TABLE OF CONTENTS PICV IOM - Warren Controls Inc. · picv_iom_revf_0114 One of the primary factors...

This document covers the installation, operation and maintenance of Series PICV (Pressure Independent Control Valves). The Series PICV maximizes efficiency and energy savings by providing precise control of maximum differential temperatures across a coil or heat exchanger independent of variations in system pressure. The Series PICV consists of two functional controlling segments. The first segment is an electrically actuated control valve, capable of responding to a control signal from a controller that is not part of the PICV. The second segment is connected in series with the first, and serves to sense and regulate a preset flowing differential pressure across the control valve segment. Both segments include pressure balanced control elements of industrial quality manufactured in accordance with ISO 9001. The PICV has a rangeability of 50:1, meaning that

good control performance can be achieved when the minimum flow requirement is as low as 1/50 of the maximum flowing GPM (LPS). A wide range of sizes, materials of construction, pressure ratings and control characteristics provide flexible configuration to meet almost any specification or system requirement. The Series PICV is factory assembled, complete with sensing lines, check valve pressure taps, and actuators, and is ready for field installation as a complete unit. The Series PICV is pre-calibrated to a customer-specified set differential pressure from 2-8 PSIG (0.14-0.55 BARG), and includes a means for calibration adjustment. A separate, customer supplied, differential pressure gauge may be installed between the check valve pressure taps on the PICV to allow for monitoring of the set differential pressure.

SERIES PICV(Pressure Independent Control Valve)

TABLE OF CONTENTSOverview / Operation ....................COVER

Configurations ...........................................2-3

Differential Pressure..............................4-8

Installation ...................................................8-9

Dimensions .......................................... 10-12

Weights .........................................................13

Maintenance ...............................................13

Water Quality ..................................... 13-14

VM5000E & VM1500E................ 15-22

TR5000X ............................................. 23-27

DPRV Actuator ..........................................28

Parts/Overhaul ................................. 32-37

Stem Adapter Setting Gages ..............38

HIGH CAPACITY

NOTE: The maximum differential pressure across the entire PICV is approximately 2 x (Set Differential Pressure) at max flow

PIC

V IO

M

PICV_IOM_REVF_0114

One of the primary factors that influence the flow of fluid through a control valve is the amount of pressure, or differential pressure across it. At any point in valve plug travel, flow through a valve will typically increase if differential pressure is raised, and decrease if it is lowered. A change in pumping pressure can therefore produce a change in rate of flow that is not related to the system controller’s output signal. With pressure independence, the amount of water flowing through a valve and the controlled load (i.e. heat exchanger coil) is more accurately controlled as a function of the control signal, and is less dependent upon varying pump pressure. Stability in the control system is enhanced when pressure independence is provided, and the control valve’s installed flow characteristic more closely resembles its inherent, or constant-pressure characteristic.

The Series PICV (Pressure Independent Control Valve) consists of two functional controlling segments. The first segment is a pressure-balanced control valve, actuated by either a high-thrust electric motor

actuator or pneumatic diaphragm actuator. The electric actuator provides precise positioning of the valve closure mechanism, and responds quickly and precisely to the electronic control signals supplied to them. The second segment is a differential pressure control valve that operates independently of the control valve segment. This segment is self-powered (self-operating) and does not burden or interact with the building automation control system. By quickly raising or lowering its own resistance to flow, the differential pressure control segment of the PICV regulates and stabilizes the pressure drop across the control valve segment by absorbing unused head pressure. This compensates for changes in pumping pressure resulting from pump switching or from varying flow demands in it’s own, or parallel flow paths and results in pressure independent operation.

OVERVIEW

OPERATION

VALVE BODIES

Body Material: Cast IronEnd Connections: ANSI 125LB FF Flanges, PN16 FF FlangesTrim Designs: Type 23 - Single Seat Cylinder Balanced, ANSI Class III Leakage Type 22 and 72 - Double Seat Balanced, ANSI Class III LeakageTrim Material: Bronze or 300 Series Stainless Steel EPDM Seal (Type 23 w/Bronze Trim) Fluoraz Seal (Type 23 w/Stainless Steel Trim)Fluid: Chilled Water Typical, Water or Water/Glycol from 35 °F- 180°F (2°C - 82°C )Trim Limits: Stainless Steel: MAX Flowing Differential Pressure, 150 PSIG (10.3 BARG) Bronze: MAX Flowing Differential Pressure, 100 PSIG (6.9 BARG)Packing: Long-Life Multi-Stack EPDM Lip Packing - Water / Water-Glycol Service

ELECTRIC ACTUATOR SPECIFICATIONS (VM-1500E AND VM-5000E)

Valve Usage: VM-1500E [Valve sizes 2 1/2, 3 & 4 Inch DN65, DN80 & DN100], VM-5000E [Valve sizes 5, 6, 8 & 10 Inch DN125, DN150, DN200, DN250]Control Signal: 4-20 mAdc (Factory Setting), 0-20 mAdc, 0-10 Vdc or 2-10 Vdc and Floating, Self-Adjusting, Field Selectable (Dip Switch)Power Consumption: VM-1500E 12VA, VM-5000E 25VATiming: VM-1500E [102 sec. / inch, 4.02 sec. / mm], VM-5000E [76 sec. / inch, 2.99 sec./mm]Feedback Signal: 4-20 mAdc (Factory Setting), 0-10 Vdc or 2-10 VdcFailure Mode: Fail-As-Is [Without VMS-25 BCM (Back-up Control Module)] Fail-Safe [With VMS-25 BCM (Back-up Control Module)]Manual Override: YesConstruction: Polycarbonate Motor Housing with Steel Linkage & Yoke. Case has one 1/2 inch (1.27 cm) NPSM Conduit AdapterConnections: Coded Screw TerminalsLocations: NEMA Type 3 / IP54Temperature Limits: Ambient 32°F - 122°F ( 0°C - 50°C )Mounting: Factory Aligned, Vertical Above Centerline of Control Valve Consult factory for preconfigured alternate orientations

VMS-25 BCM (BACK-UP CONTROL MODULE) SPECIFICATIONS

Actuator Usage: VM-1500E & VM-5000ERequired for Fail Safe OperationFailure Direction: Field SelectablePower Consumption: 24VAC, 40VAConstruction: Battery w/Circuit Board & Transformer, in Nema 4 EnclosureMounting: Wall Mount Weight: 4.25 lbs (2 kg)

Body Pressure Temperature Ratings Iron Body Temperature 125 FLG & PN16 OF OC PSIG BARG35 to 180 1.7 to 82.2 150 10.20

CONFIGURATIONS

Control Valve Size

Control Valve Flange

Control Valve Profile

Control Valve Trim Size

Control Valve Trim Material

Control Valve Motor

DPRV Size

DPRV Flange

DPRV Trim Material

DPRV Actuator

0 ANSI 125 Flanges

2 PN16 Flanges

22 Type of Control Valve Body (Sizes P8 & P1)

23 Type of Control Valve Body (Sizes P2-P6)

F Control Valve Trim Size Full

X Control Valve Trim Size Extended

1 Control Valve Trim Size 1SR

2 Control Valve Trim Size 2SR

S Stainless SteelB Bronze

E020 VM1500E - Fail As Is

E021 VM1500E - w/VMS-25 BCM

E022 VM5000E - Fail As Is

E023 VM5000E - w/ VMS-25 BCM

TIG1 TR5000-X -Fail As Is for all exceot P6_23XX Extended Port

TIG2 TR5000-X -Fail As Is Extended Port Only

0 ANSI 125 Flanges

2 PN16 Flanges

Note: Must match control valve

DS DPRV Type 72 Portion w/ SS Trim

DB DPRV Type 72 Portion w/ Brz Trim

2L DPRV Actuator Cast Iron, w/ Low DP Spring

2M DPRV Actuator Cast Iron, w/ Medium DP Spring

P2 2.5” DN65P3 3” DN80P4 4” DN100P5 5” DN125P6 6” DN150P8 8” DN200P1 10” DN250

P2 2.5” DN65P3 3” DN80P4 4” DN100P5 5” DN125P6 6” DN150P8 8” DN200P1 10” DN250

3PRESSURE INDEPENDENT CONTROL VALVE PICV_IOM_REVF_0114

DPRV DOUBLE ACTING DIAPHRAGM ACTUATOR WITH SPRING ASSIST

Control Signal: Differential Pressure from Control Valve, 2.0 to 8 PISG (0.14 to 0.55 BARD) 150 PSIG (10.3 BARD) Max StaticFluid: Chilled Water Typical, Water or Water/Glycol from 35 °F- 180°F (2°C - 82°C )Spring Pack: Low DP Spring: Adjustable 2 to 6 PSIG (0.14-0.41 BARD) Medium DP Spring: Adjustable 5 to 8 PSIG (0.34-0.55 BARD) Construction: Cast Gray Iron Class G3000, epoxy coated, epoxy coated spring, SS components, Woven Buna-N, nylon reinforced.Temperature Limits: Ambient 32°F - 122°F ( 0°C - 50°C )Mounting: Factory Aligned, Vertical Above Centerline of Control Valve Consult factory for preconfigured alternate orientations

ELECTRIC ACTUATOR SPECIFICATIONS (TR5000-X)Valve Usage: 5, 6, 8, & 10 inch, DN125, DN150, DN200, DN250Control Signal: 4-20 mAdc (Factory Setting), 0-10 Vdc, 2-10 Vdc, or 0-20 mAdc; Field Selectable (Dip Switch)Control Action: Direct Acting, Actuator Shaft Extends on Increasing Signal (Factory Setting) or

Reverse Acting, Actuator Shaft Retracts on Increasing Signal; Field Selectable (Dip Switch)Power Supply: 220 VAC Power Consumption: 12VA Timing: 90.68 Seconds / Inch (3.57 s/mm) Feedback Signal: 4-20 mAdc (Factory Setting), 0-10 Vdc, 2-10 Vdc, or 0-20 mAdc

Field Selectable (Dip Switch); Feedback Signal Increase as Actuator Shaft Extends (Factory Setting) or Feedback Signal Increases as Actuator Shaft Retracts; Field Selectable (Dip Switch)

Failure Mode: Fail Actuator Shaft Retracted on Loss of Signal (Factory Setting) or Fail Actuator Shaft Extended on Loss of Signal Field Selectable (Dip Switch); Actuator Shaft Fails In Last Position on Loss of PowerManual Override: Yes Construction: Die Cast Aluminum Motor Housing & Yoke. Painted.

Case Has Two PG11 Cable Glands Accepts 0.197 to 0.394 inch (5mm to 10mm) Diameter CableConnections: Coded Screw Terminals Locations: NEMA Type 3 / IP54 Temperature Limits: Ambient 14˚F to 122˚F ( -10˚C to 50˚C )Relative Humidity: < 95% RH (40ºC)Mounting: Factory Aligned, Vertical Above Centerline of Control Valve; Consult factory for preconfigured alternate orientations

4X 0.31 in (0.79 cm) THRU MOUNTING FOOT

8.75 in (22.23 cm)

6.69 in (16.99 cm)

6.72 in(17.O7 cm)

4.91 in(12.47 cm)

6.97 in(17.7O cm)

5.19 in (13.18 cm)

1/2 in (1.27 cm)

8.5 in (21.59 cm)

VMS-25 BCM

4 2600 Emrick Blvd • Bethlehem, PA 18020 • USA • 800-922-0085 • www.warrencontrols.com

PRODUCT MODEL (where ‘x’ is a configurable option)

LOW DP SPRING PERFORMANCE

MEDIUM DP SPRINGPERFORMANCEFLANGE

ANSI125 P2023Fx-xxxx-P20Dx-2x

2 1/2” Standard Port

ANSI125 P30231x-xxxx-P30Dx-2x

3” 1 Size Reduced Port


3” Standard Port


4” 2 Sizes Reduced Port




4” Standard Port






5” Standard Port

Set Differential Pressure (PSI)2.0 3.1 4.2 5.3

Maximum flow (GPM)92 114 133 150




































PRODUCT MODEL(where ‘x’ is a configurable option)


MEDIUM DP SPRINGPERFORMANCE FLANGE






6” Standard Port

ANSI125 P6023Xx-xxxx-P60Dx-2x

6” Extended Port

ANSI125 P80222S-xxxx-P80Dx-2x 8” 2 Sizes Reduced Port SS Trim Only

ANSI125 P80221S-xxxx-P80Dx-2x 8” 1 Size Reduced Port SS Trim Only

ANSI125 P8023Fx-E02x-P80Dx-2x

8” Standard Port

ANSI125 P10222S-xxxx-P10Dx-2x 10” 2 Sizes Reduced Port SS Trim Only

ANSI125 P10221S-xxxx-P10Dx-2x 10” 1 Size Reduced Port SS Trim Only
















Maximum flow (GPM)1003 1071 1127 1188




Maximum flow (GPM)1241 1326 1395 1471


Maximum flow (GPM)841 1048 1219 1370


Maximum flow (GPM)1421 1517 1597 1683


Maximum flow (GPM)962 1197 1394 1565


Maximum flow (GPM)1623 1734 1825 1923


Maximum flow (GPM)1039 1294 1506 1692


Maximum flow (GPM)1755 1874 1972 2079


Maximum flow (GPM)1188 1479 1721 1934


Maximum flow (GPM)2005 2142 2254 2376





PN16 P2223Fx-xxxx-P22Dx-2x

DN65 Standard Port

PN16 P32231x-xxxx-P32Dx-2x

DN80 1 Size Reduced Port


DN80 Standard Port


DN100 2 Sizes Reduced Port




DN100 Standard Port







10” Standard Port


Maximum flow (GPM)1358 1690 1967 2210


Maximum flow (GPM)2292 2448 2576 2715

Set Differential Pressure (BAR)0.14 0.21 0.29 0.37

Maximum flow (LPS)5.8 7.2 8.4 9.5


Maximum flow (LPS)9.8 10.5 11.0 11.6




Maximum flow (LPS)11.3 12.1 12.7 13.4




Maximum flow (LPS)13.5 14.5 15.3 16.0


Maximum flow (LPS)10.5 12.9 15.1 17.1


Maximum flow (LPS)17.6 18.9 19.9 20.8


Maximum flow (LPS)12.9 15.9 18.6 21.0


Maximum flow (LPS)21.6 23.2 24.5 25.7


Maximum flow (LPS)15.3 18.7 22.0 24.8


Maximum flow (LPS)25.5 27.4 28.9 30.3


Maximum flow (LPS)18.2 22.4 26.3 29.7


Maximum flow (LPS)30.5 32.7 34.5 36.2


PRODUCT MODEL (where ‘x’ is a configurable option)








DN150 Standard Port

PN16 P6223Xx-xxxx-P62Dx-2x

DN150 Extended Port

PN16 P82222S-xxxx-P82Dx-2x DN200 2 Sizes Reduced Port SS Trim Only

PN16 P82221S-xxxx-P82Dx-2x DN200 1 Size Reduced Port SS Trim Only

PN16 P8223Fx-E02x-P82Dx-2x

DN200 Standard Port




DN125 Standard Port


Maximum flow (LPS)21.3 26.1 30.7 34.6


Maximum flow (LPS)35.6 38.2 40.3 42.2


Maximum flow (LPS)24.3 29.7 34.9 39.5


Maximum flow (LPS)40.5 43.5 45.9 48.1


Maximum flow (LPS)24.7 30.3 35.6 40.2


Maximum flow (LPS)41.3 44.3 46.7 49.0


Maximum flow (LPS)28.3 34.7 40.8 46.0


Maximum flow (LPS)47.3 51 54 56


Maximum flow (LPS)32.4 39.6 46.6 53


Maximum flow (LPS)54 58 61 64


Maximum flow (LPS)37.8 46.2 54 61




Maximum flow (LPS)46.7 57 67 76












INSTALLATION

Recommended Piping: ANSI 125 Flanges should mate with piping with 125 Lb or 150 Lb Flat Faced Flanges.

Per ISA Recommended Piping Practices. Control valves perform best with a reasonable amount of upstream and downstream straight pipe prior to elbows and strainers. The general specification for this is 16 pipe diameters upstream of straight pipe and 5 pipe diameters downstream of straight pipe as minimums. However, this is a broad specification covering all pipe diameters and velocities. Many applications do not have this kind of space. While more length of straight pipe is desirable, Warren Controls has produced a table of minimum pipe diameters for use on our PICV. Failure to follow these guidelines may lead to noticeable vibrations or noise for excessive turbulence in some applications with significant head pressure. In the unlikely event of excessive noise or vibration, other remedies like special low noise trim may be available but at the expense of the user or installer when not following installation guidelines.





DN250 Standard Port

PN16 P12222S-xxxx-P12Dx-2x DN250 2 Sizes Reduced Port SS Trim Only

PN16 P12221S-xxxx-P12Dx-2x DN250 1 Size Reduced Port SS Trim Only

The above tables are recommended minimum lengths for good and stable performance. Wherever possible, longer runs of straight pipe should be used for optimal performance and stability.

• Besurethattheflowmedium,ambienttemperatureandtheselectedlocationwillnotexceedthemaximumtemperatureofthePICV,actuator, or accessories. Information can be found on the nameplate and product specifications regarding these limits.

• CheckPICVforanydamageduetoimproperstorageortransportation.Immediatelynotifyyoursalesorganizationofanydamagedgoods upon receipt. Do not attempt to move or disturb them further so photos may be taken. If the shipping container is noticeably damaged, refuse receipt as the shipping company should be held liable, until a shipping representative is available to take photos.

• VerifythatthePICVisvisuallyingoodworkingorder–notbentorcracked.

• Followgoodpipingpractices.InstallabypassaroundthePICV.InstallstopvalvesininletandoutletpipingtoprovidemeanstoisolatePICV.

• THEPICVSHOULDBEINSTALLEDASAUNIT.THESEGMENTSSHOULDNOT BE SEPARATED FOR INSTALLATION.

• CarefullyremovethePICVfromshippingcratewithaportablehoistorcrane.ThePICVistooheavyforoneoreventwopeopletoliftand hand-install depending on size. The Crane or Hoist should use a strap or chain cradle around the central flanges of the two valve assemblies to raise and maneuver the PICV into position at the pipe flanges. Efforts should be made to avoid damaging the sensing lines and actuators during this installation procedure.













PICV Minimum Lengths of Straight Pipe

PICV Size Upstream Straight Pipe

DownstreamStraight Pip

2 ½” (DN65) 16” (40.64 cm) 12” (30.48 cm)3” (DN80) 16” (40.64 cm) 12” (30.48 cm)4” (DN100) 16” (40.64 cm) 12” (30.48 cm)5” (DN125) 24” (60.96 cm) 12” (30.48 cm)6” (DN150) 32” (81.28 cm) 12” (30.48 cm)8” (DN200) 36” (91.44 cm) 14” (35.56 cm)10” (DN250) 40” (101.6 cm) 16” (40.64 cm)


• ProtectPICVanddownstreamequipmentwithanupstreamself-cleaningstrainer.

• FormaximumefficiencyandminimumwearinstallPICVIN VERTICAL POSITION with the stems POINTING UPWARD.

• Besuretoleave 6 INCHES (15.24 CM) OF CLEARANCE above the actuators to allow for actuator removal.

• Beforeinstalling,besurePICVandpipingareCLEAN INSIDE and FREE OF SCALE, chips, welding spatter, and foreign material. Thoroughly blow out or flush pipe lines.

• ThePICVmustbeinstalledwiththefluidflowinthedirectionofthearrowontheflowarrowplate.

• PipesmustbealignedsquarelywiththePICVateachconnection.

• Tightenflangeboltsevenlytopreventexcessivestressandthepossibilityofcracking.Ifmatingflangesareraisedfacedtheymustbemachined flat.

• ThePICVandaccessories(ifsoequipped)areassembled,tested,andcalibratedatthefactoryasaunit.Thenameplatespecifiesset-upparameters used.

• Supplyairorpower,instrumentsignal,andaccessoriesshouldbeconnectedtoportsorterminalsasindicatedonthePICV.

• Verificationandtuningofthesetdifferentialpressuremayberequiredunderactualoperatingconditions.


DIMENSIONS

PICV SIZES:2 1/2-4 IN (DN65-DN100)

Acv Adpv

Xcdp

Bdpv

cdpv

Hdpv

ddpv

dcv

Hcv

ccv

Bcv

WITH VM1500E ACTUATOR

Acv +/- 1/16 in (0.16 cm) All other dimensions are maximum Allow 6 in (15.24 cm) above actuator for removal service

* Includes gasket between Control Valve and Differential Pressure ValveAdpv +/- 1/16 in (0.16 cm) Xcdp +/- 1/8 in (0.32 cm) All other dimensions are maximumAllow 6 in (15.24 cm) above actuator for removal service

MODEL LISTING SIZE Acv Bcv Ccv Dcv Hcv

P2023xx-E02x-P20Dx-xx 2-1/2 9 in 4-3/4 in 5-3/4 in 4-7/8 in 14-3/4 inP3023xx-E02x-P30Dx-xx 3 10 in 5-3/8 in 6-5/8 in 4-7/8 in 14-3/4 inP4023xx-E02x-P40Dx-xx 4 13 in 6-3/8 in 7-3/4 in 4-7/8 in 14-3/4 inP2223xx-E02x-P22Dx-xx DN65 22.86 cm 12.07 cm 14.61 cm 12.38 cm 37.47 cmP3223xx-E02x-P32Dx-xx DN80 25.40 cm 13.65 cm 16.83 cm 12.38 cm 37.47 cmP4223xx-E02x-P42Dx-xx DN100 33.02 cm 16.19 cm 19.69 cm 12.38 cm 37.47 cm

Control Valve (Left)

Differential Pressure Valve (Right) Model Listing SIZE Adpv Bdpv Cdpv Ddpv Hdpv Xcdp

P2023xx-E02x-P20Dx-2L 2-1/2 7-3/4 in 4-7/8 in 4-1/8 in 9-3/4 in 22-1/8 in 16-13/16 inP2023xx-E02x-P20Dx-2M 2-1/2 7-3/4 in 4-7/8 in 4-1/8 in 9-3/4 in 26-3/4 in 16-13/16 inP3023xx-E02x-P30Dx-2L 3 9 in 5-1/8 in 4-3/8 in 9-3/4 in 22-1/8 in 19-1/16 inP3023xx-E02x-P30Dx-2M 3 9 in 5-1/8 in 4-3/8 in 9-3/4 in 26-3/4 in 19-1/16 inP4023xx-E02x-P40Dx-2L 4 11-3/8 in 6-3/8 in 5-1/4 in 9-3/4 in 22-1/8 in 24-7/16 inP4023xx-E02x-P40Dx-2M 4 11-3/8 in 6-3/8 in 5-1/4 in 9-3/4 in 26-3/4 in 24-7/16 inP2223xx-E02x-P22Dx-2L DN65 19.69 cm 12.38 cm 10.48 cm 24.77 cm 56.20 cm 42.70 cmP2223xx-E02x-P22Dx-2M DN65 19.69 cm 12.38 cm 10.48 cm 24.77 cm 67.95 cm 42.70 cmP3223xx-E02x-P32Dx-2L DN80 22.86 cm 13.02 cm 11.11 cm 24.77 cm 56.20 cm 48.42 cmP3223xx-E02x-P32Dx-2M DN80 22.86 cm 13.02 cm 11.11 cm 24.77 cm 67.95 cm 48.42 cmP4223xx-E02x-P42Dx-2L DN100 28.89 cm 16.19 cm 13.34 cm 24.77 cm 56.20 cm 62.07 cmP4223xx-E02x-P42Dx-2M DN100 28.89 cm 16.19 cm 13.34 cm 24.77 cm 67.95 cm 62.07 cm

Totalcombined*


DIMENSIONS PICV SIZES: 5-6 IN (DN125-DN150)

WITH TR5000 ACTUATOR WITH VM5000E ACTUATORWITH VM1500E ACTUATOR



MODEL LISTING SIZE Acv Bcv Ccv Dcv HcvP5023xx-E02x-P50Dx-xx 5 15-3/4 in 5-3/4 in 8-1/4 in 6-5/8 in 15-1/4 inP5023xx-TIG1-P50Dx-xx 5 15-3/4 in 5-3/4 in 8-1/4 in 7-1/2 in 16-1/4 inP6023xx-E02x-P60Dx-xx 6 17-3/4 in 6-1/2 in 8-7/8 in 6-5/8 in 15-1/4 inP6023xx-TIGx-P60Dx-xx 6 17-3/4 in 6-1/2 in 8-7/8 in 7-1/2 in 16-1/4 inP5223xx-E02x-P52Dx-xx DN125 40.01 cm 14.61 cm 20.96 cm 16.83 cm 38.74 cmP5223xx-TIG1-P52Dx-xx DN125 40.01 cm 14.61 cm 20.96 cm 19.05 cm 41.28 cmP6223xx-E02x-P62Dx-xx DN150 45.09 cm 16.51 cm 22.54 cm 16.83 cm 38.74 cmP6223xx-TIGx-P62Dx-xx DN150 45.09 cm 16.51 cm 22.54 cm 19.05 cm 41.28 cm

Model Listing SIZE Adpv Bdpv Cdpv Ddpv Hdpv XcdpP5023xx-xxxx-P50Dx-2L 5 12 in 6-7/8 in 7-5/8 in 9-3/4 in 22-1/8 in 27-13/16 inP5023xx-xxxx-P50Dx-2M 5 12 in 6-7/8 in 7-5/8 in 9-3/4 in 26-3/4 in 27-13/16 inP6023xx-xxxx-P60Dx-2L 6 14-1/8 in 7-5/8 in 8-1/2 in 9-3/4 in 22-1/8 in 31-15/16 inP6023xx-xxxx-P60Dx-2M 6 14-1/8 in 7-5/8 in 8-1/2 in 9-3/4 in 26-3/4 in 31-15/16 inP5223xx-xxxx-P52Dx-2L DN125 30.48 cm 17.46 cm 19.37 cm 24.77 cm 56.20 cm 70.64 cmP5223xx-xxxx-P52Dx-2M DN125 30.48 cm 17.46 cm 19.37 cm 24.77 cm 67.95 cm 70.64 cmP6223xx-xxxx-P62Dx-2L DN150 35.88 cm 19.37 cm 21.59 cm 24.77 cm 56.20 cm 81.12 cmP6223xx-xxxx-P62Dx-2M DN150 35.88 cm 19.37 cm 21.59 cm 24.77 cm 67.95 cm 81.12 cm


Differential Pressure Valve (Right) Total

combined*


DIMENSIONS

PICV SIZES: 8-10 IN DN200-DN250

WITH TR5000 ACTUATORWITH VM5000E ACTUATOR



MODEL LISTING SIZE Acv Bcv Ccv Dcv HcvP8022xx-E02x-P80Dx-xx 8 16-1/4 in 8-7/8 in 9-5/8 in 6-5/8 in 15 inP8022xx-TIG1-P80Dx-xx 8 16-1/4 in 8-7/8 in 9-5/8 in 7-3/8 in 16-1/4 inP1022xx-E02x-P10Dx-xx 10 20 in 9-5/8 in 10-1/8 in 6-5/8 in 15 inP1022xx-TIG1-P10Dx-xx 10 20 in 9-5/8 in 10-1/8 in 7-3/8 in 16-1/4 inP8222xx-E02x-P82Dx-xx DN200 41.28 cm 22.54 cm 24.45 cm 16.83 cm 38.10 cmP8222xx-TIG1-P82Dx-xx DN200 41.28 cm 22.54 cm 24.45 cm 18.73 cm 41.28 cmP1222xx-E02x-P12Dx-xx DN250 50.80 cm 24.45 cm 25.72 cm 16.83 cm 38.10 cmP1222xx-TIG1-P12Dx-xx DN250 50.80 cm 24.45 cm 25.72 cm 18.73 cm 41.28 cm


Differential Pressure Valve (Right) Model Listing SIZE Adpv Bdpv Cdpv Ddpv Hdpv Xcdp

P8022xx-xxxx-P80Dx-2L 8 16-1/4 in 8-7/8 in 9-5/8 in 9-3/4 in 22-1/8 in 32-9/16 inP8022xx-xxxx-P80Dx-2M 8 16-1/4 in 8-7/8 in 9-5/8 in 9-3/4 in 26-3/4 in 32-9/16 inP1022xx-xxxx-P10Dx-2L 10 20 in 9-5/8 in 10-1/8 in 9-3/4 in 22-1/8 in 40-1/16 inP1022xx-xxxx-P10Dx-2M 10 20 in 9-5/8 in 10-1/8 in 9-3/4 in 26-3/4 in 40-1/16 inP8222xx-xxxx-P82Dx-2L DN200 41.28 cm 22.54 cm 24.45 cm 24.77 cm 56.20 cm 82.71 cmP8222xx-xxxx-P82Dx-2M DN200 41.28 cm 22.54 cm 24.45 cm 24.77 cm 67.95 cm 82.71 cmP1222xx-xxxx-P12Dx-2L DN250 50.80 cm 24.45 cm 25.72 cm 24.77 cm 56.20 cm 101.76 cmP1222xx-xxxx-P12Dx-2M DN250 50.80 cm 24.45 cm 25.72 cm 24.77 cm 67.95 cm 101.76 cm

Totalcombined*


PACKING ADJUSTMENT

Series PICV packing is self-adjusting and requires no external adjustment.

MAINTENANCESeries PICV (Pressure Independent Control Valves) are for the most part

maintenance free when properly selected and installed. Rebuilding of these valves should not be necessary under normal operating conditions. For best operation

follow installation guidelines (See Installation); maintain the fluid pressures, temperature, and flow within the limits of the valve (See Specification Section and PICV Product Specification for details). In installations where high vibration exists,

electrical and sensing connections should periodically be checked for integrity. Water should be in specification of the Warren Controls water quality guidelines.

UNDER NORMAL OPERATING CONDITIONS AND GOOD WATER QUALITY MANY YEARS OF MAINTENANCE FREE SERVICE CAN BE EXPECTED!

PICV WEIGHTS

Control Valves in HVAC Water SystemsFluid Quality and Service Life Guide LinesThe purpose of these guidelines is to avoid valve and water systems problems caused by poor water quality in HVAC systems. While all cooling and heating systems are susceptible to problems, closed chilled water systems, including those containing brine or glycol, are especially prone to system and valve problems. To achieve the satisfactory operation and maximum life of your Warren Controls valve, it is important that the following recommendations are adhered to and that a water treatment, filtration and control specialists be consulted before the system start-up.

Weights for models with VM actuators do not include a VMS-25 BCM. Add 4.25 lbs (2kg) Actual shipping weights may vary.

MODEL PICV SIZECONTROL VALVE

ACTUATORDPRV

ACTUATOR TOTAL WT (LBS) TOTAL WT (KG)

P2x23xx-E02x-P2xDx-2L 2-1/2 in, DN65 VM-1500E 2L 144.00 65.32P2x23xx-E02x-P2xDx-2M 2-1/2 in, DN65 VM-1500E 2M 147.25 66.79P3x23xx-E02x-P3xDx-2L 3 in, DN80 VM-1500E 2L 172.00 78.02P3x23xx-E02x-P3xDx-2M 3 in, DN80 VM-1500E 2M 175.25 79.49P4x23xx-E02x-P4xDx-2L 4 in, DN100 VM-1500E 2L 262.00 118.84P4x23xx-E02x-P4xDx-2M 4 in, DN100 VM-1500E 2M 265.25 120.32P5x23xx-E02x-P5xDx-2L 5 in, DN125 VM-5000E 2L 345.00 156.49P5x23xx-E02x-P5xDx-2M 5 in, DN125 VM-5000E 2M 348.25 157.97P5x23xx-TIG1-P5xDx-2L 5 in, DN125 TR5000-X 2L 335.40 152.14P5x23xx-TIG1-P5xDx-2M 5 in, DN125 TR-5000-X 2M 338.65 153.61P6x23xx-E02x-P6xDx-2L 6 in, DN150 VM-5000E 2L 438.00 198.68P6x23xx-E02x-P6xDx-2M 6 in, DN150 VM-5000E 2M 441.25 200.15P6x23xx-TIGx-P6xDx-2L 6 in, DN150 TR5000-X 2L 428.40 194.32P6x23xx-TIGx-P6xDx-2M 6 in, DN150 TR-5000-X 2M 431.65 195.80P8x22xx-E02x-P8xDx-2L 8 in, DN200 VM-5000E 2L 652.00 295.75P8x22xx-E02x-P8xDx-2M 8 in, DN200 VM-5000E 2M 655.25 297.22P8x22xx-TIG1-P8xDx-2L 8 in, DN200 TR5000-X 2L 642.40 291.39P8x22xx-TIG1-P8xDx-2M 8 in, DN200 TR-5000-X 2M 645.65 292.86P1x22xx-E02x-P1xDx-2L 10 in, DN250 VM-5000E 2L 945.00 428.65P1x22xx-E02x-P1xDx-2M 10 in, DN250 VM-5000E 2M 948.25 430.12P1x22xx-TIG1-P1xDx-2L 10 in, DN250 TR5000-X 2L 935.40 424.29P1x22xx-TIG1-P1xDx-2M 10 in, DN250 TR-5000-X 2M 938.65 425.77

!DANGER

Personal injury may result from uncontrolled release of spring force. There is significant preload on the spring in the actuator on the differential pressure control segment (DPRV) of the PICV. Disassembling the actuator will release the spring force (preload) and may cause serious personal injury.


VALVE PACKING LEAKS

The service life of valve stems and packing is dependent on maintaining non-damaging fluid conditions. Inadequate treatment or filtration, not in accordance with the recommendations of this guide, or a qualified treatment specialist, can result in corrosion, scaling, or abrasive particle formation. Scale and particles migrating from pipe walls to control valves, will result in scratching the valve stem, which will prevent the packing from sealing. This problem can be avoided by the use of proper cleaning, treatment chemicals, and storage procedures. Water must be treated and soft. Trace leaks of hard water result in hard calcium carbonate particles on the outside of the valve, which will scratch the sealing members creating a packing leak. To avoid a damaging condition, the system should be cleaned prior to start-up. Filtration equipment and strainers should be employed as required and a regularly scheduled program of water condition monitoring and treatment should be followed. Side stream water filtration may be needed in closed systems, if there is no regular blow down of the system.

Control valve ‘hunting’ will cause excessive stroking of the valve stem and result in premature failure of the valve packing seal. The system must be stabilized to ensure reasonable packing life and optimal control performance.

Over sizing of a control valve will result in an un-stable condition, can result in, noise, vibration, premature trim and packing seal failure. The use of the Warren Controls ValveWorks sizing program

Will facilitate the selection of the optimum valve.

COMMISSIONING

Thorough flushing of the system is necessary before start-up as new systems, or old systems that have been shut down for an extended period of time, will usually contain dirt, Weld slag, solder flux, and pipe scale.

Water hardness should be less than 100 ppm of hard water ions (Ca++, Mg++), where 17.1 ppm = 1 Grain Hardness. Additionally, levels of chloride and sulfate should remain less than 25 ppm. When water hardness is at unacceptable levels, a water softener expert should be consulted.

ANTIFREEZE SOLUTIONS-GLYCOLS

The commonly used heat transfer glycol fluids are, either ethylene glycol or propylene glycol. Glycol concentrations of <25% often do not provide sufficient corrosion inhibiting properties and at levels <20% can actually provide a food source for bacteria. As bacteria consume the food and die off, a highly acidic condition can result. The recommended concentration for popular glycol based solutions is 25% to 60%.

WATER QUALITY RECOMMENDED PARAMETERS

Chilled Water, Closed Loops, and Hot Water Systems up to 212°F (100° C). 8.0 < pH < 10.3 Conductivity < 3000 MMHS Iron < 0.5 ppm Copper < 0.5 ppm100 ppm < Molybdenum < 150 ppm (Mild Steel Corrosion Inhibitor)

200 ppm < Molybdenum < 250 ppm (Mild Steel Corrosion Inhibitor)400 ppm < Nitrite < 1000 ppm (Mild Steel Corrosion Inhibitor) Azole > 5 ppm free and available (Yellow Metal Inhibitor) Bacteria < 1000 cells/ml (when system is cool)

Chilled Systems

Hot Systems

!CAUTION

The use of hydrazine can result in the formation of ammonia and must be con-trolled to prevent stress cor-rosion and embrittlement, which can lead to fracture of some brass alloys.

STORAGE

Systems that are stored wet should be completely filled with properly treated water and isolated to avoid slow leaks, which can cause serious corrosion problems.

Drained system should be air dried, sealed, and treated with a desiccant to prevent “atmospheric corrosion” of pipes, which is a major source of pipe scale.


VM5000E & VM1500E

ACTUATOR INSTRUCTIONS

Page

Actuator Set-up & Wiring .....................16-18

VMS-25 Installation & Wiring ....................18

VM1500E 4-20mA Feedback Kit .................19

VM5000E 4-20mA Feedback Kit ................20

VM1500E Removal & Installation ..............21

VM5000E Removal & Installation ..............21


When the actuator settings are known, it is easier to make them before the valve and actuator are installed in the system. When power is first applied to the actuator, check to see that it moves through its full range. If it does not, reset it by moving switch #9.

MANUAL OPERATION AND OVERRIDE

The actuator can be manually operated with a metric hex wrench. The VM1500E uses a 4mm hex wrench. The VM5000E uses an 8mm hex wrench. The socket is on top of the actuator. VM5000E actuators have a clutch button that must be depressed while manually operating the actuator. De-Energize the actuator before manual operation.

OVERRIDE: Connecting the neutral (terminal SN) to terminal 1 lowers the stem and to terminal 3 raises the stem. This can be done by an external switch or controller.

AUTOMATIC STROKE ADJUSTMENT

The stroke adjusts itself automatically. This happens the first time power is applied or whenever the position of switch #9 is changed.

Adjustment takes several minutes during which the actuator will move through its full stroke 2 or 3 times. The actuator remembers the settings so a power failure does not cause the actuator to reset itself. The automatic stroke adjustment does not work if the valve stroke is greater than the limits of the actuator. The maximum strokes are:

VM1500E 1 1/2” 40 MM

VM5000E 2 1/8” 55 MMAutomatic stroke adjustment ensures that the signal range covers the actual stroke of the valve.

RESET

Changing the position of switch #9 makes the actuator recalculate the stroke. Do this if the actuator has been used on another valve, tested without being on the valve, has been incorrectly mounted on the valve, or has been taken off of the valve and reinstalled.

CONTROL SIGNALS

The actuator must be set for the control signal being used and whether the signal is direct acting or reverse acting.The acceptable signals are: 24 VOLTS AC 3 POINT FLOATING or any of the following proportional signals.

24 volts ac

Terminal 1 Stem downTerminal 3 Stem up

Feedback Positive0 - 10 or 2 - 10 Vdc

Control signalPositive

24 volts ac

Common and control signal negativeIf system is grounded, then ground SN

SET-UPSP ........................ 24 volts AC power inSN ....................... Common (Ground) and control signal negative (See wiring diagrams)Y .......................... Control signal in (Positive)X .......................... Feedback signal out (Positive)1 .......................... Override3 .......................... Override

SWITCH FUNCTIONS Switch OFF ON

1 Voltage Control Signal Milliamp Control Signal2 2 - 10 Volts or 4 - 20 ma 0 - 10 volts or 0 - 20 ma3 Direct Acting Reverse Acting

(Extend on increasing signal) (Retract on increasing signal)4 Full Range Split Range5 Low Range Signal High Range Signal6 Proportional 3 Point Floating7 Equal Percentage Valve (Default) Linear Valve8 (Default) DO NOT USE9 Reset Reset

In the override position the Actuator is driven to the end position. Connecting to terminal 1 drives the stem down. Connecting to terminal 3 drives the stem up.

24 volts ac

Common andcontrol signal negative

Override


Full Range Split Range0 - 10 vdc 0 - 5 vdc 5 - 10 vdc2 - 10 vdc 2 - 6 vdc 6 - 10 vdc0 - 20 ma 0 - 10 ma 10 - 20 ma4 - 20 ma 4 - 12 ma 12 - 20 ma

Split ranges allow two actuators to be operated in sequence from one full range signal. Proportional signals are programmed with switches 1 - 5. The actuators are set for floating control by turning on switch #6. Turning switch #6 on deactivates switches 1 - 5. Please note the wiring for floating control differs from the wiring for proportional control.

SELECTING THE SIGNALFloating Switch #6 ON When switch #6 is on switches 1-5 are inactive.

Proportional Switch #6 OFF

SIGNAL SWITCH NUMBER VOLTS 1 2 4 5 2 - 10 OFF OFF OFF OFF 0 - 10 OFF ON OFF OFF 2 - 6 OFF OFF ON OFF 6 - 10 OFF OFF ON ON 0 - 5 OFF ON ON OFF 5 - 10 OFF ON ON ON

SIGNAL SWITCH NUMBER MILLIAMPS 1 2 4 5 4 - 20 ON OFF OFF OFF 0 - 20 ON ON OFF OFF 4 - 12 ON OFF ON OFF 12 - 20 ON OFF ON ON 0 - 10 ON ON ON OFF 10 - 20 ON ON ON ON

DIRECT OR REVERSE ACTING

An increasing signal can either drive the valve stem down(direct acting) or up (reverse acting).

Reverse Acting Switch #3 ON Properly selected and sized control valves utilize the default (OFF) positions for switches #7 & #8.

Contact Warren Controls (Ph: 800-922-0085) before repositioning either switch.

FLOW CHARACTERISTIC:Change Flow Characteristic Switch #7IN THE OFF POSITION STEM TRAVEL IS PROPORTIONAL TO CON-TROL SIGNAL AND DOES NOT ALTER THE FLOW CHARACTERISTIC OF VALVE. THIS IS THE POSITION SWITCH #7 SHOULD BE IN NORMALLY. When the stem travel of an actuator is proportional to the control signal, the shape (flow characteristic) of the valve’s plug determines the flow. PICV valves have an equal percentage flow characteristic. An equal percentage valve opens slowly at the start so that 25% stem travel results in less than 25% flow. When Switch #7 is in the ON position the stroke is electronically adjusted so that an equal percentage valve performs as if it had a linear flow characteristic. A linear valve opens so that 25% stem travel results in 25% flow.

EQUAL PERCENTAGE VALVE & SWITCH #7 OFF EQUAL PERCENTAGE VALVE & SWITCH #7 ON

NOTE: Previous models were equipped with three movable jumpers in place of the 9-switch block for actuator setup. For information about them contact Warren Controls (Ph: 800-922-0085).

6

Properly selected and sized control valves utilize the default (OFF) positions for switches #7 & #8. Contact Warren Controls (Ph: 800-922-0085) before repositioning either switch.

Flow Characteristic:Change Flow Characteristic Switch #7In the OFF position the stem travel is proportional to the control signal and does not alter the fl ow characteristic of the valve. This is the position this switch should be in normally. In the ON position the stroke is electronically adjusted so that an equal percent-age valve performs as a linear valve and a linear valve performs as a quick opening valve. Most 2-way control valves have an equal percentage fl ow characteristic. Usually the stem travel of an actuator is proportional to the control signal and the valve plug is shaped to adjust the fl ow. An equal percentage valve opens slowly at the start so that 25% stem travel results in less than 25% fl ow. Mixing valves usually have plugs that are linear on both ports so that the total fl ow through the valve doesn’t change with the stem position. Switch #7 should be OFF when you use mixing valves. Occasionally, you may want switch #7 to be ON.If you have an equal percentage valve and you want to control the volume of liquid such as the depth of water in a tank changingto a linear valve characteristic may work better. Steam heat depends on the quantity of steam per hour condensed. Consequently, a linear valve may work better. In these cases, turn Switch #7 ON. If you are using a linear valve in one of these applications,then leave switch #7 OFF.

Direct or Reverse ActingAn increasing signal can either drive the valve stem down (direct acting) or up (reverse acting).Direct Acting Switch #3 OFFReverse Acting Switch #3 ON


Equal Percentage Valve & Switch #7 Off

ActuatorSignal

Stro

ke

Stroke

Flow

Valve

Flow

Valve + ActuatorSignal

Equal percentage Valve & Switch #7 On

Flow

ValveStroke

Flow


Actuator

Stro

ke

Signal

Flow Coeffi cient Full Flow Switch #8 OFF Reduced Flow Switch #8 ONThis function only works when switch #7 is off.Turning switch #8 on reduces the valve stroke and then sets the control signal over the range of the reduced stroke. The result is that the valve never fully opens and it performs like a smaller valve.

6






ActuatorSignal

Stro

ke

StrokeFl

owValve

Flow



Flow

ValveStroke

Flow


Actuator

Stro

ke

Signal


6






ActuatorSignal

Stro

ke

Stroke

Flow

Valve

Flow



Flow

ValveStroke

Flow


Actuator

Stro

ke

Signal


6






ActuatorSignal

Stro

ke

Stroke

Flow

Valve

Flow



Flow

ValveStroke

Flow


Actuator

Stro

ke

Signal


6






ActuatorSignal

Stro

ke

Stroke

Flow

Valve

Flow



Flow

ValveStroke

Flow


Actuator

Stro

ke

Signal


6






ActuatorSignal

Stro

ke

Stroke

Flow

Valve

Flow



Flow

ValveStroke

Flow


Actuator

Stro

ke

Signal


SWITCH 8: FACTORY DEFAULT OFFThe correct position for Switch #8 is OFF. Do not use the Switch #8 ON. If Switch #8 is ON the valve will not function properly as a PICV.


PRODUCT: SERIES VM LINEAR ELECTRIC ACTUATORSNATURE OF FAULT: Actuator motor does not de-energize at one end of travel. Actuator does not respond to Input signal changes.PROBABLE CAUSE: Over-travel device cannot reach limit switch activation point.

CORRECTIVE ACTION(S): 1. De-energize the actuator, both power and signal.2. Remove the actuator cover and locate the two switches soldered onto the circuit board. Note

the small lever protruding through the board, between the switches.3. Using a hex wrench, declutching if necessary, manually drive the actuator away from its’ end of

travel. Note that the lever moves to a “rest” position.4. Loosen the circuit board mounting screws sufficiently to allow the board to be moved in its’

slotted mounting holes.5. Position the board so the lever is centered between the switches and re-tighten the mounting

screws. Check position again, after tightening.6. Re-energize the actuator, and perform “Auto-Stroke”. Observe that the actuator travels fully in

both directions, and comes to rest at the point dictated by the applied input signal.

LEVER, CORRECTLY POSITIONEDBETWEEN SWITCHES

INSTALLATION

1. Connect the VMS-25 to the actuators as shown. Connect NC1 or NC2 to terminal 1 on an actuator to drive the valve stem down during power failure or to terminal 3 to drive the valve stem up during a power failure.2. Connect VMS-25 to 24 volts AC power.3. Connect the red wire to the battery positive (+) and the black wire to the battery negative (-).Note: Connect the 24 volt power to the VMS-25 before connecting the battery. Connecting the battery first causes the VMS-25 to go into the power failure mode. If there are conditions other than power failure during which the actuator should be driven to the end position, replace the jumper between LN & RC with a contact that opens on demand.

TESTING

Disconnecting the jumper between LN & RC, with building power on, will drive the actuator to the power failure position. Testing the VMS-25 and the battery. Measure the voltage between TG & BT. TG is negative. When the power supply is charging correctly the voltage will be 13 - 14 volts DC. Disconnect LN or L and then measure the voltage between TG & BT. If the battery is good and adequately charged the voltage will be Between 10 - 12 volts DC. VMS-25 is a standby power supply for VM1500E and VM5000E actuators. It is intended to drive these actuators to either open or close a valve during a power failure. The VMS-25 can power one VM5000E or two VM1500E actuators.

For floating control, connect controller with dry contacts and floating mid position between terminal NO1 and 1 and 3 for

Actuator A, and between terminal NO2 and 1 and 3 for Actuator B.TERMINALS VMS-25

Operation: Proportional Normal: Terminal AC is connected to 24 VAC building power. Terminal LN supplies power to SN. Actuator responds to modulating input signal. Power Failure: Terminal AC changes to 24V square wave from inverter. Terminal C2 connects to Terminal NC2. Terminal NC2 supplies power to Termial 1 or 3 to drive actuator to fail safe position.

L System Power 24VAC LN System Neutral BT Battery Test RC Remote Control TG Test Ground C1 Relay Common 1st Motor C2 Relay Common 2nd Motor NC1 Relay Normally Closed 1st Motor NC2 Relay Normally Closed 2nd Motor NO1 Relay Normally Open 1st Motor NO2 Relay Normally Open 2nd Motor AC 24 Volt Out


VM1500E MOTOR ACTUATORInstallation of modification circuit board • PUR 1137IN KIT NUMBER KVM1500EFB4TO20MA00 to convert native 2-10 vdc feedback output to optional 4-20 mAdc.

PUR 11374-20 mAdc Mod. Board

OVERVIEW:

VM motor actuators feature a native DC voltage position feedback output available at motor terminals X (+) and SN (-). Addition of the optional circuit board shown above converts the feedback output to 4-20 mAdc, available at terminals 4-20mA (+) and N (-), capable of working into load resistances as high as 550 ohms. The circuit operates on 24 vac fed from terminal SP (hot) to terminal SP on the mod. board, and terminal SN (common) to terminal SN on the mod. board. A single wire brings feedback from motor terminal X to mod. board terminal 2-10V. An adjust-ment potentiometer on the mod. board can calibrate the 4-20 mAdc feedback out-put at any critical point in the actuator’s travel. Nominal adjustment span, when voltage feedback is 2 vdc, is from 3.5 to 4.5 mAdc output.

MATERIALS & TOOLS:

Wires and mounting screws are provided in the kit. The illustration that follows shows RED wire insulation for power (hot), BLACK for power (neutral) and GREEN for feedback. Stranded wire is used to avoid difficulty in connecting two wires to a single terminal on the motor board. A small straight-bladed screwdriver is needed for the wiring terminals, and a #2 Phillips screwdriver for the mounting screws

VM1500E KVM1500EFB4TO20MA00A. Using two mounting screws, fasten the mod. board to the two existing bosses on the motor housing. Note the rectangular wire-

clearance cutout at the upper left.B. Install the RED wire from motor board terminal SP to mod. board terminal SP.C. Install the BLACK wire from motor board terminal SN to mod. board terminal SN.D. Install the GREEN wire from motor board terminal X to mod. board terminal 2-10V.E. Installation is complete. Connect the motor actuator in accordance with the Installation, Operating & Maintenance manual, except that

feedback output is now located at mod. board terminals 4-20mA (+) and N (-).


VM5000E MOTOR ACTUATORInstallation of modification circuit board • PUR 1137IN KIT NUMBER KVM5000EFB4TO20MA00 to convert native 2-10 vdc feedback output to optional 4-20 mAdc.

PUR 11374-20 mAdc Mod. Board

OVERVIEW:

VM motor actuators feature a native DC voltage position feedback output available at motor terminals X (+) and SN (-). Addition of the optional circuit board shown above converts the feedback output to 4-20 mAdc, available at terminals 4-20mA (+) and N (-), capable of working into load resistances as high as 550 ohms. The circuit operates on 24 vac fed from terminal SP (hot) to terminal SP on the mod. board, and terminal SN (common) to terminal SN on the mod. board. A single wire brings feedback from motor terminal X to mod. board terminal 2-10V. An adjustment potentiometer on the mod. board can calibrate the 4-20 mAdc feedback output at any critical point in the actuator’s travel. Nominal adjustment span, when voltage feedback is 2 vdc, is from 3.5 to 4.5 mAdc output.

MATERIALS & TOOLS:

Wires and mounting screws are provided in the kit. The illustrations that fol-low show RED wire insulation for power (hot), BLACK for power (neutral) and GREEN for feedback. Stranded wire is used to avoid difficulty in connecting two wires to a single terminal on the motor board. A small straight-bladed screwdriver is needed for the wiring terminals, and a #2 Phillips screwdriver for the mounting screws

VM5000E KVM5000EFB4TO20MA00A. Using four mounting screws, fasten the mod. board to the existing bosses on top of the motor housing. Note the semicircular

clutch clearance cutout on the right side.B. Install the RED wire from motor board terminal SP to mod. board terminal SP.C. Install the BLACK wire from motor board terminal SN to mod. board terminal SN.D. Install the GREEN wire from motor board terminal X to mod. board terminal 2-10V.E. Installation is complete. Connect the motor actuator in accordance with the Installation, Operating & Maintenance manual,

except that feedback output is now located at mod. board terminals 4-20mA (+) and N (-).


Read all instructions carefully before beginning. TURNING THE ACTUATOR LEGS CAUSES DAMAGE TO THE AC-TUATOR AND VOIDS THE WARRANTY.

REMOVAL OF VM1500E ACTUATOR FROM VALVE1) Remove line pressure and isolate valve in piping.2) Operate actuator so plug is off seat(s) and tabs of anti-rotation device

(Item 2) can be unbent in Step 5.3) Loosen jamnut (Item 3) and thread to bottom of threads on valve

stem.4) Loosen yoke locknut until it is free of bonnet.5) Unbend tabs of anti-rotation device.6) Remove anti-rotation device from stem connector so stem connector

may be turned.7) Hold jamnut on valve stem and turn the stem connector to disengage

from valve stem. The valve stem should never be turned while the plug is in contact with the seat otherwise the seating surfaces will be damaged.

8) Remove actuator from valve._______________________________________________

INSTALLATION OF VM1500E ACTUATOR ON VALVE.THE BRASS SPACER THAT COMES WITH THE ACTUATOR MUST BE ASSEMBLED ON BOTTOM SIDE OF YOKE AS SHOWN ON DRAWING C3400002.

1) Push valve stem down until plug is seated. Note stem location.2) Install hex jamnut (Item 3) on valve stem. Thread jamnut to bottom of

threads on stem.3) Place actuator, yoke locknut, and anti-rotation device (Item 2) over

valve stem and onto bonnet. Watch orientation of yoke locknut and anti-rotation device. Anti-rotation device must be oriented so tabs can be bent around cross bar in Step 6. Actuator must rest on bonnet. If necessary use actuator manual override to reposition the stem connector. The manual override is at the top of the actuator. Turn override using a 4mm hex wrench. Do not tighten yoke locknut at this time.

4) Rotate actuator to desired orientation. For the factory default actuator position face the actuator circuit board and install the actuator on the valve with the valve upright and its inlet to the left. Thread yoke locknut onto bonnet and tighten securely. Use a blunt chisel and hammer for final tightening.

5) Lift valve stem. Hold jamnut on valve stem and turn the stem connector to engage valve stem. If necessary use actuator manual override to reposition the stem connector. The valve stem should never be turned while the plug is in contact with the seat otherwise the seating surfaces will be damaged. The minimum required stem engagement is 3/8 inch (9.53 mm). After required stem engagement is reached thread jamnut up valve stem to contact stem connector. Tighten jamnut to secure valve stem to stem connector.

6) Install anti-rotation device on cross bar and bend tabs over so stem connector will not turn.

7) Push red travel indicators on leg of actuator into contact with cross bar. Connect power to actuator. On circuit board turn dipswitch 9 ON then OFF. Actuator will perform automatic stroke adjustment. In the stem down direction the plug must reach the seat in the valve before the brass bar on the shaft inside the motor housing contacts the bottom of the motor housing. The lever extending through the hole in the circuit board deflects to depress the upper microswitch on the circuit board to stop the motor at that end of travel. In the stem up direction the plug must reach the upper seat or travel stop inside the valve before the stem connector contacts the bottom of the motor housing. The lever extending through the hole in the circuit board deflects to depress the lower microswitch to stop the motor at that end of travel. If necessary turn off power, loosen jamnut, remove anti-rotation device from stem connector, and repeat Steps 5 thru 7.

8) Turn off power. Make necessary dipswitch settings and additional wiring connections. See Set-Up and Wiring sections of these instructions.

9) Return power to actuator.10) Return line pressure to valve.11) Stroke valve several times to check operation.

Read all instructions carefully before beginning. TURNING THE ACTUATOR LEGS CAUSES DAMAGE TO THE ACTUATOR AND VOIDS THE WARRANTY.

REMOVAL OF VM5000E ACTUATOR FROM VALVE1) Remove line pressure and isolate valve in piping.2) Operate actuator so plug is off seat(s) and anti-rotation device (Item 2)

can be removed in Step 4.3) Loosen jamnut (Item 3) and thread to bottom of threads on valve stem.4) Remove anti-rotation device from stem connector so stem connector

may be turned.5) Loosen yoke locknut until it is free of bonnet.6) Hold jamnut on valve stem and turn the stem connector to disengage

from valve stem. The valve stem should never be turned while the plug is in contact with the seat otherwise the seating surfaces will be damaged.

7) Remove actuator from valve._______________________________________________

INSTALLATION OF VM5000E ACTUATOR ON VALVE.THE BRASS SPACER THAT COMES WITH THE ACTUATOR MUST BE ASSEMBLED ON BOTTOM SIDE OF YOKE AS SHOWN ON DRAWING C3400001.

1) Push valve stem down until plug is seated. Note stem location.2) Install hex jamnut (Item 3) on valve stem. Thread jamnut to bottom of

threads on stem.3) Place actuator, yoke locknut, and anti-rotation device (Item 2) over

valve stem and onto bonnet. Watch orientation of yoke locknut and anti-rotation device. Actuator must rest on bonnet. If necessary use actuator manual override to reposition the stem connector. The manual override is at the top of the actuator. There are two rubber caps on the actuator cover. One cap covers the override; the second cap covers the clutch. Remove both caps. Depress clutch and turn override using an 8mm hex wrench. Replace caps when finished to protect motor and circuit board. Do not tighten yoke locknut at this time.

4) Rotate actuator to desired orientation. For the factory default actuator position face the actuator circuit board and install the actuator on the valve with the valve upright and its inlet to the left. Thread yoke locknut onto bonnet and tighten securely. Use a blunt chisel and hammer for final tightening.

5) Lift valve stem. Hold jamnut on valve stem and turn the stem connector to engage valve stem. If necessary use actuator manual override to reposition the stem connector. The valve stem should never be turned while the plug is in contact with the seat otherwise the seating surfaces will be damaged. The minimum required stem engagement is 9/16 inch (14.29 mm). After required stem engagement is reached thread jamnut up valve stem to contact stem connector. Tighten jamnut to secure valve stem to stem connector.

6) Install anti-rotation device on cross bar so stem connector will not turn.7) Push red travel indicators on legs of actuator into contact with cross

bar. Connect power to actuator. On circuit board turn dipswitch 9 ON then OFF. Actuator will perform automatic stroke adjustment. In the stem down direction the plug must reach the seat in the valve before the cross bar on the actuator legs pushes the red travel indicators on legs of actuator against the actuator base. The lever extending through the hole in the circuit board deflects to depress the upper microswitch on the circuit board to stop the motor at that end of travel. In the stem up direction the plug must reach the upper seat or travel stop inside the valve before the cross bar pushes the red travel indicators against the bottom of the motor housing. The valve stem must not contact the bottom of the motor housing. The lever extending through the hole in the circuit board deflects to depress the lower microswitch to stop the motor at that end of travel. If necessary turn off power, loosen jamnut, remove anti-rotation device from stem connector, and repeat Steps 5 thru 7.




C3400001

C3400002


TR5000-X ACTUATOR INSTRUCTIONS

Page

Set-up & Wiring .................. 24-25

Removal & Installation ....... 26-27

ON-OFF SWITCH

With switch S3-7 OFF (Factory Default), the self-stroking button must be pressed for self-stroking to start. With switch S3-7 ON, self-stroking starts each time the actuator is powered up. If switch S3-7 is ON, self-stroking may also be started by pressing the self-stroking button for greater than 3 seconds. It is recommended that switch S3-7 be OFF.

The self-stroking function must be completed in order to calibrate the TR5000 actuator to the travel of a valve.

Position the actuator ON-OFF switch in the OFF position. Position switch S3-7 in the OFF position. Warning: If switch S3-7 is ON, the actuator will start self-stroking as soon as power is applied. The sudden movement and application of force may result in damage to the valve and personal injury. After assembling the TR5000 actuator to the

valve, connect the 220VAC power supply. Position the actuator ON-OFF switch in the ON position. Then press the self-stroking button on the PCB and hold (greater than 3 seconds) until the running light flashes red (1Hz).

–Self-strokingstarts–The actuator stem extends to the lower travel limit; the

running light flashes red (1Hz).–The actuator stem retracts to the upper travel limit; the

running light flashes red (1Hz).–The travel limits are recorded in theCPU; self-stroking is

finished (total process takes approx.150 seconds). The actuator and running light return to normal operation.

1 2Prepare for assembling actuator, take down the fixed fitting, and disentangle the clip.

Made the actuator’s stem is concentric with the valve's stem and made these two connecting faces keep coinciding. Then lock the two screws on the clip.

3 4Pulling the fixed fitting to the groove and locking by two screws. The status after assembled, face and back.

Remark: If the back side have threaded hole, then locking the other screw on the back. If not, pass over this step.

Installation

Manual device operation

B o o E Y

B o o E Y

Take down the front cover, screw off the waterjoint, for preparing wiring.

Make the wire through the water joint,connect the wire to the terminal as required.

Fit on the water joint after wiring. Install the front cover, screw the screw.

Front cover

through this hole

1 2

3 4

ERR RUN

UL DL AL MAX MIN

ERR RUN

UL DL AL MAX MIN

Connecting Sheet

TS-R5000220X12-E01-00

2Φ

42mm

max

Stro

ke

Mounting Orientation Dimensions

Chilled/hot water valve body Steam valve body Forbidded downwards Random Orientation suitable

180°

360°

Power switch

Knob Crank

Shut off and prepare for manual operation Pull out the crank and go round 180 degree

Press down the knob to limit position, keep press and start to turn the crank.

1. Turn anticlockwise for actuator axes retracts;2. Turn clockwise for actuator axes extends.

After finished the manual operation, release the knob,and pull up the knob to the up limit position.

( Any release of press is not allowed when the crank running.)

1 2

3 4TS-R5000220X12-E01-00

852 3 41

ON

OFF

S27 82 3 41

6

5 6

ON

OFF

S27

Eg.1Wiring

S2 Switch setting

warning light

S2 switch

self-stroking button

S2

ERR RUN

L ON E Y

ON1 2 3 4

CPU

OFF 7 85 6LOG

LIN

20%

0

1 2

S2

5 6 7 8 9 10AL MAX MIN

II

UI

IO

UO

1 2

DA

RA

DW

UP

DF

RF

HS

LS

3 4 5 6

S1

running light

nixie tube

connection terminal

additional function terminal

1 2 3 4UL DL

--Running light (RUN): when actuator axes retracts, running light show red; when actuator axes extends, running light show green; when do "self-stroking", running light flickering(1Hz).---Warning light (ERR): when actuator have some problem, warning light will be lighting. ---Nixie tube: The first one is function bit, the second to forth are numerical bitDescription of Nixie tube:

Function bit Description Numerical bit Description

A Fault when do "self-stroking" No show /

C Show Input signal on Numerical bit

Number between 0~100

Input signal (percent). For example, Input signal type is 0~10V, when input signal is 1 V, there will be show 1/10*100=10

F Show Output signal on Numerical bit

Number between 0~100

Output signal (percent). For example, Output signal type is 0~10V, when output signal is 1 V, there will be show 1/10*100=10

When actuator running correctly, there will be show "C" or "F" alternate in the Nixie tube, it is means that "input signal" and "output signal" be showed alternate.

---Additional function terminal: 1) Terminal 1,2 (UL): Up limit position SPDT output terminal(NO), when actuator axes retracts to limit position, this terminal will be close.2) Terminal 3,4 (UL): Down limit position SPDT output terminal(NO), when actuator axes extends to limit position, this terminal will be close.3) Terminal 5,6(UL): Fault SPDT input terminal(NO)when fault, this terminal will be close.4) Terminal 7,8(MAX): Max. signal compulsory input terminal, this terminal is external connection SPDT, when close, means a Max. input signal to actuator, and make the input signal from "O","E" terminal be of no effect.5) Terminal 9,10(MIN): Min. signal compulsory input terminal, this terminal is external connection SPDT, when close, means a Min. input signal to actuator, and make the input signal from "O","E" terminal be of no effect. Notes:1. Contact Capacity of SPDT: :1A (125VAC/30VDC)2. Contact Capacity external connection SPDT: more than 50mA /30VDC

PCB

Additional function

852 3 41

ON

OFF

S27 82 3 41

6

5 6

ON

OFF

S27

S2 Switch Function Description

1 Flow characterON LOG: equal-percentage

OFF LIN: equal-linear

2 Starting of input/ output signal

ON 20%:the starting input / output signal is 20% (namely 4~20mA or 2~10V)

OFF 0:the starting input / output signal is 0 (namely 0~20mA or 0~10V)

3 Type of input signalON II: input current signalOFF UI: input voltage signal

4 Type of output signal

ON IO: Output current signalOFF UO: Output voltage signal

5 Operating mode ON DA:DA mode (when input signal is increasing, the actuator axes extends )OFF RA: RA mode (when input signal is increasing, the actuator axes retracts)

6 Losing input signal mode

ON DW: When lose input signal (voltage type), the minimum control signal When lose input signal (current type), the minimum control signal

OFF UP: When lose input signal (voltage type), the maximum control signal When lose input signal (current type), the minimum control signal

7 Output signal mode

ON DF: when the actuator axes retracts to limit position,output signal will be minimum value when the actuator axes extends to limit position, output signal will be maximum value

OFF RF: when the actuator axes extends to limit position, output signal will be minimum value when the actuator axes retract to limit position, output signal will be maximum value

8 SensitivityON HS: the high sensitivity of input signal ≤1.5%OFF LS: the low sensitivity of input signal ≤2%

Input signal: 0~10VDC Output signal: 0~10VDCOperating mode: DALosing input signal mode:DWSensitivity of input signal ≤2%

Input signal: 4~20mA Output signal: 4~20mA Operating mode: DALosing input signal mode:DWSensitivity of input signal ≤2%

Eg.2

After assemblling TR5000-X...actuator with TL…,TW… or TF... valve body, connect AC 220V power supply. Then press down "self-stroking" button on PCB over 3 seconds until the running light flickering:– Self-stroking step starting – The actuator moving to 1 (actuator axes retracts until up limit position), running light flickering–The actuator moving to 0 (actuator axes extends until down limit position), running light flickering– written the result in CPU, self-stoking step is finished ( total process need approx.180 seconds)

Remarks: 1. When in self-stroking, actuator can not be controlled by input singal.

Debugging

M

power Input signal

Output signal

L N O E Y

Rating force 5000N Input signal 0(2)~10VDC, 0(4)~20mA Actual force 4500N~5500N Output signal 0(2)~10VDC, 0(4)~20mA Type of control proportional Voltage input impedance ＞100KPower consumption 14VA Current input impedance ＜0.50K

Motor Synchronous motor with permanent magentic Voltage output load ＞1K

Nominal stroke 42mm Current output load ＜0.5K

Running speed 2.5s/ mm (50Hz) Up and down dead band ≤1.5%

Enviromental temperature -10~50℃ (Operation condition) Sensitivity ≤2%

Enviromental humidity ≤95% RH(40℃) (Operation condition) Material of bracket Aluminum die casting

(surface anti-rust process)

IP Degree IP54 Material of cover Aluminum die casting(surface anti-rust process)

Running mode Up/ down straight travel Net weight of product 6.0 Kg

1

with manual deviceTR5000-X220-S.12

The TR5000 actuator has an ON-OFF switch. The switch must be in the ON position for the actuator to operate.

ON OFF

Chilled/hot water application Not suitable downwards

Steam application All above suitable

WIRINGPCB

Notes: 1. See separate instruction for installation of TR5000 actuator on PICV valves.2. When self-stroking, the actuator cannot be controlled by the input signal.3. The self-stroking function must be repeated each time the type of input signal or output (feedback) signal is changed.

The PCB has an aperture potentiometer. DO NOT adjust the aperture potentiometer. The aperture potentiometer is factory set to 100. If the aperture potentiometer is adjusted to less than 100, the valve will not function properly as a PICV

S1

self-stroking button

function digit

number digit

ERR

RUN

L N O E Y

connecting terminal1 2

3

4

5 6

UL DL AL

auxiliary terminal

error light

running light

CPU

maximum opening

aperturepotentiometer

2 3 4 1

ON

OFF

S2 2 3 4 1

S3

1 2 3 4 20%

0 II UI

UI II

IO UO

5 6 7 8 DA RA

DW UP

DF RF

HS LS

S2 S3

30

40

50

60 70

80

90

100

220VAC

Rating force 5000N Input signal 0(2)~10VDC, 0(4)~20MA

Actual force 4500~5500N Output signal 0(2)~10VDC, 0(4)~20MA

Type of control proportional Voltage input impedance >100K

Power consumption 12VA Current input impedance <0.167K

Motor Synchronous motor withpermanent magnetic

Voltage output load >1K

Nominal stroke 42mm, 51mm Current output load <0.5K

Running speed 3.57s/ mm (50Hz) Up and down dead band ≤2.5%

Environmental temperature -10~50ºC (Operation condition) Sensititivity low ≤2% high ≤1.5%

Environmental humidity ≤95% RH(40ºC)(Operation condition)

Material of bracket Aluminum die casting(surface anti-rust process)

IP Degree IP54 Material of cover Aluminum die casting(surface anti-rust process)

RUNNING MODE Up/down straight travel Net weight of product 5.2 Kg

DEBUGGING/SELF-STROKING

TR5000-X220S.12 / TR5000-X220-S.12-51

LIGHTS AND DISPLAY

Eg.1

S2ON

OFF

Eg.2

-- Running light (RUN): When the actuator stem retracts, the running light shows red; when the actuator stem extends, the running light shows green; When the actuator is self-stroking, the running light flashes red (1Hz). The display does not show a value when the actuator is self-stroking.

-- Warning light (ERR): When the actuator has an error, the warning light will be lit. Errors include: The actuator cannot complete the self-stoking function. The actuator cannot move the stem to the correct position for the input signal.

-- Display: The display has two parts. The first part, the single character on the left, is the function display; the second part, the three characters on the right, is the numerical display.

DESCRIPTION OF DISPLAY:

Function display shows

Meaning Numerical display shows

Meaning

A Numerical display shows aperture setting in percent

Number from 30~100

Function display shows A and numerical display shows value from 30 to 100 as aperture potentiometer is turned. The aperture value MUST be set to 100 (Factory Default). If the aperture value is less than 100 the valve will not function properly as a PICV.

C Numerical display shows input signal in percent

Number from 0~100

Input signal percent. Example: For input signal 0~10V, when input signal is 1 V, display will show 10 (1/10*100=10)

F Numerical display shows output signal in percent

Number from 0~100

Output signal percent. Example: For Output signal 0~10V, when output signal is 1 V, display will show 10 (1/10*100=10)

When the actuator is running correctly, “C” and “F” alternate in the function display. When “C” is visible, the input signal percentage is shown in the numerical display. When “F” is visible, the output signal percentage is shown in the numerical display. Additional function terminal1) Terminal 1,2 (UL): Non-functional, No terminal block present2) Terminal 3,4 (DL): Non-functional, No terminal block present3) Terminal 5,6 (AL): Fault SPDT input terminal (NO) When a fault occurs, this terminal will close. Faults include: The actuator cannot complete the self-stoking function. The actuator cannot move the stem to the correct position for the input signal. Notes: 1. Contact Capacity of SPDT:1A (125VAC/30VDC) 2. Contact Capacity external connection SPDT: more than 50mA /30VDC

Input signal: 4-20mAOutput signal: 4-20mAOperating Mode: DALoss of input signal mode: DWSensitivity of input signal 2% < _

Input signal: 0-10VDCOutput signal: 0-10VDCOperating Mode: DALoss of input signal mode: DWSensitivity of input signal 2% < _

FACTORY DEFAULT

S3

S2ON

OFFS3

1 2 3 4

1 2 3 4

5 6 7 8

5 6 7 8

S2 Dip Switch Function Posi-

tion Description

S2-1Start point of input/output signal

ON 20%: The start point of the input / output signal is 20% (The full input / output signal is 4~20mA or 2~10V) (Factory Default)

OFF 0: The start point of the input / output signal is 0% (The full input / output signal is 0~20mA or 0~10V)

S2-2Type of input signal

ON II: Input signal is current (mAdc) (Factory Default)

OFF UI: Input signal is voltage (Vdc)

S2-3ON When S2-2 is OFF, S2-3 MUST be ON

OFF When S2-2 is ON, S2-3 MUST be OFF (Factory Default)

S2-4Type of output (feedback) signal

ON IO: Output signal is current (mAdc) (Factory Default)

OFF UO: Output signal is voltage (Vdc)

S3-5Operating mode

ON DA: DA mode (When input signal is increasing, the actuator stem extends ) (Factory Default)

OFF RA: RA mode (When input signal is increasing, the actuator stem retracts)

S3-6Loss of input signal mode

ON DW: On loss of input signal, the actuator fails to the minimum input signal position. (Factory Default)

OFF UP: On loss of input signal, the actuator fails to the maximum input signal position.

S3-7Self-stroking mode

ON DF: Self-stroking starts each time the actuator is powered up.

OFF RF: Self-stroking starts ONLY when the self-stroking button is pressed for >3 sec-onds. (Factory Default)

S3-8 SensitivityON HS: High sensitivity of input signal </=1.5%

OFF LS: Low sensitivity of input signal </=2% (Factory Default)

S2 SWITCH SETTING


Read all instructions carefully before beginning. REMOVAL OF TIG1 & TIG2 TR5000-X ACTUATOR FROM VALVE

1) Remove line pressure and isolate valve in piping.2) Operate actuator so plug is off seat(s).3) Remove power and signal from actuator.4) Remove stem connector screws, then remove stem connector from

actuator stem.5) Remove clamp screws, then remove clamp from actuator yoke.6) Remove actuator from valve.

TO REMOVE STEM ADAPTER AND BONNET ADAPTERCOMPLETE STEPS 7 THRU 10.

7) Loosen jamnut on valve stem. Warning: The valve stem should never be turned while the plug is in contact with the seat otherwise the seating surfaces will be damaged voiding the warranty.

8) Remove stem adapter from valve stem.9) Remove jamnut from valve stem.10) Remove bonnet adapter from bonnet.

_____________________________________________

INSTALLATION OF T1G1 TR5000-X ACTUATOR on All PICV Valves Except 6 Inch (DN150) Extended Port Valve

1) Isolate valve body if already installed in piping.

TO INSTALL BONNET ADAPTER AND STEM ADAPTERCOMPLETE STEPS 2 THRU 6.

2) Install bonnet adapter on valve bonnet and tighten. Watch orientation.

3) Install jamnut on valve stem. Thread jamnut to bottom of threads on stem.

4) Push valve stem down until plug is seated. Note stem location.5) Install stem adapter on valve stem. With the stem down and the

plug seated, adjust position of stem adapter on valve stem so the distance from the top of the bonnet adapter to the top of the stem adapter is 1.960 +/-.012 inch (49.784 +/- .03048 mm). Warning: The valve stem should never be turned while the plug is in contact with the seat otherwise the seating surfaces will be damaged voiding the warranty. Stem adapter setting gage p/n B6020011 may also be used to set the position of the stem adapter on the valve stem. See page 38 for drawing. With the stem down and plug seated, rest the gage on top of the bonnet adapter. Adjust the stem adapter so its end lies between the two steps on the gage.

6) Thread jamnut against stem adapter and tighten.7) Remove stem connector screws, then remove stem connector with

two springs from actuator stem.8) Remove clamp screws, then remove clamp from actuator yoke.9) Place actuator over valve stem and onto bonnet adapter. Rotate

actuator to desired orientation. For the factory default actuator position, face the actuator circuit board and install the actuator on the valve with the valve upright and its inlet to the left. Engage raised pad in actuator yoke with groove in bonnet adapter. If necessary use actuator manual override to reposition the actuator stem. Install clamp in base of actuator yoke. Engage raised pads on back of clamp with groove in bonnet adapter. Install clamp screws through clamp into actuator yoke and tighten to secure actuator to bonnet adapter.

10) Place the upper center hole in unthreaded half of stem connector over pin on actuator stem. Watch orientation. Engage stem adapter with stem connector using manual override. Install stem connector screws through unthreaded half of clamp, each through a spring, into threaded half of the stem connector and tighten to secure stem adapter to stem connector.

11) Position the actuator ON-OFF switch in the OFF position. Position switch S3-7 in the OFF position. Warning: If switch S3-7 is ON, the actuator will start self-stroking as soon as power is applied. The sudden movement and application of force may result in damage to the valve and personal injury. After assembling the TR5000 actuator to the valve, connect the 220VAC power supply. Position the actuator ON-OFF switch in the ON position. Then press the self-stroking button on the PCB and hold (greater than 3 seconds) until the running light flashes red (1Hz). Actuator will perform automatic stroke adjustment. See Set-Up and Wiring sections of these instructions.



_____________________________________________

INSTALLATION OF T1G1 TR5000-X ACTUATOR ON 6 INCH (DN150) EXTENDED PORT PICV VALVE


IF THE BONNET ADAPTER AND STEM ADAPTER ARE ALREADY INSTALLED ON THE VALVE COMPLETE STEPS 2 AND 3.

2) Loosen jamnut on valve stem. Warning: The valve stem should never be turned while the plug is in contact with the seat otherwise the seating surfaces will be damaged voiding the warranty. Thread jamnut to bottom of threads on stem.

3) Thread stem adapter onto valve stem until stem threads bottom out in adapter.

IF THE BONNET ADAPTER AND STEM ADAPTER ARE NOT INSTALLED ON THE VALVE COMPLETE STEPS 4 THRU 6.



6) Install stem adapter on valve stem. Thread stem adapter onto valve stem until stem threads bottom out in adapter.

7) Push valve stem down until plug is seated. Note stem location.8) Remove stem connector screws, then remove stem connector with

two springs from actuator stem.9) Remove clamp screws, then remove clamp from actuator yoke.10) Position the actuator ON-OFF switch in the OFF position. Position

switch S3-7 in the OFF position. Warning: If switch S3-7 is ON, the actuator will start self-stroking as soon as power is applied. The sudden movement and application of force may result in damage to the valve and personal injury. After assembling the TR5000 actuator to the valve, connect the 220VAC power supply. Position the actuator ON-OFF switch in the ON position. Then press the self-stroking button on the PCB and hold (greater than


3 seconds) until the running light flashes red (1Hz). Actuator will perform automatic stroke adjustment. When automatic stroke adjustment is complete apply signal to actuator so actuator stem is fully extended. See Set-Up and Wiring sections of these instructions.

11) Remove power and signal from actuator.12) Place actuator over valve stem and onto bonnet adapter. Rotate

actuator to desired orientation. For the factory default actuator position, face the actuator circuit board and install the actuator on the valve with the valve upright and its inlet to the left. Engage raised pad in actuator yoke with groove in bonnet adapter. Install clamp in base of actuator yoke. Engage raised pads on back of clamp with groove in bonnet adapter. Install clamp screws through clamp into actuator yoke and tighten to secure actuator to bonnet adapter.

13) Place upper center hole in threaded half of stem connector over pin in actuator stem. Watch orientation. With the stem down and the plug seated, adjust position of stem adapter on valve stem so the stem connector engages the stem adapter. Warning: The valve stem should never be turned while the plug is in contact with the seat otherwise the seating surfaces will be damaged voiding the warranty. Place upper center hole in unthreaded half of stem connector over pin in actuator stem. Watch orientation. Engage stem adapter with stem connector. Install stem connector screws through unthreaded half of stem connector, each through a spring, into threaded half of stem connector. Tighten finger tight. With the stem down and the plug seated, adjust position of stem adapter on valve stem so axial play is removed.

14) Use actuator manual override to retract the actuator stem approximately 0.2 inch (5 mm).

15) Unthread stem adapter one full turn. 16) Thread jamnut against stem adapter and tighten.17) Tighten stem connector screws to secure stem connector to stem

adapter.18) Connect power to actuator. On circuit board press S1 self-stroking

button. Actuator will perform automatic stroke adjustment. 19) Turn off power. Make necessary dipswitch settings and additional

wiring connections. See Set-Up and Wiring sections of these instructions.


_____________________________________________

INSTALLATION OF TIG2 TR5000-X ACTUATOR ON - 6 INCH (DN150) EXTENDED PORT PICV VALVE


TO INSTALL BONNET ADAPTER AND STEM ADAPTER COMPLETE STEPS 2 THRU 6.



4) Push valve stem down until plug is seated. Note stem location.

5) Install stem adapter on valve stem. With the stem down and the plug seated, adjust position of stem adapter on valve stem so the distance from the top of the bonnet adapter to the top of the stem adapter is

1.606 +/-.012 inch (40.792 +/- .03048 mm). Warning: The valve stem should never be turned while the plug is in contact with the seat otherwise the seating surfaces will be damaged voiding the warranty. Stem adapter setting gage B6020012 may also be used to set the position of the stem adapter on the valve stem. See page 38 for drawing. With the stem down and plug seated, rest the gage on top of the bonnet adapter. Adjust the stem adapter so its end lies between the two steps on the gage.

6) Thread jamnut against stem adapter and tighten.7) Remove stem connector screws, then remove stem connector with

two spings from actuator stem.8) Remove clamp screws, then remove clamp from actuator yoke.9) Place actuator over valve stem and onto bonnet adapter. Rotate

actuator to desired orientation. For the factory default actuator position, face the actuator circuit board and install the actuator on the valve with the valve upright and its inlet to the left. Engage raised pad in actuator yoke with groove in bonnet adapter. If necessary use actuator manual override to reposition the actuator stem. Install clamp in base of actuator yoke. Engage raised pads on back of clamp with groove in bonnet adapter. Install clamp screws through clamp into actuator yoke and tighten to secure actuator to bonnet adapter.

10) Lift valve stem. Place the upper center hole in unthreaded half of stem connector over pin on actuator stem. Watch orientation. Engage stem adapter with stem connector using manual override. Install stem connector screws through unthreaded half of clamp, each through a spring, into threaded half of the stem connector and tighten to secure stem adapter to stem connector.

11) Position the actuator ON-OFF switch in the OFF position. Position DIP switch S3-7 in the OFF position. Warning: If DIP switch S3-7 is ON, the actuator will start self-stroking as soon as power is applied. The sudden movement and application of force may result in damage to the valve and personal injury. After assembling the TR5000 actuator to the valve, connect the 220VAC power supply. Position the actuator ON-OFF switch in the ON position. Then press the self-stroking button on the PCB and hold (greater than 3 seconds) until the running light flashes red (1Hz). Actuator will perform automatic stroke adjustment. See Set-Up and Wiring sections of these instructions.

12) Turn off power. Make necessary DIP switch settings and additional wiring connections. See Set-Up and Wiring sections of these instructions.



PICV SET DIFFERENTIAL PRESSURE ADJUSTMENT1. Remove line pressure and isolate PICV valve in piping.2. Remove upstream port and downstream port pressure sensing

lines from connections on diaphragm actuator (See drawing C3121902).

3. Connect flexible temporary air connection to upstream port pressure sensing connection on diaphragm actuator (See drawing C3121902 for location of upstream port pressure sensing connection).

4. Use marking pen to place mark on valve stem just above where it enters the valve.

WARNING: In Steps 5 thru 10, do not turn the adjusting screw so it extends more than 3-3/4 inches (9.53 cm) above the top of

the actuator (more than 26 threads are visible on the adjusting screw). Doing so may cause the adjusting screw to separate from the actuator resulting in damage and personal injury from

the uncontrolled release of pressure inside the actuator. Be careful not to damage the seal in the seal washer on the adjusting screw. The seal may be damaged by excessive turning of the adjusting screw or by pushing it over the

screw’s threads. If the seal in the seal washer is damaged the actuator will leak when line

pressure is returned to the valve.

5. Loosen locknut on adjusting screw on top of actuator and separate from seal washer. Thread locknut only to top of adjusting screw.

6. Apply air pressure to upstream port pressure sensing connection equal to desired set differential pressure plus ½ psig (0.034 BAR). Example: For set differential pressure of 5 psig (0.345 BARG), apply 5-½ psig (0.379 BARG) to upstream port pressure sensing connection. If mark made on valve stem in Step 9 moves away from valve, turn adjusting screw clockwise, looking down on actuator, until mark returns to its closest point to the valve.

7. Turn adjusting screw slowly counter-clockwise, looking down on actuator, a ½ turn at a time until mark made on valve stem in Step 9 just begins to move away from the valve.

8. Reduce air pressure to upstream port pressure sensing connection to 0 psig (0 BARG) and allow all air to bleed from actuator.

9. Slowly increase air pressure to upstream port pressure sensing connection until equal to desired set differential pressure. Mark made on valve stem should just begin to move away from the valve when pressure reaches desired set differential pressure. If mark moves too soon, turn adjusting screw clockwise an additional ½ turn then repeat Steps 13 and 14. If mark does not move, turn adjusting screw counter-clockwise an additional ½ turn then repeat Steps 13 and 14. Satisfactory adjustment should be made within 2 additional full turns of the adjusting screw.

10. Thread locknut on adjusting screw down to top of actuator and tighten securely against seal washer to create seal against actuator. If the locknut is not tightened securely the actuator will leak when line pressure is returned to the valve.

11. Install upstream port and downstream port pressure sensing lines (See drawing D3121311 (Sizes 2-1/2 thru 4 inch, P2 thru P4) or C3121900 (Sizes 5 thru 10 inch, P5 thru P1) for orientation of upstream port and downstream port pressure sensing lines).

12. Return line pressure to valve.

DPRV ACTUATOR

INSTRUCTIONS

C3121902


PICV DIAPHRAGM ACTUATORREMOVAL FROM VALVE1. Remove line pressure and isolate PICV valve in piping.2. Remove upstream port and downstream port pressure sensing

lines from connections on diaphragm actuator (See drawing C3121902).

3. Connect flexible temporary air connection to upstream port pressure sensing connection on diaphragm actuator. Apply air pressure and increase until actuator stem begins to retract into actuator.

4. Loosen yoke locknut then unthread it from valve body assembly.5. Reduce air pressure to upstream port pressure sensing connection

to 0 psig (0 BARG). Remove temporary air connection.6. Use wrench on flats of actuator stem to keep actuator stem from

turning. Loosen two jamnuts on valve stem so they are not in contact with actuator stem. Tighten two jamnuts together on valve stem.

7. Looking down on top of actuator, rotate actuator counterclockwise to unthread actuator stem from valve stem. Use wrench on jamnuts on valve stem to keep valve stem from turning. Continue rotating actuator until actuator stem is completely unthreaded from valve stem. Rotating the actuator stem relative to the actuator will damage the diaphragm and void the warranty. The diaphragm-actuated section of the PICV valve is reverse acting. The plug is on the seat when the valve stem is fully up (not down). Do not turn the valve stem if the plug is in contact with the seat. Rotating the valve stem with the plug on the seat will destroy the seating surfaces and void the warranty.

8. Remove actuator and yoke locknut from the valve.

_____________________________________________

PICV DIAPHRAGM ACTUATOR MOUNTINGON VALVE1. Remove line pressure and isolate PICV valve in piping.2. Push valve stem down until plug reaches travel stop in valve. 3. Thread two valve stem jamnuts onto valve stem. With valve stem

down and plug at travel stop in valve, position jamnuts on valve stem so the distance from the actuator yoke mounting surface of the valve bonnet to the top of the jamnuts is 2.438 inch (6.193 cm). Tighten jamnuts together.

4. Place yoke locknut on actuator yoke tapered side up.

5. Place actuator with yoke locknut over valve stem.6. Engage actuator stem with valve stem. Looking down on top of

actuator, rotate actuator clockwise to thread actuator stem onto valve stem. Continue rotating actuator until actuator stem is in contact with jamnuts on valve stem. If necessary lift actuator slightly and use wrench on jam nuts on valve stem to thread valve stem into actuator stem. Use wrench on jamnuts on valve stem to tighten valve stem to actuator stem. Use wrench on flats on actuator stem to keep actuator stem from turning. Rotating the actuator stem relative to the actuator will damage the diaphragm and void the warranty. The diaphragm-actuated section of the PICV valve is reverse acting. The plug is on the seat when the valve stem is fully up (not down). Do not turn the valve stem if the plug is in contact with the seat. Rotating the valve stem with the plug on the seat will destroy the seating surfaces and void the warranty.

7. Connect flexible temporary air connection to upstream port pressure sensing connection on diaphragm actuator (See drawing C3121902 for location of upstream port pressure sensing connection). Apply air pressure and increase until actuator yoke firmly contacts mounting boss of valve. Orient actuator with pressure sensing line connections facing PICV electric motor actuator or so existing pressure sensing line connections can be reconnected. Rotating the actuator stem relative to the actuator will damage the diaphragm and void the warranty. The diaphragm-actuated section of the PICV valve is reverse acting. The plug is on the seat when the valve stem is fully up (not down). Do not turn the valve stem if the plug is in contact with the seat. Rotating the valve stem with the plug on the seat will destroy the seating surfaces and void the warranty.

8. Thread yoke locknut onto valve bonnet. Tighten yoke locknut securely. Use a blunt chisel and hammer for final tightening. Reduce air pressure to upstream port pressure sensing connection to 0 psig.

9. If it is necessary to adjust the set differential pressure complete Steps 4 thru 10 of the PICV Set Differential Pressure Adjustment instructions.

10. Install upstream port and downstream port pressure sensing lines (See drawing D3121311 (Sizes 2-1/2 thru 4 inch, P2 thru P4) or C3121900 (Sizes 5 thru 10 inch, P5 thru P1) for orientation of upstream port and downstream port pressure sensing lines).

11. Return line pressure to valve.


C3121900


D312311


Worn or damaged parts can decrease performance and shorten valve life. A worn or damaged valve stem can damage the packing, bearings, and other bonnet parts causing a packing leak, increased hysteresis, and poor operation. A worn or damaged plug, seat ring, or o-ring can cause excessive leakage, poor shut-off, poor control, and increased hysteresis. Worn or damaged gaskets and o-rings can cause excessive leakage and poor shut-off. Should parts become worn or damaged, parts kits are available. Separate kits are available for each PICV segment; Control Valve or Differential Pressure Reducing Valve (DPRV). Repack Kits are available to replace the packing. Repack/Inspection Kits are available to allow a segment to be opened for inspection of its internal parts. Rebuild/Repack Kits are available to completely rebuild/ overhaul a segment. Parts kits come with complete step-by-step instructions. Each kit has its own part number. Please provide the PICV serial number and segment, Control Valve or Differential Pressure Reducing Valve (DPRV), to ensure getting the correct kit part number and correct parts.

PARTS/ OVERHAUL

REPACK KITP/N KXXXXXXXX007 REPACK KIT INCLUDES (see drawing C3769956)

ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION 2 1 Packing Retainer 1 V-Ring Packing Extractor 3 1 Retainer Bearing 1 Packing Spring Removal Tool 5 1 Lip Packing 1 O-Ring Retainer & O-Ring Extractor 8 1 Tube Stem Lube 1 Stem Sleeve

REPACK/INSPECTION KITSControl Valve Size 2-1/2”, 3”, 4” (DN65, DN80 & DN100) REPACK/ INSPECTION KIT INCLUDES

(See Drawing C3241354)

ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION 12 3 GASKET (See Dwg C3241354) 1 REPACK KIT

Control Valve Size 5” & 6” (DN 125 & DN150) REPACK/ INSPECTION KIT INCLUDES (See Drawing C3241556 & C3769956)

ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION 7 2 GASKET (See Dwg C3241556) 15 1 TUBE O-RING LUBE (See Dwg C3241556) 9 1 O-RING (See Dwg C3241556) 1 REPACK KIT

Control Valve Size 8” & 10” (DN200 & DN 250) REPACK/ INSPECTION KIT INCLUDES (See Drawing D3201950) ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION 14 2 GASKET (See Dwg D3201950) 1 REPACK KIT

DPRV Size 2-1/2”, 3”, 4” (DN65, DN80 & DN100) REPACK/ INSPECTION KIT INCLUDES (See Drawing C3201355)

ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION 9 1 GASKET (See Dwg C3201355) 1 REPACK KIT

DPRV Size 5” & 6” (DN 125 & DN150) REPACK/ INSPECTION KIT INCLUDES (See Drawing D3201753)

ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION 13 2 GASKET (See Dwg D3201753) 1 REPACK KIT

DPRV Size 8” & 10” (DN200 & DN 250) REPACK/ INSPECTION KIT INCLUDES (See Drawing D3201951)

ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION 4 2 GASKET (See Dwg D3201951) 1 REPACK KIT


Control Valve Size 2-1/2”, 3”, 4” (DN65, DN80 & DN100) REBUILD/ REPACK KIT INCLUDES (See Drawing C3241354 & C3769956)

ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION 1 1 VALVE STEM (See Dwg C3241354) 9 1 PLUG (See Dwg C3241354) 3 1 TRAVEL STOP (As required, See Dwg C3241354) 10 1 SEAT RING (See Dwg C3241354) 6 1 GROOVE PIN (See Dwg C3241354) 12 3 GASKET (See Dwg C3241354) 6 1 BONNET BEARING (See Dwg C3769956) 15 1 TUBE O-RING LUBE (See Dwg C3241354) 7 1 BONNET (See Dwg C3769956) 16 1 TUBE PERMATEX #2 (See Dwg C3241354) 8 1 O-RING (See Dwg C3241354) 1 REPACK KIT

Control Valve Size 5” & 6” (DN 125 & DN150) REBUILD/ REPACK KIT INCLUDES (See Drawing C3241556 & C3769956)

ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION 1 1 VALVE STEM (See Dwg C3241556) 9 1 O-RING (See Dwg C3241556) 3 1 TRAVEL STOP (As required,See Dwg C3241556) 10 1 PLUG (See Dwg C3241556) 4 1 GROOVE PIN (See Dwg C3241556) 11 1 SEAT RING (See Dwg C3241556) 6 1 BONNET BEARING (See Dwg C3769956) 15 1 TUBE O-RING LUBE (See Dwg C3241556) 7 2 GASKET (See Dwg C3241556) 16 1 TUBE PERMATEX #2 (See Dwg C3241556) 7 1 BONNET (See Dwg C3769956) 1 REPACK KIT

Control Valve Size 8” & 10” (DN200 & DN 250) REBUILD/ REPACK KIT INCLUDES (See Drawing D3201950 & C3769956)

ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION 1 1 VALVE STEM (See Dwg D3201950) 10 1 PLUG (See Dwg D3201950) 6 1 BONNET BEARING (See Dwg C3769956) 11 1 LOWER SEAT RING (See Dwg D3201950) 7 1 BONNET (See Dwg C3769956) 14 2 GASKET (See Dwg D3201950) 8 1 GROOVE PIN (See Dwg D3201950) 16 1 TUBE PERMATEX #2 (See Dwg D3201950) 9 1 UPPER SEAT RING (See Dwg D3201950) 1 REPACK KIT

DPRV Size 2-1/2”, 3”, 4” (DN65, DN80 & DN100) REBUILD/ REPACK KIT INCLUDES (See Drawing C3201355 & C3769956)

ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION 1 1 VALVE STEM (See Dwg C3201355) 7 1 TRAVEL STOP (As required, See Dwg (3201355) 4 1 GROOVE PIN (See Dwg C3201355) 9 2 GASKET (See Dwg C3201355) 6 1 BONNET BEARING (See Dwg C3769956) 12 1 TUBE PERMATEX #2 (See Dwg C3201355) 6 1 PLUG (See Dwg C3201355) 1 REPACK KIT 7 1 BONNET (See Dwg C3769956)

REBUILD/REPACK KITS

DPRV Size 5” & 6” (DN 125 & DN150) REBUILD/ REPACK KIT INCLUDES (See Drawing D3201753 & C3769956) ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION 1 1 VALVE STEM (See Dwg D3201753) 9 1 PLUG (See Dwg D3201753) 6 1 GROOVE PIN (See Dwg D3201753) 10 1 UPPER SEAT RING (See Dwg D3201753) 6 1 BONNET BEARING (See Dwg C3769956) 13 2 GASKET (See Dwg D3201753) 7 1 BONNET (See Dwg C3769956) 15 1 TUBE PERMATEX #2 (See Dwg D3201753) 8 1 LOWER SEAT RING (See Dwg D3201753) 1 REPACK KIT

DPRV Size 8” & 10” (DN200 & DN 250) REBUILD/ REPACK KIT INCLUDES (See Drawing D3201951 & C3769956)

ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION 1 1 VALVE STEM (See Dwg D3201951) 8 1 LOWER SEAT RING (See Dwg D3201951) 4 2 GASKET (See Dwg D3201951) 9 1 PLUG (See Dwg D3201951) 6 1 BONNET BEARING (See Dwg C3769956) 10 1 UPPER SEAT RING (See Dwg D3201951) 7 1 BONNET (See Dwg C3769956) 16 1 TUBE PERMATEX #2 (See Dwg D3201951) 7 1 GROOVE PIN (See Dwg D3201951) 1 REPACK KIT


C3241354


C3201355

C3769956


D3201753

D3241556


D3201950

D3201951


B6020011

B6020012


NOTES

Pressure Independent Control Valve

2600 Emrick Blvd • Bethlehem, PA 18020 • USA

800-922-0085 • www.warrencontrols.com

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