OFF VALVE PROCEDURE oame as test 1 except the high side hose is connected to test cock 3 and the low side connected 10 test cock 4 RESTORE OPERATION Close all test cocks Remove testing equipment Open shut off valves 1 and 2 1 2 SIZE gt N FLOW Ru CHECK VALVE 2 TC 1 CHECK VALVE 1 NOT SHOWN 1 Shut Off Check Check Valve 2 Shut Off Valve TC 1 Vent Hose Open to Atmosphere Connect To Connect To TC 2 for Test 1 103 Legend TC 3 for Test 2 TC 4 for Test 2 Hydraulic Hose Vent Hose Connected in h X By Pass BP Valve Procedure Steps TC Test Cock 7 10 Only Duplex Gauge or Two Bourdon Tube Gauges BP 1 FIGURE 5 Drain Hose DOUBLE CHECK VALVE 4 Shut Off Check Check EE 39 CONNECT CONNECT TO 2 TC 3 FOR TEST 1 TC43FOR TEST 2 TC 4 FOR TEST 2
22. into the body 3 Install the check valve cover and tighten bolts evenly 5 Slowly open by pass valve 1 and lower the pressure at test cock 2 approximately 2 psi below the pressure at test cock 3 Note Due to check valve disc compression both high and low side gauges may drop at the same rate approximately 10 15 psi or more After the check valve disc compresses fully the required high side pressure of 2 psi below the low side should be obtainable If this pressure differential can be maintained then check valve 1 is reported as tight or okay Proceed to test no 2 However if this pressure differential cannot be maintained proceed to step no 6 6 Open 1 shut off valve to repressurize the device 7 Loosely attach the vent hose to test cock 1 Bleed all air from the gauge and vent hose by opening by pass valve 2 Close by pass valve 2 tighten vent hose Open test cock 1 8 Close 1 shut off valve 9 Loosen the low side hose at test cock 3 and lower the pressure in the assembly approximately 10 psi Retighten hose 10 Simultaneously open by pass valves 1 and 2 very slowly If the check valve is holding tight the high side gauge will begin to drop while the low side gauge will rise Close both by pass valves If a small no more than 5 psi pressure differential is created and held then the check valve is reported as tight or okay If a pressure diff
23. isc Cap O Ring Test Cock Union Nut Tail Piece Seal O ND e Repair Kits Major Repair Kit 3 2 6 2 part no W 6759 06 2 n s packet lube Hubber Repair Kit 5 2 6 n s packet lube QUANTITY D D PART NO 1 2 Consult Factory F 3009 06 A 1750 00 K 3404 00 D 2600 00 D 2501 00 8 25 01 C 1778 06 5226 06 D 2607 00 40 300 02 40 300 01 1 2 45 103 Double Check Valve ITEM NO PARTS LIST DESCRIPTION QUANTITY 1 D 3885 00 Check Module O Ring 1 2 F 3228 00 1 Check Module 1 3 W 4302 00 2 Check Assembly 1 4 D 2422 00 2 Check O Ring 1 5 L 6104 00 Check Spacer 1 6 F 3206 05 Cap 1 T D 2568 00 Cap O Ring 1 Repair Kit 4S 003 01 1 2 3 4 7 n s packet lube Parts Listing 3 4 2 Bronze 40 100 Double Check Backflow Preventer ITEM NO DESCRIPTION 1 Body 2 Cap n s Plug 3 Spring 4 Poppet 5 Seat Disc 6 Seat Retainer 7 Screw 8 Cap O Ring 9 Test Cock 10 Check Seat 11 Check O Ring Repair Kits Major Repair Kit 4 2 5 2 6 2 7 2 8 2 10 2 11 2 n s packet lube Check Valve Repair Kit 4 5 6 7 8 10 11 n s packet lube Rubber Repair Kit 5 2 8 2 11 2 n s packet lube Replaceable Seat Kit 10 2 11 2 n s packet lube Accessories Double Check Valve Test Kit QUANTITY N D M M NO ND DYN 3 8 1 Consult Factory F 310805 K 301200
24. ve Then close the inlet shut off valve 5 Slowly open test cock No 3 After the gauge reading stabilizes and water stops running out of test cock No 3 the static pressure drop across the check valve indicated by the gauge and is recorded as such NOTE If water continues to discharge from test cock No 3 then a leaky shut off valve is evident and should be repaired or bypassed before testing continues If the water recedes from the test cock opening then move the gauge to a point level with the centerline of the check seat area and record the gauge reading as the static pressure differential across check No 1 TEST NO 2 Purpose To determine the static pressure drop across check valve No 2 Requirement The static pressure drop across check valve No 2 shall be at least 1 psid PROCEDURE 1 Open test valves No 1 and No 2 on the gauge and close test valve No 3 Attach high side hose to test cock No 3 2 Bleed all air from hose and gauge by slowly opening test cock No 3 Then slowly close test valve No 2 3 Close the outlet shut off valve Then close the inlet shut off valve 4 Slowly open test cock No 4 After the gauge reading stabilizes and water stops running out of test cock No 4 the static pressure drop across the check valve is indicated by the gauge and is recorded as such NOTE If water continues to discharge from test cock No 4 then a leaky shut off valve is evident and should be r
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