Installation, Maintenance, & Repair
Series 4000B/LF4000B
Reduced Pressure Zone Assemblies
Sizes: 1⁄2" – 2" (15 – 50mm)
4000B/LF4000B Size: 3/4"
RP/IS-A-4000B
!
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.
Local building or plumbing codes may require modifications to
the information provided. You are required to consult the local
building and plumbing codes prior to installation. If this information is not consistent with local building or plumbing codes, the
local codes should be followed.
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.
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.
Testing
For field testing procedure, refer to Ames installation sheets
IS-A-ATG-1 found on www.amesfirewater.com.
For other repair kits and service parts, refer to our Backflow
Prevention Products Repair Kits & Service Parts price list
PL-A-RP-BPD found on www.amesfirewater.com.
For technical assistance, contact your local Ames representative.
NOTICE
Inquire with governing authorities for local installation
requirements
www.amesfirewater.com
A Division of Watts Water Technologies, Inc.
Basic Installation Instructions
Please Read Prior to Installation:
1. Before installing any Ames assembly, Flush the Line thor-
oughly to remove all debris, chips and other foreign objects.
2. Ames Series 4000B/LF4000B should be installed in a hori-
zontal and upright position. This positions the relief valve below the first check valve, enabling the zone to drain through
the relief valve outlet. The shutoff valve with the test cock is
to be mounted on the inlet side of the backflow preventer.
The test cock is on the inlet side of the shutoff valve.
3. The 4000B/LF4000B should always be installed in an acces-
sible location to facilitate testing and servicing. Check the
state and local codes to ensure that the backflow preventer
is installed in compliance, such as the proper height above
the ground.
4. Water discharge from the relief valve should be vented in
accordance with code requirements. The relief valve should
never be solidly piped into a drainage ditch, sewer or sump.
The discharge should be funneled through an Ames air gap
fitting piped to a floor drain.
5. Ames recommends that a strainer be installed ahead of
Series 4000B/LF4000B assemblies to protect the discs from
unnecessary fouling.
!
CAUTION
Do not install with strainer when backflow preventer is used on
seldom used water lines which are called upon only during emergencies, such as fire sprinkler liners.
6. Backflow preventers should never be placed in pits unless
absolutely necessary and then only when and as approved
by local codes. Consult your local or state plumbing or
health inspector. Ames recommends installation indoors or
above ground in an insulated enclosure.
Main
Strainer
Clearance to
Wall 6" – 12"
Meter
Strainer
First Shutoff
Valve
Above Ground
Min. 12"
Indoors
Test Cocks
1 2 3 4
Min. 12"
Max. 60"
Air Gap
Air Gap
45˚ Angle
Start up
7. The downstream shutoff valve should be closed. Open
upstream shutoff valve slowly, fill the valve and bleed the
air through test cock 2, 3 and 4. When valve is filled, open
the downstream shutoff slowly and fill the water supply
system. This is necessary to avoid water hammer or shock
damage.
8. The installation of an Ames air gap with the drain line termi-
nating above a floor drain will handle any normal discharge
or nuisance spitting through the relief valve. However, floor
drain size may need to be designed to prevent water damage caused by catastrophic failure condition. Do not reduce
the size of the drain line from the air gap fitting.
2
Maintenance Instructions
!
WARNING
Depressurize the valve before servicing
Removing and Installing Check Assemblies
1. Remove the retainer from the body. The check valve car-
tridges can now be removed from the valve by hand or with
a screwdriver. The first check cartridge must be removed
before the second check cartridge can be removed.
2. The check seats are attached to the cage with a bayonet
3⁄4" cartridges snap apart.
NOTICE
The seats and springs of the first and second check cartridges are not interchangeable. The heavier spring and
smaller diameter seat belong with the first check cartridge.
type locking arrangement. Holding the cage in one hand,
push the seat inward and rotate counter-clockwise against
the cage. The seat, spring cage, spring and disc assembly
are now individual components.
Replacement Parts
Check Assembly 1/2" – 3/4" (15-20mm)
O-ring Seal
Injection Molded
Acetyl Resin
Stainless Steel
Spring
Check Assembly 3/4" (20mm) M3 Check Assembly 1" – 2" (25-50mm)
O-ring Seal
3. The disc assembly may now be cleaned and reassembled
or, depending on its condition, may be discarded and
replaced with a new assembly from the repair kit. O-rings
should be cleaned or replaced as necessary and lightly
greased with the FDA approved grease.
4. Reassemble the check valve cartridges. Check cartridges
are installed in the valve body with the seat facing the valve
inlet. The cartridges must be securely in place before the
retainer can be replaced. On the
to be tilted slightly into place. Replace relief valve assembly.
Seat
3
⁄4" size retainer may have
Disc Assembly Check Cage
1st Check
Module
For repair kits and parts, refer to Backflow Prevention
Products Repair Kits & Service Parts price list
PL-A-RP-BPD found on www.amesfirewater.com.
Silicone Seal
First Check Assembly
Seat
Relief
Valve
Module
Disc
Spring
Check Cage
Cover O-ring
Second Check Assembly
Retainer
Flow
Spring
Seat O-ring
3
Maintenance Instructions
Removal and Service of the Relief Valve
1. Remove the relief valve cover bolts while holding the cover
down.
2. Lift the cover straight off. The stem and diaphragm assembly
will remain with the cover as it is removed. The relief valve
spring will be free inside the body at this point.
3. The relief valve seat is located at the bottom of the body
bore, and can be removed, if necessary, for cleaning. The
disc can be cleaned without disassembly of the relief valve.
If it is determined that the relief valve diaphragm and/or disc
should be replaced, the relief valve module can be readily
disassembled without the use of special tools. The disc rubber is molded into the disc holder and is supplied as a disc
holder assembly.
4. To re-assemble the relief valve, press the seat firmly into
place in the body, center the spring on the seat, and insert
the cover and relief valve module as a unit straight into the
bore. Press down on the cover to assure proper alignment.
Insert and tighten bolts.
!
CAUTION
If cover will not press flat against body, stem assembly is crooked
and damage can result. Re-align stem and cover before bolts are
inserted.
Test cock No. 3
Test cock No. 2
First Check
Module Assembly
Relief valve Assembly
vice Parts Kit
Relief Valve Ser-
Test cock No. 4
Second Check
Module Assembly
Water Outlet
Cover
Cover O-ring
Diaphragm
Stem & Diaphragm
Assembly
Retainer
Seat
Seat O-ring
Body
Flow
After initial installation, a discharge from the relief valve opening may occur until all sealing surfaces have become seated or due
to inadequate initial flushing of pipe lines to eliminate dirt and pipe compounds. If flushing will not clear, remove the first check
valve and clean thoroughly.
Periodic relief valve discharge may occur on dead end service applications, such as boiler feed line or cooling tower makeup
lines, due to fluctuating supply pressure during a static or no flow condition. To avoid this discharge, install a check valve ahead
of the backflow assembly to “lock-in” the upstream pressure.
It is important that Series 4000B/LF4000B backflow preventers be inspected periodically for any discharge from the relief valve
which will provide a visual indication of need for cleaning or repair of check valves. Also, testing for proper operation of the
assembly should be made periodically in compliance with local codes, but at least once a year or more often, depending upon
system conditions. Most water purveyors require a test/inspection by a certified tester upon installation to verify the correct
operation of the assembly and that the installation complies with all code requirements.
Relief vent will discharge water when, during no-flow periods, (1) the first check valve is fouled or (2) the inlet pressure to
the device drops sufficiently due to upstream pressure fluctuations to affect the required operating differential between the
inlet pressure and reduced pressure zone. Otherwise, such relief (spitting) can occur when the second check is fouled during
emergency backflow or resulting from water hammer condition.
4
Testing — Reduced Pressure Zone Assemblies
Test No.1
Purpose: To test check valve No. 2 for tightness against
reverse flow.
Requirements: Valve must be tight against reverse flow under
all pressure differentials. Slowly open the ‘high’ valve A and
the ‘vent’ valve C, and keep the ‘low’ valve B closed. Open
test cock #4. Indicated pressure differential will decrease
slightly. If pressure differential continues to decrease (until the
vent opens) check valve #2 is reported as ‘leaking’.
Ball Type Test Valves
(A)
(C)
(B)
Needle
Valve
Test No. 2
Purpose: To test shutoff #2 for tightness.
Requirements: After passing Test No. 1, continue to Test
No. 2 by closing test cock #2. The indicated pressure
differential will decrease slightly. If pressure differential
continues to decrease (approaching ‘zero’), shutoff #2 is
reported to be ‘leaking’.
Test No. 3
Purpose: To test check Valve No. 1 for tightness.
Requirements: Valve must be tight against reverse flow
under all pressure differentials. Close ‘high’ valve A and open
test cock #2. Close test cock #4. Disconnect vent hose at
test cock #4. Open valves B and C, bleeding to atmosphere.
Then closing valve B restores the system to a normal static
condition. Observe the pressure differential gauge. If there is a
decrease in the indicated value, check valve No. 1 is reported
as ‘leaking’.
Test No. 4
Purpose: To test operation of pressure differential relief valve.
Requirements: The pressure differential relief valve must
operate to maintain the ‘zone’ between the two check
valves at least 2psi less than the supply pressure. Close
‘vent’ valve C. Open ‘high’ valve A. Open the ‘low’ valve
B very slowly until the differential gauge needle starts to
drop. Hold the valve at this position and observe the gauge
reading at the moment the first discharge is noted from the
relief valve. Record this as the opening differential pressure
of the relief valve.
Auxiliary
Test Cock
Test Cock
No. 1
High Hose
(Yellow)
Low Hose
(White or Red)
Test Cock
No. 2
Vent Hose
(Blue)
Test Cock
No. 4
Test Cock
No. 3
NOTICE
It is important that the differential gauge needle drops slowly. Close
test cocks #2 and #3. Use ‘vent’ hose to relieve pressure from test
kit by opening valves A, B and C. Remove all test equipment and
open shutoff #2.
5
Troubleshooting Guide
PROBLEM CAUSE SOLUTION
A. Assembly discharges from Fouled first check Disassemble and clean No. 1 check valve
differential relief valve during Fluctuating inlet pressure Control supply line water pressure
no flow condition. Outlet pressure higher than inlet pressure Disassemble, clean #2 check valve &
& leak in No. 2 check valve identify cause of back pressure.
Leak through diaphragm or around Service relief valve (page 4)
flange bolt holes of relief valve
Pressure relief valve does not close See problem D
B. Assembly discharges from No. 1 check valve wedged open Disassemble and clean No. 1 check valve
differential relief valve during O-ring displaced from groove in 1st check Disassemble and replace
a flow conditions. Pressure relief valve does not close See problem D
Fluctuating line pressure
C. Differential pressure relief valve Differential pressure across No. 1 check Repair shutoff valves
does not open during test valve stays above 2psi due to leaking
outlet gate valve
Weak or broken relief valve spring Disassemble and replace relief valve spring
Shutoff seat tube bound in body Disassemble and repair
Plugged hydraulic hose Disassemble and repair
D. Pressure relief valve does Debris on sealing surface Remove relief valve and clean
not close Plugged hydraulic hose Disassemble and clean
Damaged seat or rubber shutoff disc Remove relief valve assembly and replace
Ruptured diaphragm Disassemble and replace diaphragm
Wrinkled or improperly installed diaphragm Disassemble and properly position diaphragm
Problem Identification Procedures
When using differential pressure gauge:
A. Check differential across No. 1 check valve
READING PROBLEM
2 to 3 psid Leak in No. 1 or No. 2
check valve
4 to 7 psid and steady Malfunctioning pressure
relief valve
2 to 7 psid fluctuating Inlet pressure fluctuation
Without using differential pressure gauge:
A. Close gate valve No. 2
RESULT PROBLEM
If discharge stops Leak in No. 2 check valve
If discharge does Go to B
not stop
B. Open No. 4 testcock to produce a flow greater than
differential relief valve discharge
RESULT PROBLEM
If discharge stops Leak in No. 1 check valve
If discharge does Malfunctioning pressure
not stop relief valve
6
Notes
7
For additional information, visit our web site at: www.amesfirewater.com
WARNING: This product contains chemicals known to the
State of California to cause cancer and birth defects or
other reproductive harm.
For more information: www.watts.com/prop65
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.
www.amesfirewater.com
A Watts Water Technologies Company
RP/IS-A-4000B 1322 EDP# 1915338 © 2013 Ames Fire & Waterworks
USA: Backflow- Tel: (916) 928-0123 • Fax: (916) 928-9333
Control Valves- Tel: (713) 943-0688 • Fax: (713) 944-9445
Canada: Tel: (905) 332-4090 • Fax: (905) 332-7068
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