Apollo Precision Tools Valves 40-600, Valves 40-100, Valves 40-300, Valves 40-100-T, Valves 4S-100 User Manual
Conbraco Industries, Inc.
P.O. Box 247
Matthews, NC 28106
Phone: (704) 841-6000
Fax 704-841-6020
www.conbraco.com
BFMM4001
1-08
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”)
MAINTENANCE MANUAL
1
TABLE OF CONTENTS
Double Check Valve Backflow Preventer 1/2" - 10" &
Double Check Detector Assembly 3" - 10"
Section Page
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2, 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Trouble Shooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Maintenance Instructions 1/2" (40-103) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Maintenance Instructions 1/2" (4S-103) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Maintenance Instructions 3/4" - 2" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Maintenance Instructions 2-1/2" - 10" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Testing Procedure 1/2" - 10" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 11
Parts Listing 40-300, 1/2” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Parts Listing 4S-103, 1/2” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Parts Listing 40-100, 3/4" - 2" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 - 17
Parts Listing 2-1/2" - 10" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 - 21
Parts Listing 3" - 10" DCDA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 - 25
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
2
The 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.
Double Check Backflow Preventer
I DESCRIPTION AND OPERATION
FIGURE 1
FIGURE 2
FIGURE 3
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.
II INSTALLATION
100 PSIG
99 PSIG
98 PSIG
(NO FLOW CONDITION)
1/2" - 4S-103
(NO FLOW CONDITION)
(40 - 10X - A2)
Y - Pattern
1/2" - 40-103
99 PSIG
98 PSIG
100 PSIG
99 PSIG
98 PSIG
100 PSIG
3
(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 & testing refer to
Installation Instruction Booklet I476700 furnished with each DCDA unit. For maintenance instructions see pages
4 - 6. For parts list see pages 21 - 24.
(No Flow Condition)
FIGURE 4
40 - 10X - T2
Top Entry
4
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.
5. Remove the seat disc from the poppet.
B. Inspection
1. 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.
C. Assembly — Check Valve Poppet
1. 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. Install the spring onto the poppet.
3. Apply a thin coat of FDA approved lubricant
on cap O-Ring.
4. Guide cap over spring and poppet stem and
tighten cap.
III TROUBLE SHOOTING GUIDE
IV MAINTENANCE INSTRUCTIONS 1/2" (40-103)
SYMPTOM
1. Check valve fails to hold
1 psid.
CAUSE
a. Shut-off valve not closed
completely.
b. Check valve fouled with
debris.
c. Check poppet stem not
moving freely in guide.
CORRECTIVE ACTION
a. Close #2 shut-off valve or
inspect for possible
through leakage.
b. Inspect and clean seat
disc and seat.
c. Inspect for debris or
deposit on poppet stem
or guide.
5
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 check 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.
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.
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.
1. Holding the poppet assembly 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.
C. Assembly — Check Valve Poppet
1. Install new disc in poppet and secure with washer
and screw.
D. Assembly — Check Valve
2. Place and center the poppet assembly in the body.
3. Install the spring onto the poppet.
4. Apply a thin coat of FDA approved lubricant on cap
O-Ring.
5. Guide cap over spring and poppet stem and
tighten cap.
VI MAINTENANCE INSTRUCTIONS 3/4" - 2"
V MAINTENANCE INSTRUCTIONS 1/2" (4S-103)
6
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).
6. To remove the seat disc, remove the retaining plate
nut (On the 8" & 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 into the body.
3.
Install the check valve cover and tighten bolts evenly.
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.
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 #3.
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.
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 differential cannot be
maintained the check valve is reported as leaking.
VII MAINTENANCE INSTRUCTIONS 2-1/2" - 10"
VIII TESTING PROCEDURES
7
TEST NO. 2:
Purpose:
To test check valve #2 for tightness against reverse flow.
Requirement:
The valve shall permit no through leakage in a
direction reverse to normal flow under all conditions of
a pressure differential.
PROCEDURE:
Same as test #1 except the “high” side hose is
connected to test cock #3 and the “low” side
connected to test cock #4.
RESTORE OPERATION:
Close all test cocks. Remove testing equipment. Open
shut-off valves #1 and #2.
FIGURE 5
Check
#2
Check
#1
#1 Shut-Off
Valve
TC #1
TC #2
TC #3
TC #4
#2 Shut-Off
Valve
“Vent” Hose
Connected in
Procedure
Steps
#7-#10 Only
“High” Side
Connect To:
TC #2 for Test #1
TC #3 for Test #2
“Low” Side
Connect To:
TC #3 for Test #1
TC #4 for Test #2
“Vent” Hose
(Open to Atmosphere
During Test No. 1)
BP #2
BP #1
Legend
Hydraulic Hose
By-Pass (BP) Valve
TC Test Cock
Duplex Gauge or Two
Bourdon Tube Gauges
“Drain” Hose
8
DOUBLE CHECK VALVE
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