WATTS LFM116 Pressure Relief, Sustaining, or Backpressure Control Valve User Manual
- June 8, 2024
- WATTS
Table of Contents
LFM116 Pressure Relief, Sustaining, or Backpressure Control
Valve
User Manual
LFM116
Series LFM116 / LFM6116
Sizes: 11/4″ to 24″
WARNING
Read this Manual BEFORE using this equipment.
Failure to read and follow all safety and use information can result in death,
serious personal injury, property damage, or damage to the equipment.
Keep this Manual for future reference.
WARNING
Local building or plumbing codes may require modifications to the
information provided. You are required to consult the local building and
plumbing codes prior to installation. If the information provided here is not
consistent with local building or plumbing codes, the local codes should be
followed. This product must be installed by a licensed contractor in
accordance with local codes and ordinances.
WARNING
Need for Periodic Inspection/Maintenance: This product must be tested
periodically in compliance with local codes, but at least once per year or
more as service conditions warrant. All products must be retested once
maintenance has been performed. Corrosive water conditions and/or unauthorized
adjustments or repair could render the product ineffective for the service
intended. Regular checking and cleaning of the product’s internal and external
components helps assure maximum life and proper product function. !
NOTICE
For Australia and New Zealand: Pipeline strainers should be installed between
the upstream shutoff valve and the inlet of the backflow preventer.
It’s important that this device be tested periodically in compliance with
local codes, but at least once per year or more as service conditions warrant.
If installed on a fire sprinkler system, all mechanical checks, such as alarm
checks and backflow preventers, should be flow tested and inspected internally
in accordance with NFPA 13 and NFPA 25.
Watts product specifications in U.S. customary units and metric are approximate and are provided for reference only. For precise measurements, please contact Watts Technical Service. Watts reserves the right to change or modify product design, construction, specifications, or materials without prior notice and without incurring any obligation to make such changes and modifications on Watts products previously or subsequently sold.
Engineering Specification
**LEAD FREE*
Series LFM116**
Pressure Relief, Sustaining or Backpressure Control Valve
Full Port Ductile Iron Single Chamber Valve
Features
- Opens when upstream pressure is above setpoint
- Closes when upstream pressure is below setpoint
- Adjustable Closing Speed
- When installed on branch of tee, acts as Pressure Relief Valve
- When installed between two pressure zones, acts as Pressure Sustaining Valve
- When installed on discharge of a pump, acts as Backpressure Control Valve
- Setpoint is adjustable
Standard Components
1 – Main Valve (M100 – Single Chamber)
2 – Relief / Sustaining Control
3 – Adjustable Closing Speed
X – Isolation Cocks
Options and Accessories
- FC – Flo-Clean Strainer (Standard 1¼” – 4″)
- Y – Y-Strainer (Replaces Flo-Clean)
- AOS – Adjustable Opening Speed (Standard 1¼” – 4″)
- P – Position Indicator
- L – Limit Switch
Operation
The Pressure Relief, Sustaining or Backpressure Automatic Control Valve (ACV)
is designed to permit flow when upstream pressure is above the adjustable
setpoint of the control pilot, and throttle toward closed when upstream
pressure falls below the adjustable setpoint. It is controlled by a normally
closed control pilot designed to: 1) Open (allowing fluid out of the main
valve cover chamber) when upstream pressure is above the adjustable setpoint,
and, 2) Close (allowing fluid to fill the main valve cover chamber) when
upstream pressure is below the adjustable setpoint. An increase in upstream
pressure causes the valve to modulate toward an open position. A decrease in
upstream pressure causes the valve to modulate toward a closed position.
When the valve is installed “off the main line” on the branch of a tee, it
serves as a Pressure Relief Control Valve. The valve is normally closed, and
quickly opens when upstream pressure exceeds the pilot setting, relieving
pressure, commonly discharging to a storage reservoir, pump suction, or
atmosphere. When upstream pressure is lowered below the pilot setting, the
valve closes at a controlled, adjustable rate.
When the valve is located “in line” connecting two distribution zones, the
valve acts as a Pressure Sustaining Control Valve. When pressure in the
upstream zone falls below the pilot setting, the valve modulates toward a
closed position, sustaining pressure in the upstream zone. The valve will
close, if necessary, until upstream pressure is above the pilot setting. The
valve should be specified to include the optional opening speed control and
position indicator when used for Pressure Sustaining applications.
When the valve is installed “in line” on the discharge of a pump, it acts as
Backpressure Control Valve. When pump discharge pressure falls below the pilot
setting, the valve modulates toward a closed position, increasing backpressure
against the pump. The valve should be specified to include the optional
opening speed control when used for Backpressure applications.
- The wetted surface of this product contacted by consumable water contains less than 0.25% of lead by weight.
NOTICE
The information contained herein is not intended to replace the full product installation and safety information available or the experience of a trained product installer.
You are required to thoroughly read all installation instructions and product safety information before beginning the installation of this product.
M Series Basic Valves
Pressure Relief, Sustaining or Backpressure Control Valve
Full Port Ductile Iron Single Chamber Basic Valve
This Watts Automatic Control Valve (ACV) is a full port, single chamber basic valve that incorporates a one-piece disc and diaphragm assembly. This assembly is the only moving part within the valve allowing it to open, close, or modulate as commanded by the pilot control system. Watts ACV Main Valves are Lead Free. The Watts ACV piloting system contains Lead Free* components, ensuring all of our configurations are Lead Free compliant. Globe Pattern Single Chamber Basic Valve (M100) Angle Pattern Single Chamber Basic Valve (M1100)
Basic Valve Body Options
Standard Materials
Body and Cover: | – Ductile Iron ASTM A536 |
---|---|
Coating: | NSF Listed Fusion Bonded Epoxy Lined and Coated |
Trim: | 316 Stainless Steel |
Elastomers: | Buna-N (standard) EPDM (optional) VitonTM (optional) |
Nut, Spring and Stem: | Stainless Steel. |
Anti-Scale (Optional): | Xylan Coated Stem and Seat |
VitonTM is a trademark of The Chemours Company FC, LLC
Operating Pressure
Threaded = 400psi (27.6 bar)
150# Flanged = 250psi (17.2 bar)
300# Flanged = 400psi (27.6 bar)
Grooved End = 400psi (27.6 bar)
Operating Temperature
Buna-N: 160°F (71°C) Maximum
EPDM: 300°F (140°C) Maximum
Viton™: 250°F (121°C) Maximum
Epoxy Coating: 225°F (107°C) Maximum
Valves can be provided without internal epoxy coating consult factory
Flow Data
-
Maximum continuous flow based on velocity of 20 ft. per second.
-
Maximum intermittent flow based on velocity of 25 ft. per second.
-
Minimum flow rates based on a 20-40 psi pressure drop.
-
The Cv Factor of a value is the flow rate in US GPM at 60°F that will cause a 1psi drop in pressure.
-
Cv factor can be used in the following equations to determine Flow
(Q) and Pressure Drop (∆P):
Q (Flow) = Cv²√∆P ∆P (Pressure Drop) = (Q/Cv) -
The Cv factors stated are based upon a fully open valve.
-
Many factors should be considered in sizing control valves including inlet pressure, outlet pressure and flow rates.
-
For sizing questions including cavitation analysis consult Watts with system details.
Basic Valve
Item | Description | Material |
---|---|---|
1 | Pipe Plug | Lead Free Brass |
2 | Cover | ASTM A536 65-45-12 Epoxy Coated Ductile Iron |
3 | Cover Bearing | ASTM A276 304 Stainless Steel |
4 | Stud with Cover Nut and Washer | ASTM A570 Gr.33 Zinc Plated Steel |
5 | Body | ASTM A536 65-45-12 Epoxy Coated Ductile Iron |
6 | Spring | ASTM A276 302 Stainless Steel |
7 | Stem Nut | ASTM A276 304 Stainless Steel |
8 | Lock Washer | ASTM A276 304 Stainless Steel |
9 | Stem Washer | ASTM A276 304 Stainless Steel |
10 | Diaphragm Washer | ASTM A536 65-45-12 Epoxy Coated Ductile Iron |
11 | Diaphragm’ | Buna-N (Nitrile) |
12 | Disc Retainer | ASTM A536 65-45-12 Epoxy Coated Ductile Iron |
13 | Seat Disc’ | Buna-N (Nitrile) |
14 | Spacer Washer x5 | NY300 Fiber |
15 | Disc Guide | ASTM A743 CF8M (316) Stainless Steel |
16 | Shaft | ASTM A276 304 Stainless Steel |
17 | Seat Ring” | ASTM A743 CF8M (316) Stainless Steel |
17A | Seat Screw” (8″ and Larger) | ASTM A276 304 Stainless Steel |
18 | Seat Gasket’ | Buna-N (Nitrile) |
- Contained in Main Valve Repair Kit
**Note: 6 inch and Smaller Valves, Seat Ring is threaded
NOTICE
Installation: If unit is installed in any orientation other than horizontal (cover up) OR extreme space constraints exist, consult customer service prior to or at the time of order.
Dimensions
Flanged and Threaded Dimensions
*LEAD FREE
Model LFPV20C
Pressure Relief, Sustaining or Backpressure Pilot**
Size: 1/2″ NPT
The Model LFPV20C is a remote sensed direct acting, diaphragm actuated Pilot
that is used on various configurations of Automatic Control Valves. It is
normally held closed by the force of the adjustable spring setting above the
diaphragm. It modulates toward an open position when control pressure,
exerting force below the diaphragm, exceeds the spring setpoint, and modulates
toward a closed position when the control pressure falls below the spring
setpoint.
The LFPV20C senses control pressure through a tapped port below the diaphragm.
The large diaphragm-to-seat ratio allows it to open and close within tight
pressure tolerances, accurately positioning the Main Valve.
Turning the adjustment screw clockwise raises the control setpoint.
Turning the adjustment screw counterclockwise lowers the control setpoint.
The LFPV20C is equipped with one 1/2″ NPT inlet and outlet port and a 1/4″ NPT
side sensing port located on the power chamber. The 1/4″ side sensing port is
used to monitor upstream or downstream pressure as required by specific valve
function.
Specifications
Body Material: | Lead Free Copper Silicon Alloy |
---|---|
*Seat: | 316 Stainless Steel |
Elastomers: | Buna-N (standard) Viton TM (optional) |
EPDM (optional)
| 400psi (27.6 bar) maximum
Inlet Pressure Rating:
.
Adjustment Rating:| 20-200psi (1.4 – 13.8 bar) (standard) 0-30psi (0 – 2.1
bar) (optional)
100-300psi (6.9 – 20.7 bar) (optional) 200-450psi (13.8 – 31.0 bar) (optional)
Item | Description |
---|---|
1 | Adjusting Screw |
2 | Jam Nut |
3 | Spring Housing |
4 | Spring Guide |
5 | Spring |
6 | Cap Screw |
7 | Power Chamber |
8 | 0-Ring’ |
9 | Body |
10 | Seat |
11 | 0-Ring` |
Item | Description |
--- | --- |
12 | Nut |
13 | Lockwasher |
14 | Diaphragm Washer |
15 | Diaphragm* |
16 | Diaphragm Washer |
17 | 0-RIng’ |
18 | Stem |
19 | Retainer |
20 | Rubber Disc’ |
21 | Screw |
**LEAD FREE *
Model LFFC
Flow Control
Size: ½” NPT**
A Flow Control is an adjustable device used for tuning valve performance. It
can be installed to either control the opening or closing the speed of the
automatic control main valve. When the flow is in the direction of the needle
the flow control is an adjustable restriction. In the free flow direction the
seat moves out of the flow path to all unrestricted flow.
- The wetted surface of this product contacted by consumable water contains less than 0.25% of lead by weight.
*LEAD FREE
Model BV
Ball Valve
Size: ¼” – 1″ NPT **
Model BV Ball Valves are used in pilot lines to provide a positive shutoff in any override or maintenance situation for simple trouble shooting. This 2-piece, full port valve features: bottom loaded stems, PTFE seats and packing.
- The wetted surface of this product contacted by consumable water contains less than 0.25% of lead by weight.
**LEAD FREE *
Model LF60
Flo-Clean Strainer
Size: 1/4″ – 3/4″ NPT**
Model LF60 Flo-Clean Strainers are used to filter the fluid passing through the pilot circuit, and provide protection to pilot circuit speed controls and pilots. It is installed in the inlet body port of the Main Valve, exposing the strainer element to main line flow. The currents and flow across the screen create a self-scouring effect, cleaning the filter element.
Valve inlet with Filter installed
Body Material: Lead Free Brass (standard) Stainless Steel (optional)
Pressure Rating: 400psi (27.6 bar)
Filter Element: Monel
Screen Mesh: 40 Mesh (standard)
- The wetted surface of this product contacted by consumable water contains less than 0.25% of lead by weight.
**LEAD FREE*
Model LF60-1
Y-Pattern Strainer
Size: 1/4″ – 3/4″ NPT**
Model LF60-1 Y-Pattern Strainers are used to filter the fluid passing through the pilot circuit, and provide protection to pilot circuit speed controls and pilots. The filter element can be accessed for cleaning by removing the clean- out cap, or may be cleaned by installing an optional “blow-down” ball valve.
Dimensions
Body Material: Lead Free Copper Silicon Alloy CF8M (316) Stainless Steel
(optional)
Retainer Cap: Lead Free Copper Silicon Alloy
Cap Gasket: EPDM
Pressure Rating: 400psi (27.6 bar)
Filter Element: 304 Stainless Steel
Mesh Options: 60 Mesh (standard) 100 Mesh (optional,
- The wetted surface of this product contacted by consumable water contains less than 0.25% of lead by weight.
LEAD FREE
Model 50
Position Indicator
When specified as an option on a Control Valve, the Model 50 Position
Indicator is installed in the topmost cover port of the Main Valve and allows
for visual indication of valve position. The Model 50 is also very useful
during valve start-up and troubleshooting procedures.
A stainless steel indicating rod threads into the tapped portion of the Main
Valve stem and moves inside of a cylindrical Pyrex sight tube. The indicating
rod travels up and down, following Main Valve stem movement. The housing
protects the sight tube and indicating rod, and allows visibility on two
sides. The screw driver operated test cock installed on the top of the Model
50 housing provides a controlled method of removal of air from the cover
chamber during start-up or troubleshooting of the Main Valve.
Item | Description |
---|---|
1 | Test Cock |
2 | Housing |
3 | Gasket |
4 | Pyrex Sight Tube |
5 | Body |
6 | Indicating Rod |
7 | Stem Adaptor (8″ or Larger) |
Standard Material: Stainless Steel Housing and Body Stainless Steel Indicating
Rod
Lead Free Test Cock
Pyrex Sight Tube
Optional Material: Stainless Steel Test Cock
Pressure Rating: 400psi (27.6 bar)
- The wetted surface of this product contacted by consumable water contains less than 0.25% of lead by weight.
Dimensions
Valve Size
(in)| Dimension
(in)
---|---
11/4 – 11/2| 7 ⅜
2| 4 ⅞
2
1/2| 4⅞
3| 4 ⅞
4| 5
6| 5
8| 5 ⅞
10| 5 ⅞
12| 7¼
14| 7¼
16| 7¼
18| 7¼
20| 7¼
24*| 7¼
**LEAD FREE *
Model 51
Single Limit Switch**
The Model 51 Single Limit Switch provides visual indication of valve position,
as well as remote electrical indication of “valve open” or “valve closed”. The
single pole double throw MicroSwitch can be connected to open or close an
electrical circuit when the valve opens or closes. The adjustable collar is
normally set to contact the trip arm when
the main valve is closed. The collar can be positioned on the stem by
loosening the set-screw to actuate the switch at the desired point of valve
travel.
Body Material: Stainless Steel
Elastomers: Buna-N (standard)
EPDM (optional) Viton™ (optional)
Enclosure: NEMA 1, 3, 4 and 13 General Purpose (standard)
NEMA 1,7 and 9 Explosion Proof (optional)
Electrical: Form C SPDT Switch
15 amp. 125, 250 or 480 VAC
½ amp. 125 VDC
¼ amp. 250 VDC
½” Conduit Connection
Viton™ is a trademark of The Chemours Company FC, LLC
- The wetted surface of this product contacted by consumable water contains less than 0.25% of lead by weight.
Parts List
Item | Description |
---|---|
1 | Limit Switch |
2 | Bracket |
3 | Stem |
4 | Trip collar |
5 | Set Screw |
6 | Cap |
7 | Wiper Ring* |
8 | O-Ring* |
9 | Guide |
10 | O-Ring* |
11 | Polypak* |
12 | Locknut |
13 | Body |
14 | Pin |
15 | Coupling |
*Included in Repair Kit
Installation
Start-up of an automatic control valve requires that proper procedures be followed. Time must be allowed for the valve to react to adjustments and the system to stabilize. The objective is to bring the valve into service in a controlled manner to protect the system from damaging over-pressure.
- Clear the line free of slag and other debris.
- Install the valve so that the FLOW ARROW marked on the valve body/tag corresponds to flow through the line.
- Close upstream and downstream isolation valves.
- Open the isolation ball valves in the control tubing if so equipped. Failure to open these will prevent the valve from functioning properly.
- Install pressure gauges at locations upstream and downstream of the valve.
Valve Servicing Dimensions
The following tables detail the recommended minimum valve servicing dimensions.
Setting the Pressure Controls
STEP 1
Pre-set pilots as noted:
Pressure Sustaining –Turn Sustaining Control adjustment screw OUT,
counterclockwise, backing pressure off the spring, to allow it to stay open
while adjusting the other controls.
Pressure Reducing – Adjust OUT, counterclockwise, backing pressure off the
spring, preventing possible over-pressuring of the system.
Opening and Closing Speed – Turn the adjustment screws on the Closing Speed
and Opening Speed Controls, if the main valve is so equipped, OUT,
counterclockwise, 11/2 to 21/2 turns from full closed position.
STEP 2
To ensure proper operation, any trapped air will need to be bled off the valve
cover during startup. If your ACV includes a bleed valve, as shown to the
right, use a flat head screwdriver to slowly open the valve (See Figure 1).
If your valve does not include a bleed valve, bleed air by loosening a fitting
on the valve or a plug, at the highest point of the valve assembly.
STEP 3
Pressure the line, by opening the upstream isolation valve slowly Air is
vented through the air bleed valve or loosened fitting. Tighten the fitting
when liquid begins to vent (See Figure 1).
Repeat the process until no air is trapped in the system.
STEP 4
Slowly open downstream isolation valve to establish flow through the system.
STEP 5
Setting the Sustaining Control requires lowering the upstream pressure to the
desired minimum sustained pressure.
STEP 6
Leave the downstream isolation valve fully open and close the upstream
isolation valve until the inlet pressure drops to the desired setting.
STEP 7
Adjust the Sustaining Control screw IN, clockwise, until the inlet pressure
begins to increase, or OUT, counterclockwise to decrease, stopping at the
desired pressure (See Figure 2).
STEP 8
Allow pressure to stabilize.
STEP 9
Fine-tune the sustaining setting as required as detailed in STEP 7.
STEP 10
Open the upstream isolation valve to return to normal operation.
STEP 11
Closing Speed Needle Valve Adjustment: The closing speed needle valve
regulates fluid pressure into the main valve cover chamber, controlling the
valve closing speed. If the downstream pressure fluctuates slightly above the
desired set point, turn the adjustment screw OUT, counterclockwise, increasing
the rate of closing.
(IF INSTALLED) Opening Speed Flow Control Adjustment: The Opening speed flow
control allows free flow into the cover and restricted flow out of the cover
of the main valve. If recovery of pressure is slow upon increased downstream
demand, turn the adjustment screw OUT, counterclockwise, increasing the rate
of opening. IF recovery of downstream pressure is too quick, as indicated in a
rapid increase in pressure, possibly higher than the desired set-point, turn
the adjustment screw IN, clockwise,
decreasing the rate of opening (See Figure 3).
Automatic Control Valve Maintenance Schedule
To ensure peak performance and longevity of your automatic control valve, Watts/Ames recommends following the below standard maintenance schedule.
-
Monthly Maintenance
– Visual inspection of valve(s) for leaks
– Inspect for proper operation(s); exercise valve. -
Quarterly Maintenance
– Conduct monthly inspection.
– Validate/Re-establish necessary setpoints of controls/pilots. -
Annual Maintenance
– Conduct monthly & quarterly inspections.
– Inspect & clean all strainers.
– Inspect valve coating, touch up as required. -
3-5 Year Maintenance
– Conduct monthly, quarterly, & annual maintenance.
– Inspect & replace valve elastomers (diaphragm, O-rings,
valve/pilot seats)
– Re-establish necessary set points of controls/pilots.
Troubleshooting Guide
WARNING
Warning: The valve cannot be serviced under pressure.
Upstream and downstream Isolation Valves must be installed to protect system
piping. Accurate diagnosis and troubleshooting requires the valve to open
fully, and may subject downstream piping and equipment to high pressure and/or
flow rates. The downstream Isolation Valve should be kept closed while
diagnosing the valve.
Extreme caution should be used while performing the troubleshooting
techniques listed below.
Recommended tools for diagnosis: (3) PRESSURE GAUGES, installed to monitor
the inlet pressure, outlet pressure, and coverchamber pressure. If included, a
POSITION INDICATOR shouldbe installed to visually assess the position of the
disc & diaphragm assembly.
Test 1: Diaphragm Seal Test
- Close upstream & downstream isolation valves. Close pilot isolation valves or remove pilot control tubing to isolate valve cover from incoming fluid & pressure. Remove uppermost cover plug, test cock, or limit switch.
- With the valve cover chamber vented to atmosphere, partially open the upstream isolation valve, allowing incoming pressure to lift the disc & diaphragm assembly. A volume of water will be displaced from the cover chamber as the valve opens; consult valve specification sheets for approximate cover capacity. A continuous flow of water from the open port indicates a damaged diaphragm or loose disc & diaphragm assembly. Disassemble valve and replace diaphragm or tightendisc & diaphragm assembly.
Test 2: Seat Seal Test
- Close downstream isolation valve and install pressure gauges on an open inlet and outlet port of main valve.
- Open upstream isolation valve to allow pressure on to the valve cover. Allow valve to fully close.
- Monitor downstream pressure gauge; reading should hold steady below incoming pressure. If pressure on downstream side rises to match upstream pressure, leakage is occurring through the seat of the main valve. Disassemble valve, inspect and repair/replace any required parts. a. If gauge pressure rises to match outlet pressure (downstream of closed isolation valve) yet remains below inlet pressure, the isolation valve may be leaking as opposed to main valve seat.
Test 3: Freedom of Movement/Valve Travel Test
-
Close upstream and downstream isolation valves. Install valve position indicator.
-
Partially open upstream isolation valve and allow cover to fill with fluid & pressure, closing the valve fully. Mark the position indicator’s full closed position.
-
Isolate cover chamber from receiving fluid and pressure by closing isolation valves or removing control tubing.
-
Carefully vent cover chamber to atmosphere by opening test cock or removing a cover plug. Observe the valve position indicator as the valve travels to the full-open position. The disc & diaphragm assembly should move freely from fully closed to fully open position without binding or “grabbing” at any point during its movement.
a. The disc & diaphragm assembly may momentarily “hesitate” while travelling from fully closed to fully open position – this is a normal characteristic of diaphragm operated control valves, and does not indicate mechanical binding or improper valve operation.
b. A continuous discharge of water from the cover chamber after venting to atmosphere indicates leakage past the diaphragm. -
If necessary, disassemble valve and inspect/repair disc & diaphragm assembly.
Issue | Possible Cause | Corrective Action | Notes |
---|---|---|---|
Main Valve will not open | Closed isolation valves in pilot system. | Check | |
isolation valves, ensure open. | |||
Insufficient supply pressure. | Check upstream pressure. | Depending on water |
source, supply pressure may not be controlled by valve operator.
Main valve stem assembly corroded/ damaged.| Inspect stem assembly, clean/
replace if necessary.|
Blockage in pilot system.| Inspect & clean any installed pilot system
strainers, check orifice/speed controls for blockages.|
Missing fixed orifice assembly.| Verify installation of orifice; replace if
required/missing.| Pilot valve inlet isolation valve can be used as a
makeshift orifice assembly by partially opening from full closed position.
Improperly configured opening speed control (if equipped).| Adjust opening
speed control to verify functionality, adjust as required.| Standard setting
for opening speed control is 11/2 – 21/2 turns open from full closed position.
Can be adjusted in field.
Main Valve will not close| Closed isolation valves in pilot system| Check
isolation valves, ensure open.|
Diaphragm is damaged| Conduct diaphragm seal test repair and replace if
necessary.|
Main valve stem assembly corroded/ damaged.| Inspect stem assembly, clean/
replace if necessary.|
Blockage in main valve.| Perform freedom of movement test; if valve does not
close, disassemble and remove blockage.|
Worn/damaged valve seat.| Perform seat sealing check; disassemble and
inspect/repair seat if required.|
Valve Disassembly Instructions
Before undertaking valve disassembly, it is recommended to gather the following tools to aid you during the process:
- Small & large adjustable wrenches
- Screwdriver set
- Machinist fine metal file
- Fine wire brush
- Bench vise
- Basic valve IO&M manual
- Hammer & dull cold chisel
- Heavy-duty ratchet & socket set
- Hexagonal wrench set
- 320 grit/fine Emery cloth
- Appropriate technical bulletins for valve start-up procedures.
-
Isolate the valve from line pressure and depressurize it to ensure safe working conditions. Disconnect any electrical connections if so equipped.
-
Carefully remove Position Indicator or Limit Switches if equipped. Remove all tubing, fittings, and Control Pilots necessary to easily access and remove the cover. Remove cover nuts and washers.
-
Remove the cover. If cover is not free to be removed, loosen it by tapping upward along its outside edge with a dull cold chisel, pictured above.
a. Large valves may require the installation of lifting “eye” bolts in order to facilitate cover removal; installation ports are provided on the cover for this purpose. -
Remove the Disc and Diaphragm Assembly from the valve body by lifting straight up.
a. Large diameter valves may require a lifting “eye” bolt to be installed in the valve stem accessory threads located on the very top of the valve stem. -
Before removing Stem Nut, examine stem threads for mineral build-up. Remove deposits with a fine wire brush. Extreme care should be taken not to damage the finish on stem guiding surfaces when disassembling. Avoid applying pipe wrenches to top or bottom stem guide surfaces.
-
After removing the Stem Nut, the remainder of the Disc & Diaphragm Assembly should disassemble easily. Polish stem guide surfaces with fine emery cloth to remove any mineral deposits and inspect for excessive wear. Remove any mineral build-up from other components with wire brush or by using a Mineral Dissolving Solution. Inspect parts for wear and replace if necessary.
-
Inspect valve seat. If seat is not damaged, removal is not necessary. Valve seats 6″ and smaller are threaded into the body of the valve and require a seat removal tool (Figure 4) (Table 1 details the tool dimensions for seat removal). Valve seats 8″ and larger are held in the valve body with stainless steel cap screws. Remove seat retaining screws and lift seat straight up (Figure 5).
Table 1: Seat Removal Tool Dimension
**** Size| A| B| C| D| E (Dia.)|
---|---|---|---|---|---|---
in| Pipe Size (in)| Min. Length (in)| in| in| in| in
11/4| 1| 3.| 0.38| 0.25| 0.44| 0.55
11/2| 1| 3.| 0.38| 0.25| 0.44| 0.50
2| 11/4| 3.| 0.38| 0.25| 0.44| 0.50
21/2| 2| 4.0| 0.38| 0.38| 0.56| 0.62
3| 21/2| 5.| 0.50| 0.38| 0.56| 0.62
4| 3| 5.0| 0.50| 0.44| 0.56| 0.62
6| 5| 6.50| 0.62| 0.44| 0.56| 0.62
*Schedule 40 steel pipe
- Replace Seat Disc, Diaphragm and Spacer Washers provided in Main Valve repair kit (refer to Table 2 or 3 for correct repair kit part number). Re-assemble in the reverse order of disassembly.
Table 2: Full Port Valve (M100/M1100) Repair Kits
**** Size (in)| 1 1/4| 1 1/2| 2| 21/2| 3| 4| 6| 8| 10| 12| 14| 16
---|---|---|---|---|---|---|---|---|---|---|---|---
P/N| 0677-01| 0677-01| 0677-02| 0677-03| 0677-04| 0677-05| 0677-06| 0677-07| 0677-08| 0677-09| 0677-10| 0677-11
Table 3: Reduced Port Valve (M6100 / M61100) Repair Kits
Size (in) | 3 | 4 | 6 | 8 | 10 | 12 | 16 | 20 & 24 |
---|---|---|---|---|---|---|---|---|
P/N | 0677-02 | 0677-04 | 0677-05 | 0677-06 | 0677-07 | 0677-08 | 0677-09 | 0677-11 |
- Re-Install Disc and Diaphragm Assembly in the valve, taking care not to damage the lower guide area in the center of the valve seat.
- Re-install Cover Spring. Replace Valve Cover and tighten Cover Nuts in a crossing pattern to ensure even distribution. Test the Disc and Diaphragm Assembly for smooth travel by following the Freedom of Movement Test procedure in previous section.
- Test the integrity of the Seat Seal by following the Seat Seal Test procedure in previous section.
- Return valve to service by following instructions in the Setting the Pressure Controls section matching the valve function.
Limited Warranty : Watts Regulator Co. (the “Company”) warrants each product to be free from defects in material and workmanship under normal usage for a period of one year from the date of original shipment. In the event of such defects within the warranty period, the Company will, at its option, replace or recondition the product without charge. THE WARRANTY SET FORTH HEREIN IS GIVEN EXPRESSLY AND IS THE ONLY WARRANTY GIVEN BY THE COMPANY WITH RESPECT TO THE PRODUCT. THE COMPANY MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED. THE COMPANY HEREBY SPECIFICALLY DISCLAIMS ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. The remedy described in the first paragraph of this warranty shall constitute the sole and exclusive remedy for breach of warranty, and the Company shall not be responsible for any incidental, special or consequential damages, including without limitation, lost profits or the cost of repairing or replacing other property which is damaged if this product does not work properly, other costs resulting from labor charges, delays, vandalism, negligence, fouling caused by foreign material, damage from adverse water conditions, chemical, or any other circumstances over which the Company has no control. This warranty shall be invalidated by any abuse, misuse, misapplication, improper installation or improper maintenance or alteration of the product. Some States do not allow limitations on how long an implied warranty lasts, and some States do not allow the exclusion or limitation of incidental or consequential damages. Therefore the above limitations may not apply to you. This Limited Warranty gives you specific legal rights, and you may have other rights that vary from State to State. You should consult applicable state laws to determine your rights. SO FAR AS IS CONSISTENT WITH APPLICABLE STATE LAW, ANY IMPLIED WARRANTIES THAT MAY NOT BE DISCLAIMED, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED IN DURATION TO ONE YEAR FROM THE DATE OF ORIGINAL SHIPMENT.
USA: T:
978-689-6066 • F:
978-975-8350 •
Watts.com
Canada: T: 888-208-8927 • F:
905-481-2316 •
Watts.ca
Latin America: T: (52) 55-4122-0138 • Watts.com
ES-ACV-LFM116 2115
© 2021 Watts
References
Read User Manual Online (PDF format)
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