Installation, Operation & Maintenance Instructions

Transcription

1 Installation, Operation & Maintenance Instructions High capacity Pressure Independent Control Valve TABLE OF CONTENTS Overview...COVER Operation... 2 Set Differential Pressure Adjustment... 2 Performance... 2 Valve & Actuator Specs... 3 Installation Maintenance... 8 Parts Water Quality Electric Actuator Wiring & Switch Settings Disassemble & Re-assembly Overview 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 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. 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 3-6 PSIG ( 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.

2 Operation 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 (selfoperating) 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. Set Differential Pressure Adjustment This procedure requires the installation of a separate differential pressure gauge between the check valve pressure taps on the PICV. With the PICV installed and in a flowing condition, observe the pressure reading on the differential pressure gauge. The pressure reading on the differential pressure gauge is the set differential pressure of the control valve portion of the PICV. To adjust the set differential pressure, turn the adjusting screw on top of the actuator on the differential pressure control segment until the pressure reading is the desired set differential pressure. The set differential pressure can be adjusted from 3 to 6 PSIG. The adjustment should be made during a condition of 30-70% max flow. Valve Bodies Body Material: End Connections: Trim Designs: Trim Material: Fluid: Trim Limits: Packing: Electric Actuator Cast Iron ANSI 125 Lb. RF Flanges T23 - Single Seat Cylinder Balanced, ANSI Class IV Leakage T22 and Double Seat Balanced, ANSI Class III Leakage 300 Series Stainless Steel Fluoraz Seal (T23) Chilled Water Typical, Water or Water/Glycol from 35 F- 180 F (2 C - 82 C ) MAX Flowing Differential Pressure, 150 PSIG (10.3 BARG) Long-Life Multi-Stack EPDM Lip Packing for Water / Water- Glycol Service Specifications (VM-5000E) 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: 25 VA Timing: 76 Seconds / Inch Feedback Signal: 0-10 Vdc or 2-10 Vdc Failure Mode: Fail-As-Is (alternate battery pack available for open or close) Manual Override: Yes Construction: Polycarbonate Motor Housing with Steel Linkage & Yoke. Case has one 1/2 NPSM Conduit Adapter Connections: Coded Screw Terminals Locations: NEMA Type 2 / IP54 Indoor Only Temperature Limits: Ambient 32 F F ( 0 C - 50 C ) Mounting: Factory Aligned, Vertical Above Centerline of Control Valve Consult factory for preconfigured alternate orientations Double Acting Diaphragm Actuator with Spring Assist (Series 2) Control Signal: Differential Pressure from Control Valve, 3-6 PSIG ( Fluid: Spring Pack: Construction: BARG) Nominal, 150 PSIG ( 10.3 BARG ) Max Static Chilled Water Typical, Water or Water/Glycol from 35 F- 180 F (2 C - 82 C ) Preset to 5 PSIG unless specified, adjustable from 3 to 6 PSIG Ductile Iron, epoxy coated, epoxy coated spring, SS components, Woven neoprene diapragm. Temperature Limits: Ambient 32 F F ( 0 C - 50 C ) Mounting: Factory Aligned, Vertical Above Centerline of Control Valve Consult factory for preconfigured alternate orientations 2600 Emrick Blvd Bethlehem, PA USA

3 Weights 434 Lbs. PICV-T SS-600 PICV-T23X-472-SS-600 PICV-T23R2-472-SS-600 PICV-T23R-472-SS Lbs. PICV-T22R2-472-SS-800 PICV-T22R-472-SS-800 PICV-T SS-800 PICV-T23R2-472-SS-600 Set Differential Pressure (PSIG) PICV-T SS-600 Set Differential Pressure (PSIG) 6 REDUCED Port Maximum Flow (GPM) Standard Port Maximum Flow (GPM) (2-Sizes) Set Differential Pressure (BARG) Maximum Flow (LPS) Set Differential Pressure (BARG) Maximum Flow (LPS) PICV-T23R-472-SS-600 Set Differential Pressure (PSIG) PICV-T23x-472-SS-600 Set Differential Pressure (PSIG) 6 REDUCED Port Maximum Flow (GPM) SUPER Port Maximum Flow (GPM) Set Differential Pressure (BARG) Maximum Flow (LPS) (extended stroke) Set Differential Pressure (BARG) Maximum Flow (LPS) PICV-T22R-472-SS Reduced port Set Differential Pressure (PSIG) Maximum Flow (GPM) Set Differential Pressure (BARG) Maximum Flow (LPS) PICV-T22R2-472-SS Reduced PORT Set Differential Pressure (PSIG) Maximum Flow (GPM) (2 Sizes) Set Differential Pressure (BARG) Maximum Flow (LPS) PICV-T SS Standard Port Set Differential Pressure (PSIG) Maximum Flow (GPM) Set Differential Pressure (BARG) Maximum Flow (LPS) PICV-T22R2-472-SS Reduced Port Set Differential Pressure (PSIG) Maximum Flow (GPM) (2 Sizes) Set Differential Pressure (BARG) Maximum Flow (LPS) PICV-T22R-472-SS-010 Set Differential Pressure (PSIG) PICV-T SS-010 Set Differential Pressure (PSIG) 10 Reduced Port Maximum Flow (GPM) Standard Port Maximum Flow (GPM) Set Differential Pressure (BARG) Maximum Flow (LPS) Set Differential Pressure (BARG) Maximum Flow (LPS) Pressure Independent Control Valve IOM PICV A 0507

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6 Installation Recommended Piping: Per ISA Recommended Piping Practices. Control valves are best served when avoiding turbulent flows. 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, which due to its constant low pressure drop, the control element maintains a low velocity avoiding turbulence. PICV Minimum Lengths of Straight Pipe PICV Size Upstream Downstream Straight Pipe Straight Pipe 2 ½ 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. Be sure that the flow medium, ambient temperature and the selected location will not exceed the maximum temperature of the PICV, actuator, or accessories. Information can be found on the nameplate and product specifications regarding these limits. Check PICV for any damage due to improper storage or transportation. Immediately notify your sales organization of any damaged goods 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. Verify that the PICV is visually in good working order not bent or cracked. Follow good piping practices. Install a bypass around the PICV. Install stop valves in inlet and outlet piping to provide means to isolate PICV. The PICV should be installed as a unit. The segments should not be separated for installation. Carefully remove the PICV from shipping crate with a portable hoist or crane. The PICV is too heavy for one or even two people to lift and 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. 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 of clearance above the actuators to allow for actuator removal. See roughing dimensions for actuator removal clearance. 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. The PICV must be installed with the fluid flow in the direction of the arrow on the flow arrow plate. Pipes must be aligned squarely with the PICV at each connection. Tighten flange bolts evenly to prevent excessive stress and the possibility of cracking. If mating flanges are raised faced they must be ground flat. The PICV and accessories (if so equipped) are assembled, tested, and calibrated at the factory as a unit. The nameplate specifies set-up parameters used. Supply air or power, instrument signal, and accessories should be connected to ports or terminals as indicated on the PICV. Verification and tuning of the set differential pressure may be required under actual operating conditions Emrick Blvd Bethlehem, PA USA

7 cast iron flange dimensions and drilling templates ansi b16:1 125lb cast iron flanges dimensions in inches performance Typical satisfactory arrangement of upstream and downstream piping per ISA recommendation Pressure Independent Control Valve IOM PICV A 0507

8 Maintenance Series 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 (SEE GUIDELINES ON PAGE 15 & 16).! 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 (Type 472) of the PICV. Disassembling the actuator will release the spring force (preload) and may cause serious personal injury. Under normal operating conditions and good water quality many years of maintenance free service can be expected! Packing Adjustment Series PICV packing is self-adjusting and requires no external adjustment. 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. Should parts become worn or damaged, parts kits are available. Separate kits are available for each PICV segment T22, T23, or 472. 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 stepby-step instructions. Each kit has its own part number. Please provide the PICV serial number and segment T22, T23, or 472 to ensure getting the correct kit part number and correct parts. repack kit P/N KXXXXXXXX007 REPACK KIT INCLUDES (see drawing C ) item qty DESCRIPTION 2 1 Packing Retainer 3 1 Retainer Bearing 5 3 Lip Packing 8 1 Tube Stem Lube 1 V-Ring Packing Extractor 1 Packing Spring Removal Tool 1 O-Ring Retainer & O-Ring Extractor 1 Stem Sleeve repack/inspection kits 6 inch t23 repack/inspection kit includes (see drawing C & C ) item qty DESCRIPTION 7 2 Gasket (See Drawing C ) 7 1 Bonnet (See Drawing C ) 9 1 O-Ring (See Drawing C ) 15 1 Tube O-Ring Lube (See Drawing C ) 1 Repack Kit 2600 Emrick Blvd Bethlehem, PA USA

9 repack/inspection kits 8 inch t22 repack/inspection kit includes (see drawing D ) item qty DESCRIPTION 14 2 Gasket (See Drawing D ) 1 Repack Kit 8 inch 472 repack/inspection kit includes (see drawing D ) item qty DESCRIPTION 4 2 Gasket (See Drawing D ) 1 Repack Kit 6 inch 472 repack/inspection kit includes (see drawing D ) item qty DESCRIPTION 13 2 Gasket (See Drawing D ) 1 Repack Kit rebuild/repack kits 6 inch T23 rebuild/repack kit includes (see drawing C & C ) item qty DESCRIPTION 1 1 Valve Stem (See Drawing C ) 3 1 Travel Stop (As req. See Drawing C ) 4 1 Groove Pin (See Drawing C ) 6 1 Bonnet Bearing (See Drawing C ) 7 2 Gasket (See Drawing C ) 7 1 Bonnet (See Drawing C ) 9 1 O-Ring (See Drawing C ) 10 1 Plug (See Drawing C ) 11 1 Seat Ring (See Drawing C ) 15 1 Tube 0-Ring Lube (See Drawing C ) 16 1 Tube Permatex #2 (See Drawing C ) 1 Repack Kit 8 inch T22 rebuild/repack kit includes (see drawing D & C ) item qty DESCRIPTION 1 1 Valve Stem (See Drawing D ) 6 1 Bonnet Bearings (See Drawing C ) 7 1 Bonnet (See Drawing C ) 8 1 Groove Pin (See Drawing D ) 9 1 Upper Seat Ring (See Drawing D ) 10 1 Plug (See Drawing D ) 11 1 Lower Seat Ring (See Drawing D ) 14 2 Gasket (See Drawing D ) 16 1 Tube Permatex #2 (See Drawing D ) 1 Repack Kit 6 inch 472 rebuild/repack kit includes (see drawing D & C ) item qty DESCRIPTION 1 1 Valve Stem (See Drawing D ) 6 1 Groove Pin (See Drawing D ) 6 1 Bonnet Bearing (See Drawing C ) 7 1 Bonnet (See Drawing C ) 8 1 Lower Seat Ring (See Drawing D ) 9 1 Plug (See Drawing D ) 10 1 Upper Seat Ring (See Drawing D ) 13 2 Gasket (See Drawing D ) 15 1 Tube Permatex #2 (See Drawing D ) 1 Repack Kit 8 inch 472 rebuild/repack kit includes (see drawing D & C ) item qty DESCRIPTION 1 1 Valve Stem (See Drawing D ) 4 2 Gasket (See Drawing D ) 6 1 Bonnet Bearing (See Drawing C ) 7 1 Bonnet (See Drawing C ) 7 1 Groove Pin (See Drawing D ) 8 1 Lower Seat Ring (See Drawing D376951) 9 1 Plug (See Drawing D ) 10 1 Upper Seat Ring (See Drawing D ) 16 1 Tube Permatex #2 (See Drawing D ) 1 Repack Kit Pressure Independent Control Valve IOM PICV A 0507

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15 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. Control Valves in HVAC Water Systems Fluid Quality and Service Life Guide Lines The 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, 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. 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 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. are adhered to and that a water treatment, filtration and control specialists be consulted before the system start-up. Pressure Independent Control Valve IOM PICV A

16 Water Quality Recommended Parameters Chilled Water, Closed Loops, and Hot Water Systems up to 212 F (100 C). Chilled Systems Hot Systems 8.0 < ph < Conductivity < 3000 MMHS 3000 MMHS Iron < 0.5 ppm 0.5 ppm Copper < 0.5 ppm 0.5 ppm 100 ppm < Molybdenum < 150 ppm 150 ppm (Mild Steel Corrosion Inhibitor) 200 ppm < Molybdenum < 250 ppm 250 ppm (Mild Steel Corrosion Inhibitor) 400 ppm < Nitrite < 1000 ppm 1000 ppm (Mild Steel Corrosion Inhibitor) Azole > 5 ppm free 5 ppm and available free and ava (Yellow Metal Inhibitor) Bacteria < 1000 cells/ml 1000 cells/ml (when system (when is system cool) is cool! CAUTION The use of hydrazine can result in the formation of ammonia and must be controlled to prevent stress corrosion and embrittlement, which can lead to fracture of some brass alloys. 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% Emrick Blvd Bethlehem, PA USA

17 Assembly Stem Anti rotation connector device Bonnet lock nut Stem lock nut Mounting ange Bushing lock screw Bushing ELECTRONIC ACTUATOR Instructions It is usually easier to assemble the valve and actuator and set up the actuator before the valve is installed. The actuator will work in any position. However, the actuator must have enough clearance to be able to remove the top for wiring and service. The actuator should be higher than the valve so that if the stem packing on the valve leaks, water won t run down the valve stem and into the actuator. The maximum ambient temperature is 120 F. The valve and actuator should be readily visible so that their operation can be easily checked. VM5000E & VM1500E Stem position indicators. Slide together before energizing actuator. Stem connector The VM1500E and the VM5000E actuators can be manually operated with a hex wrench. The VM1500E uses a 4mm hex wrench. The VM5000E uses an 8mm hex wrench. The operator is at the top of the actuator and it is not necessary to remove the cover for access. On the VM5000E there are two rubber caps on the top; one covers the manual operator and the other covers the clutch. Depress the clutch while manually operating the actuator. Put the rubber caps back on when you are finished; they keep dirt and moisture away from the electronic circuit. WIRING SETUP Make sure the bushing is inserted in the mounting flange from the buttom. Screw the stem lock nut onto the valve stem. OPERATION Put the actuator over the valve bonnet and then screw the bonnet lock nut loosely onto the bonnet. Put the anti rotation device on the valve stem. Lower the stem of the actuator until TROUBLESHOOTING you can engage on the valve stem. Screw the stem connecter at least 3/8 onto the valve stem. Raise the stem far enough to make sure the actuator bottoms on the bonnet and then tighten the bonnet lock nut. REPLACEMENT Tighten the stem lock nut. See also drawing C for installation of VM1500E and drawing C for installation of VM5000E on valve.

18 Modulating X 3 1 Y SP SN Feedback Positive 0-10 or 2-10 Vdc Control signal Positive 24 volts ac Common and control signal negative If system is grounded, then ground SN Floating X 3 1 Y SP SN Override Modulating Signal X 3 1 Y SP SN 24 volts ac Terminal 1 Terminal 3 Stem down Stem up Override Common and control signal negative 24 volts ac 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 Emrick Blvd Bethlehem, PA USA

19 PRODUCT: SERIES VM LINEAR ELECTRIC ACTUATORS NATURE OF FAULT: Actuator motor does not deenergize 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 POSITIONED BETWEEN SWITCHES Pressure Independent Control Valve IOM PICV A

20 VMS-25 (Optional accessory) 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. VMS-25 L LN RC LN TG BT NC1 C1 NO1 AC LN NC2 C2 NO2 Jumper 24 volts ac VM1500E or VM5000E X 3 1 Y SP SN VM1500E or VM5000E X 3 1 Y SP SN + - Control Signal + - 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 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 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 Emrick Blvd Bethlehem, PA USA

21 ON Set-Up SP volts AC power in SN... Common (Ground) and control signal negative (See wiring diagrams on page 5) Y... Control signal in (Positive) X... Feedback signal out (Positive) 1... Override 3... Override VM1500E VM5000E X 3 1 Y SP SN X 3 1 Y SP SN ON X 3 1 Y SP SN X 3 1 Y SP SN Switch Functions Switch OFF ON 1 Control Signal Voltage Control Signal Milliamp Volts or 4-20 ma 0-10 volts or 0-20 ma 3 Direct Acting Reverse Acting (Extend on increasing signal) (Retract on increasing signal) 4 Full Range Split Range 5 Low Range Signal High Range Signal 6 Proportional 3 Point Floating 7 Equal Percentage Valve (Default) Linear Valve 8 100% Cv (Default) Reduced Cv 9 Reset Reset Pressure Independent Control Valve IOM PICV A

22 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 mm Automatic stroke adjustment ensures that the signal range covers the actual stroke of the valve. 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 these proportional signals Full Range Split Range 0-10 vdc 0-5 vdc 5-10 vdc 2-10 vdc 2-6 vdc 6-10 vdc 0-20 ma 0-10 ma ma 4-20 ma 4-12 ma 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 Signal Floating Switch #6 ON When switch #6 is on switches 1-5 are inactive. Proportional Switch #6 OFF Signal Switch Number Volts 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 ON OFF OFF OFF 0-20 ON ON OFF OFF 4-12 ON OFF ON OFF ON OFF ON ON 0-10 ON ON ON OFF ON ON ON ON 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 Emrick Blvd Bethlehem, PA USA

23 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: ) before repositioning either switch. Flow Characteristic: Change Flow Characteristic Switch #7 In the OFF position the stem travel is proportional to the control signal and does not alter the flow 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 percentage 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 changing to 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. Equal Percentage Valve & Switch #7 Off Stroke Flow Flow Signal Actuator Stroke Valve Signal Valve + Actuator Equal percentage Valve & Switch #7 On Stroke Signal Actuator Flow Stroke Valve Flow Signal Valve + Actuator Flow Coefficient Full Flow Switch #8 OFF Reduced Flow Switch #8 ON This 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. 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: ). Pressure Independent Control Valve IOM PICV A

24 DISASSEMBLE AND RE-Assembly It is usually easier to assemble the valve and actuator and set up the actuator before the valve is installed. The actuator will work in any position. However, the actuator must have enough clearance to be able to remove the top for wiring and service. The actuator should be higher than the valve so that if the stem packing on the valve leaks, water won t run down the valve stem and into the actuator. The maximum ambient temperature is 120 F. The valve and actuator should be readily visible so that their operation can be easily checked. Make sure the bushing is inserted in the mounting flange from the bottom. Screw the stem lock nut onto the valve stem. Put the actuator over the valve bonnet and then screw the bonnet lock nut loosely onto the bonnet. Put the anti rotation device on the valve stem. Lower the stem of the actuator until you can engage on the valve stem. Screw the stem connector at least 3/8 onto the valve stem. Raise the stem far enough to make sure the actuator bottoms on the bonnet and then tighten the bonnet lock nut. Tighten the stem lock nut. See also drawing C for installation of VM1500E and drawing C for installation of VM5000E on valve. The VM1500E and the VM5000E actuators can be manually operated with a hex wrench. The VM1500E uses a 4mm hex wrench. The VM5000E uses an 8mm hex wrench. The operator is at the top of the actuator and it is not necessary to remove the cover for access. On the VM5000E there are two rubber caps on the top; one covers the manual operator and the other covers the clutch. Depress the clutch while manually operating the actuator. Put the rubber caps back on when you are finished; they keep dirt and moisture away from the electronic circuit. Make sure the bushing is inserted in the mounting fl ange from the bottom. Screw the stem lock nut onto the valve stem. Put the actuator over the valve bonnet and then screw the bonnet lock nut loosely onto the bonnet. Put the anti rotation device on the valve stem. Lower the stem of the actuator until you can engage on the valve stem. Screw the stem connector at least 3/8 onto the valve stem. Raise the stem far enough to make sure the actuator bottoms on the bonnet and then tighten the bonnet lock nut. Tighten the stem lock nut. See also drawing C for installation of VM1500E and drawing C for installation of VM5000E on valve Emrick Blvd Bethlehem, PA USA

25 C Pressure Independent Control Valve IOM PICV A

26 C Emrick Blvd Bethlehem, PA USA

27 NOTES Pressure Independent Control Valve IOM PICV A

28 Pressure Independent Control Valve PICV A Emrick Blvd Bethlehem, PA USA