Jafar 1350 User manual

OPERATION AND MAINTENANCE MANUAL 01-2016
Operation and maintenance
manual for
REDUCED PRESSURE ZONE ANTIPOLLUTION
(ANTICONTAMINATION CHECK VALVES
P/N
1350
Approved for use by
President of Factory, JAFAR S.A.
Failure to comply with the guidelines and instructions in this Operation and
Maintenance Manual releases the manufacturer from all obligations, liability and guarantee.
Due to continuous business development, we reserve the right to introduce
modifications and design changes to the presented product.

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2
CONTENTS
1 TECHNICAL DESCRIPTION............................................................................................................................ 3
1.1 PRODUCT DESIGNATION AND IDENTIFICATION.............................................................................. 3
1.2 USE............................................................................................................................................................... 3
1.3 TECHNICAL SPECIFICATION.................................................................................................................. 3
2 DESIGN............................................................................................................................................................... 4
2.1 DESCRIPTION OF THE VALVE DESIGN................................................................................................ 4
2.2 MATERIALS................................................................................................................................................ 6
2.3 DIMENSIONS.............................................................................................................................................. 7
2.4 REFERENCE STANDARDS....................................................................................................................... 8
2.5 ORDERING INFORMATION ..................................................................................................................... 8
2.6 PRODUCTION AND ACCEPTANCE ........................................................................................................ 8
2.7 MARKINGS ................................................................................................................................................. 9
3 PROTECTION, STORAGE & TRANSPORT.................................................................................................... 9
3.1 PROTECTIVE COATINGS......................................................................................................................... 9
3.2 PACKAGING............................................................................................................................................... 9
3.3 STORAGE.................................................................................................................................................... 9
3.4 TRANSPORT ............................................................................................................................................... 9
4 ASSEMBLY AND INSTALLATION............................................................................................................... 10
4.1 ASSEMBLY GUIDELINES....................................................................................................................... 10
4.2 ASSEMBLY INSTRUCTIONS.................................................................................................................. 10
4.3 OPERATION.............................................................................................................................................. 11
4.4 OCCUPATIONAL HEALTH AND SAFETY........................................................................................... 11
5 WARRANTY TERMS AND CONDITIONS ................................................................................................... 11

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1 TECHNICAL DESCRIPTION
1.1 PRODUCT DESIGNATION AND IDENTIFICATION
The subject of this Operation and Maintenance Manual is:
Type BA reduced pressure zone antipollution (anticontamination) check valves.
1.2 USE
The P/N 1350 type BA low-pressure antipollution (anticontamination) check valves are intended for
protecting building water supply systems from contamination backflow within the pressure range from 0.05 MPa
to 1.6 MPa and temperatures up to +70ºC.
1.3 TECHNICAL SPECIFICATION
The P/N 1350 type BA low-pressure antipollution (anticontamination) check valves
are intended to protect water supply systems from contamination with backflow liquids.
- Available diameters: DN65-DN250
- Max medium flow rate: 4 m/s;
- Max operating pressure (PS): 1.0 MPa
1.6 MPa
- Max operating temperature (TS): 70ºC.
The valves are designed according to PN-EN 12729: 2005, a product standard for devices which
protect potable water from backflow contamination, controllable backflow preventer with a reduced pressure
zone, family B, type A.
A distinct feature of the Type BA antipollution check valves is a two-chamber design which allows
isolating the incoming medium flow and automatic removal of medium residues from the reduced
pressure chamber.
Protection against pollution of potable water in water installations and general requirements
of devices to prevent pollution by backflow are explained in PN-EN 1717: 2003, where type BA valves can be
controllable and protect potable water supply installations from pollution with Category 2 liquids.
Antipollution valves can be used as check valves in indoor installation only when placed
between a water meter and the receiver(s) and generally in horizontal pipelines. The valve body features a flow
direction arrow.
The valve connection flange design is acc. to PN-EN 1092-2: 1999, with the sizes compliant with the
nominal pressure values.
Nominal PN pressure: - 0.6 MPa
- 1.0 MPa
- 1.6 MPa
Installation length of flanged and bell socket tapped antipollution valves:
- see the size table.

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2 DESIGN
2.1 DESCRIPTION OF THE VALVE DESIGN
The Type BA antipollution check valves supplied by F.A. JAFAR S.A. are flanged valves. The
antipollution check valve is designed with a cast iron tubular body, a valve cover and two poppet valve
units, which form the valve closing components, and a membrane drain valve. The two closing components
are poppets with rubber seals. Each poppet is seated on a spring and within a guide that enables
reciprocating action. The poppet and its guide are made of brass. The poppet seal seat is located within the
guide. The valve body is divided into three chambers separated by the two poppet assemblies. Both poppets
are located on the valve outlet end which facilitates movement of the spring-supported poppet away from its
seat to open the valve under the incoming water pressure. If the water flow ceases, the spring moves the
poppet automatically to the seat which closes the valve and prevents backflow. Under the valve body cover
is a membrane valve, located within the centre line and transverse to the direction of water flow. The
membrane valve is a disk installed on a metal spindle, one end of which is within the valve cover bush and
the other is within the drain port seat, located at the valve body bottom. The chamber over the membrane
disk is open to the valve inlet chamber. The chamber under the membrane disk is the central zone between
the inlet and the outlet ends and separated by the two poppet closing components. Hence the membrane
valve is a pilot which seals off the bottom drain port when the flow comes into the valve and opens the drain
port when the flow is gone. The operating parameters of each mushroom closure assembly make the drain
port close when the medium pressure is present in the antipollution valve, followed by opening of the inlet
poppet and then opening the outlet poppet. If the pressure drops, first the inlet poppet is closed, followed by
the outlet poppet. When the inlet pressure drops to a pressure differential of 0.14 bar (0.014 MPa) between
the inlet chamber and the middle chamber, the membrane valve spring opens the drain port seat to evacuate
the middle chamber. This action applies only when the supply pressure drops. During the normal operating
cycle, the drain valve should not open.
The antipollution valve body has three tapped inspection holes, each for one zone of the valve. The Type BA
antipollution valves installed in horizontal pipes shall have the inspection holes pointing upwards. The
inspection holes are sealed with threaded plugs and facilitate control by sampling.
All inner and outer cast-iron surfaces of the valve are protected against corrosion with epoxy powder
coating.

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2.2 MATERIALS
The table below lists the structural materials of the antipollution poppet valves.
Item Part designation Material Reference standard
1 Body EN-GJS-400-15 PN-EN 1563: 2012
2 Cover EN-GJS-400-15 PN-EN-1563: 2012
3 Outlet valve guide CuZn39Pb1Al-B PN-EN 1982: 2010
4 Drain valve spindle CuZn39Pb1Al-B PN-EN 1982: 2010
5 Drain valve seat X5CrNi18-10 PN-EN 10088-1: 2014
6; 7;
18 Spring X5CrNi18-10 PN-EN 10088-1: 2014
8 Pressure disk X5CrNi18-10 PN-EN 10088-1: 2014
9 Membrane EPDM PN-EN ISO 1629: 2005
10; 11;
23 Gasket EPDM PN-EN ISO 1629: 2005
12 Head POM Manufacturer's catalogue
13 Drain valve poppet POM Manufacturer's catalogue
14 Drain valve poppet guide POM Manufacturer's catalogue
15 Valve cover bush POM Manufacturer's catalogue
16 Guide CuZn39Pb1Al-B PN-EN 1982: 2010
17 Poppet CuZn39Pb1Al-B PN-EN 1982: 2010
19 Thrust nut CuZn39Pb1Al-B PN-EN 1982: 2010
20 Retaining ring X5CrNi18-10 PN-EN 10088-1: 2014
21 Pin X5CrNi18-10 PN-EN 10088-1: 2014
22 Pressure plate X5CrNi18-10 PN-EN 10088-1: 2014
24 Drain ball valve Manufacturer's catalogue
25; 26;
27; 28;
29
O-ring EPDM PN-EN ISO 1629: 2005
30 Bolt Stainless steel PN-EN ISO 4762: 2006
31 Washer Stainless steel PN-EN ISO 7091: 2003
32 Eye bolt Steel, Fe/Zn5 PN-92/M-82472

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2.3 DIMENSIONS
DN
L
H
D
d
K
PN16 (PN10)
I
PN16 (PN10)
n
PN16 (PN10)
Weight
- [kg]
65* 356 150 185 122 145 -
80 440 155 200 138 160 30.0
100* 530 180 220 158 180 -
150* 630 210 285 212 240 -
200* 765 240 340 268 295 12(8) -
250* 770 270 405 320 355 (350) 28 (23) 12 -
[mm]
19
23
8

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2.4 REFERENCE STANDARDS
PN-EN 1074-1: 2002 Valves for water supply. Fitness for purpose requirements and appropriate
verification tests. General requirements
PN-EN 1074-3: 2002 Valves for water supply. Fitness for purpose requirements and appropriate
verification tests. Check valves.
PN-89/H-02650 Valves and pipelines. Pressure and temperature ratings.
PN-EN 1092-2: 1999 Flanges and their joints. Circular flanges for pipes,
valves, fittings and accessories, PN designated. Cast iron flanges.
PN-EN 19: 2005 Industrial valves. Marking of metallic valves
PN-EN 12266-1: 2012 Industrial valves. Testing of metallic valves. Pressure tests, test procedures
and acceptance criteria. Mandatory requirements.
PN-EN 1559-1: 2011 Founding. Technical conditions of delivery. General.
PN-EN 1563: 2012 Founding. Spheroidal graphite cast irons.
PN-EN 1370: 2012 Founding. Surface roughness inspection by
visual tactile comparators.
PN-EN 10088-1: 2014 Stainless steels. List of stainless steels.
PN-74/H-84032 Spring steel. Grades.
PN-EN 1982: 2010 Copper and copper alloys. Ingots and castings.
PN-EN 12420: 2002 Copper and copper alloys. Forgings.
PN-ISO 965-1: 2001 ISO general purpose metric screw threads. Tolerances. Principles and basic
data.
PN-EN ISO 4762: 2006 Hexagon socket head cap screws.
PN-EN 10204: 2006 Metallic products. Types of inspection documents.
PN-ISO 1629: 2005 Rubbers and latices. Nomenclature.
PN-EN 1717: 2003 Protection against pollution of potable water in water installations and
general requirements of devices to prevent pollution by backflow.
PN-EN 12729: 2005 Devices to prevent pollution by backflow of potable water. Controllable
backflow preventer with reduced pressure zone. Family B. Type A.
PN-EN 13959: 2005 Z Anti-pollution check valves. DN 6 to DN 250 inclusive Family E, type A,
B, C, and D.
PN-EN ISO 12944-5: 2009 Paints and varnishes. Corrosion protection of steel structures by protective
paint systems. Protective paint systems.
2.5 ORDERING INFORMATION
Water supply system valves are specific purpose industrial valves, therefore
purchase orders must include:
- Part Number (P/N)
- intended use, e.g. for water supply systems
and:
- nominal diameter, acc. to PN-EN ISO 6708: 1998;
- nominal pressure, acc. to PN-89/H-02650;
- type of body material, acc. to PN-EN 1563: 2012
- maximum operating temperature, acc. to PN-89/H-02650.
2.6 PRODUCTION AND ACCEPTANCE
The Type BA P/N 1350 antipollution valves are manufactured and accepted in accordance with:
PN-EN 1074-3:2002 (Valves for water supply. Fitness for purpose requirements and appropriate verification
tests. Check valves) and PN-EN 12266-1:2007 (Industrial valves. Testing of metallic valves). All valves are leak
tested (100%). The tests include external body tightness and closing tightness at high and low pressure values.

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2.7 MARKINGS
The valve marking meets the following standards: PN-EN 19: 2005, PN-EN-1074-1: 2002.
The antipollution valve bodies feature markings on the front and back walls of the body.
The marking contains the following data:
- valve type (defined by the product reference standard number)
- nominal diameter
- nominal pressure
- body material type
- manufacturer trademark
The location on the valve specified in the documentation features the nameplate which contains
the following data: - manufacturer's company name and logo;
- product serial number
- sealing temperature rating
- Polish Construction Mark "B" and/or the CE mark (as applicable)
- product type.
3 PROTECTION, STORAGE & TRANSPORT
3.1 PROTECTIVE COATINGS
All inner and outer cast-iron surfaces are protected with
electro-deposited epoxy coat. The coat has been approved for contact with foodstuffs. The anti-corrosion coating
layer minimum thickness is 250µm. The casting surface is pre-treated for epoxy coating in accordance with the
relevant technical documentation and PN-EN ISO 12944-5: 2009.
3.2 PACKAGING
The antipollution check valves are packed on EURO pallets (1200x800) and protected
with heat-shrunk film.
3.3 STORAGE
Store the antipollution check valves in sheltered rooms.
3.4 TRANSPORT
Transport the check valves on sheltered vehicles. The DN65 to DN250 valves
shall be handled on slings and secured from turning.

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4 ASSEMBLY AND INSTALLATION
4.1 ASSEMBLY GUIDELINES
The Type BA P/N cast-iron flanged antipollution check valves can be
installed in overground pipelines in horizontal orientation as shown in the following
figure. The flanged valves are designed for installation between flanged pipe connections
of a matching size. Note that the system must not expose the valve to bending or tensile stress from
loading with the unsupported pipeline sections.It is recommended to perform installation works
considering pipeline compensation due to temperature and pressure. The valve assembled and delivered
by the manufacturer is ready for installation. Disassembly of the valve components
without proper care may result in loss of integrity.
4.2 ASSEMBLY INSTRUCTIONS
Before attempting to install the valve, check the technical and commercial documents
delivered with the product to verify that the media, and especially pipeline operating parameters (flow rate
range) comply with the manufacturer's declaration. Any change in the operating conditions must be consulted
with the valve manufacturer beforehand.
Before attempting to assemble the valve, remove the main bore plugs, check the inner
surfaces of the valve and thoroughly flush with water, if necessary.
Caution! If the product has mechanical damage, do not install it in the pipeline.

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The assembly method for the anticontamination valve is shown in the following figure:
4.3 OPERATION
The antipollution check valves shall be operated according to the requirements for check valves,
in the orientation shown in the recommended installation orientation diagram. It is recommended to periodically
purge the valve with fresh water (once a year) to assure full performance. Hard solids with the size above 1mm
should be filtered out of the transmitted medium by an upstream filter to prevent seizure of the poppet gear and
damage to the seals.
Install cut-off valves upstream and downstream of the valve to allow maintenance.
Install the valve horizontally with its drain valve downwards;
connect the drain valve to a drainage system (sewage pipework or drain gullies) with a minimum of 20 mm of air
gap between the top edge of the drain line and the drain valve outlet. A filter should be installed directly
upstream of the valve. The installation site and method shall assure free access for maintenance and servicing.
Do not install the valve in a location exposed to flooding.
The product shall not be exposed to temperatures outside of the permissible operating range.
Overrunning the valve operating limits may damage the valve
and the manufacturer's suretyship liability shall not apply.
4.4 OCCUPATIONAL HEALTH AND SAFETY
The antipollution check valves are eligible for
the OHS guidelines and recommendations concerning installation of pipelines and devices for: water supply
stations, heat power plants, water treatment plants, sewage treatment plants, pumping stations and other
facilities, and eligible for the Polish Regulation concerning general OHS laws (use of personal protective
equipment for hands, legs and head, and safety garment), especially at work with low or high temperature
hazard.
Misuse of this product is prohibited.
5 WARRANTY TERMS AND CONDITIONS
The product assembled, installed and operated in compliance with this Manual is covered by a commercial
warranty from the manufacturer.
The warranty terms, conditions and period are specified in the relevant Warranty Sheet.