Dwyer Instruments BTK2 Operating Manual
Series BTK2 Backflow Prevention Test Kit
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3´ HOSE WITH FEMALE COUPLINGS
[SHOWN UNATTACHED]
Specifications - Installation and Operating Instructions
The Model BTK2 Backflow Prevention Test Kit is capable of testing hydronic
systems with test procedures recommended by ASSE, AWWA, CSA, FCCC, HRUSV, and NEWWA. The BTK2 is comprised of three valves and is specially
designed for testing backflow prevention assemblies. The tests can be completed
n almost any area by mounting the unit with the included high performance elastic
i
ord. PTFE-lined brass ball valves simplify the adjustment procedure. The large,
c
asy-to-grip needle valve allows for quick adjustment. The kit includes a 4.5˝
e
diameter diaphragm differential pressure gage (0 to 15 psid), a 1.5˝ diameter in-line
pressure gage (0 to 200 psig), three 3´ long hoses (color-coded), three sets of
brass adapter fittings for hookups to all standard size test cocks, an elastic cord for
hanging/mounting, and a durable polyethylene carrying case.
Note: It is the responsibilty of the tester to ensure that the test procedures are
*
ccepted by the local authorities.
a
Prior to testing any backflow device, the following procedures are recommended:
1. Permission should be obtained from the owner, to shut down the water supply.
This is necessary to ensure, since all testing is accomplished under no-flow
conditions. Concurrent with the request for permission to shut off the water, it is
advisable to point out that while the water is shut off during the test period, any
inadvertent use of water within the building will reduce the water pressure to zero.
In order to address this situation, it is recommended that the owner caution the
inhabitants of the building not to use the water until the backflow test is completed
and the water pressure is restored.
2. Determine the type of device to be tested i.e., double check valve or reduced
pressure principle device.
3. Determine the flow direction.
4. Number the test cocks, bleed them of potential debris, and assemble appropriate
test cock adapters and bushings that may be required.
5. Shut off the downstream (number 2) shut-off valve.
6. Wait several moments prior to hooking up the test kit hoses when testing a
reduced pressure principle device. If water exits the relief valve, in all likelihood, the
first check valve is fouled and it is impractical to proceed with the testing until the
valve is serviced. This waiting period is not necessary when testing double check
valves.
Test personnel are cautioned to be aware and follow local municipal, county, and
state testing requirements and guidelines as may be dictated by local authority.
The following test procedures are guidelines for standard, generally acceptable
test procedures but may be amended, superseded, or modified by local jurisdiction
For field testing of reduced pressure principle backflow preventers and double
check valve assemblies, the BTK2 is utilized. All test equipment should be
periodically checked for calibration.
Bulletin P-BTK2
PECIFICATIONS
S
ressure Limits: 175 psi (12 bar).
P
emperature Limits: 210°F (99°C).
T
Range: 4.5˝ gage: 0 to 15 psid (0 to 1 bar); 1.5˝ gage: 0 to 200 psi (0 to 14 bar).
Accuracy: 4.5˝ gage: ±2% FS; 1.5˝ gage: ±3-2-3% FS.
Wetted Parts:
4.5˝ Gage: Anodized aluminum;
.5˝ Gage Diaphragm: Buna-N;
4
.5˝ Gage: Brass;
1
all Valves: PTFE lined brass;
B
Needle Valve: Brass;
Hose Couplings: Brass;
Adaptors: Brass;
Hose: Rubber.
Size: Case: 9˝ H x 16˝ W x 9˝ D (228 mm H x 406 mm W x 228 mm D).
Weight: 8.9 lb (4 kg).
Pressure Vacuum Breaker
Field testing of a pressure vacuum breaker involves testing both the internal spring
loaded soft seated check valve, as well as testing the spring loaded air inlet valve.
The testing must be performed with the device pressurized and the air inlet closed.
The number 2 shut-off valve must also be closed and the air inlet valve canopy
removed. Perform with Ball Valve C closed.
Test 1 - Refer to Figure 1
Test the internal check valve for tightness of 1 psid in the direction of flow using the
following procedure.
1. With the valve body under pressure, (number 2 shut-off valve closed and
number 1 shut-off valve open), bleed test cocks number 1 and number 2.
2. Hook up the high pressure hose (yellow) to number 1 test cock (red) and the low
pressure hose (red) to number 2 test cock.
3. Bleed the high pressure hose and low pressure hose (yellow), in that order, and
close the test kit valves slowly (ball valve A & needle valve B).
4. Record the differential pressure on the gage. A reading of 1 psid is acceptable
to insure a tight check valve.
Test 2
Test the air inlet valve for a breakaway of 1 psid using the following procedure.
1. Connect the high pressure hose (yellow) to test cock number 2, and bleed the
high pressure hose (yellow).
2. Shut off number 1 shut-off valve.
3. Slowly open the needle valve B of the test kit, and observe and record the
pressure when the air inlet poppet opens. This should be a minimum of 1 psid.
Restore the valve to normal service.
DWYER INSTRUMENTS, INC.
P.O. BOX 373 • MICHIGAN CITY, INDIANA 46360, U.S.A. Fax: 219/872-9057 e-mail: info@dwyer-inst.com
Phone: 219/879-8000 www.dwyer-inst.com
ir inlet valve canopy
all Valve A
B
educed Pressure Principle Backflow Preventer
R
ield testing of a reduced pressure principle backflow preventer is accomplished
F
Ball Valve C
Needle
Valve B
Low
ressure
P
Hose
Red)
(
igure 1 - Pressure Vacuum Breaker
F
Vent Hose
(Blue)
est cock
T
o. 2
N
igh Pressure
H
Hose (Yellow)
Test cock
o. 1
N
A
Loaded air inlet valve
No. 2 shut-off valve
Check valve
o. 1 shut-off valve
N
utilizing a differential pressure gage such as the BTK2 test kit. The device is tested
for three optional characteristics: i.e., (1) the first check valve is tight and maintains a
minimum of 5 psi differential pressure, (2) the second check valve is tight against
backpressure and (3) the relief valve opens at a minimum of 2 psi below inlet supply
ressure. Testing is performed as follows:
p
tep 1 - Refer to Figure 2
S
Test to ensure that the first check valve is tight and maintains a minimum pressure of
5 psi differential pressure using the following procedure. Perform with Ball Valve C
closed.
1. Verify that number 1 shut-off valve is open. Close number 2 shut-off valve. If there
is no drainage from the relief valve, it is assumed that the first check valve is tight.
2. Close all test kit valves.
3. Connect the high pressure hose (yellow) to test cock number 2.
4. Connect the low pressure hose (red) to test cock number 3.
5. Open test cocks number 2 and number 3.
6. Open high pressure side needle valve B on test kit bleeding the air from the high
pressure hose. Close the high pressure side ball valve A.
7. Open the low pressure side needle valve B on test kit bleeding air from the low
pressure hose (red). Close the low side needle valve B. Record the differential gage
pressure reading. It should be a minimum of 5 psid.
tep 2- Refer to Figure 3
S
est to ensure that the second check valve is tight against backpressure using the
T
ollowing procedure.
f
1. Leaving the hoses hooked up as in the conclusion of Step 1, connect vent hose
(blue) to test cock number 4.
2. Open test cock number 4, the high pressure ball valve A and the bypass hose ball
alve C on the test kit. (This supplies high pressure water downstream of check valve
v
umber 2.) If the differential pressure gage reading drops and water comes out of the
n
elief valve, the second check valve is recorded as leaking. If the differential pressure
r
age reading remains steady, and no water comes out of the relief valve, the second
g
check valve is considered tight.
3. To check the tightness of number 2 shut-off valve, leave the hoses hooked up the
same as at the conclusion of Step 2 (2), and then close test cock number 2. This stops
he supply of any high pressure water downstream of check valve number 2. If the
t
ifferential pressure gage reading holds steady, the number 2 shut-off valve is
d
ecorded as being tight. If the differential pressure gage reading drops to zero, the
r
umber 2 shut-off valve is recorded as leaking.
n
With a leaking number 2 shut-off valve, the device is, in most cases, in a flow
condition and the previous readings taken are invalid. Unless a no-flow condition can
e achieved, either through the operation of an additional shut-off downstream, or the
b
se of a temporary compensating bypass hose, accurate test results will not be
u
chieved.
a
Step 3 Check that the relief valve opens at a minimum pressure of 2 psid below inlet
pressure using the following procedure.
1. With the hoses hooked up the same as at the conclusion of Step 2 (3), slowly open
p the low pressure control needle valve B on the test kit and record the differential
u
ressure gage reading at the point when the water initially starts to drip from the relief
p
alve opening. This pressure reading should not be below 2 psid.
v
This completes the standard field test for a reduced pressure principle backflow
preventer. Before removal of the test equipment, the tester should ensure that they
open number 2 shut-off valve thereby reestablishing flow. Also, the test kit should be
thoroughly drained of all water to prevent freezing by opening needle valve B, and ball
valves A and C.
lve
f va
f
o
t-
.1
sh
ck No
. 1
No
st co
Te
.2
u
ck No
st co
Ch
Te
e
ck va
.1
.3
No
lve
ck No
st co
Te
.2
4
.
No
o
N
lve
ck
ck va
e
Ch
N
st co
Te
ve
l
va
f
f
o
-
t
u
sh
2
.
o
e
valv
No.
ock
c
t
es
T
High Pressure
Hose (Yellow)
off
-
1
hut
No.2
1 s
No.
cock
t
Tes
Ball Valve A
o.1
N
o.3
e
N
k
alv
v
k
hec
C
oc
c
t
Tes
Ball Valve C
Needle
Valve B
k
hec
C
Vent Hose
(Blue)
v
Figure 2 - Reduced Pressure Principle Backflow Preventer
e
alv
o.2
N
Tes
Low Pressure
o.4
N
k
oc
c
No
t
Hose (Red)
lve
f va
f
o
t-
u
sh
.2
Temporary
Bypass Hose
(Black)
High Pressure
Hose (Yellow)
Ball Valve A
Ball Valve C
Needle
Valve B
Vent Hose
(Blue)
Low Pressure
Hose (Red)
Figure 3 - Reduced Pressure Principle Backflow Preventer
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