JOMAR Add-A-Valve User manual

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ADD-A-VALVE®
INSTALLATION INSTRUCTIONS
For Technical Support
Call 1-800-325-5690 or visit:
jomarvalve.com/aav.html
Included Parts Additional Tools
• Add-A-Valve®
• JomarS-100NE
• GasketSealant(Loctite®518)
• Brush
• ExtraViton®O-Rings(2)
• Shraeder®testcaps(2)
• Needle-nosepliers
• Flatheadscrewdriver
• Hammer
• Adjustablewrench
• Ratchetwrench
• Open-endwrench
• Emerycloth
• OptionalforDoubleStemModels(1-1/4”-2”):
ºDrill(electricorcordless)withsocketadapter
ºCordlessbackupbatteryrecommended
Before you start:
• Verifythatthereisnotariskofdeadheadingapumpduringinstallation.
• IsolatetheAdd-A-Valvelocationorreducetheowrateasmuchasthesystemwillallow.   
 Ideally,installtheAdd-A-Valveonastaticline.
ATTENTION:
Jomar requires that the Add-A-Valve® installer view the Jomar installation video prior to attempting
installation. Failure to do so will relinquish Jomar from any and all liability for improperly installing
an Add-A-Valve® device. In this case, Jomar will not be responsible, nor will it exchange or provide a
refund for any improperly installed Add-A-Valve®.
Video is available for viewing on the Jomar website at: www.jomarvalve.com/aav.html
NOTE: The Jomar Add-A-Valve® is engineered for ONE-TIME use as an emergency shut-o󱐯
device! Once the stem cutter has been raised, DO NOT lower it again.

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Step 1
BeforeinstallingtheAdd-A-Valve®,cleanthecoppertubingwitha
neemeryclothuntilthecoppertubinghasabright,shinynish.
Step 2
DisassembletheAdd-A-Valve®bodybyremovingthefour(4)316
stainlesssteelbolts.
Applythegasketsealanttobothbodyhalvesandallow1-2
minutesfordrytime.
Step 3
Applyaliberalamountoftheprovidedgasketsealant(Loctite®518)
andbrushevenlyacrosstheentirebodyhalfsurface.
CAUTION
PipehangersupportsshouldbeinstalledonbothsidesoftheAdd-A-Valve®to
eliminatestressattheendsofthevalve.Ifhangerscannotbeinstalled,itisNOT
recommendedtousetheAdd-A-Valve®.
12”

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Step 4
Assemblethetwobodyhalves
aroundthecoppertubing.
NOTE: Be sure the stem cutter is
backed out all the way so that the
cutter does not make contact with
the copper tubing.
Step 6
Totesttheinstallation,performanairtest.Toperformanairtest,
removethestemandbottomcapandscrewonthetestcapsthatare
suppliedinthekit.
Step 7
Pumpairintobothtestcapsatapproximately15-20PSI.Thisteststhe
installationsealantandvalvebodiesforleaks.
Step 8
Spraytheentirebodyofthevalvewithasoapywatersolutionand
inspectthevalveforbubbles.
Ifbubblesarevisible,repositionortightentoensureatighttandno
leaks,thenretesttheAdd-A-Valve.
DONOTproceedwiththeAdd-A-Valve®installationuntiltesting
succeeds.
Step 5
Usingaratchetandwrench, tighten the four (4) 316 stainless steel bolts in an ‘X’
pattern to a torque of 95 - 105 in/lb.Donotovertighten,asyoumaystripthebolts
andcausealeak.IfaslightgapbetweenthetwohalvesoftheAdd-A-Valve®is
detected,makesurethegapisevenlydistributedonbothsidesofthebody.
NOTE: A closed gap on one side and an open gap on the other will cause a leak.
Additionally, it will prevent the cutter from making a straight cut and will damage
the pipe, thereby making it susceptible to breakage or a leak.
Ensureevengap
distributiononallaxes/
directions.
CORRECT INCORRECT
Unevengapdistribution
canleadtoinstallfailure.
12”
CAUTION
PipehangersupportsshouldbeinstalledonbothsidesoftheAdd-A-Valve®
toeliminatestressattheendsofthevalve.Ifhangerscannotbeinstalled,itis
NOTrecommendedtousetheAdd-A-Valve®.
X

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Step 9
Aftertheairtestsaresuccessfulandnovisiblebubblesarepresent,
removebothtestcapsandreplacewiththestemcutterandthebottom
cap.
NOTE: Ensure the stem cutter is backed out all the way, to prevent the
cutter from making contact with the copper tubing.
Now,engagethestemcutter.
Useamanual3/8”socketwrench.
Usingsteadypressure,ratchetthestemcutterdownuntilbothwallsofthecoppertubing
havebeencut.
NOTE:DoNOTuseadrillmotor.
Step 11
Removebothcopperslugsandushthedebris.Todothis,removethebottomcap.
Somewatermaybetrappedhere.Ifthewaterdoesnotappeartobecompletely
shuto󱐯,removethebottomcapcompletelyandslowlyratchetthestemcutterdown
furtheruntilthewaterowstops.
Toremoveslugs,takeahammerandaatheadscrewdrivertogentlytapthehigh
sideofthetwocopperslugsintoaverticalpositionandremovetheslugswithneedle
nosepliers.
Note:Toushdebris,reversethestemcutterwithbottomcapo󱐯untilyouseeaow
ofwater.Debrisshouldbeushed.Reseatthevalveuntiltheowstopsandreplace
cap.NowusetheAdd-A-Valve®tomakearepairorasalive,hottap.The Jomar Add-
A-Valve® is engineered for ONE-TIME use as an emergency shut-o󱐯 device. Once
the stem cutter has been raised, DO NOT lower it again.
This is a TWO person operation.
Usea9/16”socketwrenchonthestemcutter,andwiththehelpofasecondperson,useanopen-end
wrenchontheouterstem.Thissetsthedepthofthecutandpreventsthecutterfrombinding.Slowlyturn
bothwrenchessimultaneously.
OPTIONAL:Adrillcanbeusedtoturnthestemcutterataconstant,slowRPM,whileusinganopenbox
wrenchtoadjustdepth.Donotadvancetheouterstemataratethatcausesthecuttertobind.Ifthecutter
beginstobind,stopthedrillandretracttheouterstemby¼turn.Slowlyrestartthedrillandcontinue
advancingtheouterstemdown.Ifusingacordlessdrill,haveabackupbatteryandadditionalsocketwrenchonhand.
NOTE: ThisoptionisfordoublestemmodelsONLY.DonotuseadrillmotoronAdd-A-Valvesizes1”andbelow(singlestemmodels).
SINGLE STEM For sizes 1/2” to 1”
DOUBLE STEM For sizes 1-1/4” to 2”
Step 10
When the stop ring is reached, the seating position of the valve is met. At this time, ratchet
approximately one to one and a half turns to expand the Viton® seal across the two pipe cuts.
Determine what size Add-A-Valve® you have and follow the corresponding directions:
12”
CAUTION
PipehangersupportsshouldbeinstalledonbothsidesoftheAdd-A-Valve®to
eliminatestressattheendsofthevalve.Ifhangerscannotbeinstalled,itisNOT
recommendedtousetheAdd-A-Valve®.