Series Picv: (Pressure Independent Control Valve)

HIGH CAPACITY SERIES PICV
(Pressure Independent Control Valve)

TABLE OF CONTENTS
PICV IOM
Overview / Operation..................... COVER

Configurations............................................2-3
Differential Pressure..............................4-8
Installation....................................................8-9
Dimensions........................................... 10-12
Weights..........................................................13
Maintenance................................................13
Water Quality...................................... 13-14
VM5000E & VM1500E................ 15-22
TR5000X.............................................. 23-27
DPRV Actuator...........................................28
Parts/Overhaul.................................. 32-37
Stem Adapter Setting Gages...............38
PICV_IOM_REVF_0114
OVERVIEW
This document covers the installation, operation and maintenance good control performance can be achieved when the minimum flow
of Series PICV (Pressure Independent Control Valves). The Series PICV requirement is as low as 1/50 of the maximum flowing GPM (LPS). A
maximizes efficiency and energy savings by providing precise control wide range of sizes, materials of construction, pressure ratings and
of maximum differential temperatures across a coil or heat exchanger control characteristics provide flexible configuration to meet almost
independent of variations in system pressure. The Series PICV any specification or system requirement. The Series PICV is factory
consists of two functional controlling segments. The first segment assembled, complete with sensing lines, check valve pressure taps,
is an electrically actuated control valve, capable of responding to and actuators, and is ready for field installation as a complete unit. The
a control signal from a controller that is not part of the PICV. The Series PICV is pre-calibrated to a customer-specified set differential
second segment is connected in series with the first, and serves to pressure from 2-8 PSIG (0.14-0.55 BARG), and includes a means for
sense and regulate a preset flowing differential pressure across the calibration adjustment. A separate, customer supplied, differential
control valve segment. Both segments include pressure balanced pressure gauge may be installed between the check valve pressure
control elements of industrial quality manufactured in accordance taps on the PICV to allow for monitoring of the set differential pressure.
with ISO 9001. The PICV has a rangeability of 50:1, meaning that
OPERATION
One of the primary factors that influence the flow of fluid through a actuator or pneumatic diaphragm actuator. The electric actuator
control valve is the amount of pressure, or differential pressure across provides precise positioning of the valve closure mechanism, and
it. At any point in valve plug travel, flow through a valve will typically responds quickly and precisely to the electronic control signals
increase if differential pressure is raised, and decrease if it is lowered. supplied to them. The second segment is a differential pressure control
A change in pumping pressure can therefore produce a change valve that operates independently of the control valve segment.
in rate of flow that is not related to the system controllers output This segment is self-powered (self-operating) and does not burden
signal. With pressure independence, the amount of water flowing or interact with the building automation control system. By quickly
through a valve and the controlled load (i.e. heat exchanger coil) is raising or lowering its own resistance to flow, the differential pressure
more accurately controlled as a function of the control signal, and is control segment of the PICV regulates and stabilizes the pressure drop
less dependent upon varying pump pressure. Stability in the control across the control valve segment by absorbing unused head pressure.
system is enhanced when pressure independence is provided, and the This compensates for changes in pumping pressure resulting from
control valves installed flow characteristic more closely resembles its pump switching or from varying flow demands in its own,
inherent, or constant-pressure characteristic. or parallel flow paths and results in pressure independent
operation.
The Series PICV (Pressure Independent Control Valve) consists of
two functional controlling segments. The first segment is a pressure- NOTE: The maximum differential pressure across the entire PICV is
balanced control valve, actuated by either a high-thrust electric motor approximately 2 x (Set Differential Pressure) at max flow
CONFIGURATIONS
Control Control Control Control Control Valve Control Valve DPRV DPRV DPRV DPRV Actuator
Valve Valve Valve Valve Trim Trim Material Motor Size Flange Trim
Size Flange Profile Size Material
P2 2.5 DN65 0 ANSI 125 22 Type of F Control Valve S Stainless Steel E020 VM1500E - P2 2.5 DN65 0 ANSI 125 DS DPRV Type 2L DPRV Actuator Cast
P3 3 DN80 Flanges Control Trim Size Full B Bronze Fail As Is P3 3 DN80 Flanges 72 Portion Iron, w/ Low DP Spring
P4 4 DN100 2 PN16 Valve X Control Valve E021 VM1500E - w/ P4 4 DN100 2 PN16 Flanges w/ SS Trim 2M DPRV Actuator Cast
P5 5 DN125 Flanges Body Trim Size VMS-25 P5 5 DN125 DB DPRV Type Iron, w/ Medium DP
P6 6 DN150 (Sizes P8 Extended BCM P6 6 DN150 Note: Must 72 Portion Spring
P8 8 DN200 & P1) 1 Control Valve E022 VM5000E - P8 8 DN200 match control w/ Brz
P1 10 DN250 23 Type of Trim Size 1SR Fail As Is P1 10 DN250 valve Trim
Control 2 Control Valve E023 VM5000E - w/
Valve Trim Size 2SR VMS-25
Body BCM
(Sizes TIG1 TR5000-X
P2-P6) -Fail As Is
for all exceot
P6_23XX
Extended Port
TIG2 TR5000-X
-Fail As Is
Extended Port
Only
VALVE BODIES
Body Material: Cast Iron
End Connections: ANSI 125LB FF Flanges, PN16 FF Flanges Body Pressure Temperature Ratings
Trim Designs: Type 23 - Single Seat Cylinder Balanced, ANSI Class III Leakage Iron Body
Type 22 and 72 - Double Seat Balanced, ANSI Class III Leakage Temperature 125 FLG & PN16
Trim Material: Bronze or 300 Series Stainless Steel O
F O
C PSIG BARG
EPDM Seal (Type 23 w/Bronze Trim)
Fluoraz Seal (Type 23 w/Stainless Steel Trim) 35 to 180 1.7 to 82.2 150 10.20
Fluid: Chilled Water Typical, Water or Water/Glycol from 35 F- 180F (2C - 82C )
Trim Limits: Stainless Steel: MAX Flowing Differential Pressure, 150 PSIG (10.3 BARG)
Bronze: MAX Flowing Differential Pressure, 100 PSIG (6.9 BARG)
Packing: Long-Life Multi-Stack EPDM Lip Packing - Water / Water-Glycol Service
ELECTRIC ACTUATOR SPECIFICATIONS (VM-1500E AND VM-5000E)

Valve Usage: VM-1500E [Valve sizes 2 1/2, 3 & 4 Inch DN65, DN80 & DN100],
VM-5000E [Valve sizes 5, 6, 8 & 10 Inch DN125, DN150, DN200, DN250]
Control Signal: 4-20 mAdc (Factory Setting), 0-20 mAdc, 0-10 Vdc or 2-10 Vdc
and Floating, Self-Adjusting, Field Selectable (Dip Switch)
Power Consumption: VM-1500E 12VA, VM-5000E 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 32F - 122F ( 0C - 50C )
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)
4X 0.31 in (0.79 cm) THRU MOUNTING FOOT
VMS-25 BCM
8.75 in (22.23 cm)

5.19 in
(13.18 cm) 6.69 in ( 16.99 cm)
6.72 in 4.91 in 6.97 in

(17.O7 cm) (12.47 cm) (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- 180F (2C - 82C )
Spring Pack: Low DP Spring: Adjustable 2 to 6 PSIG (0.14-0.41 BARD)
Medium DP Spring: Adjustable 5 to 8 PSIG (0.34-0.55 BARD)
Construction: Cast Gray Iron Class G3000, epoxy coated, epoxy coated spring, SS components, Woven Buna-N, nylon reinforced.
Temperature Limits: Ambient 32F - 122F ( 0C - 50C )
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: 90.68 Seconds / Inch (3.57 s/mm)
Feedback Signal: 4-20 mAdc (Factory Setting), 0-10 Vdc, 2-10 Vdc, or 0-20 mAdc
Field Selectable (Dip Switch); Feedback Signal Increase as Actuator Shaft Extends (Factory Setting) or Feedback
Signal Increases as Actuator Shaft Retracts; Field Selectable (Dip Switch)
Failure Mode: Fail Actuator Shaft Retracted on Loss of Signal (Factory Setting) or Fail Actuator Shaft Extended on Loss of Signal
Field Selectable (Dip Switch); Actuator Shaft Fails In Last Position on Loss of Power
Manual Override: Yes
Construction: Die Cast Aluminum Motor Housing & Yoke. Painted.
Case Has Two PG11 Cable Glands Accepts 0.197 to 0.394 inch (5mm to 10mm) Diameter Cable
Connections: Coded Screw Terminals
Locations: NEMA Type 3 / IP54
Temperature Limits: Ambient 14F to 122F ( -10C to 50C )
Relative Humidity: < 95% RH (40C)
Mounting: Factory Aligned, Vertical Above Centerline of Control Valve; Consult factory for preconfigured alternate orientations

PRESSURE INDEPENDENT CONTROL VALVE PICV_IOM_REVF_0114 3

PRODUCT MODEL LOW DP SPRING MEDIUM DP SPRING
FLANGE (where x is a configurable option) PERFORMANCE PERFORMANCE
Set Differential Pressure (PSI) Set Differential Pressure (PSI)

ANSI125 P2023Fx-xxxx-P20Dx-2x 2.0 3.1 4.2 5.3 5.7 6.5 7.2 8.0
Maximum flow (GPM) Maximum flow (GPM)
2 1/2 Standard Port 92 114 133 150 155 166 174 184

ANSI125 P30231x-xxxx-P30Dx-2x 2.0 3.1 4.2 5.3 5.7 6.5 7.2 8.0
3 1 Size Reduced Port 106 132 154 173 179 191 201 212

ANSI125 P3023Fx-xxxx-P30Dx-2x
2.0 3.1 4.2 5.3 5.7 6.5 7.2 8.0
3 Standard Port 127 158 184 207 215 229 241 255

ANSI125 P40232x-xxxx-P40Dx-2x
2.0 3.1 4.2 5.3 5.7 6.5 7.2 8.0
4 2 Sizes Reduced Port 165 206 240 269 279 298 314 331

ANSI125 P40231x-xxxx-P40Dx-2x 5.7 6.5 7.2 8.0
2.0 3.1 4.2 5.3

ANSI125 P4023Fx-xxxx-P40Dx-2x 2.0 3.1 4.2 5.3 5.7 6.5 7.2 8.0
4 Standard Port 240 299 348 391 406 433 456 481

ANSI125 P50232x-xxxx-P50Dx-2x 5.7 6.5 7.2 8.0
2.0 3.1 4.2 5.3

ANSI125 P50231x-xxxx-P50Dx-2x 5.7 6.5 7.2 8.0
2.0 3.1 4.2 5.3

ANSI125 P5023Fx-xxxx-P50Dx-2x
2.0 3.1 4.2 5.3 5.7 6.5 7.2 8.0
5 Standard Port 382 475 553 622 645 688 724 764
4 2600 Emrick Blvd Bethlehem, PA 18020 USA 800-922-0085 www.warrencontrols.com


ANSI125 P60032x-xxxx-P60Dx-2x 2.0 3.1 4.2 5.3 5.7 6.5 7.2 8.0

ANSI125 P60231x-xxxx-P60Dx-2x 2.0 3.1 4.2 5.3 5.7 6.5 7.2 8.0
ANSI125 P6023Fx-xxxx-P60Dx-2x Set Differential Pressure (PSI) Set Differential Pressure (PSI)
2.0 3.1 4.2 5.3 5.7 6.5 7.2 8.0
6 Standard Port Maximum flow (GPM) Maximum flow (GPM)

509 634 738 829 859 918 966 1018
ANSI125 P6023Xx-xxxx-P60Dx-2x Set Differential Pressure (PSI) Set Differential Pressure (PSI)
2.0 3.1 4.2 5.3 5.7 6.5 7.2 8.0
6 Extended Port Maximum flow (GPM) Maximum flow (GPM)

594 739 861 967 1003 1071 1127 1188

ANSI125 P80222S-xxxx-P80Dx-2x
2.0 3.1 4.2 5.3 5.7 6.5 7.2 8.0
8 2 Sizes Reduced Port Maximum flow (GPM) Maximum flow (GPM)
SS Trim Only 735 916 1066 1197 1241 1326 1395 1471

ANSI125 P80221S-xxxx-P80Dx-2x 2.0 3.1 4.2 5.3 5.7 6.5 7.2 8.0
8 1 Size Reduced Port Maximum flow (GPM) Maximum flow (GPM)
SS Trim Only 841 1048 1219 1370 1421 1517 1597 1683

ANSI125 P8023Fx-E02x-P80Dx-2x
2.0 3.1 4.2 5.3 5.7 6.5 7.2 8.0
8 Standard Port
962 1197 1394 1565 1623 1734 1825 1923
ANSI125 P10222S-xxxx-P10Dx-2x Set Differential Pressure (PSI) Set Differential Pressure (PSI)
2.0 3.1 4.2 5.3 5.7 6.5 7.2 8.0
10 2 Sizes Reduced Port
SS Trim Only 1039 1294 1506 1692 1755 1874 1972 2079
ANSI125 P10221S-xxxx-P10Dx-2x Set Differential Pressure (PSI) Set Differential Pressure (PSI)
2.0 3.1 4.2 5.3
10 1 Size Reduced Port 5.7 6.5 7.2 8.0
SS Trim Only 1188 1479 1721 1934 2005 2142 2254 2376

(where x is a configurable option) PERFORMANCE PERFORMANCE
FLANGE
ANSI125 P1022Fx-xxxx-P10Dx-2x Set Differential Pressure (PSI) Set Differential Pressure (PSI)
2.0 3.1 4.2 5.3 5.7 6.5 7.2 8.0
10 Standard Port 2292 2448 2576 2715
1358 1690 1967 2210

Set Differential Pressure (BAR) Set Differential Pressure (BAR)

PN16 P2223Fx-xxxx-P22Dx-2x 0.14 0.21 0.29 0.37 0.39 0.45 0.5 0.55
Maximum flow (LPS) Maximum flow (LPS)
DN65 Standard Port 5.8 7.2 8.4 9.5 9.8 10.5 11.0 11.6

PN16 P32231x-xxxx-P32Dx-2x 0.14 0.21 0.29 0.37 0.39 0.45 0.5 0.55
DN80 1 Size Reduced Port 6.7 8.3 9.7 11.0 11.3 12.1 12.7 13.4

PN16 P3223Fx-xxxx-P32Dx-2x 0.14 0.21 0.29 0.37 0.39 0.45 0.5 0.55
DN80 Standard Port 8.1 9.9 11.6 13.2 13.5 14.5 15.3 16.0

PN16 P42232x-xxxx-P42Dx-2x 0.14 0.21 0.29 0.37 0.39 0.45 0.5 0.55
DN100 2 Sizes Reduced Port 10.5 12.9 15.1 17.1 17.6 18.9 19.9 20.8

PN16 P42231x-xxxx-P42Dx-2x 0.14 0.21 0.29 0.37 0.39 0.45 0.5 0.55

PN16 P4223Fx-xxxx-P42Dx-2x 0.14 0.21 0.29 0.37 0.39 0.45 0.5 0.55
DN100 Standard Port 15.3 18.7 22.0 24.8 25.5 27.4 28.9 30.3

PN16 P52232x-xxxx-P52Dx-2x 0.14 0.21 0.29 0.37 0.39 0.45 0.5 0.55


PN16 P52231x-xxxx-P52Dx-2x 0.14 0.21 0.29 0.37 0.39 0.45 0.5 0.55

PN16 P5223Fx-xxxx-P52Dx-2x 0.14 0.21 0.29 0.37 0.39 0.45 0.5 0.55
DN125 Standard Port 24.3 29.7 34.9 39.5 40.5 43.5 45.9 48.1

PN16 P62232x-xxxx-P62Dx-2x 0.14 0.21 0.29 0.37 0.39 0.45 0.5 0.55
PN16 P62231x-xxxx-P62Dx-2x Set Differential Pressure (BAR) Set Differential Pressure (BAR)
0.14 0.21 0.29 0.37 0.39 0.45 0.5 0.55
DN150 1 Size Reduced Port 28.3 34.7 40.8 46.0 47.3 51 54 56
PN16 P6223Fx-xxxx-P62Dx-2x Set Differential Pressure (BAR) Set Differential Pressure (BAR)
0.14 0.21 0.29 0.37 0.39 0.45 0.5 0.55
DN150 Standard Port Maximum flow (LPS) Maximum flow (LPS)

32.4 39.6 46.6 53 54 58 61 64

PN16 P6223Xx-xxxx-P62Dx-2x 0.14 0.21 0.29 0.37 0.39 0.45 0.5 0.55
DN150 Extended Port 37.8 46.2 54 61 63 68 71 75

PN16 P82222S-xxxx-P82Dx-2x 0.39 0.45 0.5 0.55
0.14 0.21 0.29 0.37
DN200 2 Sizes Reduced Port
SS Trim Only 46.7 57 67 76 78 84 88 93

PN16 P82221S-xxxx-P82Dx-2x 0.14 0.21 0.29 0.37 0.39 0.45 0.5 0.55
DN200 1 Size Reduced Port Maximum flow (LPS) Maximum flow (LPS)
SS Trim Only 53 66 77 87 89 96 101 106

PN16 P8223Fx-E02x-P82Dx-2x 0.14 0.21 0.29 0.37 0.39 0.45 0.5 0.55
DN200 Standard Port 61 75 88 99 102 110 116 121

(where x is a configurable option) PERFORMANCE PERFORMANCE
FLANGE
PN16 P12222S-xxxx-P12Dx-2x Set Differential Pressure (BAR) Set Differential Pressure (BAR)
0.14 0.21 0.29 0.37 0.39 0.45 0.5 0.55
DN250 2 Sizes Reduced Port
SS Trim Only 66 81 95 107 110 118 125 131
PN16 P12221S-xxxx-P12Dx-2x Set Differential Pressure (BAR) Set Differential Pressure (BAR)
0.14 0.21 0.29 0.37 0.39 0.45 0.5 0.55
DN250 1 Size Reduced Port
SS Trim Only 76 92 109 123 126 135 143 150
PN16 P1222Fx-xxxx-P12Dx-2x Set Differential Pressure (BAR) Set Differential Pressure (BAR)
0.14 0.21 0.29 0.37 0.39 0.45 0.5 0.55
DN250 Standard Port 86 106 124 140 144 155 163 171
INSTALLATION
Recommended Piping: ANSI 125 Flanges should mate with piping with 125 Lb or 150 Lb
Flat Faced Flanges. PICV Minimum Lengths of
Straight Pipe
Per ISA Recommended Piping Practices. Control valves perform best with a reasonable PICV Size Upstream Downstream
amount of upstream and downstream straight pipe prior to elbows and strainers. The Straight Pipe Straight Pip
general specification for this is 16 pipe diameters upstream of straight pipe and 5 pipe 2 (DN65) 16 (40.64 cm) 12 (30.48 cm)
diameters downstream of straight pipe as minimums. However, this is a broad specification 3 (DN80) 16 (40.64 cm) 12 (30.48 cm)
covering all pipe diameters and velocities. Many applications do not have this kind of 4 (DN100) 16 (40.64 cm) 12 (30.48 cm)
space. While more length of straight pipe is desirable, Warren Controls has produced a 5 (DN125) 24 (60.96 cm) 12 (30.48 cm)
table of minimum pipe diameters for use on our PICV. Failure to follow these guidelines 6 (DN150) 32 (81.28 cm) 12 (30.48 cm)
may lead to noticeable vibrations or noise for excessive turbulence in some applications 8 (DN200) 36 (91.44 cm) 14 (35.56 cm)
10 (DN250) 40 (101.6 cm) 16 (40.64 cm)
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.
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 (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.

DIMENSIONS
Ddpv
PICV SIZES:
Dcv
2 1/2-4 IN (DN65-DN100) 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 DN65 22.86 cm 12.07 cm 14.61 cm 12.38 cm 37.47 cm
Acv +/- 1/16 in (0.16 cm) All other dimensions are maximum Allow 6 in (15.24 cm) above actuator for removal service
Total
Differential Pressure Valve (Right) 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 4 11-3/8 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 4 11-3/8 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 DN65 19.69 cm 12.38 cm 10.48 cm 24.77 cm 56.20 cm 42.70 cm
P2223xx-E02x-P22Dx-2M DN65 19.69 cm 12.38 cm 10.48 cm 24.77 cm 67.95 cm 42.70 cm
* 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

DIMENSIONS
PICV SIZES: 5-6 IN (DN125-DN150)
WITH TR5000 ACTUATOR WITH VM5000E ACTUATOR

P5023xx-E02x-P50Dx-xx 5 15-3/4 in 5-3/4 in 8-1/4 in 6-5/8 in 15-1/4 in
P5023xx-TIG1-P50Dx-xx 5 15-3/4 in 5-3/4 in 8-1/4 in 7-1/2 in 16-1/4 in
P6023xx-E02x-P60Dx-xx 6 17-3/4 in 6-1/2 in 8-7/8 in 6-5/8 in 15-1/4 in
P6023xx-TIGx-P60Dx-xx 6 17-3/4 in 6-1/2 in 8-7/8 in 7-1/2 in 16-1/4 in
P5223xx-TIG1-P52Dx-xx DN125 40.01 cm 14.61 cm 20.96 cm 19.05 cm 41.28 cm
P6223xx-TIGx-P62Dx-xx DN150 45.09 cm 16.51 cm 22.54 cm 19.05 cm 41.28 cm
Total
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 6 14-1/8 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 6 14-1/8 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 DN125 30.48 cm 17.46 cm 19.37 cm 24.77 cm 56.20 cm 70.64 cm
P5223xx-xxxx-P52Dx-2M DN125 30.48 cm 17.46 cm 19.37 cm 24.77 cm 67.95 cm 70.64 cm


DIMENSIONS
PICV SIZES: 8-10 IN DN200-DN250
WITH VM5000E ACTUATOR WITH TR5000 ACTUATOR

P8022xx-E02x-P80Dx-xx 8 16-1/4 in 8-7/8 in 9-5/8 in 6-5/8 in 15 in
P8022xx-TIG1-P80Dx-xx 8 16-1/4 in 8-7/8 in 9-5/8 in 7-3/8 in 16-1/4 in
P1022xx-E02x-P10Dx-xx 10 20 in 9-5/8 in 10-1/8 in 6-5/8 in 15 in
P1022xx-TIG1-P10Dx-xx 10 20 in 9-5/8 in 10-1/8 in 7-3/8 in 16-1/4 in
Total
P8022xx-xxxx-P80Dx-2L 8 16-1/4 in 8-7/8 in 9-5/8 in 9-3/4 in 22-1/8 in 32-9/16 in
P8022xx-xxxx-P80Dx-2M 8 16-1/4 in 8-7/8 in 9-5/8 in 9-3/4 in 26-3/4 in 32-9/16 in
P1022xx-xxxx-P10Dx-2L 10 20 in 9-5/8 in 10-1/8 in 9-3/4 in 22-1/8 in 40-1/16 in
P1022xx-xxxx-P10Dx-2M 10 20 in 9-5/8 in 10-1/8 in 9-3/4 in 26-3/4 in 40-1/16 in


PICV WEIGHTS
CONTROL VALVE DPRV
MODEL PICV SIZE ACTUATOR ACTUATOR TOTAL WT (LBS) TOTAL WT (KG)
P2x23xx-E02x-P2xDx-2L 2-1/2 in, DN65 VM-1500E 2L 144.00 65.32
P2x23xx-E02x-P2xDx-2M 2-1/2 in, DN65 VM-1500E 2M 147.25 66.79
P3x23xx-E02x-P3xDx-2L 3 in, DN80 VM-1500E 2L 172.00 78.02
P3x23xx-E02x-P3xDx-2M 3 in, DN80 VM-1500E 2M 175.25 79.49
P5x23xx-TIG1-P5xDx-2L 5 in, DN125 TR5000-X 2L 335.40 152.14
P5x23xx-TIG1-P5xDx-2M 5 in, DN125 TR-5000-X 2M 338.65 153.61
P6x23xx-TIGx-P6xDx-2L 6 in, DN150 TR5000-X 2L 428.40 194.32
P6x23xx-TIGx-P6xDx-2M 6 in, DN150 TR-5000-X 2M 431.65 195.80
Weights for models with VM actuators do not include a VMS-25 BCM. Add 4.25 lbs (2kg) Actual shipping weights may vary.
! MAINTENANCE
Series PICV (Pressure Independent Control Valves) are for the most part
maintenance free when properly selected and installed. Rebuilding of these valves
DANGER 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
Personal injury may result from uncontrolled PICV Product Specification for details). In installations where high vibration exists,
release of spring force. There is significant electrical and sensing connections should periodically be checked for integrity.
preload on the spring in the actuator on the Water should be in specification of the Warren Controls water quality guidelines.
differential pressure control segment (DPRV)
of the PICV. Disassembling the actuator will
release the spring force (preload) and may
cause serious personal injury.
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.

VALVE PACKING LEAKS
The service life of valve stems and packing is dependent on Control valve hunting will cause excessive stroking of the valve
maintaining non-damaging fluid conditions. Inadequate treatment stem and result in premature failure of the valve packing seal. The
or filtration, not in accordance with the recommendations of this system must be stabilized to ensure reasonable packing life and
guide, or a qualified treatment specialist, can result in corrosion, optimal control performance.
scaling, or abrasive particle formation. Scale and particles migrating
from pipe walls to control valves, will result in scratching the valve Over sizing of a control valve will result in an un-stable condition,
stem, which will prevent the packing from sealing. This problem can can result in, noise, vibration, premature trim and packing seal
be avoided by the use of proper cleaning, treatment chemicals, and failure. The use of the Warren Controls ValveWorks sizing program
storage procedures. Water must be treated and soft. Trace leaks of Will facilitate the selection of the optimum valve.
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
COMMISSIONING
cleaned prior to start-up. Filtration equipment and strainers should
be employed as required and a regularly scheduled program of Thorough flushing of the system is necessary before start-up as new
water condition monitoring and treatment should be followed. Side systems, or old systems that have been shut down for an extended
stream water filtration may be needed in closed systems, if there is period of time, will usually contain dirt, Weld slag, solder flux, and
no regular blow down of the system. pipe scale.
STORAGE
Systems that are stored wet should be completely filled with Drained system should be air dried, sealed, and treated with a
properly treated water and isolated to avoid slow leaks, which can desiccant to prevent atmospheric corrosion of pipes, which is a
cause serious corrosion problems. major source of pipe scale.
WATER QUALITY RECOMMENDED PARAMETERS
Chilled Water, Closed Loops, and Hot Water Systems up to 212F (100 C).
!
8.0 < pH < 10.3
Conductivity < 3000 MMHS
Iron < 0.5 ppm
Copper < 0.5 ppm
CAUTION Chilled Systems 100 ppm < Molybdenum < 150 ppm
(Mild Steel Corrosion Inhibitor)
Hot Systems 200 ppm < Molybdenum < 250 ppm

The use of hydrazine can
result in the formation of (Mild Steel Corrosion Inhibitor)
ammonia and must be con- 400 ppm < Nitrite < 1000 ppm
trolled to prevent stress cor- (Mild Steel Corrosion Inhibitor)
rosion and embrittlement, Azole > 5 ppm free and available
which can lead to fracture
(Yellow Metal Inhibitor)
of some brass alloys.
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%.

VM5000E &
VM1500E
ACTUATOR
INSTRUCTIONS
Page
Actuator Set-up & Wiring......................16-18
VMS-25 Installation & Wiring.....................18
VM1500E 4-20mA Feedback Kit..................19
VM5000E 4-20mA Feedback Kit.................20
VM1500E Removal & Installation ...............21
VM5000E Removal & Installation...............21

SET-UP
SP......................... 24 volts AC power in
SN........................ Common (Ground) and control signal negative
(See wiring diagrams)
Y........................... Control signal in (Positive)
X........................... Feedback signal out (Positive)
1........................... Override
3........................... Override
SWITCH FUNCTIONS
Switch OFF ON
1 Voltage Control Signal Milliamp Control Signal
2 2 - 10 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 Common and
control signal negative
24 volts ac
24 volts ac 24 volts ac
In the override position the Actuator is driven
to the end position. Connecting to terminal
Common and control signal negative Terminal 1 Stem down 1 drives the stem down. Connecting to
If system is grounded, then ground SN Terminal 3 Stem up terminal 3 drives the stem up.
When the actuator settings are known, it is easier to make them Adjustment takes several minutes during which the actuator will
before the valve and actuator are installed in the system. When move through its full stroke 2 or 3 times. The actuator remembers the
power is first applied to the actuator, check to see that it moves settings so a power failure does not cause the actuator to reset itself.
through its full range. If it does not, reset it by moving switch #9. The automatic stroke adjustment does not work if the valve stroke
is greater than the limits of the actuator. The maximum strokes are:
MANUAL OPERATION AND OVERRIDE VM1500E 1 1/2 40 MM
The actuator can be manually operated with a metric hex wrench. The VM5000E 2 1/8 55 MM
VM1500E uses a 4mm hex wrench. The VM5000E uses an 8mm hex Automatic stroke adjustment ensures that the signal range covers
wrench. The socket is on top of the actuator. VM5000E actuators have the actual stroke of the valve.
a clutch button that must be depressed while manually operating the
actuator. De-Energize the actuator before manual operation. RESET
Changing the position of switch #9 makes the actuator recalculate
OVERRIDE: the stroke. Do this if the actuator has been used on another valve,
tested without being on the valve, has been incorrectly mounted on
Connecting the neutral (terminal SN) to terminal 1 lowers the stem the valve, or has been taken off of the valve and reinstalled.
and to terminal 3 raises the stem. This can be done by an external
switch or controller. CONTROL SIGNALS
The actuator must be set for the control signal being used and
AUTOMATIC STROKE ADJUSTMENT whether the signal is direct acting or reverse acting.
The acceptable signals are: 24 VOLTS AC 3 POINT
The stroke adjusts itself automatically. This happens the first time
FLOATING or any of the following proportional signals.
power is applied or whenever the position of switch #9 is changed.

Full Range Split Range DIRECT OR REVERSE ACTING
0 - 10 vdc 0 - 5 vdc 5 - 10 vdc
2 - 10 vdc 2 - 6 vdc 6 - 10 vdc An increasing signal can either drive the valve stem down
0 - 20 ma 0 - 10 ma 10 - 20 ma (direct acting) or up (reverse acting).
4 - 20 ma 4 - 12 ma 12 - 20 ma
ReverseActing
Direct or Reverse Acting Switch #3 ON
Direct or Reverse
Direct Acting Properly selected and sized control valves utilize the default
or from
Split ranges allow two actuators to be operated in sequence AnReverse
increasingActing
signal can either drive the valve stem down (direct acting) or up (reverse acting).
An programmed
increasing signalwith
An increasingcansignal
eithercan
drive the drive
either valvethe
stem down
valve (direct
stem downacting)
(directoracting)
up (reverse
or up acting).
(reverse acting).
one full range signal. Proportional signals are Direct Acting(OFF) positions for switches
Switch #3#7 & #8.OFF
Direct Acting
Direct Acting Switch #3Switch #3OFF OFF
switches 1 - 5. The actuators are set for floating control by turning
Reverse Acting Switch #3 ON
Reverse Acting
Reverse Acting Switch #3Switch #3ON ON
on switch #6. Turning switch #6 on deactivates switches 1 - 5. Contact Warren Controls (Ph: 800-922-0085) before repositioning
Please note the wiring for floating control differs from the wiring for either switch.
proportional control. Properly selected and sized control valves utilize the default (OFF) positions for switches
ProperlyProperly
selectedselected
and sized and control valves utilize
sized control valvesthe default
utilize the (OFF)
defaultpositions for switches
(OFF) positions #7 & #8.#7Conta
for switches & #8
Warren Controls (Ph: 800-922-0085)
Warren Controls (Ph: 800-922-0085) FLOW CHARACTERISTIC:
Warren Controls (Ph: 800-922-0085) before repositioning either switch.
before repositioning either switch.
before repositioning either switch.
SELECTING THE SIGNAL Change Flow Characteristic Switch #7
Floating Flow Characteristic:
Switch #6 ON Flow Characteristic: IN THE OFF POSITION STEM TRAVEL IS PROPORTIONAL TO CON-
Flow Characteristic:
WhenChange switchFlow
#6 is Change Flow Characteristic
on Switch #7
Characteristic TROLSwitch
Change Flow CharacteristicSIGNAL#7Switch
AND DOES
#7 NOT ALTER THE FLOW CHARACTERISTIC OF
switches In the OFF position the stem travel is proportional to the control signal and does not alter the flow charac
erse
orDirectActing
Reverse Acting
or Reverse Acting In the1-5OFF are
In theinactive.
position
OFF the stem the
position travel stemis proportional
travel ISis THE to the control
proportional to the signal
control andsignal
does and
not does
alter IN the flalter
ow characteristic
notNORMALLY. of the valve
the flow characteristic of
gnal
easing can either
signal Proportional
candrive
either the valve
drive stem
the valve stem
down Switch
(direct
downstem #6
acting)
(direct or up OFF
acting)(reverse
or acting)
up acting).
(reverse is the positionVALVE. THIS should
this switch POSITION
be in normally. SWITCH In the#7ON SHOULD
positionBE the stroke is electronically adjusted
An increasing signal can either drive the valve down (direct is the orisupacting).
position the this
(reverse switch
position thisshould
acting). switch
When beshould
inthe
normally.
be
stem In the of
in normally.
travel ONIn anposition
the ON the
actuator stroke
position
is is stroke
the electronically
proportional is to adjusted
electronically
the control so that ansoequal
adjusted pe
that an
Acting Switch #3 Switch #3Switch OFF #3 OFF age valveage performs
ageasvalve performsand
a linearasvalve
as aalinear
linear
valve and a linear valve performs asvalve. a quick opening valve. Most 2-way co
Direct Acting OFF valve performs a linear valve andvalve performs
a linear as a quickasopening
valve performs a quick opening Most
valve.2-wayMost control
2-wayvalves
control have
valva
equal percentage signal, flow the shape (flowUsually
characteristic. characteristic) stemof the ofvalves plug determines
Reverse Acting Switch #3
Acting Switch #3Switch ON ON
#3 ON equal percentage flow characteristic.
equal percentage flow characteristic.Usually the stem the
Usually travelstemof the
an actuator
travel
travel
of an is
an actuator
proportional
actuator
is proportional
to the
is proportional control
to thesignal
to and
control
the control
the valv
signal and
SIGNAL SWITCH NUMBER is shapedistoshapedadjustisto shaped
the flow.to
adjust An
the the
adjust flow.
flequal
ow. An PICV
equal valves
thepercentage
flow. An equalhave
valve
percentage opens anslowly
percentage
valve equalvalve percentage
opensatslowly
theopens
start slowly
at so
thethatflow
start
at
25%socharacteristic.
thestem
start travel
that 25%
so thatresults
25% stem
stem travelinresults
lesstravel
than
in
VOLTS 1 2 4 flow. 5 Mixing
flow. valves
fl
Mixing
ow. Mixing
usually
valveshave Anvalves
usually equal
plugs usually
thatplugs
have
have
percentage
are linear plugs
that are
that
valve
on linear are
opens
both ports linear
on both
on
slowly
so that both
portsthe at ports
the
sototal
that flthe
so
start that
owtotal so
throughthe total
that
flowthe
fl
25% ow
valvethe
through
through
doesnt the
valvechange
valv
doesn
the stem position.
stem Switch
travel #7 should
results be
inwhen
lessOFFthan when25% you use
flow. mixing valves.
WhenOccasionally,
Switch Occasionally,
you #7 mayisyouin the you may want
#7s
cted and sized
lyProperly
selected and control
selected sized and
2 - 10 utilize
valves
control
sized valves
OFF
controlthe
default
utilize
valves
OFFdefault
theutilize
(OFF)OFF (OFF) thepositions
thepositions
default
OFF
stem
(OFF) position.
forthe stem
positionsSwitch
forIfposition.
switches #7 for
switches
you
&#7Switch
have
should
#8.#7
an & #7 beshould
Contact
switches
equal #8. OFF &when
Contact
#7
percentage
be
#8.OFF you use mixing
Contact
valve and
you use
you
valves.
want
mixing
to
Occasionally,
valves.
control the volume of
want
liquid
may
such
switch
as
want#7switch
the
to be ON
depth
sControls
(Ph:
Warren 800-922-0085)
(Ph: (Ph: before
800-922-0085)
Controls 0repositioning
- 10 repositioning
before
800-922-0085) OFF repositioning
either
before ON switch.
switch.
either If youOFF
OFFswitch.
either have an equal
If you have an percentage ON valve
equal percentage andvalve
position you thewant to control
andstroke
you want tothe volume
control
is electronically theofvolume
liquid of
adjusted such soasthat
liquid the
such depth of water
anasequal
the depth in of awater
tank inchaaw
of
to valve
a linear valve characteristic may work better. Steam heat depends on the ofquantity of steam perConsequ
hour co
2-6 OFF OFF ON to a linearOFFtovalve a linearcharacteristic may
characteristic work
percentage better.
may work
valve InSteam
better. heat
performs depends
Steam heat
as ifturn on the
depends
it had quantity
on
a linear the of steam
quantity
flow per hour
steam
characteristic. condensed.
perA hour condensed.
a work
linear valve may workcases,
Inbetter. these cases, #7Switch #7 ON. If you are using a linear valveof in onea
6 - 10 OFF OFF ON a linear ONvalve
a linearmay valve
then
maybetter.
leave
work Inbetter.
linear
switch
these
#7 valve
OFF.
these
opens turn Switch
cases,
so turn
that #7 ON.
Switch
25% stem If you
ON.areIf
travel using
you
results a in
are linear
25%valve
using aflow. in one
linear valve of in
these
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these
eristic:
haracteristic: then leavethen switch
leave #7switch
OFF. #7 OFF.
Flow Characteristic: 0-5 OFF ON ON OFF
haracteristic
Flow Characteristic Switch #7 Switch
Change Flow Characteristic
5 - 10 #7Switch OFF #7 ON ON ON
tion
FF the OFF
Inposition
the stemthe travel
stemistravel
position proportional
the stem to is
is proportional
travel theproportional
control
to the signal to and
control the doesand
signal
control Equal
notsignal
alternot
does Percentage
the
and flEqual
owthe
alter
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& Switch
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owthe
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osition
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position be in
should normally.
switch beshould In
in normally. the ON position
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normally. the
position stroke
the ONthe is electronically
stroke the
position adjusted
is electronically so that an
adjusted soadjusted
stroke is electronically equal percent-
that an equalso thatpercent-
an equal percent-
ms asvalve
a linear SIGNAL NUMBER
ve performs
age as avalve
linear
performs and
as aalinear
valve linear avalve
and valvelinear performs
andvalve as valve
a quick
performs
a linear as opening
a quick as
performs valve.
opening Most
valve. 2-way
Most control
2-way valves
control have
valves an havevalves
an have an
e equal
flow characteristic. MILLIAMPS
Usually the stem the 1
travel oftravel 2of an
an actuator 4 isaproportional
is proportional
quick5to opening
the control
valve.
to the signal
Most 2-way control
ercentage flow characteristic.
percentage flow Usually
characteristic. stem
Usually the stem actuator
travel of an actuator is proportional controlto and
the the valve
signal
control plug
and signal
the valveandplug
the valve plug
ust tothe flow.the An 4 - 20 valve opens ON slowly OFF start atOFFso that OFF
d is adjust
shaped toAn equal
flow.
adjust thepercentage
equal
flow. percentage valve
An equal percentage opens atslowly
valve theopens the
slowly 25%
startatso stem
that
the 25%
start travel
thatresults
sostem inresults
travelstem
25% less than 25%
in less
travel thanin25%
results less than 25%
alves plugs 0are
- 20 areonON on ON the soOFF the OFF
flow.usually
ixing valves
Mixing have
usually
valves have that
plugs
usually linear
that
have both
plugslinear
that are ports
bothso ports
linear thaton both total
that
ports flow through
total
so that flow the valve
the through
total flow thedoesnt
valve change
through doesnt
the valve with
change
doesnt withchange with
Stroke
mn.position.
Switch #7be 4be- 12 you ONyou use valves.
OFF valves. ON OFF mayyou
stem #7 should
Switch OFF#7
should whenOFF use
when mixing whenmixing Occasionally, you
mixingOccasionally, wantmay switchyou#7
want to be
switch ON.
#7 to be ON.
Stroke
Stroke
the position. Switch should be OFF you use valves. Occasionally, may want switch #7 to be ON.
Flow
Flow
Flow
Flow
qual
ave anpercentage
equal
an valve
have percentage and you
valve 12and- 20valve
want to want
you ON to
control the
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volumeON
of liquid such
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Flow
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If you equal percentage and you want the volume liquid such the in a tank changing
characteristic
artovalve may
characteristic
a linear valve work may better.
characteristic 0 - 10
work Steam
work
better.
may heat
ON
Steam depends
better. ONon the
heatSteam
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heat onON
depends of on
steam
the quantity theofper
OFF hourper
steam
quantity condensed.
of hour perConsequently,
steamcondensed. hour Consequently,
condensed. Consequently,
Signal Signal
aya work
valve may
linear better.
workmay
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In 10 turn
these
better. InSwitch
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20 turn
theseON #7 ON.
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#7
ON you
ON. are using
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you
ONON. a linear
are using
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are invalve
using one ofinthese
a linear Signal
one
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of these
in one applications, Stroke Stroke Stroke
of these applications, Signal Signal Signal
h then
ve #7 OFF.
switch #7switch
OFF. #7 OFF. ActuatorActuator Actuator Valve
leave Valve Valve Valve +Valve + Valve
Actuator + Actua
Actuator
eEqual
Valve Percentage
&Valve
ercentage Switch& #7 Off PERCENTAGE
Switch #7Switch
Off #7 Off Equal#7
percentage
Equal Equal
Valve percentage
& Switch Valve
&#7 On &#7
Switch
On #7 On
EQUAL Valve & VALVE & SWITCH OFFpercentage Valve EQUAL
Switch PERCENTAGE VALVE & SWITCH #7 ON
Stroke
Stroke
Stroke
Stroke
Stroke
Flow
Flow
Flow
Flow
Flow
Flow
Flow
Flow
Flow
Flow
Flow
Flow
Signal Signal Stroke Stroke Signal Signal Signal

Signal Signal Stroke Stroke Stroke Signal Signal Signal
Signal Stroke Signal
Actuator
ActuatorActuator Valve Valve Valve +Valve
Actuator
+ Actuator
Actuator Actuator
Actuator Valve Valve Valve Valve +Valve + Valve
Actuator + Actua
Actuator
Valve Valve + Actuator
e Valve &Valve
ercentage Switch& #7 On #7 On
Switch Flow Coeffi
FlowcientFlowcient
Coeffi Coefficient
Equal percentage Valve & Switch #7 On
Full FlowFull Flow Full FlowSwitch #8Switch #8 Switch
OFF #8OFF OFF
Flow Reduced
Reduced Reduced Flow FlowSwitch #8Switch #8 Switch
ON #8ON ON
SWITCH 8: FACTORY DEFAULT OFF This function
This onlyThis
works
function function
when
only only
switch
works works
when iswhen
off.#7switch
#7switch is off.#7 is off.
Turning#8Turning
Turning switch switch #8switch
on reduces onthe#8 on the
valve
reduces reduces
stroke
valve the
and valve
then
stroke stroke
sets
and and
sets then
the control
then sets over
thesignal thesignal
control control signal
the range
over over
of the
the the
reduced
range range
of the of the
stroke.
reduced reduc
The res
stroke.
The correct position for Switch #8 is OFF. that the valve
that the thatfully
never
valve the valve
opens
never neverit fully
andopens
fully opens
performs
and anda it
like
it performs performs
smaller like avalve.
like avalve.
smaller smaller valve.
Do not use the Switch #8 ON. If Switch #8 is ONNOTE:
the valve will not function properly as a PICV.
Stroke
NOTE: NOTE:
Stroke
Flow
Flow
Flow
Flow
Flow
Flow
Previous Previous Previous

models were
models models
equipped
were were
with
equipped equipped
three movable
with with
three three movable
jumpers
movable in
jumpers jumpers
place of
in the
place in the
of place
9-switch of the
block for9-switch
9-switch block for block
actuator setup. forsetup.
actuator actuato
Signal Signal Stroke Stroke For information
For about
For them
information
Signal Signal contact
information
about them Warren
about them
contactControls
contact
Warren (Ph: 800-922-0085).
Warren
Controls Controls
(Ph: (Ph: 800-922-0085).
800-922-0085).
Signal
NOTE: Stroke
Previous models were equipped with three movable jumpers in placeSignal
of the 9-switch block for actuator setup. For information about them contact
Actuator
Actuator Valve Valve Valve +Valve
Actuator
+ Actuator 6 6 6
Warren Controls (Ph: 800-922-0085). Valve
Actuator Valve + Actuator
ent
oefficient
owFlow
Full CoefficientSwitch #8
Flow Switch #8OFF OFF
edReduced
Flow FlowFull FlowSwitch #8 Switch #8Switch
ON #8
ON OFF
nly works
nction Reduced
onlywhen
works Flow
switch
when #7 Switch #8
is off.#7 is off.
switch ON
#8This
switch function
on reduces only
#8 on reduces works
the valvethe when
stroke
valveand switch
thenand
stroke #7 is
setsthen off.
the sets
control
the signal
controlover theover
signal rangetheofrange
the reduced stroke. The
of the reduced result
stroke. Theis result is
Turning
ever fully
valve switch
opens
never #8
fullyand itonperforms
opens reduces the valve
like
and it performs stroke
a smaller
like and then
a valve.
smaller sets the control signal over the range of the reduced stroke. The result is
valve.
that the valve never fully opens and it performs like a smaller valve.
NOTE:
dels
ious were equipped
models with three
were equipped movable
with jumpersjumpers
three movable in place in
ofplace
the 9-switch block forblock
of the 9-switch actuator setup. setup.
for actuator
Previous
ion about
informationthemmodels
themwere
contact
about equipped
Warren
contact Warrenwith
Controls three
(Ph: movable
800-922-0085).
Controls jumpers in place of the 9-switch block for actuator setup.
(Ph: 800-922-0085).
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. LEVER, CORRECTLY
6. Re-energize the actuator, and perform Auto-Stroke. Observe that the actuator travels fully in POSITIONED
both directions, and comes to rest at the point dictated by the applied input signal. BETWEEN
SWITCHES
VMS-25
For floating control, connect controller with dry contacts and
TERMINALS floating mid position between terminal NO1 and 1 and 3 for
Actuator A, and between terminal NO2 and 1 and 3 for Actuator B.
L System Power 24VAC

LN System Neutral
BT Battery Test
RC Remote Control
TG Test Ground
C1 Relay Common 1st Motor
C2 Relay Common 2nd Motor
NC1 Relay Normally Closed 1st Motor
NC2 Relay Normally Closed 2nd Motor
NO1 Relay Normally Open 1st Motor
NO2 Relay Normally Open 2nd Motor
AC 24 Volt Out
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 TESTING
1. Connect the VMS-25 to the actuators as shown. Connect NC1 or Disconnecting the jumper between LN & RC, with building
NC2 to terminal 1 on an actuator to drive the valve stem down during power on, will drive the actuator to the power failure position.
power failure or to terminal 3 to drive the valve stem up during a Testing the VMS-25 and the battery. Measure the voltage
power failure. between TG & BT. TG is negative. When the power supply is charging
2. Connect VMS-25 to 24 volts AC power. correctly the voltage will be 13 - 14 volts DC. Disconnect LN or L and
3. Connect the red wire to the battery positive (+) and the black wire then measure the voltage between TG & BT. If the battery is good
to the battery negative (-). and adequately charged the voltage will be Between 10 - 12 volts
Note: Connect the 24 volt power to the VMS-25 before connecting DC. VMS-25 is a standby power supply for VM1500E and VM5000E
the battery. Connecting the battery first causes the VMS-25 to actuators. It is intended to drive these actuators to either open or
go into the power failure mode. If there are conditions other than close a valve during a power failure. The VMS-25 can power one
power failure during which the actuator should be driven to the end VM5000E or two VM1500E actuators.
position, replace the jumper between LN & RC with a contact that
opens on demand.

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 adjust-
ment potentiometer on the mod. board can calibrate the 4-20 mAdc feedback out-
put at any critical point in the actuators travel. Nominal adjustment span, when
voltage feedback is 2 vdc, is from 3.5 to 4.5 mAdc output.
PUR 1137
4-20 mAdc Mod. Board
MATERIALS & TOOLS:
Wires and mounting screws are provided in the kit. The illustration that follows
shows RED wire insulation for power (hot), BLACK for power (neutral) and GREEN
for feedback. Stranded wire is used to avoid difficulty in connecting two wires to a
single terminal on the motor board. A small straight-bladed screwdriver is needed
for the wiring terminals, and a #2 Phillips screwdriver for the mounting screws
VM1500E KVM1500EFB4TO20MA00
A. Using two mounting screws, fasten the mod. board to the two existing bosses on the motor housing. Note the rectangular wire-
clearance cutout at the upper left.
B. Install the RED wire from motor board terminal SP to mod. board terminal SP.
C. Install the BLACK wire from motor board terminal SN to mod. board terminal SN.
D. Install the GREEN wire from motor board terminal X to mod. board terminal 2-10V.
E. Installation is complete. Connect the motor actuator in accordance with the Installation, Operating & Maintenance manual, except that
feedback output is now located at mod. board terminals 4-20mA (+) and N (-).

VM5000E MOTOR 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 actuators travel. Nominal adjustment span, when voltage feedback is 2
vdc, is from 3.5 to 4.5 mAdc output.
PUR 1137
MATERIALS & TOOLS: 4-20 mAdc Mod. Board
Wires and mounting screws are provided in the kit. The illustrations that fol-
low show RED wire insulation for power (hot), BLACK for power (neutral) and
GREEN for feedback. Stranded wire is used to avoid difficulty in connecting
two wires to a single terminal on the motor board. A small straight-bladed
screwdriver is needed for the wiring terminals, and a #2 Phillips screwdriver
for the mounting screws
VM5000E 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 (-).

Read all instructions carefully before beginning. Read all instructions carefully before beginning.
TURNING THE ACTUATOR LEGS CAUSES DAMAGE TO THE AC- TURNING THE ACTUATOR LEGS CAUSES DAMAGE TO THE
TUATOR AND VOIDS THE WARRANTY. ACTUATOR AND VOIDS THE WARRANTY.
REMOVAL OF VM1500E ACTUATOR FROM VALVE REMOVAL OF VM5000E ACTUATOR FROM VALVE
1) Remove line pressure and isolate valve in piping. 1) Remove line pressure and isolate valve in piping.
2) Operate actuator so plug is off seat(s) and tabs of anti-rotation device 2) Operate actuator so plug is off seat(s) and anti-rotation device (Item 2)
(Item 2) can be unbent in Step 5. can be removed in Step 4.
3) Loosen jamnut (Item 3) and thread to bottom of threads on valve 3) Loosen jamnut (Item 3) and thread to bottom of threads on valve stem.
stem. 4) Remove anti-rotation device from stem connector so stem connector
4) Loosen yoke locknut until it is free of bonnet. may be turned.
5) Unbend tabs of anti-rotation device. 5) Loosen yoke locknut until it is free of bonnet.
6) Remove anti-rotation device from stem connector so stem connector 6) Hold jamnut on valve stem and turn the stem connector to disengage
may be turned. from valve stem. The valve stem should never be turned while the
7) Hold jamnut on valve stem and turn the stem connector to disengage plug is in contact with the seat otherwise the seating surfaces
from valve stem. The valve stem should never be turned while the will be damaged.
plug is in contact with the seat otherwise the seating surfaces 7) Remove actuator from valve.
will be damaged. _______________________________________________
8) Remove actuator from valve.
_______________________________________________ INSTALLATION OF VM5000E ACTUATOR ON VALVE.
THE BRASS SPACER THAT COMES WITH THE ACTUATOR MUST BE ASSEMBLED
INSTALLATION OF VM1500E ACTUATOR ON VALVE. ON BOTTOM SIDE OF YOKE AS SHOWN ON DRAWING C3400001.
THE BRASS SPACER THAT COMES WITH THE ACTUATOR MUST BE ASSEMBLED
ON BOTTOM SIDE OF YOKE AS SHOWN ON DRAWING C3400002. 1) Push valve stem down until plug is seated. Note stem location.
2) Install hex jamnut (Item 3) on valve stem. Thread jamnut to bottom of
1) Push valve stem down until plug is seated. Note stem location. threads on stem.
2) Install hex jamnut (Item 3) on valve stem. Thread jamnut to bottom of 3) Place actuator, yoke locknut, and anti-rotation device (Item 2) over
threads on stem. valve stem and onto bonnet. Watch orientation of yoke locknut and
3) Place actuator, yoke locknut, and anti-rotation device (Item 2) over anti-rotation device. Actuator must rest on bonnet. If necessary use
valve stem and onto bonnet. Watch orientation of yoke locknut and actuator manual override to reposition the stem connector. The
anti-rotation device. Anti-rotation device must be oriented so tabs manual override is at the top of the actuator. There are two rubber caps
can be bent around cross bar in Step 6. Actuator must rest on bonnet. on the actuator cover. One cap covers the override; the second cap
If necessary use actuator manual override to reposition the stem covers the clutch. Remove both caps. Depress clutch and turn override
connector. The manual override is at the top of the actuator. Turn using an 8mm hex wrench. Replace caps when finished to protect
override using a 4mm hex wrench. Do not tighten yoke locknut at motor and circuit board. Do not tighten yoke locknut at this time.
this time. 4) Rotate actuator to desired orientation. For the factory default
4) Rotate actuator to desired orientation. For the factory default actuator position face the actuator circuit board and install the
actuator position face the actuator circuit board and install the actuator on the valve with the valve upright and its inlet to the left.
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
Thread yoke locknut onto bonnet and tighten securely. Use a blunt chisel and hammer for final tightening.
chisel and hammer for final tightening. 5) Lift valve stem. Hold jamnut on valve stem and turn the stem
5) Lift valve stem. Hold jamnut on valve stem and turn the stem connector to engage valve stem. If necessary use actuator manual
connector to engage valve stem. If necessary use actuator manual override to reposition the stem connector. The valve stem should
override to reposition the stem connector. The valve stem should never be turned while the plug is in contact with the seat
never be turned while the plug is in contact with the seat otherwise the seating surfaces will be damaged. The minimum
otherwise the seating surfaces will be damaged. The minimum required stem engagement is 9/16 inch (14.29 mm). After required
required stem engagement is 3/8 inch (9.53 mm). After required stem stem engagement is reached thread jamnut up valve stem to contact
engagement is reached thread jamnut up valve stem to contact stem stem connector. Tighten jamnut to secure valve stem to stem
connector. Tighten jamnut to secure valve stem to stem connector. connector.
6) Install anti-rotation device on cross bar and bend tabs over so stem 6) Install anti-rotation device on cross bar so stem connector will not turn.
connector will not turn. 7) Push red travel indicators on legs of actuator into contact with cross
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
bar. Connect power to actuator. On circuit board turn dipswitch 9 then OFF. Actuator will perform automatic stroke adjustment. In the
ON then OFF. Actuator will perform automatic stroke adjustment. In stem down direction the plug must reach the seat in the valve before
the stem down direction the plug must reach the seat in the valve the cross bar on the actuator legs pushes the red travel indicators
before the brass bar on the shaft inside the motor housing contacts on legs of actuator against the actuator base. The lever extending
the bottom of the motor housing. The lever extending through the through the hole in the circuit board deflects to depress the upper
hole in the circuit board deflects to depress the upper microswitch on microswitch on the circuit board to stop the motor at that end of
the circuit board to stop the motor at that end of travel. In the stem up travel. In the stem up direction the plug must reach the upper seat
direction the plug must reach the upper seat or travel stop inside the or travel stop inside the valve before the cross bar pushes the red
valve before the stem connector contacts the bottom of the motor travel indicators against the bottom of the motor housing. The valve
housing. The lever extending through the hole in the circuit board stem must not contact the bottom of the motor housing. The lever
deflects to depress the lower microswitch to stop the motor at that extending through the hole in the circuit board deflects to depress
end of travel. If necessary turn off power, loosen jamnut, remove anti- the lower microswitch to stop the motor at that end of travel. If
rotation device from stem connector, and repeat Steps 5 thru 7. necessary turn off power, loosen jamnut, remove anti-rotation device
8) Turn off power. Make necessary dipswitch settings and additional from stem connector, and repeat Steps 5 thru 7.
wiring connections. See Set-Up and Wiring sections of these 8) Turn off power. Make necessary dipswitch settings and additional
instructions. wiring connections. See Set-Up and Wiring sections of these
9) Return power to actuator. instructions.
10) Return line pressure to valve. 9) Return power to actuator.
11) Stroke valve several times to check operation. 10) Return line pressure to valve.
11) Stroke valve several times to check operation.

C3400001
C3400002

TR5000-X
ACTUATOR
INSTRUCTIONS
Page
Set-up & Wiring................... 24-25
Removal & Installation........ 26-27

Dimensions s
3 Press do
and start
S2 Switch setting
S2
Function
Switch
ON LOG: equal-percentage
1 Flow character
OFF LIN: equal-linear
42mm max
Stroke
Starting of input/ ON 20%:the starting input / output sign
2
output signal OFF 0:the starting input / output1. signal i
Chilled/hot water application
Chilled/hot water valve body
Steam application
Steam valve body
Turn anticl
with manual device Not suitable downwards
Forbidded downwards All ON
above II:
suitableinput current signal 2. Turn clock

3 Type of inputRandom
signal Orientation suitable
TR5000-X220-S.12
TR5000-X220S.12 / TR5000-X220-S.12-51 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, 0(4)~20MA
signal 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
n 14VA Current input impedance 0.50K ON
DW: When lose input signal (voltag
Power
Synchronous motorconsumption
with 12VA Current input impedance <0.167K When lose input signal (curren
Losing input signal
Voltage output load 1K 6
permanent magentic
Motor Synchronous motor with Voltage output load mode
>1K OFF UP: When lose input signal (voltag
42mm Current output load
permanent magnetic
0.5K When lose input signal (curren
2.5s/ mm (50Hz) Up and down 42mm,
dead band ON DF: when the actuator axes retract
Nominal stroke 51mm 1.5% Current output load <0.5K when the actuator axes extend
erature -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 when the actuator axes retract
dity Material of bracket
Environmental temperature -10~50C (Operation condition) Sensititivity low 2% high 1.5%
(Operation condition) (surface anti-rust process) ON HS: the high sensitivity of input sign
Environmental humidity 95% RH(40C) Aluminum die casting
Material of bracket 8 Sensitivity
Aluminum die casting
IP54 Material of cover OFF LS: the low sensitivity of input signa
(surface anti-rust process)
(Operation condition) (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
Eg.1 ON
(surface anti-rust process)
Operating mode: DA Eg
PCB OFF
Losing input signal mode:DW
1 2 5 6
RUNNING MODE Up/down straight
self-stroking button travel Net weight of product 5.23Kg4 7 8
Sensitivity of input signal 2%
S2
S2 ON
S2 switch Additional function
PCB
1 2 1 2 3 4 5 6
LOG 20% II IO DA DW DF HS OFF 1 2 3 4 5 6 7 8
S1
M ON-OFF SWITCH
LIN 0 UI RA UP S2
ON
UO RF LS
--RunningOFF light (RUN): when actuator axes retracts, running light show red
WIRING CPU
self-stroking button
4when 5 do 1 2 3 4
7 "self-stroking", 5 6
running 7 8
light flickering(1Hz).
CPU
nixie tube 1 2 3 6
IO S3 DA DW DF HS
8
The TR5000 actuator has an
S2 20% II UI
---Warning S2
light (ERR): when actuator have some problem, warning light w
0 UI II UO RA UP RF LS
ON-OFF switch.
warning light running light
S1
ON ---Nixie tube: The first oneThe is function bit, thebe
switch must second
in to forth are numerical
Description
S3 of Nixie tube:
the ON position for the
ERR RUN S2
function digit
OFF 1 2 3 4 1 2 3 4
O E Y error light
Function bit actuator to operate. Numerical bit
Description
60 70
Input signal
50
A Fault when do "self-stroking" No show

80 ERR
40 90
L N O E Y 30 connection
maximum RUN terminal
Show Input signal on Number Input signa
100
opening
Output signal C
Numerical bit between 0~100
aperture running light 220VAC
potentiometer number digit
auxiliary terminal
Show Output signal on Number Output sig
1 2 3 4 5 6 7 8 9 10
F
UL DL AL MAX MIN L N O E Numerical bit
Y between 0~100
3 5 6 ON OFF
additional function terminal 1 2 4 When actuator running correctly, there will be show "C" or "F" alternate in
connecting terminal
be showed alternate.
UL DL AL
---Additional function terminal:

DEBUGGING/SELF-STROKING
1) Terminal 1,2 (UL): Up limit position SPDT output terminal(NO), when act
5000-X...actuator with TL,TW or TF... valve body, connect AC 220V power supply. Then press down 2) Terminal 3,4 (UL): Down limit position SPDT output terminal(NO), when
on PCB over 3 seconds
With until the
switch S3-7 OFFrunning light
(Factory flickering:
Default), the self-stroking button must be valve, connect3)the 220VAC
Terminal powerFault
5,6(UL): supply.
SPDTPosition the actuator ON-OFF
input terminal(NO)when fault, this termina
tarting
pressed for self-stroking to start. With switch S3-7 ON, self-stroking starts switch in the 4)
ONTerminal
position. Then press
7,8(MAX): Max.the self-stroking
signal compulsorybutton on the this termina
input terminal,
g 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 PCB and holdsignal to actuator, and make the input signal from "O","E" terminal be of no
(greater than 3 seconds) until the running light flashes
5) Terminal 9,10(MIN): Min. signal compulsory input terminal, this termina
g to 0 (actuator axes extends until down limit position), running light flickering
may also be started by pressing the self-stroking button
CPU, self-stoking step is finished ( total process need approx.180 seconds) for greater than red (1Hz). signal to actuator, and make the input signal from "O","E" terminal be of no
Notes:
3 seconds. It is recommended that switch S3-7 be OFF.
1. Contact Capacity of SPDT: :1A (125VAC/30VDC)
Self-stroking2.starts
Contact Capacity external connection SPDT: more than 50mA /30VDC
ng, actuatorThe
canself-stroking function
not be controlled must
by input be
singal.completed in order to calibrate the The actuator stem extends to the lower travel limit; the
TR5000 actuator to the travel of a valve. running light flashes red (1Hz).
The actuator stem retracts to the upper travel limit; the
Position the actuator ON-OFF switch in the OFF position. Position switch running light flashes red (1Hz).
S3-7 in the OFF position. Warning: If switch S3-7 is ON, the actuator The travel limits are recorded in the CPU; self-stroking is
will start self-stroking as soon as power is applied. The sudden finished (total process takes approx.150 seconds). The
movement and application of force may result in damage to the actuator and running light return to normal operation.
valve and personal injury. After assembling the TR5000 actuator to the
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
S2 SWITCH SETTING FACTORY DEFAULT
S2 Dip Posi- Eg.1

Function Description ON
Switch tion
S2 S3
ON 20%: The start point of the input / output signal is 20% (The full input / output OFF
Start point of
signal is 4~20mA or 2~10V) (Factory Default) 1 2 3 4 5 6 7 8
S2-1 input/output
OFF 0: The start point of the input / output signal is 0% (The full input / output signal is Input signal: 4-20mA
signal
0~20mA or 0~10V) Output signal: 4-20mA
Operating Mode: DA
Type of input ON II: Input signal is current (mAdc) (Factory Default)
S2-2 Loss of input signal mode: DW
signal OFF UI: Input signal is voltage (Vdc) Sensitivity of input signal <_ 2%
ON When S2-2 is OFF, S2-3 MUST be ON
S2-3
OFF When S2-2 is ON, S2-3 MUST be OFF (Factory Default) Eg.2
Type of output ON IO: Output signal is current (mAdc) (Factory Default) ON
S2 S3
S2-4 (feedback) OFF UO: Output signal is voltage (Vdc) OFF
signal 1 2 3 4 5 6 7 8
ON DA: DA mode (When input signal is increasing, the actuator stem extends ) (Factory
Operating Input signal: 0-10VDC
S3-5 Default) Output signal: 0-10VDC
mode
OFF RA: RA mode (When input signal is increasing, the actuator stem retracts) Operating Mode: DA
Loss of input signal mode: DW
ON DW: On loss of input signal, the actuator fails to the minimum input signal position. Sensitivity of input signal <_ 2%
Loss of input
S3-6 (Factory Default)
signal mode
OFF UP: On loss of input signal, the actuator fails to the maximum input signal position.
ON DF: Self-stroking starts each time the actuator is powered up.
Self-stroking
S3-7 OFF RF: Self-stroking starts ONLY when the self-stroking button is pressed for >3 sec-
mode
onds. (Factory Default)
ON HS: High sensitivity of input signal </=1.5%
S3-8 Sensitivity
OFF LS: Low sensitivity of input signal </=2% (Factory Default)
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 Meaning Numerical Meaning
display display
shows shows
A Numerical display shows aperture Number Function display shows A and numerical display shows value from 30 to 100 as
setting in percent from aperture potentiometer is turned. The aperture value MUST be set to 100 (Factory
30~100 Default). If the aperture value is less than 100 the valve will not function properly
as a PICV.
C Numerical display shows input Number Input signal percent. Example: For input signal 0~10V, when input signal is 1 V,
signal in percent from display will show 10 (1/10*100=10)
0~100
F Numerical display shows output Number Output signal percent. Example: For Output signal 0~10V, when output signal is 1
signal in percent from V, display will show 10 (1/10*100=10)
0~100

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 self-
stoking function. The actuator cannot move the stem to the correct position for the input signal.
Notes: 1. Contact Capacity of SPDT:1A (125VAC/30VDC)

2. Contact Capacity external connection SPDT: more than 50mA /30VDC
Read all instructions carefully before beginning. 10) Place the upper center hole in unthreaded half of stem connector
REMOVAL OF TIG1 & TIG2 TR5000-X ACTUATOR FROM VALVE over pin on actuator stem. Watch orientation. Engage stem adapter
with stem connector using manual override. Install stem connector
1) Remove line pressure and isolate valve in piping. screws through unthreaded half of clamp, each through a spring,
2) Operate actuator so plug is off seat(s). into threaded half of the stem connector and tighten to secure stem
3) Remove power and signal from actuator. adapter to stem connector.
4) Remove stem connector screws, then remove stem connector from 11) Position the actuator ON-OFF switch in the OFF position. Position
actuator stem. switch S3-7 in the OFF position. Warning: If switch S3-7 is ON, the
5) Remove clamp screws, then remove clamp from actuator yoke. actuator will start self-stroking as soon as power is applied.
6) Remove actuator from valve. The sudden movement and application of force may result
in damage to the valve and personal injury. After assembling
TO REMOVE STEM ADAPTER AND BONNET ADAPTER the TR5000 actuator to the valve, connect the 220VAC power
COMPLETE STEPS 7 THRU 10. supply. Position the actuator ON-OFF switch in the ON position.
Then press the self-stroking button on the PCB and hold (greater
7) Loosen jamnut on valve stem. Warning: The valve stem should than 3 seconds) until the running light flashes red (1Hz). Actuator
never be turned while the plug is in contact with the seat will perform automatic stroke adjustment. See Set-Up and Wiring
otherwise the seating surfaces will be damaged voiding the sections of these instructions.
warranty. 12) Turn off power. Make necessary dipswitch settings and additional
8) Remove stem adapter from valve stem. wiring connections. See Set-Up and Wiring sections of these
9) Remove jamnut from valve stem. instructions.
10) Remove bonnet adapter from bonnet. 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 All PICV Valves Except 6 Inch (DN150) Extended Port Valve
INSTALLATION OF T1G1 TR5000-X ACTUATOR ON
1) Isolate valve body if already installed in piping. 6 INCH (DN150) EXTENDED PORT PICV VALVE
TO INSTALL BONNET ADAPTER AND STEM ADAPTER 1) Isolate valve body if already installed in piping.
COMPLETE STEPS 2 THRU 6.
IF THE BONNET ADAPTER AND STEM ADAPTER ARE ALREADY
2) Install bonnet adapter on valve bonnet and tighten. Watch INSTALLED ON THE VALVE COMPLETE STEPS 2 AND 3.
orientation.
3) Install jamnut on valve stem. Thread jamnut to bottom of threads on 2) Loosen jamnut on valve stem. Warning: The valve stem should
stem. never be turned while the plug is in contact with the seat
4) Push valve stem down until plug is seated. Note stem location. otherwise the seating surfaces will be damaged voiding the
5) Install stem adapter on valve stem. With the stem down and the warranty. Thread jamnut to bottom of threads on stem.
plug seated, adjust position of stem adapter on valve stem so the 3) Thread stem adapter onto valve stem until stem threads bottom out
distance from the top of the bonnet adapter to the top of the stem in adapter.
adapter is 1.960 +/-.012 inch (49.784 +/- .03048 mm). Warning: The
valve stem should never be turned while the plug is in contact IF THE BONNET ADAPTER AND STEM ADAPTER ARE NOT
with the seat otherwise the seating surfaces will be damaged INSTALLED ON THE VALVE COMPLETE STEPS 4 THRU 6.
voiding the warranty. Stem adapter setting gage p/n B6020011
may also be used to set the position of the stem adapter on the 4) Install bonnet adapter on valve bonnet and tighten. Watch
valve stem. See page 38 for drawing. With the stem down and plug orientation.
seated, rest the gage on top of the bonnet adapter. Adjust the stem 5) Install jamnut on valve stem. Thread jamnut to bottom of threads on
adapter so its end lies between the two steps on the gage. stem.
6) Thread jamnut against stem adapter and tighten. 6) Install stem adapter on valve stem. Thread stem adapter onto valve
7) Remove stem connector screws, then remove stem connector with stem until stem threads bottom out in adapter.
two springs from actuator stem. 7) Push valve stem down until plug is seated. Note stem location.
8) Remove clamp screws, then remove clamp from actuator yoke. 8) Remove stem connector screws, then remove stem connector with
9) Place actuator over valve stem and onto bonnet adapter. Rotate two springs from actuator stem.
actuator to desired orientation. For the factory default actuator 9) Remove clamp screws, then remove clamp from actuator yoke.
position, face the actuator circuit board and install the actuator 10) Position the actuator ON-OFF switch in the OFF position. Position
on the valve with the valve upright and its inlet to the left. Engage switch S3-7 in the OFF position. Warning: If switch S3-7 is ON, the
raised pad in actuator yoke with groove in bonnet adapter. If actuator will start self-stroking as soon as power is applied.
necessary use actuator manual override to reposition the actuator The sudden movement and application of force may result in
stem. Install clamp in base of actuator yoke. Engage raised pads on damage to the valve and personal injury. After assembling the
back of clamp with groove in bonnet adapter. Install clamp screws TR5000 actuator to the valve, connect the 220VAC power supply.
through clamp into actuator yoke and tighten to secure actuator to Position the actuator ON-OFF switch in the ON position. Then
bonnet adapter. press the self-stroking button on the PCB and hold (greater than

3 seconds) until the running light flashes red (1Hz). Actuator will 1.606 +/-.012 inch (40.792 +/- .03048 mm). Warning: The valve stem
perform automatic stroke adjustment. When automatic stroke should never be turned while the plug is in contact with the seat
adjustment is complete apply signal to actuator so actuator stem is otherwise the seating surfaces will be damaged voiding the
fully extended. See Set-Up and Wiring sections of these instructions. warranty. Stem adapter setting gage B6020012 may also be used
11) Remove power and signal from actuator. to set the position of the stem adapter on the valve stem. See page
12) Place actuator over valve stem and onto bonnet adapter. Rotate 38 for drawing. With the stem down and plug seated, rest the gage
actuator to desired orientation. For the factory default actuator on top of the bonnet adapter. Adjust the stem adapter so its end lies
position, face the actuator circuit board and install the actuator between the two steps on the gage.
on the valve with the valve upright and its inlet to the left. Engage 6) Thread jamnut against stem adapter and tighten.
raised pad in actuator yoke with groove in bonnet adapter. Install 7) Remove stem connector screws, then remove stem connector with
clamp in base of actuator yoke. Engage raised pads on back of clamp two spings from actuator stem.
with groove in bonnet adapter. Install clamp screws through clamp 8) Remove clamp screws, then remove clamp from actuator yoke.
into actuator yoke and tighten to secure actuator to bonnet adapter. 9) Place actuator over valve stem and onto bonnet adapter. Rotate
13) Place upper center hole in threaded half of stem connector over actuator to desired orientation. For the factory default actuator
pin in actuator stem. Watch orientation. With the stem down and position, face the actuator circuit board and install the actuator on
the plug seated, adjust position of stem adapter on valve stem so the valve with the valve upright and its inlet to the left. Engage raised
the stem connector engages the stem adapter. Warning: The pad in actuator yoke with groove in bonnet adapter. If necessary use
valve stem should never be turned while the plug is in contact actuator manual override to reposition the actuator stem. Install
with the seat otherwise the seating surfaces will be damaged clamp in base of actuator yoke. Engage raised pads on back of clamp
voiding the warranty. Place upper center hole in unthreaded half with groove in bonnet adapter. Install clamp screws through clamp
of stem connector over pin in actuator stem. Watch orientation. into actuator yoke and tighten to secure actuator to bonnet adapter.
Engage stem adapter with stem connector. Install stem connector 10) Lift valve stem. Place the upper center hole in unthreaded half of
screws through unthreaded half of stem connector, each through stem connector over pin on actuator stem. Watch orientation.
a spring, into threaded half of stem connector. Tighten finger tight. Engage stem adapter with stem connector using manual override.
With the stem down and the plug seated, adjust position of stem Install stem connector screws through unthreaded half of clamp,
adapter on valve stem so axial play is removed. each through a spring, into threaded half of the stem connector and
14) Use actuator manual override to retract the actuator stem tighten to secure stem adapter to stem connector.
approximately 0.2 inch (5 mm). 11) Position the actuator ON-OFF switch in the OFF position. Position
15) Unthread stem adapter one full turn. DIP switch S3-7 in the OFF position. Warning: If DIP switch S3-7
16) Thread jamnut against stem adapter and tighten. is ON, the actuator will start self-stroking as soon as power
17) Tighten stem connector screws to secure stem connector to stem is applied. The sudden movement and application of force
adapter. may result in damage to the valve and personal injury. After
18) Connect power to actuator. On circuit board press S1 self-stroking assembling the TR5000 actuator to the valve, connect the 220VAC
button. Actuator will perform automatic stroke adjustment. power supply. Position the actuator ON-OFF switch in the ON
19) Turn off power. Make necessary dipswitch settings and additional position. Then press the self-stroking button on the PCB and hold
wiring connections. See Set-Up and Wiring sections of these (greater than 3 seconds) until the running light flashes red (1Hz).
instructions. Actuator will perform automatic stroke adjustment. See Set-Up and
20) Return power to actuator. Wiring sections of these instructions.
21) Return line pressure to valve. 12) Turn off power. Make necessary DIP switch settings and additional
22) Stroke valve several times to check operation. wiring connections. See Set-Up and Wiring sections of these
instructions.
_____________________________________________ 13) Return power to actuator.
14) Return line pressure to valve.
INSTALLATION OF TIG2 TR5000-X ACTUATOR ON - 6 15) Stroke valve several times to check operation.
INCH (DN150) EXTENDED PORT PICV 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

C3121902
DPRV
ACTUATOR
INSTRUCTIONS
PICV SET DIFFERENTIAL PRESSURE 6. Apply air pressure to upstream port pressure sensing connection
equal to desired set differential pressure plus psig (0.034 BAR).
ADJUSTMENT Example: For set differential pressure of 5 psig (0.345 BARG),
1. Remove line pressure and isolate PICV valve in piping.
apply 5- psig (0.379 BARG) to upstream port pressure sensing
2. Remove upstream port and downstream port pressure sensing
connection. If mark made on valve stem in Step 9 moves away
lines from connections on diaphragm actuator (See drawing
from valve, turn adjusting screw clockwise, looking down on
C3121902).
actuator, until mark returns to its closest point to the valve.
3. Connect flexible temporary air connection to upstream port
7. Turn adjusting screw slowly counter-clockwise, looking down on
pressure sensing connection on diaphragm actuator (See
actuator, a turn at a time until mark made on valve stem in
drawing C3121902 for location of upstream port pressure
Step 9 just begins to move away from the valve.
sensing connection).
8. Reduce air pressure to upstream port pressure sensing
4. Use marking pen to place mark on valve stem just above where
connection to 0 psig (0 BARG) and allow all air to bleed from
it enters the valve.
actuator.
WARNING: In Steps 5 thru 10, do not 9. Slowly increase air pressure to upstream port pressure sensing
connection until equal to desired set differential pressure. Mark
turn the adjusting screw so it extends more
than 3-3/4 inches (9.53 cm) above the top of made on valve stem should just begin to move away from the
the actuator (more than 26 threads are visible valve when pressure reaches desired set differential pressure.
on the adjusting screw). Doing so may cause the If mark moves too soon, turn adjusting screw clockwise an
adjusting screw to separate from the actuator additional turn then repeat Steps 13 and 14. If mark does not
resulting in damage and personal injury from move, turn adjusting screw counter-clockwise an additional
the uncontrolled release of pressure inside the turn then repeat Steps 13 and 14. Satisfactory adjustment should
actuator. Be careful not to damage the seal in be made within 2 additional full turns of the adjusting screw.
the seal washer on the adjusting screw. The
seal may be damaged by excessive turning of 10. Thread locknut on adjusting screw down to top of actuator
the adjusting screw or by pushing it over the and tighten securely against seal washer to create seal against
screws threads. If the seal in the seal washer actuator. If the locknut is not tightened securely the actuator
is damaged the actuator will leak when line will leak when line pressure is returned to the valve.
pressure is returned to the valve. 11. Install upstream port and downstream port pressure sensing
lines (See drawing D3121311 (Sizes 2-1/2 thru 4 inch, P2 thru P4)
5. Loosen locknut on adjusting screw on top of actuator and or C3121900 (Sizes 5 thru 10 inch, P5 thru P1) for orientation of
separate from seal washer. Thread locknut only to top of upstream port and downstream port pressure sensing lines).
adjusting screw. 12. Return line pressure to valve.

PICV DIAPHRAGM ACTUATOR 5. Place actuator with yoke locknut over valve stem.
6. Engage actuator stem with valve stem. Looking down on top of
REMOVAL FROM VALVE actuator, rotate actuator clockwise to thread actuator stem onto
valve stem. Continue rotating actuator until actuator stem is in
2. Remove upstream port and downstream port pressure sensing
contact with jamnuts on valve stem. If necessary lift actuator
lines from connections on diaphragm actuator (See drawing
slightly and use wrench on jam nuts on valve stem to thread
C3121902).
valve stem into actuator stem. Use wrench on jamnuts on valve
stem to tighten valve stem to actuator stem. Use wrench on flats
pressure sensing connection on diaphragm actuator. Apply air
on actuator stem to keep actuator stem from turning. Rotating
pressure and increase until actuator stem begins to retract into
the actuator stem relative to the actuator will damage the
actuator.
diaphragm and void the warranty. The diaphragm-actuated
4. Loosen yoke locknut then unthread it from valve body assembly.
section of the PICV valve is reverse acting. The plug is on the
5. Reduce air pressure to upstream port pressure sensing connection
seat when the valve stem is fully up (not down). Do not turn
to 0 psig (0 BARG). Remove temporary air connection.
the valve stem if the plug is in contact with the seat. Rotating
6. Use wrench on flats of actuator stem to keep actuator stem from
the valve stem with the plug on the seat will destroy the
turning. Loosen two jamnuts on valve stem so they are not in
seating surfaces and void the warranty.
contact with actuator stem. Tighten two jamnuts together on
valve stem.
pressure sensing connection on diaphragm actuator (See
7. Looking down on top of actuator, rotate actuator counterclockwise
drawing C3121902 for location of upstream port pressure sensing
to unthread actuator stem from valve stem. Use wrench on
connection). Apply air pressure and increase until actuator yoke
jamnuts on valve stem to keep valve stem from turning. Continue
firmly contacts mounting boss of valve. Orient actuator with
rotating actuator until actuator stem is completely unthreaded
pressure sensing line connections facing PICV electric motor
from valve stem. Rotating the actuator stem relative to the
actuator or so existing pressure sensing line connections can
actuator will damage the diaphragm and void the warranty.
be reconnected. Rotating the actuator stem relative to the
The diaphragm-actuated section of the PICV valve is reverse
actuator will damage the diaphragm and void the warranty.
acting. The plug is on the seat when the valve stem is fully up
The diaphragm-actuated section of the PICV valve is reverse
(not down). Do not turn the valve stem if the plug is in contact
acting. The plug is on the seat when the valve stem is fully up
with the seat. Rotating the valve stem with the plug on the
(not down). Do not turn the valve stem if the plug is in contact
seat will destroy the seating surfaces and void the warranty.
with the seat. Rotating the valve stem with the plug on the
8. Remove actuator and yoke locknut from the valve.
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
PICV DIAPHRAGM ACTUATOR MOUNTING to 0 psig.
ON VALVE 9. If it is necessary to adjust the set differential pressure
complete Steps 4 thru 10 of the PICV Set Differential Pressure
2. Push valve stem down until plug reaches travel stop in valve.
Adjustment instructions.
3. Thread two valve stem jamnuts onto valve stem. With valve stem
10. Install upstream port and downstream port pressure sensing lines
down and plug at travel stop in valve, position jamnuts on valve
(See drawing D3121311 (Sizes 2-1/2 thru 4 inch, P2 thru P4) or
stem so the distance from the actuator yoke mounting surface of
C3121900 (Sizes 5 thru 10 inch, P5 thru P1) for orientation
the valve bonnet to the top of the jamnuts is 2.438 inch (6.193 cm). of upstream port and downstream port pressure sensing
Tighten jamnuts together. lines).
4. Place yoke locknut on actuator yoke tapered side up. 11. Return line pressure to valve.

C3121900

D312311

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; 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.
REPACK KIT
P/N KXXXXXXXX007 REPACK KIT INCLUDES (see drawing C3769956)
ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION
2 1 Packing Retainer 1 V-Ring Packing Extractor
3 1 Retainer Bearing 1 Packing Spring Removal Tool
5 1 Lip Packing 1 O-Ring Retainer & O-Ring Extractor
8 1 Tube Stem Lube 1 Stem Sleeve
REPACK/INSPECTION KITS
Control Valve Size 2-1/2, 3, 4 (DN65, DN80 & DN100) REPACK/ INSPECTION KIT INCLUDES
(See Drawing C3241354)
12 3 GASKET (See Dwg C3241354) 1 REPACK KIT
DPRV Size 2-1/2, 3, 4 (DN65, DN80 & DN100) REPACK/ INSPECTION KIT INCLUDES (See Drawing C3201355)
9 1 GASKET (See Dwg C3201355) 1 REPACK KIT
Control Valve Size 5 & 6 (DN 125 & DN150) REPACK/ INSPECTION KIT INCLUDES
(See Drawing C3241556 & C3769956)
7 2 GASKET (See Dwg C3241556) 15 1 TUBE O-RING LUBE (See Dwg C3241556)
9 1 O-RING (See Dwg C3241556) 1 REPACK KIT
DPRV Size 5 & 6 (DN 125 & DN150) REPACK/ INSPECTION KIT INCLUDES (See Drawing D3201753)
13 2 GASKET (See Dwg D3201753) 1 REPACK KIT
Control Valve Size 8 & 10 (DN200 & DN 250) REPACK/ INSPECTION KIT INCLUDES (See Drawing D3201950)
DPRV Size 8 & 10 (DN200 & DN 250) REPACK/ INSPECTION KIT INCLUDES (See Drawing D3201951)

REBUILD/REPACK KITS
Control Valve Size 2-1/2, 3, 4 (DN65, DN80 & DN100) REBUILD/ REPACK KIT INCLUDES
(See Drawing C3241354 & C3769956)
1 1 VALVE STEM (See Dwg C3241354) 9 1 PLUG (See Dwg C3241354)
3 1 TRAVEL STOP (As required, See Dwg C3241354) 10 1 SEAT RING (See Dwg C3241354)
6 1 GROOVE PIN (See Dwg C3241354) 12 3 GASKET (See Dwg C3241354)
6 1 BONNET BEARING (See Dwg C3769956) 15 1 TUBE O-RING LUBE (See Dwg C3241354)
7 1 BONNET (See Dwg C3769956) 16 1 TUBE PERMATEX #2 (See Dwg C3241354)
8 1 O-RING (See Dwg C3241354) 1 REPACK KIT
DPRV Size 2-1/2, 3, 4 (DN65, DN80 & DN100) REBUILD/ REPACK KIT INCLUDES
(See Drawing C3201355 & C3769956)
1 1 VALVE STEM (See Dwg C3201355) 7 1 TRAVEL STOP (As required, See Dwg (3201355)
4 1 GROOVE PIN (See Dwg C3201355) 9 2 GASKET (See Dwg C3201355)
6 1 BONNET BEARING (See Dwg C3769956) 12 1 TUBE PERMATEX #2 (See Dwg C3201355)
6 1 PLUG (See Dwg C3201355) 1 REPACK KIT
7 1 BONNET (See Dwg C3769956)
Control Valve Size 5 & 6 (DN 125 & DN150) REBUILD/ REPACK KIT INCLUDES
(See Drawing C3241556 & C3769956)
1 1 VALVE STEM (See Dwg C3241556) 9 1 O-RING (See Dwg C3241556)
3 1 TRAVEL STOP (As required,See Dwg C3241556) 10 1 PLUG (See Dwg C3241556)
4 1 GROOVE PIN (See Dwg C3241556) 11 1 SEAT RING (See Dwg C3241556)
6 1 BONNET BEARING (See Dwg C3769956) 15 1 TUBE O-RING LUBE (See Dwg C3241556)
7 2 GASKET (See Dwg C3241556) 16 1 TUBE PERMATEX #2 (See Dwg C3241556)
7 1 BONNET (See Dwg C3769956) 1 REPACK KIT
DPRV Size 5 & 6 (DN 125 & DN150) REBUILD/ REPACK KIT INCLUDES (See Drawing D3201753 & C3769956)
1 1 VALVE STEM (See Dwg D3201753) 9 1 PLUG (See Dwg D3201753)
6 1 GROOVE PIN (See Dwg D3201753) 10 1 UPPER SEAT RING (See Dwg D3201753)
6 1 BONNET BEARING (See Dwg C3769956) 13 2 GASKET (See Dwg D3201753)
7 1 BONNET (See Dwg C3769956) 15 1 TUBE PERMATEX #2 (See Dwg D3201753)
8 1 LOWER SEAT RING (See Dwg D3201753) 1 REPACK KIT
Control Valve Size 8 & 10 (DN200 & DN 250) REBUILD/ REPACK KIT INCLUDES
(See Drawing D3201950 & C3769956)
1 1 VALVE STEM (See Dwg D3201950) 10 1 PLUG (See Dwg D3201950)
6 1 BONNET BEARING (See Dwg C3769956) 11 1 LOWER SEAT RING (See Dwg D3201950)
7 1 BONNET (See Dwg C3769956) 14 2 GASKET (See Dwg D3201950)
8 1 GROOVE PIN (See Dwg D3201950) 16 1 TUBE PERMATEX #2 (See Dwg D3201950)
9 1 UPPER SEAT RING (See Dwg D3201950) 1 REPACK KIT
DPRV Size 8 & 10 (DN200 & DN 250) REBUILD/ REPACK KIT INCLUDES (See Drawing D3201951 & C3769956)
1 1 VALVE STEM (See Dwg D3201951) 8 1 LOWER SEAT RING (See Dwg D3201951)
4 2 GASKET (See Dwg D3201951) 9 1 PLUG (See Dwg D3201951)
6 1 BONNET BEARING (See Dwg C3769956) 10 1 UPPER SEAT RING (See Dwg D3201951)
7 1 BONNET (See Dwg C3769956) 16 1 TUBE PERMATEX #2 (See Dwg D3201951)
7 1 GROOVE PIN (See Dwg D3201951) 1 REPACK KIT

C3241354

C3201355
C3769956

D3241556
D3201753

D3201950
D3201951

B6020011
B6020012

NOTES

PICV_IOM_REVF_0114
Pressure Independent
Control Valve
2600 Emrick Blvd Bethlehem, PA 18020 USA

800-922-0085 www.warrencontrols.com

Series Picv: (Pressure Independent Control Valve)

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Series Picv: (Pressure Independent Control Valve)

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HIGH CAPACITY SERIES PICV

(Pressure Independent Control Valve)

Overview / Operation..................... COVER

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

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

8.75 in (22.23 cm)

6.72 in 4.91 in 6.97 in

8.5 in (21.59 cm)

1/2 in (1.27 cm)

DPRV DOUBLE ACTING DIAPHRAGM ACTUATOR WITH SPRING ASSIST

ELECTRIC ACTUATOR SPECIFICATIONS (TR5000-X)

PRESSURE INDEPENDENT CONTROL VALVE PICV_IOM_REVF_0114 3

Set Differential Pressure (PSI) Set Differential Pressure (PSI)

Set Differential Pressure (PSI) Set Differential Pressure (PSI)

Set Differential Pressure (PSI) Set Differential Pressure (PSI)

Set Differential Pressure (PSI) Set Differential Pressure (PSI)

Set Differential Pressure (PSI) Set Differential Pressure (PSI)

Set Differential Pressure (PSI) Set Differential Pressure (PSI)

Set Differential Pressure (PSI) Set Differential Pressure (PSI)

Set Differential Pressure (PSI) Set Differential Pressure (PSI)

Set Differential Pressure (PSI) Set Differential Pressure (PSI)

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

Set Differential Pressure (PSI) Set Differential Pressure (PSI)

Set Differential Pressure (PSI) Set Differential Pressure (PSI)

6 Standard Port Maximum flow (GPM) Maximum flow (GPM)

6 Extended Port Maximum flow (GPM) Maximum flow (GPM)

Set Differential Pressure (PSI) Set Differential Pressure (PSI)

Set Differential Pressure (PSI) Set Differential Pressure (PSI)

Set Differential Pressure (PSI) Set Differential Pressure (PSI)

PRESSURE INDEPENDENT CONTROL VALVE PICV_IOM_REVF_0114 5

PRODUCT MODEL LOW DP SPRING MEDIUM DP SPRING

Set Differential Pressure (BAR) Set Differential Pressure (BAR)

Set Differential Pressure (BAR) Set Differential Pressure (BAR)

Set Differential Pressure (BAR) Set Differential Pressure (BAR)

Set Differential Pressure (BAR) Set Differential Pressure (BAR)

Set Differential Pressure (BAR) Set Differential Pressure (BAR)

Set Differential Pressure (BAR) Set Differential Pressure (BAR)

Set Differential Pressure (BAR) Set Differential Pressure (BAR)

6 2600 Emrick Blvd Bethlehem, PA 18020 USA 800-922-0085 www.warrencontrols.com

Set Differential Pressure (BAR) Set Differential Pressure (BAR)

Set Differential Pressure (BAR) Set Differential Pressure (BAR)

Set Differential Pressure (BAR) Set Differential Pressure (BAR)

DN150 Standard Port Maximum flow (LPS) Maximum flow (LPS)

Set Differential Pressure (BAR) Set Differential Pressure (BAR)

Set Differential Pressure (BAR) Set Differential Pressure (BAR)

Set Differential Pressure (BAR) Set Differential Pressure (BAR)

Set Differential Pressure (BAR) Set Differential Pressure (BAR)

PRESSURE INDEPENDENT CONTROL VALVE PICV_IOM_REVF_0114 7

8 2600 Emrick Blvd Bethlehem, PA 18020 USA 800-922-0085 www.warrencontrols.com

Pipes must be aligned squarely with the PICV at each connection.

PRESSURE INDEPENDENT CONTROL VALVE PICV_IOM_REVF_0114 9

Control Valve (Left)

* Includes gasket between Control Valve and Differential Pressure Valve

10 2600 Emrick Blvd Bethlehem, PA 18020 USA 800-922-0085 www.warrencontrols.com

WITH TR5000 ACTUATOR WITH VM5000E ACTUATOR

Control Valve (Left)

* Includes gasket between Control Valve and Differential Pressure Valve

PRESSURE INDEPENDENT CONTROL VALVE PICV_IOM_REVF_0114 11

WITH VM5000E ACTUATOR WITH TR5000 ACTUATOR

Control Valve (Left)

* Includes gasket between Control Valve and Differential Pressure Valve

12 2600 Emrick Blvd Bethlehem, PA 18020 USA 800-922-0085 www.warrencontrols.com