Apollo RP4A Installation, Operation & Maintenance Manual
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Apollo RP4A Installation, Operation & Maintenance Manual

2-1/2 inch - 12 inch reduced pressure principle. reduced pressure detector assembly
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INSTALLATION, OPERATION & MAINTENANCE MANUAL
2-1/2" - 12" Reduced Pressure Principle | Reduced Pressure Detector Assembly
RP4A | RPLF4A | RPDA4A | RPDLF4A | RPDA24A | RPDA2LF4A
ES1600 IOM BFMMRP4ALBF rev.a

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  • Page 1 INSTALLATION, OPERATION & MAINTENANCE MANUAL 2-1/2” - 12” Reduced Pressure Principle | Reduced Pressure Detector Assembly RP4A | RPLF4A | RPDA4A | RPDLF4A | RPDA24A | RPDA2LF4A ES1600 IOM BFMMRP4ALBF rev.a...
  • Page 2 INSTALLATION, OPERATION & MAINTENANCE MANUAL TABLE OF CONTENTS SECTION DESCRIPTION PAGE Reduced Pressure Principle Backflow Preventer RP4A / RPLF4A Description and Operation Installation Troubleshooting Guide Maintenance Instructions (RP/RPDA mainline) 2-1/2” - 6” 8” - 12” 7-11 Testing Procedures 12-13 Reduced Pressure Detector Assembly RPDA4A / RPDALF4A & RPDA24A / RPDA2LF4A...
  • Page 3 ES1600 REV A. BFMMRP4ALBF DESCRIPTION AND OPERATION The Reduced Pressure Principle (RP) device consists of two independently-acting, spring-loaded check valves, together with a hydraulically dependent, mechanically independent pressure differential relief valve, located in the zone between the check valves. Two resilient seated shut-off valves and four test cocks complete the assembly.
  • Page 4 INSTALLATION, OPERATION & MAINTENANCE MANUAL III. TROUBLESHOOTING SYMPTOM CAUSE CORRECTIVE ACTION Relief valve continuously discharges during 1. #1 check valve fouled with debris. 1. Inspect and clean seat disc and seat no-flow condition. 2. #2 check valve fouled with debris 2.
  • Page 5 ES1600 REV A. BFMMRP4ALBF MAINTENANCE INSTRUCTIONS - 2-1/2” – 6” Open test cocks #2, #3, and #4 to relieve pressure from the device. Both shut-off valves must be closed. CHECK REMOVAL Note: If the first check disc needs only to be cleaned, it is not necessary to remove the entire check module from the valve body. See the next section, “Check Maintenance”, for seat disc cleaning instructions.
  • Page 6 9. Insert the seat into the RV body. Ensure that it is fully seated. 10. Lubricate the bushing o-ring with Apollo® supplied lubricant, Dow 111 or equal and insert the assembled RV module into the valve body. Ensure the diaphragm bead is seated properly before installing the RV cover.
  • Page 7 ES1600 REV A. BFMMRP4ALBF MAINTENANCE INSTRUCTIONS - 8” – 12” 8” – 12” SIZES Open test cocks #2, #3, and #4 to relieve pressure from the device. Both shut-off valves must be closed. NOTE: On 10” & 12” models, the flow divider (FD) must be removed before the checks are removed. To remove the FD, remove the ¼” nut holding it in place.
  • Page 8 INSTALLATION, OPERATION & MAINTENANCE MANUAL MAINTENANCE INSTRUCTIONS - 1/2” – 6” FIGURE 6 FIGURE 7 B. CHECK MAINTENANCE (CAN BE ACHIEVED WITHOUT REMOVING ENTIRE CHECK.) If only cleaning of the first check is necessary, simply remove the six (6) reusable locknuts for 8” valves / eight (8) nuts for 10” & 12” valves on the black plastic disc retainer (See Figure 8).
  • Page 9 5. Lubricate the stem, stem o-ring, and RV seat o-ring with Apollo® supplied lubricant, DOW 111 or equal. Reassemble RV cartridge. 6. Remove the RV seat by grasping the cage and pulling straight out. A flat screwdriver may be necessary to aid in removal.
  • Page 10 INSTALLATION, OPERATION & MAINTENANCE MANUAL MAINTENANCE INSTRUCTIONS - 2-1/2” – 6” FIGURE 9 8” DIAPHRAGM RV SEAT RELIEF VALVE CARTRIDGE COVER BOLTS COVER RV SEAT BODY BUSHING O-RING O-RING 1/4" SCREW DISC WASHER DISC STEM STEM O-RING BUSHING SPRING DIAPHRAGM 1/4"...
  • Page 11 5. Lubricate the stem, stem o-ring, and RV seat o-ring with Apollo® supplied lubricant, DOW 111 or equal. Reassemble RV cartridge. 6. Remove the RV seat by grasping the cage and pulling straight out. A flat screwdriver may be necessary to aid in removal.
  • Page 12 INSTALLATION, OPERATION & MAINTENANCE MANUAL TESTING PROCEDURES V. TESTING PROCEDURES NOTE: This 3 valve test kit procedure may not be approved in all jurisdictions. Consult your local water purveyor for acceptable test procedures. See Figure 10 for test schematic. TEST NO. 1 PURPOSE: TO TEST OPERATION OF THE PRESSURE DIFFERENTIAL RELIEF VALVE.
  • Page 13 ES1600 REV A. BFMMRP4ALBF TESTING PROCEDURES TEST NO. 3 PURPOSE: IS THE STATIC PRESSURE DROP ACROSS CHECK VALVE NO. 1 MAINTAINED AT LEAST 3 PSI ABOVE THE RELIEF VALVE OPENING POINT? NO BYPASS HOSE USED IN TESTS 1 AND 2 1.
  • Page 14 INSTALLATION, OPERATION & MAINTENANCE MANUAL DESCRIPTION AND OPERATION The Reduced Pressure Detector Assembly (RPDA Type 1) contains a mainline RP incorporating two independently acting, spring-loaded check valves with a diaphragm-actuated spring-loaded relief valve located between the checks and a bypass line consisting of an approved RP assembly and a water meter.
  • Page 15 ES1600 REV A. BFMMRP4ALBF RPDA BYPASS TYPES RPDA4A TYPE 1 RPDALF4A TYPE 1 RPDA24A TYPE 2 RPDA2LF4A TYPE 2 Customer Service (704) 841-6000 backflow.apollovalves.com...
  • Page 16 INSTALLATION, OPERATION & MAINTENANCE MANUAL PART NUMBER DIAGRAM - 2-1/2” - 6” RP4A, RPLF4A RPDA4A, RPDALF4A (MAINLINE) RPDA24A, RPDA2LF4A (MAINLINE) “ A p l ” Flow Controls Customer Service (704) 841-6000 www.apolloflowcontrols.com...
  • Page 17 ES1600 REV A. BFMMRP4ALBF PARTS LIST - 2-1/2” - 6” RP4A / RPDA4A (MAINLINE) / RPDA24A (MAINLINE) PARTS LIST RPLF4A / RPDALF4A (MAINLINE) / RPDA2LF4A (MAINLINE) PARTS LIST PART NUMBER ITEM # DESCRIPTION QTY. 2-1/2” 3” 4” 6” Shut-off Valve See Pages 26 &...
  • Page 18 INSTALLATION, OPERATION & MAINTENANCE MANUAL REPAIR KITS - 2-1/2” - 6” REPAIR KITS (MAINLINE) 2-1/2” - 6” SIZE CHECK RUBBER ONLY KIT (ONE KIT REPAIRS ONE CHECK) 2-1/2” & 3” 4” 6” REPAIR KIT MODEL NUMBER RK4A3CMR RK4A4CMR RK4A6CMR ITEM # ORDERING NUMBER 4A-000-01 4A-00A-01...
  • Page 19 ES1600 REV A. BFMMRP4ALBF PART NUMBER DIAGRAM - 8” - 12” RP4A, RPLF4A RPDA4A, RPDALF4A (MAINLINE) RPDA24A, RPDA2LF4A (MAINLINE) REVERSE ANGLE 8" ONLY Customer Service (704) 841-6000 backflow.apollovalves.com...
  • Page 20 INSTALLATION, OPERATION & MAINTENANCE MANUAL PARTS LIST - 8” - 12” RP4A / RPDA4A (MAINLINE) / RPDA24A (MAINLINE) PARTS LIST RPLF4A / RPDALF4A (MAINLINE) / RPDA2LF4A (MAINLINE) PARTS LIST PART NUMBER ITEM # DESCRIPTION QTY. 8” 10” 12” Shut-off Valve See Page 26 &...
  • Page 21 ES1600 REV A. BFMMRP4ALBF REPAIR KITS - 8” - 12” REPAIR KITS (MAINLINE) 8” - 12” SIZE CHECK RUBBER ONLY KIT (ONE KIT REPAIRS ONE CHECK) 8” 10” & 12” REPAIR KIT MODEL NUMBER RK4A8CMR RK4A12INCMR Item # Ordering Number 4A-00E-01 4A-00H-01 not shown...
  • Page 22 INSTALLATION, OPERATION & MAINTENANCE MANUAL PART LIST - BYPASS SINGLE CHECK (TYPE 2) FIGURE 13 W977005 SINGLE CHECK VALVE (LEAD FREE*) INDIVIDUAL PARTS ARE ONLY AVAILABLE FOR BULK SALES. ITEM PART # DESCRIPTION PLEASE REFER TO THE APPROPRIATE REPAIR KITS BELOW. K-4587-06 Tailpiece C-1844-05...
  • Page 23 ASSEMBLY - CHECK VALVE MODULE 1. Install new or cleaned check valve module into body (ensure check o-ring is in place). 2. Apply a thin coat of Apollo® supplied lubricant, DOW 111 or equal, on cap o-ring. 3. Install cap.
  • Page 24 INSTALLATION, OPERATION & MAINTENANCE MANUAL BYPASS KITS 2-1/2" & 3" TYPE 1 BYPASS LINE Note: Before attaching bypass line, remove #2 test cock, nipple, and reducer and move to the opposite side of the gate valve. 1/2" X 1-1/2" Long Nipple 1/2"...
  • Page 25 ES1600 REV A. BFMMRP4ALBF BYPASS KITS 4" Note: Before attaching bypass line, remove #2 test cock, nipple, and TYPE 1 reducer and move to the opposite side of the gate valve. BYPASS LINE 1/2" X 2" Long Nipple 1/2" Ball Valve without Tapped Port 1/2"...
  • Page 26 INSTALLATION, OPERATION & MAINTENANCE MANUAL BYPASS KITS 6" Note: Before attaching bypass line, remove #2 test cock and nipple TYPE 1 and move them to the opposite side of the gate valve. BYPASS LINE 1/2" X 5" Long Nipple 1/2" Ball Valve without Tapped Port 1/2"...
  • Page 27 ES1600 REV A. BFMMRP4ALBF BYPASS KITS 8" Note: Before attaching bypass line, remove #2 test cock and nipple TYPE 1 and move them to the opposite side of the gate valve. BYPASS LINE 1/2" X 7-1/2" Long Nipple 1/2" Ball Valve without Tapped Port 1/2"...
  • Page 28 INSTALLATION, OPERATION & MAINTENANCE MANUAL BYPASS KITS 10" TYPE 1 BYPASS LINE 1/2" X 6" Long Nipple 1/2" X 7-1/2" Long Nipple 1/2" Coupling 1/2" X 3" Long Nipple 1/2" Ball Valve without Tapped Port 1/2" RPLF4A Reduced Pressure Backflow Preventer Test Cock Adjustment Joint Retainer 3/4"...
  • Page 29 ES1600 REV A. BFMMRP4ALBF BYPASS KITS 12" TYPE 1 BYPASS LINE 1/2" X 6" Long 3/4" Male X Nipple 1/2" Female Fitting 1/2" X 7-1/2" Long Nipple 3/4" Ball Valve 1/2" Ball Valve M X F NPT Adjustment Joint Retainer without Tapped Port 1/2"...
  • Page 30 INSTALLATION, OPERATION & MAINTENANCE MANUAL BYPASS KITS 3/4" Male NPT X 1/2" Female NPT Fitting 2-1/2" & 3" 1/2" X 2-1/2" Long Nipple TYPE 2 1/2" Ball Valve Without Tapped Port BYPASS 1/2" Close Nipple LINE (~1" Long) 1/2" Single Check Valve Test Cock Rubber Washer 2 Each...
  • Page 31 ES1600 REV A. BFMMRP4ALBF BYPASS KITS 3/4" Male NPT X 6" 1/2" Female NPT Fitting TYPE 2 1/2" Close Nipple (~1" Long) 1/2" Ball Valve BYPASS Without Tapped Port LINE 1/2" X 3" Long Nipple 1/2" Single Check Valve Rubber Washer 2 each Water Meter Test Cock...
  • Page 32 INSTALLATION, OPERATION & MAINTENANCE MANUAL BYPASS KITS 10" TYPE 2 BYPASS LINE 1/2" X 3" Long Nipple 1/2" X 2" 3/4" Male NPT X Long Nipple 1/2" Female NPT Fitting APPLY TEFLON TAPE TO PIPE THREADS AND INSTALL 1/2" Single COMPONENTS AS SHOWN.
  • Page 33 ES1600 REV A. BFMMRP4ALBF BYPASS KITS APPLY TEFLON TAPE TO PIPE THREADS AND INSTALL 12" COMPONENTS AS SHOWN. TYPE 2 BYPASS LINE 3/4" Male NPT X 1/2" Female NPT Fitting 1/2" Ball Valve 1/2" X 2" Long Nipple 1/2" X 3" 1/2"...
  • Page 34 INSTALLATION, OPERATION & MAINTENANCE MANUAL PARTS LIST DIAGRAM – BYPASS RP (TYPE 1) W965505 REDUCED PRESSURE BYPASS VALVE (LEAD FREE*) “ A p l ” Flow Controls Customer Service (704) 841-6000 www.apolloflowcontrols.com...
  • Page 35 ES1600 REV A. BFMMRP4ALBF PARTS LIST & REPAIR KITS – BYPASS RP (TYPE 1) TYPE 1 BYPASS RP PARTS LIST ITEM DESCRIPTION PART# Body Q-6891-05 Nameplate I-9169-00 Nameplate Tack I-2614-00 Test Cock 78LF-292-01 F-3847-05 Cap O-Ring D-4881-00 Check Module O-Ring D-4880-00 RV Cover Bolts B-1793-00...
  • Page 36 ASSEMBLY - CHECK VALVE MODULE 1. If the check seat was removed, install the new o-ring and lubricate with Apollo® supplied lubricant, Dow 111, or equivalent. 2. Line up the seat with the bore and push it firmly into place.
  • Page 37 ES1600 REV A. BFMMRP4ALBF SHUT-OFF VALVES SHUT-OFF VALVE PART NUMBERS (UL LISTED ASSEMBLIES MUST HAVE INDICATING TYPE SHUT-OFF VALVES ON INLET AND OUTLET.) SHUT-OFF VALVE OPTIONS -- 2-1/2” ASSEMBLY DESCRIPTION (INLET X OUTLET) INLET OUTLET SUFFIX FLANGE NRS X FLANGE NRS W-5310-00 W-5310-00 FLANGE OS&Y X FLANGE OS&Y...
  • Page 38 INSTALLATION, OPERATION & MAINTENANCE MANUAL SHUT-OFF VALVES SHUT-OFF VALVE PART NUMBERS (UL LISTED ASSEMBLIES MUST HAVE INDICATING TYPE SHUT-OFF VALVES ON INLET AND OUTLET.) SHUT-OFF VALVE OPTIONS -- 4” ASSEMBLY DESCRIPTION (INLET X OUTLET) INLET OUTLET POST PLATE OPERATING NUT SUFFIX FLANGE NRS X FLANGE NRS W-2870-00...
  • Page 39 ES1600 REV A. BFMMRP4ALBF SHUT-OFF VALVES SHUT-OFF VALVE PART NUMBERS (UL LISTED ASSEMBLIES MUST HAVE INDICATING TYPE SHUT-OFF VALVES ON INLET AND OUTLET.) SHUT-OFF VALVE OPTIONS -- 8” ASSEMBLY DESCRIPTION (INLET X OUTLET) INLET OUTLET POST PLATE OPERATING NUT SUFFIX FLANGE NRS X FLANGE NRS W-2872-00 W-2872-00...
  • Page 40 Phone: (704) 841-6000 Fax: (704) 841-6020 Regional Management List now available online at: http://conbra.co/rmlist Check our website for the most up-to-date information on all our products. www.apolloflowcontrols.com...

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