Wilkins 375 XL 1.25 inch thru 2 inch Lead Free Reduced Principle Backflow Device

Wilkins 375 XL 1.25 inch thru 2 inch Lead Free Reduced Principle Backflow Device
Model 375XL LEAD-FREE*
Reduced Pressure Principle (1-1/4”- 2”)
a
®
company
*This product contains a weighted average lead content less than 0.25% for wetted surfaces, and is no-lead law compliant.
*Certified to NSF/ANSI 61-G
 Installation  Testing  Maintenance Instructions
CAUTION: Installation of Backflow
Preventers must be performed by qualified, licensed personnel. The installer
should be sure the proper device has
been selected for the particular installation. Faulty installation could result in
an improperly functioning device.
WILKINS Model 375XL Reduced Pressure
Principle Backflow Preventers are for use
on potable water lines where a health
hazard could exist if a backflow situation
were to occur.
Proper performance is dependent upon
following these installation instructions
and prevailing governmental and industry
standards and codes. Failure to do so,
according to WILKINS Limited Warranty
"...releases WILKINS of any liability that it
might otherwise have with respect to that
device." Such failure could also result in
an improperly functioning device.
Damage to the device could result wherever
water hammer and/or water thermal expansion could create excessive line pressure.
Where this could occur, shock arresters
and/or pressure relief valves should be
installed downstream of the device.
1. Before installing a Model 375XL Backflow
Preventer, flush the line thoroughly to remove
all debris, chips and other foreign matter. If required, a strainer should be placed upstream
of the Backflow Preventer.
CAUTION: Do not use a strainer in
seldom used emergency waterlines
such as fire lines.
2. Provide adequate space around the
installed unit so that the test cocks will be
accessible for testing and servicing.
3. WARNING: If installation of a Model
375XL is in a building, a suitable drain arrangement MUST be provided to drain off
spillage from the relief valve. An air gap at
least two times the pipe diameter must be
provided between the relief valve and the
drain piping to prevent a cross-connection.
Air Gap AG-12 not intended to support
weight of drain pipe.
CAUTION: Do not pipe the relief valve
solidly to a floor drain, sewer or sump.
CAUTION: An adequately sized drain is
required to prevent possible water damage
due to relief valve discharge.
PROTECTIVE
ENCLOSURE
3/4" 375 RP
ZURN
WILKINS
175 PSIG 180ß F
OPTIONAL
WATER
METER
3” PIPE
(DRAIN LINE CAN
BE ANY STANDARD
PIPING MATERIAL)
AIR GAP
12" MIN.
30" MAX.
FLOOR
DRAIN
INLET SHUT OFF
4. Install valve at least 12 inches above
surrounding flood level.
5. Always consult local codes for installation
methods, approvals and guidance.
OUTDOOR INSTALLATION
Model 375XL Backflow Preventers may
be installed outdoors only if the device
is protected against freezing conditions.
Exposure to freezing conditions will result
in improper function or damage to the
device. The installation location must be
kept above 32°F. All the basic installation
instructions apply.
If installation is in a pit or vault, the Backflow
Preventer must never be submerged in
water because this could cause a crossconnection. Make sure that the pit or vault
always remains dry by providing ample
drainage.
INDOOR INSTALLATION
Indoor installation is preferred in areas
that are subject to freezing conditions. All
the basic installation instructions apply to
such installations.
PARALLEL INSTALLATION
Where uninterrupted service from a single
meter connection must be maintained, two
or more Backflow Preventers may be connected in parallel. All the basic installation
instructions apply to parallel installation.
Be sure to allow adequate room between
the units for testing and repair.
PLACING THE DEVICE IN SERVICE
After the installation of a Model 375XL has
been completed, place the unit in service
as follows:
DIRECTION OF FLOW
375XL REDUCED PRESSURE PRINCIPLE
1. Start with both shut-off valves closed.
Slowly open the inlet shut-off valve until the
backflow preventer is completely pressurized. A brief discharge from the relief valve
may occur while the device is pressurizing.
The discharge should cease by the time the
shut-off valve is fully open. Device should
function properly. If the discharge does not
stop, refer to "MAINTENANCE INSTRUCTIONS" for repair procedures.
2. After the device has been pressurized,
vent all trapped air from both check valves
by slightly opening each of the four test
cocks.
3. Slowly open the downstream shut-off
valve. The Model 375XL Reduced Pressure Principle Backflow Preventer is now
in service.
4. If "spitting" or intermittent discharges
from the relief valve are noted, it could be
a result of pressure fluctuation and/or a
water hammer condition in the system. If
such conditions exist, install water pressure reducing valves or water hammer
shock arresters in compliance with industry
standards as needed.
5. After the Model 375XL has been properly installed, test the device (see "TEST
PROCEDURES"). If the device fails the
test, remove the first and second check valves and thoroughly flush the device. If
the relief valve fails to operate properly,
inspect the sensing passage for clogging
(see "MAINTENANCE INSTRUCTIONS").
Clean rubber seals of all debris and place
unit back in service.
WILKINS, a ZURN company
a
®
company
1747 Commerce Way, Paso Robles, CA 93446 Phone:805/238-7100 Fax:805/238-5766
1
Testing Procedures
MODEL 375XL REDUCED PRESSURE PRINCIPLE
ASSEMBLY
Equipment Required: Differential pressure gauge test kit.
TEST NO. 1
Purpose:
Test #2 check valve for tightness against reverse flow.
Requirement:
The valve must close tight against reverse flow under all pressure
differentials.
Procedure:
1.
2.
3.
4.
5.
Attach the "HIGH" hose to test cock #2 and the "LOW" hose to test cock #3.
Close #2 shut-off valve.
Open test cocks #2 and #3.
Open by-pass valves "C" and "A" and bleed to atmosphere until all air is expelled.
Close by-pass valve "A". Open by-pass valve "B" and bleed to atmosphere until all air is expelled. Close by-pass
valves "B" and "C".
6. Attach the "VENT" hose to test cock #4.
7. Slowly open by-pass valves "A" and "C" and keep by-pass
valve "B" closed.
8. Open test cock #4.
9. Indicated pressure differential will drop slightly. If pressure
differential does not continue to decrease, the #2 check
valve is considered tight.
TEST NO. 2
Purpose:
Test #1 check valve for tightness and record pressure drop across
#1 check valve.
Requirement:
The static pressure drop across the #1 check valve should be at
least 3.0 PSID greater than the relief valve opening point (TEST
NO. 3).
Procedure:
1. Close by-pass valve "A"
2. Close test cock #4, and disconnect "VENT" hose from test cock #4.
3. Open by-pass valves "B" and "C" bleeding to atmosphere, then close by-pass valve "B" restoring the system to
normal static condition.
4. Observe the pressure differential gauge and note this as
the #1 check valve PSID.
TEST NO. 3
Purpose:
To test operation of the differential relief valve.
Requirement:
The pressure differential relief valve must operate to maintain the
"ZONE" between the two check valves at least 2 PSID less than
the supply pressure.
Procedure:
1. Close by-pass valve "C" and open by-pass valve "A".
2. Open by-pass valve "B" very slowly until differential gauge
needle starts to drop. Hold the valve at this position and observe the gauge reading at the moment the first dis
charge is noted from the relief valve. Record this as the opening differential pressure of the relief valve.
MODEL
375XL A123456
SERIAL #
#1 TEST COCK
#2 TEST COCK
TOP VIEW
#3 TEST COCK
#4 TEST COCK
FLOW
375 RP
2
ZURN
FLOW
/ WILKINS
175 PSIG 180˚ F
#2 SHUT-OFF
VALVE
#1 SHUT-OFF
VALVE
BY-PASS
VALVE "A"
BY-PASS
VALVE "C"
BY-PASS
VALVE "B"
VENT HOSE
HIGH SIDE HOSE
LOW SIDE HOSE
Maintenance Instructions
All Model 375XL Reduced Pressure Principle Backflow Preventers
must be inspected and maintained by licensed personnel at least
once a year or more frequently as specified by local codes. Replacement of worn or damaged parts must only be made with genuine
"WILKINS" parts. The WILKINS Certificate of Limited Warranty
provides that failure to do so "...releases WILKINS of any liability
that it might otherwise have with respect to that device." Such
failure could also result in an improperly functioning device.
The Model 375XL Reduced Pressure Principle Assemblies should
be thoroughly flushed after backflow conditions occur to prevent
any type of corrosive deterioration to its components. Failure to
do so could result in malfunction of the device.
GENERAL MAINTENANCE
1. Clean all parts thoroughly with water after disassembly.
2. Carefully inspect rubber seal rings, diaphragms and o-rings
2
for damage.
3. Test unit after reassembly for proper operation (see "Testing
Procedures").
SERVICING CHECK VALVES
1. Close inlet and outlet shut-off valves.
2. Open No. 2, No. 3 and No. 4 test cocks to release pressure
from valve.
3. Unscrew 4 screws holding body down lift valve body upward.
4. Twist and remove sleeve from body. Using finger or blunt
object, push in outlet end of body, both checks should slide
out the body inlet. A short object like a socket can be placed
on a flat surface. Place body over object so it pushes
into valve outlet and push down on body.
5. Twist spring retainers counter-clockwise to remove from seat and access poppets.
6. Inspect the rubber seal ring for cuts or embedded debris. To remove seal ring, remove screw and seal ring retainer.
WILKINS, a ZURN company
a
®
company
1747 Commerce Way, Paso Robles, CA 93446 Phone:805/238-7100 Fax:805/238-5766
Maintenance Instructions
If the reverse side of the seal ring is unused, it is possible to invert the seal ring. This would be considered a temporary
solution to fixing a fouled check and should be replaced
with a new seal ring as soon as possible.
7. Inspect seat surface for nicks or dings and replace if
necessary. Use fingernail to check for dings.
Re-grease seat o-rings.
8. Inspect seat o-ring sealing areas in body and wipe clean.
9. Reverse the above procedures to reinstall check valve
assembly. Drop #2 check assembly in body. Then drop
#1 check assembly in and turn until #1 spring retainer
lines up with #2 seat. Then push both assemblies into
body. Insert sleeve against checks. (Place sleeve down
against flat surface and push on body with rocking motion.) Care should be taken to make sure the heavy spring is installed in the No. 1 check valve.
10. Rock body side to side to help o-rings slide in. If it does
not drop in completely, do not use screws to force it.
An overly greased o-ring might slide out of groove at top
of ball valve. Use a screw driver to push o-ring back in
groove, then push body down in.
SEAT O-RING
#1 CHECK SEAT
POPPET SCREW
SEAL RING RETAINER
POPPET SEAL RING
POPPET
SPACER (1-1/4” & 1-1/2”)
#2 CHECK ASSY
#1 CHECK SPRING
#1 CHECK SPRING
RETAINER
BOLT
SLEEVE
BODY OUTLET
O-RING
BOLT
SLEEVE
O-RING
BODY INLET
O-RING
SERVICING RELIEF VALVE
1. Remove three bolts holding relief valve module to body.
2. Pull down and remove relief module to expose seat and
seal ring. These can be inspected without further disassembly. CAUTION: do not lose small o-ring or large o-ring
that fit between module and check body.
3. To inspect diaphragm or replace seat/diaphragm stem
assembly, remove the four screws holding the two module
halves together. CAUTION: do not lose small o-ring.
4. Remove stem assembly. Inspect diaphragm and plunger
o-ring for damage. Replace any damaged parts and apply a light coat of grease to plunger o-ring and place on
plunger. CAUTION: stem assembly is internally spring
loaded. Seat can be unscrewed from plunger to replace
diaphragm or spring. The seat surface must not be nicked
during disassembly or reassembly.
5. There are two o-rings that fit into the cover surface, one
large, one small. These o-rings should not be greased.
Insert stem into cover. Place second module half onto
cover. Push the seat down into the cover with your thumb
to align diaphragm bolt holes with cover and then insert
four bolts and tighten.
6. Inspect o-ring that seals between module and check body.
Replace if necessary. Apply grease to the o-ring and then
place on step on check body. Place small o-ring into groove
between the two front bolts holes in relief valve module.
7. Slide relief valve module onto check body. Rocking side
to side can help it slide on over o-ring. Replace three
remaining bolts.
8. Place device in service and test per "TESTING PROCEDURES.
BODY
RV SEAL RING
RV SEAL
RING RETAINER
RV SCREW
XL
RV BODY
O-RING
RV SENSING
PORT O-RING
RV COVER
BOLTS
RV SEAT
RV BODY
FLANGE
RV SPRING GUIDE
RV SPRING
RV DIAPHRAGM
RV
PLUNGER
RV PLUNGER
O-RING
RV
COVER O-RING
RV SENSING
PORT O-RING
RV COVER
RV COVER BOLTS
& NUTS
FLOW CHARACTERISTICS
PRESSURE LOSS
(PSIG)
0.0
3.2
20
FLOW RATES (l/s)
6.3
9.5
12.6
1-1/4" (32mm)
2" (50mm)
1-1/2" (40mm)
15
15.8
138
103
69
10
5
0
50
100
FLOW RATES (GPM)
150
200
34
250
PRESSURE LOSS
(kpa)
MODEL 375XL 1-1/4" - 2" (STANDARD & METRIC)
⃟ Rated Flow (Established by approval agencies)
a
®
company
WILKINS, a ZURN company 3
1747 Commerce Way, Paso Robles, CA 93446 Phone:805/238-7100 Fax:805/238-5766
Troubleshooting
When the relief valve discharges intermittently it can be almost always assumed that the device is functioning correctly and that the
discharge is caused by systems problem such as inlet pressure fluctuations or water hammer due to quick closing valves.
POSSIBLE CAUSES
CORRECTIVE ACTION
1. SUDDEN OR RAPID SPITTING
1. Drop in inlet pressure.
2. Sudden increase in downstream pressure due to water hammer from quick closing shut-off valve installed downstream.
A. Install an in-line spring loaded check valve upstream of backflow.
B. Install pressure reducing valve up
stream of backflow unit.
C. Install in-line spring loaded check valve downstream of backflow as close to source as possible, but not closer than 4 feet.
2. LIGHT INTERMITTENT DRIP
1. Slightly fouled #1 check
A. Clean #1 check and turn check valve seal ring over or replace.
PROBLEM
Continuous discharge of the relief valve signifies a failure of some part of the device. To help determine the specific area of failure,
close the #2 shut-off valve. If the discharge stops, the #2 check requires service. If the discharge continues, the #1 check requires
service.
1. CONTINUOUS DISCHARGE
1. Fouled #1 check.
2. Fouled relief valve seat.
3. Fouled #2 check.
A. Clean check valves and turn check valve seal rings over or replace.
B. Clean relief valve seat and turn
relief valve seal ring over or replace.
In summation, the amount of discharge is proportional to degree of fouling. Most problems occur in the #1 check which is where
debris enters the backflow preventer first.
Performance Characteristics
SPECIFICATIONS
Maximum working water pressure
175PSI
Maximum working water temperature 180°F
Hydrostatic test pressure
350PSI
End connections
Threaded NPT
ANSI B1.20.1
Capacity thru Schedule 40 Pipe
Pipe size 5 ft/sec 7.5 ft/sec 10 ft/sec 15 ft/sec
1/2"
Relief Valve Discharge Rates
(Worst case condition- If 1st check or relief valve is lodged wide open)
BACKFLOW PREVENTERS
MODEL 375XL, 475XL & 975XL2 RP & RPDA
ZONE PRESSURE (U.S. PSIG)
200
3/4" - 1"
1-1/4" - 2"
2-1/4" - 6"
5
7
9
14
3/4"
8
12
17
25
1"
13
20
27
40
1 1/4"
23
35
47
70
1 1/2"
32
48
63
95
2"
52
78
105
167
8" - 10"
REPAIR KIT FOR 375XL's
150
RUBBER PARTS
100
1-1/4" - 2"
50
1-1/4" - 2"
RK114-375R
COMPLETE INTERNALS
RK114-375
VESSEL
1-1/4" - 2"
0
0
200
400
600
RK114-375V
800
FLOW RATE (U.S. GPM)
Proper performance is dependent upon licensed, qualified personnel performing regular, periodic testing according
to WILKINS' specifications and prevailing governmental & industry standards and codes and upon following these
installation instructions. Failure to do so releases WILKINS of any liability that it might otherwise have with respect
to that device. Such failure could also result in an improperly functioning device.
a
IS375XL-114-2 (REV. 9/09)
®
company
WILKINS, a ZURN company 4
1747 Commerce Way, Paso Robles, CA 93446 Phone:805/238-7100 Fax:805/238-5766
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