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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Setup and Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Electrical Travel Switches and Manual Travel Stop Adjustments . . . . . . . . . . . . . . . . . . . . . 8

Setting Travel Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Setting the Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Calibrating the Servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

External Feedback Potentiometer for Actuators without Servos . . . . . . . . . . . . . . . . . . . . . 10

Contents of the Feedback Potentiometer Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Setting the Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Actuator Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Servo Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Red LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

VA-9070 Series Electric Rotary Actuators for

Two-Position and Modulating Service

Technical Bulletin Code No. LIT-977325

Issued May 2018

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

General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Tools Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Procedure for VA-9072 Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Procedure for VA-9075, VA-9076, VA-9077, VA-9078, VA-907A, and VA-907B Actuators 23

Appendix A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

VA-9072 Actuators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

VA-9075 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

VA-9076, VA-9077, VA-9078, VA-907A, and VA-907B Actuators . . . . . . . . . . . . . . . . . . 31

Appendix B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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

VA-9070 Series quarter-turn, electric rotary actuators with manual override can be

used 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 six and sixty 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 120V motor in the VA-9070 Series actuator is a permanent induction split

capacitor design (single phase AC power). The 24VAC motor in the VA-9070

Series actuator is a permanent magnet-brush D.C. motor. 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), 1/3 hp 120 VAC and 1/2 hp 220 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 shows 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 22

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

Open

For Heater

Only

Open

Neutral

120 VAC

Blue

Red

Ye ll ow o r

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

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 1.

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 potentiometer. See the Setting the Potentiometer section in this

document.

3. Calibrate the servo. See the Calibrating 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.

Setting Travel Limit Switches

If the unit came assembled to a valve, the switches have been factory-set and DO

NOT need adjustment. Johnson Controls uses cam design along with 2 SPDT

mechanical switches to set the open and closed position of the valve. The green

cam actuates the open switch when the actuator reaches the open position.

Similarly, the red cam actuates the ‘closed’ switch when the actuator reaches the

‘closed’ position. Standard factory setting of the travel limit switches means 90°

travel between open and close positions. Cams for each switch are adjustable for

applications where less than 90-degree travel is desired between the open and

closed positions.

Complete the following procedure to adjust the travel limit cams.

Note: For Housing Size 130, 180, ignore steps 1 and 10.

1. Remove the indicator rotor by pulling away from the indicator shaft as shown

in Figure 4.

2. Manually operate the actuator clockwise until the valve reaches the desired

closed position.

Figure 4: Setting the Travel Limit Switches

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

3. Loosen the cam locking screw shown in Figure 6.

Note: It is possible that the rotation of one cam may move the other cam. If this

occurs, hold the other knobs or cams during adjustment.

4. Rotate the red cam adjustment knob by hand or with a flat head screwdriver

until the red cam lobe just activates (depresses) the ‘closed’ switch from a

clockwise direction.

Note: If fixed auxiliary switches are installed, the auxiliary cam activates prior to

the main cam.

5. Tighten the cam locking screw.

6. Manually operate the actuator counterclockwise until the valve reaches the

desired open position.

7. Loosen the cam locking screw.

8. Rotate the green cam adjustment knob until the green cam lobe activates

(depresses) the open switch from a counterclockwise direction.

9. Tighten the cam locking screw.

10. Place the indicator rotor back on the indicator shaft.

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.

Calibrating the Servo

Note: The Servo NXT is not remotely controllable during the autocalibration

sequence. If autocalibration needs to be aborted, pull the handwheel.

Autocalibration mode is entered by pressing and holding the Autocalibration

button for at least three seconds. Entering Autocalibration mode starts the

autocalibration sequence: a series of commands performed by Servo NXT on the

actuator to determine the operating points. During the autocalibration sequence,

the Servo NXT should be monitored to ensure it operates correctly. The product

settings’ indicators change state to show that autocalibration has been entered, and

continue to flash at the end of travel until autocalibration completes. Upon

completion of the autocalibration sequence, the product settings’ indicators return

to normal.

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