Watts 4000ss-fs series Operating instructions

RP/IS-A-4000SS/5000SS-FS

5000SS-OSY-FS

NOTICE

For Australia and New Zealand, line strainers should be installed

between the upstream shutoff valve and the inlet of the backflow

preventer.

Testing

For field testing procedure, refer to Ames installation sheets

IS-A-ATG-1 at www.amesfirewater.com.

For other repair kits and service parts, refer to the Backflow

Prevention Products Repair Kits & Service Parts price list

PL-A-RP-BPD at www.amesfirewater.com.

For technical assistance, contact your local Ames representative.

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.

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.

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.

Installation, Maintenance, and Repair Manual

SilverBullet™Series 4000SS-FS, 5000SS-FS

Reduced Pressure Zone Assemblies

Reduced Pressure Detector Assemblies

21⁄2" – 6"

NOTICE

The information contained herein is not intended to replace the full

product installation and safety information available or the experi-

ence of a trained product installer. You are required to thoroughly

read all installation instructions and product safety information

before beginning the installation of this product.

Inquire with governing authorities for local installation

requirements.

NOTICE

Use of the integrated flood sensor does not replicate the need to

comply with all required instructions, codes, and regulations related

to installation, operation, and maintenance of this product, including

the need to provide proper drainage in the event of a discharge.

Watts®is not responsible for the failure of alerts due to

connectivity or power issues.

Series 4000SS-FS and 5000SS-FS are each equipped with an

integrated flood sensor that detects excessive relief valve discharges

and triggers notification of potential flood events.

NOTICE

An add-on connection kit is required to activate the integrated flood

sensor. Without the connection kit, the flood sensor is a passive

component and will not communicate with any other device.

(A retrofit sensor connection kit is also available for existing installa-

tions. See “Add-on and Retrofit Sensor Connection Kits,” for

ordering details.)

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.

Assembly body should not be painted.

• 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.

• 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.

• 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.

• The 4000SS and 5000SS assemblies are not recommended for

pit installations. Where necessary, an air gap drain may be con-

nected to the relief valve to minimize flooding of the surrounding

area. Flooding may cause a cross-connection. Contact local code

authorities for proper installations.

• If installing on a fire protection system, purge air from the fire sys-

tem. Fill the system slowly with all inspectors test valves open.

Installation Guidelines

Indoor Installation

Outdoor Installation

WARNING

Depressurize valve before servicing.

Before servicing, be certain the shutoff valves are closed. Then

use the following procedure to remove the check assemblies.

Slowly open all ball valves to relieve air and water pressure.

Loosen the bolts on the groove coupler and remove the groove

coupling and cover plate from the valve body. (See Figure 1.)

2. Remove check assembly #1 by hand, turning the screws counter-

clockwise to release the check and remove it through the top access

port. Do not use the check arm as a handle to unscrew the unit. If

the check cannot be loosened by hand, insert a long screwdriver

between the valve body and the check. (See Figure 2). Gently apply

pressure against the check until it is loosened. Finish unscrewing by

hand. (See Figure 3.) Unscrew check #2 by turning counterclockwise,

placing a long screwdriver across the lugs and applying pressure to

loosen the check. (See Figure 4.) Fin

ish un

screw

ing by hand.

(For 6" only) To clean check #1, locate the check arm opening

stud on the outlet flange of the valve assembly. Slide the check

arm over the stud with the check threads facing downward. (See

Figure 5A.) Tighten the ¼" nut on the stud to secure the cam bar.

Slowly pull the assembly outward to open the check, allowing

exposure of the seat clapper area for cleaning.

To clean check #2, lift the cam arm and hold it in the open

position. (See Figure 4.) Raise the clapper so that the end of the

check arm rests between the roller and the clapper. (See Figure

5B.) Thoroughly clean the seat area and clapper sealing surfaces

of both checks. Inspect seats, clapper sealing surfaces, check

arms, and O-rings for damage, nicks, and debris. If not damaged,

gently close the clapper. If damaged, install a new check assembly

or O-ring, or both.

4. Before reinstalling the checks, thoroughly clean the O-ring groove

and lubricate the O-ring with an FDA Approved lubricant. Insert

and thread check #2 first and then check #1. Check #2 should

be tightened by inserting a long screwdriver between the lugs to

tighten firmly. (See Figure 2.) Do not overtighten. Tighten check #1

firmly by hand only. Replace the cover plate, clean groove coupler

gasket, and groove. Replace the groove coupler. Repressurize and

bleed air from all the test cocks.

#1 Cam

Check #2 Cam

Check

Screwdriver

#1 Cam Check

21/2" – 6" RP (Short Cam)

O-ring Seal

& Groove

Seat Clapper

Roller

Spring

Cam Arm

#2 Cam Check DC & RP

O-ring Seal

& Groove Lug

Seat

O-ring Seal & Groove

Clapper

6" Only

Roller

Cam Arm

Spring

Cam Bar Open Pin

Valve Outlet Flange

Threaded Stud on Flange

6" 1st Check DC

6" 2nd Check

DC & RP

Cleaning

Position

Flow

ITEM DESCRIPTION ITEM DESCRIPTION

1#1 Cam-Check 7Groove Coupler

2#2 Cam-Check 8Groove Coupler Gasket

3#1 Cam-Check O-ring 9 Relief Valve (complete assembly)

4#2 Cam-Check O-ring 10 Relief Valve Hose

5Cover Plate 11 Relief Valve Body O-ring

6Ball Valve 12 Washer, Shutoff

Servicing the First and Second Checks

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5A

Figure 5B

Servicing the Relief Valve

WARNING

Depressurize valve before servicing.

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

valve. (See the components in relief valve in Figure 1.)

ITEM DESCRIPTION

21 Relief Valve Body

22 Rubber Shutoff Disc

23 Piston Diaphragm Assembly

24 Hex Head Bolt

25 Disc Retainer

26 Sleeve

27 Bottom Bolt

28 Bottom Flange (w st. elbow)

29 Bottom st. elbow

30 O-ring disc

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 (item 26) completely off the diaphragm and inspect the

diaphragm for tears, holes, or excessive wrinkles. If the diaphragm

is dam

aged, or

der a new piston-diaphragm assembly.

To reassemble the relief valve

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 three discharge slots near the top of the body by rubbing the

end of an index finger around the entire seat surface; access the

seat sur

face through the slots or the bottom of the body. The seat

must be free of nicks. If nicks are discovered, remove the body and

install a new relief valve assembly.

Position the diaphragm on the piston assembly so that it is fac

ing

up. (See Figure 3.)

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.

5. While still holding the sleeve, slide it up over the diaphragm and,

using your thumb and index finger, position the bead of the dia-

phragm 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. Place the

piston assembly on a flat, firm surface with diaphragm facing up.

(See Figure 4.)

6. Cup a 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 the cupped hand. The trapped air in the dia-

phragm forces the diaphragm between the inside of the sleeve and

the outside of the piston. Ensure that the diaphragm is fully seated.

If diaphragm is wrinkled, repeat the previous step.

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 ma

chined groove in the flanged end of the body.

Run an index finger around the outside of the diaphragm bead to

ensure it is seated smoothly.

Position the bottom flange cover on the bottom of the relief valve

body and secure it by hand-tightening the four bottom bolts.

Tighten the four bottom bolts to approximately 15 ft-lb with a 5/16"

socket or open-end wrench, then reattach the relief valve hose to

the elbow in the bottom flange cover. Reattach the flood sensor to

the relief valve and mount the activation module to sensor.

NOTICE

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

the backflow preventer.

To disassemble the relief valve

Detach the activation module, if installed, from the flood sensor

then use a #2 Phillips screwdriver to remove the sensor from the

relief valve.

2. Disconnect the relief valve hose from the elbow in the bottom

flange cover at the swivel hose connection. Do not remove the

elbow.

3. If the valve is to be removed from the backflow preventer for

service, place a screwdriver blade or flat bar across the edges of

two of the hex head screws in the bottom flange cover and turn

counterclockwise to loosen the relief valve assembly.

Remove the four bottom bolts from the bottom of the relief valve

assembly with a 5⁄16" socket or open-end wrench. Remove the

bottom flange cover.

Remove the piston assembly and sleeve from the relief valve body

by placing the 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 2.) Pull the piston assembly

free of the body by grasping the sleeve and pulling down.

Figure 2

Figure 3

Figure 1

Figure 4

Ball Type Test Valves

Follow the requirements of each test when performed to ensure

successful installation, operation, and maintenance of the

backflow preventer.

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 No.

4. Indicated pressure differential is expected to decrease slightly.

If pressure differential continues to decrease (until the vent

opens) check valve No. 2 is reported as ‘leaking.’

Test No. 2

Purpose: To test shutoff No. 2 for tightness.

Requirements: After passing test No. 1, continue to test No. 2

by closing test cock No. 2. The indicated pressure differential is

expected to decrease slightly. If pressure differential continues

to decrease (approaching ‘zero’), shutoff No. 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

No. 2. Close test cock No. 4. Disconnect vent hose at test cock

No. 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 2 psi 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 when the first discharge

is noted from the relief valve. Record this as the opening

differential pressure of the relief valve.

NOTICE

The differential gauge needle MUST drop slowly. Close test

cocks No. 2 and No. 3. Use the ‘vent’ hose to relieve pressure

from the test kit by opening valves A, B, and C. Remove all

test equipment and open shutoff No. 2.

CAUTION

To prevent freezing, hold Test Kit vertically to drain differential

gauge and hoses prior to placing in case.

Testing Reduced Pressure Zone Assemblies

(A) (C)

High Hose

(Yellow)

Low Hose

(White or Red)

Vent Hose

(Blue)

Test Cock

No. 1

Test Cock

No. 2

Test Cock

No. 3 Test Cock

No. 4

(B)

Needle

Valve

Problem Identification Procedures

When using differential pressure gauge

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 test cock 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

PROBLEM CAUSE SOLUTION

Assembly discharges from differential relief valve during

no flow condition

Fouled first check Disassemble and clean check valve #1

Fluctuating inlet pressure Control supply line water pressure

Install a soft-seated, spring-loaded check valve upstream

of the assembly

Outlet pressure higher than inlet pressure and leak in

check valve #2

Disassemble and clean check valve #2 and identify cause

of backpressure

Leak through diaphragm or around flange bolt holes of

relief valve

Service relief valve

Pressure relief valve does not close See problem 'Pressure relief valve does not close'

Assembly discharges from differential relief valve during

a flow condition

Check valve #1 wedged open Disassemble and clean check valve #1

O-ring displaced from groove in check #1 Disassemble and replace

Pressure relief valve does not close See problem 'Pressure relief valve does not close'

Fluctuating line pressure Install pressure sustaining check upstream of backflow

Differential pressure relief valve does not open during test Differential pressure across check valve #1 stays above

2.0 psi due to leaking outlet gate valve

Repair shutoff valves

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

Pressure relief valve does not close Debris on sealing surface Remove relief valve and clean

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

Troubleshooting

Add-on and Retrofit Sensor Connection Kits for Building Management Systems

ORDERING CODE ADD-ON/RETROFIT KIT DESCRIPTION

88009418 FP-BF-BMS-21/2-10

BMS Sensor Connection Kit

Series 4000SS-FS

Series 5000SS-FS

Sizes 2½" to 6"

Includes sensor activation module with cable, ground wire, and power adapter. Use

this kit to activate the integrated flood sensor and enable flood detection capabilities

on the relief valve of a new installation linked to a BMS controller (not included).

88009419 FP-RFK-BF-BMS-CFS-21/2-10

BMS Sensor Retrofit Connection Kit

Series 4000SS

Series 5000SS

Sizes 2½" to 6"

Includes flood sensor, sensor activation module with cable, ground wire, and

power adapter. Use this kit to install the flood sensor and enable flood detection

capabilities on the relief valve of an existing installation linked to a BMS controller

(not included).

Add-on and Retrofit Sensor Connection Kits for Cellular Communication

ORDERING CODE ADD-ON/RETROFIT KIT DESCRIPTION

88009420 FP-BF-CFS-21/2-10

Cellular Sensor Connection Kit

Series 4000SS-FS

Series 5000SS-FS

Sizes 2½" to 6"

Includes sensor activation module with cable, Cellular Gateway with mounting kit,

ground wire, and power adapter. Use this kit to activate the integrated flood sensor

and enable flood detection capabilities on the relief valve of a new installation linked

to a cellular network to send alerts by email message, SMS text message, or

voice call.

88009421 FP-RFK-BF-CFS-21/2-10

Cellular Sensor Retrofit Connection Kit

Series 4000SS

Series 5000SS

Sizes 2½" to 6"

Includes flood sensor, sensor activation module with cable, Cellular Gateway with

mounting kit, ground wire, and power adapter. Use this kit to install the flood sensor

and enable flood detection capabilities on the relief valve of an existing installation

linked to a cellular network to send alerts by email message, SMS text message,

or voice call.

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