General Pump 100723 Cold Water Safety Relief Valve

1. Introduction

This manual provides essential information for the safe and effective installation, operation, and maintenance of your General Pump 100723 Cold Water Safety Relief Valve. Please read this manual thoroughly before installation or use to ensure proper function and prevent injury or damage.

The General Pump 100723 is a cold water safety relief valve designed to protect high-pressure systems from over-pressurization. It features a side discharge with a hose barb and is suitable for flow rates up to 6.0 GPM, with a pressure range of 2000 to 6000 PSI.

2. Safety Information

WARNING: Failure to follow these safety instructions could result in serious injury or property damage.

• Always wear appropriate personal protective equipment (PPE), including eye protection, when working with high-pressure systems.
• Ensure the system is depressurized before attempting any installation, maintenance, or repair.
• Verify that the valve's pressure rating matches or exceeds the maximum operating pressure of your system.
• Do not modify the valve in any way. Unauthorized modifications can compromise safety and void the warranty.
• Ensure the discharge port is directed away from personnel and sensitive equipment.
• This valve is designed for cold water applications only, within a temperature range of 32°F to 150°F (0°C to 65°C).

3. Product Overview

The General Pump 100723 Safety Relief Valve is constructed from durable brass, ensuring longevity and resistance to corrosion in cold water environments. It is designed to provide reliable over-pressure protection for various high-pressure washing systems.

Figure 1: General Pump 100723 Cold Water Safety Relief Valve. This image shows the brass valve with its threaded inlet, side discharge hose barb, and hexagonal end cap.

Key Features:

• High Pressure Safety: Rated for 2500-6000 PSI relief pressure.
• Universal Fit: One model accommodates a wide range of pressures without requiring spring changes.
• Quiet Operation: Engineered for reduced whistling and chatter compared to other brands.
• Accuracy: Provides highly accurate pressure relief across its full operating range.
• Compatibility: Designed to fit any brand of pump.

4. Setup and Installation

Proper installation is critical for the safe and effective operation of the safety relief valve.

1. Depressurize System: Ensure the entire high-pressure system is completely depressurized and isolated from the power source before beginning installation.
2. Identify Installation Point: The safety relief valve should be installed in a location where it can effectively protect the system from over-pressurization, typically on the discharge side of the pump or before any components that could be damaged by excessive pressure.
3. Thread Connection: The valve features a 3/8" NPT inlet. Apply appropriate thread sealant (e.g., PTFE tape or pipe thread compound) to the male threads of the system connection point. Carefully thread the valve into place, ensuring a secure, leak-free connection. Do not overtighten.
4. Discharge Hose Connection: Connect a suitable discharge hose to the 1/4" hose barb side outlet. Secure the hose with a hose clamp to prevent accidental disconnection during discharge. The hose must be capable of handling the full flow and pressure of the system during a relief event and should be routed to a safe drainage area, away from personnel and equipment.
5. System Check: Once installed, slowly repressurize the system and check for any leaks around the valve connections. Observe the system pressure to ensure it operates within safe limits.

5. Operating Principles

The General Pump 100723 Safety Relief Valve is a passive safety device. It operates automatically when the system pressure exceeds its set relief pressure. When this occurs, the valve will open, discharging excess fluid through its side outlet until the system pressure returns to a safe level. The valve will then automatically re-seat, stopping the discharge.

This valve is designed to relieve pressure between 2500 PSI and 6000 PSI. It is factory-set and does not require field adjustment for different pressure ranges within its specified limits, simplifying installation and ensuring consistent performance.

6. Maintenance

Regular inspection and maintenance will help ensure the longevity and reliable operation of your safety relief valve.

• Visual Inspection: Periodically inspect the valve for any signs of wear, corrosion, leaks, or damage. Check the discharge hose for kinks, blockages, or deterioration.
• Cleanliness: Keep the exterior of the valve clean. Ensure the discharge port is free from obstructions.
• Functionality Check: If possible and safe to do so, periodically test the valve's functionality by intentionally (and safely) exceeding the system's normal operating pressure to confirm the valve opens and re-seats correctly. This should only be performed by qualified personnel in a controlled environment.
• Replacement: If the valve shows signs of significant wear, damage, or fails to operate correctly during a test, it must be replaced immediately with an identical General Pump 100723 model. Do not attempt to repair internal components.

7. Troubleshooting

This section addresses common issues you might encounter with the safety relief valve.

• Valve Constantly Discharging:
  Possible Causes: System pressure is consistently too high; valve is stuck open due to debris; valve spring is fatigued or damaged.
  Solutions: Check system pressure and adjust if necessary; depressurize and inspect valve for debris (replace if necessary); replace the valve.
• Valve Not Discharging During Over-pressure:
  Possible Causes: Valve is clogged; valve is stuck closed; incorrect valve for system pressure.
  Solutions: Depressurize and inspect valve for blockages (replace if necessary); replace the valve; verify the valve's pressure rating matches system requirements.
• Leaks Around Connections:
  Possible Causes: Improperly applied thread sealant; loose connection; damaged threads.
  Solutions: Depressurize system, reapply thread sealant, and retighten connection; inspect threads for damage and replace if necessary.

8. Specifications

9. Warranty and Support

For warranty information, technical support, or replacement parts, please contact General Pump directly or refer to their official website. Keep your purchase receipt as proof of purchase.

General Pump Contact Information: Please refer to the manufacturer's official website or product packaging for the most current contact details.