WATTS LFM6113-19 Pump Control Control Valve Instruction Manual

WATTS LFM6113-19 Pump Control Control Valve

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.
• Local building or plumbing codes may require modifica-tions 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.
• 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.

Standard Components

1. – Main Valve (M100 – Single Chamber)
2. – Pressure Sustaining Control
3.  – Model 22 Accelerator Control
4.  – Limit Switch
5. – 3-Way Solenoid
6.  – Check Valve
7.  – Adjustable Opening Speed
8. – Adjustable Closing Speed
   • X – Isolation Cocks
   • Y – Y-Strainer

Operation

the Pump Control Valve with Backpressure Feature is designed to minimize the surges associated with the starting and stopping of pumps. The valve slowly opens and closes as required to control pumping related surges, and throttles to maintain a minimum back-pressure against the pump during the pumping cycle. The pump starts and stops against a closed valve.

Pump Start Up: When the pump is signaled to start, the 3-Way Solenoid is energized, directing pressure into the cover chamber of the 3-way Accelerator Pilot. The Accelerator Pilot allows the main valve cover chamber to be vented downstream, causing the valve to open at a controlled rate, gradually admitting pumping pressure into the distribution system. The rate of opening is controlled by the adjustable opening speed control, which restricts the speed of fluid and pressure evacuating the main valve cover chamber. The valve remains open during the pumping cycle.

Backpressure Feature: During the pumping cycle, the valve acts as a Backpressure Control Valve. When pump discharge pressure falls below an adjustable minimum, the valve modulates toward a closed position, increasing backpressure against the pump. Throttling (Backpressure) action is controlled by a normally closed control pilot designed to: 1) Open (allowing fluid out of the main valve cover cham-ber) when pump discharge pressure is above the adjustable setpoint, and, 2) Close (allowing fluid to fill the main valve cover chamber through the integral orifice of the Accelerator Pilot) when pump dis-charge pressure is below the adjustable setpoint. An increase in pump discharge pressure causes the valve to modulate toward an open position. A decrease in pump discharge pressure causes the valve to modulate toward a closed position.

Pump Shutdown: When the pump is signaled to turn off, the 3-Way Solenoid is de-energized, venting the cover chamber of the 3-way Accelerator Pilot. The Accelerator Pilot allows the main valve cover chamber to be connected to upstream pressure, causing the valve to close at a controlled rate. The valve slowly begins to close while the pump continues to operate. The closing rate of the valve is controlled by the adjustable closing speed control, which restricts the speed of fluid and pressure entering the main valve cover chamber. When the valve reaches the closed position, the limit switch is actuated, turning the pump off.

Hydraulic Check Feature: When the pump is turned off and down-stream pressure is greater than upstream pressure, downstream pres-sure is admitted to the main valve cover chamber through a check valve in the pilot control system, closing the valve, preventing reversal of flow.

Manual Operation: Engaging the Solenoid Manual operator simulates power to the solenoid, manually opening the main valve. Disengaging the Solenoid Manual operator returns the valve to the closed position.

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.

1. Prior to installation, flush line to remove debris.
2. Install valve so the flow arrow matches flow through the line, and gauges to monitor valve inlet and outlet pressures.
3. Install isolation valves upstream and downstream of the main valve.
4. Provide adequate clearance for valve servicing and maintenance. Refer to valve servicing dimensions on next page. Avoid installing valves 6″ and larger in the vertical position (main valve stem horizontal). Automatic Control Valves (ACVs) are designed for horizontal in-line instal-lation, with the cover facing up (main valve stem vertical). Slow operation or premature stem and guide wear may occur if valve is not installed according to factory recommendations. Consult factory for detailed engineering review prior to ordering if valve is to be installed other than horizontally in-line.
5. If valve is equipped with a pilot control system, extra precautions should be made during installation to protect the piping circuit from dam-age. Only remove the pilot control system from the valve if necessary. Tubing and fittings should be kept clean and replaced exactly as removed. Consult appropriate hydraulic schematic to ensure proper re-assembly.
6. Connect solenoid wiring leads to desired switching device, using safe, standard electrical practices.
7. Install a pressure gauge at a location upstream of the valve.
8. After installation, vent entrapped air from valve cover and pilot system by following instructions on Technical Bulletin.

Valve Servicing Dimensions

Globe

Angle

Commissioning the Booster Pump Control Valve

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 during while adjusting the other controls.
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, 1½ to 2½ turns from full closed position.
3-Way Solenoid – Confirm that the manual operator is turn counter clockwise to a full OUT position (See Figure 1).
STEP 2
Energize the solenoid to check actuation and to confirm connec-tion to power source.
STEP 3
De-energize the solenoid prior to initial pump start.
STEP 4
Loosen a tube fitting or cover plug at the main valve to allow air to vent during start-up.
STEP 5
Energize the solenoid at pump start to open the main valve, checking that the main valve opens. Air is vented through the loosened fitting. Tighten the fitting when liquid begins to vent.

STEP 6
Opening Speed Flow Control Adjustment: The Opening speed needle valve restricts flow out of the cover of the main valve. If the main valve is opening too slowly turn the adjustment screw OUT, counterclockwise, increasing the rate of opening (See Figure 2B). If the main valve is opening too quickly, turn the adjustment screw IN, clockwise, decreasing the rate of opening (See Figure 2A). Setting the Sustaining Control

STEP 7
Setting the Sustaining Control requires lowering the upstream pressure to the desired minimum sustained pressure.
STEP 8
Leave the downstream isolation valve full open and close the upstream isolation valve until the inlet pressure drops to the desired setting.
STEP 9
Adjust the Sustaining Control screw IN, clockwise, until the inlet pressure begins to increase (See Figure 3A), or OUT, counter-clockwise, to decrease (See Figure 3B), stopping at the desired pressure.

STEP 10
Allow pressure to stabilize.
STEP 11
Fine-tune the sustaining setting as required as detailed in STEP 8.
STEP 12
Open upstream isolation valve to return to normal operation.
STEP 12
De-energize solenoid to check that the main valve closes.
STEP 13
At valve closure booster pump will stop. Adjust limit switch collar to final position to ensure positive actuation of limit switch elec-trical contact, if necessary, by sliding up/down to location

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: The valve cannot be serviced under pressure. Upstream and downstream Isolation Valves must be installed to protect system piping. Accurate diagnosis and trouble-shooting 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 cover chamber pressure. If included, a POSITION INDICATOR should be installed to visually assess the position of the disc & diaphragm assembly.

Test 1: Diaphragm Seal Test

1. 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.
2. 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 tighten disc & diaphragm assembly.

Test 2: Seat Seal Test

1. Close downstream isolation valve and install pressure gauges on an open inlet and outlet port of main valve.
2. Open upstream isolation valve to allow pressure on to the valve cover. Allow valve to fully close.
3. 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.
   •  If gauge pressure rises to match outlet pressure (down-stream 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

1. Close upstream and downstream isolation valves. Install valve position indicator.
2. 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.
3. Isolate cover chamber from receiving fluid and pressure by closing isolation valves or removing control tubing.
4. 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.
   • The disc & diaphragm assembly may momentarily “hesi-tate” 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.
   •  A continuous discharge of water from the cover chamber after venting to atmosphere indicates leakage past the diaphragm.
5. If necessary, disassemble valve and inspect/repair disc & diaphragm assembly.

Troubleshooting Guide

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.|
Improperly configured opening speed control.| Adjust opening speed control to verify functionality, adjust as required.| Standard setting for open- ing speed control is 1 1/2

– 2 1/2 turns open from full closed position. Can be adjusted in field.

Pressure Sustaining Control not oper- able| Rebuild or replace Pressure Sustaining Control|
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/re- pair seat if required.|
Improperly configured closing speed control.| Adjust closing speed control to verify functionality, adjust as required.| Standard setting for closing speed control is

11/2 – 21/2 turns open from full closed position. Can

be adjusted in field.

Solenoid will not actuate| Possible Cause: Low or no voltage| Check voltage at the solenoid connection, insuring that it has the minimum of 85% of the coils rated voltage.| Should be performed by licensed electrician
Manual operated is engaged| Turn manual operator counter- clockwise to disengage|

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.

1. Isolate the valve from line pressure and depressurize it to ensure safe working conditions. Disconnect any electrical connections if so equipped.
2. 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.
3. 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, pic-tured above.
   • 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.
4. Remove the Disc and Diaphragm Assembly from the valve body by lifting straight up.
   •  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.
5.  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.
6. 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.
7. 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 5) (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 6).
   Table 1: Seat Removal Tool Dimension
   Size| A| B| C| D| E (Dia.)| F
   ---|---|---|---|---|---|---
   in| Pipe Size (in)| Min. Length (in)| in| in| in| in
   11/4| 1| 3.12| 0.38| 0.25| 0.44| 0.55
   11/2| 1| 3.12| 0.38| 0.25| 0.44| 0.50
   2| 11/4| 3.38| 0.38| 0.25| 0.44| 0.50
   21/2| 2| 4.0| 0.38| 0.38| 0.56| 0.62
   3| 21/2| 4.5| 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
8. 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)| 11/4| 11/2| 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

9. 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.
10. 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.
11. Test the integrity of the Seat Seal by following the Seat Seal Test procedure in previous section.
12. Return valve to service by following instructions on the Technical Bulletin matching the valve function.

ACV Assembly Diagram – Series LFM113-19

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.

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

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