Warren Controls PICV User Manual

HIGH CAPACITY

PICV IOM

SERIES PICV

(Pressure Independent Control Valve)

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

OVERVIEW

This document covers the installation, operation and maintenance
of Series PICV (Pressure Independent Control Valves). The Series PICV
maximizes efficiency and energy savings by providing precise control
of maximum differential temperatures across a coil or heat exchanger
independent of variations in system pressure. The Series PICV
consists of two functional controlling segments. The first segment
is an electrically actuated control valve, capable of responding to
a control signal from a controller that is not part of the PICV. The
second segment is connected in series with the first, and serves to
sense and regulate a preset flowing differential pressure across the
control valve segment. Both segments include pressure balanced
control elements of industrial quality manufactured in accordance
with ISO 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
control valve is the amount of pressure, or differential pressure across
it. At any point in valve plug travel, flow through a valve will typically
increase if differential pressure is raised, and decrease if it is lowered.
A change in pumping pressure can therefore produce a change
in rate of flow that is not related to the system controller’s output
signal. With pressure independence, the amount of water flowing
through a valve and the controlled load (i.e. heat exchanger coil) is
more accurately controlled as a function of the control signal, and is
less dependent upon varying pump pressure. Stability in the control
system is enhanced when pressure independence is provided, and the
control valve’s installed flow characteristic more closely resembles its
inherent, or constant-pressure characteristic.

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

PICV_IOM_REVF_0114

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

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

switching or from varying flow demands in it’s own,
or parallel flow paths and results in pressure independent
operation.

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

CONFIGURATIONS

Control
Valve
Size

P2

2.5” DN65

P3

3” DN80

P4

4” DN100

P5

5” DN125

P6

6” DN150

P8

8” DN200

P1

10” DN250

Control
Valve
Flange

0

ANSI 125

Flanges

2

PN16

Flanges

Control
Valve
Profile

22

Type of

Control
Valve
Body
(Sizes P8
& P1)

23

Type of

Control
Valve
Body
(Sizes
P2-P6)

Control
Valve Trim
Size

F

Control Valve

Trim Size Full

X

Control Valve

Trim Size
Extended

1

Control Valve

Trim Size 1SR

2

Control Valve

Trim Size 2SR

Control Valve
Trim Material

S

Stainless Steel

B

Bronze

Control Valve
Motor

E020

VM1500E ­Fail As Is

E021

VM1500E - w/
VMS-25
BCM

E022

VM5000E -

Fail As Is

E023

VM5000E - w/

VMS-25

BCM

TIG1

TR5000-X

-Fail As Is
for all exceot
P6_23XX
Extended Port

TIG2

TR5000-X

-Fail As Is
Extended Port
Only

DPRV
Size

P2

2.5” DN65

P3

3” DN80

P4

4” DN100

P5
P6

6” DN150

P8

8” DN200

P1

10” DN250

VALVE BODIES

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

5” DN125

DPRV
Flange

DPRV
Trim

DPRV Actuator

Material

DS

DB

DPRV Type

72 Portion

w/ SS Trim

DPRV Type

72 Portion

w/ Brz

Trim

2L

DPRV Actuator Cast

Iron, w/ Low DP Spring

2M

DPRV Actuator Cast

Iron, w/ Medium DP

Spring

0

ANSI 125

Flanges

2

PN16 Flanges

Note: Must
match control
valve

Body Pressure Temperature Ratings

Iron Body
Temperature 125 FLG & PN16

O

F

35 to 180 1.7 to 82.2 150 10.20

O

C PSIG BARG

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

Valve Usage: VM-1500E [Valve sizes 2 1/2, 3 & 4 Inch DN65, DN80 & DN100],
VM-5000E [Valve sizes 5, 6, 8 & 10 Inch DN125, DN150, DN200, DN250]
Control Signal: 4-20 mAdc (Factory Setting), 0-20 mAdc, 0-10 Vdc or 2-10 Vdc
and Floating, Self-Adjusting, Field Selectable (Dip Switch)
Power Consumption: VM-1500E 12VA, VM-5000E 25VA
Timing: VM-1500E [102 sec. / inch, 4.02 sec. / mm], VM-5000E [76 sec. / inch, 2.99 sec./mm]
Feedback Signal: 4-20 mAdc (Factory Setting), 0-10 Vdc or 2-10 Vdc
Failure Mode: Fail-As-Is [Without VMS-25 BCM (Back-up Control Module)]
Fail-Safe [With VMS-25 BCM (Back-up Control Module)]
Manual Override: Yes
Construction: Polycarbonate Motor Housing with Steel Linkage & Yoke.
Case has one 1/2 inch (1.27 cm) NPSM Conduit Adapter
Connections: Coded Screw Terminals
Locations: NEMA Type 3 / IP54
Temperature Limits: Ambient 32°F - 122°F ( 0°C - 50°C )
Mounting: Factory Aligned, Vertical Above Centerline of Control Valve
Consult factory for preconfigured alternate orientations

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

Actuator Usage: VM-1500E & VM-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)

VMS-25 BCM

5.19 in

(13.18 cm)

4X 0.31 in (0.79 cm)

8.75 in (22.23 cm)

6.69 in (16.99 cm)

THRU MOUNTING FOOT

6.72 in

(17.O7 cm)

8.5 in (21.59 cm)

1/2 in (1.27 cm)

4.91 in

(12.47 cm)

6.97 in

(17.7O cm)

DPRV DOUBLE ACTING DIAPHRAGM ACTUATOR WITH SPRING ASSIST

Control Signal: Differential Pressure from Control Valve,

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

ELECTRIC ACTUATOR SPECIFICATIONS (TR5000-X)

Valve Usage: 5, 6, 8, & 10 inch, DN125, DN150, DN200, 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 14˚F to 122˚F ( -10˚C to 50˚C )
Relative Humidity: < 95% RH (40ºC)
Mounting: Factory Aligned, Vertical Above Centerline of Control Valve; Consult factory for preconfigured alternate orientations

PRESSURE INDEPENDENT CONTROL VALVE PICV_IOM_REVF_0114

3

FLANGE

PRODUCT MODEL

(where ‘x’ is a configurable option)

LOW DP SPRING
PERFORMANCE

MEDIUM DP SPRING
PERFORMANCE

ANSI125

ANSI125

ANSI125

ANSI125

ANSI125

P2023Fx-xxxx-P20Dx-2x

2 1/2” Standard Port

P30231x-xxxx-P30Dx-2x

3” 1 Size Reduced Port

P3023Fx-xxxx-P30Dx-2x

3” Standard Port

P40232x-xxxx-P40Dx-2x

4” 2 Sizes Reduced Port

P40231x-xxxx-P40Dx-2x

4” 1 Size Reduced Port

Set Differential Pressure (PSI)

2.0 3.1 4.2 5.3

Maximum flow (GPM)

92 114 133 150

Set Differential Pressure (PSI)

2.0 3.1 4.2 5.3

Maximum flow (GPM)

106 132 154 173

Set Differential Pressure (PSI)

2.0 3.1 4.2 5.3

Maximum flow (GPM)

127 158 184 207

Set Differential Pressure (PSI)

2.0 3.1 4.2 5.3

Maximum flow (GPM)

165 206 240 269

Set Differential Pressure (PSI)

2.0 3.1 4.2 5.3

Maximum flow (GPM)

204 254 295 332

Set Differential Pressure (PSI)

5.7 6.5 7.2 8.0

Maximum flow (GPM)

155 166 174 184

Set Differential Pressure (PSI)

5.7 6.5 7.2 8.0

Maximum flow (GPM)

179 191 201 212

Set Differential Pressure (PSI)

5.7 6.5 7.2 8.0

Maximum flow (GPM)

215 229 241 255

Set Differential Pressure (PSI)

5.7 6.5 7.2 8.0

Maximum flow (GPM)

279 298 314 331

Set Differential Pressure (PSI)

5.7 6.5 7.2 8.0

Maximum flow (GPM)

344 367 386 407

ANSI125

ANSI125

ANSI125

ANSI125

P4023Fx-xxxx-P40Dx-2x

4” Standard Port

P50232x-xxxx-P50Dx-2x

5” 2 Sizes Reduced Port

P50231x-xxxx-P50Dx-2x

5” 1 Size Reduced Port

P5023Fx-xxxx-P50Dx-2x

5” Standard Port

Set Differential Pressure (PSI)

2.0 3.1 4.2 5.3

Maximum flow (GPM)

240 299 348 391

Set Differential Pressure (PSI)

2.0 3.1 4.2 5.3

Maximum flow (GPM)

287 357 416 467

Set Differential Pressure (PSI)

2.0 3.1 4.2 5.3

Maximum flow (GPM)

335 417 486 546

Set Differential Pressure (PSI)

2.0 3.1 4.2 5.3

Maximum flow (GPM)

382 475 553 622

Set Differential Pressure (PSI)

5.7 6.5 7.2 8.0

Maximum flow (GPM)

406 433 456 481

Set Differential Pressure (PSI)

5.7 6.5 7.2 8.0

Maximum flow (GPM)

485 518 545 574

Set Differential Pressure (PSI)

5.7 6.5 7.2 8.0

Maximum flow (GPM)

566 604 636 670

Set Differential Pressure (PSI)

5.7 6.5 7.2 8.0

Maximum flow (GPM)

645 688 724 764

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

4

FLANGE

PRODUCT MODEL

(where ‘x’ is a configurable option)

LOW DP SPRING
PERFORMANCE

MEDIUM DP SPRING
PERFORMANCE

ANSI125

ANSI125

ANSI125

ANSI125

P60032x-xxxx-P60Dx-2x

6” 2 Sizes Reduced Port

P60231x-xxxx-P60Dx-2x

6” 1 Size Reduced Port

P6023Fx-xxxx-P60Dx-2x

6” Standard Port

P6023Xx-xxxx-P60Dx-2x

6” Extended Port

ANSI125

P80222S-xxxx-P80Dx-2x

8” 2 Sizes Reduced Port

SS Trim Only

Set Differential Pressure (PSI)

2.0 3.1 4.2 5.3

Maximum flow (GPM)

389 484 564 633

Set Differential Pressure (PSI)

2.0 3.1 4.2 5.3

Maximum flow (GPM)

445 555 646 725

Set Differential Pressure (PSI)

2.0 3.1 4.2 5.3

Maximum flow (GPM)

509 634 738 829

Set Differential Pressure (PSI)

2.0 3.1 4.2 5.3

Maximum flow (GPM)

594 739 861 967

Set Differential Pressure (PSI)

2.0 3.1 4.2 5.3

Maximum flow (GPM)

735 916 1066 1197

Set Differential Pressure (PSI)

5.7 6.5 7.2 8.0

Maximum flow (GPM)

657 701 738 778

Set Differential Pressure (PSI)

5.7 6.5 7.2 8.0

Maximum flow (GPM)

752 803 845 891

Set Differential Pressure (PSI)

5.7 6.5 7.2 8.0

Maximum flow (GPM)

859 918 966 1018

Set Differential Pressure (PSI)

5.7 6.5 7.2 8.0

Maximum flow (GPM)

1003 1071 1127 1188

Set Differential Pressure (PSI)

5.7 6.5 7.2 8.0

Maximum flow (GPM)

1241 1326 1395 1471

ANSI125

P80221S-xxxx-P80Dx-2x

8” 1 Size Reduced Port

SS Trim Only

ANSI125

ANSI125

P8023Fx-E02x-P80Dx-2x

8” Standard Port

P10222S-xxxx-P10Dx-2x

10” 2 Sizes Reduced Port

SS Trim Only

ANSI125

P10221S-xxxx-P10Dx-2x

10” 1 Size Reduced Port

SS Trim Only

Set Differential Pressure (PSI)

2.0 3.1 4.2 5.3

Maximum flow (GPM)

841 1048 1219 1370

Set Differential Pressure (PSI)

2.0 3.1 4.2 5.3

Maximum flow (GPM)

962 1197 1394 1565

Set Differential Pressure (PSI)

2.0 3.1 4.2 5.3

Maximum flow (GPM)

1039 1294 1506 1692

Set Differential Pressure (PSI)

2.0 3.1 4.2 5.3

Maximum flow (GPM)

1188 1479 1721 1934

Set Differential Pressure (PSI)

5.7 6.5 7.2 8.0

Maximum flow (GPM)

1421 1517 1597 1683

Set Differential Pressure (PSI)

5.7 6.5 7.2 8.0

Maximum flow (GPM)

1623 1734 1825 1923

Set Differential Pressure (PSI)

5.7 6.5 7.2 8.0

Maximum flow (GPM)

1755 1874 1972 2079

Set Differential Pressure (PSI)

5.7 6.5 7.2 8.0

Maximum flow (GPM)

2005 2142 2254 2376

PRESSURE INDEPENDENT CONTROL VALVE PICV_IOM_REVF_0114

5

FLANGE

PRODUCT MODEL

(where ‘x’ is a configurable option)

LOW DP SPRING
PERFORMANCE

MEDIUM DP SPRING
PERFORMANCE

ANSI125 P1022Fx-xxxx-P10Dx-2x

10” Standard Port

PRODUCT MODEL

FLANGE

PN16

PN16

PN16

(where ‘x’ is a configurable option)

P2223Fx-xxxx-P22Dx-2x

DN65 Standard Port

P32231x-xxxx-P32Dx-2x

DN80 1 Size Reduced Port

P3223Fx-xxxx-P32Dx-2x

DN80 Standard Port

Set Differential Pressure (PSI)

2.0 3.1 4.2 5.3

Maximum flow (GPM)

1358 1690 1967 2210

LOW DP SPRING
PERFORMANCE

Set Differential Pressure (BAR)

0.14 0.21 0.29 0.37

Maximum flow (LPS)

5.8 7.2 8.4 9.5

Set Differential Pressure (BAR)

0.14 0.21 0.29 0.37

Maximum flow (LPS)

6.7 8.3 9.7 11.0

Set Differential Pressure (BAR)

0.14 0.21 0.29 0.37

Maximum flow (LPS)

8.1 9.9 11.6 13.2

Set Differential Pressure (PSI)

5.7 6.5 7.2 8.0

Maximum flow (GPM)

2292 2448 2576 2715

MEDIUM DP SPRING
PERFORMANCE

Set Differential Pressure (BAR)

0.39 0.45 0.5 0.55

Maximum flow (LPS)

9.8 10.5 11.0 11.6

Set Differential Pressure (BAR)

0.39 0.45 0.5 0.55

Maximum flow (LPS)

11.3 12.1 12.7 13.4

Set Differential Pressure (BAR)

0.39 0.45 0.5 0.55

Maximum flow (LPS)

13.5 14.5 15.3 16.0

PN16

PN16

PN16

PN16

P42232x-xxxx-P42Dx-2x

DN100 2 Sizes Reduced Port

P42231x-xxxx-P42Dx-2x

DN100 1 Size Reduced Port

P4223Fx-xxxx-P42Dx-2x

DN100 Standard Port

P52232x-xxxx-P52Dx-2x

DN125 2 Sizes Reduced Port

Set Differential Pressure (BAR)

0.14 0.21 0.29 0.37

Maximum flow (LPS)

10.5 12.9 15.1 17.1

Set Differential Pressure (BAR)

0.14 0.21 0.29 0.37

Maximum flow (LPS)

12.9 15.9 18.6 21.0

Set Differential Pressure (BAR)

0.14 0.21 0.29 0.37

Maximum flow (LPS)

15.3 18.7 22.0 24.8

Set Differential Pressure (BAR)

0.14 0.21 0.29 0.37

Maximum flow (LPS)

18.2 22.4 26.3 29.7

Set Differential Pressure (BAR)

0.39 0.45 0.5 0.55

Maximum flow (LPS)

17.6 18.9 19.9 20.8

Set Differential Pressure (BAR)

0.39 0.45 0.5 0.55

Maximum flow (LPS)

21.6 23.2 24.5 25.7

Set Differential Pressure (BAR)

0.39 0.45 0.5 0.55

Maximum flow (LPS)

25.5 27.4 28.9 30.3

Set Differential Pressure (BAR)

0.39 0.45 0.5 0.55

Maximum flow (LPS)

30.5 32.7 34.5 36.2

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

6

FLANGE

PRODUCT MODEL

(where ‘x’ is a configurable option)

LOW DP SPRING
PERFORMANCE

MEDIUM DP SPRING
PERFORMANCE

PN16

PN16

PN16

PN16

PN16

P52231x-xxxx-P52Dx-2x

DN125 1 Size Reduced Port

P5223Fx-xxxx-P52Dx-2x

DN125 Standard Port

P62232x-xxxx-P62Dx-2x

DN150 2 Sizes Reduced Port

P62231x-xxxx-P62Dx-2x

DN150 1 Size Reduced Port

P6223Fx-xxxx-P62Dx-2x

DN150 Standard Port

Set Differential Pressure (BAR)

0.14 0.21 0.29 0.37

Maximum flow (LPS)

21.3 26.1 30.7 34.6

Set Differential Pressure (BAR)

0.14 0.21 0.29 0.37

Maximum flow (LPS)

24.3 29.7 34.9 39.5

Set Differential Pressure (BAR)

0.14 0.21 0.29 0.37

Maximum flow (LPS)

24.7 30.3 35.6 40.2

Set Differential Pressure (BAR)

0.14 0.21 0.29 0.37

Maximum flow (LPS)

28.3 34.7 40.8 46.0

Set Differential Pressure (BAR)

0.14 0.21 0.29 0.37

Maximum flow (LPS)

32.4 39.6 46.6 53

Set Differential Pressure (BAR)

0.39 0.45 0.5 0.55

Maximum flow (LPS)

35.6 38.2 40.3 42.2

Set Differential Pressure (BAR)

0.39 0.45 0.5 0.55

Maximum flow (LPS)

40.5 43.5 45.9 48.1

Set Differential Pressure (BAR)

0.39 0.45 0.5 0.55

Maximum flow (LPS)

41.3 44.3 46.7 49.0

Set Differential Pressure (BAR)

0.39 0.45 0.5 0.55

Maximum flow (LPS)

47.3 51 54 56

Set Differential Pressure (BAR)

0.39 0.45 0.5 0.55

Maximum flow (LPS)

54 58 61 64

PN16

P6223Xx-xxxx-P62Dx-2x

PN16

DN150 Extended Port

P82222S-xxxx-P82Dx-2x

DN200 2 Sizes Reduced Port

SS Trim Only

PN16

P82221S-xxxx-P82Dx-2x

DN200 1 Size Reduced Port

SS Trim Only

PN16

P8223Fx-E02x-P82Dx-2x

DN200 Standard Port

Set Differential Pressure (BAR)

0.14 0.21 0.29 0.37

Maximum flow (LPS)

37.8 46.2 54 61

Set Differential Pressure (BAR)

0.14 0.21 0.29 0.37

Maximum flow (LPS)

46.7 57 67 76

Set Differential Pressure (BAR)

0.14 0.21 0.29 0.37

Maximum flow (LPS)

53 66 77 87

Set Differential Pressure (BAR)

0.14 0.21 0.29 0.37

Maximum flow (LPS)

61 75 88 99

Set Differential Pressure (BAR)

0.39 0.45 0.5 0.55

Maximum flow (LPS)

63 68 71 75

Set Differential Pressure (BAR)

0.39 0.45 0.5 0.55

Maximum flow (LPS)

78 84 88 93

Set Differential Pressure (BAR)

0.39 0.45 0.5 0.55

Maximum flow (LPS)

89 96 101 106

Set Differential Pressure (BAR)

0.39 0.45 0.5 0.55

Maximum flow (LPS)

102 110 116 121

PRESSURE INDEPENDENT CONTROL VALVE PICV_IOM_REVF_0114

7

FLANGE

PRODUCT MODEL

(where ‘x’ is a configurable option)

LOW DP SPRING
PERFORMANCE

MEDIUM DP SPRING
PERFORMANCE

PN16

P12222S-xxxx-P12Dx-2x

DN250 2 Sizes Reduced Port

SS Trim Only

PN16

P12221S-xxxx-P12Dx-2x

DN250 1 Size Reduced Port

SS Trim Only

PN16

P1222Fx-xxxx-P12Dx-2x

DN250 Standard Port

Set Differential Pressure (BAR)

0.14 0.21 0.29 0.37

Maximum flow (LPS)

66 81 95 107

Set Differential Pressure (BAR)

0.14 0.21 0.29 0.37

Maximum flow (LPS)

76 92 109 123

Set Differential Pressure (BAR)

0.14 0.21 0.29 0.37

Maximum flow (LPS)

86 106 124 140

INSTALLATION

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

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

Set Differential Pressure (BAR)

0.39 0.45 0.5 0.55

Maximum flow (LPS)

110 118 125 131

Set Differential Pressure (BAR)

0.39 0.45 0.5 0.55

Maximum flow (LPS)

126 135 143 150

Set Differential Pressure (BAR)

0.39 0.45 0.5 0.55

Maximum flow (LPS)

144 155 163 171

PICV Minimum Lengths of
Straight Pipe

PICV Size Upstream

Straight Pipe

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

Downstream

Straight Pip

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.

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

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• ProtectPICVanddownstreamequipmentwithanupstreamself-cleaningstrainer.

• FormaximumefficiencyandminimumwearinstallPICVIN VERTICAL POSITION with the stems POINTING UPWARD.

• Besuretoleave 6 INCHES (15.24 CM) OF CLEARANCE above the actuators to allow for actuator removal.

• Beforeinstalling,besurePICVandpipingareCLEAN INSIDE and FREE OF SCALE, chips, welding spatter, and foreign material.

Thoroughly blow out or flush pipe lines.

• ThePICVmustbeinstalledwiththefluidflowinthedirectionofthearrowontheflowarrowplate.

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

• Tightenflangeboltsevenlytopreventexcessivestressandthepossibilityofcracking.Ifmatingflangesareraisedfacedtheymustbe

machined flat.

• ThePICVandaccessories(ifsoequipped)areassembled,tested,andcalibratedatthefactoryasaunit.Thenameplatespecifiesset-up

parameters used.

• Supplyairorpower,instrumentsignal,andaccessoriesshouldbeconnectedtoportsorterminalsasindicatedonthePICV.

• Verificationandtuningofthesetdifferentialpressuremayberequiredunderactualoperatingconditions.

PRESSURE INDEPENDENT CONTROL VALVE PICV_IOM_REVF_0114

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DIMENSIONS

ddpv

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

Control Valve (Left)

Hcv

ccv

Bcv

dcv

WITH VM1500E ACTUATOR

Hdpv

cdpv

Bdpv

Acv Adpv

Xcdp

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
P3223xx-E02x-P32Dx-xx DN80 25.40 cm 13.65 cm 16.83 cm 12.38 cm 37.47 cm
P4223xx-E02x-P42Dx-xx DN100 33.02 cm 16.19 cm 19.69 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)

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
P3223xx-E02x-P32Dx-2L DN80 22.86 cm 13.02 cm 11.11 cm 24.77 cm 56.20 cm 48.42 cm
P3223xx-E02x-P32Dx-2M DN80 22.86 cm 13.02 cm 11.11 cm 24.77 cm 67.95 cm 48.42 cm
P4223xx-E02x-P42Dx-2L DN100 28.89 cm 16.19 cm 13.34 cm 24.77 cm 56.20 cm 62.07 cm
P4223xx-E02x-P42Dx-2M DN100 28.89 cm 16.19 cm 13.34 cm 24.77 cm 67.95 cm 62.07 cm

combined*

* 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

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

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

WITH TR5000 ACTUATOR WITH VM5000E ACTUATOR

DIMENSIONS

Control Valve (Left)

MODEL LISTING SIZE Acv Bcv Ccv Dcv Hcv

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-E02x-P52Dx-xx DN125 40.01 cm 14.61 cm 20.96 cm 16.83 cm 38.74 cm
P5223xx-TIG1-P52Dx-xx DN125 40.01 cm 14.61 cm 20.96 cm 19.05 cm 41.28 cm
P6223xx-E02x-P62Dx-xx DN150 45.09 cm 16.51 cm 22.54 cm 16.83 cm 38.74 cm
P6223xx-TIGx-P62Dx-xx DN150 45.09 cm 16.51 cm 22.54 cm 19.05 cm 41.28 cm

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

Differential Pressure Valve (Right)

Model Listing SIZE Adpv Bdpv Cdpv Ddpv Hdpv Xcdp

P5023xx-xxxx-P50Dx-2L 5 12 in 6-7/8 in 7-5/8 in 9-3/4 in 22-1/8 in 27-13/16 in
P5023xx-xxxx-P50Dx-2M 5 12 in 6-7/8 in 7-5/8 in 9-3/4 in 26-3/4 in 27-13/16 in
P6023xx-xxxx-P60Dx-2L 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
P6223xx-xxxx-P62Dx-2L DN150 35.88 cm 19.37 cm 21.59 cm 24.77 cm 56.20 cm 81.12 cm
P6223xx-xxxx-P62Dx-2M DN150 35.88 cm 19.37 cm 21.59 cm 24.77 cm 67.95 cm 81.12 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

combined*

Total

PRESSURE INDEPENDENT CONTROL VALVE PICV_IOM_REVF_0114

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DIMENSIONS

PICV SIZES: 8-10 IN DN200-DN250

WITH TR5000 ACTUATORWITH VM5000E ACTUATOR

Control Valve (Left)

MODEL LISTING SIZE Acv Bcv Ccv Dcv Hcv

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
P8222xx-E02x-P82Dx-xx DN200 41.28 cm 22.54 cm 24.45 cm 16.83 cm 38.10 cm
P8222xx-TIG1-P82Dx-xx DN200 41.28 cm 22.54 cm 24.45 cm 18.73 cm 41.28 cm
P1222xx-E02x-P12Dx-xx DN250 50.80 cm 24.45 cm 25.72 cm 16.83 cm 38.10 cm
P1222xx-TIG1-P12Dx-xx DN250 50.80 cm 24.45 cm 25.72 cm 18.73 cm 41.28 cm

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

Dierential Pressure Valve (Right)

Model Listing SIZE Adpv Bdpv Cdpv Ddpv Hdpv Xcdp

P8022xx-xxxx-P80Dx-2L 8 16-1/4 in 8-7/8 in 9-5/8 in 9-3/4 in 22-1/8 in 32-9/16 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
P8222xx-xxxx-P82Dx-2L DN200 41.28 cm 22.54 cm 24.45 cm 24.77 cm 56.20 cm 82.71 cm
P8222xx-xxxx-P82Dx-2M DN200 41.28 cm 22.54 cm 24.45 cm 24.77 cm 67.95 cm 82.71 cm
P1222xx-xxxx-P12Dx-2L DN250 50.80 cm 24.45 cm 25.72 cm 24.77 cm 56.20 cm 101.76 cm
P1222xx-xxxx-P12Dx-2M DN250 50.80 cm 24.45 cm 25.72 cm 24.77 cm 67.95 cm 101.76 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

combined*

Total

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

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