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****** Page 1 ****** RI) -500 Reduced Pressure Backflow Preventer OPERATIONS, MAINTENANCE AND TROUBLESHOOTING GUIDE

****** Page 2 ****** Table of Contents Features, Applications and Specifications Installation. Operation…. Testing Procedures Maintenance Troubleshooting Guide…. Replacement Parts List 2 • RI) 500 Operations, Maintenance and Troubleshooting Guide A.R.I. 3 …5 ..6 .9

****** Page 3 ****** Features, Applications and Specifications The RP-500 Reduced Pressure Backflow Preventer consists of: Two independent-acting sprmg loaded check valves – an inlet and an outlet valve. An automatic differential Relief Valve (located in the “zone” between the check valves) Two resilient seated shut off valves — one on the inlet, the other on the outlet. Four test cocks. PRODUCT FEATURES Compact, lightweight size makes it easy and quick to install. Requires only a Phillips-head screwdriver to disassemble and reassemble — no special tools needed Durable, made of non-corrosive plastic thermal resin material: Withstands the toughest environments. Unlike a brass Backflow Preventer, the RP-500 is less susceptible to vandalism and theft. UV resistant endures heat and direct sun. Low head loss — optimizes energy, saving energy costs. The RP-500 is approved by the following Standards Authorities: Approved under • USA : NSF61 (Drinking water), ASSE 1013, ANNAVA C511, Approved by the Foundation for Cross Connection Control and Hydraulic Research at the University of Southern California, Listed for Uniform Plumbing Code. Australia : AS4020 (Drinking water), Watermark AS2845.1. France : ACS. APPLICATIONS To protect potable water lines and other installations against backsiphonage and backpressure of contaminated water. For ifflgation system and water handling applications. SPECIFICATIONS Operating pressure: up to 150 psi Operating temperature: up to 1100 F Valve sizes: 1/2″ 3/4″ l” 11/4″ 11/2″ 2″ .3 Operations, Maintenance and Troubleshooting Ggide A.RI.

****** Page 4 ****** Installation GENERAL INSTALLATION GUIDELINES A. B. C. D. E. F. Install the RP-500 Backflow Preventer in a location accessible to periodic field testing and maintenance. Mount the RP-500 in a horizontal position with adequate clearance from walls and/ or obstructions. A 12″ to 33″ clearance is needed between the lowest portion of the device and floor. Adequate drainage is needed for discharge. A Drainage Funnel is provided so the discharge may be piped away (See FIGURFÅ 1). NOTE: Never place the RP-5()() where it may become submerged in standing water. Before installing the RP-5()0, thoroughly flush all upstream piping to remove debris. When the shut-off valves are supplied separately, install them with a Test Cock on the Inlet Shut- off valve. It is recommended that a strainer be installed before the inlet of the RP-500 to prevent debris from entering the device. After installing the assembly, close the Outlet Shut-off Valve, pressurize the RP-500 and release the air through Test Cock 4. Then, open the Outlet Shut-off Valve. FIGURE 1 Outlet Shut-Off Valve Test Cock 4 Drainage Funnel Air Gap Drainage Funnel Test Cock 3 Test Cock 2 Inlet Shut-Off Valve Test Cock 1 RECOMMENDATIONS Do not install in areas subject to extended periods of freezing temperatures. The product must be protected from excessive pressure increases, caused by thermal expansion or water hammer, which can cause damage to the valve. DO NOT USE ANY PIPE DOPE, OIL, GREASE OR SOLVENT ON ANY PARTS unless instructed to do so. Parts should fit together freely. Do not force parts to fit. 4. Operations, Maintenance and Troubleshooting Guide A. R. l.

****** Page 5 ****** Operation During normal flow, the two check valves open to supply water downstream. The Relief Valve is power- activated by upstream pressure and is kept shut by a diaphragm, through the internal control system. In the zone, the area between the check valves, pressure is maintained at approximately 6.3 psi lower than the water supply pressure. The Outlet Check Valve is spring-loaded to maintain a nummum pressure decrease of 1 psi (see FIGURE 2). negative pressure or sub-atmospheric conditions occur, the Inlet Check Valve closes to prevent backflow. If the Outlet Check Valve fails, the pressure between the two check valves rises, openmg the Relief Valve and releasing the water to the atmosphere. The Relief Valve operates on differential pressure. Supply pressure on the upstream side of the Inlet Check Valve acts against the diaphragm to close the Relief Valve during normal operation. In the event of backpressure or backsiphonage, the Relief Valve will open to maintain the pressure in the “zone” at 2 psi less than the inlet pressure. Note: If water continues to drain from the Relief Valve, check the Troubleshooting section for probable causes and solutions. FIGURE 2 Outlet Shut-Off Valve Relief Valve Inlet Shut-Off Valve Inlet Check Valve (Spring-loaded) Zoon Inlet Shut-Off Valve Outlet Check Valve (Spring-loaded) Relief Valve Seat Seal Operations, Maintenance and Troubleshooting Ggide A.RI. •

****** Page 6 ****** Testing Procedures To remain in compliance with local codes it is important to periodically test the RP- 500. (As service conditions warrant, it should be tested at least once per year or more.) Test set-up is illustrated in FIGURE 3 on page 7. Equipment: USC approved test kit required. Test No. 1 Purpose: To test operation of the pressure differential Relief Valve. Requirement: The pressure differential Relief Valve must operate to maintain a mmlmum pressure of 2 psi less than the supply pressure in the “zone” (the area between the fivo Check Valves). Procedure (see FIGURE 3, page 7): 1. 2. 3. 4. 5. 6. 7. To flush debris, release the water through all four Test Cocks. NOTE: Open Test Cock 2 slowly to avoid accidental dumping of the Relief Valve. Connect the “high” side (gray) hose to check Test Cock 2. Connect the “10€’ side (yellow) hose to check Test Cock 3. Open Test Valves 2 and 3. Slowly open Test Cock 3 and release all air from the gauge and hoses through the “vent (red) hose. While Test Cock 3 is open, slowly open Test Cock 2 and release all air again through the “vent’ (red) hose. Close Test Valve 3, and then close Test Valve 2. Close Outlet Shut-off Valve. Slowly open Test Valve 3 until the differential gauge starts to drop. NOTE: It is important that the differential gauge drops slowly. To do so, maintain Test Valve 3 at this position and observe the differential pressure reading at the moment the first discharge is noted from the Relief Valve. Record this reading as the opening differential pressure of the Relief Valve and close Test Valve 3. Test No. 2 Purpose: To check Outlet Check Valve for tightness against reverse flow. Requirement: The Check Valve should not allow through leakage in a direction opposite to normal flow under all conditions of a pressure differential. Procedure (See FIGUR 3, page7): 1. 2. 3. 4. 5. 6. The Outlet Valve should be in the closed position (from Test 1). Loosely attach the “vent” (red) hose to Test Cock 4. Release all air from the “vent” (red) hose by opening Test Valve 2. Close Test Valve 2 and tighten hose connection to Test Cock 4. mien open Test Cock 4. Loosen the side Cyellow) hose at Test Cock 3 slightly and re-establish the normal reduced pressure within the zone. Retighten hose. open Test valve 2 If the differential pressure remains steady then the Outlet Check Valve is working properly. If the differential pressure drops causing the Relief Valve to open, then Outlet Check Valve should be recorded as “leaking ‘ and Test 3 cannot be completed. 6. Operations, Maintenance and Troubleshooting Guide A. R. l.

****** Page 7 ****** Testing Procedures, cont. Test No. 3 Purpose: To test the static differential pressure across the Inlet Check Valve. Requirement: The static differential pressure across Inlet Check Valve must be a minimum of 3 psi more than the opening differential pressure of the Relief Valves as recorded in Test 1. Procedure (See FIGURE 3): With the testing equipment installed as stated in Test 2, the static differential pressure across the Inlet Check Valve will be indicated on the gauge and should be recorded as such. NOTE: The gauge should be steady and not falling. Restore Operation (See FIGURE 3): Close all Test Cocks, open all Test Valves, open the Outlet Shut-off Valve and carefully remove all test equipment. NOTE: Refer to Troubleshooting Guide to resolve any problems incurred during field-testing. FIGURE 3 Low Side Hose (yellow) Test Cock 4 Outlet Shut-Otf Valve Gauge Test Valve 3 I Test Valve 2 o 1100 F Outlet Check Valve Test Valve 1 5 o Test Cock 3 MODEL RP5CD PAT9{T PENDING hydraulic Hose Test Valve High Side Hose (gray) Test Cack 2 o Test Cock 1 Inlet Check Valve Inlet Shut-Off Valve x Operations, Maintenance and Troubleshooting Ggide A.RI.

****** Page 8 ****** Maintenance How to Disassemble the RP-500 1. Close the Outlet Shut-off Valve (12), then close Inlet Shut-off Valve (11). 2. Release pressure from the assembly by opening Test Cocks 2, 3 and 4 (8). CAUTION: The cover is spring-loaded and should be removed carefully to avoid personal injury. No. Part 3. 4. 5. 6. 7. 8. Use a Phillips-head screwdriver to remove the Relief Valve cover screws (1.1) while holding the cover (l) down. Lift the cover (1) straight up. Remove the Relief Valve Assembly (3). Remove the Relief Valve Spring (4). Remove the Retainer (5). Remove the Inlet and Outlet Check Valves (6) (7). NOTE: Clean all the parts that have been removed. Then reassemble, or depending on their condition, discard and replace with new replacement parts. O-rings should be cleaned or replaced as necessary and lightly greased with NSF 61-approved silicone-based grease. How to Assemble the RP-500 1. 2. 3. 4. 5. Securely install the Inlet and Outlet Check Valves (6) (7). Install the Retainer (5). Place the Relief Valve Spring (4) in position. Install the Relief Valve Assembly (3). Put on the cover (1), hold it down and tighten the screws (1.1). CAUTION: RP-500 1/2″ 3/4″ 1″ – Secure the screws with a recommended torque of 1.84 pound force feet (2.5 Nm). RP-500 1 1/4″ 1 1/2″ 2″ – Secure the screws with a recommended torque of 6.64 pound force feet (9 Nm). Part List 1. 1.1 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Cover Assembly Cover Screws Relief Valve Assembly Relief valve spring Retainer Inlet Check Valve Assembly Outlet Check Valve Assembly Body Assembly Test Cocks (#1, #4) Adaptor Assembly Clamp Assembly Inlet Shut-off Valve Outlet Shut-off Valve Drainage Funnel 12 O O 11 8. Operations, Maintenance and Troubleshooting Guide 13 A.RI.

****** Page 9 ****** Troubleshooting Guide SYMPTOM Relief Valve continuously discharges during no-flow settings.. Relief Valve continuously discharges during flow and no-flow settings. Relief Valve does not open during field test no. 1 Inlet Check Valve (5) does not hold backpressure. Pressure differential is low across the Inlet Check Valve (5) during Field Test 3 (Does not meet 3 PSID nummum) CAUSE A. Inlet Check Valve @) is fouled with debris. B. Outlet Check Valve (1) is fouled with debris coupled with a backpressure condition. A. Relief Valve fouled with debris. B. Damaged diaphragm (allows water to pass through, from inlet to zone). C. The passage to inlet side of diaphragm plugged. A. Outlet Shut-off Valve (12) is not closed completely. B Test equipment improperly installed. A. Outlet Shut-off Valve (12) is not closed completely. B. Outlet Check Valve (6) is fouled with debris. A. Check Valve (6) is fouled with debris. B. Upstream pressure fluctuations causing inaccurate gauge reading. SOLUTION A. Inspect and clean the seat and seal. B. Inspect and clean the seat and seal. A. Clean Relief Valve Assembly (2). B. Replace the Relief Valve Assembly (2). C. Inspect and clean the passage in the Cover (1) and the Body (2). A. Close Outlet Shut-off Valve (12) or inspect for possible through leakage. B. Recheck test procedure. A. Close Shut-off Valve (12) Of inspect for possible through leakage. B. Inspect and clean the seat and seal. A. Inspect and clean the seat and seal. B. Eliminate pressure fluctuation. Operations, Maintenance and Troubleshooting Ggide A.RI.

****** Page 10 ****** Replacement Parts List 0266-5101 PART 1 . Cover Assembly 2. Relief Valve Assembly 3. Relief Valve Spring 4. Retainer 5. Inlet Check Vakve Assembly 6. Outlet Check Valve Assembly 7. Adaptor Assembly 1/2″ NPT 3/4″ NPT 1″ NPT 1 1/4″ NPT 11/2″ NPT 2″ NPT MODELS CATALOG NO. 0466-0501 -KIT 0466-9601 0266-7696 0266-3101 0466-0276-IN 0466-0276-OUT 0466-4850BT-KlT 0466-4834BT-KlT 0466-4801 BT-KIT QNT 1 1 1 1 1 1 2 2 2 2 1 1 1 MODELS 11/4″ 11/2″ CATALOG NO. 0465-0502-KIT 0466-9602 0266-769602S2 0266-3102AN 0465-027602-IN 0466-027602-OUT 0466-48114NT-KlT 0466-48112NT-KlT 0466-4802NT-KlT 8. Clamp Assembly 9. Inlet Shut Off Valve 10. Outlet Shut Off Valve 11. Drainage Funnel 0466-99-KIT 0310-7301 NTBQ 0310-7301 NTBQ _FFFBFH _FF_BFH 0466-9902-KIT 0310-7302NTBQ- 0310-7302NTBQ- 0266-5102AN FFFBFH FF_BFH 2″ QNT 1 1 1 1 1 1 2 2 2 2 1 1 1 I O • RI)-500 Operations, Maintenance and Troubleshooting Guide A.RI.

****** Page 11 ****** a c ecoent?aits T Oblesboofing Maintenance an O perations,

****** Page 12 ****** A.R.I. USA, Inc. Tel: 559-246-7585 e-mail: Tel: 877-536-6201 0302-USIMB-RP500-10







A.R.I. RP-500 (01) PDF MANUAL

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