Zurn Wilkins 6-ZW209HP Installation, Troubleshooting, Maintenance Instructions

Model ZW209H
Pressure Reducing and Pressure Sustaining Valve
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

Installation / Start-up
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 flow 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 ZW209H, 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 flow as indicated on
the valve model tag with the proper direction of flow 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 ZW209H 6" and
larger, be installed 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.
ZW209H SCHEMATIC
STANDARD COMPONENTS
1 Main Valve
2 850MXL Isolation Valve
3 SXL Wye Type Strainer
4 Pressure Gauge
5 Restriction Tube Fitting
6 PRXL Pressure Reducing Control
7 PV-RLF Pressure Relief Valve
START-UP
CAUTION: To prevent personnel injury and damage to equipment check
that downstream venting is adequate prior to start-up and test pro-
cedures. All adjustments under pressure should be made slowly
while under flowing conditions. If the main valve closes too fast it
may cause surging in upstream piping.
1. Open isolation valves (2) in the pilot system (see ZW209H sche-
matic).
2. Then slowly open the upstream shutoff valve only enough to fill main
valve assembly and pilot system.
!
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
®
LEAD-FREE*
Troubleshooting

OPTIONAL FEATURES
C 40XL2 Hydraulic Check w/
Isolation Valve
L SC1 Closing Speed Control
O SC1 Opening Speed Control
Z ZPI Valve Position Indicator
1747 Commerce Way, Paso Robles, CA 93446 Phone:855-663-9876 Fax:805-238-5766
Maintenance Instructions

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.
3. 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
plugs or fittings 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 fittings. 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 valve, if valve is equipped with SC1 Flow controls (O
or L on ZW209H schematic) it is necessary to back out the set screw a
minimum of 3 turns from initial set point.
5. Turn the relief pilot adjustment screw counterclockwise until the screw
starts to spin freely to lower the relief pressure so the pressure reducing
pilot can be set first.
6. 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.
7. Next it is advisable to flow water through the valve to ensure all air
has escaped from system. With water flowing through the valve the
Zurn Wilkins PRV pilot can be set to the desired pressure. To adjust the
pressure reducing pilot, loosen jam nut on adjustment screw and either
turn adjustment screw in (to increase outlet pressure) or out (to decrease
outlet pressure). Tighten jam nut on pilot when the desired setting has
been made.
8. To verify proper operation of ZW209H close and open downstream
shut off valve several times to ensure downstream pressure is stable at
set pressure.
9. Next the relief/sustaining pilot must be set at the desired sustaining
pressure. With water still flowing through the main valve use the up-
stream isolation valve to throttle water flow into the ZW209H. Close the
upstream isolation valve until the inlet pressure at the ZW209H is below
the desired sustaining set pressure.
10. With water flowing through the ZW209H start to turn the relief/sus-
taining pilot adjustment screw clockwise until the valve starts to modulate
and the inlet pressure starts to increase. Continue turning the adjustment
screw clockwise until the inlet pressure is at the desired set pressure.
11. If the inlet pressure cannot be adjusted lower than the desired set re-
lief/sustaining pressure then set the relief valve by turning the adjustment
screw clockwise until the spring is fully compressed. The control valve
will close. Next, slowly turn the adjustment screw counterclockwise until
water starts to flow through the control valve. Now the relief valve is set
to the current inlet pressure. Use the table on the next page to set the re-
lief pressure at a different pressure than the current inlet pressure. Turn
the adjustment screw clockwise to increase set pressure or counter-
clockwise to decrease set pressure. Add or subtract from the current inlet
pressure by turning the adjustment screw the number of turns required to
reach the desired set pressure based on the adjustment table.
®
ZURN WILKINS
1
www.zurn.com