Zurn Wilkins ZW209FP Installation manual

1
INSTALLATION
NOTE: Prior to installation of the ZW209FP, ensure that all
1. During the installation of a ZW209FP in a sprinkler system,
Underwriter Laboratories (UL) requires NFPA 13 “Standard for
Installation of Sprinkler Systems” be followed.
2. Upon installation UL also requires that the ZW209FP be
tested in accordance with NFPA 13 or NFPA 14. Thereafter the
valve shall be inspected, tested, and maintained in accordance to
NFPA 25 “Standard for the Inspection, Testing, and Maintenance
of Water-Based Fire Protection Systems”. NOTE: Initial testing
must be done with the design inlet pressure so the proper
3. For making adjustments and servicing allow for adequate
space around the valve.
4. When installing a ZW209FP valve gate valves installed on
both inlet and outlet are recommended for maintenance allowing
for isolation of valve.
5. Position the ZW209FP in line matching the direction of as
indicated on the valve model tag with the proper direction of
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.
6. Valves installed in sprinkler or standpipe systems shall have
the following:
a) Unions or rubber gasket installed immediately up
stream or downstream to permit replacement.
b) A relief valve (at least ½” size and 175 psi max.) installed
on the downstream side and plumbed to a safe drainage.
c) Pressure gauges installed on the inlet and outlet.
d) Shall not be set for less than 50 psi.
Installation  Start-up  Maintenance Instructions
Model ZW209FP
Fire Protection Pressure Reducing Valve Assembly
1-1/4", 1-1/2", 2", 2-1/2", 3", 4" & 6"
ZURN WILKINS
1747 Commerce Way, Paso Robles, CA 93446 Phone:[phone] Fax:[phone]
ZW209FP
Class 300 Flanged
Max 300 psi Inlet
ZW209FPG
Grooved
Max 300 psi Inlet
ZW209FPX
Class150 Flanged
Max 250 psi Inlet
7. It is suggested that a line size tee connection be installed
downstream of sprinkler system valves to allow full testing
as required every years per NFPA 25.
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Trapped air may cause outlet pressure at low
9. Zurn Wilkins valves are designed to operate in both the verti-
cal and horizontal positions. However, it is recommended that
ZW209FP’s 6” and larger, be installation in the horizontal position.
The horizontal positioning of the larger valves avoids premature
wear due to mass of plunger assemblies as well as allows for
greater accessibility during annual inspections, and maintenance.
START-UP
CAUTION: To prevent personnel injury and damage to equip-
ment check that downstream venting is adequate prior to
start-up and test procedures. All adjustments under pressure
If
the main valve closes too fast it may cause surging in upstream
piping.
1. Slowly open the upstream shutoff valve only enough to
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.
2. As the valve is 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 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
3. At this point with the upstream shutoff valve partially open,
slowly open the downstream shut off valve. Flow will begin to
occur and pressure should build up in valve and eventually
stabilize.
Installation / Start-up
DESCRIPTION
The Zurn Wilkins ZW209FP pilot operated pressure reducing
valve is designed for suppression systems
to reduce high inlet pressures to a safe and stable outlet
pressure. The pilot assembly reacts to changes in downstream
pressure allowing the main valve to modulate between the
closed and open position ensuring a constant downstream
set pressure. Once the downstream pressure reaches the
pilot setting, the main valve will seal shut preventing damage
downstream. Pressure regulation is not dependent upon
rate, resulting in minimal pressure loss through the valve.
In addition the ZW209FP and ZW209FPG come standard
with red epoxy coating internally and externally for corrosion
protection, as well as isolation valves and pressure gauges for
quick and easy maintenance or repair
ZW209FPTH
Threaded
Max 300 psi Inlet
®
®
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Installation / Start-up
2ZURN WILKINS
1747 Commerce Way, Paso Robles, CA 93446 Phone:[phone] Fax:[phone]
4. To adjust pressure setting on the PV-PRD, water must be
through the pilot in order to accurately set pressure
(refer to table 1 for recommended Then loosen jam nut
on adjustment screw and either turn adjustment screw in (to
increase pressure) or out (to decrease pressure) of the PV-PRD.
5. To verify proper operation of ZW209FP slowly close and
open downstream shut off valve several time to ensure down-
stream pressure is stable at set pressure.
6. The suggested calculations (Table 1) are based on
the through schedule 40 pipe. Maximum continuous
is approximately 20 ft/s (6.1 m/s) & maximum intermittent is
approximately 25 ft/s (7.6 m/s) and minimum continuous is
approximately 1 ft/s (0.3 m/s). Many factors should be considered
in sizing pressure reducing valves including inlet pressure,
outlet pressure, and rates.
NOTE: For additional system protection a pressure relief
valve (1/2” min) shall be installed downstream of pressure
reducing valve.
Table 1
VALVE
SIZE
inches 1-1/4 1-1/2 2 2-1/2 346
mm 32 40 50 65 80 100 150
MINIMUM FLOW RATES TO SET VALVE (GPM)15 15 100 35 60 100 220
MAX. FLOW RATE (GPM) 125 160 250 375 600 1000 2250
ZW209FPG SCHEMATIC
STANDARD COMPONENTS
1. Main Valve
2. SXL "Wye"
3. Pressure Gauge
4. Restriction Tube Fitting
5. PV-PRD Pressure Reducing Control
3
1
3
5
4
2
FLOW
The Zurn Wilkins ZW209FP utilizes a pressure reducing pilot valve that installs on the discharge side of the control circuitry. The
pilot Model PV-PRD is a direct acting, normally open, spring loaded, diaphragm actuated valve. The operation of the ZW209FP
begins with accurately sizing the valve, then tuning the control circuitry by adjusting the PV-PRD to the desired downstream
pressure.
Inlet pressure is piped to the inlet of the PV-PRD. A sensing line runs internally from the discharge side of the pilot to its lower con-
trol chamber under the diaphragm. Thus, downstream pressure exceeding the preset of the pilot acts to close the pilot valve while
the adjustable spring in the pilot seeks to keep it open. The result is a modulating action in the pilot that is transmitted to the cover
of the main valve. This creates a mirror modulation of the diaphragm assembly in the main valve. Downstream pressure is main-
tained with narrow limits regardless of changing rates or varying inlet pressure.
Drip Tight Closing Operation
With the use of a three way pilot control, inlet
pressure is directed to the cover where the
pressure forces the valve closed.
Full Open Operation
Using a three way pilot control, pressure relief
(typically to atmosphere) can be controlled to
the cover that enables the inlet pressure to
open the main valve.
Modulating Action
Utilizing a Wilkins modulating control sys-
tem, pressure changes to the cover can be
controlled, allowing the valve to throttle and
compensate for changes.
Operation
®
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0
1
10
100
10 100 1000 10000
PRESSURE DROP (PSI)
FLOW (GPM)
BODY MINIMUM FRICTION LOSS
PRESSURE REDUCTION LIMIT
0
50
100
150
200
250
300
020406080100 120
OUTLET PRESSURE (PSI)
INLET PRESSURE (PSI)
ZURN WILKINS
1747 Commerce Way, Paso Robles, CA 93446 Phone:[phone] Fax:[phone]
Maintenance Instructions
2-1/2"
4" 6"
Safe
operating zone
Cavitation damage
zone (intermittent
operation allowed)
Noise
zone
Damage Zone
UL Limit Noise Limit
FLOW CHARACTERISTICS
MAINTENANCE (Main Valve)
In addition to complying with UL standard NFPA 25 every
years, scheduled preventative maintenance and inspection is
highly recommended. It is also recommended that a repair kit
with a new diaphragm, disc, and o-rings be on hand before
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. With all isolation valves closed to the ZW209FP, begin
slowly removing in the pilot system until residual
pressure is removed. After excess pressure has been relieved
begin removal of pilot tubing to cover.
2. Begin loosening cover bolts and remove cover lifting up
to slide cover bushing off plunger shaft. For valves larger than
6” it is recommended that lifting lugs and a hoist be used due
excessive weight of the larger covers.
3. Once the cover is removed the plunger spring and spring
washer can be removed. Then remove the diaphragm assem-
bly by grabbing the stem or lifting from two sides of the dia-
phragm. Be sure to lift straight up to avoid binding the stem in
the seat bushing, as damage can occur. NOTE: Again with the
larger size valves 6” and up it is recommended that a lifting lug
and hoist be used to remove larger plunger assemblies.
4. Place diaphragm assembly in a vise with the bottom hex
secured. Remove the stem nut and inspect threads for dam-
age, corrosion, or pitting.
5. After inspecting the stem and removing the nut the diaphragm
*Notes for Body Minimum Friction Loss Chart:
Minimum inlet pressure is 10 psi higher than set point or the additional body friction loss at intended whichever is higher. (fric-
tion loss may be important at above 20 ft/s)
Example: A 6” valve intended to 2000 GPM at 150 psi has a friction loss of 20 psi at 2000 GPM. The minimum inlet pressure
would be 150 + 20 = 170 psi. When inlet pressure is below set point, the outlet pressure will be the pressure at the inlet minus the
friction loss.
assembly can be dismantled. When disassembling be sure to
clean, inspect, and save all components. Replace any damaged
components as necessary.
6. Next clean and inspect the seat inside the main valve body.
If excessive water deposits are present grit sand paper can
be used to clean. The seat is designed to be removed, but typi-
cally does not require removal. If damage is noticeable or seat
is excessively worn, replace the seat before reassembly.
7. Refer to www.zurn.com to ZW209 instruction sheet for
more detailed instructions for disassembly and reassembly of
main valve.
REASSEMBLY
Prior to reassembly clean, inspect, and replace any parts as
needed.
1. Using a vise, diaphragm assembly can be held and as-
sembled in the reverse order as disassembly section.
2. Clamp valve stem hex in a vise and reassemble diaphragm
assembly. Make sure to center diaphragm on plunger before
placing diaphragm disc. Refer to ZW209 instruction sheet at
www.zurn.com or call product support 877-222-5356 for further
assistance.
3. Once diaphragm assembly is assembled, gently lower
stem into seat guide. Rotate diaphragm as needed until bolt
holes line up with body bolt holes.
4. Install spring then the cover. Tighten bolts in a cross pat-
tern. Be careful not to pinch the diaphragm when inserting and
tightening cover bolts.
5. Reattach pilot assembly and tighten all bolts and as
needed. Test system per UL standard NFPA 25.
3"2" 8" 10"
1-1/2"
1-1/4"
Do not operate
in this area
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®

MAINTENANCE (3/8" PV-PRD VALVE)
The PV-PRD pressure reducing control may be installed in
any position. There is one inlet port and two outlets, for either
straight or angle installation. A arrow is marked on the
body and should be oriented as needed.
DISASSEMBLY
Prior to disassembly, relieve all pressure in pilot system and
then remove the PV-PRD.
1. Secure valve body and remove main cap on bottom of
valve using an adjustable wrench.
2. Use a 13 mm socket to remove the plunger.
3. Next remove adjustment cover (plastic cover), 3/8” adjust-
ment bolt with nut, 8 socket head screws around the pilot bell
using a 5/32 hex key, spring, and spring disc.
4. At this point the PRV stem yoke is free to move and can be
slid out of the valve body.
5. Continue to remove the 5/16” diaphragm nut, lock washer,
and diaphragm retainer.
6. After completely disassembling, thoroughly clean and
inspect all components before reassembly. Replace any parts
as necessary after inspection.
7. The pilot seat generally does not need to be removed, but
if after inspection it requires replacement it can be removed
with a 1/2” socket.
3/8" PV-PRD VALVE
REASSEMBLY
Reassembly of the PV-PRD is the reverse of disassembly.
1. Install the new o-ring on top of pilot yoke threads followed
by new diaphragm and diaphragm retainer. Then place lock
washer over pilot yoke stem along with the 5/16” diaphragm nut
and tighten. Diaphragm bolt holes must be centered on yoke
legs. See following diagram
2. Next carefully slide yoke assembly into body and around
pilot seat. ZURN WILKINS
1747 Commerce Way, Paso Robles, CA 93446 Phone:[phone] Fax:[phone]
ISZW209FP-114-6 (REV. 8/13)
ITEM DESCRIPTION
1 BODY
2 SEAT
3O-RING
4 STEM
5 SEAL RETAINER
6O-RING
7 SEAL RING
8 PLUNGER
9DIAPHRAGM
10 DIAPHRAGM DISC
11 WASHER
12 3/4-16 UNF NUT
13 LOWER SPRING WASHER
14 SPRING
15 UPPER SPRING BUSHING
16 COVER BUSHING
17 COVER
18 WASHER
19 1/2-13X2" CAP SCREW
20 3/4" NPT PLUG
NOTE: Line up diaphragm screw holes with holes in body.
Move yoke up and down checking for yoke contacting or
dragging on valve body.
3. Then attach plunger to the bottom of the pilot yoke via the
main cap hole and tighten with a 13 mm socket.
4. Install main cap in bottom of valve body with new o-ring.
5. Install spring, spring disc, 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. Install adjusting screw by hand with jam nut. Set valve
once reinstalled into main valve pilot system. For setting pilot
refer to “Start Up” section on page one. For further assistance
or ordering replacement parts go to www.zurn.com or call pro-
duct support 877-222-5356.
PV-PRD SPECS:
Adjustment Range Pressure: 50-165 psi
(Flowing residual outlet pressure)
Max Static Outlet Pressure: 175 psi
Max Inlet Pressure: 300 psi
NOTE : All adjustments should be made with a pressure
ITEM DESCRIPTION
13/8" PRV-PILOT BODY, LEAD FREE BRASS
2PLUNGER, SS W/BUNA NITRILE 90 SHORE
3MAIN CAP, LEAD FREE BRASS
4ADJUSTMENT COVER
53/8"-16 ADJUSTMENT BOLT, BRASS
63/8" PILOT SEAT, SS
720-200 PSI SPRING, CHROME SILICON
8DIAPHRAGM DISC, SS
9SPRING DISC, SS
10 PILOT BELL, BRASS
11 O-RING, BUNA NITRILE NSF LISTED
12 5/16"-18 DIAPHRAGM NUT, SS
13 10-32X5/8 SOCKET HEAD CAP SCREW
14 DIAPHRAGM, NYLON REINFORCED BUNA
NITRILE
15 PRV STEM YOKE, SS
16 3/8"-16 JAM HEX NUT, SS
17 5/16" INTERNAL TOOTH LOCK WASHER, SS
18 O-RING, BUNA NITRILE NSF LISTED
19 UL TAG RED, BRASS
18
12
14
17
15
8
6
1
2
7
10
3
13
11
5
4
16
9
20
15
12
14
9
6
3
2
1
17
16
20
11
13
19
18
6
8
7
4
5
10
Maintenance Instructions
CENTER YOKE LEGS
BETWEEN
DIAPHRAGM HOLES
YOKE LEGS
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