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Febco 825Y

Operation and Maintenance Manual Reduced Pressure Backflow Prevention Assemblies

MODELS 825y, 825ya, 825, 825d, 825yd & 826yd

Read and understand this manual
prior to installing, operating or servicing this equipment.

SPX Process Equipment reserves the right to incorporate our latest design and material changes without notice or obligation. Design features, materials of construction and dimensional data, as described in this bulletin, are provided for your information only and should not be relied upon unless confirmed in writing. Certified drawings are available upon request.

3816 South Willow Avenue Fresno, California 93725

Telephone 559-441-5300 Fax 559-441-5301

E-Mail: febco@processequipment.spx.com Web Site: www.spxpe.com

MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD

Table of Contents

Warranty . . .
How To Order Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Features and Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation Guidelines. . . . . . .
Freeze Protection Procedures
Vandalism Protection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Service Procedures. .
Trouble Shooting Procedures and Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Field Testing Procedures
Service Procedures Model 825Y (3/4–2") . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Lists and Part Numbers Model 825Y (3/4–2"). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exploded View of Model 825Y (3/4–2") . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Procedures Models 825, 825D and 825YD (21/2–3") . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Procedures Models 825, 825D and 825YD (4–10"). . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Lists and Part Numbers Model 825 (21/2–10”). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exploded View of Model 825 (21/2–10") . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Lists and Part Numbers Models 825D and 825YD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exploded View Models 825D and 825YD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts List and Exploded View of Model 825D and 825YD Check Assembly. . . . . . . . . . . . . . . Parts List and Exploded View of Model 825 and 825D Relief Valve . . . . . ................ Parts List and Exploded View of Model 825YD Relief Valve. . . . . . . . . . . . ................ Parts List and Exploded View of Model 826YD Relief Valve and Bypass . ................ Service Procedure Relief Valve Models 825, 825D and 825YD (21/2–10") . ................ Spring Removal Tool Instructions Model 825 (21/2–10"). . . . . . . . . . . . . . . ................ Commercially Available Parts Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................

Inside Front Inside Front

Cover Cover .. . . 5 6 7 .. . . 8 9 11 13 16 18 18 20 22 24 24 25 26 27 28 29 30 32 33 36

...... .

...... . . . . . . . .

...... . ...... . ...... . ...... . ...... . ...... . ...... . . . . . . . . ...... . ...... . ...... . ...... . ...... . ...... . ...... . ...... .

.. .

.. . . . .

14, . .. .. . . .. .. . .. . . .. . . . .. . . .. .. . . .. . .. .. . . .. 34,

10, 12, 15, 17, .. . 19, 21, 23, .. . . . . .. . .. . .. . .. . .. . 31, .. . 35,

3

MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD

SPX Process Equipment Limited Product Warranty

1. Limited Warranty. SPX Corporation (“SPX”) warrants equipment and parts manufactured by it and supplied hereunder to be free from defects in materials and workmanship for a period of twelve (12) months after shipment (or installation, if by SPX). SPX warrants any service performed for the Buyer hereunder to be free from defects in workmanship for a period of twelve (12) months from the date of service. THIS IS SPX’S ONLY WARRANTY. SPX MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. No employee or agent of SPX is authorized to make any warranty other than that which is specifically set forth herein. The provisions in any specification, brochure or chart issued by SPX are descriptive only and are not warranties. In no event shall SPX be liable for breach of warranty or otherwise in any manner whatsoever for: (i) normal wear and tear; (ii) corrosion, abrasion or erosion; (iii) any equipment, parts, software or services which, following delivery or per- formance by SPX, has been subjected to accident, abuse, misapplication, improper repair, alteration, improper installation or maintenance, neglect, or excessive operating conditions; (iv) defects resulting from Buyer’s specifications or designs or those of its contractors or subcontractors other than SPX; or (v) defects resulting from the manufacture, distribution, promotion or sale of Buyer’s own products. Buyer waives this limited warranty if Buyer fails to install and operate the equipment or part according to SPX instructions, or if someone not authorized by SPX attempts to repair or modify the equipment or part, including the attachment of any actuator.

2. Exclusive Remedy for Breach of Warranty. If within such period any such equipment, parts or services shall be proved to SPX’s satisfaction to be defective, such equipment or parts shall be repaired or replaced at SPX’s option, and defective services shall be corrected. This is Buyer’s sole remedy. All removal and installation of equipment or parts shall be at Buyer’s expense. SPX’s obligation: (i) shall be limited to such repair or replacement, F.O.B. its factory, (ii) shall be conditioned upon SPX receiving written notice of any alleged defect within ten (10) days after its discovery and, at SPX’s option, return of such equipment or parts prepaid to its factory, and (iii) shall not be enforceable until Buyer has paid SPX in full for all goods and services. SPX may in its sole discretion elect to perform warranty work at the site of the equipment or parts, and if so elected, Buyer shall provide reasonable access and facilities for SPX to perform such warranty work.

3. Software Warranty. SPX warrants that any software sold or provided by SPX will, when properly installed, execute its programmed instructions. SPX does not warrant that software will operate uninterrupted or error free.

4. Warranty for Third Party Products. With respect to equipment and parts not manufactured by SPX, the warranty obligations of SPX shall in all respects conform and be limited to the warranty extended to SPX by the supplier. SPX’s obligation and liability with respect to such warranty shall be limited to the amount received by SPX from the Buyer on account of such specific equipment or parts. Buyer agrees that if equipment and parts sold hereunder are resold by Buyer, Buyer will include in the contract for resale provisions which limit recoveries against SPX in accordance with this contract. In case of Buyer’s failure to include in any such contract for resale the terms providing for such limitations, Buyer shall indemnify and hold SPX harmless against any liability, loss, cost, damage, or expense (including reasonable attorney’s fees) arising out of or resulting from such failure.

5. Limitation of Liability. In no event will SPX be liable for any indirect, incidental, special, consequential, punitive or similar damages including, but not limited to, lost profits, loss of data or business interruption losses. In no event will the total, aggregate liability of SPX under this agreement exceed the contract price for the equipment, parts, software and/or services for which liability is claimed. The liability limitations shall apply even if SPX has been notified of the possibility or likelihood of such damages occurring and regardless of the form of action, whether in contract, negligence, strict liability, tort, products liability or otherwise. The parties agree that these limits of liability shall survive and continue in full force and effect despite any termination or expiration of the contract between SPX and buyer. Any action by buyer against SPX must be commenced within one year after the cause of action has accrued. (3268995v2 — 19915/093237Revision Date: 12/1/2003)

How to Order Repair Parts

1) Locate item number and kit number in this maintenance manual.

2) Verify the size of the valve the parts are to be used on.

3) Provide full model number. On large assemblies (21/2–10"), the model number is located on the name plate. On small assemblies (3/4–2"), the model number is cast on the body.

  1. 4)  Identify the "type" code on 21/2–10" size valves (Ductile Iron bodies use Type D or YD code on name plate).

  2. 5)  Give part number. Provide new part number if appropriate.

  3. 6)  A serial number (located on the I.D. plate) will assist in ordering the proper kits.

  4. 7)  Some parts are sold only in kit form.

©SPX Process Equipment, April 2005

MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD

Feature and Operating Procedures

Reduced Pressure Backflow

Preventer

FEBCO manufactures several models of Reduced Pres- sure Backflow preventers. The Model 825Y and 825YA are available in sizes 3/4–2" with bronze body and cover as standard. Other materials are available. The FEBCO Model 825 sizes 21/2–10" were manufactured with cast iron. The FEBCO Model 825 Type D and 825 Type YD sizes 21/2"–10" are manufactured with standard body material of ductile iron.

The FEBCO Reduced Pressure Backflow preventer assem- bly consists of two independently operating, spring loaded check valves with a pressure differential relief valve located between the two checks. The pressure drop across the first check valve is approximately 6.0 PSID with no flow. The relief valve consists of a hydraulically balanced diaphragm

with the high pressure side hydraulically connected to the upstream side of the first check. The low pressure side is hydraulically connected to the reduced pressure zone, thus the relief valve remains closed during normal operation. The low pressure side of the diaphragm is spring loaded to force the relief valve open when the pressure drop across the first check (and across the diaphragm) reduces to ap- proximately 2.5 PSID. A complete assembly includes two shut-off valves and four test cocks.

Example sectional views below show typical com- ponents and flow passages with correspond- ing pressure readings (no flow conditions) at the various locations within the assembly.

Model 825Y (3/4–2")

Figure No. 1

Model 825YD (21/2–10")

Figure No. 2

First Check

Inlet Shut-Off

Inlet Shut-Off

Outlet Shut-Off

100 PSI

94 PSI

*Relief Valve
Rotated 90o for Clarity

First Check

Second Check

93 PSI

100 PSI

94 PSI

93 PSI

Second Check

Relief Valve*

*Relief Valve
Rotated 90o for Clarity

Outlet Shut-Off

Reduced Pressure Zone

Relief Valve*

5

6

MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD

Installation Guidelines

Proper installation of the assembly is essential to the protection of the water supply

  1. The assembly should be installed in a horizontal position with a minimum clearance of 12" be- tween the relief valve discharge port and floor or grade, and a minimum of 18" horizontal clearance around the unit for access and ease of testing and maintenance of the relief valve.

  2. Approval agencies do not recommend installation of a Reduced Pressure Assembly in a pit. Flooding of the pit can result in cross connection contamination. If local codes permit installation of a Reduced Pressure As- sembly in a pit, adequate drainage must be provided to prevent the pit from flooding under maximum discharge conditions.

  3. Placement of the assembly should be planned where water discharged from the relief port will not be objection- able or cause damage to property and/or equipment.

  4. To be approved by the University of Southern California Foundation for Cross-Connection Control and Hydrau- lic Research (USC), the assembly must be purchased and installed with resilient seated shut-offs to ensure bubble tight closure for more consistent results during testing. CAUTION: Open and close resilient seated shut-offs slowly to prevent water hammer damage to the system and assembly.

  5. Since the FEBCO Reduced Pressure Assembly is de- signed to be serviced while in line, the unit need not be removed from the line during servicing.

  6. Ensure the supply water pressure does not exceed the manufacturer’s maximum water pressure rating of the assembly to avoid damage to the system or the assem- bly caused by system pressure. In addition, protection must be provided against thermal water expansion, extreme backpressure and/or water hammer.

  7. Most field problems occur because dirt or debris present in the system at the time of installation becomes trapped in the first check seating area resulting in continuous discharge from the relief valve in a static or backflow condition. THE SYS- TEM SHOULD BE FLUSHED BEFORE THE AS- SEMBLY IS INSTALLED. However, to effectively flush the system after the assembly has been installed, remove the internal components of both checks and open the inlet shut-off to allow water to flow for a sufficient time to flush debris from the line and assembly. If debris In the water system continues to cause fouling, a strainer can be installed upstream of the assembly.

Typical Installations

Flow
Wye Strainer

Figure No. 3

Flow

30" Max. 12" Min.

Figure No. 4

Air Gap Drain Drain Support

Maintain approved air gap distance

Support 3" and Larger

INDOOR INSTALLATION

Air Gap Drain

MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD

Freeze Protection Procedure

The reduced pressure backflow prevention assembly is subject to damage if the internal water is allowed to freeze. It is suggested that all assemblies be in- stalled with resilient seated shut-offs so that a drip tight closure can be achieved to prevent refilling of the assembly after the freeze protection procedure is performed. The unit must be protected from freezing by a heated enclosure, draining, insulation using heat tape, or other suitable means. However, the unit must always be accessible for testing and maintenance. If the sys-

5b.Open the ball valve approximately 45 degrees while draining the pipeline and assembly to allow water be- tween the ball and valve body to drain. Leave the ball valve in this position for the winter to prevent freeze damage.

5c.The ball valves must be fully closed before the system is repressurized. OPEN AND CLOSE BALL VALVES SLOWLY TO PREVENT DAMAGE TO THE SYSTEM CAUSED BY WATER HAMMER.

Model 825, 825D and 825YD (21/2–10")
Reduced Pressure Zone and Relief Valve Freeze Protection

  1. Slowly close supply valve within freeze protected area, open air bleed valves on No. #1 check valve and relief valve (3 places), and open No. #2 and #3 test cocks. Water within the zone will be drained to the lowest point of the relief valve discharge port (relief valve seat). A minor amount of water will remain in the bottom of the valve body, but this is not sufficient to cause freezing damage.

  2. With this procedure, about one-half of the relief valve will be drained. To drain the relief valve on Models 825 and 825D, loosen the relief valve cover bolts and allow the relief valve to drain. Retighten bolts before repressurizing system. To drain relief valve on Models 825YD, open the two air bleeds (one on the body, the other on the cover), then remove drain plugs. Replace drain plugs before repressurizing system.

  3. The system design must provide a means for draining upstream of the #1 check valve and downstream of the #2 check valve. Test cocks #1, #2, and #4 and the air bleed valve on #2 check valve may be opened to allow air to enter to assist in draining. Depending on system design, these sections should be able to be drained to the pipe centerline.

  4. Position the assembly shut-off valves and test cocks in the half open/half closed position to allow com- plete draining of the assembly shut-off valve bodies and test cocks.

  5. Some units contain a drain plug in the bottom of the second check body. Open test cocks and re- move plug to drain.

tem will be shut down during freezing weather, use the following procedure to drain internal passages.

The Model 825YA can be removed from the line as a winterizing pro- cedure. See Figure 5 for proper ball valve procedure.

Figure No. 5

Model 825Y (3/4–2") Reduced Pressure Zone and

Relief Valve Freeze Protection

1. Slowly close the main shut-off valve upstream of the assembly, which provides water to the system.

2. Drain system water upstream of the first check by means other than through the assembly.

Check Valve Draining Procedure

3a. First check (zone) Open #2 and #3 test cocks. All water between the first and second check valves will drain through the relief valve port.

3b.Second check (downstream)—Remove the second check cap, spring and disc holder. All water down- stream of the second check (that is higher than the outlet shut-off valve) will drain through the body.

Relief Valve Draining Procedure

4a. If device is equipped with optional drain plugs, remove plugs in the relief valve cover and body. Open #2 and #3 test cocks. All water will drain through plug holes.

4b. For standard models (not equipped with optional drain plugs) loosen the relief valve cover and allow water to drain from both sides of the diaphragm.

Ball Valve Shut-Off Draining Procedure

5a.If the assembly has been installed with ball valve shut-off valves, they must also be properly drained to prevent freeze damage. After draining procedure has been completed on the backflow prevention assembly, position all ball valve shut-offs and test cocks in a half open/half closed (45 degree) position. (see Figure 5)

7

MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD

Vandalism Protection Procedure

1. If the unit is installed where vandalism may be a prob- lem, the assembly should be protected and secured. On 3/4–2" units the handles of shut-off valves can be removed to discourage tampering. On 21/2–10" units a chain can be looped between shut-offs and locked in position to prevent tampering with shut-off valves. Test cock handles can also be removed. On backflow prevention assemblies installed in conjunction with fire sprinkler systems, an alarm can be placed on the OS&Y shut-off valves that will sound if unauthorized closure should occur.

2. A protective cage can be installed over the unit to discourage vandals. If a cage is used, it should be installed so that adequate clearance is available for maintenance and testing or it should be completely removable. Also allow for any discharge from the relief valve to fully drain from the protective cage.

3. Some units include screw driver adjusted test cocks for vandal resistance.

8

MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD

General Service Procedures

General Service Instructions applicable to all models and sizes.

  1. FEBCO backflow prevention assemblies can be ser- viced with commonly available tools and are designed for ease of maintenance. The assemblies are designed to be serviced in line, so the unit should not need to be removed from the line during servicing.

  2. The most common cause of check fouling and relief valve discharge is dirt and debris in the seating areas.

    The line should be flushed clean of debris before instal- lation of the assembly. To flush the line after installation of the assembly, slowly close the inlet shut-off valve, remove the covers and internal assemblies of both check valves and open the inlet shut-off valve to allow sufficient flow of water through the assembly to clear all sand, debris, etc. from the line. If debris in the water continues to cause fouling, a strainer may be installed upstream of the assembly.

  3. Rinse all parts with clean water before reassembly.

  4. Do not use any petroleum based oil, grease, solvent or pipe dope on any parts unless instructed to do so. Use only water resistant lubricants that comply with FDA requirements for use in potable water systems.

  5. Carefully inspect diaphragms, seals and seating surfaces for damage or debris. If the check valve seat disc has been severely cut at the seat ring diameter, the assembly has been subjected to extremely high and re- peated back pressure. Either thermal water expansion or water hammer are the most likely causes. If back pressure persists, consider installation of a pressure relief valve downstream of the assembly.

  6. Use caution to avoid damaging any guiding sur- faces while handling parts. Do not force parts to- gether. The o-ring seals used in FEBCO assemblies require only a small tightening force to ensure a positive seal.

  7. Test unit after servicing to ensure proper operation.

8. Refer to applicable parts list and figures for visual aid information

Figure No. 6

Suggested Tool Kits

Model 825Y (3/4–2")

•1 Crescent wrench ( 10")
•1 Medium Phillips screwdriver
•1 Medium straight blade screw driver •Allen head wrench (3/16" & 1/4" size) •1 Thin blade knife or reamer
•1 Socket (1/2" and 9/16" size) •Differential pressure test kit
•FDA approved lubricant
•Needle nose pliers

Model 825, 825D and 825YD (21/2–10")

•1 Crescent wrench (12")
•1 Medium Phillips screw driver
•1 Medium straight blade screw driver •1 Set of drive sockets (3/8" or 1/2")
•1 Spring removal tool (see page 33) •1 Torque wrench
•Differential pressure test kit
•FDA approved lubricant

9

MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD

Trouble Shooting Procedure

With Differential Pressure Gauge

SYMPTOM NO. 1:
Check Differential Across No. 1 Check Valve

READING

PROBLEM

2 to 3 PSID

Leak in No. 1 or No. 2 check valve

6 to 8 PSID and steady

Malfunctioning pressure relief valve

2 to 7 PSID fluctuating

Inlet pressure fluctuating

Without Differential Pressure Gauge

SYMPTOMS NO. 1 and NO. 2:

A) Close Gate Valve No. 2

RESULT

PROBLEM

If discharge stops

Leak in No. 2 check valve

If discharge does not stop

Go to "B"

B) Open No. 4 testcock to produce a flow greater than differential relief valve discharge

RESULT

PROBLEM

If discharge stops

Leak in No. 1 check valve

If discharge does not stop

Malfunctioning pressure relief valve

With Differential Pressure Gauge

SYMPTOM NO. 2:
Check Differential Across No. 1 Check Valve

READING

PROBLEM

2 to 3 PSID

Leak in No. 1 or No. 2 check valve

6 to 8 PSID and steady

Malfunctioning pressure relief valve

Trouble Shooting Guide

Symptom:

Cause:

Solution:

1. Continuous discharge from relief valve dur- ing NO-FLOW condition (discharge stops with water flow).

With this symptom, the pressure drop across the No. 1 check valve would be 2 to 3 PSID.

If a flow of water (more than the discharge) is created through the valve, the pressure drop should increase to approximately 7 PSID.

a. Debris fouling No. 1 check valve.

a. Inspect and clean.

b. Outlet pressure higher than inlet pressure and debris fouling No. 2 check valve.

b. Inspect and clean.

c. Disc holder/stem not moving freely in guide(s).

c. Inspect for dirt or other foreign material.

d. Damaged seat or seat disc.

d. Inspect and replace. Seat disc can be reversed.

e. Leakage at o-ring on the seat ring or disc holder/stem (825, 825D, 825YD).

e. Inspect and replace o-ring.

f. Leakage under seat disc due to dirt or damage disc holder or disc.

f. Inspect and replace or repair.

g. Leakage through diaphragm due to stretched holes or cut (825 & 835YD).

g. Inspect and replace diaphragm.

2. Intermittent discharge from relief valve during NO-FLOW condition. With this symptom, the pressure drop across the No. 1 check valve would be varying from about 2 to 7 PSID.

a. Inlet line pressure variations causing relief valve to discharge:

a. Elimate or reduce pressure variations.

b. Pressure surges (water hammer) causing relief valve to discharge as pressure wave passes through "ZONE."

b. Eliminate or reduce pressure surges.

3. Continuous discharge from relief valve dur- ing FLOW and NO-FLOW conditions.

With this symptom, the pressure drop across the No. 1 check valve would be 7 PSID or more at all times.

a. Seat disc dislodged from cavity in the in the main stem (this can be caused by pressure surges during initial filing of system lines.)

a. Reposition disc in main stem cavity. Repressurize system slowly.

b. Debris fouling the relief valve seat.

b. Inspect and clean.

c. Debris fouling the relief valve seat passage.

c. Inspect and clean.

d. Dirt or scaling jamming main stem or spring button.

d. Inspect and clean or replace.

e. Leakage at main stem or o-ring/ diaphram.

e. Inspect and clean or replace o-ring and/ or main stem.

f. Jammed main stem due to excessive torque on center bolt (825 and 825D).

f. Do not exceed 15 inch-pound torque on main stem center bolt.

10

MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD

Trouble Shooting Guide (Continued)

Symptom:

Cause:

Solution:

4. Relief valve does not open above 2.0 PSID during field testing.

a. Outlet gate valve not closed completely.

a. Check for debris blocking gate.

b. Plugged low pressure hydraulic passage (from “ZONE” to inner diaphragm).

b. Inspect and clean.

c. Improper alignment of internal parts during reassembly (causing high resistance to movement).

c. Disassemble and center the button, spring and main stem.

d. Jammed main stem due to excessive torque on center bolt (825 and 825D only).

d. Do not exceed 15 inch-pound torque on main stem center bolt.

5. First check pressure drop is low (less than 5 PSID) during field testing.

a. Debris fouling first check seat.

a. Inspect and clean.

b. Debris fouling second check seat with backpressure.

b. Inspect and clean.

c. Inlet pressure variations causing inaccurate gauge reading.

c. Eliminate pressure variations.

d. Disc holder not perpendicular to stem (therefore, disc not parallel to seat ring) (825, 825D and 825YD).

d. Inspect and reassemble if required. NOTE: SPRING MUST BE
REMOVED WHEN TIGHTENING DISC HOLDER TO STEM.

e. Damaged seat or seat disc.

e. Inspect and replace as required.

f. Worn guide, bushings or stem.

f. Inspect and replace as required.

g. Guide not properly seated in cover (825, 825D and 825YD only).

g. Inspect and reassemble.

6. Discharge from drain hole in relief valve spacer (825 and 825D only).

a. Leakage under diaphragm retaining screw (8 places).

a. Apply thin layer of sealant around each thread, insert on bottom and reassemble.

b. Leakage under diaphragm at main stem diameter.

b. Apply thin layer of sealant
on button at the main stem
diameter. DO NOT EXCEED 15 INCH POUNDS when tightening center bolt.

c. Hole in diaphragm.

c. Replace diaphragm with fabric side towards the button.

7. Second check fails to hold back pressure during field testing.

a. Outlet gate valve not closed completely.

a. Check for debris blocking gate.

b. Debris fouling second check seat.

b. Inspect and clean.

c. Disc holder/stem not moving freely in guide(s).

c. Inspect for dirt or other foreign material.

d. Disc holder not perpendicular to stem (therefore, disc not parallel to seat ring) (825, 825D & 825YD).

d. Inspect and reassemble if required. NOTE: SPRING MUST BE
REMOVED WHEN TIGHTENING DISC HOLDER TO STEM.

e. Damaged seat or seat disc.

e. Inspect and replace as required.

f. Worn guide, bushings or stem.

f. Inspect and replace as required.

g. Guide not properly seated in cover (825, 825D & 825YD only).

g. Inspect and reassemble.

NOTE: If check valve seat disc has been severely cut at the seat ring diameter, the assembly is being subject to extremely high and repeated back pressure. Either thermal water expansion or water hammer are the most likely causes.

11

MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD

Field Testing Procedures

Purpose of Test

To test the operation of the DIFFERENTIAL PRESSURE RELIEF VALVE and CHECK VALVE.

Equipment Required for Test

Differential Pressure Gauge test kit. Equal to the RPTK1 (shown on page 13).

Test Differential Relief Valve

The Differential relief valve must operate to keep the zone between the two check valves at least 2 PSI less than the supply pressure.

  1. Slowly close the outlet shut-off on the discharge side of the backflow preventer.

  2. Open air bleeds and test cocks until all air from the check valves is released.

  3. Connect the “high” side of the differential pres- sure gauge to test cock #2 and the “low” side to test cock #3.

  4. Open test cock #2 and test cock #3 and bleed all air from the hose and gauge.

  5. Slowly open the bypass valve needle #1 until the dif- ferential gauge needle starts to drop. Hold the bypass in this position and observe the reading on the gauge at the moment the first discharge is noted from the relief valve. The differential pressure at the time the relief valve opens must be no lower than 2 PSI.

Test Check Valve 1

The check valve must be at least 3 PSI more than the relief valve opening pressure.

1. Open test cock #4 to flow a small amount of water through the unit to restore normal pressures.

2. Observe the differential gauge with bypass valve #1 closed and test cock #2 and #3 open. The gauge should remain at a reading of at least 3 PSI above the relief valve. If it drops below this, the check valve is leaking and must be serviced.

Test Check Valve 2

The check valve must be tight against reverse flow under all pressure differentials.

1. Connect the “high” side of the differential pressure gauge to test cock #4 (3rd hose).

2. Open test cock #4. With bypass needle valve #1 closed and bypass valve #2 open, observe gauge reading. The differential pressure should not drop to the relief valve opening point.

Restore Operation

1. Restore all valves and test cocks to their original positions. Open and close resilient seated shut- offs slowly to prevent damage to the system and assembly.

6. Close the bypass needle valve.

FEBCO Model 825Y (3/4–2") Reduced Pressure Assembly

Figure No. 7

FEBCO Model 825YD (21/2–10") Reduced Pressure Assembly

Test Cock #1

Inlet Shut-Off Value

Test Cock #2

Bypass Needle Valve #1

Test Cock #3

Test Cock #4
Differential Pressure Gauge

12

Differential Pressure Gauge

Bypass Needle Valve #1 Test Cock #2

Bypass Valve #2

Test Cock #3

Test Cock #4

Inlet Shut-Off Value

Test Cock #1

Outlet Shut-Off Value

Check Valve #1 Check Valve #2

Outlet Shut-Off Value

Figure No. 8

Bypass Valve #2

Check Valve #1

Relief Valve

Check Valve #2

MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD

Field Testing Procedures (Continued)

Test for the 826YD

This device is tested with the same procedure as the Model 825YD. However, the bypass 825Y 3/4" valve must be isolated from the mainline valve using the 3/4" ball valves during the test and tested separately.

Proper Bypass Operations

Flow 3 GPM through the bypass by opening the mainline test cock #4. Use the flow meter for this measurement (1 gallon flow in a 20 second time period). After the flow rate has been set, collect the discharge flow in a container for 20 seconds. The volume of water collected should be one gallon.

FEBCO Model 826YD (21/2–10") Reduced Pressure Assembly

Figure No. 9

Restore Operation

After testing restore all valves to their original positions.

Note: This is a suggested typical test method. Check with your local code for approved test procedures in your area.

Testing with the FEBCO Test Kit

The FEBCO Test Kit includes gauge, complete with hoses, fittings, adapters and laminated instructions in a compact plastic case. The FEBCO Test Kit includes a differential pressure gauge used to test all approved Reduced Pressure Assemblies including the FE- BCO Models 825Y, 825YA, 825YD Reduced Pressure Assemblies and the 826YD Reduced Pressure Detector Check.

Figure No. 10

13

MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD

Service Procedure 825Y and YA (3/4–2")

1.

Check Valve Inspection/Repair Model 825Y (3/4–2") (See Figure No. 11)

  1. Close inlet and outlet shut-off valves. Bleed residual pressure by opening first the #4 test cock, then the #3 and #2 test cocks See Figure No. 7 for test cock locations

  2. Unscrew Cap using appropriate size wrench.

CAUTION: Cap is spring loaded. First check spring force on 3/4" to 11/2" is 10 lb. First check spring force on 11/2" to 2" is 28 lb. Retain cap with appropriate amount of hand force to avoid injury. Second check spring force is ap- proximately 1/4 of the first check spring.

2. Check Valve Seat Replacement Model 825Y (3/4–2") (See Figure No. 11)

a. Hold disc holder assembly in one hand and remove screw and disc washer.

CAUTION: The use of pliers or other tools may dam- age the guiding surfaces and require unnecessary replacement. Do not scratch or mark sealing or guiding surfaces.

b. Inspectseatdiscforwearorcutsremoveoldseat disc and install new, or turn used disc over if new seat disc is not available.

NOTE: The seat discs are symmetrical. It is usually possible to turn the disc over and obtain an effective seal.

c. If the seat disc has been severely cut along the seat ring diameter, the assembly is being subjected to extremely high back pressure from thermal water expansion, water hammer or other causes of excessive water pressure. Seat discs damaged in such a manner should be replaced and not turned over to be reused.

3. Check Valve Reassembly Model 825Y (3/4–2") (See Figure No. 11)

  1. Position the disc in the cleaned holder and retain with disc washer and screw. CAUTION: DO NOT OVERTIGHTEN SCREW, SECURE WITH AP- PROXIMATELY 12 INCH-LBS.

  2. Positionthespringaroundthecenteringringofthe disc holder and reinsert the disc holder assembly into the check body.

    NOTE: Ensure the heavy check spring is installed in the No. 1 check valve or the valve will not operate properly and a continuous discharge may occur.

  3. Apply a thin coating of FDA approved lubricant on the o-ring in the cap and thread cap onto the check valve body using the appropriate sized wrench.

c. Remove the spring and disc holder assembly.

  1. Inspect guiding bore of the cap and poppet stem for any buildup of calcium or other mineral depos- its. If this condition exists, it may be removed with the careful use of an appropriate size reamer or a thin blade knife. 3/4–11/4" cap —5/8" (.6250) reamer 11/2–2" cap—7/8" (.8750) reamer.

  2. Check disc holder and stem movement in the guide to ensure they move freely. Debris can inhibit proper movement.

14

MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD

Service Procedure 825Y and YA (3/4–2") (Continued)

d. Closethe#4,#3,and#2testcocksandslowly open first the inlet and then outlet shut-off valves and return the assembly to service. See Figure No. 7 for test cock locations.

e. Test the assembly to ensure it is operating properly.

4. Relief Valve Inspection/Repair Model 825Y (3/4–2") (See Figure No. 11)

  1. Slowly close the inlet and outlet shut-off valves and bleed off the residual pressure by opening first test cocks # 4, then # 3 and # 2. See Figure No. 7 for test cock locations.

  2. Removecapscrews,diaphragmcover,diaphragm and port bushing of relief valve.

  3. Remove the integral relief valve assembly by pull- ing straight out of the body to remove the internal assembly.

  4. Remove the disc washer and seat disc by un- threading the screw.

  5. To remove spring and/or main stem from the guide, keep unit compressed and remove the screw (item 18) located in the center of the but- ton. Push the main stem through the guide and remove the o-ring from the main stem. Inspect and clean or replace o-ring and seat disc as required. Clean all parts thoroughly with clean water before reassembly.

5.

Relief Valve Seat Removal Model 825Y (3/4–2")

Standard only on units manufactured after Octo- ber of 1988 with serial numbers higher than listed below. See Figure No. 11 for exploded view of this relief valve.

Serial #‘s of new Model 825Y with replaceable valve seat ring:

1/4" Serial No. S6528 and above 1" Serial No. S6163 and above 11/2" Serial No. S5710 and above 2" Serial No. S5089 and above

  1. While relief valve is disassembled, remove the two Allen head socket capscrews using the ap- propriate sized Allen head wrench. (3/16" Allen head wrench for 3/4" and 1" assemblies, and 1/4" Allen head wrench for 11/2" and 2" assemblies.)

  2. Pullthereliefvalvebodyfromthemainvalvebody. Pull the discharge shield from the seat ring

  3. Remove seat ring with the appropriate sized socket or needle nose pliers. Use care to avoid damage to the seat edge. Replaceable relief valve seat is standard only on units manufactured after October of 1988.

d. Inspect seat ring, o-rings, bushings, and gasket seals for damage. Rinse all parts with clean water before reassembly.

15

MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD

Service Procedure 825Y and YA (3/4–2") (Cont.)

6. Relief Valve Reassembly Model 825Y (3/4–2") (See Figure No. 11)

  1. Lubricate the seat ring o-ring with FDA approved lubricant and thread seat ring into the valve body until seated. Do not over tighten. (Replaceable relief valve seat ring standard on units manufac- tured after October of 1988.)

  2. Position the discharge shield over the seat ring diameter and, taking care not to damage the two flow passages, reinstall o-rings and guide bushings.

  3. Carefully place the relief valve body over the bushing and tighten the two capscrews to retain the relief valve body to the main valve body. New capscrew sealing washers should be installed to avoid leakage.

  4. Lubricate the o-rings and main stem using FDA approved lubricant. Place the main stem and spring into the guide and replace the flat head screw located at the center button.

  5. Place the disc washer and seat disc in position and retain with machine screw. Depress the dia- phragm button to ensure it is free moving.

  1. Place the relief valve module into the relief valve body and mount the diaphragm. Be careful to position the diaphragm over the port bushing. Replace the relief valve cover and tighten the capscrews.

  2. After completing reassembly by, slowly open the inlet shut-off valve. Then bleed air from each chamber and from the relief valve cover by open- ingtestcocks#4,#3,and#2.SeeFigureNo.7 for test cock locations. Slowly open outlet shut-off valve and return the valve to service.

  3. Test the assembly to ensure it is operating properly.

16

MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD

Model 825Y and YA (3/4–2") Parts

Model 825Y & YA Part Numbers (Sizes 3⁄4– 2")

ITEM DESCRIPTION QTY.* SIZE SIZE SIZE SIZE SIZE NO. 3⁄4" 1" 11⁄4" 11⁄2" 2"

3 Bushing 3 500-290 500-290 500-290 500-290 500-290

4 O-ring 2 398-202-72 398-202-72 398-202-72 398-202-72 398-202-72

5 Gasket 2 340-078 340-078 340-078 340-079 340-079

6 Capscrew 2 515-513-05 515-513-05 515-513-05 515-514-06 515-514-06

7 Cap 2 101-134 101-134 101-134 101-135 101-135

8 O-ring 2 398-226-72 398-226-72 398-226-72 398-235-72 398-235-72

9 Disc Holder 2 500-270 500-270 500-270 500-278 500-278

10 Seat Disc 2 400-099 400-099 400-099 400-103 400-103

11 Washer 2 300-084 300-084 300-084 300-108 300-108

12 Screw 2 516-543-03 516-543-03 516-543-03 516-543-03 516-543-03

13 Spring (Inlet) 1 630-125 630-125 630-125 630-137 630-137

14 Spring (Outlet) 1 630-115 630-115 630-115 630-118 630-118

15 Bolt 4 511-514-06 511-514-06 511-514-06 ----- -----

15 Bolt 8 ----- ----- ----- 511-515-07 511-515-07

16 Cover 1 101-029 101-029 101-046 101-035 101-035

17 Diaphragm 1 400-101 400-101 400-101 400-104 400-104

18 Screw 1 700-107 700-107 700-107 519-513-03 519-513-03

19 Button 1 500-284 500-284 500-284 300-107 300-107

20 Spring 1 630-126 630-126 630-126 630-138 630-138

21 Mainstem 1 500-273 500-273 500-273 500-280 500-280

22 O-ring 1 398-113-72 398-113-72 398-113-72 398-120-72 398-120-72

23 Guide 1 500-277 500-277 500-277 500-281 500-281

24 O-ring 1 398-022-72 398-022-72 398-022-72 398-127-72 398-127-72

25 Seat Disc 1 400-102 400-102 400-102 400-105 400-105

26 Washer 1 300-104 300-104 300-104 300-105 300-105

27 Screw 1 700-137 700-137 700-137 519-513-03 519-513-03

101 Seat Ring (Relief Valve) 1 200-779 200-779 ----- 200-780 200-780

102 O-ring (Relief Valve) 1 398-019-72 398-019-72 ----- 398-026-72 398-026-72

103 Elbow (YA only) 2 101-194 101-195 ----- 101-189 101-190

104 O-ring (YA only) 2 398-223-72 398-223-72 ----- 398-230-72 398-230-72

* Quantity required per valve.

Shut-Offs: Model 825Y & YA

ITEM DESCRIPTION QTY.* SIZE SIZE SIZE SIZE SIZE NO. 3⁄4" 1" 11⁄4" 11⁄2" 2"

29 Ball Valve (Inlet) 1 781-053 781-054 781-055 781-056 781-057

29A Ball Valve (Outlet) 1 781-048 781-049 781-050 781-051 781-052

30 Testcock 4 781-074 781-074 781-075 781-075 781-075

* Quantity required per valve.

17

MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD

Model 825Y, 825YR and YA (3/4–2") Parts (Cont.)

DESCRIPTION

Check Valve Rubber Kit (2 ea. 8, 10)
Relief Valve Rubber ( 1 ea. 17, 22, 24, 25)
Check Valve Assembly (1 ea. 8, 9, 10, 11, 12)
Relief Valve Assembly (1 ea. 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27)
RV Seat Ring Kit (101, 102)
Complete Rubber Parts Kit (3, 4, 5, 8, 10, 17, 22, 24,
25, 102)
825YR Seat Ring Repair Kit (35, 36)

QTY. *

1 Kit

1 Kit 2 Assy.

1 Assy. 1 Kit 1 Kit1 Kit

SIZE SIZE3/4" 1"905-042 905-042 905-043 905-043 905-044 905-044

905-045 905-045 905-113 905-113905-111 905-111905-280 905-280

SIZE SIZE 11/4" 11/2"

  1. 905-042  905-053

  2. 905-043  905-054

  3. 905-044  905-055

  4. 905-045  905-056

----- 905-114905-111 905-112

SIZE 2"905-053 905-054 905-055

905-056 905-114905-112

* Quantity required per valve.

Model 825Y (3/4–2")

Figure No. 11

15*

30* 101102 8*4

29A 14

104 (O-ring)103

18*

Relief Valve Assembly

19
20 22

23 24* 6

7

8* 13

* Denotes Commercial Parts Available (see page 35).
Unit is shown with ball valve shut-offs.
Some parts are sold in kits only. Consult Parts Price List for specifics.

7

Model 825YA (3/4–2")

Figure No. 12

18

103

Washer21 2526

27

30*

Relief Valve Body

3 4Discharge Shield10

16 117

29

Check Assembly

912 11

-----

905-281 905-281

MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD

Service Procedures 825, 825D, 825YD and 826YD (21/2–3")

1.

Check Valve Disassembly Models 825, 825D and 825YD (Sizes 21/2–3") (See Figure No. 13)

  1. Slowly close outlet shut-off valve and inlet shut-off valve. Bleed residual pressure by opening #4, #3 and # 2 test cocks. See Figure No. 8 for test cock location.

  2. Removecoverboltsuniformlywhileholdingcover in place. Remove cover.

CAUTION: Spring is retained in body by cover.

c. If the seat disc has been severely cut along the seat disc ring diameter, the assembly is being subjected to extremely high back pressure from thermal water expansion, water hammer, or other causes of excessive water pressure. A disc dam- aged in such a manner should be replaced and not turned over to be reused.

3a. Valve Seat Removal (Sizes 21/2–3") Threaded-in Seat Ring Type Models Model 825 (See Figure No. 13)

1. Remove seat ring by un-threading in counter- clockwise direction being careful not to damage the internal epoxy coating in valve. A tool to aid in this process is described in Figure No. 21 on page 33.

  1. Remove bushing and bushing nut (item 2A & 2B).

  2. Remove o-ring.

2.

c. Lift check assembly from body being careful not to damage internal epoxy coating.

d. If necessary, un-thread bushing (item 4A) from cover.

Check Assembly Repair Models 825 825D and 825YD (Sizes 21/2–3") (See Figures No. 13 & 14)

  1. Un-thread nut on stem and remove disc washer and seat disc.

  2. Inspect seat disc for wear or damage. Replace with new seat disc or turn used disc over if new disc is not available.

    NOTE: The discs are symmetrical. It is usually possible to turn the disc over and obtain an effective seal.

19

MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD

Service Procedures 825, 825D, 825YD and 826YD (21/2–3") (Continued)

3b. Valve Seat Removal (Sizes 21/2–3") Bolted in Seat Ring Type Models 825D & 825YD (See Figure No. 16)

  1. Remove the three capscrews and washers retaining the seat ring.

  2. Pull the seat ring from the valve body being careful not to damage the internal epoxy coating of valve.

  3. If necessary, un-thread the bushing (Item 2A) from the seat ring.

  4. Remove the o-ring.

4a. Valve Seat Reassembly (Sizes 21/2–3') Thread- ed-in Seat Ring Type Models Model 825 (See Figure No. 13)

  1. Lubricate o-ring with FDA approved lubricant and replace on seat ring.

  2. Reinsert bushing into seat ring center.

  3. Thread seat ring into valve body in clockwise di- rection being careful not to damage the internal epoxy coating of valve.

4b. Valve Seat Reassembly (Sizes 21/2–3") Bolted-in Seat Ring Type Models Model 825D & 825YD (See Figure No. 13)

  1. Lubricate o-ring with FDA approved lubricant and replace in seat ring.

  2. Thread bushing into seat ring.

  3. Place the seat ring carefully into body and retain with three capscrews and washers being care- ful not to damage the internal epoxy coating of valve.

5. Check Valve Reassembly (Sizes 21/2–3") (See Figures No. 13 & 14)

a. Position the disc in the cleaned holder and retain with disc washer. Insert stem into disc holder, replace the nut on stem and tighten.

NOTE: On older Model 825 valves, the disc holder is sealed to the stem with a sealant. If the seal is broken, the stem and holder must be cleaned and new sealant applied. Newer valves, Models 825D and 825YD, use an o-ring so a sealant is not required.

  1. Thread bushing into cover.

  2. Carefully place stem of check assembly into seat ring bushing. Replace spring centering diameter on the disc washer.

    NOTE: Be sure the heavier spring (6 PSI) is placed in first check and lighter spring (2 PSI) is placed in second check or the unit will not operate properly and discharge from the relief valve could occur. The wire diameter is visibly thicker on the heavier spring and thinner on the lighter spring. Care should be taken to avoid damaging internal epoxy coating of valve.

  3. Place cover on check body securing spring and stem into cover.

  4. Bolt cover onto check body while holding cover in place with appropriate hand force. Spring will be retained in body by cover.

  5. Slowly open inlet shut-off valve. Bleed air from valve by opening first the # 4 test cock, then the # 3, # 2 and # 1 test cocks and air bleeds on all covers. See Figure No. 8 for test cock locations.

  6. Slowly open outlet shut-off valve and return the valve to service.

  7. Test the assembly to ensure it is operating properly.

20

MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD

Service Procedures 825, 825D and 825YD (4–10")

  1. Check Valve Disassembly (Sizes 4–10") (See Figures No. 13 & 14)

    1. Slowly close outlet gate valve then slowly close inlet gate valve. Bleed residual pressure by open- ing first the #4 test cock, then #3, and #2 test cocks. See Figure No. 8 for test cock locations.

    2. Remove cover bolts and cover. Unscrew bolts uniformly to avoid binding of the cover. The spring will push the cover approximately 1/2 inch off the top of the valve body.

  2. Seat Disc Removal (Sizes 4–10')

    CAUTION: The newer model 825 cast iron units have threaded disc holders with four (4) cast lugs, (6 lugs on 10" assemblies), 1/2" high located on back side, outside the spring diameter. If the Model 825 you are servicing does not have these lugs, SPRING TENSION MUST BE RELEASED BY USING THE SPRING REMOVAL TOOL BEFORE FURTHER DISAS- SEMBLY. DO NOT ATTEMPT TO REMOVE SPRING TENSION ON OLDER MODEL 825s WITHOUT THE USE OF THIS TOOL. SEE SPRING REMOVAL IN- STRUCTIONS. Newer Models 825, 825D and 825YD assemblies have the disc holder threaded on the stem. Therefore, the seat disc can be removed without releas- ing spring tension on these newer models.

    a. Un-thread retaining nut from stem and remove disc washer and seat disc.

b. Inspect seat disc for wear or damage. Replace with new seat disc or turn used disc over if new disc is not available.

NOTE: The discs are symmetrical. It is usually pos- sible to turn the disc over and obtain an effective seal.

c. If the seat disc has been severely cut along the seat disc ring diameter, the assembly is being subjected to extremely high back pressure from thermal water expansion, water hammer, or other causes of excessive water pressure. A seat disc damaged in this manner should be replaced and not turned over for reuse.

d. Remove disc holder from stem.

NOTE: On older Model 825 valves, the disc holder is sealed to the stem with a sealant. If the seal is broken, the stem and holder must be cleaned and new sealant applied. Newer valves, Models 825D and 825YD use an o-ring so a sealant is not required.

3. Spring Removal (Sizes 4–10") (See Figures No. 13 & 14)

CAUTION: TO AVOID POSSIBLE INJURY, DO NOT ATTEMPT TO REMOVE SPRING TENSION WITH- OUT THE USE OF THE SPRING REMOVAL TOOL SHOWN IN FIGURE NO. 20 ON PAGE 32. ON OLDER MODEL 825 VALVES, IT IS NECESSARY TO REMOVE THE SPRING BEFORE THE RUBBER SEAT DISC CAN BE REMOVED.

  1. Leave check assembly in body.

  2. Install long studs in body 180 degrees apart.

  3. Place spring removal tool over stud and retain with

nuts. (See Figure No. 20 for dimensions.)

21

MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD

Service Procedures 825, 825D and 825YD (4–10") (Continued)

  1. Un-thread capscrew (Item 7A) using 9/16" hex socket.

  2. Release spring tension by un-threading nuts on long studs. Use alternating turns to keep tool parallel to valve body.

  3. Remove spring guide and stem assembly.

  4. Remove guide bushing by un-threading.

4a. Valve Seat Removal (Sizes 4–10") Threaded-in Seat Ring Type Model 825 (See Figure No. 13)

1. Remove check valve as described above.

4b. Valve Seat Removal (Sizes 4–10") Bolted in Seat Ring Type Model 825D and 825YD (See Figure No. 14)

  1. Remove check valve as described above.

  2. Remove the three capscrews and washers retaining the seat ring.

  3. Pull the seat ring from the valve body.

  4. Un-thread the bushing (Item 2A) from the seat ring.

  5. Remove the o-ring.

5a. Valve Seat Reassembly (Sizes 4–10") Threaded-in Seat Ring Type Models Model 825 (See Figure No. 13)

  1. Lubricate o-ring with FDA approved lubricant. Reposition the o-ring in the seat ring groove.

  2. Replace the bushing and bushing nut (if used) in the seat ring (the bushing and nut is used on older Model 825).

  3. Thread the seat ring into the seating area in a clockwise direction. Be careful not to damage internal epoxy coated surfaces.

5b. Valve Seat Reassembly (Sizes 4–10") Bolted-in Seat Ring Type Models

2. Remove seat ring by un-threading in the counterclock- Model 825D and 825YD

22

wise direction. For ease of removal, Figure No. 21 on page 33 defines a simple tool for this purpose.

3. Remove bushing and bushing nut if used (bushing and nut is used on older Model 825).

4. Remove o-ring.

(See Figure No. 14)

  1. Lubricate o-ring with FDA approved lubricant. Reposition the o-ring in the seat ring groove.

  2. Thread the bushing into the seat ring.

  3. Place the seat ring carefully into the valve body and retain with three capscrews and washers being careful not to damage the internal expoxy coated surfaces.

6. Check Valve Reassembly Models 825, 825D and 825YD

  1. Use reverse procedure for assembly.

  2. Make sure the o-ring is properly placed in the groove. Do not force the cover into the body.

  3. Do not damage epoxy coated surfaces.

  4. Test unit to ensure proper operation.

MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD

Model 825 (21/2–10") Parts

Check Valve Body: Model 825

ITEM DESCRIPTION QTY.* SIZE SIZE SIZE SIZE SIZE SIZE NO. 21⁄2" 3" 4" 6" 8" 10"

2 Seat Ring 2 780-273 780-274 780-275 780-276 780-277 780-278

2A Bushing 2 780-280 780-280 780-281 780-281 780-282 780-282

3 Guide 2 ----- ----- 190-001 190-002 190-003 190-004

4 Cover 2 780-306 780-307 780-308 780-309 780-310 780-311

4A Bushing 2 780-312 780-312 780-313 780-313 780-313 780-313

5 Disc Holder 2 190-013 190-014 190-005 190-006 190-007 190-008

6 Disc Washer 2 190-016 190-017 190-009 190-010 190-011 190-012

7 Stem 2 780-332 780-333 780-334 780-335 780-336 780-337

7A Screw 2 ----- ----- 511-515-08 511-515-08 511-515-08 511-515-08

7B Washer 2 ----- ----- 780-338 780-338 780-338 780-338

9 Spring (Outlet) 780-341 780-342 780-343 780-344 780-345 780-346

10 Spring (Inlet) 780-349 780-350 780-351 780-352 780-353 780-354

11 Seat Disc 2 780-357 780-358 780-359 780-360 780-361 780-362

12 O-ring 2 398-238-72 398-246-72 398-254-72 398-264-72 398-273-72 780-095

13 Capscrew 16 511-516-08 511-516-08 511-517-08 511-519-12 511-520-12

13 Capscrew 24 ----- ----- ----- ----- ----- 511-520-14

14 O-ring 2 398-244-72 398-252-72 398-263-72 398-272-72 398-451-72 740-102

15 Locknut 2 521-547-00 521-547-00 521-550-00 521-550-00 521-551-00 521-551-00

16 Gasket 3 780-365 780-366 780-367 780-368 780-369 780-370

17 Bolt 12 511-019-18 511-019-20 ----- ----- ----- -----

17 Bolt 24 ----- ----- 521-019-22 521-020-26 521-020-28 -----

17 Bolt 36 ----- ----- ----- ----- ----- 511-021-30

17A Nut 12 521-019-00 521-019-00 ----- ----- ----- -----

17A Nut 24 ----- ----- 521-019-00 521-020-00 521-020-00 -----

17A Nut 36 ----- ----- ----- ----- ----- 521-021-00

40 Plug Cock 4 781-047 781-047 781-047 781-048 781-048 781-048

41 Nipple 4 571-181-44 571-181-44 571-181-44 571-181-55 571-181-55 571-181-55

50 Air Bleed 4 9594A110 9594A110 9594A110 9594A110 9594A110 9594A110

51 O-ring 2 398-014-72 398-014-72 398-116-72 398-116-72 398-118-72 398-118-72

121 Relief Valve Assem. 1 902-440L 902-440L 902-446L 902-446L 902-446L 902-446L

* Quantity required per valve.

Shut-Offs: Model 825

ITEM DESCRIPTION QTY.* SIZE SIZE SIZE SIZE SIZE SIZE NO. 21⁄2" 3" 4" 6" 8" 10"

42 Resilient Sealed NRS (Inlet) 2 781-005 781-006 781-007 781-008 781-009 781-010

42 Resilient Sealed OS&Y (Inlet) 2 780-891 780-893 780-895 780-897 780-899 780-901

42A Resilient Sealed NRS (Outlet) 2 781-011 781-012 781-013 781-014 781-015 781-016

42A Resilient Sealed OS&Y (Outlet) 2 780-890 780-892 780-894 780-896 780-898 780-900

* Quantity required per valve.

23

MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD

Model 825 (21/2–10") Parts (Continued)

Assemblies / Kits: Model 825

DESCRIPTION

**Relief Valve Assembly (121) (825)

(825D)

SIZE 21/2"

905-526 905-100

905-085

905-086

902-386 905-059

905-066 905-036

SIZE 3"

905-100 905-100

905-087

905-088

902-385 905-060

905-066 905-037

SIZE 4"

905-101 905-100

902-466

902-467

902-384 905-061

905-067 905-038

SIZE 6"

905-101 905-101

902-468

905-469

902-383 905-062

905-067 905-039

SIZE 8"

905-522 905-522

902-470

902-471

902-382 905-063

905-067 905-040

SIZE 10"

905-522 905-522

902-472

902-473

902-381 905-064

905-067 905-041

Spring Assembly #1 Check

(3, 4A, 5, 6, 7, 7A, 10, 11, 15, 51)

Spring Assembly #2 Check

(3, 4, 5, 6, 7, 7A, 7B, 9, 10, 11, 15, 51)

Seat Ring Kit (2, 2A, 12)

Rubber Parts, CI & DI Boddies (11, 14, 51)

Relief Valve Kit (Rubber Parts)

(26, 27, 32, 39, 49, - 2 ea.)

LG Mounting Kit (16, 17, 17A, 40, 41, Both Ends)

**882255YYDDRReleielifevfavlvaelviesiussuesdefdorforerprelapcleamcemnte.nSte.eSeFeiguFriegu1r8eo1n8poangpea2g9efo2r8dfeotradilse.tails.

* Quantity required per valve.

Model 825 (21/2–10") Cast Iron Body

Figure No. 13

121
Relief Valve for Model 825YD (see Figure No. 13 on page 28 for exploded view)

36

4–10" Only
Disc Holder & Spring Assembly (for 21/2–3", see Figure No. 14)

2A 2

12

13*

4 14

50

44 43

17*

42*

1, 1A Body

* Denotes Commercial Parts Available (see page 34 and 35).
24 Some parts are sold in kits only. Consult Parts Price List for specifics.

41*
40*

16

42A*

17A

MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD

Model 825 Type D and YD (21/2–10") Parts

Check Valve Body: Model 825D & 825YD

ITEM DESCRIPTION QTY.* SIZE SIZE SIZE SIZE SIZE SIZE NO. 21⁄2" 3" 4" 6" 8" 10"

2 Seat Ring 2 101-145 101-144 101-136 101-137 101-138 101-139

2A Bushing 2 500-291 500-291 500-292 500-292 780-282 780-282

2C Washer 6 360-079 360-079 360-078 360-078 360-078 360-078

2D Capscrew 6 519-513-04 519-513-04 511-514-06 511-514-06 511-514-06 511-514-06

3 Guide 2 ----- ----- 190-001 190-002 190-003 190-004

4 Cover 2 902-497 902-498 902-499 902-500 902-501 902-502

4A Bushing 2 780-312 780-312 780-313 780-313 780-313 780-313

5 Disc Holder 2 190-013 190-014 190-005 190-006 190-007 190-008

6 Disc Washer 2 190-016 190-017 190-009 190-010 190-011 190-012

7 Stem 2 780-332 780-333 780-334 780-335 780-336 780-337

7A Screw 2 ----- ----- 511-515-08 511-515-08 511-515-08 511-515-08

7B Washer 2 ----- ----- 780-338 780-338 780-338 780-338

9 Spring (Outlet) 780-341 780-342 780-343 780-344 780-345 780-346

10 Spring (Inlet) 780-349 780-350 780-351 780-352 780-353 780-354

11 Seat Disc 2 780-357 780-358 780-359 780-360 780-361 780-362

12 O-ring (Seat Ring) 2 398-237-72 398-242-72 398-253-72 398-263-72 398-272-72 398-274-72

13 Capscrew 16/24 511-516-08 511-516-08 511-517-10 511-519-12 511-520-12 511-520-14

14 O-ring(Cover) 2 398-346-72 398-354-72 398-365-72 398-374-72 398-379-72 398-381-72

15 Locknut 2 521-547-00 521-547-00 521-550-00 521-550-00 521-551-00 521-551-00

16 Gasket 3 780-365 780-366 780-367 780-368 780-369 780-370

17 Bolt 10 511-019-18 511-019-20 ----- ----- ----- -----

17 Bolt 18 ----- ----- 511-019-22 511-020-26 511-020-28

17 Bolt 36 ----- ----- ----- ----- ----- 511-021-30

17A Nut 14 521-019-00 521-019-00 ----- ----- ----- -----

17A Nut 30 ----- ----- 521-019-00 521-020-00 521-020-00 -----

17A Nut 36 ----- ----- ----- ----- ----- 521-021-00

17B Stud 2 513-019-26 513-019-26 ----- ----- ----- -----

17B Stud 6 ----- ----- 513-019-26 513-020-32 513-020-32 -----

39 Nipple 1 573-181-81 573-181-81 573-181-81 573-183-11 573-183-11 573-183-11

40 Plug Cock 4 781-047 781-047 781-047 781-048 781-048 781-048

41 Nipple 3 571-181-44 571-181-44 571-181-44 571-181-55 571-181-55 571-181-55

41A Nipple 2 571-181-43 571-181-43 571-181-43 571-181-53 571-181-53 571-181-53

41B Tee 571-131-42 571-131-42 571-131-42 571-131-52 571-131-52 571-131-52

43 Tube Fitting 90o 1 571-231-23 571-231-23 571-231-23 571-231-23 571-231-23 571-231-23

43A Tube Fitting 1 571-211-23 571-211-23 571-211-23 571-211-23 571-211-23 571-211-23

50 Air Vent 4 9594A110 9594A110 9594A110 9594A110 9594A110 9594A110

51 O-ring 2 398-014-72 398-014-72 398-116-72 398-116-72 398-118-72 398-118-72

* Quantity required per valve. (See Page 27 for Assemblies and Kits)Shut-Offs: Model 825D & 825YD

ITEM DESCRIPTION SIZE SIZE SIZE SIZE SIZE SIZE NO. 21⁄2" 3" 4" 6" 8" 10"

42 Resilient Sealed NRS (Inlet) 781-005 781-006 781-007 781-008 781-009 781-010

42 Resilient Sealed OS&Y (Inlet) 780-891 780-893 780-895 780-897 780-899 780-901

42A Resilient Sealed NRS (Outlet) 781-011 781-012 781-013 781-014 781-015 781-016

42A Resilient Sealed OS&Y (Outlet) 780-890 780-892 780-894 780-896 780-898 780-900

(Parts List continued on page 27)

25

42*

39

17A

44* 43*

MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD

Model 825D and 825YD (21/2–10")

Figure No. 14

2C 12*

42A*

2D 2A

16

2

1, 1A

41A* 43A*

41A* 41B*

41*
40*

121

Relief Valve for Model 825YD (see Figure No.16 on page 29 for exploded view)

* Denotes Commercial Parts Available (see page 34 and 35).
Some parts are sold in kits only. Consult Parts Price List for specifics.

26

50
13*

4 14*

50

17*

Figure No. 15

9, 10 7

15

11 6

MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD

Model 825 Type D and YD (21/2–10") Parts

G

Assemblies / Kits: Model 825YD

DESCRIPTION

Spring Assembly #1 Check
(3, 4A, 5, 6, 7, 7A, 7B, 10, 11, 15, 51)
Spring Assembly #2 Check
(3, 4A, 5, 6, 7, 7A, 7B, 9, 10, 11, 15, 51)
Seat Ring Kit (2, 2A, 2C, 2D, 12)
Rubber Parts, CI & DI Boddies (11, 14, 51)
Large Mounting Kit (16, 17, 17A, 17B, 40, 41,
Both Ends)
Relief Valve Assy (Type YD Only) (21 - 50)
Relief Valve Kit - Rubber (26, 27, 27A, 31A, 32) Relief Valve Seat Ring Kit (22A, 22B, 36, 36A, 36B) Internal Modular Assembly - Relief Valve Kit

SIZE 21/2"

905-085

905-086

902-386YD905-059

905-036

905-100 905-102 905-103 905-104

SIZE 3"

905-087

905-088

902-385YD905-060

905-037

905-100 905-102 905-103 905-104

SIZE 4"

902-466

902-467

902-384YD905-061

905-038

905-100 905-102 905-103 905-104

SIZE 6"

902-468

905-469

902-383YD905-062

SIZE 8"

902-470

902-471

902-382YD905-063

SIZE 10"

902-472

905-473

902-381YD905-064

905-041

905-101 905-102 905-103 905-104

4

Check Assembly 4–10" 825D and 825YD

4A

9, 10

3

7A 7B

4A

5

Spring Assembly

Check # 1 905-085 or 905-087

Check #2 905-086 or 905-088

51

Cover and Check 21/2–3" 825D and 825YD
Figure No. 16

905-039 905-040

905-101 905-101 905-102 905-102 905-103 905-103 905-104 905-104

27

MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD

Model 825 and 825D (21/2–10") Parts

Relief Valve Body: Model 825 & 825D

ITEM DESCRIPTION NO.

SIZE 3"780-372 780-377 780-379

21 Diaphragm

  1. 23  Diaphragm

  2. 24  Diaphragm

  3. 25  Bolt

25A Nut

  1. 26  Diaphragm

  2. 27  Diaphragm

  3. 28  Spring

  4. 29  Spring Button

  5. 30  Main Stem

  1. 32  Seat Disc

  2. 33  Disc Washer

  1. 35  Orifice Bolt

  2. 36  Seat Ring (825)

36 Seat Ring (825D)39 O-ring

  1. 48  Capscrew

  2. 49  Daphragm Washer

* Quantity required per valve.

Cover Spacer Button

Relief Valve Assembly Model 825 and 825D

22

48

36 35

Figure No. 17

29

28

49 21

25

24 26

48

30 39

33 32

* Denotes Commercial Parts Available (see page 34).

28

SIZE 4"780-372 780-377 780-379

SIZE 6"780-372 780-377 780-379

SIZE 8"780-372 780-377 780-379

SIZE 10"780-372 780-377 780-379

QTY.* SIZE21⁄2"

1 780-372
1 780-377
1 780-379
8 511-515-22 511-515-22 511-515-22 511-515-22 511-515-22 511-515-22 8 521-515-00 521-515-00 521-515-00 521-515-00 521-515-00 521-515-00

1 780-381 780-381
1 780-383 780-383
1 780-385 780-385
1 780-388 780-388
1 780-391 780-391
1 780-395 780-395
1 780-397 780-397
1 780-399 780-399
1 780-402 780-403
1 780-403 780-403
1 398-222-72 398-222-72 398-330-72 398-330-72 398-330-72 398-330-72

8 700-137 2 780-415

700-137 780-415

27

700-137 780-415

49

700-137 700-137 780-415 780-415

700-137 780-415

25A

23

780-381 780-381 780-381 780-383 780-383 780-383 780-386 780-386 780-386 780-389 780-389 780-389 780-392 780-392 780-392 780-395 780-395 780-395 780-398 780-398 780-398 780-399 780-399 780-399 780-404 780-404 780-405 780-403 780-404 780-405

780-381 780-383 780-386 780-389 780-392 780-395 780-398 780-399 780-405 780-405

Relief Valve Model 825YD

33 32

35

Figure No. 18

31 27A

34

30 31A

MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD

Model 825 Type YD (21/2–10") Parts

50 25

21
23

22 23

48

36

36B 36A

38

28 24

22B 22A50

39** 37

26

Denotes Commercial Parts Available (see page 34).

905-104 Relief Valve Module

*
** See page 34 for size.

27

29

MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD

Model 826 Type YD (21/2–10") Parts

Relief Valve with Bypass: Model 826YD

REF NO.9 9

42

61 61B

DESCRIPTION

1st Check Spring 2nd Check Spring

Resilient Wedge OS&Y Gate Valve

Bypass Kit
Meter (Std. - Gal.)

SIZE 21⁄2"780-349 630-140

780-891

905-127 780-666

SIZE 3"780-350 630-141

780-893

905-127 780-666

SIZE 4"630-142 780-778

780-895

905-127 780-666

SIZE 6"630-143 780-779

780-897

905-127 780-666

SIZE 8"630-144 780-780

780-899

905-127 780-666

SIZE 10"630-145 780-781

780-901

905-127 780-666

The following information, combined with the information in this Manual, gives you all the necessary technical information for the 826YD.

For information on Installation, Servicing, Field Testing and Trouble Shooting, please refer to those section in this Maintenance Manual.

The items listed above are used only on the Model 826YD and are not interchangeable with the Model 825YD.

Model 826YD

Figure No. 19

30

61B

61

MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD

Service Procedures
Relief Valve 825, 825D and 825YD (21/2–10")

1a. Relief Valve Disassembly Non-Modular Type Relief Valve Models 825 and 825D
(See Figures No. 13 and 16)

  1. Remove copper tubing from relief valve body.

  2. Un-thread the relief valve completely from the check valve body, leaving the seat ring in the check valve body. NOTE: If the seat ring is removed with the relief valve, the seat ring must be un-threaded from the relief valve diaphragm plate, being careful not to damage the seat ring threads and seating surface.

  3. Remove cover bolts and nuts, diaphragm cover and spacer from the relief valve assembly.

  4. Turn the relief valve upside down, un-thread screw (Item 35) using a 9/16 hex socket, and remove dia- phragm assembly, spring button and spring.

  5. Un-thread screw (Item 48) and remove diaphragm washer and diaphragm from diaphragm button.

  6. Push main stem out of bottom of relief valve body.

  7. Remove o-ring from body.

2a. Relief Valve Reassembly Non-Modular Type Relief Valve Model 825 and 825D (See Figure No. 17)

  1. Assemble washer, outer diaphragm, spacer, diaphragm button, inner diaphragm and washer by securing with capscrews to form diaphragm assembly. When install- ing diaphragms, make sure side of diaphragm marked “button side” (fabric side) is toward diaphragm button and that diaphragm is not pinched.

  2. Lubricate main stem o-ring with FDA approved lubricant. Place seat disc on main stem and place disc washer on seat disc.

  3. Slide main stem bolt through main stem assembly and place inside relief valve body cavity with main stem bolt protruding.

  4. Position spring over bolt and fit diaphragm assembly over spring. Compress diaphragm assembly into spring until main stem bolt threads into diaphragm assembly. Secure using a torque wrench. DO NOT TIGHTEN MAIN STEM BOLT BEYOND 15 INCH- LBS. OR DISTORTION OF THE MAIN STEM (ITEM 30) WILL OCCUR.

  5. Thread seat ring into main valve body and thread relief valve into seat ring.

  1. Reconnect copper tubing to relief valve.

  2. Slowly open inlet shut-off valve and bleed air by opening first test cock #4, then test cocks #3, and #2 and all air bleeds.

  3. Slowly open outlet shut-off valve and return the valve to service.

  4. Test the assembly to ensure it is operating properly.

3a. Relief Valve Seat Disc Replacement Modular Type Relief Valve Model 825YD (See Figure No. 18)

  1. Disconnect sensing tubing. Remove relief valve cover (Item 21) by loosening cover bolts (Item 25) and remove the outer diaphragm (Item 26).

  2. Grasp the relief valve button (Item 24) with one hand. Insert fingers into the rectangular relief valve port on the bottom of the relief valve and apply force to the seat disc. Pull the relief valve module straight out from the body. DO NOT TWIST.

  3. Place the relief valve module on a flat surface. Hold- ing the main stem with one hand, loosen and remove the lower guide (Item 35) and disc washer (Item 33). Remove the rubber seat disc (Item 32) and turn over or replace as required. Inspect all parts and clean us- ing clean water. Refer to section 5a on replacing relief valve diaphragms if this procedure is necessary.

  4. Replace the disc washer and lower guide and tighten. Lubricate the o-ring (Item 31a), with FDA avpproved lubricant. Insert the relief valve module into relief valve body, using your fingers to help guide the lower guide into the bushing (Item 36a) on the relief valve seat ring. Push the module straight in. DO NOT TWIST.

  5. If the relief valve module does not have a center label piece covering the screw (Item 48), inspect the screw for burrs. If a burr is visible, remove or cover burr with a piece of flexible tape. This will protect the surface of the diaphragm.

  6. Replace the diaphragm, placing the fabric side

    against the button. Work the rolled edge into the space between the module and the body making sure it is not pinched or buckled.

  7. Replace the cover, tighten the cover bolts, and reconnect the sensing tubing. Return to service and test the assembly to ensure proper operation.

    31

MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD

Service Procedures
Relief Valve 825, 825D and 825YD (21/2–10") (Cont.)

4a. Relief Valve Seat Ring Replacement Modular Type Relief Valve Model 825YD (See Figures No. 14 & 18)

  1. Disconnect sensing tubing. Loosen and remove the four mounting bolts (Item 38) from the adapter. Remove the relief valve.

  2. Pull the seat ring (Item 36) out from the relief valve body and inspect for damage. Replace as required.

  3. Reposition the relief valve to the adapter insuring the o-ring (Item 36b) is properly positioned. Tighten the mounting bolts.

  4. Reconnect the sensing tubing. Return to service and test the assembly to ensure proper operation.

5a. Relief Valve Inner Diaphragm Replacement / Modular Type Relief Valve Model 825YD (See Figure No. 18)

  1. Disconnect the sensing tubing. Remove the cover (Item 21) by loosening and removing cover bolts (Item 25).

  2. Remove the outer diaphragm (Item 26). Grasp the relief valve button (Item 24) with one hand. Insert your fingers into the rectangular relief valve port on the bottom of the relief valve and apply force to the seat disc. Pull the relief valve module straight out DO NOT TWIST.

  3. Remove the lower guide (item 35) and disc washer (item 33). Place the relief valve module upside down on a clean flat surface. Remove the center label piece protecting the screw head and save this piece for reassembly. With one hand apply force sufficient to hold the button against the main stem. Keep the spring (Item 28) compressed (spring is ap- proximately 35 lbs.) while unscrewing the pan head screw (item 48). Remove the screw and relieve the spring tension. Remove the button and spring.

32

4. Remove the main stem and un-thread the retainer (Item 34) from the upper guide (Item 32). Remove the slip ring (Item 27a) and inner diaphragm (item 27). Inspect, clean and replace parts as required.

5. To reassemble, position the bead on the inner diaphragm into the groove of the upper guide. Place the slip ring over the diaphragm. Lubricate the re- tainer threads using an FDA approved lubricant and thread the retainer onto the upper guide. Tighten to 60 inch-lbs. of torque.

6. Insert the main stem into the diaphragm and “roll” the diaphragm into position by grasping the end of the diaphragm and main stem with one hand and push the upper guide towards your other hand.

7. Test to make sure diaphragm is positioned properly by sliding the upper guide back and forth through the full travel. It must move freely and easily.

8. Once the inner diaphragm has been rolled, force the end of the main stem snug against the end of the inner diaphragm. The screw hole in the end of the main stem should be visible.

9. Replace the spring and button and tighten the screw while holding the button in place.

10. Make sure the screw (Item 48) is free of burrs that may cut the outer diaphragm. Reposition the center label piece, that you have saved during disassembly, over the screw head.

11. Replace the disc washer and lower guide insuring that the seat disc is clean and in position. Lubricate the upper guide o-ring (Item 31a) using an FDA ap- proved lubricant, to ease installation. DO NOT USE LUBRICANT ON ANY OTHER PART.

12. Position the relief valve module back into the body using your finger to help guide the lower guide into the relief valve seat ring bushing. Push the module straight in. DO NOT TWIST.

13.Replace the outer diaphragm, placing the fabric side against the button. Work the rolled edge into the space between the module and the body, makings sure it is not pinched or buckled.

14.Replace the cover, tighten the cover bolts, and reconnect the sensing tubing. Return the valve to service and test to ensure proper operation.

MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD

Spring Removal Tool

NOTE: This information is provided to expedite servicing of FEBCO products. One tool may be fabricated for use on all required sizes by drilling all holes at appropriate dimensions in a single steel plate of maximum required length. See page 21 for instructions on use.

To order a FEBCO spring removal tool order part number 905-121.

CAUTION: To avoid possible injury during use, do not fabri- cate tool from lesser strength material or to smaller dimen- sions than the minimums shown.

Seat Ring Tool

For Model 825 Only.

Figure No. 20

"C" DIA 2 PL "S

1" DIA

1/2" Steel Plate (Min)

Dimensions (Inches)

V alve Size

ABCDE

4" 9 1/2 4 1/4 5/8 1/2 - 13 5 1/2

6" 12 1/2 5 5/8 3/4 5/8 - 1 1 5 1/2

8" 14 1/4 6 3/8 7/8 3/4 - 10 7

10" 16 1/2 7 1/2 7/8 3/4 - 10 7

"B"

"B"

"D" Threaded Rod

A

"E"

Figure No. 21

"B"

"D"

"E" DIA Thru

"A" Std. Wt. Pipe (Steel)

Dimensions (Inches)

Valve Size

ABCDE

11/2" 11/2 6 3/8 3/4 3/4

2" 11/2" 6 3/8 3/4 3/4

21/2" 21/2" 8 1/2 1 1

3" 3 8 1/2 1 1

4" 4 9 1/2 1 1

6" 6 10 5/8 1 1

8" 8 12 5/8 1 1

10" 8 12 5/8 1 1

NOTE: This information is provided to expedite servicing of FEBCO products. See page 22 for instructions on use.

"C" Milled Notch "C" x "C" SO - 120o Apart 3 Places

33

34

Commercial Parts for Refief Valve - Model 825 & 825 D (11/2–10")

Item No.

DESC.

Material

SIZE 11/2"

SIZE 2"

SIZE 21/2"

SIZE 3"

SIZE 4"

SIZE 6"

SIZE 8"

SIZE 10"

25/
25A Nut

ST STL

3/8-16 x 2 1/2(8)

3/8-16 x 21/2(8)

3/8-16 x 23/4(8)

3/8-16 x 23/4(8)

3/8-16 x 23/4(8)

3/8-16 x 23/4(8)

3/8-16 x 23/4(8)

3/8-16 x 23/4(8)

Bolt &
39 O-ring BUNA-N

568-214 1 x 11/4 x 1/8

568-222 11/2 x 13/4 x 1/8

568-222 11/2 x 13/4 x 1/8

568-222 11/2 x 13/4 x 1/8

568-330 21/8 x 21/2 x 3/16

568-330 21/8 x 21/2 x 3/16

568-330 21/8 x 21/8 x 3/16

568-330 21/8 x 21/2 x 3/16

48 Cap Screw

ST STL

10-32 x 1/2Socket Head (8)

10-32 x 1/2Socket Head (8)

10-32 x 1/2Socket Head (8)

10-32 x 1/2Socket Head (8)

10-32 x 1/2Socket Head (8)

10-32 x 1/2Socket Head (8)

10-32 x 1/2Socket Head (8)

10-32 x 1/2Socket Head (8)

Commercial Parts for Main Valve - Model 825 (11/2–10")

Item No.

DESC. Material

SIZE 11/2"

SIZE 2"

SIZE 21/2"

SIZE 3"

SIZE 4"

SIZE 6"

SIZE 8"

SIZE 10"

2B 7A

Bushing Nut

7/16-20 Hex (2)

9/16-18 Hex (2)

9/16-18 Hex* (2)

9/16-18 Hex* (2)

7/8-14 Jam* (2)

7/8-14 Jam* (2)

12 13

O-ring BUNA-N

568-228 21/4 x 21/2 x 1/8(2)

568-231 25/8 x 27/8 x 1/8(2)

568-238 31/2 x 33/4 x 1/8(2)

568-246 41/2 x 43/4 x 1/8(2)

568-254 51/2 x 53/4 x 1/8(2)

568-264 71/2 x 73/4 x 1/8(2)

568-273 93/4 x 10 x 1/8(2)

105/16 x 109/16 x 1/8(2)

14

O-ring BUNA-N

568-234 3 x 31/4 x 1/8(2)

568-240 33/4 x 4 x 1/8(2)

568-244 41/4 x 41/2 x 1/8(2)

568-252 51/4 x 51/2 x 1/8(2)

568-263 71/4 x 71/2 x 1/8(2)

568-272 91/2 x 93/4 x 1/8(2)

568-451 11 x 111/2 x 1/4(2)

123/4 x 13 x 1/8(2)

1517

Lock-Nut ST STL

3/8-24 (15)

1/24-20 (15)

1/2-20 (15)

1/2-20 (15)

3/4-16 (15)

3/4-16 (15)

7/8-14 (15)

7/8-14 (15)

40 51

Test BRASS Cocks

1/4" IPS (4)

1/4" IPS (4)

1/2" IPS (4)

1/2" IPS (4)

1/2" IPS (4)

3/4" IPS (4)

3/4" IPS (4)

3/4" IPS (4)

ST STL Screw ST STL

3/8-16 x 1 (2)

3/8-16 x 1 (2)v

3/8-16 x 1 (2)

3/8-16 x 1 (2)

Cap- ST STL Screw

1/2-13 x 11/4(8)

3/8-16 x 7/8(12)

7/16-14 x 1 (16)

7/16-14 x 1 (16)

1/2-13 x 11/4(16)

5/8-11 x 11/2(16)

3/4-10 x 11/2(16)

3/4-10 x 13/4(24)

Bolt & STEEL Nut

1/2-13 x 13/4(12)

5/8-11 x 2 (12)

5/8-11 x 21/4(12)

5/8-11 x 21/2(12)

5/8-11 x 23/4(24)

3/4-10 x 3 (24)

3/4-10 x 31/4(24)

7/8-9 x 31/2(36)

O-ring BUNA-N

568-0141/2 x 5/8 x 1/16

568-014 1/2 x 5/8 x 1/16

568-116
3/4 x 15/16 x 3/32

568-116
3/4 x 15/16 x 3/32

568-118
7/8 x 1 1/16 x 3/32

568-118
7/8 x 1 1/16 x 3/32

These parts are commercially available through most ha
* Denotes parts only used on valves manufactured prior to 1981.

35

Commercial Parts for Main Valve - Model 825Y (3/4–2")

Item No.

DESC. Material SIZE SIZE SIZE SIZE SIZE3/4" 1" 11/4" 11/2" 2"

These parts are commercially available through most hardware distributors or retailers.

4 6 8 12

O-ring BUNA-N 568-202 568-202 568-202 568-202 568-202

15

Bolt

ST STL

5/16-18 x 3/4Hex Head

5/16-18 x 3/4Hex Head

5/16-18 x 3/4Hex Head

3/8-16 x 7/8Hex Head

3/8-16 x 7/8Hex Head

18

Screw

ST STL

1/4-20 x 3/880o Flat Head

1/4-20 x 3/880o Flat Head

1/4-20 x 3/880o Flat Head

1/4-20 x 3/880o Flat Head

1/4-20 x 3/880o Flat Head

22 24

O-ring BUNA-N 568-113 568-113 568-113 568-120 568-120 O-ring BUNA-N 568-022 568-022 568-022 568-127 568-127

*

Denotes parts only used on valves manu factured prior to 1981.

27

Screw

ST STL

10-32 x 3/8Round Head

10-32 x 3/8Round Head

10-32 x 3/8Round Head

1/4-20 x 1/2Round Head

1/4-20 x 1/2Round Head

28 29

Plug

BRASS

1/8" IPS

1/8" IPS

1/8" IPS

1/4" IPS

1/4" IPS

30 102

Test Cock O-ring

BRONZE BUNA-N

1/8" IPS 568-019

1/8" IPS 568-019

1/4" IPS

1/4" IPS 568-026

1/4" IPS 568-026

25

Cap Screw

ST STL

3/8-16 x 1 (8)

3/8-16 x 1 (8)

3/8-16 x 1 (8)

3/8-16 x 1 (8)

3/8-16 x 1 (8)

3/8-16 x 1 (8)

31A

O-ring

BUNA-N

568-145 29/16 x 23/4 x 3/32

568-145 29/16 x 23/4 x 3/32

568-145 29/16 x 23/4 x 3/32

568-145 29/16 x 23/4 x 3/32

568-145 29/16 x 23/4 x 3/32

568-145 29/16 x 23/4 x 3/32

36B

O-ring

BUNA-N

568-229 23/8 x 25/8 x 1/8

568-229 23/8 x 25/8 x 1/8

568-229 23/8 x 25/8 x 1/8

568-229 23/8 x 25/8 x 1/8

568-229 23/8 x 25/8 x 1/8

568-229 23/8 x 25/8 x 1/8

38 39 48

Cap Screw

ST STL ST STL ST STL

5/16-18 x 7/8 Hex (4)

5/16-18 x 7/8 Hex (4)

5/16-18 x 7/8 Hex (4)

5/16-18 x 7/8 Hex (4)

5/16-18 x 7/8 Hex (4)

5/16-18 x 7/8 Hex (4)

Cap ST STL Screw

1/4-20 x 5/8 1/4-20 x 5/8 1/4-20 x 5/8 15/16-18 x 3/4 15/16-18 x 3/4Allen Head Allen Head Allen Head Allen Head Allen Head

O-ring BUNA-N 568-226 568-226 568-226 568-235 568-235

Screw

ST STL

1/4-28 x 3/8Pan Head

1/4-28 x 3/8 Pan Head

1/4-28 x 3/8Pan Head

1/4-28 x 3/8Pan Head

1/4-28 x 3/8Pan Head

Gate valves, testcocks, flange gaskets, etc., are also commer- cially available, but not listed.

Gate Valve (w side tap)

BRONZE BRONZE

3/4" NPT
1/8" IPS Side Tap

1" NPT
1/8" IPS Side Tap

11/4" NPT
1/4" IPS Side Tap

11/2" NPT
1/4" IPS Side Tap

2" NPT
1/4" IPS Side Tap

Commercial Parts for Relief Valve - Model 825YD (21/2–10")

Item No.

DESC.

Material

SIZE 21/2"

SIZE 3"

SIZE 4"

SIZE 6"

SIZE 8"

SIZE 10"

22A

O-ring

BUNA-N

568-2021/4 x1/2 x1/8

568-2021/4 x1/2 x1/8

568-2021/4 x1/2 x1/8

568-2021/4 x1/2 x1/8

568-2021/4 x1/2 x1/8

568-2021/4 x1/2 x1/8

Pipe Nipple

1 1/2" IPS x Close

1 1/2" IPS x Close

1 1/2" IPS x Close

2" IPS x Close

2" IPS x Close

2" IPS x Close

Cap Screw

1/4-20 x 1/2Pan Head

1/4-20 x 1/2Pan Head

1/4-20 x 1/2Pan Head

1/4-20 x 1/2Pan Head

1/4-20 x 1/2Pan Head

1/4-20 x 1/2Pan Head

36 backflow device is also known as an RPZ valve. RPZ stands for Reduced Pressure Zone. This device is installed onto your plumbing system to protect your drinking water and the city water supply from contaminants.

RPZ valves are required when a house or building is equipped with an irrigation system, fire suppression system, or a large boiler (hereinafter referred to as Systems). Contaminants can enter an irrigation system from fertilizer or pesticides that are sprayed onto lawns. In the case of a boiler or fire suppression system, water sits stagnant or trapped in these systems, which leads to a build-up of bacteria and increased mineral content from the piping system.

If there is a water leak in the house, house water service break, city water main break, hydrant flushing, or hydrant use due to a fire, the water pressure in the house or city water mains can drop lower than the water pressure in the Systems. This can cause water from the Systems to back-up into the drinking water supply. The next time you or a neighbor turns on a faucet for a drink of water, the water received could contain contaminants. Even small fluctuations in city water mains that occur due to uneven water use from one neighborhood to the next can cause drops in pressure large enough to cause a back-flow and therefore contamination to occur.

If a drop in city or building water pressure occurs, the RPZ valve will open up, dumping water out rather than allowing the potentially  contaminated water to back-flow into the water supply. For these reasons, Illinois State Law requires the use of an RPZ as outlined in the Illinois State Plumbing code and Illinois Environmental Protection Agency. All city governments must comply with these laws. The law not only requires the use of an RPZ device but that device must be tested once every year. Only a licensed plumber with a Cross Connection Certification License can test and certify the proper operation of an RPZ valve. Once the RPZ is tested, the certification paperwork is forwarded by the plumber to the city.

It should also be noted that no building, house or system that currently requires protection by an RPZ is “grandfathered” from not having the proper device installed.