Ames 6000HMB User Manual

Installation, Maintenance, & Repair
Series 4000SS/5000SS

Reduced Pressure Zone Assemblies & Reduced Pressure Detector Assemblies

Sizes: 2

1

⁄2" – 6" (65 – 150mm)**

4000SS

RP/IS-A-4000SS/5000SS

!

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.

!

WARNING

You are required to consult the local building and plumbing
codes prior to installation. If the information in this manual
is not consistent with local building or plumbing codes,
the local codes should be followed. Inquire with governing
authorities for additional local requirements.

!

WARNING

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. If installed on
a fire suppression system, all mechanical checks, such as alarms
and backflow preventers, should be flow tested and inspected in
accordance with NFPA 13 and/or NFPA 25. All products must be
retested once maintenance has been performed. 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.

NOTICE

For Australia and New Zealand, line strainers should be installed
between the upstream shutoff valve and the inlet of the backflow
preventer.

NOTICE

The flange gasket bolts for the gate valves should be
retightened during installation as the bolts may have loosened
due to storage and shipping.

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.

** Metric Dimensions are nominal pipe diameter. This product is produced with
ASME/ANSI flanged end connections.

!

WARNING

The installation and maintenance of backflow assemblies
should be performed by a qualified, licensed technician.
Failure to do so may result in a malfunctioning assembly.

www.amesfirewater.com

A Watts Water Technologies Company

Installation Guidelines

NOTICE

The flange gasket bolts for the gate valves should be
retightened during installation as the bolts may have loosened
due to storage and shipping.

NOTICE

Assembly body should not be painted.

Please Read Prior to Installation:

1. Before installing any Ames assembly, Flush the Line thoroughly
to remove all debris, chips and other foreign objects. Failure to
do so may make the assembly inoperable.

2. The Ames 4000SS and 5000SS Reduced Pressure Zone As­semblies are approved by ASSE (American Society of Sanitation
Engineers) to be installed in horizontal positions. Local water
authorities must approve all installation configurations.

3. Allow sufficient clearance around the installed assembly to
conduct testing, servicing, and inspection. Allow a minimum of 12"
from the flood level to the bottom of the assembly.

4. The 4000SS and 5000SS are not recommended for pit installa­tions. Where necessary, an Air Gap drain may be connected to
the relief valve to minimize flooding of the surrounding area. Flood­ing may cause a cross-connection. Be sure to contact local code
authorities for proper installations.

5. If installing on fire protection system, be sure to purge air from fire
system. Fill system slowly with all inspectors test valves open.

6

10

1

Item # Description

1. #1 Cam-Check

2. #2 Cam-Check

3. #1 Cam-Check O-ring

4. #2 Cam-Check O-ring

5. Cover Plate

6. Ball Valve

7. Groove Coupler

3

9

Figure 1

12

5

8

7

2

4

11

Flow

Item # Description

8. Groove Coupler Gasket

9. Relief Valve
(Complete assembly)

10. Relief Valve Hose

11. Relief Valve Body O-ring

12. Ball Valve (Cover)

Indoor Installation

Outdoor Installation

2

Maintenance Instructions

!

WARNING

Depressurize valve before servicing.

Figure 2

Removing Cam-Checks

1. Shut down water system and lock out system if possible. Slowly
open all ball valves to relieve air and water pressure. Loosen
bolts on groove coupler and remove groove coupler and cover
plate from valve body.

2. Remove #1 Cam-Check Assembly by using your hands to
unscrew (turn counterclockwise) Cam-Check and remove
through top access port. Do not use Cam Arm as a handle
to unscrew Cam-Check. If Cam-Check cannot be loosened
by hand, insert a long screwdriver between valve body and
Cam-Check (see Figure 3). Gently apply pressure against the
Cam-Check until loosened. Finish unscrewing by hand. Un­screw #2 Cam-Check (turn counterclockwise) by placing a long
screwdriver across lugs and applying pressure to loosen #2
Cam-Check. Finish unscrewing by hand.

1

3. To clean #1 Cam-Check (except 2
Check), locate the Cam Arm opening stud on the outlet flange
of the valve assembly. Slide the Cam Arm over the stud with the
check threads facing downward (Figure 5A). Tighten
stud to secure cam bar. Slowly pull the assembly outward to
open check. The clapper so that the end of the Cam Arm rests
between roller and clapper (Figure 5B).

Thoroughly clean the seat area and clapper sealing surfaces of

both Cam-Checks. Rinse Cam-Checks and O-rings thoroughly.
Inspect seats, clapper sealing surfaces, Cam Arms, and O-rings
for damage, nicks, and debris. If damaged, install a new Cam­Check assembly and/or O-ring or shutoff disc.

4. Before reinstallation of check assembly, thoroughly clean
O-ring groove and lubricate with F.D.A. approved lubricant.
Insert and thread #2 Cam-Check first and then #1 Cam-Check.
#2 Cam-Check should be tightened by inserting a long screw­driver between lugs to tighten firmly (see Figure 2). Do not over
tighten. Tighten #1 Cam-Check firmly by hand only. Replace
cover plate, clean groove coupler gasket and groove. Replace
groove coupler. Close ball valves. Repressurize and bleed air
from all test cocks.

/2" – 4" (65-100mm) DC

1

/4" nut on

A

B

Screwdriver

#1 Cam
Check

#2 Cam
Check

Figure 3

#1 Cam Check

21/2" – 6" (65-150mm) RP (Short Cam)

Spring

Cam Arm

O-ring Seal
& Groove

Seat Clapper

Roller

Figure 4

#2 Cam Check DC & RP

O-ring Seal
& Groove

Seat

Lug

Spring

Cam Arm

Roller

Clapper

O-ring Seal & Groove

C

6" Only

Figure 5A

Cam Bar Open Pin

Valve Outlet Flange
Threaded Stud on Flange

6" (150mm) 1st Check DC
6" (150mm) 2nd Check
DC & RP

Figure 5B

Cleaning
Position

For repair kits and parts, refer to our Backflow Pre­vention Products Repair Kits & Service Parts price list
PL-A-RP-BPD found on www.amesfirewater.com.

3

Relief Valve Service Instructions

!

WARNING

The relief valve may be serviced while on or off the backflow pre­venter valve.

NOTICE

Do not use a pipe wrench to remove the relief valve assembly
from the backflow preventer.

Relief Valve Disassembly

1. Disconnect the relief valve hose from the elbow in the bottom
flange cover at the swivel hose connection. Do not remove the
elbow.

2. If the valve is to be removed from the backflow preventer for
service, place a screwdriver blade or flat bar across the edges
of 2 of the hex head screws in the bottom flange cover and
turn counterclockwise to loosen the relief valve assembly. (see
Figure 2)

3. Remove the 4 bottom bolts from the bottom of the relief valve
assembly with a
bottom flange cover.

4. Remove the piston assembly & sleeve from the relief valve body
by placing your index fingers through the slots in the side of the
body and pressing down on the top of the disc retainer in the
top of the piston assembly. (See Figure 7.)

5. Pull the piston assembly free of the body by grasping the sleeve
and pulling down.

6. Grip the sleeve and the piston assembly by the head of the hex
head bolt. Pull up on the sleeve to extend the diaphragm. Slide
the sleeve (Part #7013340) completely off of the diaphragm and
inspect the diaphragm for tears, holes or excessive wrinkles. If
the diaphragm is damaged, order a new piston/diaphragm as­sembly.

Depressurize valve before servicing.

5

/16" socket or open-end wrench. Remove the

4

Relief Valve Reassembly

1. Thoroughly clean all inside surfaces of the relief valve body.

2. Inspect the relief valve body seat surface located at the top
edge of the 3 discharge slots near the top of the body by rub­bing the end of the index finger around the entire seat surface;
access the seat surface through the slots or the bottom of the
body. The seat must be free of nicks. If nicks are discovered,
remove the body & install a new relief valve assembly.

3. Position the diaphragm on the piston assembly so that it is fac­ing up as shown in Figure 8.

4. Now fold the top (ribbed) edge of the diaphragm inward, grasp
the sleeve with the ribbed edge up and slide the sleeve down
over the piston assembly as shown in Figure 8.

5. While still holding the sleeve, slide it up over the diaphragm and,
using your thumb & index finger, position the bead of the dia­phragm so that it wraps over the outside of the rib on the top
of the sleeve so that the sleeve is held by the diaphragm. Now
place the piston assembly on a flat, firm surface with diaphragm
facing up as shown in Figure 9.

6. Cup your hand slightly to form an air trap and force the sleeve
down over the piston assembly with a rapid slap (hard) on
the open end of the diaphragm with your cupped hand. The
trapped air in the diaphragm will force the diaphragm between
the inside of the sleeve and the outside of the piston. Ensure
that the diaphragm is fully seated by running the end of a dull
“butter” knife in the formed diaphragm. If diaphragm is wrinkled,
repeat previous step.

7. Slide the piston assembly and sleeve into the relief valve body
with the hex head bolt entering the flanged end of the body
first. Slide the piston assembly in until the diaphragm lip is
smoothly seated in the machined groove in the flanged end of
the body. By running your index finger around the outside of
the diaphragm bead, you will ensure it is seated smoothly.

8. Position the bottom flange cover on the bottom of the relief
valve body and secure by hand tightening the 4 bottom bolts.

9. Now tighten the 4 bottom bolts to approximately 15 ft.-lbs. with

5

/16" socket or open-end wrench.

a

10. Reattach the relief valve hose to the elbow in the bottom flange
cover.

27

31

22

23

21

Figure 6

Relief Valve

30

24
25

26

28
29

Figure 7

Figure 8

Figure 6

Item # Part Description

21. Relief Valve Body

22.* Rubber Shut-Off Disc.

23.* Piston Diaphragm Assembly

24. Hex Head Bolt

25. Disc. Retainer

26. Sleeve

27. Bottom Bolt

28. Bottom Flange (w/St. Elbow)

29. Elbow St 90 3/8

30.* O-Ring Disk

31. RV Spring

Figure 9

5

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’.

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’.

Auxiliary

Test Cock

Ball Type Test Valves

(White or Red)

(A)

Low Hose

(C)

(B)
Needle
Valve

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.

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.

!

CAUTION

To prevent freezing, hold Test Kit vertically to drain differential
gauge and hoses prior to placing in case.

High Hose

(Yellow)

Test Cock

Test Cock

No. 1

No. 2

Test Cock

No. 3

Vent Hose

(Blue)

Test Cock

No. 4

6

Troubleshooting Guide

PROBLEM CAUSE SOLUTION

A. Assembly discharges from differential

relief valve during no flow condition.

B. Assembly discharges from differential

relief valve during a flow condition.

C. Differential pressure relief valve does

not open during test due to leaking
outlet gate valve.

D. Pressure relief valve does not close Debris on sealing surface

Fouled first check

Fluctuating inlet pressure

Outlet pressure higher than inlet pressure
& leak in No. 2 check valve

Leak through diaphragm or around flange
bolt holes of relief valve

Pressure relief valve does not close

No. 1 check valve wedged open

O-ring displaced from groove in 1st check

Pressure relief valve does not close
Fluctuating line pressure

Differential pressure across No. 1 check
valve stays above 2psi due to leaking
outlet gate valve

Weak or broken relief valve spring

Shut off seat tube bound in body

Plugged hydraulic hose

Plugged hydraulic hose

Damaged seat or rubber shut off disc

Ruptured diaphragm

Wrinkled or improperly installed diaphragm

Disassemble and clean No. 1check valve

Control supply line water pressure

Disassemble, clean #2 check valve &
identify cause of back pressure.

Service relief valve (page 3)

See problem D

Disassemble and clean No. 1 check valve

Disassemble and replace

See problem D

Repair shut-off valves

Disassemble and replace relief valve spring

Disassemble and repair

Disassemble and repair

Remove relief valve and clean

Disassemble and clean

Remove relief valve assembly and replace

Disassemble and replace 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 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 not stop Go to B

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 not stop Malfunctioning pressure relief valve

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-4000SS/5000SS 1326 EDP# 7016813 © 2013 Ames Fire & Waterworks

USA: Backflow- Tel: [phone] • Fax: [phone]

Control Valves- Tel: [phone] • Fax: [phone]

Canada: Tel: [phone] • Fax: [phone]