Manual

ManualsBrandsWarren Controls ManualsEquipmentPICV Series

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 CONTENTS

Overview / 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

PICV IOM

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

Summary of content (40 pages)

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PICV IOM HIGH CAPACITY SERIES PICV (Pressure Independent Control Valve) TABLE OF CONTENTS Overview / Operation..................... COVER Configurations............................................2-3 Differential Pressure..............................4-8 Installation....................................................8-9 Dimensions........................................... 10-12 Weights..........................................................13 Maintenance................................................
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CONFIGURATIONS Control Valve Size Control Valve Flange P2 2.
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4X 0.31 in (0.79 cm) THRU MOUNTING FOOT VMS-25 BCM 8.75 in (22.23 cm) 5.19 in (13.18 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) 8.5 in (21.59 cm) 1/2 in (1.27 cm) DPRV DOUBLE ACTING DIAPHRAGM ACTUATOR WITH SPRING ASSIST Control Signal: Fluid: Spring Pack: Construction: Temperature Limits: Mounting: Differential Pressure from Control Valve, 2.0 to 8 PISG (0.14 to 0.55 BARD) 150 PSIG (10.
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FLANGE ANSI125 PRODUCT MODEL (where ‘x’ is a configurable option) P2023Fx-xxxx-P20Dx-2x 2 1/2” Standard Port ANSI125 P30231x-xxxx-P30Dx-2x 3” 1 Size Reduced Port ANSI125 P3023Fx-xxxx-P30Dx-2x 3” Standard Port ANSI125 P40232x-xxxx-P40Dx-2x 4” 2 Sizes Reduced Port ANSI125 P40231x-xxxx-P40Dx-2x 4” 1 Size Reduced Port ANSI125 P4023Fx-xxxx-P40Dx-2x 4” Standard Port ANSI125 P50232x-xxxx-P50Dx-2x 5” 2 Sizes Reduced Port ANSI125 P50231x-xxxx-P50Dx-2x 5” 1 Size Reduced Port ANSI125 P5023Fx-xxxx-P50
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PRODUCT MODEL FLANGE ANSI125 (where ‘x’ is a configurable option) P60032x-xxxx-P60Dx-2x 6” 2 Sizes Reduced Port ANSI125 P60231x-xxxx-P60Dx-2x 6” 1 Size Reduced Port ANSI125 P6023Fx-xxxx-P60Dx-2x ANSI125 ANSI125 P6023Xx-xxxx-P60Dx-2x ANSI125 2.0 3.1 4.2 5.7 633 657 Maximum flow (GPM) 389 484 3.1 4.2 555 5.7 3.1 634 725 752 4.2 3.
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PRODUCT MODEL FLANGE ANSI125 (where ‘x’ is a configurable option) P1022Fx-xxxx-P10Dx-2x 10” Standard Port PRODUCT MODEL FLANGE PN16 (where ‘x’ is a configurable option) P2223Fx-xxxx-P22Dx-2x DN65 Standard Port PN16 P32231x-xxxx-P32Dx-2x DN80 1 Size Reduced Port PN16 P3223Fx-xxxx-P32Dx-2x DN80 Standard Port PN16 P42232x-xxxx-P42Dx-2x DN100 2 Sizes Reduced Port PN16 P42231x-xxxx-P42Dx-2x DN100 1 Size Reduced Port PN16 P4223Fx-xxxx-P42Dx-2x DN100 Standard Port PN16 P52232x-xxxx-P52Dx-2x DN125
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FLANGE PN16 PRODUCT MODEL (where ‘x’ is a configurable option) P52231x-xxxx-P52Dx-2x DN125 1 Size Reduced Port PN16 P5223Fx-xxxx-P52Dx-2x DN125 Standard Port PN16 P62232x-xxxx-P62Dx-2x DN150 2 Sizes Reduced Port PN16 P62231x-xxxx-P62Dx-2x DN150 1 Size Reduced Port PN16 P6223Fx-xxxx-P62Dx-2x DN150 Standard Port PN16 P6223Xx-xxxx-P62Dx-2x DN150 Extended Port PN16 PN16 PN16 P82222S-xxxx-P82Dx-2x DN200 2 Sizes Reduced Port SS Trim Only P82221S-xxxx-P82Dx-2x DN200 1 Size Reduced Port SS Trim O
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PRODUCT MODEL FLANGE PN16 PN16 PN16 (where ‘x’ is a configurable option) LOW DP SPRING PERFORMANCE MEDIUM DP SPRING PERFORMANCE P12222S-xxxx-P12Dx-2x DN250 2 Sizes Reduced Port SS Trim Only Set Differential Pressure (BAR) P12221S-xxxx-P12Dx-2x DN250 1 Size Reduced Port SS Trim Only Set Differential Pressure (BAR) P1222Fx-xxxx-P12Dx-2x Set Differential Pressure (BAR) DN250 Standard Port 0.14 0.21 0.29 Set Differential Pressure (BAR) 0.37 0.39 Maximum flow (LPS) 66 81 0.14 0.21 95 0.
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• Protect PICV and downstream equipment with an upstream self-cleaning strainer. • For maximum efficiency and minimum wear install PICV IN VERTICAL POSITION with the stems POINTING UPWARD. • Be sure to leave 6 INCHES (15.24 CM) OF CLEARANCE above the actuators to allow for actuator removal. • Before installing, be sure PICV and piping are CLEAN INSIDE and FREE OF SCALE, chips, welding spatter, and foreign material. Thoroughly blow out or flush pipe lines.
PAGE 10
DIMENSIONS PICV SIZES: 2 1/2-4 IN Ddpv Dcv (DN65-DN100) WITH VM1500E ACTUATOR Hdpv Hcv Ccv Cdpv Bcv Bdpv Acv Adpv Xcdp Control Valve (Left) MODEL LISTING P2023xx-E02x-P20Dx-xx P3023xx-E02x-P30Dx-xx P4023xx-E02x-P40Dx-xx P2223xx-E02x-P22Dx-xx P3223xx-E02x-P32Dx-xx P4223xx-E02x-P42Dx-xx SIZE 2-1/2 3 4 DN65 DN80 DN100 Acv Bcv Ccv Dcv Hcv 9 in 10 in 13 in 22.86 cm 25.40 cm 33.02 cm 4-3/4 in 5-3/8 in 6-3/8 in 12.07 cm 13.65 cm 16.19 cm 5-3/4 in 6-5/8 in 7-3/4 in 14.61 cm 16.83 cm 19.
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DIMENSIONS PICV SIZES: 5-6 IN (DN125-DN150) WITH TR5000 ACTUATOR WITH VM5000E ACTUATOR Control Valve (Left) MODEL LISTING P5023xx-E02x-P50Dx-xx P5023xx-TIG1-P50Dx-xx P6023xx-E02x-P60Dx-xx P6023xx-TIGx-P60Dx-xx P5223xx-E02x-P52Dx-xx P5223xx-TIG1-P52Dx-xx P6223xx-E02x-P62Dx-xx P6223xx-TIGx-P62Dx-xx SIZE 5 5 6 6 DN125 DN125 DN150 DN150 Acv Bcv Ccv Dcv Hcv 15-3/4 in 15-3/4 in 17-3/4 in 17-3/4 in 40.01 cm 40.01 cm 45.09 cm 45.09 cm 5-3/4 in 5-3/4 in 6-1/2 in 6-1/2 in 14.61 cm 14.61 cm 16.51 cm 16.
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DIMENSIONS PICV SIZES: 8-10 IN DN200-DN250 WITH VM5000E ACTUATOR WITH TR5000 ACTUATOR Control Valve (Left) MODEL LISTING P8022xx-E02x-P80Dx-xx P8022xx-TIG1-P80Dx-xx P1022xx-E02x-P10Dx-xx P1022xx-TIG1-P10Dx-xx P8222xx-E02x-P82Dx-xx P8222xx-TIG1-P82Dx-xx P1222xx-E02x-P12Dx-xx P1222xx-TIG1-P12Dx-xx SIZE 8 8 10 10 DN200 DN200 DN250 DN250 Acv Bcv Ccv Dcv Hcv 16-1/4 in 16-1/4 in 20 in 20 in 41.28 cm 41.28 cm 50.80 cm 50.80 cm 8-7/8 in 8-7/8 in 9-5/8 in 9-5/8 in 22.54 cm 22.54 cm 24.45 cm 24.
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PICV WEIGHTS MODEL P2x23xx-E02x-P2xDx-2L P2x23xx-E02x-P2xDx-2M P3x23xx-E02x-P3xDx-2L P3x23xx-E02x-P3xDx-2M P4x23xx-E02x-P4xDx-2L P4x23xx-E02x-P4xDx-2M P5x23xx-E02x-P5xDx-2L P5x23xx-E02x-P5xDx-2M P5x23xx-TIG1-P5xDx-2L P5x23xx-TIG1-P5xDx-2M P6x23xx-E02x-P6xDx-2L P6x23xx-E02x-P6xDx-2M P6x23xx-TIGx-P6xDx-2L P6x23xx-TIGx-P6xDx-2M P8x22xx-E02x-P8xDx-2L P8x22xx-E02x-P8xDx-2M P8x22xx-TIG1-P8xDx-2L P8x22xx-TIG1-P8xDx-2M P1x22xx-E02x-P1xDx-2L P1x22xx-E02x-P1xDx-2M P1x22xx-TIG1-P1xDx-2L P1x22xx-TIG1-P1xDx-2M PICV SIZ
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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.
PAGE 15
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...............
PAGE 16
SET-UP SP......................... 24 volts AC power in SN........................ Common (Ground) and control signal negative (See wiring diagrams) Y........................... Control signal in (Positive) X........................... Feedback signal out (Positive) 1........................... Override 3...........................
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Full Range 0 - 10 vdc 2 - 10 vdc 0 - 20 ma 4 - 20 ma DIRECT OR REVERSE ACTING Split Range 0 - 5 vdc 5 - 10 vdc 2 - 6 vdc 6 - 10 vdc 0 - 10 ma 10 - 20 ma 4 - 12 ma 12 - 20 ma An increasing signal can either drive the valve stem down (direct acting) or up (reverse acting).
PAGE 18
PRODUCT: SERIES VM LINEAR ELECTRIC ACTUATORS NATURE 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.
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VM1500E MOTOR ACTUATOR Installation of modification circuit board • PUR 1137 IN KIT NUMBER KVM1500EFB4TO20MA00 to convert native 2-10 vdc feedback output to optional 4-20 mAdc. 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.
PAGE 20
VM5000E MOTOR ACTUATOR Installation of modification circuit board • PUR 1137 IN KIT NUMBER KVM5000EFB4TO20MA00 to convert native 2-10 vdc feedback output to optional 4-20 mAdc. 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.
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Read all instructions carefully before beginning. TURNING THE ACTUATOR LEGS CAUSES DAMAGE TO THE ACTUATOR AND VOIDS THE WARRANTY. Read all instructions carefully before beginning. TURNING THE ACTUATOR LEGS CAUSES DAMAGE TO THE ACTUATOR AND VOIDS THE WARRANTY. REMOVAL OF VM1500E ACTUATOR FROM VALVE REMOVAL OF VM5000E ACTUATOR FROM VALVE 1) 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.
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C3400001 C3400002 22 2600 Emrick Blvd • Bethlehem, PA 18020 • USA • 800-922-0085 • www.warrencontrols.
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TR5000-X ACTUATOR INSTRUCTIONS Page Set-up & Wiring................... 24-25 Removal & Installation........
PAGE 24
Dimensions s 3 Stroke 42mm max S2 Switch setting with manual device Φ 0(2)~10VDC, 0(4)~20mA Input signal 4500N~5500N Input signal 5000N Output signal proportional Voltage input impedance ＞100K 14VA Current input impedance ＜0.50K Rating force Actual force n proportional 42mm Current output load ＜0.5K permanent magnetic 2.5s/ mm (50Hz) Nominal stroke Up and down 42mm, dead band 51mm ≤1.
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S2 SWITCH SETTING S2 Dip Switch Function S2-1 Start point of input/output signal S2-2 Type of input signal S2-3 S2-4 S3-5 S3-6 Type of output (feedback) signal Operating mode Loss of input signal mode S3-7 Self-stroking mode S3-8 Sensitivity Position FACTORY DEFAULT Eg.
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_____________________________________________ 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.
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11) 12) 13) 14) 15) 16) 17) 18) 19) 20) 21) 22) 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. Remove power and signal from actuator. Place actuator over valve stem and onto bonnet adapter. Rotate actuator to desired orientation.
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C3121902 DPRV ACTUATOR INSTRUCTIONS PICV SET DIFFERENTIAL PRESSURE ADJUSTMENT 1. 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.
PAGE 29
PICV DIAPHRAGM ACTUATOR REMOVAL FROM VALVE 1. 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.
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C3121900 30 2600 Emrick Blvd • Bethlehem, PA 18020 • USA • 800-922-0085 • www.warrencontrols.
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D312311 PRESSURE INDEPENDENT CONTROL VALVE PICV_IOM_REVF_0114 31
PAGE 32
PARTS/ OVERHAUL 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.
PAGE 33
REBUILD/REPACK KITS Control Valve Size 2-1/2”, 3”, 4” (DN65, DN80 & DN100) REBUILD/ REPACK KIT INCLUDES (See Drawing C3241354 & C3769956) ITEM 1 3 6 6 7 8 QTY 1 1 1 1 1 1 DESCRIPTION ITEM VALVE STEM (See Dwg C3241354) 9 TRAVEL STOP (As required, See Dwg C3241354) 10 GROOVE PIN (See Dwg C3241354) 12 BONNET BEARING (See Dwg C3769956) 15 BONNET (See Dwg C3769956) 16 O-RING (See Dwg C3241354) QTY 1 1 3 1 1 1 DESCRIPTION PLUG (See Dwg C3241354) SEAT RING (See Dwg C3241354) GASKET (See Dwg C3241354) TUBE O
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C3241354 34 2600 Emrick Blvd • Bethlehem, PA 18020 • USA • 800-922-0085 • www.warrencontrols.
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C3201355 C3769956 PRESSURE INDEPENDENT CONTROL VALVE PICV_IOM_REVF_0114 35
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D3241556 D3201753 36 2600 Emrick Blvd • Bethlehem, PA 18020 • USA • 800-922-0085 • www.warrencontrols.
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D3201950 D3201951 PRESSURE INDEPENDENT CONTROL VALVE PICV_IOM_REVF_0114 37
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B6020011 B6020012 38 2600 Emrick Blvd • Bethlehem, PA 18020 • USA • 800-922-0085 • www.warrencontrols.
PAGE 39
NOTES PRESSURE INDEPENDENT CONTROL VALVE PICV_IOM_REVF_0114 39
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PICV_IOM_REVF_0114 Pressure Independent Control Valve 2600 Emrick Blvd • Bethlehem, PA 18020 • USA 800-922-0085 • www.warrencontrols.