SERIES PICV PICV IOM. (Pressure Independent Control Valve) TABLE OF CONTENTS OVERVIEW OPERATION HIGH CAPACITY

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1 HIGH CAPACITY SERIES PICV (Pressure Independent Control Valve) PICV IOM TABLE OF CONTENTS Overview / Operation...COVER Configurations Differential Pressure Installation Dimensions Weights...13 Maintenance...13 Water Quality VM5000E & VM1500E TR5000X DPRV Actuator...28 Parts/Overhaul Stem Adapter Setting Gages...38 PICV_IOM_REVF_0114 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 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 pressurebalanced control valve, actuated by either a high-thrust electric motor 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 ( 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. 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. NOTE: The maximum differential pressure across the entire PICV is approximately 2 x (Set Differential Pressure) at max flow

2 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 P2 2.5 DN65 P3 3 DN80 P4 4 DN100 P5 5 DN125 P6 6 DN150 P8 8 DN200 P1 10 DN250 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 Steel B 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 P2 2.5 DN65 P3 3 DN80 P4 4 DN100 P5 5 DN125 P6 6 DN150 P8 8 DN200 P1 10 DN250 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 VALVE BODIES Body Material: Cast Iron End Connections: ANSI 125LB FF Flanges, PN16 FF Flanges Trim Designs: Type 23 - Single Seat Cylinder Balanced, ANSI Class III Leakage Type 22 and 72 - Double Seat Balanced, ANSI Class III Leakage Trim 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 Body Pressure Temperature Ratings Iron Body Temperature 125 FLG & PN16 O F O C PSIG BARG 35 to to 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 25VA Timing: 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 Vdc Failure Mode: Fail-As-Is [Without VMS-25 BCM (Back-up Control Module)] Fail-Safe [With VMS-25 BCM (Back-up Control Module)] Manual Override: Yes Construction: Polycarbonate Motor Housing with Steel Linkage & Yoke. Case has one 1/2 inch (1.27 cm) NPSM Conduit Adapter Connections: Coded Screw Terminals Locations: NEMA Type 3 / IP54 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 VMS-25 BCM (BACK-UP CONTROL MODULE) SPECIFICATIONS Actuator Usage: VM-1500E & VM-5000E Required for Fail Safe Operation Failure Direction: Field Selectable Power Consumption: 24VAC, 40VA Construction: Battery w/circuit Board & Transformer, in Nema 4 Enclosure Mounting: Wall Mount Weight: 4.25 lbs (2 kg)

3 VMS-25 BCM 4X 0.31 in (0.79 cm) THRU MOUNTING FOOT 5.19 in (13.18 cm) 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) 8.5 in (21.59 cm) 1/2 in (1.27 cm) 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 Static Fluid: 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 ( BARD) Medium DP Spring: Adjustable 5 to 8 PSIG ( BARD) Construction: Cast Gray Iron Class G3000, epoxy coated, epoxy coated spring, SS components, Woven Buna-N, nylon reinforced. 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 ELECTRIC ACTUATOR SPECIFICATIONS (TR5000-X) Valve Usage: 5, 6, 8, & 10 inch, DN125, DN150, DN200, DN250 Control 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: 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 Power Manual Override: Yes Construction: Die Cast Aluminum Motor Housing & Yoke. Painted. Case Has Two PG11 Cable Glands Accepts to inch (5mm to 10mm) Diameter Cable Connections: 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 PRESSURE INDEPENDENT CONTROL VALVE PICV_IOM_REVF_0114 3

4 FLANGE PRODUCT MODEL (where x is a configurable option) LOW DP SPRING PERFORMANCE MEDIUM DP SPRING PERFORMANCE ANSI125 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-P50Dx-2x 5 Standard Port Emrick Blvd Bethlehem, PA USA

5 FLANGE PRODUCT MODEL (where x is a configurable option) LOW DP SPRING PERFORMANCE MEDIUM DP SPRING PERFORMANCE ANSI125 P60032x-xxxx-P60Dx-2x 6 2 Sizes Reduced Port ANSI125 P60231x-xxxx-P60Dx-2x 6 1 Size Reduced Port ANSI125 P6023Fx-xxxx-P60Dx-2x 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 PRESSURE INDEPENDENT CONTROL VALVE PICV_IOM_REVF_0114 5

6 FLANGE PRODUCT MODEL (where x is a configurable option) LOW DP SPRING PERFORMANCE MEDIUM DP SPRING PERFORMANCE ANSI125 P1022Fx-xxxx-P10Dx-2x 10 Standard Port FLANGE PRODUCT MODEL (where x is a configurable option) LOW DP SPRING PERFORMANCE MEDIUM DP SPRING PERFORMANCE PN16 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 2 Sizes Reduced Port Emrick Blvd Bethlehem, PA USA

7 FLANGE PRODUCT MODEL (where x is a configurable option) LOW DP SPRING PERFORMANCE MEDIUM DP SPRING PERFORMANCE PN16 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 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 PRESSURE INDEPENDENT CONTROL VALVE PICV_IOM_REVF_0114 7

8 FLANGE PRODUCT MODEL (where x is a configurable option) LOW DP SPRING PERFORMANCE MEDIUM DP SPRING PERFORMANCE 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 PN16 P1222Fx-xxxx-P12Dx-2x DN250 Standard Port 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. PICV Minimum Lengths of Straight Pipe PICV Size Upstream Straight Pipe Downstream Straight 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) 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 Emrick Blvd Bethlehem, PA USA

9 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. 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 machined 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. PRESSURE INDEPENDENT CONTROL VALVE PICV_IOM_REVF_0114 9

10 DIMENSIONS PICV SIZES: 2 1/2-4 IN (DN65-DN100) Dcv Ddpv WITH VM1500E ACTUATOR Hdpv Hcv Ccv Cdpv Bcv Bdpv Acv Adpv Xcdp Control Valve (Left) 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 in P3023xx-E02x-P30Dx-xx 3 10 in 5-3/8 in 6-5/8 in 4-7/8 in 14-3/4 in P4023xx-E02x-P40Dx-xx 4 13 in 6-3/8 in 7-3/4 in 4-7/8 in 14-3/4 in P2223xx-E02x-P22Dx-xx DN cm cm cm cm cm P3223xx-E02x-P32Dx-xx DN cm cm cm cm cm P4223xx-E02x-P42Dx-xx DN cm cm cm cm cm Acv +/- 1/16 in (0.16 cm) All other dimensions are maximum Allow 6 in (15.24 cm) above actuator for removal service Differential Pressure Valve (Right) * Includes gasket between Control Valve and Differential Pressure Valve Adpv +/- 1/16 in (0.16 cm) Xcdp +/- 1/8 in (0.32 cm) All other dimensions are maximum Allow 6 in (15.24 cm) above actuator for removal service Total combined* 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 in P2023xx-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 in P3023xx-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 in P3023xx-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 in P4023xx-E02x-P40Dx-2L /8 in 6-3/8 in 5-1/4 in 9-3/4 in 22-1/8 in 24-7/16 in P4023xx-E02x-P40Dx-2M /8 in 6-3/8 in 5-1/4 in 9-3/4 in 26-3/4 in 24-7/16 in P2223xx-E02x-P22Dx-2L DN cm cm cm cm cm cm P2223xx-E02x-P22Dx-2M DN cm cm cm cm cm cm P3223xx-E02x-P32Dx-2L DN cm cm cm cm cm cm P3223xx-E02x-P32Dx-2M DN cm cm cm cm cm cm P4223xx-E02x-P42Dx-2L DN cm cm cm cm cm cm P4223xx-E02x-P42Dx-2M DN cm cm cm cm cm cm Emrick Blvd Bethlehem, PA USA

11 DIMENSIONS PICV SIZES: 5-6 IN (DN125-DN150) WITH TR5000 ACTUATOR WITH VM5000E ACTUATOR Control Valve (Left) MODEL LISTING SIZE Acv Bcv Ccv Dcv Hcv P5023xx-E02x-P50Dx-xx /4 in 5-3/4 in 8-1/4 in 6-5/8 in 15-1/4 in P5023xx-TIG1-P50Dx-xx /4 in 5-3/4 in 8-1/4 in 7-1/2 in 16-1/4 in P6023xx-E02x-P60Dx-xx /4 in 6-1/2 in 8-7/8 in 6-5/8 in 15-1/4 in P6023xx-TIGx-P60Dx-xx /4 in 6-1/2 in 8-7/8 in 7-1/2 in 16-1/4 in P5223xx-E02x-P52Dx-xx DN cm cm cm cm cm P5223xx-TIG1-P52Dx-xx DN cm cm cm cm cm P6223xx-E02x-P62Dx-xx DN cm cm cm cm cm P6223xx-TIGx-P62Dx-xx DN cm cm cm cm cm Acv +/- 1/16 in (0.16 cm) All other dimensions are maximum Allow 6 in (15.24 cm) above actuator for removal service Differential Pressure Valve (Right) * Includes gasket between Control Valve and Differential Pressure Valve Adpv +/- 1/16 in (0.16 cm) Xcdp +/- 1/8 in (0.32 cm) All other dimensions are maximum Allow 6 in (15.24 cm) above actuator for removal service Total combined* Model Listing SIZE Adpv Bdpv Cdpv Ddpv Hdpv Xcdp P5023xx-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 in P5023xx-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 in P6023xx-xxxx-P60Dx-2L /8 in 7-5/8 in 8-1/2 in 9-3/4 in 22-1/8 in 31-15/16 in P6023xx-xxxx-P60Dx-2M /8 in 7-5/8 in 8-1/2 in 9-3/4 in 26-3/4 in 31-15/16 in P5223xx-xxxx-P52Dx-2L DN cm cm cm cm cm cm P5223xx-xxxx-P52Dx-2M DN cm cm cm cm cm cm P6223xx-xxxx-P62Dx-2L DN cm cm cm cm cm cm P6223xx-xxxx-P62Dx-2M DN cm cm cm cm cm cm PRESSURE INDEPENDENT CONTROL VALVE PICV_IOM_REVF_

12 DIMENSIONS PICV SIZES: 8-10 IN DN200-DN250 WITH VM5000E ACTUATOR WITH TR5000 ACTUATOR Control Valve (Left) MODEL LISTING SIZE Acv Bcv Ccv Dcv Hcv P8022xx-E02x-P80Dx-xx /4 in 8-7/8 in 9-5/8 in 6-5/8 in 15 in P8022xx-TIG1-P80Dx-xx /4 in 8-7/8 in 9-5/8 in 7-3/8 in 16-1/4 in P1022xx-E02x-P10Dx-xx in 9-5/8 in 10-1/8 in 6-5/8 in 15 in P1022xx-TIG1-P10Dx-xx in 9-5/8 in 10-1/8 in 7-3/8 in 16-1/4 in P8222xx-E02x-P82Dx-xx DN cm cm cm cm cm P8222xx-TIG1-P82Dx-xx DN cm cm cm cm cm P1222xx-E02x-P12Dx-xx DN cm cm cm cm cm P1222xx-TIG1-P12Dx-xx DN cm cm cm cm cm Acv +/- 1/16 in (0.16 cm) All other dimensions are maximum Allow 6 in (15.24 cm) above actuator for removal service Differential Pressure Valve (Right) * Includes gasket between Control Valve and Differential Pressure Valve Adpv +/- 1/16 in (0.16 cm) Xcdp +/- 1/8 in (0.32 cm) All other dimensions are maximum Allow 6 in (15.24 cm) above actuator for removal service Total combined* Model Listing SIZE Adpv Bdpv Cdpv Ddpv Hdpv Xcdp P8022xx-xxxx-P80Dx-2L /4 in 8-7/8 in 9-5/8 in 9-3/4 in 22-1/8 in 32-9/16 in P8022xx-xxxx-P80Dx-2M /4 in 8-7/8 in 9-5/8 in 9-3/4 in 26-3/4 in 32-9/16 in P1022xx-xxxx-P10Dx-2L in 9-5/8 in 10-1/8 in 9-3/4 in 22-1/8 in 40-1/16 in P1022xx-xxxx-P10Dx-2M in 9-5/8 in 10-1/8 in 9-3/4 in 26-3/4 in 40-1/16 in P8222xx-xxxx-P82Dx-2L DN cm cm cm cm cm cm P8222xx-xxxx-P82Dx-2M DN cm cm cm cm cm cm P1222xx-xxxx-P12Dx-2L DN cm cm cm cm cm cm P1222xx-xxxx-P12Dx-2M DN cm cm cm cm cm cm Emrick Blvd Bethlehem, PA USA

13 PICV WEIGHTS MODEL PICV SIZE CONTROL VALVE ACTUATOR DPRV ACTUATOR TOTAL WT (LBS) TOTAL WT (KG) P2x23xx-E02x-P2xDx-2L 2-1/2 in, DN65 VM-1500E 2L P2x23xx-E02x-P2xDx-2M 2-1/2 in, DN65 VM-1500E 2M P3x23xx-E02x-P3xDx-2L 3 in, DN80 VM-1500E 2L P3x23xx-E02x-P3xDx-2M 3 in, DN80 VM-1500E 2M P4x23xx-E02x-P4xDx-2L 4 in, DN100 VM-1500E 2L P4x23xx-E02x-P4xDx-2M 4 in, DN100 VM-1500E 2M P5x23xx-E02x-P5xDx-2L 5 in, DN125 VM-5000E 2L P5x23xx-E02x-P5xDx-2M 5 in, DN125 VM-5000E 2M P5x23xx-TIG1-P5xDx-2L 5 in, DN125 TR5000-X 2L P5x23xx-TIG1-P5xDx-2M 5 in, DN125 TR-5000-X 2M P6x23xx-E02x-P6xDx-2L 6 in, DN150 VM-5000E 2L P6x23xx-E02x-P6xDx-2M 6 in, DN150 VM-5000E 2M P6x23xx-TIGx-P6xDx-2L 6 in, DN150 TR5000-X 2L P6x23xx-TIGx-P6xDx-2M 6 in, DN150 TR-5000-X 2M P8x22xx-E02x-P8xDx-2L 8 in, DN200 VM-5000E 2L P8x22xx-E02x-P8xDx-2M 8 in, DN200 VM-5000E 2M P8x22xx-TIG1-P8xDx-2L 8 in, DN200 TR5000-X 2L P8x22xx-TIG1-P8xDx-2M 8 in, DN200 TR-5000-X 2M P1x22xx-E02x-P1xDx-2L 10 in, DN250 VM-5000E 2L P1x22xx-E02x-P1xDx-2M 10 in, DN250 VM-5000E 2M P1x22xx-TIG1-P1xDx-2L 10 in, DN250 TR5000-X 2L P1x22xx-TIG1-P1xDx-2M 10 in, DN250 TR-5000-X 2M Weights for models with VM actuators do not include a VMS-25 BCM. Add 4.25 lbs (2kg) Actual shipping weights may vary.! 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. 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. PACKING ADJUSTMENT Series PICV packing is self-adjusting and requires no external adjustment. UNDER NORMAL OPERATING CONDITIONS AND GOOD WATER QUALITY MANY YEARS OF MAINTENANCE FREE SERVICE CAN BE EXPECTED! 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, 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. PRESSURE INDEPENDENT CONTROL VALVE PICV_IOM_REVF_

14 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. 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. 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. 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. WATER QUALITY RECOMMENDED PARAMETERS! 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. Chilled Systems Hot Systems 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 ppm 100 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) 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

15 VM5000E & VM1500E ACTUATOR INSTRUCTIONS Page Actuator Set-up & Wiring 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 PRESSURE INDEPENDENT CONTROL VALVE PICV_IOM_REVF_

16 SET-UP SP 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... Override SWITCH FUNCTIONS Switch OFF ON 1 Voltage Control Signal Milliamp Control Signal 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 (Default) DO NOT USE 9 Reset Reset Feedback Positive 0-10 or 2-10 Vdc Override Control signal Positive 24 volts ac Common and control signal negative If system is grounded, then ground SN 24 volts ac Terminal 1 Stem down Terminal 3 Stem up 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. 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. 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 Emrick Blvd Bethlehem, PA USA

17 Flow Flow Flow Flow 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 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 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. 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 EQUAL PERCENTAGE VALVE & SWITCH #7 OFF EQUAL PERCENTAGE VALVE & SWITCH #7 ON Stroke Signal Actuator Stroke Valve Signal Valve + Actuator Stroke Signal Actuator fficient Stroke Valve Signal Valve + Actuator SWITCH 8: FACTORY DEFAULT OFF The 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. 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 PICV_IOM_REVF_

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. 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 TERMINALS 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. VMS-25 L LN BT RC TG C1 C2 NC1 NC2 NO1 NO2 AC System Power 24VAC System Neutral Battery Test Remote Control Test Ground Relay Common 1st Motor Relay Common 2nd Motor Relay Normally Closed 1st Motor Relay Normally Closed 2nd Motor Relay Normally Open 1st Motor Relay Normally Open 2nd Motor 24 Volt Out 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. 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

19 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. 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: PUR madc Mod. Board 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 KVM1500EFB4TO20MA00 A. Using two mounting screws, fasten the mod. board to the two existing bosses on the motor housing. Note the rectangular wireclearance 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 (-). PRESSURE INDEPENDENT CONTROL VALVE PICV_IOM_REVF_

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. 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: PUR madc Mod. Board Wires and mounting screws are provided in the kit. The illustrations that follow 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 KVM5000EFB4TO20MA00 A. 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 (-) Emrick Blvd Bethlehem, PA USA

21 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 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. 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 C ) 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 antirotation 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 VALVE 1) 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 C ) 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. 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. PRESSURE INDEPENDENT CONTROL VALVE PICV_IOM_REVF_

22 C C Emrick Blvd Bethlehem, PA USA

23 TR5000-X ACTUATOR INSTRUCTIONS Page Set-up & Wiring Removal & Installation PRESSURE INDEPENDENT CONTROL VALVE PICV_IOM_REVF_

24 S2 Switch Function 1 Flow character ON OFF LOG: equal-percentage LIN: equal-linear Starting of input/ ON 20%:the starting input / output sign 2 output signal Chilled/hot water application Steam OFF application 0:the starting input / output signal i with manual device Not suitable downwards All above ON suitable II: input current signal 3 Type of input signal TR5000-X220-S.12 TR5000-X220S.12 / TR5000-X220-S OFF UI: input voltage signal Type of output ON IO: Output current signal 5000N Rating force Input signal 5000N 0(2)~10VDC, 0(4)~20mA Input signal 4 0(2)~10VDC, signal 0(4)~20MA OFF UO: Output voltage signal 4500N~5500N Output signal 0(2)~10VDC, 0(4)~20mA Actual force 4500~5500N Output signal 0(2)~10VDC, 0(4)~20MA ON DA:DA mode (when input signal is proportional Voltage input impedance >100K 5 Operating mode Type of control proportional Voltage input impedance >100K OFF RA: RA mode (when input signal is 14VA Current input impedance <0.50K ON DW: When lose input signal (voltag Synchronous Power motor consumption with 12VA Current input impedance <0.167K Losing input signal When lose input signal (curren Voltage output load >1K 6 permanent magentic Motor Synchronous motor with Voltage output load >1K mode OFF UP: When lose input signal (voltag 42mm Current output permanent load magnetic <0.5K When lose input signal (curren 2.5s/ mm (50Hz) ON DF: when the actuator axes retract Nominal stroke Up and down 42mm, dead band 51mm 1.5% Current output load <0.5K when the actuator axes extend rature -10~50 (Operation condition) Sensitivity 2% 7 Output signal mode Running speed 3.57s/ mm (50Hz) Up and down dead band 2.5% OFF RF: when the actuator axes extend 95% RH(40 ) Aluminum die casting ity Material of bracket when the actuator axes retract (Operation condition) Environmental temperature -10~50ºC (Operation (surface condition) anti-rust process) Sensititivity low 2% high 1.5% ON HS: the high sensitivity of input sign Aluminum die casting 8 Sensitivity IP54 Environmental humidity Material of cover 95% RH(40ºC) Material of bracket Aluminum die casting OFF LS: the low sensitivity of input signa (Operation condition) (surface anti-rust process) (surface anti-rust process) Up/ down straight travel Net weight of product 6.0 Kg Input signal: 0~10VDC IP Degree IP54 Material of cover Aluminum die castingoutput signal: 0~10VDC (surface anti-rust process) Operating mode: DA Eg Losing input signal mode:dw RUNNING MODE Up/down straight travel Net weight of product 5.2 Kg Sensitivity of input signal 2% M WIRING O E Y Input signal Output signal PCB self-stroking button CPU S2 20% II UI IO S3 DA DW DF HS 0 UI II UO RA UP RF LS S1 ON S2 S3 function digit OFF error light ERR maximum RUN 100 opening aperture running light 220VAC potentiometer number digit auxiliary terminal ON-OFF SWITCH The TR5000 actuator has an ON-OFF switch. The switch must be in the ON position for the actuator to operate UL DL AL L N O E Y connecting terminal ON OFF 000-X...actuator with TL,TW or TF... valve body, connect AC 220V power supply. Then press down on PCB over With 3 seconds switch S3-7 until the OFF running (Factory light Default), flickering: the self-stroking button must be arting pressed for self-stroking to start. With switch S3-7 ON, self-stroking starts to 1 (actuator axes retracts until up limit position), running light flickering each time the actuator is powered up. If switch S3-7 is ON, self-stroking to 0 (actuator axes extends until down limit position), running light flickering CPU, self-stoking may also step be is started finished by ( total pressing process the need self-stroking approx.180 button seconds) for greater than 3 seconds. It is recommended that switch S3-7 be OFF. g, actuator The can self-stroking not be controlled function by input must singal. 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 DEBUGGING/SELF-STROKING 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-stroking starts 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 the CPU; self-stroking is finished (total process takes approx.150 seconds). The actuator and running light return to normal operation. 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

25 S2 SWITCH SETTING S2 Dip Switch S2-1 S2-2 S2-3 S2-4 S3-5 S3-6 S3-7 Function Start point of input/output signal Type of input signal Type of output (feedback) signal Operating mode Loss of input signal mode Self-stroking mode S3-8 Sensitivity Position ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF Description 20%: The start point of the input / output signal is 20% (The full input / output signal is 4~20mA or 2~10V) (Factory Default) 0: The start point of the input / output signal is 0% (The full input / output signal is 0~20mA or 0~10V) II: Input signal is current (madc) (Factory Default) UI: Input signal is voltage (Vdc) When S2-2 is OFF, S2-3 MUST be ON When S2-2 is ON, S2-3 MUST be OFF (Factory Default) IO: Output signal is current (madc) (Factory Default) UO: Output signal is voltage (Vdc) DA: DA mode (When input signal is increasing, the actuator stem extends ) (Factory Default) RA: RA mode (When input signal is increasing, the actuator stem retracts) DW: On loss of input signal, the actuator fails to the minimum input signal position. (Factory Default) UP: On loss of input signal, the actuator fails to the maximum input signal position. DF: Self-stroking starts each time the actuator is powered up. RF: Self-stroking starts ONLY when the self-stroking button is pressed for >3 seconds. (Factory Default) ON HS: High sensitivity of input signal </=1.5% OFF LS: Low sensitivity of input signal </=2% (Factory Default) Eg.1 Input signal: 4-20mA Output signal: 4-20mA Operating Mode: DA Loss of input signal mode: DW Sensitivity of input signal <_ 2% Eg.2 ON S2 OFF FACTORY DEFAULT ON S2 S3 OFF S Input signal: 0-10VDC Output signal: 0-10VDC Operating Mode: DA Loss of input signal mode: DW Sensitivity of input signal <_ 2% LIGHTS AND DISPLAY -- 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 A C F Meaning Numerical display shows aperture setting in percent Numerical display shows input signal in percent Numerical display shows output signal in percent Numerical display shows Number from 30~100 Number from 0~100 Number from 0~100 Meaning 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. Input signal percent. Example: For input signal 0~10V, when input signal is 1 V, display will show 10 (1/10*100=10) 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 terminal 1) Terminal 1,2 (UL): Non-functional, No terminal block present 2) Terminal 3,4 (DL): Non-functional, No terminal block present 3) Terminal 5,6 (AL): Fault SPDT input terminal (NO) When a fault occurs, this terminal will close. Faults include: The actuator cannot complete the selfstoking 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

26 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 ADAPTER COMPLETE 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 ADAPTER COMPLETE 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 /-.012 inch ( / 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 B 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. 12) Turn off power. Make necessary dipswitch settings and additional wiring connections. See Set-Up and Wiring sections of these instructions. 13) Return power to actuator. 14) Return line pressure to valve. 15) Stroke valve several times to check operation. INSTALLATION OF T1G1 TR5000-X ACTUATOR ON 6 INCH (DN150) EXTENDED PORT PICV VALVE 1) Isolate valve body if already installed in piping. 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. 4) Install bonnet adapter on valve bonnet and tighten. Watch orientation. 5) Install jamnut on valve stem. Thread jamnut to bottom of threads on stem. 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 Emrick Blvd Bethlehem, PA USA

27 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. 20) Return power to actuator. 21) Return line pressure to valve. 22) Stroke valve several times to check operation. INSTALLATION OF TIG2 TR5000-X ACTUATOR ON - 6 INCH (DN150) EXTENDED PORT PICV VALVE /-.012 inch ( / 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 B 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. 13) Return power to actuator. 14) Return line pressure to valve. 15) Stroke valve several times to check operation. 1) Isolate valve body if already installed in piping. TO INSTALL BONNET ADAPTER AND STEM ADAPTER COMPLETE 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 PRESSURE INDEPENDENT CONTROL VALVE PICV_IOM_REVF_

28 C 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 C ). 3. Connect flexible temporary air connection to upstream port pressure sensing connection on diaphragm actuator (See drawing C 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 D (Sizes 2-1/2 thru 4 inch, P2 thru P4) or C (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 Emrick Blvd Bethlehem, PA USA

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 C ). 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 MOUNTING ON VALVE 1. 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 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 C 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 D (Sizes 2-1/2 thru 4 inch, P2 thru P4) or C (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. PRESSURE INDEPENDENT CONTROL VALVE PICV_IOM_REVF_

30 C Emrick Blvd Bethlehem, PA USA

31 D PRESSURE INDEPENDENT CONTROL VALVE PICV_IOM_REVF_

32 PARTS/ OVERHAUL REPACK KIT 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. P/N KXXXXXXXX007 REPACK KIT INCLUDES (see drawing C ) 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 KITS Control Valve Size 2-1/2, 3, 4 (DN65, DN80 & DN100) REPACK/ INSPECTION KIT INCLUDES (See Drawing C ) ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION 12 3 GASKET (See Dwg C ) 1 REPACK KIT DPRV Size 2-1/2, 3, 4 (DN65, DN80 & DN100) REPACK/ INSPECTION KIT INCLUDES (See Drawing C ) ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION 9 1 GASKET (See Dwg C ) 1 REPACK KIT Control Valve Size 5 & 6 (DN 125 & DN150) REPACK/ INSPECTION KIT INCLUDES (See Drawing C & C ) ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION 7 2 GASKET (See Dwg C ) 15 1 TUBE O-RING LUBE (See Dwg C ) 9 1 O-RING (See Dwg C ) 1 REPACK KIT DPRV Size 5 & 6 (DN 125 & DN150) REPACK/ INSPECTION KIT INCLUDES (See Drawing D ) ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION 13 2 GASKET (See Dwg D ) 1 REPACK KIT Control Valve Size 8 & 10 (DN200 & DN 250) REPACK/ INSPECTION KIT INCLUDES (See Drawing D ) ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION 14 2 GASKET (See Dwg D ) 1 REPACK KIT DPRV Size 8 & 10 (DN200 & DN 250) REPACK/ INSPECTION KIT INCLUDES (See Drawing D ) ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION 4 2 GASKET (See Dwg D ) 1 REPACK KIT Emrick Blvd Bethlehem, PA USA

33 REBUILD/REPACK KITS Control Valve Size 2-1/2, 3, 4 (DN65, DN80 & DN100) REBUILD/ REPACK KIT INCLUDES (See Drawing C & C ) ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION 1 1 VALVE STEM (See Dwg C ) 9 1 PLUG (See Dwg C ) 3 1 TRAVEL STOP (As required, See Dwg C ) 10 1 SEAT RING (See Dwg C ) 6 1 GROOVE PIN (See Dwg C ) 12 3 GASKET (See Dwg C ) 6 1 BONNET BEARING (See Dwg C ) 15 1 TUBE O-RING LUBE (See Dwg C ) 7 1 BONNET (See Dwg C ) 16 1 TUBE PERMATEX #2 (See Dwg C ) 8 1 O-RING (See Dwg C ) 1 REPACK KIT DPRV Size 2-1/2, 3, 4 (DN65, DN80 & DN100) REBUILD/ REPACK KIT INCLUDES (See Drawing C & C ) ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION 1 1 VALVE STEM (See Dwg C ) 7 1 TRAVEL STOP (As required, See Dwg ( ) 4 1 GROOVE PIN (See Dwg C ) 9 2 GASKET (See Dwg C ) 6 1 BONNET BEARING (See Dwg C ) 12 1 TUBE PERMATEX #2 (See Dwg C ) 6 1 PLUG (See Dwg C ) 1 REPACK KIT 7 1 BONNET (See Dwg C ) Control Valve Size 5 & 6 (DN 125 & DN150) REBUILD/ REPACK KIT INCLUDES (See Drawing C & C ) ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION 1 1 VALVE STEM (See Dwg C ) 9 1 O-RING (See Dwg C ) 3 1 TRAVEL STOP (As required,see Dwg C ) 10 1 PLUG (See Dwg C ) 4 1 GROOVE PIN (See Dwg C ) 11 1 SEAT RING (See Dwg C ) 6 1 BONNET BEARING (See Dwg C ) 15 1 TUBE O-RING LUBE (See Dwg C ) 7 2 GASKET (See Dwg C ) 16 1 TUBE PERMATEX #2 (See Dwg C ) 7 1 BONNET (See Dwg C ) 1 REPACK KIT DPRV Size 5 & 6 (DN 125 & DN150) REBUILD/ REPACK KIT INCLUDES (See Drawing D & C ) ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION 1 1 VALVE STEM (See Dwg D ) 9 1 PLUG (See Dwg D ) 6 1 GROOVE PIN (See Dwg D ) 10 1 UPPER SEAT RING (See Dwg D ) 6 1 BONNET BEARING (See Dwg C ) 13 2 GASKET (See Dwg D ) 7 1 BONNET (See Dwg C ) 15 1 TUBE PERMATEX #2 (See Dwg D ) 8 1 LOWER SEAT RING (See Dwg D ) 1 REPACK KIT Control Valve Size 8 & 10 (DN200 & DN 250) REBUILD/ REPACK KIT INCLUDES (See Drawing D & C ) ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION 1 1 VALVE STEM (See Dwg D ) 10 1 PLUG (See Dwg D ) 6 1 BONNET BEARING (See Dwg C ) 11 1 LOWER SEAT RING (See Dwg D ) 7 1 BONNET (See Dwg C ) 14 2 GASKET (See Dwg D ) 8 1 GROOVE PIN (See Dwg D ) 16 1 TUBE PERMATEX #2 (See Dwg D ) 9 1 UPPER SEAT RING (See Dwg D ) 1 REPACK KIT DPRV Size 8 & 10 (DN200 & DN 250) REBUILD/ REPACK KIT INCLUDES (See Drawing D & C ) ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION 1 1 VALVE STEM (See Dwg D ) 8 1 LOWER SEAT RING (See Dwg D ) 4 2 GASKET (See Dwg D ) 9 1 PLUG (See Dwg D ) 6 1 BONNET BEARING (See Dwg C ) 10 1 UPPER SEAT RING (See Dwg D ) 7 1 BONNET (See Dwg C ) 16 1 TUBE PERMATEX #2 (See Dwg D ) 7 1 GROOVE PIN (See Dwg D ) 1 REPACK KIT PRESSURE INDEPENDENT CONTROL VALVE PICV_IOM_REVF_

34 C Emrick Blvd Bethlehem, PA USA

35 C C PRESSURE INDEPENDENT CONTROL VALVE PICV_IOM_REVF_

36 D D Emrick Blvd Bethlehem, PA USA

37 D D PRESSURE INDEPENDENT CONTROL VALVE PICV_IOM_REVF_

38 B B Emrick Blvd Bethlehem, PA USA

39 NOTES PRESSURE INDEPENDENT CONTROL VALVE PICV_IOM_REVF_

40 PICV_IOM_REVF_0114 Pressure Independent Control Valve 2600 Emrick Blvd Bethlehem, PA USA