CALEFFI 535H Series, 5353H Series, 5356H Series, 5359H Series, 5357H Series Installation, Commissioning And Servicing Instructions

www.caleffi.com

535H series pressure reducing valve

NA10397.02

© Copyright 2018 Caleffi

535H Series

Installation, commissioning and servicing instructions

Function

Pressure reducing valves are devices which, when
installed on water systems, reduce and stabilize the
pressure of the water entering from the water supply
main. This pressure, in general, is too high and
variable for domestic systems to operate correctly.

The 535H series pressure reducing valves, ideal for
residential and commercial applications, feature a dial
indicator with direct readout allowing easy pressure pre­adjustment. After installation, the valve will control at the
pre-adjusted pressure setting.

The valve is constructed of DZR low-lead forged brass
and incorporates a unique noise reducing and high
flow seat design, is easily serviced with a replaceable

ASSE 1003

NSF 61

with the US and Canadian plumbing codes.

cartridge and has an integral stainless steel filter
(35 mesh), suitable for water systems that may
contain sediment and debris.

The valve is ICC-ES certified to ASSE 1003, CSA B356,
NSF 61, NSF 372, low lead laws and listed by ICC-ES.
It meets codes IPC, IRC and UPC for use in accordance

Product range

5353H Series
threaded union connections, sizes ½",
5356H Series
connections, sizes
5357H Series
crimp connections, sizes
5359H Series
connections, sizes ½",

Pre-adjustable pressure reducing valve with or without pressure gauge and NPT female

Pre-adjustable pressure reducing valve with or without pressure gauge and union press

¾” and 1".

Pre-adjustable pressure reducing valve with or without pressure gauge and union PEX

¾” and 1".

Pre-adjustable pressure reducing valve with or without pressure gauge and union sweat

¾”, 1", 1¼", 1½" and 2".

1

¾”, 1", 1¼", 1½" and 2".

SAFETY INSTRUCTION

This safety alert symbol will be used in this manual to draw attention to safety related
instructions. When used, the safety alert symbol means.

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN A SAFETY HAZARD.

WARNING: This product can expose you to chemicals including lead, which is known to
the State of California to cause cancer and birth defects or other reproductive harm. For more
information go to www.P65Warnings.ca.gov.

CAUTION: All work must be performed by qualified personnel trained in the
proper application, installation, and maintenance of systems in accordance
with all applicable codes and ordinances.

CAUTION: If the 535H series pressure reducing valve is not installed,
commissioned and maintained properly, according to the instructions contained
in this manual, it may not operate correctly and may endanger the user.

CAUTION: Make sure that all the connecting pipework is water tight.

CAUTION: When making the water connections, make sure that the

connecting pipework is not mechanically over-stressed. Over time this could
cause breakages, with consequent water losses which, in turn, could cause
harm to property and/or people.

CAUTION: Water temperatures higher than 100°F (38°C) can be dangerous.
During the installation, commissioning and maintenance of the 535H PRV,
take the necessary precautions to ensure that such temperatures do not
endanger people.

Leave this manual for the user

2

CONSIGNE DE SÉCURITÉ

Ce symbole d'avertissement servira dans ce manuel à attirer l'attention sur la
sécurité concernant instructions. Lorsqu'il est utilisé, ce symbole signifie.

ATTENTION! DEVENEZ ALERTE ! VOTRE SÉCURITÉ EST EN JEU ! NE
PAS SUIVRE CES INSTRUCTIONS PEUT PROVOQUER UN RISQUE DE
SECURITE.

AVERTISSEMENT:

est connu dans l’État de Californie pour causer le cancer, dommages à la naissance ou autre. Pour

plus d’informations rendez-vous www.P65Warnings.ca.gov.

Ce produit peut vous exposer à des produits chimiques comme le plomb, qui

ATTENTION: Tous les travaux doivent être effectués par du personnel
qualifié formé à la bonne application, installation et maintenance des systèmes
conformément aux codes et règlements locaux.

ATTENTION:

service et entretenu correctement, selon les instructions contenues dans ce manuel,
il peut ne pas fonctionner correctement et peut mettre en danger l'utilisateur.

ATTENTION: S'assurer que tous les raccordements sont étanches.

ATTENTION: Lorsque vous effectuez les raccordements d'eau, assurez-

vous que la tuyauterie reliant réducteur de pression n'est pas mécaniquement
des overstressed. Au fil du temps, ceci pourrait causer des ruptures, avec
pour consequence des pertes en eau qui, à leur tour, peuvent causer des
dommages à la propriété et/ou les gens.

ATTENTION: les températures de l'eau supérieure à 100°F (38°C) peut
être dangereux. Au cours de l'installation, mise en service et l'entretien de
le réducteur de pression, Série 535H, prendre les precautions nécessaires
afin de s'assurer que de tells températures ne compromettent pas les gens.

Si le réducteur de pression, Série 535H, n'est pas installé, mis en

LAISSEZ CE MANUEL AVEC L’UTILISATEUR

3

Technical specifications

Materials: - Body: DZR low-lead brass EN 12165 CW724R

- Cover: glass reinforced nylon PA66M40/1

- Control stem: stainless steel EN 10088-3 (AISI 303)

- Moving parts: DZR low-lead brass EN 12165 CW724R

- Diaphragm & seals: peroxide-cured EPDM

- Compensation piston rings: PTFE

- Filter stainless steel EN 10088-3 (AISI 304)

- Seat: stainless steel EN 10088-3 (AISI 303)

- Shuttle: PPSG40

Max working pressure: 300 psi (20 bar)
Downstream pressure setting range: 15 - 90 psi (1 - 6 bar)
Factory setting: 45 psi (3 bar)
Max. working temperature: 180°F (80°C)
Pressure gauge scale: 0 - 100 psi (0 - 7 bar)
Filter mesh size: 0.51 mm (35 mesh)
Suitable fluids: water

Main connections: -NPT female and sweat union

-Press and PEX crimp union
Lay length (¾" press connection): size
Pressure gauge connection:

½",

¾”, 1", 1¼", 1½" and 2"

¾”: 4¼

"; size 1": 5

1

/8" NPT female

¾” & 1"

¾”

Approvals

1. ICC-ES certified to ASSE 1003, CSA B356, NSF 61 and NSF 372.

2. NSF/ANSI 372-2011, Drinking Water System Components-Lead Content Reduction of Lead
in Drinking Water Act, California Health and Safety Code 116875 S.3874, Reduction in Drinking
Water Act, certified by ICC-ES, file PMG-1360.

4

Hydraulic characteristics

Flow rate

0.05

Graph 1 (Circulation speed)

V (f/s)

15

10

8

6 1.8

5

4 1.2

3 0.9

2 0.6

1.5

0.3

1”

3

0.2

4

1 1/4”1/2” 3/4”

5

0.3

1

0.9

1

2

0.1

0.4

0.5

1 /2”1

10

2”

20

30

40

506070

80

3

4

1

1.5

2

2.5

5

V (m/s)

5

4

3

0.45

0.3

0.150.5

0.1

90

(gpm)

(/s)

6

5

Graph 2 (Pressure drop)

∆

p (psi)

20

15

10

7

5

3

FALL OFF PRESSURE

1/2 in

3/4 in

1 in

1 1/4 in

1 1/2 in

2 in

∆

p (kPa)

150

117
103

90

68
62

48

35

28

20

2

1.5

20

1

0.4

10

0.5

1

0.9

0.05

Reference values: Upstream pressure = 116 psi (800 kPa)

2

0.1

5

3

4

0.2

0.3

1.5

30

40

506070

2

3

2.5

14

10

90

80

(gpm)

(/s)

5

4

6

Flow rate

Downstream presssure = 43 psi (300 kPa)

Sizing procedure

Flow velocity is recommended to be kept within 3 to 6 feet per second when calculating the
correct pressure reducing valve size. This will prevent noise in the pipes and rapid wear of
appliances.

The correct diameter of the pressure reducing valve is taken from graph 1 on the basis of the
design flow rate taking into account an ideal flow velocity of between 3 and 6 f/s (blue band).

Example:
For 8 gpm, select the ¾” size valve (see arrow on graph 1).

The pressure drop is taken from graph 2 also on the basis of where the design flow rate
intersects the curve for the valve size already selected (the downstream pressure falls by an
amount equal to the pressure drop, with respect to the set pressure at no flow condition).

Example:
For 8 gpm the Dp = 7.3 psi (see arrow on graph 2).

Design Flow Rate

Size ½" ¾" 1" 1¼" 1½" 2"

gpm 4 to 7.3 7 to 12.5 10 to 19 17 to 34 24 to 44 37 to 70

6

Installation

Before following the numbered steps listed, the installer must:

a) Be sure this pressure reducing valve is compatible with the other equipment in the system that
it may interact with or come into contact;

b) Assess and acknowledge all hazards related to the use of the this product, including potential
leakage, by installing this unit properly;

c) Install shut-off valve with pressure ports or similar equipment to measure the upstream pressure.

1) Turn all the faucets on before installing the pressure reducing valve, to flush the system and
expel any air remaining in the pipes.

2) Install shut-off valves upstream and downstream to facilitate maintenance operations.

3) The pressure reducing valve may be installed on either vertical or horizontal pipe. However, it
must not be installed upside down.

4) Close the downstream shut-off valve.

5) This mechanical pre-adjustment system, with the operating knob and pressure indicator visible
from both sides, allows the pressure reducing valve to be set to the required value in the system
prior to installation. The pressure indicator features incremental step movement, so that the
pressure can be adjusted continuously and the value displayed at 15 psi increments.

6) Set using the operating knob on the upper part of the valve. The pressure reducing valves are
factory set to a pressure of 45 psi.

7) Because the pre-adjustment dial displays in 15 psi increments, the optional downstream outlet
pressure gauge can be used to show the exact outlet pressure, which is especially useful for
applications requiring this precision.

8) After installation, the internal mechanism will automatically control the pressure, until the set
value has been reached.

9) Slowly reopen the downstream shut-off valve.

s

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80
5

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0 S
8
5

5

80
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Installation recommendations

1. Installation below ground

Installation below the ground is not advisable.

2. Outdoor installation
Pressure reducing valves should not be installed outside the building unless properly protected from

freezing and the weather.

3. Water hammer

Water hammer is a common reason for pressure reducing valve failures. Specific devices should
be installed to absorb water hammer for systems with this risk.

7

Installation

Upstream pressure (kPa)

Upstream pressure (PSI)

When installing the pressure reducing valve upstream of a hot water tank, installing an expansion
tank, or similar, is recommended to absorb the increase in pressure due to the thermal expansion
of water.

When installing in large buildings, short pipes or expansion valves, and/or similar equipment, is
recommended to limit the increased pressure due to the thermal expansion of water caused by
temperature changes downstream of the pressure reducing valve itself (or downstream of the first
and second stage pressure reducing valves, if two are used).

Cavitation diagram

14

2000

1600

1200

Cavitation

800

400

100

Downstream set pressure (PSI)

29

high risk

200

58

400

Downstream set pressure (kPa)

expansion expansion

1° stage

PRV

87

116

Normal working

conditions

600

800

Out of working

conditions

2° stage

145

1000

0 Seri
8
5

PRV

s
e

174

290

232

174

116

58

1200

To minimize the risk of cavitation within the valve that may result in malfunctioning with erosion
of the valve sealing area, vibrations and noise, it is highly recommended to refer to the working
conditions represented in the above diagram. Due to the numerous factors and variable conditions
experienced such as system pressure, water temperature, air presence, flow rate and velocity,
which may affect the behavior of the pressure reducing valve, it is advisable that the pressure ratio
between the upstream pressure and the downstream set pressure is kept ideally to a value 2:1
and no greater than a value of 3:1 (For example, upstream 150 psi (10 bar), set pressure 75 psi
(5 bar), the pressure ratio = 150/75 = 2:1). In these conditions, the possible risk of cavitation and
malfunctioning is minimized, however this does not exclude the possible effects of the many other
variables within the system under operating conditions. If the pressure ratio exceeds the indicated
limit, the system design pressure or use of 1st stage pressure reducing valves shall be reviewed
(For example, 1st stage reducing pressure from 200 to 100 psi and then 2nd stage from 100 to
58 psi). Piping upstream and downstream of the pressure reducing valve shall be supported in
accordance with the manufacturer’s instructions, and any local authority requirements, to avoid
the creation and transfer of vibration and/or noise into the installation.

8

PVC jumper nipple with male union
thread. The length of the jumper nipple
matches the 535H valve face-to-face
dimension, allowing the piping to be
completed prior to the installation of valve
and permitting quick change out from the
jumper to the valve.

Code Description

Face-to-Face

Dimension

NA11304 Jumper nipple for 535H ½" series 3"
NA11305 Jumper nipple for 535H ¾" series 3

9

/16"

NA11306 Jumper nipple for 535H 1" series 3 ¾"
NA11307 Jumper nipple for 535H 1¼" series 4

5

/16"

NA11308 Jumper nipple for 535H 1½" series 4 ¾"
NA11309 Jumper nipple for 535H 2" series 5 ¼"

9

Maintenance

The pressre reducing valve must be checked and serviced to comply with applicable regulations.
Even when installed, commissioned and serviced properly, the pressure reducing valve's
internal components are subject to normal wear and tear, which may result in leaks and other
malfunctions. Check or good working order and service and clean the cartridge at least every 12
months.

The cartridge, containing the diaphragm, strainer, seat, valve plug and compensating piston,
is pre-assembled as a self-contained unit with a cover and can be removed for inspection and
maintenance. When checking, cleaning or replacing the cartridge:

1) Shut off the inlet and outlet isolation valves.

2) The downstream pressure setting can be left at the set value.

3) Remove the upper cover, using a spanner. This cover is integral with the cartridge.

4) Check and clean the filter.

5) If needed, the self-contained cartridge can be completely replaced. When the cartridge is
crewed back into the body, the pressure indicating window will return the value to the original
position.

6) Reopen the shut off valves and the pressure will return to the original set value.

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Troubleshooting

System failures are not always caused by the
pressure reducing valve. Most frequently:

1. Increased downstream pressure in the
presence of a water heater

If the downstream pressure increases

beyond the desired setting due to an
inline water heater, install an expansion
tank between the pressure reducing
valve and the water heater to absorb
the increased pressure, caused by
water expansion from heating.

2.The pressure reducing valve does not

maintain downstream setting value

If the pressure reducing valve does

not maintain the downstream setting, it most likely is due to impurities acccumulating
on the valve seat, causing unnecessary flow to pass-through, increasing the downstream
pressure. Proper maintenance and cleaning of the removable cartridge is recommended.

11

Leave this manual at the service of users for their use

Caleffi North America, Inc.
3883 W. Milwaukee Road
Milwaukee, WI 53208
T: 414.238.2360 F: 414.238.2366

12

04-20-18