Zurn Wilkins ZW209FP Installation manual

1
®
INSTALLATION
NOTE: Prior to installation of the ZW209FP, ensure that all debris is
ushed out the piping system before installed.
1. During the installation of a ZW209FP in a sprinkler system, Underwriter
Laboratories (UL) requires NFPA 13 “Standard for Installation of Sprin-
kler 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 Pro-
tection Systems”. NOTE: Initial testing must be done with the design
inlet pressure so the proper outlet pressure can be veried.
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 ow as indi-
cated 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 thor-
ough in checking and inspecting for proper installation and makeup.
6. Valves installed in sprinkler or standpipe systems shall have the fol-
lowing:
a) Unions or rubber gasket ttings installed immediately upstream
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
Globe and Angle Pattern Bodies
8" & 10"
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 ow testing as required every
ve years per NFPA 25.
8. Bleed all trapped air from supply riser and sprinkler system. Trapped
air may cause outlet pressure uctuations at low ows.
9. Zurn Wilkins valves are designed to operate in both the vertical and
horizontal positions. However, it is recommended that ZW209FP’s 6” and
larger, be installation in the horizontal position. The horizontal position-
ing 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 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. 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.
2. 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.
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 specically for re 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 ow rate,
resulting in minimal pressure loss through the valve. In addition the
ZW209FP comes 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. The
ZW209FP is available in both globe and angle pattern bodies.
ZW209FPTH
Threaded
Max 300 psi Inlet
®
www.zurn.com
!WARNING: Cancer and Reproductive Harm - www.P65Warnings.ca.gov
!ADVERTENCIA: Cáncer y daño reproductivo - www.P65Warnings.ca.gov
!AVERTISSEMENT: Cancer et néfastes sur la reproduction - www.P65Warnings.ca.gov

Installation / Start-up
4. To adjust pressure setting on the PV-PRD, water must be
owing through the pilot in order to accurately set pressure
(refer to table 1 for recommended ow). 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 ow calculations (Table 1) are based on
the ow through schedule 40 pipe. Maximum continuous ow
is approximately 20 ft/s (6.1 m/s) & maximum intermittent is
approximately 25 ft/s (7.6 m/s) and minimum continuous ow 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 ow 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 8 10
mm 200 250
MINIMUM FLOW RATES TO SET VALVE (GPM) 400 600
MAX. FLOW RATE (GPM) 4000 6000
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 ne 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 ow 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 Zurn Wilkins modulating control
system, pressure changes to the cover can be
controlled, allowing the valve to throttle and
compensate for changes.
Operation
2
ZURN WILKINS
1747 Commerce Way, Paso Robles, CA 93446 Phone:[phone] Fax:[phone]
www.zurn.com
®

PRESSURE REDUCTION LIMIT
0
50
100
150
200
250
300
020 40 60 80 100 120
OUTLET PRESSURE (PSI)
INLET PRESSURE (PSI)
Maintenance Instructions
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 ve
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 are tting 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 ow, whichever is higher. (fric-
tion loss may be important at ows above 20 ft/s)
Example: A 6” valve intended to ow 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 ne 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 nd 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 tting as
needed. Test system per UL standard NFPA 25.
Do not operate
in this area
3
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 MINIMUM 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" Globe
3" Angle
4" Globe & Angle
6" Globe
6" Angle
8" Globe
8" Angle
10" Globe
10" Angle

MAINTENANCE
(1/2" PV-PRD VALVE)
The PV-PRD pressure reducing control may be installed in any
position.
DISASSEMBLY
Prior to disassembly, relieve all pressure in pilot system.
1. Secure valve body and remove main cap on bottom of
valve using an adjustable wrench.
2. 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.
3. Use the 5/32 hex key in the plunger screw and a wrench
on the diaphragm nut to unscrew one end of the stem.
4. At this point the PRV stem 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 upper diaphragm retainer, diaphragm, diaphragm o-ring,
lower diaphragm washer, stem guide, stem o-ring, and plunger
from the stem.
6. After complete disassembly, 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 1-1/8” socket.
1/2" PV-PRD VALVE
REASSEMBLY
Reassembly of the PV-PRD is the reverse of disassembly.
1. Install the lower diaphragm washer (with round edge
toward the diaphragm), new o-ring, followed by new diaphragm
and diaphragm retainer. Then place lock washer over stem
threads along with the 5/16” diaphragm nut and tighten.
ISZW209FP-8-10 (REV. D 6/17)
ITEM DESCRIPTION
1BODY (GLOBE OR ANGLE)
2 SEAT
3 O-RING
4 STEM
5 SEAL RETAINER
6 O-RING
7 SEAL RING
8 PLUNGER
9 DIAPHRAGM
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
2. Next slide stem assembly into body through pilot seat.
3. Then slide the plunger onto the stem via the main cap 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 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: 8" 50 - 165 psi
10" 50 - 155 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
gauge and while owing water through the main valve.
ITEM DESCRIPTION
1ADJUSTMENT COVER
23/8-16 ADJUSTMENT BOLT
3PILOT BELL, BRASS
4SPRING DISC, SS
5DIAPHRAGM DISC, SS
610-32x5/8 SOC HEAD CAP SCREW
7ACL STEM SHAFT
8RELIEF PILOT SEAT, SS
9O-RING, BUNA NITRILE, NSF
LISTED
10 ACL PLUNGER ASSY.
11 STEM O-RING
12 WASHER STEM GUIDE
13 1/2 PRD MAIN CAP
14 O-RING, BUNA -N, NSF LISTED
15 DIAPHRAGM WASHER
16 DIAHPRAGM
17 1/2" BODY, CAST SILICON BRASS
18 O-RING, BUNA NITRILE NSF LISTED
19 UL TAG RED, BRASS
20 5/16" INT TEETH LOCKWASHER
21 5/16-18 DIAPHRAGM NUT
22 20-200 PSI SPRING
23 3x8-16 JAM HEX NUT
20
15
12
14
9
6
3
2
1
17
16
20
11
13
19
18
6
8
7
4
5
10
Maintenance Instructions
1
2
3
4
23
22
5
16
15
10
13
14 12
7
8
9
11
21
20
18
17
6
6
19
4
ZURN WILKINS
1747 Commerce Way, Paso Robles, CA 93446 Phone:[phone] Fax:[phone]
www.zurn.com
®