Installation Guide

ManualsBrandsZurn ManualsPlumbing4 in. Iron Pressure Reducing Valve with Low Flow Bypass

Model ZW209 & ZW209BP LEAD-FREE*

Pressure Reducing Valve Assembly & with Low Flow By-Pass

Globe and Angle Pattern Bodies

1 1/4", 1 1/2", 2", 2-1/2", 3", 4", 6", 8",10", 12", 14" & 16"

*Contains a weighted average lead content less than 0.25% for wetted surfaces

NOTE: Flushing of all pipe lines is to be performed to remove all

debris prior to installing valve.

NOTE: If installation is subject to very low ow or potentially static

conditions it is recommended a pressure relief valve (1/2" minimum)

be installed downstream of the pressure reducing valve for additional

system protection.

1. For making adjustments and servicing allow for adequate space around

the valve before installing valve.

2. When installing a ZW209 or ZW209BP, gate valves installed on both inlet

and outlet are recommended for maintenance allowing for isolation of valve.

3. Position the valve in line matching the direction of ow as indicated 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.

4. Zurn Wilkins valves are designed to operate in both the vertical and

horizontal positions. However, it is recommended that ZW209 6” and

larger, be installated in the horizontal position. The horizontal positioning

of the larger valves avoids premature wear due to the mass of plunger

assemblies as well as allows for greater accessibility during annual inspec-

tions, and maintenance.

ZW209 SCHEMATIC

STANDARD COMPONENTS

1 Main Valve

2 850MXL Isolation Valve

3 SXL Wye Type Strainer

4 Pressure Gauge

5 Restriction Tube Fitting

6 PRXL PRV (15-150 psi)

7 *PRXL Pressure Reducing

Control By-Pass (ZW209BP only)

 Installation  Troubleshooting  Maintenance Instructions

the valve assembly it is also recommended that a ZPI valve position

indicator be installed to aid in verifying proper valve movement.

3. 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. Use caution when loosening plugs. 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.

4. Before setting pilot valve, if valve is equipped with SC1 speed

controls (O or L on ZW209 schematic) it is necessary to back out the

adjusting screw a minimum of 3 turns from closed position.

5. At this point with the upstream supply shutoff valve partially open,

slowly open the downstream system shut off valve. Flow will begin to

occur and pressure should build up in valve and eventually stabilize.

6. Next it is advisable to ow water through the valve to ensure all air

has been escaped from system. High ow may be needed to ush all air.

With water owing through the valve the Zurn Wilkins Pressure Reducing

Valve (PRV) pilot can be set to the desired pressure. To adjust the pilot,

loosen jam nut on adjustment screw and either turn adjustment screw in

(to increase pressure) or out (to decrease pressure). Tighten jam nut on

pilot when the desired setting has been made. Flow at least 5-10 gpm

minimum. Higher ow is better for more accurate setting. If valve has a

low ow bypass, or a parallel installation, you must close a ball valve in

the bypass line and isolate any parallel valves.

7. For ZW209BP the low ow by-pass control must be set 5-10 psi

greater than main Pilot PRV. Isolate the main valve by closing the

downstream pilot ball valve below the pilot. Open the low ow bypass

ball valves. To set the low ow bypass, you only want a trickle of water

owing. Adjust the bypass PRV to 5 psi higher than the main pilot PRV.

If you cannot determine the ow, then close the downstream ball valve

and then slowly crack the downstream ball valve just until the needle on

the pressure gauge drops a small amount (a downstream valve must be

partially open to allow for a small amount of ow). Now set the bypass

statically 5 psi higher than the main pilot PRV setting. Once the bypass

PRV is set slowly open both ball valves on the bypass and open all 3 ball

valves in the main pilot PRV piping. Tighten the bypass PRV jam nut.

To verify proper operation of ZW209 & ZW209BP slowly close and open

downstream system shut off valve several times to ensure downstream

pressure is stable at set pressure.

8. After pilot system has been adjusted and the valve is properly regulat-

ing the main valve opening and closing speed controls (O or L) can be

adjusted as needed. Start with the opening speed control “O” three turns

from fully closed. Unscrew stem to speed up the valve opening (will help

if downstream pressure drops too far when there is a sudden increase of

demand). If wild pressure uctuations and chatter occur at low ow, turn

the setting screw in slowly until valve stabilizes. A closing speed control

“L” is not normally used on a pressure reducing valve because a closing

speed control can cause downstream high pressure surges. If present,

start with this wide open by unscrewing the stem completely. Adjust by

turning in to slow the closing speed only as needed, but never more than

three turns from fully closed. Tighten the locknuts on the speed controls

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. Open the pilot ball valves (2) in the pilot system (see ZW209 or

ZW209BP schematic).

2. Then slowly open the upstream supply shutoff valve only enough

to ll main valve assembly and pilot system. Prior to pressurizing

Troubleshooting

The following troubleshooting information in Tables deals strictly with the

ZW209 and ZW209BP valve and pilot systems. It is recommended to

verify that the pilot system is properly functioning before troubleshooting

the main valve. All trouble shooting can be

Installation / Start-up

FLOW

OPTIONAL FEATURES

C 40XL Hydraulic Check w/

Isolation Valve

L SC1 Closing Speed Control

O SC1 Opening Speed Control

Z ZPI Valve Position Indicator

6 PV-PRD (20-200 psi)

! 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

Summary of content (5 pages)

PAGE 1
Model ZW209 & ZW209BP LEAD-FREE* Pressure Reducing Valve Assembly & with Low Flow By-Pass Globe and Angle Pattern Bodies ® 1 1/4", 1 1/2", 2", 2-1/2", 3", 4", 6", 8",10", 12", 14" & 16" *Contains a weighted average lead content less than 0.25% for wetted surfaces  Installation  Troubleshooting  Maintenance Instructions Installation / Start-up NOTE: Flushing of all pipe lines is to be performed to remove all debris prior to installing valve.
PAGE 2
Troubleshooting performed without disassembly. It is also recommended to permanently install a model ZPI valve position indicator. PILOT SYSTEM FUNCTION CHECK 1. To verify if the Pilot PRV is properly regulating pressure, first slowly close the downstream pilot and bypass ball valves in the pilot systems. Allow the cover to fill and the main valve to close. To close the valve, it may be necessary to open a downstream valve so there is flow going through the ZW209.
PAGE 3
DIAPHRAGM MOVEMENT CHECK 1. The diaphragm movement check can be determined during the diaphragm check by removing the top center plug or it can It can also be performed with the use of a valve position indicator model ZPI. 2. Replace cover plugs and open pilot ball valves on upstream and cover. 3. Closing the downstream pilot ball valves will direct the flow to the cover causing it to close.
PAGE 4
INSPECTION OF COMPONENTS Cleaning of components is required for proper inspection. Lime deposits are common in systems that use water. To remove deposits, fine grit wet/dry sandpaper (400 grit or higher) can be used. If deposits cannot be removed, off the shelf lime deposit remover can be used. Prepare a solution following the lime deposit remover instructions and soak components (excluding rubber components) until lime deposits are removed.
PAGE 5
Flow Characteristics BODY MINIMUM FRICTION LOSS le 8 An " G gl lob e e 10 "G lo be 12 "G lo be 14 "G lo be 16 "G lo be 8" 6" 6" A n Gl gl obe e 4" G lo b e & An gl e ng 2 An " G gle lob e 2- 21/ 1/ 2" 2" An G gle lob e 3" 3" An G gl lob e e 10 "A ng le 2" 1 ob -1/2 "A e Gl An gle & 10 11/ 2" 11/ 4" Gl ob e PRESSURE DROP (PSI) 100 1 0 10 100 1000 FLOW (GPM) 10000 PRESSURE REDUCTION LIMIT Damage Zone 300 Cavitation damage zone (intermittent operation allowed) 250 INLET PRESSURE