Febco TK-1 Installation guide

Brand: Febco

Model: TK-1

Type: Installation guide

Designed for operator convenience and rugged reliability in a compact pack-

age. The FEBCO TK-1 offers the latest in gauge technology in a durable

custom-fitted case with room for tools.

Features:

• Lightweightbodyfordurability&chemicalresistance.

• Color-codedvalvesandhosesforeaseofuse.

• Largeanti-parallaxdialwhichindicates descendingmeasurement,

accurate to ± 1 percent of full scale.

• Replaceablehosefilterandvalvestem sealsforfieldreliability.

• Topmounteddrain/purgevalvesandconvenientlylocatedlinepressure

gauge.

• Completekitcontainsgaugewithcolor-codedvalvesandhoses,hose

adapter,shockcordforeasymountingandpurgehoseencasedina

durable case with room for tools.

• Forwardneedlevalvepositionsforeasyaccess.

Specifications:

• Maximumworkingpressure-200psig(13.8bar)

• Maximumworkingtemperature-200°F(93ºC)

• Gauge-4.5"diameterface,dualscale 0-15psidand0-1kg/cm2,±1%

accuracy full scale

• Testvalves-Threeneedlevalves

• Pressuregauge-0-200PSIsystemgauge

• Hoses-Three6footcolor-codedhoseswithfemalethreadedswivel

couplings.

• Adapter-Three

⁄4"x

⁄4"bushings

Three

⁄2"x

⁄4"bushings

Three

⁄8"x

⁄4"bushings

Three

⁄4"Flaredfittings

• Oneshockcord.

• Onemoistureresistantinstructionguide

• Onelightweightdurablecarryingcase

Caution: To avoid freeze damage to the test kit it should be stored in a

dry warm area when not in use.

IS-F-TK-1

INSTALLATION INSTRUCTIONS

Series TK-1

Backflow Preventer Test Kit

Sizes: 2

⁄2" – 10" (65 – 250mm)

TK-1

Bleed Valve B

Bleed Valve A

Connections

Needle Valves

Test No. 1

765 Shown

Test Procedure for Pressure

Type Vacuum Breaker

Note: For both of the following tests the test kit must be held at the same

level as assembly being tested.

A.Beforestartingtestallneedlevalvesandbleedvalvesmustbeclosed.

B.Flushtestcock#2and#1.

Test No. 1 – Air Inlet

Requirement:Airinletmuststarttoopenwhendownstreampressureis

1.0psiorabove.

Step1 Removenutontopofhoodandremovehood.

Step2 InstallhosebetweentestcockNo.2andconnection"A"onhigh

side(red)ontestkit.

Step3 OpentestcockNo.2andneedlevalve"A"highside(red)ontest

kit.

Step4 Openbleedvalve"A"ontopoftestkit.Bleedairfromhose.

 Thenclosebleedvalve"A"ontopoftestkit.

Step5 CloseshutoffvalveNo.2thenshutoffvalveNo.1.

Step6 Slowlyopenneedlevalve"C"bypass(yellow)justasairinlet

 opens.Recorddifferentialpressure.

Step7 ClosetestcockNo.2andremovehose.

Step8 Closeneedlevalve"C"bypass(yellow).

Step9 OpenshutoffvalveNo.1.

Test No. 2 – Test Check Valve Pressure Drop

Requirement:Supplypressuredropmustbe1.0PSIDorabovewhen

waterflowstopsfromtestcockNo.2.

Step10 InstallhosebetweentestcockNo.1andconnection"A"high

 side(red)ontestkit.

Step11 OpentestcockNo.1andbleedvalve"A"ontopoftestkit.

 Openbleedvalve"A"ontopoftestkitandbleedairfromhose.

 Shutoffbleedvalve"A"ontopoftestkit.

Step12 Closeshutoffvalve#1.

Step13 OpentestcockNo.2.WhenflowofwateroutoftestcockNo.

 2stops,thedifferentialreadingisthepressuredroprecord

Step14 ClosetestcockNo.1andtestcockNo.2.

Step15 Replacehoodandnutontopofhood.OpenshutoffvalvesNos.

1then2.

Test No. 2

765 Shown

Bleed Valve A Bleed Valve B

Test Cock No. 2

Test Cock

Bleed Valve A Bleed Valve B

Test Cock No. 2

Test Cock

Test Procedure for Reduced

Pressure Assembly

A. Allneedlevalvesmustbeclosedontestkit.

B. OpentestcockNo.4andflushtestcocksNos.1,2and3onreduced

pressureassemblythenclosetestcockNo.4.

C. Attachhosesasshown.Bleedairfromkit,closeNo.2shutoff.

Test No. 1 - Check Valve No. 2

Purpose:TotestcheckvalveNo.2fortightnessagainstreverseflow.

Requirements: Valve must be tight against reverse flow under all pressure

differentials.

Step1 Slowlyopentheneedlevalve"A"highside(red)and"C"bypass

(yellow).Keepthe"B"low(blue)closed.

Step2 OpentestcockNo.4.OpentestcockNo.2andtestcockNo.3

afteropeningtestcockNo.4.

Step3 Indicatedpressuredifferentialwilldecreaseslightly.Ifpressure

differentialcontinuestodecrease(untiltheventopens)theNo.

2checkvalveisreportedas"leaking".

Test No. 2 - Shutoff Valve No. 2

Purpose:TotestshutoffvalveNo.2fortightness.

Step1 AfterpassingTestNo.1,continuetotestNo.2byclosingtest

cockNo.2.

Step2 Theindicatedpressuredifferentialwilldecreaseslightly.Ifpres-

suredifferentialcontinuestodecrease(approaching"zero")the

No.2shutoffvalveisreportedtobe"leaking".

Note:AleakingNo.2shutoffwillgiveafalsereadingintestsNo.3and4.

Test No. 3 - To test No. 1 Check Valve

Purpose:TotestcheckvalveNo.1fortightness.

Requirements: Valve must be tight against reverse flow under all pressure

differentials.

Step1 Closeneedlevalve"A"highside(red)andopentestcockNo.2.

Step2 ClosetestcockNo.4.Disconnectbypasshose(yellow)attest

cockNo.4.

Step3 Openneedlevalve"B"low(blue)and"C"bypass(yellow),bleed-

ingtoatmosphere,thenclosingneedlevalve"B"(blue)restores

the system to a normal static condition.

Step4 Observethepressuredifferentialgauge.Ifthereisadecreasein

theindicatedvalue,theNo.1checkvalveisreportedas"leaking"

Test No. 4 - Pressure Differential Relief Valve

Purpose: To test operation of pressure differential relief valve.

Requirements: The pressure differential relief valve must operate to main-

tainthe"zone"betweenthetwocheckvalvesatleast2psi(14kPa)less

than the supply pressure.

Step1 Closeneedlevalve"C"bypass(yellow).

Step2 Openneedlevalve"A"highside(red).

Step3 Openneedlevalve"B"low(blue)veryslowlyuntilthedifferential

gauge needle starts to drop.

Step4 Holdthevalveatthispositionandobservethegaugereading

at the moment the first discharge is noted from the relief valve.

Recordthisastheopeningdifferentialpressureoftherelief

valve.Note:itisimportantthatthedifferentialgaugeneedle

drops slowly.

Step5 ClosetestcocksNos.2and3.Removehosefromtestcocks

Nos.2and3.

Step6 Usebypasshose(yellow)torelievepressurefromtestkitby

openingneedlevalve"A","B"and"C"andbleedvalves"A"and

“B”.

Step7 RemovealltestequipmentandopenNo.2shutoffvalveofthe

device.

Bleed Valve A

Bleed Valve B

High

(red)

Bypass

(yellow)

Low

(blue)

860 Shown

MAINTENANCE MANUAL

Test Procedure for Double

Check Valve Assembly

A. Beforestartingtest,allneedlevalvesandbleedvalvesontestkitmust

be closed.

B. Flush test cocks before test.

NOTE:Supplypressuregaugereadingwilldecreasewhenperformingthis

test procedure.

Test No. 1 - Check Valve No. 1

NOTE:Closeallneedlevalve"A","B"and"C"andbleedvalve"A"and"B"on

test kit.

Step1 InsureshutoffNo.1isopen,shutoffNo.2isclosed.

Step2 Installhighsidehosebetweenconnection"A"highsideandtest

cockNo.3,lowsidehosebetween"B"lowsideandtestcock

No.2andopenbothtestcockNo.2and3.

Step3 Openbleedvalve"A"tobleedairfromthehighside.Close

 "A"thenopenbleedvalve"B"tobleedlowside.Close"B".

Step4 Connectbypasshosebetweenconnection"C"bypassand

looselytotestcockNo.1.Openneedlevalves"A"highsideand

"C"bypasstoventairfrombypasshose.Tightenbypasshoseat

testcockNo.1,opentestcockNo.1.

Step5 CloseshutoffNo.1.Slowlyopenbleed"B"untildifferential

 gaugerisesto2psiandclose.Ifthedifferentialreadingdoes

 notdecrease,recordcheckvalveas"tight".

Step6 Closealltestcocksandopenbleedvalves"A"and"B".Then

closeneedlevalves"A","B"and"C"andbleedvalves"A"and"B".

Removehosesfromtestcocks.

Test No. 2 - Check Valve No. 2

Step7 MovethehighsidehosetotestcockNo.4,lowsidehoseto

testcockNo.3andopenbothtestcockNo.3and4.Remove

bypasshosefromtestcockNo.1,openshutoffvalveNo.1.

Step8 Openbleedvalve"A"tobleedairfromthehighside.Close

bleed"A"thenopenbleed"B"tobleedlowside.Closebleed"B".

Step9 ConnectbypasshoselooselytotestcockNo.1.Openneedle

valves"A"highsideand"C"bypasstoventairfromthebypasshose.

TightenbypasshoseattestcockNo.1,opentestcockNo.1.

Step10 CloseshutoffNo.1,thenslowlyopenbleed"B"untildifferential

gaugerisesto2PSIandclose.Ifthedifferentialreadingdoes

notdecrease,recordcheckastight.Closealltestcocksand

removehoses.Openbleedvalves"A"and"B".Restorevalveto

original working condition.

NOTE: The assembly will fail both the first and second check

valvetestsabove,ifshutoffNo.2leaksexcessively.Totestfor

aleakyNo.2shutoff,usethefollowingprocedure.

Test for Leaky No. 2 Shutoff

Step11 ConnectthehighsidehosetotestcockNo.1,lowsidehose

totestcockNo.4.OpentestcocksNo.1and4.Closeshutoffs

No.1and2.

Step12 Closeneedlevalve"C"bypass.Openneedlevalve"A"highside,

thenopenneedlevalve"B"lowsideoneturn,loosenhoseat

testcockNo.4toremoveair.Retightenhose.

Step13 Ifthedifferentialgaugerisesabove0thereisexcessiveleakage

atshutoffNo.2anditmustbereplacedtotesttheassembly.

Bleed Valve A

Bleed Valve B

High

(red)

Bypass

(yellow)

Low

(blue)

850 Shown

A Division of Watts Water Technologies, Inc.

USA: 4381 N. Brawley • Ste. 102 • Fresno, CA • 93722 • Tel. (559) 441-5300 • Fax: (559) 441-5301 • www.FEBCOonline.com

Canada: 5435 North Service Rd. • Burlington, ONT. • L7L 5H7 • Tel. (905) 332-4090 • Fax: (905) 332-7068 • www.FEBCOonline.ca

Limited Warranty: FEBCO 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.