Honeywell VPI Series User manual

VPI PRESSURE INDEPENDENT

CONTROL VALVES AND ACTUATORS

INSTALLATION INSTRUCTION

® U.S. Registered Trademark.

APPLICATION

Honeywell pressure independent control valve (PICV) is

used in heating and cooling systems in applications

with Air Handling Units, Fan Coil Units, chilled ceilings,

zone control, or other terminal unit applications.

Honeywell VPI series provides modulating control with

full authority regardless of any fluctuations in the

differential pressure of the system. Honeywell VPI

series combines an externally adjustable automatic

balancing valve, a differential pressure control valve,

and a full authority modulating control valve.

Honeywell VPI series makes it simple to achieve 100%

control of the water flow in the building while creating

high comfort and energy savings at the same time. An

additional benefit is that no balancing is required if

further stages are added to the system, or if the

dimensioned capacity is changed. Energy-saving due

to optimal control, lower flow, and pump pressure.

Maximized ΔT due to faster response and increased

system stability

Application Notes

Valve sizing is important for correct system operation.

Undersized valves do not have sufficient capacity at

maximum load.

Proper Use

These valves are intended for use in chilled water and

hot water closed-loop applications only, with a media

temperature range of -20ºC to +120ºC (-4ºF to

+248ºF), and static pressures up to 580psi. Not

suitable for oil, combustible gases, or high-

temperature steam.

These valves are to be operated with the appropriate

and compatible Honeywell actuators only. Refer VPI

series PICV Product Datasheets for more details on

valve and actuators compatibility.

Water should be properly filtered, treated, and

conditioned for good operating performance, and

according to according to VDI 2035 with up to 50 %

Glycol (oxygen concentration less than 0.2 g/m3, pH

8...9.5; Fe<0.5 mg/kg; Cu<0.1 mg/kg). The installation

of strainers and filters is recommended. Do not use

manual balancing valves.

IMPORTANT: The presence of excessive iron oxide

(red rust) in the system voids the valve warranty.

Effective Flow Rate

The built-in differential pressure regulator makes fluid

flow through the valve independent of changes in

supply. The pressure regulator virtually eliminates

cavitation in the valve and decouples the control valve

from the effects of piping components such as

reducers and elbows.

Pressure independent control valves are sized to match

design coil flow regardless of coil connection size.

These valves eliminate the need to balance the system

for proper flow and allow chillers to be operated at

design temperature differential for maximum

efficiency at every load condition.

Flow Characteristic

The VPI series Pressure Independent Control Valves

have: Linear flow characteristic and can be converted

to an equal percentage in the actuator.

VPI Pressure Independent Control Valves & Actuators

31-00383-01 2

DECLARATION OF REACH CONFORMITY

Article 33 Communication

REGULATION (EC) NO 1907/2006 [REACH]

According to Article 33 of Reach Regulation be informed that these products may contain lead (CAS: 7439-92-1) up

to 2.0-2.5% in any brass used in valve housings, headnuts, p/t plugs, flushing caps etc.

PREREQUISITE

When installing this product...

1. Read these instructions carefully. Failure to follow them could damage the product or cause a hazardous

condition.

2. Check ratings given in instructions and on the product to ensure the product is suitable for your application.

3. The installer must be a trained, experienced service technician.

4. After installation is complete, check out product operation as provided in these instructions.

Preparation

CAUTION

Equipment Damage Hazard

Foreign particles like dirt and metal chips can damage the valve seat and diaphragm.

For trouble-free operation of the product, good installation practice must include initial system flushing and chemical

water treatment. Clean the lines upstream of particles larger than 1/16 inch diameter (welding slag, pipe scale, sand,

and other suspended particulate).

Do not use boiler additives, solder flux, and wetted materials which are petroleum-based or contain mineral oil,

hydrocarbons, or ethylene glycol acetate. Compounds that can be used, with a minimum 50% water dilution, are

diethylene glycol, ethylene glycol, and propylene glycol (antifreeze solutions).

If installing these valves in an addition to, or retrofitting an existing building, do not assume that the fluid in the existing

piping meets these criteria.

1. Before installing the valves, flush the system.

2. It is recommended to install strainers in front of the valves to protect against clogging due to foreign particles.

Strainer baskets should be installed, checked and cleaned as required during flushing and normal operation.

3. Use clean water according to the guidelines in VDI 2035. VDI 2035 recommends water quality as per

conductance value <100 μS/cm, oxygen content of up to 0.1 mg/l, pH of 8.2-10.0 and requires low turbidity

<1FTU and consequently low content of alkaline earths.

4. It is recommended to treat water with chemical to achieve required water quality. If using any additives, please

contact Honeywell for guidance.

VPI PRESSURE INDEPENDENT CONTROL VALVES & ACTUATORS

3 31-00383-01

MECHANICAL INSTALLATION

Installation for DN15-32

IMPORTANT: Hold valve with a pipe wrench by

hexagonal fitting ONLY. Do NOT handle the valve

body with the pipe wrench; product damage may

result.

Refer VPI series PICV Product Datasheets for more

details on valve and actuator dimensions.

1. Clean the lines upstream of particles larger than

1/16 in. diameter (welding slag, pipe scale and

other contaminants) to properly flush the system.

2. Proceed with installation once the system

specifics (expansion/contraction of the system

and its medium as well as operating pressures) are

within tolerances.

3. Eliminate air from the system.

4. See, Figure 1 to familiarize yourself with the valve

and its components. The Valve body (D) is the

housing marked with an arrow to show flow

direction. The Flow regulator (C) which is pre-

installed in valve body, regulates flow. Pressure

ports (A) facilitates user to gauge pressure across

ends. The Plugs (B) comes with valve models

without pressure ports. See VPI series PICV

Product Datasheets for details on models with and

without pressure ports.

Figure 1. DN15-32 Valve Components

IMPORTANT: Flow arrow must point in the direction

of the flow for proper operation. Valves must be

installed avoiding unnecessary pull or twist in the

valve housing.

5. Install the valve housing with the flow directional

arrow pointing in the correct direction.

6. For threaded connections please clear threads on

both valve and piping of debris. Honeywell

recommends thread or pipe sealant (Permabond

A1044 or equivalent). When using Teflon tape, it is

recommended to use 4-6 rounds of tape applied

tightly in clockwise rotation. When using hemp as

pipe sealant, ensure no strands are left in the valve

or piping.

Flow Setting

The Flow regulator is provisioned with dial with scale

settings to allow user to set desired flow rate. For more

information about flow rate as per dial settings, see

Table 1. Flow Chart for DN15-32. The procedure for

scale setting is as follows:

1. Set the desired flow rate by adjusting scale setting

of the dial with a special adjustment key.

Figure 2 Flow Setting

2. For DN15/20 (LF) and DN32 valve models, large

white digits, numbered 1 to 5, indicate full turns

and digits from small sub-dial, numbered 0 to 9,

indicate 1/10 of full turn.

Figure 3 Dial Gauge for DN 15/20 (LF) and DN32

3. For DN15/20/25 (HF) valve models, scale is

opposite. Here large white digits, numbered 0 to 9,

indicate 1/10 of full turn and small digits from

sub-dial, numbered 0 to 5, indicate full turn.

Figure 4 Dial Gauge 3. For DN15/20/25 (HF)

4. Install the compatible and required actuator as per

application and/or system design. See Installation

of Actuators compatible with DN 15-50 for more

details on how to install the actuator.

VPI Pressure Independent Control Valves & Actuators

31-00383-01 2

Flow Setting Chart for DN 15 -32

Table 1. Flow Chart for DN15-32

DN15LF-DN20LF

DN15HF-DN25HF

DN32

Setting

l/sec

l/hr

GPM

l/sec

l/hr

GPM

l/sec

l/hr

GPM

0.0178

0.282

0.240

865

3.81

1.0

0.0393

142

0.624

0.282

1010

4.46

1.1

0.0580

209

0.920

0.322

1160

5.10

1.2

0.0743

268

1.180

0.361

1300

5.72

1.3

0.0887

319

1.41

0.399

1430

6.32

1.4

0.102

366

1.61

0.172

620

2.73

0.435

1570

6.90

1.5

0.113

408

1.80

0.200

720

3.17

0.471

1700

7.47

1.6

0.124

446

1.96

0.228

820

3.61

0.506

1820

8.02

1.7

0.134

482

2.12

0.258

930

4.10

0.540

1940

8.56

1.8

0.143

516

2.27

0.294

1060

4.67

0.573

2060

9.08

1.9

0.152

549

2.42

0.325

1170

5.15

0.605

2180

9.59

2.0

0.161

580

2.56

0.350

1260

5.55

0.636

2290

10.1

2.1

0.170

611

2.69

0.375

1350

5.95

0.667

2400

10.6

2.2

0.178

641

2.82

0.396

1430

6.28

0.696

2510

11.0

2.3

0.186

671

2.95

0.417

1500

6.61

0.725

2610

11.5

2.4

0.194

700

3.08

0.439

1580

6.96

0.753

2710

11.9

2.5

0.202

728

3.21

0.458

1650

7.27

0.780

2810

12.4

2.6

0.210

756

3.33

0.481

1730

7.62

0.807

2900

12.8

2.7

0.218

783

3.45

0.500

1800

7.93

0.832

3000

13.2

2.8

0.225

810

3.56

0.522

1880

8.28

0.858

3090

13.6

2.9

0.232

835

3.68

0.542

1950

8.59

0.882

3180

14.0

3.0

0.239

860

3.79

0.550

1980

8.72

0.906

3260

14.4

3.1

0.245

883

3.89

0.558

2010

8.85

0.930

3350

14.7

3.2

0.252

906

3.99

0.567

2040

8.99

0.953

3430

15.1

3.3

0.257

927

4.08

0.575

2070

9.12

0.975

3510

15.5

3.4

0.263

946

4.17

0.583

2100

9.25

0.997

3590

15.8

3.5

0.268

965

4.25

0.597

2150

9.47

1.02

3670

16.1

3.6

VPI PRESSURE INDEPENDENT CONTROL VALVES & ACTUATORS

3 31-00383-01

Replacement of Flow regulator

The Flow regulator are engineered and designed with more life span. Follow below procedures in case if the old flow

regulator needs replacement with the new one.

Procedure to remove the Flow Regulator

The procedure to remove Flow Regulator is as follows:

1. Remove the installed actuator (if any) as stated in Procedure to remove the Actuator.

2. Isolate the valve.

3. Use the pipe wrench or appropriate tool to rotate Flow Regulator in counterclockwise direction to remove from the

valve body. See Figure 5.

Figure 5. Removing Flow regulator from Valve body

Procedure to install the Flow Regulator

The procedure to install Flow Regulator is as follows:

1. Prior to installing the Flow regulator, the system should be properly flushed.

2. Insert the Flow Regulator in valve body and rotate with the pipe wrench or appropriate tool in Clockwise direction

to fit flow regulator in valve body. Follow the reverse sequence of steps shown in Figure above.

3. Open isolation valves slowly. Fast opening of isolation valves under high pressure may cause damage to the seat

or diaphragm of the Flow regulator.

4. Set the desired flow rate by adjusting the Flow Regulator with special adjustment key.

5. Install the actuator as stated in Procedure to install the Actuator.

VPI Pressure Independent Control Valves & Actuators

31-00383-01 2

Installation for DN40-50

IMPORTANT: Hold valve with a pipe wrench by hexagonal fitting ONLY. Do NOT handle the valve body with the pipe

wrench; product damage may result.

Refer VPI series PICV Product Datasheets for more details on valve and actuator dimensions.

The procedure to install DN 40-50 valve is as follows:

1. Clean the lines upstream of particles larger than 1/16 in. diameter (welding slag, pipe scale and other

contaminants) to properly flush the system.

2. Proceed with installation once the system specifics (expansion/contraction of the system and its medium as well

as operating pressures) are within tolerances.

3. Eliminate air from the system.

4. See Figure 6 to familiarize yourself with the valve and its components. The Valve Body (A) is the housing marked

with an arrow to show flow direction. The Flow Regulator (B) which is fixed with valve body, regulates flow.

IMPORTANT: Do not disassemble or attempt to remove the Flow regulator from the valve body. Doing so may

damage the valve and will void warranty.

Pressure ports (C) facilitates user to gauge pressure across ends. The Plugs (D) comes with valve models without

pressure ports. See VPI series PICV Product Datasheets for more details on models with and without pressure

ports.

Figure 6 DN40-50 Valve Components

IMPORTANT: Flow arrows must point in the direction of the flow for proper operation.

5. Install the valve housing with the flow directional arrow pointing in the correct direction.

6. For threaded connections please clear threads on both valve and piping of debris. Honeywell recommends thread

or pipe sealant (Permabond A1044 or equivalent). When using Teflon tape, it is recommended to use 4-6 rounds

of tape applied tightly in clockwise rotation. When using hemp as pipe sealant, ensure no strands are left in the

valve or piping.

IMPORTANT: Never use mineral oil or petrol-based grease or oil on the O-rings.

7. Set the desired flow rate by adjusting scale setting of the dial with a special adjustment key.

VPI PRESSURE INDEPENDENT CONTROL VALVES & ACTUATORS

3 31-00383-01

Flow Setting for DN40-50

The Flow regulator is provisioned with dial with scale settings to allow user to set desired flow rate. For more

information about flow rate as per dial settings, see Table 2. Flow Settings Chart for DN40-50. The procedure for scale

setting is as follows:

1. Set the desired flow rate by adjusting scale setting of the dial with a special adjustment key.

Figure 7 Flow setting for DN 40- 50

2. For DN40/50, large white digits numbered 1 to 5 including in-between positions showed by dots (one dot for

every 0.1 positions). The specific position is defined by a sign mark on top of the housing.

Figure 8 Dial Gauge for DN 40- 50

3. Install the compatible and required actuator as per application and/or system design.

VPI Pressure Independent Control Valves & Actuators

31-00383-01 4

Flow Setting Chart for DN40 –DN50

Table 2. Flow Settings Chart for DN40-50

DN40-DN50

Setting

l/sec

l/hr

GPM

0.528

1900

8.36

1.0

0.633

2278

10.0

1.1

0.738

2655

11.7

1.2

0.843

3033

13.3

1.3

0.947

3410

15.0

1.4

1.05

3787

16.7

1.5

1.16

4163

18.3

1.6

1.26

4537

20.0

1.7

1.36

4909

21.6

1.8

1.47

5279

23.2

1.9

1.57

5646

24.8

2.0

1.67

6011

26.4

2.1

1.77

6372

28.0

2.2

1.87

6730

29.6

2.3

1.97

7083

31.2

2.4

2.06

7432

32.7

2.5

2.16

7776

34.2

2.6

2.25

8115

35.7

2.7

2.35

8449

37.2

2.8

2.44

8777

38.6

2.9

2.53

9098

40.0

3.0

2.61

9413

41.4

3.1

2.70

9721

42.8

3.2

2.78

10021

44.1

3.3

2.86

10314

45.4

3.4

2.94

10599

46.6

3.5

3.02

10875

47.8

3.6

3.10

11142

49.0

3.7

3.17

11400

50.2

3.8

3.24

11649

51.3

3.9

3.30

11888

52.3

4.0

3.37

12116

53.3

4.1

3.43

12334

54.3

4.2

3.48

12540

55.2

4.3

3.54

12735

56.0

4.4

3.59

12919

56.8

4.5

3.64

13090

57.6

4.6

3.68

13249

58.3

4.7

3.72

13395

58.9

4.8

3.76

13527

59.5

4.9

3.79

13647

60.0

5.0

VPI PRESSURE INDEPENDENT CONTROL VALVES & ACTUATORS

5 31-00383-01

Installation of DN50-250

IMPORTANT: Hold threaded valve with a pipe wrench by hexagonal fitting ONLY. Do NOT handle the valve body with

the pipe wrench; product damage may result.

Refer VPI series PICV Product Datasheets for more details on valve and actuator dimensions.

The procedure to install for DN 50 –250 is as follows:

1. Clean the lines upstream of particles larger than 1/16 in. diameter (welding slag, pipe scale, and other

contaminants) to properly flush the system.

2. Proceed with installation once the system specifics (expansion/contraction of the system and its medium as well

as operating pressures) are within tolerances.

3. Eliminate air from the system.

4. Valves are marked to show flow direction, see Figure 9. Install the valve housing with the flow directional arrow

pointing in the correct direction.

Figure 9. Flow direction icon on DN50-250 valve

IMPORTANT: Flow arrows must point in the direction of the flow for proper operation.

5. Valves must be installed avoiding unnecessary pull or twist in the valve housing.

6. For flanged connections make sure if both flange surfaces are clear.

7. Flange ends are compatible with DIN steel flanges PN10, PN16, PN25, and/or PN40 according to EN1092-1 or

ANSI steel flanges class 150 and/ or 300 according to ASME B16.5. depending on the product ordered. Flanges

are not supplied by Honeywell.

See VPI series PICV Product Datasheets for more details on the flange selection of DN50-250 valves.

8. O-rings are supplied with the valve body and are used to seal connections. It is recommended to grease O-rings

with silicone grease.

IMPORTANT: Never use mineral oil or petrol-based grease or oil on the O-rings.

9. Please make sure these are properly placed in O-ring grooves on valve inlet and outlet, before installing the

housing.

10. Please note that DN200-250 (8”-10”) contains two O-ring grooves. Use the inner groove for DN200 / 8” flanges

and outer groove for DN250 / 10” flanges.

Figure 10. Groove location on DN200-250 valve

Install the compatible and required actuator as per application and/or system design. See Installation of Actuators

compatible with DN50 –250 for more details on how to install the actuator.

VPI Pressure Independent Control Valves & Actuators

31-00383-01 6

Flow Setting Chart for DN50-100

Table 3. Flow Setting Chart for DN50-100

DN50

DN65

DN80LF

DN80HF

DN100LF

DN100HF

l/sec

l/hr

GPM

l/sec

l/hr

GPM

l/sec

l/hr

GPM

l/sec

l/hr

GPM

l/sec

l/hr

GPM

l/sec

l/hr

GPM

2.57

9240

40.7

2.57

9240

40.7

3.55

12800

56.3

4.73

17000

75.0

4.73

17000

75.0

3.68

13300

58.3

2.81

10100

44.6

2.81

10100

44.6

3.85

13900

61.0

5.29

19000

83.8

5.29

19000

83.8

4.42

15900

70.0

3.05

11000

48.3

3.05

11000

48.3

4.13

14900

65.5

5.82

21000

92.3

5.82

21000

92.3

5.13

18500

81.3

3.27

11800

51.9

3.27

11800

51.9

4.41

15900

69.9

6.33

22800

100

6.33

22800

100

5.82

21000

92.3

3.49

12500

55.2

3.49

12500

55.2

4.67

16800

74.0

6.82

24500

108

6.82

24500

108

6.50

23400

103

3.69

13300

58.4

3.69

13300

58.4

4.92

17700

78.0

7.28

26200

115

7.28

26200

115

7.15

25700

113

3.88

14000

61.5

3.88

14000

61.5

5.16

18600

81.7

7.72

27800

122

7.72

27800

122

7.78

28000

123

4.06

14600

64.3

4.06

14600

64.3

5.38

19400

85.3

8.14

29300

129

8.14

29300

129

8.40

30200

133

4.23

15200

67.0

4.23

15200

67.0

5.60

20200

88.8

8.54

30700

135

8.54

30700

135

8.99

32400

142

4.39

15800

69.6

4.39

15800

69.6

5.81

20900

92.1

8.91

32100

141

8.91

32100

141

9.57

34400

152

4.54

16300

72.0

4.54

16300

72.0

6.01

21600

95.2

9.27

33400

147

9.27

33400

147

10.1

36400

160

4.68

16900

74.2

4.68

16900

74.2

6.19

22300

98.2

9.61

34600

152

9.61

34600

152

10.7

38400

169

4.82

17300

76.4

4.82

17300

76.4

6.37

22900

101

9.93

35700

157

9.93

35700

157

11.2

40200

177

4.94

17800

78.4

4.94

17800

78.4

6.54

23600

104

10.2

36800

162

10.2

36800

162

11.7

42100

185

5.06

18200

80.2

5.06

18200

80.2

6.71

24100

106

10.5

37800

167

10.5

37800

167

12.2

43800

193

5.17

18600

82.0

5.17

18600

82.0

6.86

24700

109

10.8

38800

171

10.8

38800

171

12.6

45500

200

5.28

19000

83.7

5.28

19000

83.7

7.00

25200

111

11.0

39700

175

11.0

39700

175

13.1

47100

207

5.38

19400

85.2

5.38

19400

85.2

7.14

25700

113

11.3

40500

178

11.3

40500

178

13.5

48700

214

5.47

19700

86.6

5.47

19700

86.6

7.28

26200

115

11.5

41300

182

11.5

41300

182

13.9

50200

221

5.55

20000

88.0

5.55

20000

88.0

7.40

26600

117

11.7

42000

185

11.7

42000

185

14.3

51600

227

5.63

20300

89.2

5.63

20300

89.2

7.52

27100

119

11.9

42700

188

11.9

42700

188

14.7

53000

233

5.70

20500

90.4

5.70

20500

90.4

7.63

27500

121

12.0

43400

191

12.0

43400

191

15.1

54300

239

5.77

20800

91.5

5.77

20800

91.5

7.74

27900

123

12.2

43900

194

12.2

43900

194

15.4

55600

245

5.84

21000

92.5

5.84

21000

92.5

7.84

28200

124

12.4

44500

196

12.4

44500

196

15.8

56800

250

5.90

21200

93.5

5.90

21200

93.5

7.94

28600

126

12.5

45000

198

12.5

45000

198

16.1

58000

255

5.96

21400

94.4

5.96

21400

94.4

8.03

28900

127

12.6

45500

200

12.6

45500

200

16.4

59100

260

6.01

21600

95.2

6.01

21600

95.2

8.12

29200

129

12.7

45900

202

12.7

45900

202

16.7

60200

265

6.06

21800

96.0

6.06

21800

96.0

8.20

29500

130

12.9

46300

204

12.9

46300

204

17.0

61200

269

6.10

22000

96.8

6.10

22000

96.8

8.28

29800

131

13.0

46700

205

13.0

46700

205

17.3

62100

274

6.15

22100

97.5

6.15

22100

97.5

8.36

30100

133

13.1

47000

207

13.1

47000

207

17.5

63000

278

6.19

22300

98.2

6.19

22300

98.2

8.44

30400

134

13.1

47300

208

13.1

47300

208

17.8

63900

281

6.23

22400

98.8

6.23

22400

98.8

8.51

30600

135

13.2

47600

209

13.2

47600

209

18.0

64700

285

6.27

22600

99.4

6.27

22600

99.4

8.58

30900

136

13.3

47800

210

13.3

47800

210

18.2

65500

288

6.31

22700

101

6.31

22700

101

8.65

31100

137

13.4

48100

212

13.4

48100

212

18.4

66200

292

6.35

22900

101

6.35

22900

101

8.72

31400

138

13.4

48300

213

13.4

48300

213

18.6

66900

295

6.39

23000

101

6.39

23000

101

8.78

31600

139

13.5

48500

214

13.5

48500

214

18.8

67600

297

6.42

23100

102

6.42

23100

102

8.85

31900

140

13.5

48700

214

13.5

48700

214

18.9

68200

300

6.46

23300

102

6.46

23300

102

8.91

32100

141

13.6

48800

215

13.6

48800

215

19.1

68700

303

6.50

23400

103

6.50

23400

103

8.98

32300

142

13.6

49000

216

13.6

49000

216

19.2

69200

305

6.54

23500

104

6.54

23500

104

9.04

32600

143

13.7

49200

217

13.7

49200

217

19.4

69700

307

6.58

23700

104

6.58

23700

104

9.11

32800

144

13.7

49300

217

13.7

49300

217

19.5

70200

309

6.62

23800

105

6.62

23800

105

9.18

33000

145

13.7

49500

218

13.7

49500

218

19.6

70600

311

6.67

24000

106

6.67

24000

106

9.25

33300

147

13.8

49600

218

13.8

49600

218

19.7

70900

312

6.72

24200

106

6.72

24200

106

9.32

33500

148

13.8

49800

219

13.8

49800

219

19.8

71300

314

6.77

24400

107

6.77

24400

107

9.39

33800

149

13.9

49900

220

13.9

49900

220

19.9

71600

315

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