Watts Lfm116-52 Installation and operating instructions

Installation, Operation and Maintenance

Pressure Relief and Surge Anticipator Control Valve

Sizes: 1¼" 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

Setting the Pressure Controls .............................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

psi

AVOIDFREEZING

100

140

120

160

190

200

Model LFM116-52/LFM6116-52

IOM-ACV-116-52_6116-52

Standard Components

Operation

The Combination Surge Anticipator and Pressure Relief Automatic

Control Valve (ACV) is designed to minimize the effects of water

hammer and pressure surges resulting from: 1) Normal pump start-

ing and stopping operations or 2) Mechanical or electrical power

failure situations. The valve senses hydraulic pressure changes

directly from the pump station discharge header, and opens to

relieve pipeline surges when pump station discharge header pres-

sure falls below the adjustable spring setting of the low pressure

opening pilot OR exceeds the adjustable spring setting of the high

pressure relief pilot. These two pressure conditions occur during

normal pump starting and stopping operations or when an active

pumping cycle is interrupted by electrical or mechanical failure.

X X

7A 7B

P(L)

CLOSES VALVE

OPENS VALVE

FLOW

X / Y

Supply

Pressure

1. Clear the line free of slag and other debris.

2. Install the valve so that the FLOW ARROW marked on the valve body/tag corresponds to flow through the line.

3. Close upstream and downstream isolation valves.

4. Open the ball valves or isolation cocks in the control tubing if so equipped. Failure to open these will prevent the valve from func-

tioning properly.

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.

High Pressure Relief Operation: When discharge header pressure exceeds the adjustable setpoint, the high pressure relief pilot

opens, venting main valve cover pressure downstream, causing the valve to quickly open and dissipate the high pressure surge. When

discharge header pressure falls below the adjustable setpoint, the high-pressure relief pilot closes, allowing pressure to fill the main

valve cover chamber, slowly closing the valve. This condition occurs during normal pump starting and stopping operations.

Low Pressure Opening Operation (Surge Anticipation): When discharge header pressure falls below the adjustable setpoint, the

low-pressure pilot opens and the drain pilot closes, "storing" main valve cover pressure in the hydraulic accumulator. The main valve

opens at an adjustable rate in anticipation of the returning high-pressure wave. This condition occurs during a mechanical or electrical

power failure situation.

Valve Closing: When discharge header pressure recovers above the adjustable setpoint, the low-pressure pilot closes, allowing header

pressure to fill the main valve cover chamber. The main valve closes at an adjustable rate to avoid creating additional pressure surges.

The accumulator drain pilot opens, releasing the "stored" main valve cover pressure.

If discharge header pressure does not "recover" above the low-pressure opening setpoint, the "stored" pressure in the hydraulic accu-

mulator allows the main valve to close, avoiding system siphonage or draining the pumping system.

1 – Main Valve (M100 – Single Chamber)

2 – Adjustable Closing Speed

3 – Adjustable Opening Speed

4 – Pressure Relief Control

5 – Low Pressure Control

6 – Accumulator Drain Valve

7 – Test Valves

8 – Pressure Gauge

9 – Hydraulic Accumulator

P – Position Indicator

Y – Y-Strainer

X – Isolation Cocks

Installation

LFM116-52 (Globe) Pressure Relief and Surge Anticipator

Control Valve

STEP 1

Pre-set pilots as noted:

Low Pressure Control – Adjust OUT, counterclockwise, allowing the valve to be brought up to the desired pressure in a controlled

manner.

Relief Control – Turn the adjustment screw OUT, clockwise, backing pressure off the spring, allowing valve to be brought up to the

desired high pressure in a controlled manner.

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.

STEP 2

To ensure proper operation, any trapped air will need to be bled off

the valve cover during startup. If your ACV includes a bleed valve,

use a flat head screwdriver to slowly open the valve (Figure 1).

If your valve does not include a bleed valve, bleed air by loosen-

ing a fitting on the valve or a plug, at the highest point of the valve

assembly.

STEP 3

Pressure the line, by opening the upstream isolation valve slowly

Air is vented through the air bleed valve or loosened fitting.

Tighten the fitting when liquid begins to vent (See Figure 1).

Repeat the process until no air is trapped in the system.

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

Counterclockwise to OPEN

bleed valve

Setting the Pressure Controls

The following tables detail the recommended minimum valve servicing dimensions.

FLOW FLOW

FLOW

Valve Servicing Dimensions

Figure 1

Position Indicator

Setting the High Pressure

Relief Control

STEP 4

Slowly open downstream isolation valve to establish flow through

the system.

STEP 5

With pump operating, throttle a downstream isolation valve

closed.

STEP 6

Adjust the Relief Control adjustment screw IN, clockwise, until the

inlet pressure rises to the desired high pressure relief setting (See

Figure 2).

Figure 2

PV20C — Pressure Sustaining Control

Clockwise to increase inlet

pressure

Counterclockwise to decrease

inlet pressure

Setting the Low Pressure

Control

STEP 7

Close test valve 7A (See Figure 3) and use test valve 7B to reduce

gauge pressure to the desired low pressure tip point. (typically

10-20 PSI below static line pressure).

Clockwise to CLOSE

Test Valve

Counterclockwise to INCREASE

the rate of opening

Clockwise to DECREASE

rate of opening

STEP 8

Slowly turn the 263 Low Pressure Control (See Figure 4) adjust-

ment screw IN, clockwise, until the main valve starts to open. This

setting can be confirmed by opening the test valve 7A, which will

raise the gauge pressure, then slowly lowering the gauge pressure

using test valve 7B until the main valve starts to open. When the

low pressure control is finally set, ensure that test valve 7A is left

fully open.

STEP 9

Once the approximate time for the pressure wave to return has

been calculated, the main valve can be cycled using test valves

and the opening speed adjusted such that the main valve will be

open before the wave arrives. The closing speed control (See

Figure 5) should be adjusted so that the main valve will not com-

mence closing until after the wave has passed. Closing speed

should not be so rapid that main valve closure itself creates sig-

nificant line shock.

Figure 5

Flow Control

Figure 3

Test Cock

Counterclockwise to CLOSE

main valve

Clockwise to OPEN

main valve

Figure 4

263RS - Low Pressure Control

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.

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.

Missing fixed orifice assembly. Verify installation of orifice;

replace if required/missing.

Pilot valve inlet isolation

valve can be used as a

makeshift orifice assembly

by partially opening from

full closed position.

Improperly configured opening speed

control (if equipped).

Adjust opening speed control

to verify functionality, adjust as

required.

Standard setting for

opening speed control is

1½ - 2½ turns open from

full closed position. Can

be adjusted in field.

Main Valve will not

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/repair

seat if required.

Troubleshooting Guide

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

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 6) (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 7).

Figure 7

*Schedule 40 steel pipe

Figure 6

Valve Body

Valve Seat

All-Thread

Nut and Washer

2PLCS

Angle or

Channel Iron

120

B (Min)

E Dia. 4 Holes

90 Apart

TYP <3 PLCS>

120 Apart

C TYP <3 PLCS>

Table 1: Seat Removal Tool Dimension

Size (in) 3 4 6 8 10 12 16 20 & 24

P/N 0677-01 0677-01 0677-02 0677-03 0677-04 0677-05 0677-09 0677-11

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 2: Full Port Valve (M100/M1100) Repair Kits

Table 3: Reduced Port Valve (M6100 / M61100) Repair Kits

Optional

Xylan

Coating

17A

ACV Assembly Diagram – Series LFM116-52

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

USA: T: (978) 689-6066 • F: (978) 975-8350 • Watts.com

Canada: T: (888) 208-8927 • F: (905) 481-2316 • Watts.ca

Latin America: T: (52) 55-4122-0138 • Watts.com

Limited Warranty: Watts Regulator Co. (the “Company”) warrants each product to be free from defects in material and workmanship under normal usage for a period of one year from the date of

original shipment. In the event of such defects within the warranty period, the Company will, at its option, replace or recondition the product without charge.

THE WARRANTY SET FORTH HEREIN IS GIVEN EXPRESSLY AND IS THE ONLY WARRANTY GIVEN BY THE COMPANY WITH RESPECT TO THE PRODUCT. THE COMPANY MAKES NO OTHER

WARRANTIES, EXPRESS OR IMPLIED. THE COMPANY HEREBY SPECIFICALLY DISCLAIMS ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO THE IMPLIED

WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

The remedy described in the first paragraph of this warranty shall constitute the sole and exclusive remedy for breach of warranty, and the Company shall not be responsible for any incidental, special

or consequential damages, including without limitation, lost profits or the cost of repairing or replacing other property which is damaged if this product does not work properly, other costs resulting

from labor charges, delays, vandalism, negligence, fouling caused by foreign material, damage from adverse water conditions, chemical, or any other circumstances over which the Company has no

control. This warranty shall be invalidated by any abuse, misuse, misapplication, improper installation or improper maintenance or alteration of the product.

Some States do not allow limitations on how long an implied warranty lasts, and some States do not allow the exclusion or limitation of incidental or consequential damages. Therefore the above

limitations may not apply to you. This Limited Warranty gives you specific legal rights, and you may have other rights that vary from State to State. You should consult applicable state laws to

determine your rights. SO FAR AS IS CONSISTENT WITH APPLICABLE STATE LAW, ANY IMPLIED WARRANTIES THAT MAY NOT BE DISCLAIMED, INCLUDING THE IMPLIED WARRANTIES OF