Hayward PBV series Manual

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HAYWARDFLOWCONTROL
SeriesPBVBackPressureValveand
SeriesRPVPressureReliefValve
INSTALLATION,OPERATION,ANDMAINTENANCE
INSTRUCTIONS

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TABLE OF CONTENTS
SafetyWarnings
SafetyPrecautions
Introduction
Description
Installation
Unpacking
Installation
Operation
Start-up
AdjustingtheSetPressure
Maintenance
RoutineMaintenance
PartsDetail
SpareParts
Specifications
Dimensions
LimitedWarranty

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SAFETY WARNINGS
PLEASE READ THE FOLLOWING INFORMATION PRIOR TO INSTALLING AND USING
HAYWARD SERIES PBV BACK PRESSURE VALVE AND SERIES RPV PRESSURE
RELIEF VALVES. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PRODUCT DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY, OR EVEN DEATH.
1. Hayward Flow Control (Hayward), a division of Hayward Industries, guarantees its
products against defective material and workmanship only. Hayward assumes no
responsibility for property damage or personal injury resulting from improper
installation, misapplication, or abuse of any product.
2. Hayward assumes no responsibility for property damage or personal injury resulting
from chemical incompatibility between its products and the process fluids to which they
are exposed. Determining whether a particular PVC, CPVC, PP or PVDF product is
suitable for an application is the responsibility of the user. Chemical compatibility
charts provided in Hayward literature are based on ambient temperatures of 70°F and
are for reference only.
3. Hayward products are designed for use with non-compressible liquids.
4. The maximum recommended fluid velocity through any Hayward product is eight feet
per second (8 ft/s). Higher fluid velocity can result in damage due to the water hammer
effect.
5. Piping systems must be designed and supported to prevent excess mechanical loading
on Hayward products due to system misalignment, weight, shock, vibration, and the
effects of thermal expansion and contraction.
6. The effect of temperature on plastic piping systems must be considered when the
systems are initially designed. The pressure rating of plastic systems must be reduced
with increasing temperature. Maximum operating pressure is dependent upon material
selection as well as operating temperature. Before installing any Hayward product,
consult Hayward product literature for pressure vs. temperature curves to determine
any operating pressure or temperature limitations.
WARNING
Hayward PVC and CPVC products should NEVER be used or tested
with compressible fluids such as compressed air or nitrogen. Use of
PVC and CPVC products in compressible fluid applications may
result in product damage, property damage, personal injury, or even
death.
WARNING
The Series PBV and RPV is intended for use in liquid service only.
Do not attempt to use this valve for controlling air or gases. Use of
this product in air or gas service may result in product damage,
property damage, personal injury, or even death.

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7. PVC and CPVC plastic products become brittle below 40°F. Use caution in their
installation and operation below this temperature.
8. Due to differential thermal expansion rates between metal and plastic, transmittal of
pipe vibration and pipe loading forces, DIRECT INSTALLATION OF PLASTIC
VALVES INTO METAL PIPING SYSTEMS IS NOT RECOMMENDED. Wherever
installation of plastic valves into metal piping systems is necessary, it is recommended
that at least 10 pipe diameters in length of plastic pipe be installed upstream and
downstream of the plastic valve to compensate for the factors mentioned above.
9. Published operating requirements are based on testing of new valves using clean
water at 70°F. Valve performance is affected by many factors including fluid chemistry,
viscosity, specific gravity, flow rate, and temperature. These should be considered
when sizing Hayward products.
10. Systems should always be depressurized and drained prior to installing or maintaining
any Hayward product.
11. Always follow your site and or company procedures for any safety training and or site
specific precautions or warnings in addition to those in this document.
WARNING
Hayward PVC and CPVC products should not be used in services with
operating temperature below 34°F.
WARNING
Failure to depressurize and drain system prior to installing or
maintaining valve may result in product damage, property damage,
personal injury, or even death.

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SAFETY PRECAUTIONS
Alwaysfollow thesafetyinstructionbelow:
Wearprotectiveclothingandglasseswhenworking
withornearchemicals.
RefertotheMSDSforallchemicalsused.
Useonly GenuineHaywardparts.Useofotherparts
mayresultindamagetoequipmentorinjuryand
invalidatewarranty.
Flushallcomponentsthatareincontactwith
chemicalspriortoservicing.
Secureallchemicalsandequipmentmakingthem
inaccessibletochildrenandpets.
Disposeallchemicalsandwasteaccordingtoall
local,stateandfederalregulations.
Stoptheflowofchemicalsthroughthesystemprior
toworkingonthevalve.
DoNotexceedthemaximumoperatingpressure.

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INTRODUCTION
Description:
Back Pressure Valve
The Hayward Series PBV, diaphragm back pressure valve, is used to
enhance the performance of chemical feed pumps and systems by
providing a constant discharge head pressure. These valves also function
as an anti-siphon valve. The diaphragm is held against the seat by the
internal spring. Back pressure is adjustable from 10 - 150 psi via the
adjustment screw. When the inlet pressure exceeds the preset pressure
the diaphragm lifts off the seat and the chemical flows to the injection point.
After each discharge stroke of the pump, as the pressure drops, the
diaphragm reseats itself.
Pressure Relief Valve
Hayward Series RPV, diaphragm pressure relief valve, is designed to
protect chemical feed pumps and systems from overpressure caused by
defective equipment or blockages in the chemical line. The 3 port design
allows chemical to flow through the valve via an internal chamber. When
the pressure in the chemical line exceeds the preset pressure of the valve
the diaphragm lifts off the seat and the chemical then flows out the bottom
port back to the chemical tank. Relief pressure is adjustable via the
adjustment screw in the top of the valve.

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INSTALLATION
Unpacking:
The carton should contain:
1 Backpressure valve or Pressure Relief valve
1 Instruction Manual
Accessories as ordered
Installation:
As a general rule, installation should follow the layout as outlined in the
“TYPICAL INSTALLATION” drawing. See page 11.
Back Pressure Valve:
Generally, the back pressure valve can be installed anywhere in the
discharge line, provided there is some downstream pressure at the dosage
point. If there is no downstream pressure the back pressure valve should
be installed at the dosage point to prevent siphoning and drainage of the
chemical line. The valve can be installed either vertically or horizontally.
The flow must be across the valve in the direction of the arrow. All PBVs
are factory set at 50 psi, unless otherwise specified. Field adjustment is
possible with the adjustment screw.
Back pressure valve performance will be enhanced with the installation of
a pulsation dampener to smooth out the discharge / suction cycles of the
pump. Thus, the diaphragm is free to float inside the valve chamber,
minimizing the wear on the stress points of the diaphragm. Pulsation
dampeners will also reduce the pressure drop across the valve by reducing
peak flows. Backpressure valves should be installed downstream of the
dampener. For most applications diaphragm type dampeners are required.
Generally speaking 5 to 10% dampening is sufficient. Consult with your
pump manufacturer to get his recommendations.

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Pressure Relief Valve:
3 Port Valves:
Installation should be made as close to the chemical pump discharge valve
as possible, without any equipment, especially shut-off valves, between the
valve and the pump. Direction of flow must be across the valve; however
the side of entry is not important. The valve can be installed either vertically
or horizontally. The relief port is on the bottom of the valve.
2 Port 180° Valves:
Installation of a tee should be made as close to the chemical pump
discharge valve as possible, without any equipment, especially shut-off
valves, between the valve and the pump. The flow can travel at 90° or 180°
through the tee, with the relief valve connected to the 3rd port of the tee.
Direction of relief flow must be in the direction of the arrow on the valve.
2 Port 90° Valves:
Installation of a tee should be made as close to the chemical pump
discharge valve as possible, without any equipment, especially shut-off
valves, between the valve and the pump. The flow can travel at 90° or 180°
through the tee, with the relief valve connected to the 3rd port of the tee.
Direction of relief flow must be in the side of the valve with the relief port
being on the bottom.
The optimum installation for any relief valve is to vent the relief port back to
the chemical tank, or directly to a containment area. However if this is not
possible, the relief port can be piped back into the suction side of the
pump. This will apply the suction head to the relief port. To compensate,
divide the NPSH by 4 and add this pressure to the relief valve setting. Do
not put a shut off valve in the relief line.
All RPVs are factory set at 50 psi, however field adjustment is possible
with the adjustment screw.

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Important Precautions:
Do not over tighten the connection piping.
Threading metal pipe or pipe fittings into plastic valves is not
recommended. See page 4.
Do not use thread sealant. Hayward recommends the use of
PTFE tape only for thread sealing.
Check to ensure that the valve bolts are tight.
Do not bottom out the adjustment screw.

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INJECTION
VALVE
HAYWARD
DRAIN VALVE
HAYWARD SHUT OFF
VALVE
HAYWARD Y-STRAINER
HAYWARD ISOLATING BALL VALVES
OPTIONAL PRESSURE RELIEF PIPING
CHEMICAL
CONTAINER
HAYWARD
CALIBRATION
CYLINDER
HAYWARD PRESSURE
RELIEF VALVE
CHEMICAL
FEED PUMP
PULSATION
DAMPENER
HAYWARD BACK PRESSURE / ANTI-SYPHON VALVE
C/W OPTIONAL PRIMING VALVE
PRESSURE
GAUGE
TYPICAL INSTALLATION
HAYWARD
BULK HEAD
FITTINGS

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OPERATION
Start-up:
Before starting the chemical feed system make sure the
backpressure and safety valves are installed correctly and the proper
pressures are set for the application. The valves are factory set at 50
psi unless otherwise specified. Valves can be field adjusted.
Adjusting Set Pressure:
The set pressure of the valves can be adjusted to any pressure value
between the maximum and minimum value as stated on the valve ID
tag. This is done via the adjustment screw located under the black
cap on the top of the valve. To increase the pressure, turn the screw
clockwise. This should be done with the pump operating and a
pressure gauge installed between the pump and the back pressure
valve. If no gauge is installed the pressure can be estimated to
change approximately 25 psi per revolution for ¼” and 3/8” valves,
approximately 8 psi per revolution for ½” through 4” valves using the
standard 150 psi spring. Consult factory for other spring options.
Caution:
Pressure setting changes should be made only after careful
consideration of the effect of the change on the entire hydraulic
system, including the chemical feed pump.
Never attempt to adjust the valve outside the pressure limit of the
spring as improper operation and/or damage to the valve and/or
system components may occur.

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MAINTENANCE
General:
Hayward valves were designed with a minimum amount of
maintenance required to keep the valves in operation. However,
periodic replacement of the diaphragm is required. The Hayward
design permits routine inspection and repair without removing the
valve from the pump line after depressurizing and flushing the valve.
Unscrew the pressure adjustment screw to remove the pressure from
the diaphragm. Remove the 4 bolts and lift off the valve top.
After the diaphragm and the valve seat have been inspected and
replaced if necessary, (White PTFE side down), check the adjustment
spring. Make sure there is no rust or corrosion. Place the support disc
and the spring onto the valve body and slide the top back over the four
bolts.
Tighten the 4 bolts, and then replace the adjustment screw. Turn the
adjustment screw clockwise to approximately the same position as it
was prior to disassembly. If an exact pressure setting is required or a
different pressure is desired a pressure gauge should be used to verify
the setting. Turning the adjustment screw clockwise will increase
pressure.
Use only genuine Hayward Valve parts in your Hayward
Valves.
Caution:
Ensure that the chemical feed system is not under pressure
and that the chemical lines have been flushed with water before
starting disassembly.

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PARTS DETAIL
1
Body Bolting - SS
2
Cap Nut - SS
3
Washer (not shown)
4
Dome
5
Body
6
Spring
7
Compressor
8
Diaphragm
9
Adjustment Screw
10
Protective Vinyl Cap

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SPARE PARTS:
Part or Kit
Number
Description
PBVDIAPE050
1/4" - 1/2" Diaphragm PTFE/EPDM
PBVDIAPE100
3/4" - 1" Diaphragm PTFE/EPDM
PBVDIAPE200
1-1/2" - 2" Diaphragm PTFE/EPDM
PBVDIAPV050
1/4" - 1/2" Diaphragm PTFE/FPM
PBVDIAPV100
3/4" - 1" Diaphragm PTFE/FPM
PBVDIAPV200
1-1/2" - 2" Diaphragm PTFE/FPM
PBV1SPRNG050
1/4" - 1/2" Pressure Spring 10 - 150 psi
PBV1SPRNG100
3/4" - 1" Pressure Spring 10 - 150 psi
PBV1SPRNG200
1-1/2" - 2" Pressure Spring 10 - 150 psi
PBV0SPRNG050
1/4" - 1/2" Pressure Spring 0 - 50 psi
PBV0SPRNG100
3/4" - 1" Pressure Spring 0 - 50 psi
PBV2SPRNG050
1/4" - 1/2" Pressure Spring 10 - 250 psi
PBV2SPRNG100
3/4" - 1" Pressure Spring 10 - 250 psi
PBVKITPE037
Rebuild Kit 1/4" - 1/2" (Diaphragm PTFE/EPDM,
Compressor, Adjustment Screw, Spring 10-150psi)
PBVKITPE100
Rebuild Kit 3/4" - 1" (Diaphragm PTFE/EPDM,
Compressor, Adjustment Screw, Spring 10-150psi)
PBVKITPE200
Rebuild Kit 1-1/2" - 2" (Diaphragm PTFE/EPDM,
Compressor, Adjustment Screw, Spring 10-150psi)
SPECIFICATIONS

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Sizes:
1/4”, 3/8”, 1/2”, 3/4”, 1”, 1-1/2”, 2”, 3”, 4”
Flow Rates @ 150 psi
Size:
Pulsating
Continuous
1/4”
3/8”
1/2”
3/4”
1”
1-1/2”
2”
3”
4”
100 USgph
200 USgph
300 USgph
367 USgph
462 USgph
1388 USgph
1533 USgph
5157 USgph
5157 USgph
5 USgpm
10 USgpm
15 USgpm
19.2 USgpm
24.2 USgpm
72.7 USgpm
80.3 USgpm
270 USgpm
270 USgpm
Max Temp:
(Body Material)
PVC: 140°F CPVC: 190°F
PP: 180°F PVDF: 300°F
Max Operating
Pressure @ 70°F
PVC, CPVC, PVDF: 250 psi
PP: 150 psi
Pressure Adjustment
Standard: 10 - 150 psi; Optional: 0 –50
psi, 10 –250 psi
Materials of Construction:
Diaphragm
PTFE / EPDM, FPM, & PTFE / FPM
Valve Body
PVC, CPVC, PP, PVDF
Dome
Glass Filled Noryl®

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DIMENSIONS
Size
A
B
C
in / mm
in/mm
in/mm
1/4”
3.55
/
90.2
2.35
/
59.7
0.750
/
19.1
3/8”
3.55
/
90.2
2.35
/
59.7
0.750
/
19.1
1/2”
4.25
/
108
2.35
/
59.7
1.08
/
27.4
3/4”
5.56
/
141
3.50
/
88.9
1.13
/
28.6
1”
5.86
/
149
3.50
/
88.9
1.25
/
31.8
1-1/2”
8.35
/
212
4.90
/
124
1.83
/
46.4
2”
8.90
/
226
4.90
/
124
2.15
/
54.6
3”
Please Consult Hayward Tech Services
4”
*Three port design for ¼” –1” RPV.
Optional Port configurations available, consult Hayward.
*

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NOTES

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NOTES

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TWO YEAR WARRANTY: All products manufactured by Hayward are
warranted against defects in material or workmanship for a period of two
years from date of shipment. Our sole obligation under this warranty is to
repair or replace, at our option, any product or any part or parts thereof found
to be defective. HAYWARD MAKES NO OTHER REPRESENTATION OR
WARRANTY, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO,
ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE. The warranty set forth above is the only warranty
applicable to Hayward products and in no event shall Hayward be liable for
any delay, work stoppage, cartage, shipping, loss of use of equipment, loss of
time, inconvenience, loss of profits of any direct or indirect incidental resulting
from or attributable to a breach of warranty. The remedies under this
warranty shall be the only remedies available. OUR MAXIMUM
LIABILITY SHALL NOT IN ANY EVENT EXCEED THE CONTRACT PRICE
FOR THE PRODUCT.
Note:
Noryl is a registered trademark of SABIC Innovative Plastics IP B.V.