Zurn-Wilkins 112-600XL Installation Guide
Contents
1. supplied in repair kit and install stem unit in body 4 Center washer on stem Screw plunger into stem unit CAUTION Do not over tighten plunger it is possible to break the threaded end of the plunger 5 Install new spring spring disc and friction ring then replace bell housing by tightening clockwise Turn adjustment bolt clockwise until adjustment bolt touches spring disc 6 Install new screen cap gaskets and replace caps by tightening clockwise 7 Turn adjustment bolt into bell housing to old setting then enter dwelling and turn on several faucets 8 Turn on water service Let water run for several seconds then turn off faucets in dwelling 9 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 pressure is reduced below 75 psi NOTE When reducing pressure open a downstream faucet to relieve pressure 10 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 50 psi To readjust reduced pressure loosen outer locknut and turn adjustment bolt clo2. them b House service lines may at times be inadequate 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 siz
3. Model 600XL Pressure Reducing Valve with Integral By pass 1 2 3 4 1 1 1 4 1 1 2 amp 2 This product contains a weighted average lead content less than 0 25 for wetted surfaces LEAD FREE ZURN WILKINS Installation U Testing Q Maintenance Instructions REPAIR KIT INSTRUCTIONS HOW TO MAKE REPAIRS Shut off service before starting disassembly 1 Open faucet on dwelling to remove line pressure 2 Note distance that adjustment bolt protrudes from bell housing Loosen locknut on adjustment bolt then turn adjustment bolt out of bell housing until free of spring tension 3 Loosen main cap and remove counterclockwise 4 Loosen plunger and remove counterclockwise Remove old seal ring then insert new seal ring 5 Loosen strainer cap counterclockwise and remove screen 6 Unscrew bell housing counterclockwise and remove spring spring disc and friction ring 7 Remove stem assembly from regulator Inspect area in body where stem 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 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 diaphragm disc and diaphragm bolt nut Tighten bolt nut securely CAUTION Be sure the rounded edge of the diaphragm disc is next to the diaphragm 3 Lubricate o ring with grease
4. bolt on bell housing Valve may be installed 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 Proposition 65 Warning This product contains chemicals known to the State of California to cause ZURN cancer or birth defects or other reproductive harm WILKINS 1 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 syst
5. ckwise into bell housing to raise reduced pressure or counterclockwise 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 inspec tion testing and cleaning ADJUSTMENT _ lt BOLT LOCKNUT ee NAMEPLATE ag BELL PARNE FRICTION RING 1 2 1 1 2 only A o SEALED CAGE WASHER _ SPRING DISC SPRING DIAPHRAGM NUT BOLT DIAPHRAGM DISC DIAPHRAGM F is yo UNION x STEM GASKET i ee J UNION NUT Fy 2 SEAT GASKET HU SCREEN s SEAT CAP GaskET aa WASHER STRAINER CAP 2 SEAL RING PLUNGER CAP caskeT E LUIS MAIN CAP INDICATES PARTS SUPPLIED IN REPAIR KITS spring disc not included in sizes 1 1 2 2 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 adjustment
6. e Velocity is naturally high and noise of fast moving 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 IS600XL REV 8 13
7. em demand at the lower pressure When actual water 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
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