ZURN 600XL Pressure Reducing Valve with Integral By Pass Instruction Manual

: June 4, 2024
: ZURN

Table of Contents

INSTALLATION INSTRUCTIONS
Troubleshooting
References
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Reducing Valve with Integral By-Pass
Instruction Manual

Model 600XL
LEAD-FREE

Pressure Reducing Valve with Integral By-pass
(1/2″, 3/4″, 1″, 1 1/4″, 1 1/2″ & 2″)
*This product contains a weiof ghted average lead content less than 0.25% for wetted surfaces.
REPAIR KIT INSTRUCTIONS ON HOW TO MAKE REPAIRS:
(Shut off service before the starting disassembly)

ZURN 600XL Pressure Reducing Valve with Integral By
Pass

Open faucet on the dwelling to remove line pressure.
Note the distance that the adjustment bolt protrudes from the bell housing. Loosen locknut on adjustment bolt, then turn adjustment bolt out of bell housing until free of spring tension.
Loosen the main cap and remove it counterclockwise.
Loosen the plunger and remove it counterclockwise. Remove the old seal ring then in sert the new seal ring.
Loosen strainer cap counterclockwise and remove the screen.
Unscrew the bell housing counterclockwise and remove the spring, spring disc and friction ring.
Remove stem assembly from the regulator. Inspect the area in the 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:

Open the shut-off valve slowly and flush the body and line of any debris.
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).
Lubricate the o-ring with grease supplied in repair kit and install the stem unit in the body.
Center washer on stem. Screw plunger into stem unit.
CAUTION: Do not over-tighten the plunger; it is possible to break the threaded end of the plunger.
Install new spring, spring disc, and friction ring then replace bell housing by tightening clockwise. Turn the adjustment bolt clockwise until tthe he adjustment bolt touches the spring disc.
Install new screen, and cap gaskets and replace caps by tightening clockwise.
Turn adjustment bolt into bell housing to old setting then enter dwelling and turn on several faucets.
Turn on the water service. Let the water run for several seconds then turn off the faucets in the dwelling.
Adjust the regulator to the desired pressure by turning the 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 the pressure is reduced below 75 psi.
NOTE: When reducing pressure, open a downstream faucet to relieve pressure
Tighten the locknut when desired pressure is achieved.

INSTALLATION INSTRUCTIONS

Install valve in line with an arrow on valve body pointing in direction of flow. Before installing the reducing valve, flush out line to remove loose dirt and scale which might damage the seal ring and seat. All valves will be furnished with stock settings to reduce to 50 psi. To readjust reduced pressure. loosen the outer locknut and turn the adjustment bolt clockwise (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 inspection, testing and cleaning. The valve shall be installed in an accessible location. Also, it is recommended that a suitable strainer be installed upstream of the valve.
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 the lock washer at the adjustment bolt slowly. Look for any trapped water pressure under the sealed cage washer. Relieve pressure before removing the bell.
CAUTION: Anytime a reducing valve is adjusted, a pressure gauge must be used downstream to verify the correct pressure setting. Do not bottom out the adjustment bolt on the bell housing. The valve may be installed in any position.
WARRANTY: ZURN WILKINS Valves are guaranteed against defects of material or workmanship when used for the services recommended. 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 the date of purchase, it will be repaired or replaced free of charge. ZURN WILKINS’ liability shall be limited to our agreement to repair or replace the valve only.
WARNING: Cancer and Reproductive Harm – www.P65Warnings.ca.gov

Troubleshooting

Pipelines in a water supply system must be of sufficient carrying capacity to maintain adequate pressure at the most remote hr highest fixture. Under the maximum probable fixture use. Minimum adequate pressure is generally 8 to 15 lbs. but may be more. depending on the equipment being supplied. Relatively high service pressures which can create high water velocities s in pipelines 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 in an attempt to eliminate such a condition may reduce pipeline capacities below that which is adequate for maximum probable use. When high service pressures are in effect, either continuously or periodically. the application of a pressure-reducing valve will be successful only when the installed pipeline is of adequate size to satisfy the system demand at the lower pressure. When actual water demands are unknown. the valve size should be no less then the existing pipe size.

PROBLEM
Pressure creeps or builds up In the system above the setting of pressure reducing valve.
POSSIBLE CAUSE OR CAUSES
A.Thermal expansion of water as it is being heated.
B.Foreign matter on seating face of the 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 a new seal ring. Temporary repairs may be made by turning the seal ring over. Replace with new stem o-ring and/or cartridge
Pressure and fixture flow is unsteady.
A.Low water supply pressure in mains is 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 inadequate for the Size of some pipelines may need to be increased. The pressure setting of the reducing valve may be too low.
C. Try increasing pressure before changing pipelines.
Small, inadequate flow from fixtures.
A. Pipelines to fixtures may be too small or the house main supply may be inadequate for normal fixture demand.
B. Heavy periodic demands by appliances in the house.
C. Screen clogged with debri
A. Pipelines to fixtures may be too the mall 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.
Valve appears to be noisy; hums, whist,less or chatters.
A. Hum or whistle is usually caused by a high velocity.
B. Chatter usually originates with a 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 the 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 streamlined piping of a relatively small size. Velocity is naturally high and the noise of fast-moving water is not unusual.

ZURN 600XL Pressure Reducing Valve with Integral By Pass -
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