Installation and operating instructions KEMPER Backflow Preventer
Contents
1. JHL ONIAGNLS H313V 1113 994 vg 9 T xipuedd y 0 uui 0 OF Oo Lu UU E F 132. and then falls again Close bleeder valve The bleeder valve must be closed tightly again KEMPER 5 6 Connect differential pressure manometer and absolute pressure manometer for function test output anti pollution check valve Connect the test hose from Test valve B to the connection marked on the differential pressure manometer Connect absolute pressure manometer with adapter to Test valve C 5 7 Function test outlet anti pollution check valve Open the stop valve before and after the valve and fill the valve Read pressure on scale and write down the value Close stop valves and use Test valve B and Bleeder valve B to depressurise the middle pressure zone During this it is possible that a slight pressure drop occurs on the scale due to setting Wait at least 2 minutes The outlet side anti pollution check valve is leakproof when the pressure remains constant during this time 8 KEMPER 6 Removal installation and cleaning the drain valve Both anti pollution check valves and the drain valve can be removed for maintenance purposes All work can be performed without removing the housing from the pipeline inline service Only authorised specialists are allowed to perform maintenance oo Se 8 9 10 11 Close cut off valves 1 and 2 Reduce the pressure by opening the ball valves Unscrew pressure control line 14 on the drain valve After loosening the screws pull dow
3. protection and hygiene regulations the user operating organisation 15 given the following specifications As per DIN EN 1717 Point 4 6 perform regularly scheduled maintenance on the safeguards As per DIN EN 806 5 1 x annual maintenance is applicable Europe wide Check their proper functioning in regularly scheduled intervals in compliance with the national or regional stipulations For DE in accordance with DVGW W 570 1 April 2007 under 4 7 it is stipulated that the maintenance must be performed 1 x annually For CH perform the maintenance inspection as per SVGW W3 Supplement 1 2000 W TPW 126 April 1994 and W TPW 135 April 1994 In W TPW 135 in Point 3 Maintenance the maintenance inspection is stipulated as periodical but at least every 2 years W TPW 126 requires the backflow preventer BA to be checked for the first time after the first year of operation In addition Offprint no 1377 of SVGW 8 96 is pointed out For NL in VEWIN Waterwerkblad WB 1 4 G November 2005 under Point 4 it is stipulated that backflow preventers BA need to be checked for proper operation and maintained 1x annually The following applies The functional and maintenance measures cover the function test visual inspection of the interior parts and the cleaning or replacement of the functioning parts as stated under Points 3 and 4 in the operating instructions This inspection should also include the related valves Only authorised specialists are allo
4. Installation and operating instructions KEMPER Backflow Preventer BA Figure 361 1 Prerequisites for installation Install the backflow preventer in frost free areas only Comply with standards DIN EN 1717 DIN 1988 DIN EN 12056 DIN 1986 100 N Provide a drain line N Comply with the direction of flow Application area According to DIN EN 1717 in order to maintain flawless functioning of the BA backflow preventer a flanged dirt trap must be installed in the direction of flow before the BA backflow preventer Type BA backflow preventers that accord with DIN EN 12729 are used to secure drinking water plants against back pressures and siphon back flow Fluids up to and including Fluid Category 4 as per DIN EN 1717 1988 100 are secured They can be used for residential buildings industrial and commercial purposes with consideration of their specifications Normally normal functioning with pressure fluctuations the vent hole of the middle pressure chamber only allows a few drops through During malfunctions the vent hole can allow the full volume flow of the service pipe through For that reason dimension the wastewater connection to be sufficiently large according to DIN EN 12056 and DIN 1986 100 Assume the volume flow that could arise through the service pipe on the backflow preventer BA pay attention to the nominal flow rate The backflow preventer BA can secure the following hazard potential in accordance with the Fluid Categor
5. anti pollution check valve Remove the anti pollution check valve Remove the drain valve rr Drain valve does not open Clogged pressure control line Remove and clean the pressure control line Table 4 Troubleshooting 9 Technical data Total pressure drop max 1 0 bar at nominal flow Flow media Water at 60 C Operating pressure max 10 bar Minimum supply pressure 1 5 bar Ball valve connection G with connection size DN 65 150 191 DN 150 Table 5 Technical data MEE KEMPER 10 Flow diagram Connection sizes DN 65 to 150 1 1 Pressure drop in valve Ap bar Druckabfall im Ventil A o Co Table 6 Materials 12 Accessories p bar o NEN o Wo ____ MEN DN 80 SRR bn Canan differential pressure measuring case Differential pressure manometer in a representative aluminium case ideal for inspecting and maintaining all KEMPER BA Backflow Preventers Figures 360 and 361 Content of the Differential Pressure Measurement Kit Figure 360 99 Differential pressure manometer with scale range to 1 bar 2 G1 4 adapters with plug coupling A A 2 test hoses preassembled with plug and socket connections and bleed valves 11 2 G1 2 G1 4 adapters 1 absolute pressure manometer with scale range to 10 bar MEE KEMPER Replacement tools a
6. ection e The backflow preventer must be easily accessible at all times Manometer connections and controls must not be obstructed e While installing backflow preventers make sure the water that leaks during the separation process is safely drained off Installation in shafts and rooms endangered by flooding is prohibited For inspection and maintenance reasons provide cut off valves in the direction of flow before and after the backflow preventer e The backflow preventer must be installed flood proof e Provide the drain valve control with an effective safeguard i e in case of failure the vent hole opens completely In this case for 1 bar pressure in the middle chamber calculate with the following dimensions Dimension the dewatering line correspondingly ON s w w Table 3 Drain lines sewage system connection dimensioning 4 Commissioning Commission the backflow preventer in this sequence 1 Slowly open cut off valves 1 and 2 e During this process it is possible the drain valve opens intermittently 2 Vent the system through ball valves 3 4 and 5 e Open each ball valve until water comes out It is important to open every ball valve to make sure that all chambers are vented 3 The backflow preventer is ready for operation Figure 4 Commissioning the BA Backflow Preventer safeguards KS Yo in Lg MEE 4 KEMPER 5 Inspection In compliance with standards on drinking water
7. i pollution check valve is spring preloaded 5 Check for leakproofness by filling water from the rear e Leaky anti pollution check valves must be replaced Repair is not possible 6 Assemble in the reverse sequence e For DN 65 150 grease O ring and thread well on the anti pollution check valve with Unisilikon 250 e Do not damage the O ring when installing e The tightening torque for the anti pollution check valve is 100 120 Nm Close the ball valves Open the cut off valves Vent the system through the ball valves Check the backflow preventer see Chapters 5 1 to 5 3 Connect the dust plugs to the ball valves Or C 7 Important information instructions for your safety Use the device solely in a technically flawless condition and as intended for use safety and hazard aware while complying with the installation and operating instructions Have all malfunctions that could impair safety repaired immediately The BA Backflow Preventer Figure 361 is intended solely for the application areas named in these installation and operating instructions Any different use or use beyond and above that is considered non intended usage 8 Troubleshooting Eros _________________ 5 causes Remedy __ 6__ ____ water network behind the backflow preventer BENE backflow preventer Supply side anti pollution check valve Remove and clean anti pollution check or drain valve valve Is soiled 1 Leaky supply
8. lity e Make drain lines without any tight bends and keep them short Connection dimension acc Table 2 e Install the drain line so that the drain connection and the drain valve can be removed for inspection e A material steadying zone of 5 x DN after the BA is recommended MEE 2 KEMPER Figure 2 Connection area Figure 3 BA Backflow Preventer protection device with installation prerequisites and dimensions Connection sizes 65 80 _ 100 150 _____8______600 ___600 ___600 ___600_ NEN NN 160 160 160 200 D 15 150 150 150 E 34 a 345 375 75 Dimensions in mm Table 2 Dimensions for installation prerequisites MEE KEMPER 3 1 Notes for secure installation e f there are supply pressure fluctuations without water removal a short triggering of the drain valve can occur For that reason we recommend installing a pressure reducing valve before the backflow preventer e The room in which the backflow preventer is installed must be freely accessible at all times and always be frost free Ensure good ventilation e f the drain line is also being used by other equipment plants it must be correspondingly dimensioned pump stations sewage system e No additional unprotected drinking water connections are permitted after the backflow preventer e Within the downstream system the individual connections are not secured from each other against backflow If required provide individual prot
9. n drain connection 7 and unscrew with the help of an oil filter strap Take off the drain valve If necessary clean or replace e f no dirt particles are visible but a fault was observed while inspecting the drain valve see Chapter 5 2 the drain valve should be replaced see accessories spare parts e Clean the area around the valve seat and the opening slot e g by carefully blowing out Assemble in the reverse sequence e Grease the O rings well with Unisilikon 250 or a grease that does not contain mineral oil ATTENTION Otherwise it is possible that the O rings will be destroyed e Replace damaged O rings see Chapter 13 Spare parts Close the ball valves Slowly open the cut off valves Vent the system through the ball valves Check the drain valve see Chapter 5 2 12 Connect the dust plugs to the ball valves N Never dismantle the anti pollution check valve and drain valve from each other High danger of injury Figure 7 Removal installation and cleaning the drain valve MEE 9 KEMPER 6 1 Removal installation and inspecting the anti pollution check valve refer to Figure 4 1 Close cut off valves 1 and 2 2 Reduce pressure by opening ball valves 3 4 and 5 3 Take off cover 4 Remove the anti pollution check valve e For DN 65 150 first unscrew the discharge anti pollution check valve and then the supply anti pollution check valve You can obtain an assembly tool as an accessory N Danger of injury The ant
10. nctions in the backflow preventer BA For that reason always use slowly closing valves or drives that close slowly If the inlet side static system pressure is high it is recommended to install a pressure reducing valve in the supply line Zone 2 T Zone 1 Zone 3 Supply side anti Discharge side anti pollution check valve pollution check valve Drain valve Figure 1 Sectional view Dimension _ oS O Nominal width DN 6 80 __ 100 150 installation height H mm 245 245 245 285 installation height mm 270 270 30 30 Installation depth D mm 60 60 6o 6o Nominalflowatdeltap 1bar m h 45 54 85 191 Table 1 Dimensions Backflow Preventer BA Figure 361 3 Installation The BA Backflow Preventer must be installed level Provide cut off valves in front of and behind the backflow preventer In addition a dirt trap must be connected upstream which prevents the backflow preventer from damage and functional impairments due to coarse dirt Install the backflow preventer free of tension and without flexural moment as follows 1 Thoroughly rinse connecting pipe 2 Check connections on backflow preventer for cleanliness Figure 2 3 Install backflow preventer as in Figure 3 While doing so comply with the following points and those in Chapter 3 1 e Flow in direction of arrow e Maintain installation clearances e Make sure there is good accessibi
11. nt as per 4 3 Open Test valves A and B and vent the measurement lines through the bleeder valves on the test hoses Then close the bleeder valves and leave Test valve A and B open 6 KEMPER Close the stop valve before and after the valve Using the bleeder valve the test hose Test valve B slowly bleed the pressure of the middle pressure zone and watch the differential pressure display at the same time The differential pressure rises until the anti pollution sg Dee check valve starts to open The drain valve must not trigger during this Close the bleeder valve on the test hose Test hose B The differential pressure must remain constant Note During the measurement it is mandatory that there is no flow in the backflow preventer BA 5 5 Function test drain valve Connect measuring instrument as per 4 3 Open Test valves A and B and vent the measurement pl i lines through the bleeder valves on the test hoses Then close the bleeder valves and leave Test valve A and B open B C J Close stop valve before and after the valve fop Using the bleeder valve on the test hose Test valve A slowly bleed the supply pressure of the supply pressure zone and watch the differential pressure display and drain valve at the same time The drain valve must trigger before the display reaches the value 140 mbar when the valve triggers the differential pressure initially rises only slightly
12. nti pollution check valve For flange version DN 65 100 For flange version DN 150 Assembly wrench DN 65 DN 100 Figure 361 99 009 DN 150 Figure 361 99 010 13 Spare parts Anti pollution check valve supply side DN 65 DN 100 Figure 361 98 002 DN 150 Figure 361 98 006 010 GE Ball valve DN 65 DN 150 Figure 361 99 004 Gebr Kemper GmbH Co KG Metallwerke Harkortstr 5 D 57462 Olpe Tel 0 27 61 891 0 Fax 0 27 61 891 1 75 info kemper olpe de www kemper olpe de K410036100002 00 01 14 Technical subject to change Anti pollution check valve discharge side DN 65 DN 100 Figure 361 98 003 DN 150 Figure 361 98 007 Gasket set DN 65 DN 100 Figure 361 99 005 DN 150 Figure 361 99 008 EI Bleed valve DN 65 DN 150 Figure 361 98 001 MEE KEMPER 12U9UJUJ0 2U9UJUJO JU9UJUJO0 JUW 9 A 4 2942 19 1no 1591 uon un J UlGJp 1591 UOIpung 9A GA 429Q uonnjjod 1106 19JU 1 91 uonoun J 9JnssoJd jenuMoyig L 0 0 Tequ f e1nsseud qunsseud oneis de WIp 9u1u69 5 CI nopo ui pinjJ C up 94132905 den wip 9u132942 0015 99 C jo ssouiu2n ye 941 Jo uonooedsur jenstA SOAIBA uon2910Jd 941 Jo 5 PIUBUTIUICW 001129050 001129950 T SNOILINYLSNI 59NIIVH3dO ONY
13. wed to perform maintenance Document the inspection on the attached control plate with date and signature In addition Appendix 1 on inspection and maintenance is recommended Put the Backflow preventer BA cartridge through a visual inspection in the installed state during every maintenance to the extent this is possible through the housing opening The manufacturer recommends replacing the cartridge every 10 years Comply with local regulations Measuring instrument for differential pressure measurement Suitable differential pressure manometer The KEMPER differential pressure measurement case Figure 360 99 is recommended 5 1 Connect test adapter Screw on adapter G1 2 G1 4 Screw on adapter G1 4 with plug on coupling MEE 5 KEMPER 5 2 Preparing the differential pressure manometer Connect the test hose with the adapter and of the differential pressure manometer to each side 5 3 Connect differential pressure manometer for function test inlet anti pollution check valve an For each test hose plug on and latch a quick coupler to the adapter bleeder valves must be closed on the hoses Connect the test hose of Test valve A to manometer Connect the test hose of Test valve B to the connection marked on the differential pressure manometer A Supply pressure zone B Middle pressure zone C Back pressure zone 5 4 Function test inlet anti pollution check valve Connect measuring instrume
14. y Category 4 applies to backflow preventer BA Fluids that present a health hazard to humans due to the presence of one or more toxic or highly toxic substances or one or more radioactive mutagenic or carcinogenic substances The higher the classification the greater the risk potential For each category DIN EN 1717 stipulates specific protection valves The Backflow Preventer BA Figure 361 is approved without restriction for use up to and including Category 4 A continual bacterial risk Fluid Category 5 in extant piping systems must not exist 2 Operating principle The KEMPER BA Backflow Preventer is subdivided into 3 zones In Zone 1 the pressure is higher than in Zone 2 and there again higher than in Zone 3 A drain valve is connected to Zone 2 which opens latest when the pressure difference between Zones 1 and 2 has decreased to less than 0 14 bar The water from Zone 2 flows outdoors That precludes the risk of back pressure or siphon back flow in the supply network The pipeline is interrupted and the drinking water network is protected Intermittent dripping from the BA Backflow Preventer at the drain valve is not necessarily a malfunction Under such circumstances the BA Backflow Preventer separates as intended MEE 4 KEMPER Note Do not connect any fast closing valves or stopping equipment before or after the valve Fast closing e g of solenoid valves or ball valves on devices and machines can lead to serious malfu
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