Model ZW209FP

Fire Protection Pressure Reducing Valve Assembly ®

Globe and Angle Pattern Bodies
8" & 10"
 Installation  Start-up  Maintenance Instructions
DESCRIPTION
The Zurn Wilkins ZW209FP pilot operated pressure reducing valve is
designed specifically for fire 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 flow rate,
ZW209FP ZW209FPG ZW209FPX
resulting in minimal pressure loss through the valve. In addition the
Class 300 Flanged Grooved Class150 Flanged
ZW209FP comes standard with red epoxy coating internally and
Max 300 psi Inlet Max 300 psi Inlet Max 250 psi Inlet
externally for corrosion protection, as well as isolation valves and
pressure gauges for quick and easy maintenance or repair. The ZW209FPTH
ZW209FP is available in both globe and angle pattern bodies. Threaded
Max 300 psi Inlet

Installation / Start-up
INSTALLATION 7. It is suggested that a line size tee connection be installed downstream
NOTE: Prior to installation of the ZW209FP, ensure that all debris is of sprinkler system valves to allow full flow testing as required every
flushed out the piping system before installed. five years per NFPA 25.
1. During the installation of a ZW209FP in a sprinkler system, Underwriter
8. Bleed all trapped air from supply riser and sprinkler system. Trapped
Laboratories (UL) requires NFPA 13 “Standard for Installation of Sprin-
air may cause outlet pressure fluctuations at low flows.
kler Systems” be followed.
9. Zurn Wilkins valves are designed to operate in both the vertical and
2. Upon installation UL also requires that the ZW209FP be tested in
horizontal positions. However, it is recommended that ZW209FP’s 6” and
accordance with NFPA 13 or NFPA 14. Thereafter the valve shall be
larger, be installation in the horizontal position. The horizontal position-
inspected, tested, and maintained in accordance to NFPA 25 “Standard
ing of the larger valves avoids premature wear due to mass of plunger
for the Inspection, Testing, and Maintenance of Water-Based Fire Pro-
assemblies as well as allows for greater accessibility during annual
tection Systems”. NOTE: Initial testing must be done with the design
inspections, and maintenance.
inlet pressure so the proper outlet pressure can be verified.
START-UP
3. For making adjustments and servicing allow for adequate space
CAUTION: To prevent personnel injury and damage to equipment
around the valve.
check that downstream venting is adequate prior to start-up and test
4. When installing a ZW209FP valve gate valves installed on both inlet and procedures. All adjustments under pressure should be made slowly
outlet are recommended for maintenance allowing for isolation of valve. while under flowing conditions. If the main valve closes too fast it
may cause surging in upstream piping.
5. Position the ZW209FP in line matching the direction of flow as indi-
cated on the valve model tag with the proper direction of flow in the
1. Slowly open the upstream shutoff valve only enough to fill main valve
system. Once attached to line double check all fasteners/bolts in the
assembly and pilot system. Prior to pressurizing the valve assembly it
pilot system and on main valve are tight and there is no damage prior
is also recommended that a ZPI valve position indicator be installed
to pressurizing system.
to aid in verifying proper valve movement.
NOTE: Pressure in some applications can be very high so be thor-
ough in checking and inspecting for proper installation and makeup. 2. As the valve is filling with water, it is necessary to bleed the main valve
and pilot system of air. To vent air, partially open or loosen the highest
6. Valves installed in sprinkler or standpipe systems shall have the fol- plugs or fittings in the system. The ZPI valve position indicator is a
lowing: great location, as it has a test cock at the top to vent air pressure. It
a) Unions or rubber gasket fittings installed immediately upstream may be necessary to bleed system more than once. After removal of
or downstream to permit replacement. air in the system tighten all loose fittings. NOTE: If valve is installed
b) A relief valve (at least ½” size and 175 psi max.) installed on the vertically, it will be necessary to loosen some upper cover bolts until
downstream side and plumbed to a safe drainage. you have vented all the air from the cover chamber.
c) Pressure gauges installed on the inlet and outlet.
d) Shall not be set for less than 50 psi. 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.

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ZURN WILKINS
1
®

1747 Commerce Way, Paso Robles, CA 93446 Phone:855-663-9876 Fax:805-238-5766

www.zurn.com
 Installation / Start-up
4. To adjust pressure setting on the PV-PRD, water must be
flowing through the pilot in order to accurately set pressure
4 5
(refer to table 1 for recommended flow). 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. 2
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. 3 3
6. The suggested flow calculations (Table 1) are based on
the flow through schedule 40 pipe. Maximum continuous flow
is approximately 20 ft/s (6.1 m/s) & maximum intermittent is
approximately 25 ft/s (7.6 m/s) and minimum continuous flow is
approximately 1 ft/s (0.3 m/s). Many factors should be considered FLOW
in sizing pressure reducing valves including inlet pressure,
outlet pressure, and flow rates. 1
NOTE: For additional system protection a pressure relief
valve (1/2” min) shall be installed downstream of pressure ZW209FPG SCHEMATIC
reducing valve. STANDARD COMPONENTS
Table 1 1. Main Valve
2. SXL "Wye"
inches 8 10 3. Pressure Gauge
VALVE
4. Restriction Tube Fitting
SIZE
mm 200 250 5. PV-PRD Pressure Reducing Control

MINIMUM FLOW RATES TO SET VALVE (GPM) 400 600

MAX. FLOW RATE (GPM) 4000 6000

Operation
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 fine 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 flow rates or varying inlet pressure.

Drip Tight Closing Operation Full Open Operation Modulating Action

With the use of a three way pilot control, inlet Using a three way pilot control, pressure relief Utilizing a Zurn Wilkins modulating control
pressure is directed to the cover where the (typically to atmosphere) can be controlled to system, pressure changes to the cover can be
pressure forces the valve closed. the cover that enables the inlet pressure to controlled, allowing the valve to throttle and
open the main valve. compensate for changes.

ZURN WILKINS
2
®

1747 Commerce Way, Paso Robles, CA 93446 Phone:855-663-9876 Fax:805-238-5766

www.zurn.com
Flow Characteristics
PRESSURE REDUCTION LIMIT
BODY MINIMUM FRICTION LOSS UL Limit Damage Zone Noise Limit
300

be le le
100

lo g g
G An An
Cavitation damage

e
2" " &

gl
1/ /2 e

An
zone (intermittent

1- 1-1 lob

&
G

gl be
gl lob
250

e
operation allowed)

gl ob

be
be
e

gl ob
4"

An Glo
gl lob

ng Glo
An G

An Gl

lo
1/

An Gl
e
e

e
2" /2"

G
1-

An " G

3" 3"

6" 6"

e
8"

" A 0"
e

4"
1
Do not operate

le
2

INLET PRESSURE (PSI)

2-

1
PRESSURE DROP (PSI)

in this area

8"
1/
2"
Noise

2-
200

10
zone
10

150
Safe
operating zone
100
1

50

0
0
0 20 40 60 80 100 120
10 100 1000 10000
FLOW (GPM) OUTLET PRESSURE (PSI)

* 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 flow, whichever is higher. (fric-
tion loss may be important at flows above 20 ft/s)
Example: A 6” valve intended to flow 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.

Maintenance Instructions
MAINTENANCE (Main Valve) assembly can be dismantled. When disassembling be sure to
In addition to complying with UL standard NFPA 25 every five clean, inspect, and save all components. Replace any damaged
years, scheduled preventative maintenance and inspection is components as necessary.
highly recommended. It is also recommended that a repair kit
with a new diaphragm, disc, and o-rings be on hand before 6. Next clean and inspect the seat inside the main valve body.
work begins If excessive water deposits are present fine grit sand paper can
DISASSEMBLY be used to clean. The seat is designed to be removed, but typi-
Warning: With the ability to perform inspections and cally does not require removal. If damage is noticeable or seat
maintenance without removal from the system. It is very is excessively worn, replace the seat before reassembly.
important that all shut off valves be closed and all pres-
sure relieved in the valve before beginning disassembly. 7. Refer to www.zurn.com to find ZW209 instruction sheet for
Failure to do so can result in personnel injury or equip- more detailed instructions for disassembly and reassembly of
ment damage. main valve.
1. With all isolation valves closed to the ZW209FP, begin REASSEMBLY
slowly removing flare fitting in the pilot system until residual Prior to reassembly clean, inspect, and replace any parts as
pressure is removed. After excess pressure has been relieved needed.
begin removal of pilot tubing to cover.
1. Using a vise, diaphragm assembly can be held and as-
2. Begin loosening cover bolts and remove cover lifting up sembled in the reverse order as disassembly section.
to slide cover bushing off plunger shaft. For valves larger than
6” it is recommended that lifting lugs and a hoist be used due 2. Clamp valve stem hex in a vise and reassemble diaphragm
excessive weight of the larger covers. assembly. Make sure to center diaphragm on plunger before
placing diaphragm disc. Refer to ZW209 instruction sheet at
3. Once the cover is removed the plunger spring and spring www.zurn.com or call product support 877-222-5356 for further
washer can be removed. Then remove the diaphragm assem- assistance.
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 3. Once diaphragm assembly is assembled, gently lower
the seat bushing, as damage can occur. NOTE: Again with the stem into seat guide. Rotate diaphragm as needed until bolt
larger size valves 6” and up it is recommended that a lifting lug holes line up with body bolt holes.
and hoist be used to remove larger plunger assemblies.
4. Install spring then the cover. Tighten bolts in a cross pat-
4. Place diaphragm assembly in a vise with the bottom hex tern. Be careful not to pinch the diaphragm when inserting and
secured. Remove the stem nut and inspect threads for dam- tightening cover bolts.
age, corrosion, or pitting.
5. Reattach pilot assembly and tighten all bolts and fitting as
5. After inspecting the stem and removing the nut the diaphragm needed. Test system per UL standard NFPA 25.

ZURN WILKINS
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®

1747 Commerce Way, Paso Robles, CA 93446 Phone:855-663-9876 Fax:805-238-5766

www.zurn.com
 Maintenance Instructions
ITEM DESCRIPTION
2. Next slide stem assembly into body through pilot seat.
17 1 BODY (GLOBE OR ANGLE)
20 2 SEAT
16
15
3 O-RING 3. Then slide the plunger onto the stem via the main cap hole
20 4 STEM
5 SEAL RETAINER
followed by the small stem o-ring, stem guide and cap screw.
11 12
13 14
6 O-RING While holding diaphragm nut, tighten the cap screw with Allen
19 10
7 SEAL RING
wrench.
8 PLUNGER
18
9 9 DIAPHRAGM
6
6 10 DIAPHRAGM DISC
4. Install main cap in bottom of valve body with new o-ring.
8
5 11 WASHER
7
3 12 3/4-16 UNF NUT 5. Install spring, spring disc, and pilot bell on the valve body.
4
13 LOWER SPRING WASHER
2
14 SPRING
6. Insert socket head cap screws into pilot bell holes and
1 15 UPPER SPRING BUSHING
16 COVER BUSHING
thread into valve body. Tighten all screws in a cross pattern.
17 COVER
18 WASHER 7. Install adjusting screw by hand with jam nut. Set valve
19 1/2-13X2" CAP SCREW once reinstalled into main valve pilot system. For setting pilot
20 3/4" NPT PLUG refer to “Start Up” section on page one. For further assistance
or ordering replacement parts go to www.zurn.com or call pro-
MAINTENANCE
duct support 877-222-5356.
(1/2" PV-PRD VALVE)
The PV-PRD pressure reducing control may be installed in any
position.

DISASSEMBLY ITEM DESCRIPTION

Prior to disassembly, relieve all pressure in pilot system. 1 ADJUSTMENT COVER
1. Secure valve body and remove main cap on bottom of 2 3/8-16 ADJUSTMENT BOLT
valve using an adjustable wrench. 1
3 PILOT BELL, BRASS

23 4 SPRING DISC, SS
2. Next remove adjustment cover (plastic cover), 3/8” adjust- 2
5 DIAPHRAGM DISC, SS
ment bolt with nut, 8 socket head screws around the pilot bell
using a 5/32 hex key, spring, and spring disc. 6 10-32x5/8 SOC HEAD CAP SCREW
22 3
7 ACL STEM SHAFT

3. Use the 5/32 hex key in the plunger screw and a wrench 8 RELIEF PILOT SEAT, SS

on the diaphragm nut to unscrew one end of the stem. 21

4
9
O-RING, BUNA NITRILE, NSF
LISTED
5 10 ACL PLUNGER ASSY.
4. At this point the PRV stem is free to move and can be slid 20
11 STEM O-RING
6
out of the valve body.
19 12 WASHER STEM GUIDE
7
13 1/2 PRD MAIN CAP
5. Continue to remove the 5/16” diaphragm nut, lock washer, 18
8 14
and upper diaphragm retainer, diaphragm, diaphragm o-ring, 17
O-RING, BUNA -N, NSF LISTED

lower diaphragm washer, stem guide, stem o-ring, and plunger 9

15 DIAPHRAGM WASHER

from the stem. 16 16 DIAHPRAGM

10
15 17 1/2" BODY, CAST SILICON BRASS

6. After complete disassembly, thoroughly clean and inspect all 11 18 O-RING, BUNA NITRILE NSF LISTED
components before reassembly. Replace any parts as necessary 14 12 19 UL TAG RED, BRASS
after inspection. 20 5/16" INT TEETH LOCKWASHER
13 6
21 5/16-18 DIAPHRAGM NUT
7. The pilot seat generally does not need to be removed, but
22 20-200 PSI SPRING
if after inspection it requires replacement it can be removed
23 3x8-16 JAM HEX NUT
with a 1-1/8” socket.

1/2" PV-PRD VALVE

PV-PRD SPECS:
REASSEMBLY Adjustment Range Pressure: 8" 50 - 165 psi
Reassembly of the PV-PRD is the reverse of disassembly. 10" 50 - 155 psi
(Flowing residual outlet pressure)
1. Install the lower diaphragm washer (with round edge Max Static Outlet Pressure: 175 psi
toward the diaphragm), new o-ring, followed by new diaphragm Max Inlet Pressure: 300 psi
and diaphragm retainer. Then place lock washer over stem NOTE : All adjustments should be made with a pressure
threads along with the 5/16” diaphragm nut and tighten. gauge and while flowing water through the main valve.

ZURN WILKINS
4
®

1747 Commerce Way, Paso Robles, CA 93446 Phone:855-663-9876 Fax:805-238-5766

ISZW209FP-8-10 (REV. D 6/17) www.zurn.com