Resideo Braukmann TKA295 Pressure-Test Kit

Safety Guidelines

Follow the installation instructions. Use the appliance according to its intended use, in good condition, and with due regard to safety and risk of danger. The appliance is exclusively for use in the applications detailed in these instructions. Any other use will not be considered to comply with requirements and would invalidate the warranty. Assembly, commissioning, servicing, and adjustment work may only be carried out by authorized persons. Immediately rectify any malfunctions which may influence safety.

Description of Function

The pressure-test kit is used for inspection and maintenance of backflow preventer type BA. It consists of a differential pressure gauge, needle valves, bleed valves, and various hoses. The differential pressure gauge compares the differential pressure between two chambers in the backflow preventer. Needle valves regulate and control pressures between chambers, keeping them constant during measurement. Integrated filters prevent dirt particles from entering the gauge.

Application

This pressure-test kit is used in conjunction with the following backflow preventers: BA195, BA295S, BA295I, BA295STN, BA295STN-C, BA298F, BA298IF. It is intended solely for the inspection and maintenance of these specified backflow preventers and must be used as a complete unit. Using individual components is not permitted.

Technical Data

Scope of Delivery

The pressure-test kit includes:

• Differential pressure gauge (1 pc.)
• Manometer, sidewise (1 pc.)
• Hoses with quick release fastener, coloured (3 pcs.)
• Bleed tube, clear (1 pc.)
• Needle valves, coloured (3 pcs.)
• Bleed valves, coloured (2 pcs.)
• Adapter fittings (3 pcs. each)
• Carrying case (1 pc.)

Assembly and Installation

During use, follow the operating instructions, local requirements, and general codes of practice. Observe the flow direction of the backflow preventer (indicated by an arrow). All needle valves and bleed valves on the pressure-test kit must be closed. Connect the clear bleed tube to the bleed valves (red and blue) on the top of the housing.

Inspection of Backflow Preventer

Regular maintenance is mandatory according to DIN EN 1717. Maintenance must be carried out by authorized personnel. Frequency: at least every six months (depending on local conditions). Refer to the backflow preventer's installation instructions.

7.1. Testing Discharge Valve

The backflow preventer shifts to shutoff position if the differential pressure between the middle and inlet chamber falls below 0.14 bar.

1. Close shutoff valve B.
2. Open shutoff valve A. The backflow preventer is pressurized, and water flows through the check valve.
3. Install appropriate adapter fittings on all ball valves.
4. Connect the red hose between ball valve P1 and the red needle valve connection on the back of the housing.
5. Connect the blue hose between ball valve P2 and the blue needle valve connection on the back of the housing.
6. Close all needle and bleed valves.
7. Open ball valves P1 and P2. If possible, route the bleed tube to a discharge or use a vent surge tank.
8. Bleed the high side: Slowly open and close the red bleed valve on the housing top until no more air escapes.
9. Bleed the low side: Slowly open the blue bleed valve on the housing top.
10. Close the blue bleed valve once the differential pressure gauge pointer reaches the upper scale range.
11. Observe the pressure drop on the differential pressure gauge. If the discharge valve opens, the inlet check valve is faulty and must be replaced before further testing. Refer to backflow preventer maintenance.
12. Slowly open the red needle valve on the back of the housing (max. a quarter turn).
13. Slowly open the blue needle valve on the back of the housing (max. a quarter turn).
14. Observe the differential pressure gauge. The differential pressure drops to the opening pressure of the discharge valve.
15. The discharge valve opens and drips. The respective opening pressure must be consulted from the installed backflow preventer's installation instructions.
16. If the discharge valve does not open: Close both red and blue needle valves on the back of the housing and continue with section 7.1.1.
17. Close the red and blue needle valves on the back of the housing. Continue with section 7.2.

7.1.1. Shutoff Valve B May Be Faulty

1. Slowly open and close shutoff valve B again.
2. Repeat steps 11 to 15 of section 7.1. If the discharge valve still does not open, shutoff valve B is faulty and must be replaced before further checks.

7.2. Testing Outlet Check Valve

The diagram illustrates the setup for testing the outlet check valve.

1. Connect the yellow hose to the yellow needle valve connection on the back of the housing and route the other end to a discharge if possible.
2. Slowly open the red needle valve on the back of the housing.
3. Slowly open the yellow needle valve on the back of the housing. The yellow hose is deaerated.
4. Close the yellow needle valve on the back of the housing.
5. Connect the yellow hose to ball valve P3.
6. Slowly open ball valve P3.
7. Slowly open the blue bleed valve on the top of the housing.
8. Close the blue bleed valve once the differential pressure gauge pointer reaches the upper scale range.
9. Slowly open the yellow needle valve on the back of the housing.
10. Observe the differential pressure gauge. The differential pressure does not drop to the discharge valve opening point. If the discharge valve does not open, the test is finished (successfully). If the discharge valve opens, the check valve must be replaced before further testing. Refer to backflow preventer maintenance.

7.3. Testing Inlet Check Valve

The diagram illustrates the procedure for testing the inlet check valve.

1. Connect the red hose between ball valve P1 and the red needle valve connection on the back of the housing.
2. Connect the blue hose between ball valve P2 and the blue needle valve connection on the back of the housing.
3. Close all needle and bleed valves.
4. Open ball valves P1 and P2. Route bleed tubes to a discharge or use a vent surge tank if possible.
5. Bleed the high side: Slowly open and close the red bleed valve on the housing top until no more air escapes.
6. Bleed the low side: Slowly open the blue bleed valve on the housing top.
7. Close the blue bleed valve once the differential pressure gauge pointer reaches the upper scale range.
8. Observe the pressure drop on the differential pressure gauge.
9. Slowly open the blue needle valve. The differential pressure rises until the inlet check valve begins to open. The discharge valve must not drain; otherwise, it is leaky and must be replaced.
10. Close the blue needle valve. The differential pressure must remain constant; otherwise, the inlet check valve is leaky and must be replaced.
11. Open the shutoff valves before and after the backflow preventer. Close ball valves.

Maintenance

8.1. Differential Pressure Gauge

If the accuracy of the differential pressure gauge is outside the specified range (see Chapter 4), the gauge must be recalibrated. Send the complete pressure-test kit to: Ademco 1 GmbH, Hardhofweg 40, 74821 Mosbach.

Disposal

The pressure-test kit consists of Red-bronze, brass, steel, plastic. Observe local regulations for correct waste recycling and disposal.

Troubleshooting

General Care

Thoroughly clean and dry the pressure-test kit. During storage, leave all needle valves and bleed valves open. Do not place the pressure-test kit damp in the carrying case.