AMES 982GD User manual

Installation, Operation and Maintenance
Pump Control Control Valve with Backpressure Feature
Sizes: 2" to 24"
NOTICE
For Australia and New Zealand: Pipeline strainers should be
installed between the upstream shutoff valve and the inlet of
the backflow preventer.
It’s important that this device be tested periodically in compli-
ance with local codes, but at least once per year or more as
service conditions warrant. If installed on a fire sprinkler system,
all mechanical checks, such as alarm checks and backflow
preventers, should be flow tested and inspected internally in
accordance with NFPA 13 and NFPA 25.
WARNING
!
Read this Manual BEFORE using this equipment.
Failure to read and follow all safety and use information
can result in death, serious personal injury, property
damage, or damage to the equipment.
Keep this Manual for future reference.
Table of Contents Page
Introduction............................................2
Installation ............................................2
Commissioning the Booster Pump Control Valve ..............3
Maintenance Schedule...................................6
Trouble Shooting Guide ..................................6
Valve Disassembly Instructions ........................ 8
ACV Schematic .......................................11
Local building or plumbing codes may require modifica-
tions to the information provided. You are required to
consult the local building and plumbing codes prior
to installation. If the information provided here is not
consistent with local building or plumbing codes, the
local codes should be followed. This product must be
installed by a licensed contractor in accordance with
local codes and ordinances.
WARNING
!
Need for Periodic Inspection/Maintenance: This product
must be tested periodically in compliance with local codes,
but at least once per year or more as service conditions
warrant. All products must be retested once maintenance
has been performed. Corrosive water conditions and/or
unauthorized adjustments or repair could render the product
ineffective for the service intended. Regular checking and
cleaning of the product’s internal and external components
helps assure maximum life and proper product function.
WARNING
!
Model 982GD / 682GD
IOM-A-ACV-982_682

982GD (Globe) Pump Control Control Valve with Backpressure Feature
2 IOM-A-ACV-982_682 2115 EDP# 1917092 © 2021 Watts
Standard Components
Operation
The Pump Control Valve with Backpressure Feature is designed to
minimize the surges associated with the starting and stopping of
pumps. The valve slowly opens and closes as required to control
pumping related surges, and throttles to maintain a minimum back-
pressure against the pump during the pumping cycle. The pump
starts and stops against a closed valve.
Pump Start Up: When the pump is signaled to start, the 3-Way
Solenoid is energized, directing pressure into the cover chamber of
the 3-way Accelerator Pilot. The Accelerator Pilot allows the main
valve cover chamber to be vented downstream, causing the valve
to open at a controlled rate, gradually admitting pumping pressure
into the distribution system. The rate of opening is controlled by the
adjustable opening speed control, which restricts the speed of fluid
and pressure evacuating the main valve cover chamber. The valve
remains open during the pumping cycle.
Backpressure Feature: During the pumping cycle, the valve acts
as a Backpressure Control Valve. When pump discharge pressure
falls below an adjustable minimum, the valve modulates toward a
closed position, increasing backpressure against the pump. Throttling
(Backpressure) action is controlled by a normally closed control pilot
designed to: 1) Open (allowing fluid out of the main valve cover cham-
ber) when pump discharge pressure is above the adjustable setpoint,
and, 2) Close (allowing fluid to fill the main valve cover chamber
through the integral orifice of the Accelerator Pilot) when pump dis-
charge pressure is below the adjustable setpoint. An increase in pump
discharge pressure causes the valve to modulate toward an open
position. A decrease in pump discharge pressure causes the valve to
modulate toward a closed position.
1
XX
Y/FC
2
3
5
6
7
6
8
XX
4(L)
CLOSES VALVE
OPENS VALVE
FLOW
Installation
1. Prior to installation, flush line to remove debris.
2. Install valve so the flow arrow matches flow through the line, and gauges to monitor valve inlet and outlet pressures.
3. Install isolation valves upstream and downstream of the main valve.
4. Provide adequate clearance for valve servicing and maintenance. Refer to valve servicing dimensions on next page. Avoid installing valves
6" and larger in the vertical position (main valve stem horizontal). Automatic Control Valves (ACVs) are designed for horizontal in-line instal-
lation, with the cover facing up (main valve stem vertical). Slow operation or premature stem and guide wear may occur if valve is not
installed according to factory recommendations. Consult factory for detailed engineering review prior to ordering if valve is to be installed
other than horizontally in-line.
5. If valve is equipped with a pilot control system, extra precautions should be made during installation to protect the piping circuit from dam-
age. Only remove the pilot control system from the valve if necessary. Tubing and fittings should be kept clean and replaced exactly as
removed. Consult appropriate hydraulic schematic to ensure proper re-assembly.
6. Connect solenoid wiring leads to desired switching device, using safe, standard electrical practices.
7. Install a pressure gauge at a location upstream of the valve.
8. After installation, vent entrapped air from valve cover and pilot system by following instructions on Technical Bulletin.
Start-up of an automatic control valve requires that proper procedures be followed. Time must be allowed for the valve to react to adjustments and the
system to stabilize. The objective is to bring the valve into service in a controlled manner to protect the system from damaging over-pressure.
Pump Shutdown: When the pump is signaled to turn off, the 3-Way
Solenoid is de-energized, venting the cover chamber of the 3-way
Accelerator Pilot. The Accelerator Pilot allows the main valve cover
chamber to be connected to upstream pressure, causing the valve to
close at a controlled rate. The valve slowly begins to close while the
pump continues to operate. The closing rate of the valve is controlled
by the adjustable closing speed control, which restricts the speed of
fluid and pressure entering the main valve cover chamber. When the
valve reaches the closed position, the limit switch is actuated, turning
the pump off.
Hydraulic Check Feature: When the pump is turned off and down-
stream pressure is greater than upstream pressure, downstream pres-
sure is admitted to the main valve cover chamber through a check
valve in the pilot control system, closing the valve, preventing reversal
of flow.
Manual Operation: Engaging the Solenoid Manual operator simulates
power to the solenoid, manually opening the main valve. Disengaging
the Solenoid Manual operator returns the valve to the closed position.
1 – Main Valve (905GD – Single Chamber)
2 – Pressure Sustaining Control
3 – Model 22 Accelerator Control
4 – Limit Switch
5 – 3-Way Solenoid
6 – Check Valve
7 – Adjustable Opening Speed
8 – Adjustable Closing Speed
X – Isolation Cocks
Y – Y-Strainer

The following tables detail the recommended minimum valve servicing dimensions.
A
B
C
FLOW FLOW
FLOW
D
FLOW
Valve Servicing Dimensions
IOM-A-ACV-982_682 2115 EDP# 1917092 © 2021 Watts 3
Commissioning the Booster Pump Control Valve
STEP 1
Pre-set pilots as noted:
Pressure Sustaining – Turn Sustaining Control adjustment screw, OUT, counterclockwise, backing pressure off the spring, to allow it to
stay open during while adjusting the other controls.
Opening and Closing Speed – Turn the adjustment screws on the Closing Speed and Opening Speed Controls, if the main valve is so
equipped, OUT, counterclockwise, 1½ to 2½ turns from full closed position.
3-Way Solenoid – Confirm that the manual operator is turn counter clockwise to a full OUT position (See Figure 1).
STEP 2
Energize the solenoid to check actuation and to confirm connec-
tion to power source.
STEP 3
De-energize the solenoid prior to initial pump start.
STEP 4
Loosen a tube fitting or cover plug at the main valve to allow air to
vent during start-up.
STEP 5
Energize the solenoid at pump start to open the main valve,
checking that the main valve opens. Air is vented through the
loosened fitting. Tighten the fitting when liquid begins to vent.
Globe
Angle
Size (in) 1¼ 1½ 2 2½ 3 4 6 8 10 12 14 16 20 24
A (in) 16 16 20 22 22 24 32 34 38 44 48 52 56 56
B (in) 10 10 12 14 14 16 24 26 28 30 34 40 48 48
Size (in) 1¼ 1½22½ 3 4 6 8 10 12 14 16
C (in) 16 16 20 22 22 24 32 34 38 44 48 52
D (in) 10 10 12 14 14 16 24 26 28 30 34 40
Clockwise for MANUAL
Operation
Figure 1
3-Way Solenoid

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Setting the Sustaining Control
STEP 7
Setting the Sustaining Control requires lowering the upstream
pressure to the desired minimum sustained pressure.
STEP 8
Leave the downstream isolation valve full open and close the
upstream isolation valve until the inlet pressure drops to the
desired setting.
STEP 9
Adjust the Sustaining Control screw IN, clockwise, until the inlet
pressure begins to increase (See Figure 3A), or OUT, counter-
clockwise, to decrease (See Figure 3B), stopping at the desired
pressure.
STEP 10
Allow pressure to stabilize.
STEP 11
Fine-tune the sustaining setting as required as detailed in STEP 8.
STEP 12
Open upstream isolation valve to return to normal operation.
STEP 12
De-energize solenoid to check that the main valve closes.
STEP 13
At valve closure booster pump will stop. Adjust limit switch collar
to final position to ensure positive actuation of limit switch elec-
trical contact, if necessary, by sliding up/down to location (See
Figure 4).
STEP 6
Opening Speed Flow Control Adjustment: The Opening speed
needle valve restricts flow out of the cover of the main valve.
If the main valve is opening too slowly turn the adjustment screw
OUT, counterclockwise, increasing the rate of opening (See Figure
2B).
If the main valve is opening too quickly, turn the adjustment screw
IN, clockwise, decreasing the rate of opening (See Figure 2A).
Figure 4
Limit Switch in Closed Position
Counterclockwise to INCREASE
the rate of opening
Clockwise to DECREASE
rate of opening
2A 2B
Figure 2
Flow Control
Figure 3
PV20C — Pressure Sustaining Control
Clockwise to increase inlet
pressure
3A 3B
Counterclockwise to decrease
inlet pressure

To ensure peak performance and longevity of your automatic
control valve, Watts/Ames recommends following the below
standard maintenance schedule.
• Monthly Maintenance
– Visual inspection of valve(s) for leaks
– Inspect for proper operation(s); exercise valve.
• Quarterly Maintenance
– Conduct monthly inspection.
– Validate/Re-establish necessary setpoints of controls/pilots.
• Annual Maintenance
– Conduct monthly & quarterly inspections.
– Inspect & clean all strainers.
– Inspect valve coating, touch up as required.
• 3-5 Year Maintenance
– Conduct monthly, quarterly, & annual maintenance.
– Inspect & replace valve elastomers (diaphragm, O-rings,
valve/pilot seats)
– Re-establish necessary set points of controls/pilots.
Automatic Control Valve Maintenance Schedule
Troubleshooting Guide
Warning: The valve cannot be serviced under pressure.
Upstream and downstream Isolation Valves must be installed
to protect system piping. Accurate diagnosis and trouble-
shooting requires the valve to open fully, and may subject
downstream piping and equipment to high pressure and/or
flow rates. The downstream Isolation Valve should be kept
closed while diagnosing the valve.
Extreme caution should be used while performing the
troubleshooting techniques listed below.
WARNING
!
Recommended tools for diagnosis: (3) PRESSURE GAUGES,
installed to monitor the inlet pressure, outlet pressure, and cover
chamber pressure. If included, a POSITION INDICATOR should
be installed to visually assess the position of the disc &
diaphragm assembly.
Test 1: Diaphragm Seal Test
1. Close upstream & downstream isolation valves. Close pilot
isolation valves or remove pilot control tubing to isolate valve
cover from incoming fluid & pressure. Remove uppermost
cover plug, test cock, or limit switch.
2. With the valve cover chamber vented to atmosphere,
partially open the upstream isolation valve, allowing incoming
pressure to lift the disc & diaphragm assembly. A volume of
water will be displaced from the cover chamber as the valve
opens; consult valve specification sheets for approximate
cover capacity. A continuous flow of water from the open port
indicates a damaged diaphragm or loose disc & diaphragm
assembly. Disassemble valve and replace diaphragm or tighten
disc & diaphragm assembly.
Test 2: Seat Seal Test
1. Close downstream isolation valve and install pressure gauges
on an open inlet and outlet port of main valve.
2. Open upstream isolation valve to allow pressure on to the
valve cover. Allow valve to fully close.
3. Monitor downstream pressure gauge; reading should hold
steady below incoming pressure. If pressure on downstream
side rises to match upstream pressure, leakage is occurring
through the seat of the main valve. Disassemble valve, inspect
and repair/replace any required parts.
a. If gauge pressure rises to match outlet pressure (down-
stream of closed isolation valve) yet remains below inlet
pressure, the isolation valve may be leaking as opposed to
main valve seat.
Test 3: Freedom of Movement/Valve
Travel Test
1. Close upstream and downstream isolation valves. Install valve
position indicator.
2. Partially open upstream isolation valve and allow cover to fill
with fluid & pressure, closing the valve fully. Mark the position
indicator’s full closed position.
3. Isolate cover chamber from receiving fluid and pressure by
closing isolation valves or removing control tubing.
4. Carefully vent cover chamber to atmosphere by opening test
cock or removing a cover plug. Observe the valve position
indicator as the valve travels to the full-open position. The disc
& diaphragm assembly should move freely from fully closed to
fully open position without binding or “grabbing” at any point
during its movement.
a. The disc & diaphragm assembly may momentarily “hesi-
tate” while travelling from fully closed to fully open position
– this is a normal characteristic of diaphragm operated
control valves, and does not indicate mechanical binding
or improper valve operation.
b. A continuous discharge of water from the cover chamber
after venting to atmosphere indicates leakage past the
diaphragm.
5. If necessary, disassemble valve and inspect/repair disc &
diaphragm assembly.
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Troubleshooting Guide
6 IOM-A-ACV-982_682 2115 EDP# 1917092 © 2021 Watts IOM-A-ACV-982_682 2115 EDP# 1917092 © 2021 Watts 7
Issue Possible Cause Corrective Action Notes
Main Valve will not
open
Closed isolation valves in pilot system. Check isolation valves, ensure
open.
Insufficient supply pressure. Check upstream pressure. Depending on water
source, supply pressure
may not be controlled by
valve operator.
Main valve stem assembly corroded/
damaged
Inspect stem assembly, clean/
replace if necessary.
Blockage in pilot system. Inspect & clean any installed
pilot system strainers, check
orifice/speed controls for
blockages.
Improperly configured opening speed
control.
Adjust opening speed control
to verify functionality, adjust as
required.
Standard setting for open-
ing speed control is 1 1/2
- 2 1/2 turns open from full
closed position. Can be
adjusted in field.
Pressure Sustaining Control not oper-
able
Rebuild or replace Pressure
Sustaining Control
Main Valve will not
close
Closed isolation valves in pilot system Check isolation valves, ensure
open.
Diaphragm is damaged Conduct diaphragm seal test,
repair and replace if necessary.
Main valve stem assembly corroded/
damaged.
Inspect stem assembly, clean/
replace if necessary.
Blockage in main valve. Perform freedom of movement
test; if valve does not close,
disassemble and remove
blockage.
Worn/damaged valve seat. Perform seat sealing check;
disassemble and inspect/re-
pair seat if required.
Improperly configured closing speed
control.
Adjust closing speed control
to verify functionality, adjust as
required.
Standard setting for
closing speed control is
11/2 - 21/2 turns open from
full closed position. Can
be adjusted in field.
Solenoid will not
actuate
Possible Cause: Low or no voltage Check voltage at the solenoid
connection, insuring that it has
the minimum of 85% of the
coils rated voltage.
Should be performed by
licensed electrician
Manual operated is engaged Turn manual operator counter-
clockwise to disengage

Valve Disassembly Instructions
Before undertaking valve disassembly, it is recommended to gather the following tools to aid you during the process:
• Small & large adjustable wrenches
• Screwdriver set
• Machinist fine metal file
• Fine wire brush
• Bench vise
• Basic valve IO&M manual
• Hammer & dull cold chisel
• Heavy-duty ratchet & socket set
• Hexagonal wrench set
• 320 grit/fine Emery cloth
• Appropriate technical bulletins for
valve start-up procedures.
1. Isolate the valve from line pressure and depressurize it to ensure safe working conditions. Disconnect any electrical
connections if so equipped.
2. Carefully remove Position Indicator or Limit Switches if equipped. Remove all tubing, fittings, and Control Pilots
necessary to easily access and remove the cover. Remove cover nuts and washers.
3. Remove the cover. If cover is not free to be removed, loosen it by tapping upward along its outside edge with a dull cold chisel, pic-
tured above.
a. Large valves may require the installation of lifting “eye” bolts in order to facilitate cover removal; installation ports are provided on
the cover for this purpose.
4. Remove the Disc and Diaphragm Assembly from the valve body by lifting straight up.
a. Large diameter valves may require a lifting “eye” bolt to be installed in the valve stem accessory threads located on the very
top of the valve stem.
5. Before removing Stem Nut, examine stem threads for mineral build-up. Remove deposits with a fine wire brush. Extreme care should
be taken not to damage the finish on stem guiding surfaces when disassembling. Avoid applying pipe wrenches to top or bottom
stem guide surfaces.
VALVE COVER
BRASS BAR STOCK
(ANGLE UPWARD)
HAMMER
6 IOM-A-ACV-982_682 2115 EDP# 1917092 © 2021 Watts IOM-A-ACV-982_682 2115 EDP# 1917092 © 2021 Watts 7

Size A B C D E (Dia.) F
in Pipe Size (in) Min. Length (in) in in in in
1¼ 1 3.12 0.38 0.25 0.44 0.55
1½ 1 3.12 0.38 0.25 0.44 0.50
2 1¼3.38 0.38 0.25 0.44 0.50
2½ 2 4.0 0.38 0.38 0.56 0.62
3 2½4.5 0.50 0.38 0.56 0.62
4 3 5.0 0.50 0.44 0.56 0.62
6 5 6.50 0.62 0.44 0.56 0.62
6. After removing the Stem Nut, the remainder of the Disc & Diaphragm Assembly should disassemble easily. Polish stem guide
surfaces with fine emery cloth to remove any mineral deposits and inspect for excessive wear. Remove any mineral build-up from
other components with wire brush or by using a Mineral Dissolving Solution. Inspect parts for wear and replace if necessary.
7. Inspect valve seat. If seat is not damaged, removal is not necessary. Valve seats 6" and smaller are threaded into the body of the
valve and require a seat removal tool (Figure 5) (Table 1 details the tool dimensions for seat removal). Valve seats 8" and larger are
held in the valve body with stainless steel cap screws. Remove seat retaining screws and lift seat straight up (Figure 6).
Figure 6
*Schedule 40 steel pipe
Figure 5
Valve Body
Valve Seat
All-Thread
Nut and Washer
2PLCS
Angle or
Channel Iron
120
B (Min)
E Dia. 4 Holes
90 Apart
D
TYP <3 PLCS>
120 Apart
C TYP <3 PLCS>
F
A
Table 1: Seat Removal Tool Dimension
8 IOM-A-ACV-982_682 2115 EDP# 1917092 © 2021 Watts IOM-A-ACV-982_682 2115 EDP# 1917092 © 2021 Watts 9

8. Replace Seat Disc, Diaphragm and Spacer Washers provided in Main Valve repair kit (refer to Table 2 or 3 for correct repair kit part
number). Re-assemble in the reverse order of disassembly.
9. Re-Install Disc and Diaphragm Assembly in the valve, taking care not to damage the lower guide area in the center of the valve
seat.
10. Re-install Cover Spring. Replace Valve Cover and tighten Cover Nuts in a crossing pattern to ensure even distribution. Test the Disc
and Diaphragm Assembly for smooth travel by following the Freedom of Movement Test procedure in previous section.
11. Test the integrity of the Seat Seal by following the Seat Seal Test procedure in previous section.
12. Return valve to service by following instructions on the Technical Bulletin matching the valve function.
Size (in) 1¼ 1½22½ 3 4 6 8 10 12 14 16
P/N 0677-01 0677-01 0677-02 0677-03 0677-04 0677-05 0677-06 0677-07 0677-08 0677-09 0677-10 0677-11
Table 3: Reduced Port Valve (605GD/605AD) Repair Kits
Table 2: Full Port Valve (905GD/905AD) Repair Kits
8 IOM-A-ACV-982_682 2115 EDP# 1917092 © 2021 Watts IOM-A-ACV-982_682 2115 EDP# 1917092 © 2021 Watts 9
Size (in) 3 4 6 8 10 12 16 20 & 24
P/N 0677-02 0677-04 0677-05 0677-06 0677-07 0677-08 0677-09 0677-11

10 IOM-A-ACV-982_682 2115 EDP# 1917092 © 2021 Watts IOM-A-ACV-982_682 2115 EDP# 1917092 © 2021 Watts 11
Optional
Xylan
Coating
17A
6
1
2
3
4
5
7
8
9
11
12
13
14
15
16
17
18
10
Item Description Material
1Pipe Plug Lead Free Brass
2Cover ASTM A536 65-45-12 Epoxy Coated Ductile Iron
3Cover Bearing ASTM A276 304 Stainless Steel
4Stud with Cover Nut and Washer ASTM A570 Gr.33 Zinc Plated Steel
5Body ASTM A536 65-45-12 Epoxy Coated Ductile Iron
6Spring ASTM A276 302 Stainless Steel
7Stem Nut ASTM A276 304 Stainless Steel
8Lock Washer ASTM A276 304 Stainless Steel
9Stem Washer ASTM A276 304 Stainless Steel
10 Diaphragm Washer ASTM A536 65-45-12 Epoxy Coated Ductile Iron
11 Diaphragm* Buna-N (Nitrile)
12 Disc Retainer ASTM A536 65-45-12 Epoxy Coated Ductile Iron
13 Seat Disc* Buna-N (Nitrile)
14 Spacer Washer* x5 NY300 Fiber*
15 Disc Guide ASTM A743 CF8M (316) Stainless Steel
16 Shaft ASTM A276 304 Stainless Steel
17 Seat Ring** ASTM A743 CF8M (316) Stainless Steel
17A Seat Screw** (8" and Larger) ASTM A276 304 Stainless Steel
18 Seat Gasket* Buna-N (Nitrile)
* Contained in Main Valve Repair Kit
**Note: 6 inch and Smaller Valves, Seat Ring is threaded
Installation: If unit is installed in any orientation other than
horizontal (cover up) OR extreme space constraints exist,
consult customer service prior to or at the time of order.
NOTICE
ACV Assembly Diagram – Series 982GD

10 IOM-A-ACV-982_682 2115 EDP# 1917092 © 2021 Watts IOM-A-ACV-982_682 2115 EDP# 1917092 © 2021 Watts 11
NOTES

IOM-A-ACV-982_682 2115 EDP# 1917092 © 2021 Watts
USA: Backflow T: [phone] • F: [phone] • AmesFireWater.com
USA: Control Valves T: [phone] • F: [phone] • AmesFireWater.com
Canada: T: [phone] • F: [phone] • AmesFireWater.ca
Latin America: T: (52) 55-4122-0138 • AmesFireWater.com