Zurn-Wilkins 3-500XLFC Installation Guide
Contents
1. sure the rounded edge of the diaphragm disc is next to the diaphragm 3 Lubricate o ring with grease supplied in repair kit and install stem unit in body Install new spring spring disc and friction ring 4 Replace bell housing by tightening clockwise Turn adjustment bolt clockwise until adjustment bolt touches spring disc 5 Center washer on stem Screw plunger into stem unit CAUTION Do not over tighten plunger it is possible to break threaded end of plunger Install new cap gasket and replace cap by tightening clockwise Turn adjustment bolt into bell housing to old setting Enter dwelling and turn on several faucets Turn on water service Let water run for several seconds then turn off faucets in dwelling 10 Adjust the regulator to desired pressure by turning adjustment bolt clockwise into bell housing to raise pressure or counterclockwise out of bell housing to lower pressure It is recommended a pressure gauge be installed downstream of the regulator to ensure pres sure is reduced below 75 psi NOTE When reducing pressure open a downstream faucet to relieve pressure 11 Tighten locknut when desired pressure is achieved INSTALLATION INSTRUCTIONS Install valve in line with arrow on valve body pointing in direction of flow Before installing reducing valve flush out line to remove loose dirt and scale which might damage seal ring and seat All valves will be furnished with stock settings to reduce to approxi2. Model 500XL LEAD FREE ZURN Pressure Reducing Valve with Integral By pass 1 2 3 4 1 1 1 4 1 1 2 2 2 1 2 amp 3 T WILKINS This product contains a weighted average lead content less than 0 25 for wetted surfaces Installation U Testing U Maintenance Instructions REPAIR KIT INSTRUCTIONS HOW TO MAKE REPAIRS Shut off service before starting disassembly 1 Open faucet or hose bibb in dwelling to remove line pressure 2 Loosen cap and remove counterclockwise 3 Loosen plunger and remove counterclockwise insert new seal ring 4 Note distance that adjustment bolt protrudes from bell housing Loosen locknut on adjustment bolt then turn adjustment bolt out of bell housing to remove spring tension 5 Unscrew bell housing counterclockwise and remove spring spring disc and friction ring 6 Remove stem unit from regulator Inspect area in body where o ring guides for pitting or scratches Smooth bore with emery cloth if needed This area must be smooth for the valve to function correctly 7 Disassemble stem unit by holding stem securely while removing diaphragm bolt nut Discard old stem and diaphragm Retain diaphragm disc and diaphragm bolt nut for use on new stem TO REASSEMBLE 1 Open shut off valve slowly and flush body and line of any debris 2 Assemble new stem unit using new stem o ring diaphragm the old diaphragm disc and diaphragm bolt nut Tighten bolt nut securely CAUTION Be
3. d in any position be limited to our agreement to repair or replace the valve only WARRANTY ZURN WILKINS Valves are guaranteed against defects of material or workmanship when used for the services recom mended If in any recommended service a defect develops due to material or workmanship and the device is returned freight prepaid to ZURN WILKINS within 12 months from date of purchase it will be repaired or replaced free of charge ZURN WILKINS liability shall cause cancer or birth defects or other reproductive harm Proposition 65 Warning This product contains chemicals known to the State of California to ZURN Troubleshooting Pipe lines in a water supply system must be of sufficient car rying capacity to maintain adequate pressure at the most remote or highest fixture Under the maximum probable fixture use minimum adequate pressure is generally 8 to 15 Ibs but may be more depending on the equipment being supplied Relatively high service pressures which can create high water velocities in in an attempt to eliminate such a condition may reduce pipe line capacities below that which is adequate for maximum probable use When high service pressures are in effect either continu ously or periodically the application of a pressure reducing valve will be successful only when the installed pipe line is of adequate size to satisfy the system demand at the lower pressure When actual wat
4. dequate for the load Size of some pipelines may need to be increased Pressure setting of reducing valve may be too low c Try increasing pressure before changing pipelines 3 Small inadequate flow from fixtures A Pipelines to fixtures may be too small or house main supply may be inadequate for normal fixture demand B Heavy periodic demands by appliances in the house C Screen clogged with debris SOLUTION a It may be necessary to increase pipe sizes only in some sections of the system leading to the offending appliances or fixtures Increasing the house service mains might be necessary if small supply is general at all fixtures b Raise pressure gradually by readjusting valve until this point is determined c Clean screen 4 Valve appears to be noisy hums whistles or A chatters Hum or whistle is usually caused by a high velocity of flow in pipelines causing vibration B Chatter usually originates with worn seat washer or loosely installed seal ring SOLUTION a Pipelines could be small or too light Reducing valves could be too small Pipes and valves being small would accentuate this condition b Inspect seal ring If a deep channel appears on seal ring face replace or use the opposite side c Frequently noise appears in a faucet or appliance and seems to originate from the reducing valve There is a general tendency to use streamline piping of a relatively small size Velocity is naturally high and noise of fast mo
5. er demands are unknown the valve size should be no less then the existing pipe size pipe lines would allow use of smaller pipes to satisfy fixture use However high velocity tends to cause whistling and humming Reduction of pressure by the use of a pressure reducing valve PROBLEM POSSIBLE CAUSE OR CAUSES 1 Pressure creeps or builds up in system above A Thermal expansion of water as it is being heated the setting of pressure reducing valve B Foreign matter on seating face of seal ring C Cut worn or chipped seal ring D Cut or worn stem o ring or worn o ring groove SOLUTION a This is a natural consequence It may happen each time that the heater runs A pressure relief valve or expansion tank must be installed This will not prevent pressure rise but should limit it to a safe level b Flush the reducing valve by opening one or two fixture outlets wide If this does not correct the problem remove seal ring for cleaning c Replace with new seal ring Temporary repairs may be made by turning the seal ring over d Replace with new stem o ring and or cartridge 2 Pressure and fixture flow is unsteady A Low water supply pressure in mains caused possibly by high area demand during certain periods of the day B Heavy periodic demands by appliances in the house SOLUTION a This is a water department problem It is due to the mains being inadequate for the demands made on them b House service lines may at times be ina
6. mately 50 psi To readjust reduced pressure loosen outer locknut and turn adjustment bolt clockwise into bell housing to raise reduced pressure or counter clockwise out of bell housing to lower reduced pressure NOTICE Annual inspection and maintenance is required of all plumbing system components To ensure proper performance and maximum life this product must be subject to regular inspection testing and cleaning OON DD ge ee BOLT a 5 SEALED CAGE Z WASHER Fa NAMEPLATE BELL HOUSING _ _ FRICTION RING SPRING DISC 1 2 1 1 2 only ee SPRING DIAPHRAGM gt BOLT NUT ep ia Se SS DISC DIAPHRAGM ss N STEM UNION NUT i _ O RING TAILPIECE gt inca GASKET SEAT GASKET ZE SEAT WASHER cm NN SEAL RING Ss PLUNGER NCAP GASKET s INDICATES PARTS SUPPLIED IN REPAIR KITS spring disc not included in sizes 1 1 2 3 Regulators in series Where the desired pressure reduction is more than a 4 to 1 ratio i e 200psi to 50psi multiple regulators in series should be installed SEALED CAGE WARNING Loosen lock washer at adjustment bolt slowly Look for any trapped water pressure under the sealed cage washer Relieve pressure before removing bell CAUTION Anytime a reducing valve is adjusted a pressure gauge must be used downstream to verify correct pressure setting Do not bottom out adjust ment bolt on bell housing Valve may be installe
7. ving water is not unusual ZURN WILKINS 1747 Commerce Way Paso Robles CA 93446 Phone 855 663 9876 Fax 805 238 5766 2 www zurn com ISSOOXL REV 8 13
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