Zurn Wilkins ZW206 User manual

INSTALLATION
NOTE: Flushing of all pipe lines is to be performed to remove all debris
prior to installing valve.
1. For making adjustments and servicing allow for adequate space around
the valve before installing valve.
2. When installing a ZW206 valve, gate valves installed (a minimum of
one pipe diameter apart) on both inlet and outlet are recommended for
maintenance allowing for isolation of the valve.
3. PositiontheZW206inlinematchingthedirectionofowasindicatedon
thevalvemodeltagwiththeproperdirectionofowinthesystem.Once
attachedtoline,doublecheckallfasteners/boltsinthepilotsystemandon
mainvalvearetightandthereisnodamagepriortopressurizingsystem.
NOTE: Pressure in some applications can be very high so be thorough
in checking and inspecting for proper installation and makeup.
4. Zurn Wilkins valves are designed to operate in both the vertical and
horizontal positions. However, it is recommended that ZW206 6” and larger,
be installation in the horizontal position. The horizontal positioning of the
larger valves avoids premature wear due to the mass of plunger assemblies
aswell asallows forgreater accessibilityduring annualinspections, and
maintenance.
5. Be sure to comply with all local and national electrical codes when
wiring the solenoid control.
START-UP
CAUTION: To prevent personnel injury and damage to equipment
check that downstream venting is adequate prior to start-up and test
procedures. All adjustments under pressure should be made slowly
while under owing conditions. If the main valve closes too fast it
may cause surging in upstream piping.
1. Openisolationvalves(2)inthepilotsystem(seeZW206schematic).
2. Thenslowlyopentheupstreamshutoffvalveonlyenoughtollmain
valveassemblyandpilotsystem.Priortopressurizingthevalveassembly
it is also recommended that a ZPI valve position indicator be installed to
aidinverifyingpropervalvemovement.
3. Asthevalveisllingwithwater,itisnecessarytobleedthemainvalve
andpilotsystemofair.Toventair,partiallyopenorloosenthehighestplugs
orttingsinthesystem.TheZPIvalvepositionindicatorisagreatlocation,
asithasatestcockatthetoptoventairpressure.Itmaybenecessaryto
bleedsystemmorethanonce.Afterremovalofairinthesystemtightenall
loosettings.
NOTE: If valve is installed vertically, it will be necessary to loosen
some upper cover bolts until you have vented all the air from the
cover chamber.
4. Ifvalveisequippedwithspeedcontrols(OorLonZW206schematic)
itisnecessarytobackoutthesetscrewaminimumof3turnsfrominitial
set point.
5. Nextitisadvisabletoowwaterthroughthevalvetoensureallairhas
escapedfromsystem.Itwillbenecessarytoeitherenergizeorde-energize
the solenoid to open the valve depending on the option installed.
6. Withtheupstreamshutoffvalvepartiallyopen,slowlyopenthedown-
stream shut off valve. Flow will begin to occur and pressure should build
upinvalveandeventuallystabilize.
7.Verifyoperationofthevalvebyenergizingorde-energizingthesolenoid
to open and close the valve.
1
Installation Troubleshooting Maintenance Instructions
Model ZW206
SolenoidControlValve(4”andLarger)
Globe and Angle Pattern Bodies
ZURN WILKINS
1747 Commerce Way, Paso Robles, CA 93446 Phone:[phone] Fax:[phone]
Troubleshooting
Installation / Start-up
8.Onceoperationofthevalveisveried,thespeedcontrolsif
installed can be set. When setting speed controls, turning the adjustment
screwintothespeedcontrolbodywillrestricttheamountofowthrough
the needle valve. Depending on whether the control is for opening or clos-
ing (refer to ZW206 schematic) the control will either slow the opening or
closing of the main valve when the adjustment screw is turned into the
speed control. Adjust as needed and tighten jam nut. In general a closing
speed control on a ZW206 should be at least 3 turns in from the furthest
open position to prevent high pressure surges upstream.
OPERATION
ThefollowingtroubleshootinginformationinTables1&2dealsstrictly
withtheZW206valveandpilotsystem.Itisrecommendedtoverifythat
thepilotsystemisproperlyfunctioningbeforetroubleshootingthemain
valve. All troubleshooting can be performed without removing the cover.
ItisalsorecommendedtopermanentlyinstallamodelZPIvalveposi-
tion indicator and an additional gauge in one of the cover connections.
STANDARD COMPONENTS
1. Main Valve
2.850MXLIsolationValve
3.SXLWyeTypeStrainer
4.PPV-SOL33-WaySolenoidCntrl.
5.3-WayAcceleratorPilot
OPTIONAL FEATURES
C40XLHydraulicCheck
w/Isolation Valve
LSC1ClosingSpeedControl
OSC1orSC2OpeningSpeed
Control
Z ZPI Visual Position Indicator
SCHEMATIC DIAGRAM
OUTLET
12
SOL
3
4” - 16”
INLET
ZW206 NORMALLY CLOSED
(ENERGIZE TO OPEN)
3
INLET
2
1
SOL
SOL
















ACL
COVER
ZW206 NORMALLY OPEN
(ENERGIZE TO CLOSE)
OUTLET
ACL
COVER
ACCL
PILOT
3-WAY
CONTROL
INLET COVER
OUTLET




®
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Troubleshooting
2ZURN WILKINS
1747CommerceWay,PasoRobles,CA93446Phone:[phone]Fax:[phone]
PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION
1. Solenoid Valve not
Opening/Closing
1.Lostelectricalsignaltosolenoid 1.Replaceorrepairanydamagedwiringorreplace
Solenoid
2.Clogged"Wye"Strainer 2.(Seeplugged"Wye"Strainerremedy)
3. Closed Ball Valves 3.Openballvalve
4. Incorrect voltage at solenoid 4.Supplycorrectvoltagestampedoncoilorreplacecoil.
2."Wye"Strainerplugged 1. Clogged with debris or mineral deposits 1. Disassemble and remove obstruction
TABLE 1. SOLENOID / PILOT SYSTEM TROUBLESHOOTING
ClosetheoutletballvalvetoclosetheACV.Ifinstalled,verify
the valve position indicator (model ZPI) is closed.
4.Proceedwithventingoutletdownstreampressurebyopening
a source downstream. When opening the downstream source if
thereiscontinuousow,themainvalveisnotsealingproperly.
It is recommended that the main valve be disassembled and
inspected(Referto“Disassembly”section).
5.Ifthemainvalveissealing,testthepilotbyenergizingor
de-energizingthesolenoidtoclosethemainvalve.Withthe
solenoid set to close the ACV, open the outlet ball valve. If there
iscontinuosowthroughtheACVnow,eithertheaccelerator
pilotorsolenoidarenotsealingproperly.Itisrecommendedto
check the solenoid and accelerator pilot for damage. Refer to
troubleshooting for the solenoid and accelerator pilot.
SOLENOID/PILOT SYSTEM FUNCTION CHECK
CAUTION: During testing of solenoids electrical voltages are
required. Extra care should be taken when handling and testing
toavoidpersonnelinjuryanddamagetovalve.Priortodisas-
sembling pilot or main valve be sure to cut all power to solenoid.
1.Toverifyifthesolenoidisproperlyfunctioning,rstdetermine
which solenoid option is on the valve. Refer to Valve Catalog
No. on solenoid name plate and voltage stamped on side of
green coil.
2.Afterdeterminingwhichsolenoidvoltageisrequired,apply
required voltage to energize solenoid. You should hear an au-
dible “Click” when the solenoid opens and closes. If there is no
audible“Click”inspectallwiringinthesystemandsolenoidfor
possible damage (See Table 6.)
3.Toverifyiftheentirepilotsystemisoperatingcorrectlyopen
theupstreamgatevalveandslowlypressurizeentirevalve.
®
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PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION
1.ACLdoesnotsealon
upper seat
1. The spring is over compressed 1. Disassemble and remove obstruction
2. Foreign matter obstruction between
diaphragmassy.andbellorseatandplunger
2. Disassemble and remove obstruction, replace parts
asnecessary
3. Cut, worn or chipped plunger seal or seat 3. Replace with new plunger or seat.
4.Damageddiaphragmorstemo-rings 4.Disassembleandreplacediaphragmoro-ring
5.ACLbellportisclogged 5. Remove obstruction
2.ACLdoesnotsealon
lower seat
1. Weak or no spring compression 1. Check and replace spring as needed
2. Cut, worn or chipped plunger seal or seat 2. Replace with new plunger or seat.
3.Damageddiaphragmorstemo-rings 3.Disassembleandreplacediaphragmoro-ring
4. Foreign matter between plunger or stem
guide and lower seat
4. Disassemble and remove obstruction
5.ACLbellportisclogged 5. Remove obstruction
6.Loosediaphragmnut 6.Disassembleandre-tightenthediaphragmnut
3.Leakagefromvalve 1.Damageddiaphragmorlowerseato-ring 1. Disassemble and replace damaged part as needed
2. Ports not sealed 2.RemoveandreinstallportttingswithTeontapeor
pipe sealant
TABLE 2. ACCELERATOR TROUBLESHOOTING

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TABLE 3. MAIN VALVE TROUBLESHOOTING
When performing troubleshooting and diagnosis checks it is recommended that the following steps be performed in sequential
order for best results.
PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION
1. Main Valve fails to open 1. No pressure at valve Inlet 1. Check Inlet pressure
2.Mainvalvediaphragmassemblyinoperative 2. Disassemble, clean, and polish stem, replace defec-
tive parts
3. Pilot Valve (Solenoid) not opening
1)LostelectricalsignaltoSolenoid 1. Inspect all wiring and replace as needed
2) Damaged Solenoid 2. Disassemble and replace as needed
2. Main Valve fails to close 1.Lostelectricalsignaltosolenoid 1. Inspect all wiring and replace as needed
2. Damaged Solenoid 2. Disassemble and replace as needed
3. Foreign matter between disc and seat or
worn disc
3. Disassemble the main valve, remove debris, clean parts,
and replace defective parts
4. Scale on stem or diaphragm ruptured 4. Clean parts, and replace defective parts
5."Wye"Strainerplugged 5. Remove, clean, and/or replace
6. Closed Ball Valve/s 6.OpenBallValves
DIAGNOSIS CHECKS
CAUTION: Do not service valve while under pressure.
When performing diagnosis checks on the ZW206 when
the valve is fully open, high ow rates and high down-
stream pressures can occur. In order to prevent harm to
personnel, equipment, and downstream piping be sure
that there are no blocked valves in the system before
performing checks.
DIAPHRAGM CHECK
1.Slowlycloseupstreamshutoffvalveandrelieveallpres-
sure downstream.
2. With all pressure relieved in the main valve, close both
pilot inlet and outlet ball valves on the main valve and remove
side plug on cover and leave off.
3.Thenopenupstreamshutoffvalvepartially,allowingwater
toowthroughthevalve.Whileowingwater,monitorthe
openingonthecover.Ifuidbeginstoowoutoftheopen
holeonthecover,thenthereismostlikelydamagetothedia-
phragmoruidisleakingpastthediaphragmassemblydue
toalooseassembly.Itisrecommendedthatthevalvecover
be removed to investigate the leakage (To remove cover see
“Maintenance”sectionforprocedures).Ifnowaterowsoutof
coverthenthediaphragmisgoodandyoumayproceedtothe
diaphragm movement check.
DIAPHRAGM MOVEMENT CHECK
1. The diaphragm movement check can be determined during
the diaphragm check or it can also be performed with the use
of a valve position indicator model ZPI.
2. Replace cover plug and open pilot ball valves on inlet and
cover.
3.Openingtheinletandcoverballvalveswilldirecttheow
to the cover causing it to close. NOTE: Slow or delayed
closing of main valve is normal. This is due to time to
ll, pressurize cover, and stretch the diaphragm into the
closed position. This normal delay is not binding of the
valve assembly.
4.Itmaybenecessarytoenergizethesolenoidtocloseif
ZW206optionis“NormallyOpen”.
5. Using the valve position indicator make note of the closed
position on the indicator. Compare distance of the open mark
to the close mark and compare to Table 3.
6.Verifythatthemainvalveisclosed,byopeningadown-
stream source (not the outlet isolation ball valve on the main
body).Ifwatercontinuouslyows,thenthemainvalveisnot
sealingproperly.Doublecheckthevalvemovementmatches
thevaluesinTable3andrefertothedisassemblyprocedures
section if it does not. This is an indication that the main valve
3
ZURN WILKINS
1747 Commerce Way, Paso Robles, CA 93446 Phone:[phone] Fax:[phone]
®

Maintenance Instructions
7. For smaller valves (6” and below) diaphragm checks can
beperformedbyhandwiththeuseofavalvestemtool.The
valve stem tool can be made using Table 4 to create a “T” bar
handle with the appropriate threads on the opposite end of the
“T” handle.
8. To perform the diaphragm check using the vale stem tool,
rstremoveallpressureinthesystemandventthecover.Then
remove the center plug on the cover and insert tool into the top
ofthestemthreads.Oncethetoolisinserted,thevalvecanbe
liftedupandthevalvemovementcanbemeasuredbycreating
TABLE 4. VALVE STEM THREAD SIZE
SEAL CHECK
1. To check the seal of the valve disc, an additional pressure
gauge will be needed downstream of main valve.
2.Withthevalveowingslowlyclosepilotoutletballvalvesto
applypressuretocoverandallowtoclose.Ifthesolenoidop-
tionis“NormallyClosed”thesolenoidwillhavetobeenergized
toopenandallowowtocover.
3. Monitor the pressure on the inlet and installed outlet gauge.
The pressure on the outlet side should be zero. If the pressure
matches inlet pressure, the main valve is leaking or the outlet
ballvalveonthepilotsystemisallowingpressuretocreepby.
Eitherwayitisrecommendedthatthevalvebedisassembled
andinspected(referto“Disassembly”section).
PREVENTATIVE MAINTENANCE
The Zurn Wilkins ZW200 Models requires minimal mainte-
nance.However,itishighlyrecommendedtoscheduleannual
inspectionsandtohavearepairkitbeforedisassembly work
begins.
Disassembly
Warning: With the ability to perform inspections. And
maintenance without removal from the system, it is very
important that all shut off valves be closed and all pres-
sure relieved in the valve before beginning disassembly.
Failure to do so can result in personnel injury or equip-
ment damage.
1.Verifythatallpressuresourcesareclosed,upanddown-
stream of valve.
2.Removepressureinpilotsystembylooseningthetubet-
tingstothevalvebodyandcover.Whenallpressurehasbeen
vented, continue to disassemble the pilot control valve and
covertubing.NOTE:Takingapicturebeforeteardowncanhelp
withre-assemblyofpilotsystem.
3.Nextremovethecoverbylooseningandremovingthecover
bolts.Ifthecoverdoesnotcomeoffeasilyitmaybenecessary
to loosen the cover using a brass chisel and rubber mallet. Ap-
plythechiselunderthecoverpointingupwardawayfromvalve
bodyandtapbottomofcoverwiththechiselandmalletto
loosenthecover.Oncethecoverisloose,pullcoverstraightup
to avoid damaging the stem and stem bearing in the cover.
4.Withthecoverremoved,thediaphragmassemblycanbere-
moved. To avoid damaging the seat bushing, grab the stem and
lift straight up. For larger valves 8” and up it is recommended that
aneyeboltwiththeproperstemthreadsbeusedwithahoist
tolifttheassemblyoutofthevalve(seeTable3forappropriate
stem threads).
5.Nextitisrecommendedthatthediaphragmassemblybe
placedinavisewiththebottomhexnutsecured.Oncesecured
remove the spring and stem nut. While removing the nut in-
spect the stem threads. Clean stem with a wire brush if mineral
deposits or corrosion are present.
6. After inspecting the stem and removing the nut the dia-
phragmassemblycanbedismantled.Ifthevalvehasnotbeen
servicedinawhileitispossiblethattheassemblywillrequire
theuseofarubbermalletorprybarstodismantletheassem-
bly.Ifthisisthecasegentlytaporprythecomponentsuntilthe
components are free to move. When disassembling be sure to
clean,inspect,andsaveallcomponents.Replaceanydamaged
componentsasnecessary.
7. The last component to inspect is the seat which is in the
bodyofthemainvalve.Duringinspectionoftheseat,cleanand
polishasnecessarywithnegritwet/drysandpaper(400grit
orhigher).Typically,aftercleaningthereisnovisualdamageor
excessive wear the seat should not require removal. If damage
ispresentortheseatisexcessivelyworntheseatshouldbe
replaced.
8. To remove the seat, on valves 6” and smaller the seat is
threadedintothebodyandwillrequireaseatremovaltool.
Care should be taken when removing the seat to avoid damaging.
INSPECTION OF COMPONENTS
Cleaningofcomponentsisrequiredforproperinspection.Lime
depositsarecommoninsystemsthatusewater.Toremove
is not sealing due to an obstruction between the seat and the
sealoradamagedseal.Ifwaterdoesstopowingandthe
measured valve movement does not match Table 3, then there
ispossibledamageunderthecover.Removecovertoidentify
obstructionandreplacepartsasnecessary.
4ZURN WILKINS
1747CommerceWay,PasoRobles,CA93446Phone:[phone]Fax:[phone]
®
www.zurn.com
TABLE 3. VALVE STEM TRAVEL
VALVESIZE
(in)
VALVESIZE
(mm)
STEMTRAVEL
(in)
STEMTRAVEL
(mm)
1-1/4"-1-1/2" 38 0.4 10.2
2" 50 0.7 18.0
2-1/2" 65 0.8 21.3
3" 80 0.9 23.4
4" 100 1.1 28.8
6" 150 1.7 43.4
8" 200 2.4 59.7
10" 250 2.8 71.1
12" 300 3.4 86.4
14" 350 3.8 96.5
16" 400 4.3 109.2
marks on the tool in the opened and closed positions. Replace
orrepairanypartsasnecessary.
VALVESIZE(in) THREADSIZEUNFINTERNAL
1-1/4"-1-1/2" 10-32
2" 10-32
2-1/2" 10-32
3" 1/4-20
4" 1/4-20
6" 1/4-20
8" 3/8-16
10" 3/8-16
12" 3/8-16
14" 3/8-16
16" 3/8-16

depositsnegritwet/drysandpaper(400gritorhigher)canbe
used. If deposits cannot be removed, off the shelf lime deposit
remover can be used. Prepare a solution following the lime
deposit remover instructions and soak components (excluding
rubber components) until lime deposits are removed.
CAUTION: When handling chemicals (acids) be sure to use
proper safety equipment (gloves and eye protection) and prac-
tices. After soaking components, be sure to thoroughly rinse
all components before handling and re-assembling valve.
Onceallvalvecomponentshavebeencleaned,inspecteach
component looking for damage, abnormal wear & corrosion,
and replace all components that look questionable. Replace all
rubbercomponentsincludingthediaphragm,o-ringsanddisc
each time the vale is serviced or inspected (rubber components
are standard in ZW200 repair kits.
REASSEMBLY
1.Firstreinstallseatintobody.Besuretouselubearound
seato-ringbeforetightening.Tightenseataccordingtotorque
values in Table 5 using seat tool.
2. Next place valve stem in a vise clamping on the hex portion
ofthestem.Thenassemblethediaphragmassemblyasshown.
When assembling be sure that the diaphragm is centered on the
raisedstepofthediscretainer.Itisalsorecommendedtoapply
lubetostemthreadsando-ringsbeforetightening.Thentighten
the stem nut according to Table 5 for torque values.
3.Lowerdiaphragmassemblycarefullyintotheseatbearing.
Be careful not to damage the seat or stem while installing as-
sembly.Rotatetheassemblyasneededuntiltheboltholeson
thediaphragmlineupwiththebodyboltholes.
4. Place lower spring disc on the diaphragm disc and place
springontopoftheassembly.Theninstallcover,aligningthe
bolt holes and insuring that the cover is not pinching the dia-
phragm between the bolt holes.
5. Install cover bolts and tighten in a star pattern to the torque
values in Table 5.
TABLE 5. VALVE TORQUE SETTINGS
9.Slowlyopenupstreamisolationvalvetopressurizethe
systemandcheckforanyleaks.
10.Stopleaksasneededandproceedto“Start-Up”and
“DiagnosisCheck”sectionsforreturningvalvetopropersystem
operations.
COVER CENTER PLUG
COVER BOLTS
COVER NUTS (8" AND LARGER)
COVER PLUG
COVER
COVER BEARING (STEM GUIDE)
UPPER SPRING DISC (4" AND LARGER) * †
SPRING †
LOWER SPRING DISC (4" AND LARGER) * †
STEM NUT
STEM WASHER
DIAPHRAGM WASHER
(DIAPHRAGM DISC)
DIAPHRAGM*
UPPER STEM O-RING*
DISC RETAINER
(PLUNGER)
LOWER STEM O-RING*
DISC (SEAL RING)*
DISC GUIDE
(SEAL RING RETAINER)
STEM
SEAT SCREWS (8" AND LARGER) ‡
SEAT ‡
COVER STUDS (8" AND LARGER)
SEAT O-RING ‡
BODY
BODY PLUGS
STEM ASSEMBLY †
* RUBBER REPAIR KIT ITEMS
† COMPLETE REPAIR KIT ITEMS
‡ SEAT REPAIR KIT
WILKINS
SOLENOIDPN DESCRIPTION VOLTAGE
PV-SOL3-NO SOLENOIDFORNORMALLYOPENZW206
(ENERGIZETOCLOSE)
120vac
PV-SOL3-NC SOLENOIDFORNORMALLYCLOSEDZW206
(ENERGIZETOOPEN)
120vac
PV-SOL3-24NO SOLENOIDFORNORMALLYOPENZW206
(ENERGIZETOCLOSE)
24vac
PV-SOL3-24NC SOLENOIDFORNORMALLYCLOSEDZW206
(ENERGIZETOOPEN)
24vac
TABLE 6. SOLENOID OPTIONS
6.Beforeinstallingcentercoverplugmanuallycheckthat
assemblyhasfulloperatingtravelbeforeinstallingthepilot
assembly(referto“DiaphragmMovement”inthediagnosis
checks section).
7.Oncefulloperationrangeofthemainvalveisveriedbegin
reinstallingpilotsystem.
8.Afterinstallingpilotsystemdoublecheckthatallplugs,
bolts,andttingsaresealedandtightbeforeapplyingpressure.
5
ZURN WILKINS
1747 Commerce Way, Paso Robles, CA 93446 Phone:[phone] Fax:[phone]
www.zurn.com
®
VALVE
SIZE
(in)
COVER
(ft-lbs)
DIAPHRAGM
ASSEMBLY
(ft-lbs)
THREADED
SEAT
(ft-lbs)
SEAT
BOLTS
(ft-lbs)
1-1/4" 3.5 7.5 11 N/A
1-1/2" 3.5 7.5 11 N/A
2" 15 20-25 30 N/A
2-1/2" 25 25-35 60 N/A
3" 25 35-45 70 N/A
4" 55 40-50 85 N/A
6" 110 50-60 95 N/A
8" 120 60-70 N/A 7.4
10" 184 70-75 N/A 7.4
12" 200 110-115 N/A 7.4
14" 275 170-175 N/A 7.4
16" 360 230-240 N/A 7.4

MAINTENANCE (PV-ACL-3 VALVE)
The3-WayAcceleratorPilotmaybeinstalledinanyposition.
The valve ports are labeled below.
DISASSEMBLY
Priortodisassembly,relieveallpressureinpilotsystemand
thenremovethePV-ACL-3.Notethepilotconnectionsand
reinstall the pilot with the same connection placement when
nishedwithmaintenance.
1.Securevalvebodyandremovebottomseatonbottomof
valve using an adjustable wrench.
2. Next remove 8 socket head screws around the pilot bell
usinga5/32”hexkey.
3. Remove the pilot bell and the spring.
4.Usea5/32”hexkeyforthebottomplungerscrewanda
12mm socket or adjustable wrench on the diaphragm nut to
disassembletheplunger/diaphragmassembly.Unscrewone
end of the stem.
5.Atthispointslidetheplunger/diaphragmassemblyoutof
thevalvebody.
6. Use soft jaws or a towel and pliers to clamp the stem. Re-
movetheplunger,stemguide,screw,andsmallo-ringfromthe
plungerassemblyand2largewashers,diaphragm,lockwasher,
o-ringandnutfromthediaphragmassembly.
7.Aftercompletedisassembly,thoroughlycleanandinspect
allcomponentsbeforereassembly.Replaceanypartsasnec-
essaryafterinspection.
8.Thepilotseatgenerallydoesnotneedtoberemoved,but
if after inspection it requires replacement it can be removed
witha1-1/16”socket.
PV-ACL-3 VALVE
REASSEMBLY
ReassemblyofthePV-ACL-3isthereverseofdisassembly.
1. Install one of the large washers (with round edge toward
thediaphragm),thenewo-ring,andthediaphragmfollowedby
the second large washer (with round edge toward the diaphragm).
Then place lock washer over stem threads along with the 5/16”
diaphragm nut and tighten.
2.Nextslidestemassemblyintobodythroughpilotseat.
2.Nextslidestemassemblyintobodythroughpilotseat.
3. Then slide the plunger onto the stem via the bottom seat
holefollowedbythesmallstemo-ring,stemguideandcap
screw. While holding diaphragm nut, tighten the cap screw with
Allen wrench.
4.Installbottomseatinbottomofvalvebodywithnewo-ring.
The cross shaped stem guide must slide into the bottom seat.
5.Installspringandpilotbellonthevalvebody.
6. Insert socket head cap screws into pilot bell holes and
threadintovalvebody.Tightenallscrewsinacrosspattern.
7.Reinstallintothepilotsystemoncemaintenanceiscom-
pleted. For further assistance or ordering replacement parts go
towww.zurn.comorcallproductsupport877-222-5356.
PV-ACL-3 SPECS
MaxInletPressure: 400psi
13
6
57
11
4
10
8
12
2
1
18 17 1416 15
9
9
3
ITEM DESCRIPTION
1O-RING
2PILOTSEAT
3TAG,ACCELERATORPILOT
4DIAPHRAGM WASHER
5ACLSTEMSPRING
6ACLBELL
75/16-18DIAPHRAGMNUT
85/16"INTTEETHLOCKWASHER
910-32x5/8SKTHEADCAPSCREW
ITEM DESCRIPTION
10 DIAPHRAGM
11 ACLSTEM
12 BODY
13 DIAPHRAGMO-RING
14 O-RING,BUNA-N
15 STEMO-RING
16 STEM GUIDE
17 ACLMAINCAP/SEAT
18 ACLPLUNGERASSY.
INLET
OUTLET
DIRECTION
OF
FLOW
COVER
CONTROL
6ZURN WILKINS
1747CommerceWay,PasoRobles,CA93446Phone:[phone]Fax:[phone]
www.zurn.com
®

7
ISZW206-4-10(REV.C6/17)
Flow Characteristics
ZURN WILKINS
1747 Commerce Way, Paso Robles, CA 93446 Phone:[phone] Fax:[phone]
www.zurn.com
®
0
1
10
100
10 1001000 10000
PRESSURE DROP (PSI)
FLOW (GPM)
BODY M INIMUM FRICTION LOSS
1-1/4"Globe&Angle
1-1/2"Angle
1-1/2"Globe
2" Globe
2" Angle
2-1/2"Globe
2-1/2"Angle
3" Angle
4" Globe & Angle
6" Angle
8" Angle
6" Globe
8" Globe
3" Globe
10" Angle
10" Globe 12" Globe
14" Globe
16" Globe
Note: If the valve is to be used for continuous ow, it is very important to maintain a ow rate through the
valve below the maximum continuous ow rate. It may be necessary to install a gate or buttery valve down-
stream to throttle the ow rate and prevent damage to the valve.