Johnson Controls VA-9070 Series Service manual

1VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating

Service Technical Bulletin

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Internal and External Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Electrical Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Mechanical Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Manual Override Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Pre-installation Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Multiple Actuator (Parallel) Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Setup and Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Electrical Travel Switches and Manual Travel Stop Adjustments . . . . . . . . . . . . . . . . . . . . . 9

Closed Travel Switch and Travel Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Open Travel Switch and Travel Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Setting the Input Control Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Setting the Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Setting the Servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

External Feedback Potentiometer for Actuators without Servos . . . . . . . . . . . . . . . . . . . . . 11

Contents of the Feedback Potentiometer Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Setting the Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Actuator Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Servo Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

VA-9070 Series Electric Rotary Actuators for

Two-Position and Modulating Service

Technical Bulletin Code No. LIT-977325

Issued August 15, 2014

VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin2

Green LED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Red LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Disassembly and Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Procedure for VA-9072 Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Procedure for VA-9075, VA-9076, VA-9077, VA-9078, VA-907A, and VA-907B Actuators 24

Appendix A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

VA-9072 Actuators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

VA-9075 Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

VA-9076, VA-9077, VA-9078, VA-907A, and VA-907B Actuators . . . . . . . . . . . . . . . . . . 32

Appendix B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin 3

VA-9070 Series Electric Rotary Actuators for

Two-Position and Modulating Service Technical

Bulletin

Introduction

The VA-9070 Series (Bray® Series 70) are quarter-turn, electric rotary actuators

with manual override, designed for use on most Johnson Controls® VF Series

Butterfly Valves sized for up to 18,000 lb·in (2034 N·m) of torque.

VA-9070 Series electric actuators cannot be used on the VF4000 Series and

VF5000 Series Butterfly Valves. Operating speeds vary between 6 and 60 seconds.

Internal and External Components

The VA-9070 Series actuator is divided into two internal sections: the power center

below the switch plate and the control center above the switch plate. The power

center contains the capacitor and gear motor, with its spur gear train. The power

center drives a final non-backdriveable worm gear output. The power center also

houses an override mechanism for manual operation. The control center has

several user-accessible components: the camshaft assembly, limit switches,

terminal strips, torque switches, heater, and servo.

On the outside of the actuator housing are adjustable mechanical travel stops, a

large position indicator, the manual override handwheel, and dual conduit entry

ports. The external coating is a polyester powder coat, providing resistance to

Ultraviolet (UV) radiation exposure and chemical exposure.

Electrical Operation

The motor in the VA-9070 Series actuator is a permanent induction split capacitor

design (single phase AC power). Travel limit switches are mechanical Form C

Single-Pole, Double-Throw (SPDT) switches with two independent circuits. These

SPDT switches are rated at 10 amperes (75 to 80% power factor), 1/2 hp 125 VAC,

and 3/4 hp 250 VAC.

If the torque capacity of the actuator is exceeded to the point where the motor stalls

and overheats, a thermal protector switch built into the motor windings

automatically disconnects the motor power. Once the motor cools sufficiently, the

thermal switch resets.

Mechanical Operation

Mechanically, the ratio of the gear motor determines the speed of the actuator. The

gear motor uses high-efficiency spur gears with different ratios for the different

speeds. Initial gear reduction through the spur gears transfers to the worm shaft.

The final gear reduction and output happens through a non-backdriveable worm

gear set. An indicator-camshaft linked to the output shaft determines positioning.

The manual override drives the worm shaft when engaged.

VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin4

Manual Override Operation

The manual override operates similarly to the adjusting knob on a mechanical

wristwatch. To engage the manual override, pull the handwheel to its outermost

position. When the manual override engages, the actuator stops electrical

operation.

A yellow position indicator provides visual indication that the manual override is

engaged. Dry contacts on an internal switch can provide remote electrical

indication of the override status.

Spring plungers hold the two handwheel positions (engaged and disengaged) in

place. The handwheel remains in position until physically moved. Rotating the

handwheel in a clockwise direction rotates the output shaft in the same clockwise

(closed) direction. Rotating the handwheel in a counterclockwise direction rotates

the output shaft in the same counterclockwise (open) direction.

Pre-installation Storage

A temporary conduit entry plug, installed in shipped actuators, prevents foreign

matter from entering the actuator. Store the actuator properly in a dry,

temperature-controlled area to prevent moisture from entering through this

temporary plug. Replace the temporary conduit plug with a permanent conduit

plug if the actuator is stored for a long period of time or stored in adverse

conditions. Prevent condensation from forming by maintaining a near constant

external temperature and supplying power to the heater internal to the actuator.

Installation

Mounting

VA-9070 Series electric actuators are suitable for direct mounting on

Johnson Controls VF Series Butterfly Valves. VA-9070 Series Electric Actuators

cannot be used on the VF4000 and VF5000 Series Butterfly Valves. Installing the

VA-9070 Series actuator onto other quarter-turn valves or devices requires proper

mounting hardware.

When mounting the actuator in the standard position, orient the actuator with its

handwheel in a vertical plane and parallel to the pipeline. When mounting the

actuator on a vertical pipe, position the actuator with the conduit entries on the

bottom to prevent condensation from entering the actuator by way of the conduit.

In all cases, position the conduit to prevent drainage into the actuator.

Mount the actuator to the valve using the following procedure:

1. Manually operate the actuator until the output shaft of the actuator lines up

with the valve stem. If possible, use an intermediate position, such as valve

disc/stem and actuator half-open.

2. Place the proper sleeve adaptor (if required) onto the valve stem. Apply a small

amount of grease to the sleeve adaptor to ease assembly.

VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin 5

3. Install the furnished mounting studs by threading them all the way into the

actuator base. Insert the short, threaded length into the actuator.

4. Mount the actuator onto the valve stem. Be sure the mounting studs are

properly aligned with the holes in the top plate of the valve or the mounting

bracket. If necessary, manually override the actuator to align the mounting

studs with the mounting holes.

5. Lower the actuator onto the valve and secure it tightly in place with the

furnished hex nuts and lock washers.

Wiring

Connect the actuator to field wiring:

1. Remove the metal conduit plug for the power connection. Each actuator has

two conduit entries (one for power and one for control).

2. Terminate all field wiring at the actuator terminal strip in accordance with the

wiring diagrams attached to the inside of the actuator cover.

Note: The terminal strip accepts wire sizes ranging from 10 to 22 AWG

(12 to 22 AWG for the servo). Do not use wire smaller than 18 AWG.

Note: The motor full load current is noted on the nameplate of the actuator.

Note: The heaters use approximately 0.5 amperes at 110 volts.

3. Properly seal the conduit connections to maintain the weatherproofed integrity

of the actuator enclosure.

Note: The square-head conduit plug is weatherproofed but may eventually

degrade. If the square-head conduit plug degrades, replace it with a

metal plug.

Figure 1 shows typical field wiring for a two-position actuator, whereas Figure 2

shows typical field wiring for a modulating actuator.

VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin6

Figure 1: Typical Wiring Diagram of VA-9070 Series Two-Position Electric Rotary

Actuator

RED

BLUE

CLOSE N.O.

(VOLTAGE FREE)

OPEN N.O.

(VOLTAGE FREE)

COM

N.O.

N.C.

AUX OPEN

OPEN

GREEN

CAM

RED

CAM

COM

AUX CLOSE

OVERRIDE SW

COM

YELLOW

BLUE

RED

YELLOW

HEATER

Ground Ground

Open

For Heater

Only

Open

Neutral

120 VAC Blue

Red

Yellow or

Black

Motor

FIG:977319_Fig2

VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin 7

Figure 2: Typical Wiring Diagram of VA-9070 Series Modulating Electric

Rotary Actuator

Calibrate Status

Input (-)

Input (+)

+5 VOLTS

Output (-)

Output (+)

Motor Close

Motor Open

Neutral

Line Neutral

Line Power

Com

Common

CB OPEN

CB CLOSE

Common

Handwheel

Common

OP Torque

CL Torque

Common

Close Limit

Open Limit

HTR

+5 VDC at 50 mA

(If Required)

Neutral

120 VAC

Ground

Outgoing

Feedback

Signal

1,2

Single

Phase

Supply

Heater

Incoming

Command

Signal

FIG:fldwrng

FUSE

Open Speed

Close Speed

Deadband

12345678910

WHT

BLK

WHT -

ORN

GRY +

Feedback

Potentiometer

Green

Cam

Red

Cam

N.O.

Com

N.O.

N.C.

Manual Override Switch

Torque

Switch

OPEN

BLU

RED

YLW

or BLK

Motor

YLW

BLU

BLU N.C.

N.C.

RED

4-20 mA 4-20 mA

0-5 V 0-5 V

0-10 V 0-10 V

2-10 V

ON ON

ONOFF OFF

OFF OFF

OFF

OFF OFF

OFF

OFF OFF

OFF

OFF OFF

OFF

Switch Switch

Switch

COMMAND INPUT COMMAND OUTPUT

REVERSE

ACTING

FORWARD

ACTING

FAIL

DISABLE FAIL

ENABLE

FAIL

CLOSE FAIL

OPEN

TORQUE SW

ENABLE TORQUE S

DISABLE

1 - Isolate the command signal and the feedback signal from each other and any other circuits.

2 - The servo powers the feedback loop. Do not supply external power.

ORN

PRP

VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin8

Multiple Actuator (Parallel) Wiring

Use a multiple pole switch to connect two VA-9070 Series electric actuators. See

the Correct Wiring schematic in Figure 3.

Do not connect more than one actuator to a Single-Pole, Double-Throw (SPDT)

switch. In the actuator, voltage is present on the non-powered motor winding

(opposite to the powered motor winding). Connecting the voltage-containing,

non-powered motor winding to another voltage-containing, non-powered motor

winding interferes with the motor performance. See the Incorrect Wiring

schematic in Figure 3.

Setup and Adjustment

To set up and adjust the actuator, use the following procedure:

1. Set up and adjust the electrical travel switches and manual travel stops. See the

Electrical Travel Switches and Manual Travel Stop Adjustments section in this

document.

2. Set the input control signal. See the Setting the Input Control Signal section in

this document.

3. Set the potentiometer. See the Setting the Potentiometer section in this

document.

4. Set the servo. See the Setting the Servo section in this document.

Figure 3: Correct and Incorrect Wiring Schematics

Neutral Live

Open

Motor Motor

DPDT

Switch

Field

Wiring

Actuator A Actuator B

Neutral

Live

Open

Motor Motor

Field

Wiring

SPDT

Switch

Actuator A

Actuator B

Correct Wiring Incorrect Wiring

FIG: wir_crrct_incrrct

VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin 9

Electrical Travel Switches and Manual Travel Stop Adjustments

You must set the electrical travel switches to trigger prior to reaching the

mechanical travel stops. The travel switches are labeled for open and close. The

cams are color-coded (green for open; red for closed).

Manual travel stops are designed to prevent manual overtravel, not to stall the

electric motor. The travel stops have an adjustment range of approximately

10 degrees.

Closed Travel Switch and Travel Stop Adjustment

1. Loosen the mechanical stop for the closed position and back it off so that it

does not interfere with actuator travel. The closed stop is located on the right

when viewed from the travel stop side of the actuator.

2. Remove the indicator rotor by pulling it up. This action exposes the machined

groove on the end of the camshaft, which is the reference for the valve disc

position.

3. Manually operate the actuator handwheel Clockwise (CW) until the valve

reaches the desired closed position.

4. Rotate the red adjusting knob (by hand or with a flat-head screwdriver) until

the cam lobe barely trips the switch from a CW direction.

Note: If the rotation of one cam moves the other cam, hold the other knobs or

cams during adjustment.

5. With the travel switch in the closed position, rotate the handwheel one-half

turn CW, then turn the closed travel stop CW until it stops against the output

gear. Lock the travel stop bolts.

Figure 4: Setting the Travel Limit Switches

FIG:set_lim

VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin10

Open Travel Switch and Travel Stop Adjustment

Manually operate the actuator handwheel Counterclockwise (CCW) until the valve

is fully open. Follow the same procedure as outlined in the Closed Travel Switch

and Travel Stop Adjustment section, except use the green cam (open) and the

travel stop located on the left side (as seen when viewed from the travel stop side

of the actuator).

Setting the Input Control Signal

Set the input control signal for the input type used.

See Figure 2 for the location of the input control signal switches.

Setting the Potentiometer

1. Manually operate the actuator handwheel until the unit is in the fully closed

position.

2. Rotate the black potentiometer drive gear adjustment knob to barely engage the

potentiometer gear segment at the closed position.

3. Manually operate the actuator to the fully open position.

4. Fine-tune the potentiometer adjustment at this end to equalize the difference

between the ends. The potentiometer gear segment should maintain

engagement with the drive gear throughout full actuator travel.

Setting the Servo

1. Wire the input signal to the incoming command signal terminals. Ensure that

you maintain proper polarity when making wiring connections.

2. Connect the power supply and activate the actuator.

3. Check the Status Light-Emitting Diode (LED).

• If the red Status LED is flashing, see the Servo Troubleshooting section.

• If the green Status LED is flashing, press and hold the CALIBRATE button

until the green Status LED flashes rapidly (approximately 2 seconds), then

release the CALIBRATE button. The servo drives the valve to the open and

close travel limit switch settings. When the calibration is complete, the

green Status LED resumes flashing at the normal rate.

• If the Status LED alternately flashes red, then flashes green, the calibration

has failed. To resolve the problem, see the Servo Troubleshooting section.

Table 1: Input Control Signal Switch Settings

Switch Input Signal

4-20 mA DC 0 to 5 V DC 0 to 10 V DC 2 to 10 V

1OFFONONON

2OFF OFF ON ON

3OFF OFF OFF ON

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