Apollo RP4A Installation, Operation & Maintenance Manual Download Page 36

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Customer Service

(704) 841-6000

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.apolloflowcontrols.com

“Apollo”

Flow Controls

INSTALLATION, OPERATION & MAINTENANCE

MANUAL

DISASSEMBLY - CHECK VALVE MODULE

1. Close #2 bypass line shut-off valve, then close #1 bypass line shut-off valve.

2. Bleed pressure from the assembly by opening all test cocks on bypass RP.

3. Unscrew cap using hex head provided.

4. Push down and turn the spring retainer 90° to remove. Remove the spring. Remove the poppet from the check seat.

5. Normally, the check seat need not be removed. If removal is required, rock it back and forth while pulling outward.

DISASSEMBLY - CHECK VALVE POPPET

CAUTION: Do not use pliers or other tools, which may damage or scratch the plastic stem.

1. Holding the poppet assembly in one hand, remove screw and retaining washer.

2. Remove the seat disc.

3. All parts should be carefully inspected for any damage or excessive wear and thoroughly rinsed in clean water prior to reassembly. Replace worn

parts as necessary.

ASSEMBLY - CHECK VALVE POPPET

1. Install new or cleaned disc in poppet and secure with washer and screw.

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.

3. Place and center the poppet assembly in the check seat.

4. Install the spring onto the poppet.

5. Install the spring retainer onto the spring by pushing down into the grooves of the check seat and turning 90°. Ensure spring retainer pops up

about 1/8” and locks into the lugs. CAUTION: Ensure the spring retainer orientation matches that in the parts list drawing or the device’s flow will

be significantly restricted (i.e. - do not install the spring retainer upside down).

6. Apply a thin coat of Apollo®

supplied lubricant, DOW 111 or equal, on cap o-ring.

7. Install cap.

DISASSEMBLY - RELIEF VALVE

1. Remove cover bolts, cover, and diaphragm.

2. Grasp the diaphragm plate and pull the assembly straight out of the body.

3. Hold the relief valve assembly in one hand and remove the screw.

4. Remove the seat disc.

Note: Items 5 through 7 are not normally required.

5. Turn the assembly over, keeping the spring compressed by holding down on the diaphragm plate, remove screw.

6. Remove the diaphragm plate, spring, and bushing from the RV stem. Note the orientation of the bushing with respect to the spring.

7. Remove the o-ring from the RV stem.

8. Normally, the RV seat need not be removed. If removal is required, rock it back and forth while pulling outward.

9. All parts should be carefully inspected for any damage or excessive wear and thoroughly rinsed in clean water prior to reassembly. Replace worn

parts as necessary.

ASSEMBLY - RELIEF VALVE

1. Apply a thin coat of Apollo®

supplied lubricant, Dow 111, or equal on o-rings before installing.

2. Install o-ring on RV seat. Line up the seat with the bore and push firmly into place.

3. If the RV stem has been disassembled, install o-ring onto RV stem.

4. Slide bushing over RV stem and position spring onto bushing. Note the correct position of the bushing from step #6 in disassembly instructions.

(Spring must fit over the smaller shoulder of the bushing upon reassembly.)

5. Position diaphragm plate and compress spring, install screw into RV stem.

6. Turn the assembly over and install seat disc and screw.

7. Install o-ring onto bushing.

8. Slide complete assembly into the body.

9. Position diaphragm over flange, install cover, and tighten bolts evenly.

10. Open #1 shut-off valve and bleed air out of the unit through #2, #3, and #4 test cocks; then open #2 shut-off valve.

11. Test complete assembly to ensure proper operation.

IX. MAINTENANCE INSTRUCTIONS - BYPASS RP (TYPE 1)

Summary of Contents for RP4A

Page 1: ...INSTALLATION OPERATION MAINTENANCE MANUAL 2 1 2 12 ReducedPressurePrinciple Reduced Pressure Detector Assembly RP4A RPLF4A RPDA4A RPDLF4A RPDA24A RPDA2LF4A ES1600 IOM BFMMRP4ALBF rev a ...

Page 2: ...ure Detector Assembly RPDA4A RPDALF4A RPDA24A RPDA2LF4A VI Description and Operation 14 VII Installation 14 VIII Maintenance Instructions Bypass Single Check Type 2 23 IX Maintenance Instructions Bypass RP Type 1 36 PARTS LIST 2 1 2 6 RP RPDA Mainline 16 17 8 12 RP RPDA Mainline 13 14 2 1 2 12 RPDA2 Type 2 Bypass Single Check 15 2 1 2 12 RPDA Type 1 Bypass RP 28 REPAIR KITS 2 1 2 6 Check Valves 18...

Page 3: ...iping thoroughly to remove foreign matter prior to installing the device 4 The device should be installed in the horizontal position A clearance between the lower most portion of the device and flood grade or floor should be provided for ease of maintenance 5 If shut off valves are provided separately they must include tapped bosses for attachment of the sensing hose the 1 test cock and the 2 test...

Page 4: ...r debris or deposits on poppet stem or guide 5 Switch springs to proper check location Relief valve discharges intermittently in a spitting action during no flow condition 1 Pressure fluctuations or water hammer from supply 1 Eliminate or reduce supply pressure fluctuations Relief valve does not open during test No 1 2 2 shut off valve not closed completely 3 Test equipment improperly installed 4 ...

Page 5: ...g clip by pinching the clip ears together This will disengage the clip from its groove Remove clip and check retaining ring Pull check module straight out of body The check module is sealed in place with an o ring See Figure 3 B CHECK MAINTENANCE If only cleaning of the first check is necessary simply remove the three 3 reusable locknuts for 2 1 2 3 valves four 4 nuts for 4 6 valves on the black p...

Page 6: ...s seated properly in the RV body before installing the RV cover If it is necessary to disassemble the RV module and or remove the RV seat 1 Remove the RV module as described above 2 Remove the 5 16 screw on the diaphragm plate Use caution as this will disengauge the spring 3 Remove the 5 16 screw on the seat disc washer 4 Inspect all components for damage paying particular attention to the diaphra...

Page 7: ...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 disc cleaning instructions 1 Take off the cover coupling by removing the two bolts and nuts 2 Lift off the cover The gasket may remain on the valve body See Figure 6 Note The 10 12 valves are equipped with lifting tabs for cover lifting only...

Page 8: ...ocknuts for 8 valves eight 8 nuts for 10 12 valves on the black plastic disc retainer See Figure 8 Remove the check handles and washers and lift the disc retainer and disc out of the body Rinse the disc with clean water or replace if necessary The disc may be flipped over for a temporary repair but should be replaced if damaged Replace the disc disc retainer washer handle and nuts Do not over tigh...

Page 9: ...t sensing hose and replace if damaged 11 Reinstall sensing hose to RV cover nipple If it is necessary to disassemble the RV module and or remove the RV seat 1 Remove the RV module as described above 2 Remove the 1 4 screw on the diaphragm plate Use caution as this will disengauge the spring 3 Remove the 1 4 screw on the seat disc washer 4 Inspect all components for damage paying particular attenti...

Page 10: ...O RING BUSHING O RING RV BODY 1 4 SCREW 1 4 SCREW DISC WASHER DISC STEM STEM O RING BUSHING SPRING DIAPHRAGM PLATE BOLT STEM O RINGS BUSHING SPRING DIAPHRAGM PLATE RV BODY RV SEAT O RING RV SEAT BUSHING O RING RELIEF VALVE CARTRIDGE COVER COVER BOLTS NIPPLE SCREW DISC WASHER DISC STEM DIAPHRAGM PLATE DIAPHRAGM SHROUD 1 4 SCREW IV MAINTENANCE INSTRUCTIONS 2 1 2 6 FIGURE 9 8 FIGURE 10 10 12 ...

Page 11: ...body 8 Replace cover and bolts 9 Inspect sensing hose and replace if damaged 10 Reinstall sensing hose to RV cover nipple If it is necessary to disassemble the RV module and or remove the RV seat 1 Remove the RV module as described above 2 Remove the 5 8 screw on the diaphragm plate Use caution as this will disengauge the spring 3 Remove the 3 8 screw on the seat disc washer 4 Inspect all componen...

Page 12: ...ding If the relief valve does not open go to step 10 9 Close the high and low valves on the gauge and go to test No 2 10 The No 2 shutoff valve may be leaking Reopen and close No 2 shutoff valve to attempt a better shutoff Repeat steps 6 through 8 If the relief valve does not open a bypass hose is required not to be confused with the bypass hose on the gauge 11 Large leaks may require a garden hos...

Page 13: ...the static pressure drop across check valve No 1 TESTING PROCEDURE FOR SINGLE CHECK ON RPDA TYPE 2 BYPASS Note The first check of the mainline valve is also the first check of the bypass assembly and the test results for the first mainline check should be recorded as the first check of the bypass assembly If the local water authority requires a second test for the first check perform the test agai...

Page 14: ...N VII INSTALLATION 1 The RPDA must be installed in an accessible location to facilitate periodic field testing and maintenance 2 Flush all upstream piping thoroughly to remove foreign matter prior to installing the device 3 The device must be installed in the horizontal position A clearance of 12 to 30 between the lower most portion of the device and flood grade or floor should be provided for eas...

Page 15: ...15 Customer Service 704 841 6000 backflow apollovalves com ES1600 REV A BFMMRP4ALBF RPDA24A TYPE 2 RPDA2LF4A TYPE 2 RPDA4A TYPE 1 RPDALF4A TYPE 1 RPDA BYPASS TYPES ...

Page 16: ...tomer Service 704 841 6000 www apolloflowcontrols com Apollo Flow Controls INSTALLATION OPERATION MAINTENANCE MANUAL RP4A RPLF4A RPDA4A RPDALF4A MAINLINE RPDA24A RPDA2LF4A MAINLINE PART NUMBER DIAGRAM 2 1 2 6 ...

Page 17: ...W 9670 05 21 Check Retaining Ring 2 E 2960 00 E 2868 00 E 2869 00 22 Check Retaining Clip 2 L 8063 00 L 7996 00 L 8037 00 23 Seat Spring Sub Assy 1 W 9715 05 W 9717 05 W 9719 05 24 Check Seat O ring 1 D 5171 00 D 4869 00 D 5000 00 25 Seat Disc 1 D 4958 00 D 4862 00 D 4890 00 26 Disc Retainer 1 L 7800 00 F 3862 00 F 3863 00 27 Washer QTY E 2905 00 1 E 2920 00 1 E 2878 00 4 28 Handle 1st Chk Only 1 ...

Page 18: ... ONE CHECK SIZE 2 1 2 3 4 6 REPAIR KIT MODEL NUMBER RK4A3DCRP2CMC RK4A4DCRP2CMC RK4A6DCRP2CMC ITEM ORDERING NUMBER 4A 000 14 4A 00A 14 4A 00C 14 not shown Lubricant I 9016 00 12 2nd Check Module S Assy W 9857 05 W 9667 05 W 9671 05 24 Check O ring D 5171 00 D 4869 00 D 5000 00 16 Cover O ring D 4976 00 D 4870 00 D 5001 00 RP RELIEF VALVE RUBBER KIT REPAIR KIT MODEL NUMBER RK4A6RVR ITEM ORDERING NU...

Page 19: ...S1600 REV A BFMMRP4ALBF REVERSE ANGLE 8 ONLY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 17 16 15 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 18 19 20 21 22 15 PART NUMBER DIAGRAM 8 12 RP4A RPLF4A RPDA4A RPDALF4A MAINLINE RPDA24A RPDA2LF4A MAINLINE ...

Page 20: ... Retainer 1 F 3899 00 F 3903 00 21 Washer 2 E 2897 00 22 Handle 2 H 3828 00 H 3813 00 23 Adapter w Extension 1 K 4618 00 N A 24 Elbow Street 1 K 4600 00 N A 25 Nipple 1 K 3982 00 N A 26 Sensing Hose 1 W 9898 00 W 9898 00 27 Street Elbow 1 K 4600 00 28 RV Body 1 Q 6992 05 Q 7102 05 29 RV Seat O ring 1 D 4883 00 D 3506 00 30 RV Seat 1 L 8047 00 L 8169 00 31 Bushing O ring 1 D 2565 00 D 4858 00 32 RV...

Page 21: ...62 05 17 Check O ring D 4935 00 D 4997 00 RP RELIEF VALVE RUBBER KIT SIZE 8 10 12 REPAIR KIT MODEL NUMBER RK4A8RVR RK4A12INRVR ITEM ORDERING NUMBER 4A 00E 04 4A 00H 04 not shown Lubricant I 9016 00 29 RV Seat O ring D 4883 00 D 3506 00 31 Bushing O ring D 2565 00 D 4858 00 33 Diaphragm D 2564 00 D 2591 00 39 RV Seat Disc D 2563 00 D 2595 00 41 Stem O ring D 2562 00 D 2594 00 not shown Dia Plate O ...

Page 22: ... INDIVIDUAL PARTS ARE ONLY AVAILABLE FOR BULK SALES PLEASE REFER TO THE APPROPRIATE REPAIR KITS BELOW BYPASS SINGLE CHECK REPAIR KITS 4A 003 12 CHECK REPAIR KIT INCLUDES ITEMS 4 6 AND 7 1 EA 4A 003 13 CHECK COMPLETE KIT INCLUDES ITEMS 1 9 1 EA Note All bronze components listed are lead free LEAD FREE The wetted surfaces of this product shall contain no more than 0 25 lead by weighted average Compl...

Page 23: ...ALF 62G BPC NO METER 4ALF 60G BPG 4ALF 62G BPG 12 GALLONS PER MIN 4ALF 60H BPE 4ALF 62H BPE CUBIC FT PER MIN 4ALF 60H BPC 4ALF 62H BPC NO METER 4ALF 60H BPG 4ALF 62H BPG A DISASSEMBLY CHECK VALVE MODULE 1 Close 2 bypass line shut off valve then close 1 bypass line shut off valve 2 Bleed pressure from the assembly by opening the upstream test cock located on the bypass line 1 shut off valve and the...

Page 24: ...remove 2 test cock nipple and reducer and move to the opposite side of the gate valve 3 4 MNPT X 1 2 FNPT Fitting 2 ea 1 2 X 1 1 2 Long Nipple 1 2 Ball Valve without Tapped Port 1 2 RPLF4A Reduced Pressure Backflow Preventer 1 2 Meter Connector 2 ea Water Meter Rubber Washer 2 ea 1 2 Street Elbow Meter Nut 2 ea 1 2 Ball Valve with Tapped Port Note Location of Port 1 2 Close Nipple 4 ea 1 Long 1 2 ...

Page 25: ...gate valve 3 4 MNPT X 1 2 FNPT Fitting 2 ea Test Cock 1 2 Close Nipple 1 Long 3 ea 1 2 Tee 1 2 X 2 1 2 Long Nipple 1 2 Ball Valve with Tapped Port Note Location of Port Meter Nut 2 ea Meter Connector Water Meter Rubber Washer 2 ea Adjustment Joint Coupling 1 2 RPLF4A Reduced Pressure Backflow Preventer 1 2 Ball Valve without Tapped Port 1 2 X 2 Long Nipple 1 2 90 Elbow 2 ea Adjustment Joint Nut Ad...

Page 26: ...osite side of the gate valve 3 4 Male X 1 2 Female Fitting 2 ea 1 2 Tee 1 2 Close Nipple 1 Long 2 ea 1 2 X 2 Long Nipple 2 ea 1 2 90 Elbow 2 ea 1 2 X 4 Long Nipple 1 2 Ball Valve with Tapped Port Note Location of Port Meter Nut 2 ea Meter Connector Water Meter Rubber Washer 2 ea Adjustment Joint Coupling 1 2 RPLF4A Reduced Pressure Backflow Preventer 1 2 Ball Valve without Tapped Port 1 2 X 5 Long...

Page 27: ...lve Test Cock 3 4 Male NPT X 1 2 Female NPT Fitting 2 ea 1 2 Tee 1 2 Close Nipple 1 Long 2 ea 1 2 X 2 Long Nipple 1 2 90 Elbow 2 ea 1 2 X 4 Long Nipple 2 ea 1 2 Ball Valve with Tapped Port Note Location of Port Meter Nut 2 ea Meter Connector Rubber Washer 2 ea Water Meter Adjustment Joint Coupling 1 2 RPLF4A Reduced Pressure Backflow Preventer 1 2 Ball Valve without Tapped Port 1 2 X 7 1 2 Long Ni...

Page 28: ... 2 X 6 Long Nipple 1 2 X 5 Long Nipple 1 2 Ball Valve with Tapped Port Note Location of Port Meter Nut 2 ea Rubber Washer 2 ea Water Meter Meter Connector Adjustment Joint Adapter Adjustment Joint O ring Adjustment Joint Nut Adjustment Joint Retainer 1 2 RPLF4A Reduced Pressure Backflow Preventer 1 2 Ball Valve without Tapped Port 1 2 X 3 Long Nipple 1 2 Coupling 1 2 X 7 1 2 Long Nipple 1 2 X 6 Lo...

Page 29: ...Nipple 1 2 X 6 Long Nipple 1 2 Coupling 1 2 90 Elbow 3 ea 1 2 X 9 Long Nipple 1 2 X 4 Long Nipple 1 2 Ball Valve with Tapped Port Note Location of Port 1 2 Meter Connector Water Meter Rubber Washer 2 ea Adjustment Joint Adapter Adjustment Joint O ring Meter Nut 2 ea Adjustment Joint Nut Adjustment Joint Retainer 1 2 RPLF4A Reduced Pressure Backflow Preventer 1 2 Ball Valve without Tapped Port 1 2 ...

Page 30: ...n of Port Test Cock 2 1 2 3 TYPE 2 BYPASS LINE Test Cock 1 2 90 Elbow 1 2 Close Nipple 1 Long Adjustment Joint Retainer Adjustment Joint Nut Adjustment Joint O ring Adjustment Joint Adapter Meter Nut Water Meter Rubber Washer 2 each 1 2 Single Check Valve 1 2 Ball Valve Without Tapped Port 3 4 Male NPT X 1 2 Female NPT Fitting 4 TYPE 2 BYPASS LINE 1 2 X 2 Long Nipple 1 2 X 2 Long Nipple 1 2 X 2 Lo...

Page 31: ... 2 Long Nipple 1 2 X 5 Long Nipple 1 2 X 3 Long Nipple Test Cock 8 TYPE 2 BYPASS LINE APPLY TEFLON TAPE TO PIPE THREADS AND INSTALL COMPONENTS AS SHOWN Test Cock 1 2 X 2 Long Nipple 1 2 Ball Valve with Tapped Port Note Location of Port 1 2 Street Elbow 1 2 Coupling Adjustment Joint Retainer Adjustment Joint Nut Adjustment Joint O ring Adjustment Joint Adapter Water Meter Rubber Washer 2 each 1 2 S...

Page 32: ...asher 2 each Water Meter Meter Nut 1 2 Single Check Valve 3 4 Male NPT X 1 2 Female NPT Fitting 1 2 Coupling 1 2 90 Elbow 1 2 45 Elbow 1 2 Ball Valve with Tapped Port Note Location of Port 1 2 X 3 Long Nipple 1 2 X 2 1 2 Long Nipple 1 2 X 6 Long Nipple 1 2 X 4 1 2 Long Nipple 1 2 X 3 Long Nipple 1 2 X 2 Long Nipple APPLY TEFLON TAPE TO PIPE THREADS AND INSTALL COMPONENTS AS SHOWN APPLY TEFLON TAPE...

Page 33: ...pling 1 2 90 Elbow 1 2 45 Elbow 3 4 Male NPT X 1 2 Female NPT Fitting 1 2 Ball Valve Rubber Washer 2 each Water Meter 1 2 Single Check Valve Meter Adapter Meter Nut 1 2 Coupling 1 2 X 4 Long Nipple 1 2 X 2 1 2 Long Nipple 1 2 X 4 Long Nipple 1 2 X 9 Long Nipple 1 2 X 2 Long Nipple 1 2 X 3 Long Nipple APPLY TEFLON TAPE TO PIPE THREADS AND INSTALL COMPONENTS AS SHOWN BYPASS KITS ...

Page 34: ... Customer Service 704 841 6000 www apolloflowcontrols com Apollo Flow Controls INSTALLATION OPERATION MAINTENANCE MANUAL PARTS LIST DIAGRAM BYPASS RP TYPE 1 W965505 REDUCED PRESSURE BYPASS VALVE LEAD FREE ...

Page 35: ...e for bulk sales Please refer to the appropriate repair kits below TYPE 1 RELIEF VALVE MODULE SUBASSEMBLY PARTS LIST ITEM DESCRIPTION PART QTY 25 RV Diaphragm Plate Screw B 1749 00 1 26 RV Diaphragm Plate E 2222 00 1 27 RV Spring A 2542 00 1 28 RV Bushing I 9225 00 1 29 RV Stem O Ring D 4891 00 1 30 RV Stem G 4791 00 1 31 RV Seat Disc D 4833 00 1 32 RV Seat Disc Washer NONE 1 33 RV Seat Disc Screw...

Page 36: ...retainer upside down 6 Apply a thin coat of Apollo supplied lubricant DOW 111 or equal on cap o ring 7 Install cap E DISASSEMBLY RELIEF VALVE 1 Remove cover bolts cover and diaphragm 2 Grasp the diaphragm plate and pull the assembly straight out of the body 3 Hold the relief valve assembly in one hand and remove the screw 4 Remove the seat disc Note Items 5 through 7 are not normally required 5 Tu...

Page 37: ...FLANGE OS Y X MONITORED BFV W 4734 00 W 5245 00 N A N A 04 FLANGE OS Y X FLANGE POST INDICATOR W 4734 00 W 5311 00 E 2922 00 C 2640 00 06 FLANGE OS Y X GROOVE OS Y W 4734 00 W 5283 00 N A N A 07 GROOVE OS Y X GROOVE OS Y W 5283 00 W 5283 00 N A N A 08 MONITORED BFV X MONITORED BFV W 5245 00 W 5245 00 N A N A 09 FLANGE OS Y X GROOVE POST INDICATOR W 4734 00 W 9370 00 E 2922 00 C 2640 00 010 GROOVE ...

Page 38: ...GROOVE OS Y W 2876 00 W 2895 00 E 3025 00 C 2776 00 021 GROOVE POST INDICATOR X MONITORED BFV W 2876 00 W 5246 00 E 3025 00 C 2776 00 022 MONITORED BFV X FLANGE OS Y W 5246 00 W 2889 00 E 3025 00 C 2776 00 023 SHUT OFF VALVE OPTIONS 6 ASSEMBLY DESCRIPTION INLET X OUTLET INLET OUTLET POST PLATE OPERATING NUT SUFFIX FLANGE NRS X FLANGE NRS W 2871 00 W 2871 00 N A N A 02 FLANGE OS Y X FLANGE OS Y W 2...

Page 39: ... E 3026 00 C 2777 00 019 FLANGE POST INDICATOR X FLANGE OS Y W 2872 00 W 2890 00 E 3026 00 C 2777 00 020 GROOVE POST INDICATOR X GROOVE OS Y W 2878 00 W 2897 00 E 2036 00 C 2777 00 021 GROOVE POST INDICATOR X MONITORED BFV W 2878 00 W 5248 00 E 2036 00 C 2777 00 022 MONITORED BFV X FLANGE OS Y W 5248 00 W 2890 00 E 2036 00 C 2777 00 023 SHUT OFF VALVE OPTIONS 10 ASSEMBLY DESCRIPTION INLET X OUTLET...

Page 40: ...BF rev a 8 17 www apolloflowcontrols com Regional Management List now available online at http conbra co rmlist Phone 704 841 6000 Fax 704 841 6020 Check our website for the most up to date information on all our products ...

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