IOM-F-825_826 I N S TA L L AT I O N , O P E R AT I O N , M A I N T E N A N C E Operation and Maintenance Manual Reduced Pressure Backflow Prevention Assemblies Models 825Y, 825YA, 825, 825D, 825YD & 826YD Series 825YA Series 825Y Series 826YD TABLE OF CONTENTS Features and Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD Feature and Operating Procedures Reduced Pressure Backflow Preventer FEBCO manufactures several models of Reduced Pressure Backflow preventers. The Model 825Y and 825YA are available in sizes 3/4–2" with bronze body and cover as standard. Other materials are available. The FEBCO Model 825 sizes 21/2–10" were manufactured with cast iron.
MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD Installation Guidelines Proper installation of the assembly is essential to the protection of the water supply 1. The assembly should be installed in a horizontal position with a minimum clearance of 12" between the relief valve discharge port and floor or grade, and a minimum of 18" horizontal clearance around the unit for access and ease of testing and maintenance of the relief valve. 2.
MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD Freeze Protection Procedure for the winter to prevent freeze damage. The reduced pressure backflow prevention assembly is subject to damage if the internal water is allowed to freeze. It is suggested that all assemblies be installed with resilient seated shutoffs so that a drip tight closure can be achieved to prevent refilling of the assembly after the freeze protection procedure is performed.
MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD Vandalism Protection Procedure 1. If the unit is installed where vandalism may be a problem, the assembly should be protected and secured. On 3/4–2" units the handles of shutoff valves can be removed to discourage tampering. On 21/2–10" units a chain can be looped between shutoffs and locked in position to prevent tampering with shutoff valves. Test cock handles can also be removed.
MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD General Service Procedures General Service Instructions applicable to all models and sizes. 1. FEBCO backflow prevention assemblies can be serviced with commonly available tools and are designed for ease of maintenance. The assemblies are designed to be serviced in line, so the unit should not need to be removed from the line during servicing. 2.
MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD Troubleshooting Procedure With Differential Pressure Gauge Without Differential Pressure Gauge SYMPTOM NO. 1: SYMPTOMS NO. 1 AND NO. 2: CHECK DIFFERENTIAL ACROSS NO. 1 CHECK VALVE A) Close Gate Valve No. 2 READING PROBLEM RESULT PROBLEM 2 to 3 PSID Leak in No. 1 or If discharge stops Leak in No. 2 check valve No.
MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD Troubleshooting Guide (Continued) SYMPTOM: CAUSE: 4. Relief valve does not open above 2.0 psid during a. Outlet gate valve not closed completely. a. Check for debris blocking gate. b. Plugged low pressure hydraulic passage b. Inspect and clean. field testing. SOLUTION: (from “ZONE” to inner diaphragm). c. Improper alignment of internal parts during reassembly (causing high resistance to c.
MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD Field Testing Procedures Purpose of Test To test the operation of the DIFFERENTIAL PRESSURE RELIEF VALVE and CHECK VALVE. Test Check Valve 1 Equipment Required for Test The check valve must be at least 3 psi more than the relief valve opening pressure. Differential Pressure Gauge test kit. Equal to the RPTK1 (shown on page 13). 1. Open test cock #4 to flow a small amount of water through the unit to restore normal pressures.
MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD Field Testing Procedures (Continued) Test for the 826YD Restore Operation This device is tested with the same procedure as the Model 825YD. However, the bypass 825Y 3/4" valve must be isolated from the mainline valve using the 3/4" ball valves during the test and tested separately. After testing restore all valves to their original positions. Proper Bypass Operations Flow 3 GPM through the bypass by opening the mainline test cock #4.
MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD Service Procedure 825Y and YA (3/4–2") 1. Check Valve Inspection/Repair Model 825Y (¾–2") (See Figure No. 11) a. Close inlet and outlet shut-off valves. Bleed residual pressure by opening first the #4 test cock, then the #3 and #2 test cocks. See Figure No. 7 for test cock locations b. Unscrew Cap using appropriate size wrench. CAUTION: Cap is spring loaded. First check spring force on / " to 11/2" is 10 lb.
MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD Service Procedure 825Y and YA (3/4–2") (Continued) d. Close the #4, #3, and #2 test cocks and slowly open first the inlet and then outlet shutoff valves and return the assembly to service. See Figure No. 7 for test cock locations. e. Test the assembly to ensure it is operating properly. 4. Relief Valve Inspection/Repair Model 825Y (3/4–2") (See Figure No. 11) a.
MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD Service Procedure 825Y and YA (3/4–2") (Cont.) 6. Relief Valve Reassembly Model 825Y (3/4–2") (See Figure No. 11) a. Lubricate the seat ring o-ring with FDA approved lubricant and thread seat ring into the valve body until seated. Do not over tighten. (Replaceable relief valve seat ring standard on units manufactured after October of 1988.) b.
MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD Model 825Y and YA (3/4–2") Parts Model 825Y & YA Part Numbers (Sizes ¾–2”) ITEM DESCRIPTION NO. 3 Bushing 3 SIZE ¾" 500-290 SIZE 1" 500-290 SIZE 1¼" 500-290 SIZE 1½" 500-290 SIZE 2" 500-290 QTY.
MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD Model 825Y, 825YR and YA (3/4–2") Parts (Cont.) Assemblies / Kits: Model 825Y & YA DESCRIPTION QTY. * 1 Kit Check Valve Rubber Kit (2 ea. 8, 10) 1 Kit Relief Valve Rubber ( 1 ea. 17, 22, 24, 25) 2 As sy. Check Valve As sembly (1 ea. 8, 9, 10, 11, 12) Relief Valve Assembly (1 ea. 17, 18, 19, 20, 21, 22, 23, 1 As sy.
MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD Service Procedures 825, 825D, 825YD and 826YD (21/2–3") 1. Check Valve Disassembly Models 825, 825D and 825YD (Sizes 21/2–3") (See Figure No. 13) a. Slowly close outlet shutoff valve and inlet shutoff valve. Bleed residual pressure by opening #4, #3 and # 2 test cocks. See Figure No. 8 for test cock location. b. Remove cover bolts uniformly while holding cover in place. Remove cover. 3a.
MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD Service Procedures 825, 825D, 825YD and 826YD (21/2–3") (Continued) 3b. Valve Seat Removal (Sizes 2½–3") Bolted in Seat Ring Type Models 825D & 825YD (See Figure No. 14) 1. Remove the three capscrews and washers retaining the seat ring. 5. Check Valve Reassembly (Sizes 2½–3") (See Figures No. 15 & 16) a. Position the disc in the cleaned holder and retain with disc washer. Insert stem into disc holder, replace the nut on stem and tighten. 3.
MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD Service Procedures 825, 825D and 825YD (4–10") 1. Check Valve Disassembly (Sizes 4–10") (See Figures No. 15 & 16) a. Slowly close outlet gate valve then slowly close inlet gate valve. Bleed residual pressure by opening first the #4 test cock, then #3, and #2 test cocks. See Figure No. 8 for test cock locations. b. Remove cover bolts and cover. Unscrew bolts uniformly to avoid binding of the cover.
MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD Service Procedures 825, 825D and 825YD (4–10") (Continued) d. Un-thread capscrew (Item 7A) using 9/16" hex socket. 4b. Valve Seat Removal (Sizes 4–10") Bolted in Seat Ring Type Model 825D and 825YD (See Figure No. 14) 1. Remove check valve as described above. 2. Remove the three capscrews and washers retaining the seat ring. 3. Pull the seat ring from the valve body. 4. Un-thread the bushing (Item 2A) from the seat ring. 5. Remove the o-ring.
MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD Model 825 (21/2–10") Parts Check Valve Body: Model 825 ITEM DESCRIPTION NO. 2 Seat Ring 2 SIZE 2½" 780-273 SIZE 3" 780-274 SIZE 4" 780-275 SIZE 6" 780-276 SIZE 8" 780-277 SIZE 10" 780-278 QTY.
MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD Model 825 (21/2–10") Parts (Continued) Assemblies / Kits: Model 825 DESCRIPTION **Relief Valve Assembly (121) (825) (825D) Spring Assembly #1 Check (3, 4A, 5, 6, 7, 7A, 10, 11, 15, 51) Spring Assembly #2 Check (3, 4, 5, 6, 7, 7A, 7B, 9, 10, 11, 15, 51) Seat Ring Kit (2, 2A, 12) Rubber Parts, CI & DI Boddies (11, 14, 51) Relief Valve Kit (Rubber Parts) (26, 27, 32, 39, 49, - 2 ea.
MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD Model 825 Type D and YD (21/2–10") Parts Check Valve Body: Model 825D & 825YD ITEM NO.
MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD Model 825D and 825YD (21/2–10") Figure No. 14 50 13* 4 14* 50 2D 16 2A 2C 42A* 2 12* 17* 1, 1A 17A 39 42* 41A* 43A* 41A* 41B* 44* 43* 41* 40* 121 Relief Valve for Model 825YD (see Figure No.18 on page 26 for exploded view) * Denotes Commercial Parts Available (see page 31-33). Some parts are sold in kits only. Consult Parts Price List for specifics.
MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD Model 825 Type D and YD (21/2–10") Parts Assemblies / Kits: Model 825D G Assemblies / Kits: Model 825YD DESCRIPTION Spring As sembly #1 Check (3, 4A, 5, 6, 7, 7A, 7B, 10, 11, 15, 51) Spring As sembly #2 Check (3, 4A, 5, 6, 7, 7A, 7B, 9, 10, 11, 15, 51) Seat Ring Kit (2, 2A, 2C, 2D, 12) Rubber Parts, CI & DI Boddies (11, 14, 51) Large Mounting Kit (16, 17, 17A, 17B, 40, 41, Both Ends) Relief Valve Assy (Type YD Only) (21 - 50) Relief Valve Ki
MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD Model 825 and 825D (21/2–10") Parts Relief Valve Body: Model 825 & 825D 1 SIZE 2½" 780-372 23 Diaphragm Spacer 1 780-377 24 Diaphragm Button 1 780-379 780-379 780-379 780-379 780-379 780-379 25 Bolt 8 511-515-22 511-515-22 511-515-22 511-515-22 511-515-22 511-515-22 25A Nut 8 521-515-00 521-515-00 521-515-00 521-515-00 521-515-00 521-515-00 26 Diaphragm 1 780-381 780-381 780-381 780-381 780-381 780-381
MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD Model 825 Type YD (21/2–10") Parts Relief Valve Body: Model 825YD 33 35 32 Relief Valve Model 825YD 30 Figure No. 18 31A 31 27A 27 34 28 22A 24 22B 39** 50 48 36 36B 37 36A 50 25 22 26 21 905-104 Relief Valve Module 23 38 * Denotes Commercial Parts Available (see page 31-33). ** See page 32 for size.
MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD Model 826 Type YD (21/2–10") Parts Relief Valve with Bypass: Model 826YD REF NO. 9 9 42 61 61B SIZE 2½" 780-349 SIZE 3" 780-350 SIZE 4" 630-142 SIZE 6" 630-143 SIZE 8" 630-144 SIZE 10" 630-145 2nd Check Spring Resilient W edge OS&Y Gate Valve 630-140 630-141 780-778 780-779 780-780 780-781 780-891 780-893 780-895 780-897 780-899 780-901 Bypass Kit 905-127 905-127 905-127 905-127 905-127 905-127 Meter (Std. - Gal.
MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD Service Procedures Relief Valve 825, 825D and 825YD (21/2–10") 1a. Relief Valve Disassembly Non-Modular Type Relief Valve Models 825 and 825D (See Figures No. 13 and 17) 6. Reconnect copper tubing to relief valve. 1. Remove copper tubing from relief valve body. 8. Slowly open outlet shut-off valve and return the valve to service. 2.
MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD Service Procedures Relief Valve 825, 825D and 825YD (21/2–10") (Cont.) the upper guide (Item 32). Remove the slip ring (Item 27a) and inner diaphragm (item 27). Inspect, clean and replace parts as required. 5. To reassemble, position the bead on the inner diaphragm into the groove of the upper guide. Place the slip ring over the diaphragm.
MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD Spring Removal Tool Figure No. 20 Dimensions (Inches) 9 /2 12 1/2 14 1/4 4 1/4 5 5/8 6 3/8 5 /8 /4 7 /8 1 3 5 10" 16 1/2 7 1 /2 7 A B 1 C /8 D E /2 - 13 /8 - 1 1 3 /4 - 10 5 1/2 5 1/2 7 3 7 /4 - 10 "B" NOTE: This information is provided to expedite servicing of FEBCO products.
ST STL BUNA-N 25/ Bolt & 25A Nut O-ring Cap Screw 39 48 568-222 11⁄2 x 13⁄4 x 1⁄8 10-32 x 1⁄2 Socket Head (8) 10-32 x 1⁄2 Socket Head (8) ⁄ -16 x 21⁄2 (8) 38 SIZE 2" 568-214 1 x 11⁄4 x 1⁄8 ⁄ -16 x 21⁄2 (8) 38 SIZE 11⁄2" 10-32 x 1⁄2 Socket Head (8) 568-222 11⁄2 x 13⁄4 x 1⁄8 ⁄ -16 x 23⁄4 (8) 38 SIZE 21⁄2" 10-32 x 1⁄2 Socket Head (8) 568-222 11⁄2 x 13⁄4 x 1⁄8 ⁄ -16 x 23⁄4 (8) 38 SIZE 3" ST STL Bushing Nut Screw O-ring CapScrew O-ring 2B 7A 12 13 14 Bolt & Nut Test Cocks O
Test Cock O-ring 30 102 BUNA-N BRONZE BRONZE BRONZE BRASS ST STL BUNA-N BUNA-N ST STL ST STL ST STL BUNA-N ST STL BUNA-N Material ⁄ -28 x ⁄ Pan Head 15 16 ⁄ -28 x ⁄ Pan Head 15 16 568-019 ⁄ " IPS 18 ⁄ " NPT 1⁄8" IPS Side Tap 34 ⁄ " IPS 18 568-019 ⁄ " IPS 18 1" NPT 1⁄8" IPS Side Tap ⁄ " IPS 18 568-022 10-32 x 3⁄8 Round Head 568-022 10-32 x 3⁄8 Round Head 568-113 1⁄4-20 x 3⁄8 80º Flat Head 1⁄4-20 x 3⁄8 80º Flat Head 568-113 ⁄ -18 x 3⁄4 Hex Head ⁄ -18 x 3⁄4 Hex Head 38
Screw Screw O-ring CapScrew O-ring Lock-Nut Bolt & Nut Test Cocks Nipple Nipple Tee Tube Fit. 90º Tube Fit.
MAINTENANCE MANUAL MODELS 825Y, 825YA, 825, 825D, 825YD & 826YD How to Order Repair Parts 1) Locate item number and kit number in this maintenance manual. 2) Verify the size of the valve the parts are to be used on. 3) Provide full model number. On large assemblies (21/2–10"), the model number is located on the name plate. On small assemblies (3/4–2"), the model number is cast on the body. 4) Identify the "type" code on 21/2–10" size valves (Ductile Iron bodies use Type D or YD code on name plate).
