Watts Ames Colt Series User manual

RP/IS-A-C200/C300

Installation, Maintenance, and Repair Manual

Colt™Series C200, C300, LFC300

Double Check Valve Assemblies

Double Check Detector Assemblies

Sizes: 21⁄2" – 10"

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.

You are required to consult the local building and plumbing

codes prior to installation. If the information in this manual

is not consistent with local building or plumbing codes,

the local codes should be followed. Inquire with governing

authorities for additional local requirements.

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. If installed on

a ﬁre suppression system, all mechanical checks, such as alarms

and backﬂow preventers, should be ﬂow tested and inspected in

accordance with NFPA 13 and/or NFPA 25. 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 components helps assure

maximum life and proper product function.

WARNING

NOTICE

Inquire with governing authorities for local installation

requirements.

NOTICE

For Australia and New Zealand, line strainers should be installed

between the upstream shutoff valve and the inlet of the backflow

preventer.

It is important that this device be tested periodically in

compliance 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.

NOTICE

Due to shipping, storage, and general handling, the Victaulic

Coupling for the shutoff valves may have loosened and should be

retightened during installation.

C200-OSY-TS

Integrated supervisory tamper switches on

gate valves add protection against fire

Testing

For field testing procedure, refer to Ames installation sheets

IS-A-ATG-1 at watts.com..

For other repair kits and service parts, refer to the Backflow

Prevention Products Repair Kits & Service Parts price list

PL-A-RP-BPD at watts.com..

For technical assistance, contact your local Ames representative.

Basic Installation Instructions

Most field problems occur because dirt and debris present in

the system at the time of installation becomes trapped in the

check valves. The system should be flushed before the valve

is installed. If the system is not flushed until after the valve is

installed, remove both check modules from the valve and open

the inlet shutoff to allow water to flow for a sufficient time to flush

debris from the water line. If debris in the water system contin-

ues to cause fouling, a strainer can be installed upstream of the

backflow assembly.

Series C200 and C300 may be installed in either horizontal or

vertical position as long as the backflow assembly is installed in

accordance with the direction of the flow arrow on the assem-

bly and the local water authority approves the installation. The

assembly should be installed with adequate clearance around the

valve to allow for inspection, testing, and servicing. A minimum

clearance of 12" is needed between the lower portion of the

assembly and the floor or grade.

The control valves on the OSY-TS model have integrated super-

visory tamper switches that require connection to a fire alarm

control panel.

NOTICE

Assembly body should not be painted.

Horizontal Installation

Vertical Installation

Wiring the Tamper Switch

The supervisory tamper switch consists of two SPDT switches.

The device is designed to send a signal when the valve is closed

and when the switch is removed from the valve. In the neutral

position, the switch indicates the valve is fully open. Closing

the valve causes the switch rod to come out of the valve stem

groove, activating the switch. Removing the device also activates

the switch.

Use the schematic diagram and the wiring notes for proper

wiring of the tamper switch to a fire alarm control panel. (For

more information refer to Tamper Switch Wiring Instructions at

watts.com.)

CAUTION

Before wiring supervisory switches in fire protection sys-

tems, refer to the following standards:

NFPA 13: Standard for the Installation of Sprinkler Systems

NFPA 25: Inspection, Testing, Maintenance of Water-based Fire

Protection Systems

NFPA 70: National Electrical Code

NFPA 72: National Fire Alarm Code

CSA C22.1 NO.1 Canadian Electrical Code, Part 1, Safety

Standard for Electrical Installations Section 32

CAN/ULC-S524, Standard for Installation of Fire Alarm Systems

Wiring Notes

• Connection to power limited circuitry is required.

• The auxiliary switch is for supplemental use only and shall not

be used for fire alarm signaling applications.

• Switch functions are checked at the factory. Checking the

switch after field installation is strongly advised. Check conti-

nuity with the valve fully open. Switch functions activate within

two (2) turns from open.

WARNING

Metallic conduit required by NEC for proper grounding conduit

joint must be sealed with a conductive sealant.

Install switch in accordance with National Electrical Code and/or

local ordinances.

Wiring methods shall be in accordance with CSA C22.1,

Canadian Electrical Code, Part 1, Safety Standard for Electrical

Installations, Section 32 and CAN/ULC-S524, Standard for

Installation of Fire Alarm Systems Assure All Devices Are Properly

Grounded.

WARNING

Before servicing any Ames valve, it is mandatory to shut down

the water system by closing both the inlet and outlet shutoff

valves. After the shutoff valves are closed, open test cocks

No. 2, No. 3, and No. 4 to relieve pressure within the backflow

assembly.

1. After test cock No. 3 has been opened to relieve pressure,

remove it from the housing. (See Figure A.)

2. Insert a No. 3 screwdriver through the hole on the top of the

cover sleeve and using both hands rotate the cover sleeve

approximately 1/4-turn clockwise and 1/4-turn counter-clock-

wise to break the sleeve O-ring seals. Using the screwdriver,

slowly slide the cover sleeve to the downstream side of the

housing. (See Figure B.)

3. Remove the stainless steel check retainer from the housing.

(See Figure B.)

4. Remove the No. 1 check module by inserting two flat blade

screwdrivers into the slots on either side of the check module

and gently pry the check module toward the open zone. (See

Figure C.)

5. Repeat step 4 to remove check module No. 2. (For servic-

ing 6" checks, see the maintenance instructions for 8"–10"

checks on p. 4.)

6. To clean or inspect either check module, insert a No. 3

screwdriver through the downstream side of the check mod-

ule. (See Figures D and E.) When the screwdriver is in place,

remove the E-clip and pin connecting the structural member.

The check clapper opens with no tension. (See Figure F.)

7. Thoroughly clean the seating area. The sealing disc can be

removed, if necessary, by detaching the screws that con-

nect the keeper plate to the clapper. The sealing disc may be

reversed and reinstalled if the elastomer is cut or damaged.

8. Wash the check module and O-ring and inspect for any dam-

age. If damaged, reinstall new parts.

9. Apply an FDA-approved lubricant to the O-ring, next replace

the pin and E-clip in the structural members, then remove the

screwdriver and reinstall the check modules. Assemble the

housing by reversing the order of these instructions.

Maintenance Instructions 21⁄2" – 6"

Figure A Figure B Figure C

Figure D Figure E Figure F

Material/Tool Requirements

• No. 4 Phillips screwdriver or 3/8" diameter rod, length suf-

ficient to span diameter of check (See Figures A and B.)

• 1/2– 13" x 5" fully threaded hex bolt (Service bolt)

• 3/4" open end or socket wrench

Instructions

WARNING

Before servicing any Ames valve, it is mandatory to shut

down the water system by closing both the inlet and outlet

shutoff valves. After shutoff valves are closed, open test cock

No. 2, No. 3, and No. 4 to relieve pressure within the backflow

assembly.

1. After test cock No. 3 has been opened to relieve pressure,

remove test cock No. 3 from the housing. When repairing an

8" or 10" device, remove both Victaulic couplers from the

body. Slide the downstream Victaulic coupler gasket to the

downstream side of the housing. The upstream Victaulic

coupler gasket stays in place.

2. Remove the checks requiring maintenance.

3. Locate the service hole and thread in the service bolt by

hand until it contacts the linkage. (See Figure A.)

4. Continue to thread in the service bolt with the wrench until

the service hole in the linkage is aligned with the service

notches on the spring arbors. (See Figure A.)

5. Insert the Phillips screwdriver through the arbors and service

hole of the linkage ensuring that the tip of the screwdriver

extends past the ends of the arbors by a minimum of 1/4".

(See Figure B.)

6. Back out the service bolt until the load is transferred to the

screwdriver. Continue to back out the service bolt until suf-

ficient clearance is achieved to remove the complete spring

mechanism.

7. To disconnect the linkage, remove the retaining clip and pin.

(Store in a safe location for reinstallation.)

8. To remove the spring mechanism, grasp the screwdriver at

the center and pull the complete assembly straight out and

store it in a safe place.

9. Reinstall by reversing the order of these instructions.

WARNING

While the spring mechanism is removed for check servicing,

never pull the screwdriver out or off the support notches on the

arbors. Doing so may cause bodily injuries.

Maintenance Instructions 8" – 10"

Figure A

Figure B

Service Hole

Ball Type Test Valves

Needle

Valve

High Hose

(Yellow)

Low Hose

(White or Red)

Vent Hose

(Blue)

Test Cock Test Cock Test Cock Test Cock

No. 1 No. 2 No.3 No.4

Test Check Valve No. 1

1. Ensure shutoff No. 1 is open, and shutoff No. 2 is closed.

2. Connect the high side hose to test cock No. 3, the low side

to test cock No. 2, and open both test cock No. 2 and test

cock No. 3.

3. Open valve C, then open A to bleed air from the high side.

Close valve A, then open B to bleed low side. Close valve B.

4. Connect the vent hose loosely to test cock No. 1. Open

valve A to vent air from the vent hose. Tighten the vent hose

at test cock No. 1, and open test cock No. 1.

5:. Close shutoff No. 1. Slowly loosen the hose at test cock No.

2 until the differential gauge rises to 2psi and retighten the

hose. If the differential reading does not decrease, record the

check valves as “tight.”

Test Check Valve No. 2

1. Move the high side hose to test cock No. 4, the low side

to test cock No. 3, and open both test cock No. 3 and test

cock No. 4. Remove the vent hose from test cock No. 1,

and open shutoff No. 1.

2. Open valve C, then open valve A to bleed air from the high

side. Close valve A, then open valve B to bleed the low side.

Close valve B.

3:. Connect the vent hose loosely to test cock No. 1. Open

valve A to vent air from the vent hose. Tighten the vent hose

at test cock No. 1, and open test cock No. 1.

4. Close shutoff No. 1, then slowly loosen the hose at test

cock No. 3 until the differential gauge rises to 2psi and

retighten the hose. If the differential reading does not

decrease, record the check as tight. Remove all the hoses

and restore the valve to original working condition.

WARNING

The assembly will fail both the first and second check valve tests

above, if shutoff No. 2 leaks excessively. To test for a leaky No.

2 shutoff, use the following procedure.

Test for Leaky No. 2 shutoff

1. Connect the high side to test cock No. 1, the low side to test

cock No. 4. Open test cock No. 1 and test cock No. 4. Close

shutoffs No. 1 and No. 2.

2. Close valve C. Open valve A, next open valve B 1/2 turn, then

loosen the hose at test cock No. 4 to remove air. Retighten

the hose.

3. If the differential gauge rises above 0 (zero), there is excessive

leakage at shutoff No. 2. The shutoff must be replaced to test

the assembly.

Testing Double Check Valve Assemblies

6. Closure Sleeve Test Cock with O-ring

7. Closure Sleeve

5. E-clip and Clevis Pin

4. Elastomer Shutoff Disc

2. Second Check Module

8. Sleeve O-ring

3. Check Module O-ring

1. First Check Module

Parts

For repair kits and parts, refer to the Backflow Prevention

Products Repair Kits & Service Parts price list

PL-A-RP-BPD at watts.com.

Notes

Limited Warranty: Ames Fire & Waterworks (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 MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED IN DURATION TO ONE YEAR FROM THE DATE OF ORIGINAL SHIPMENT.

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

USA: Control Valves T: (713) 943-0688 • F: (713) 944-9445 • AmesFireWater.com

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

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

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