VA-908x Series Electric Rotary Actuators for Two-Position and Modulating Service Installation Instructions VA-908x Code No. LIT-12011566 Issued August 24, 2009 Applications The VA-908x Series Electric Rotary Actuators are designed for direct mounting in an upright position on VF Series Butterfly Valves. The VA-908x is available in two different sizes, for two-position and modulating service. All models feature two independently adjustable, travel limit switches for the open and closed position, each factory-set for 90 valve rotation. Powered by a rugged, high-torque, single-phase reversible motor, the VA-908x actuators are designed to withstand stall torque for reliable performance in even the most demanding applications. The watertight actuator enclosure meets National Electrical Manufacturers Association (NEMA) 4, 4X, and 6 ratings, as well as IP67 standards. IMPORTANT: The VA-708x Series Electric Valve Actuators are intended to control saturated steam, hot water, and chilled water flow under normal equipment operating conditions. Where failure or malfunction of the VA-708x Series Valve Actuator could lead to personal injury or property damage to the controlled equipment or other property, additional precautions must be designed into the system. Incorporate and maintain other devices, such as supervisory or alarm systems or safety or limit controls, intended to warn of or protect against failure or malfunction of the VA-708x Series Valve Actuator. IMPORTANT: Do not cover the actuator with thermal insulating material. High ambient temperatures may damage the actuator, and a hot water pipe, or other heat source may overheat it. Installation Special Tools Needed 3/4 in. wrench (for mounting bolts) small flatblade screwdriver (for wiring) 2.5 mm Allen wrench (for limit adjustments) 6 mm Allen wrench (for stop adjustments) Figure 1: VA-908x Series Electric Rotary Actuator VA-908x Series Electric Rotary Actuators for Two-Position and Modulating Service Installation Instructions 1
Dimensions Figure 2: VA-908x Series Electric Rotary Actuators Dimensions, in. (mm) Table 1: VA-908x Series Electric Rotary Actuators Dimensions, in. (mm) A B C D E F G H I J K L M N P Q R S 17.13 (435) 13.23 (336) 8.54 (217) 15.98 (406) 2.36 (60) 11.69 (297) 4.92 (125) 45 M12 4 7.09 (180) 0.39 (10) 1.38 (35) 2 0.63 (16) 5.16 (131) 9.06 (230) 1/2 NPT 2 VA-908x Series Electric Rotary Actuators for Two-Position and Modulating Service Installation Instructions
Accessories Table 2: VA-908x Series Electric Rotary Actuators Accessories and Repair Parts 1 Description Code Number Servo Control Kits, for all VA-908x Series Electric Actuators VA-908X-601 Mounting and Adaptor Kits for VF Series Standard-Pressure and Standard-Temperature Two-Way Valves Used when Mounting VA-9087 Series Electric Rotary Actuators on 16 in. VF Series Butterfly VA-9087-1600 Valves Used when Mounting VA-9087 Series Electric Rotary Actuators on 18 and 20 in. VF Series VA-9087-2000 Butterfly Valves Used when Mounting VA-9088 Series Electric Rotary Actuators on 16 in. VF Series Butterfly VA-9088-1600 Valves Used when Mounting VA-9088 Series Electric Rotary Actuators on 18 and 20 in. VF Series VA-9088-2000 Butterfly Valves Mounting and Adaptor Kits for VF Series High-Pressure, High-Temperature Class 150 Two-Way Valves Used when Mounting VA-9087 Series Electric Rotary Actuators on 14 in. Class 150 High VA-9087-1410 Performance Butterfly Valves Used when Mounting VA-9088 Series Electric Rotary Actuators on 16 in. Class 150 High VA-9088-1610 Performance Butterfly Valves Mounting and Adaptor Kits for VF Series High-Pressure, High-Temperature Class 300 Two-Way Valves Used when Mounting VA-9087 Series Electric Rotary Actuators on 10 in. Class 300 High VA-9087-1230 Performance Butterfly Valves Used when Mounting VA-9088 Series Electric Rotary Actuators on 12 in. Class 300 High VA-9088-1230 Performance Butterfly Valves Used when Mounting VA-9088 Series Electric Rotary Actuators on 14 in. Class 300 High VA-9088-1430 Performance Butterfly Valves Limit Switch Kit For All Models of VA-9087 and VA-9088 Series Electric Rotary Actuators VA-908X-604 Thermostat/Heater Kit For All Models of VA-9087 and VA-9088 Series Electric Rotary Actuators VA-908X-602 Feedback Potentiometer Kit 0 to 1,000 Ohms, for All Models of VA-9087 and VA-9088 Series Electric Rotary Actuators VA-908X-603 1. For non-standard accessories and repair parts, contact your local Johnson Controls representative. VA-908x Series Electric Rotary Actuators for Two-Position and Modulating Service Installation Instructions 3
Repair Parts Figure 3: VA-908x, 110 VAC, Single Phase Actuators Repair Parts 4 VA-908x Series Electric Rotary Actuators for Two-Position and Modulating Service Installation Instructions
Figure 4: VA-908x, 110 VAC, Single Phase Actuators Repair Parts VA-908x Series Electric Rotary Actuators for Two-Position and Modulating Service Installation Instructions 5
Mounting VA-908x Series electric actuators are suitable for direct mounting on most Johnson Controls VF Series Butterfly Valves. VA-908x Series Electric Actuators cannot be used on the VF4000 and VF5000 Series Butterfly Valves with the M9000 Series Actuators. Installing the VA-908x 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. 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. Seal the casing and conduit entrance after wiring to prevent dust or water contamination. The angle of actuator installation must between 0 and 180 degrees. Do not install the actuator upside-down or below a horizontal position greater than 180 degrees. Do not install the actuator when hazardous or explosive gases may be present. The frequency of open and close operation is restricted to every 5 minutes. Do not set a cycle frequency greater than once every 5 minutes. When more than one electric actuator needs to operate simultaneously, connect each actuator with individual cables. Do not connect actuators that operate simultaneously in parallel. Connect the ground wire to the terminal labeled PE inside the electric actuator (see Figure 5). 6 VA-908x Series Electric Rotary Actuators for Two-Position and Modulating Service Installation Instructions
Wiring!!! CAUTION: Risk of Electric Shock Disconnect power supply before making electrical connections to avoid electric shock. CAUTION: Risk of Property Damage Do not apply power to the system before checking all wiring connections. Short circuited or improperly connected wires may result in permanent damage to the equipment. IMPORTANT: Make all wiring connections in accordance with local, national, and regional regulations. Do not exceed the electrical ratings of the VA-908x Actuators. 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 5 shows typical field wiring for an on/off service actuator, and Figure 6 shows typical field wiring for a modulating actuator. VA-908x Series Electric Rotary Actuators for Two-Position and Modulating Service Installation Instructions 7
Single Phase, On/Off Service Figure 5: VA-908x, 110 VAC, Single Phase, On/Off Service 8 VA-908x Series Electric Rotary Actuators for Two-Position and Modulating Service Installation Instructions
Single Phase, Modulating Service Figure 6: VA-908x, 110 VAC, Single Phase, Modulating Service VA-908x Series Electric Rotary Actuators for Two-Position and Modulating Service Installation Instructions 9
Setup and Adjustments Adjust Travel Cams and Limit Switches Note: Travel cams are adjusted with a 2.5 mm hex key. LS1 and LS2 Use the LS1 (Open) and LS2 (Close) travel switch cams to set the preferred Open and Close valve positions. The motor is powered via the travel switches Normally Open (N.O.) contacts. To start the motor, adjust the cams to depress the travel switch lever. To stop the motor, adjust the cam so that the travel switch lever is not depressed. LS3 and LS4 Voltage-free auxiliary travel indication switch cams that you set at any position between 0 and 90 degrees to provide remote position indication. LS2 Close travel switch cam. Rotate the cam clockwise to decrease the closed position, and vice versa. LS1 Open travel switch cam. Rotate the cam clockwise to increase full open position, and vice versa. Adjust the Torque Cam (Factory-Set) Figure 8: Torque Cam Adjustment (Factory-Set) Figure 7: Travel Limit Switch Adjustment LS4 Auxiliary switch cam is factory-set at fully closed position. You can set LS4 cam at an intermediate position if required. LS3 Auxiliary switch cam is factory-set at fully open position. You can set LS3 cam at an intermediate position if required. Close Direction TS2 Counter-clockwise: increases torque value trip setting. Clockwise: decreases torque value trip setting. Open Direction TS1 Counter-clockwise: decreases torque value trip setting. Clockwise: increases torque value trip setting. Mechanical Stops For Electric Operation See Adjust Travel Cams and Limit Switches. The motor should be stopped by the end of the travel limit switches (LS1 and LS2) being activated by their respective cams. 10 VA-908x Series Electric Rotary Actuators for Two-Position and Modulating Service Installation Instructions
For Manual Operation Adjust the mechanical stops for manual operation (Figure 9). 1. Loosen the locknuts and use the 6 mm Allen wrench to back-out the travel stop bolts. Figure 9: Mechanical Stops 2. Adjust Open (LS1) and Close (LS2) travel limit switch cams to the desired end-of-travel positions. 3. Adjust the handwheel drive actuator to the fully open position (confirm that open travel position switch is activated). Turn the handwheel one half-turn, opening the actuator a half-turn more. Use the 2.5 mm hex key to screw the travel bolt in until it comes to a stop against the internal stop pad. 4. Secure the travel bolt by tightening the locknut against the housing. 5. Adjust the handwheel drive actuator to the fully closed position (confirm that closed travel position switch is activated). Turn the handwheel one half-turn, closing the actuator a half-turn more. Use the 2.5 mm hex key to screw the travel bolt in until it comes to a stop against the internal stop pad. 6. Secure the travel bolt by tightening the locknut against the housing. Potentiometer The potentiometers turns with the transmission shaft and provides a feedback signal that indicates position (Figure 10). For two-position controllers, potentiometer terminals 1, 2, and 3 are wired to terminal blocks 5, 6, and 7. When a valve is closed, the resistance between: Terminal Block 5 and 6 = 1K Ohm Terminal Block 6 and 7 = 0K Ohm When a valve is opened, the resistance between: Terminal Block 5 and 6 = 0K Ohm Terminal Block 6 and 7 = 1K Ohm For modulating controllers, potentiometer terminals 1, 2, and 3 are wired to terminal blocks 8, 9, and 10. When a valve is closed, the resistance between: Terminal Block 8 and 9 = 5K Ohm Terminal Block 9 and 10 = 0K Ohm When a valve is opened, the resistance between: Terminal Block 8 and 9 = 0K Ohm Terminal Block 9 and 10 = 5K Ohm Figure 10: Potentiometer VA-908x Series Electric Rotary Actuators for Two-Position and Modulating Service Installation Instructions 11
FIG: mod_cntrl_brd Calibration MODE SET DOWN UP 0001 MODE 24V = DC SET UP 0001 24V = DC 0001 12V = DC VR2-Feedback adjustment (10 V or 20 ma) Figure 11: Modulating Control Board: Interface 12 VA-908x Series Electric Rotary Actuators for Two-Position and Modulating Service Installation Instructions
Set the DIP Switches! CAUTION: Risk of Electric Shock Disconnect supply power to the VA-908x actuator before attempting to adjust the DIP switch setting. Failure to disconnect the supply power may result in electric shock. S1 and S2 Select Input Signal 4-20 ma: 1 = ON, 2 = OFF 1-5 VDC: 1 = OFF, 2 = OFF 2-10 VDC: 1 = OFF, 2 = ON S3, S4, and S5 Select Output Signal 2-10 VDC: 3 = ON, 4 = OFF, 5 = ON 4-20 ma: 3 = OFF, 4 = ON, 5 = OFF S6 OFF Valve fully closed on 4 ma, or 1 V, or 2 V Input Signal, and fully open on 20 ma, or 5 V, or 10 V Input Signal S6 ON for Reverse Operation S7 and S8 Position on Loss of Incoming Control Signal Valve fully closed: 7 = ON, 8 = OFF Valve fully opened: 7 = OFF, 8 = ON Valve stops where it is: 7 = ON, 8 = ON Calibrate the Fully Open and Fully Close Signals 1. Press and hold the Set button for 2 seconds; LED9 illuminates and the settings adjustment feature enters manual mode. 2. Press and hold the Up button until the actuator runs to fully-open and supplies the input signal (5 V, or 10 V, or 20 ma). 3. Press and release the Mode button once. The Open setting is finished. 4. Press and release the Set button once to complete the Open setting. 5. Press and hold the Down button until the actuator run to fully-closed and supplies input signal (1 V, or 2 V, or 4 ma). 6. Press and release the Mode button once. The Close setting is finished. 7. Press and release the Set button once to complete the Close setting. VA-908x Series Electric Rotary Actuators for Two-Position and Modulating Service Installation Instructions 13
Troubleshooting Table 3: Actuator Troubleshooting Chart Problem Possible Cause Solutions Motor Does Not Operate Incorrect power supply and/or voltage? Use a meter to verify that the power supply and voltage are correct. Blisters on the capacitor? Replace the capacitor. Gear train locked up? Remove the motor to check the gear train. Motor Stops Running Short circuit in the power supply? Check the wiring. Foreign objects in the pipeline? Check for obstructions. Unable to Fully Open/Fully Close Loose or misaligned cam? Adjust or tighten the cam(s). Bent valve stem? Replace the valve stem. Mechanical stop adjustment incorrect? Check position of stops and adjust if necessary. Valve Stops Operating When Motor Gear worn out? Replace the gear. Is Running Sleeve adaptor worn out or broken? Replace the sleeve adaptor. Abnormal Control for Operating Two or More Actuators Simultaneously Broken valve stem or actuator transmission shaft? Controlling circuit connected in tandem or parallel? Replace the valve stem or actuator transmission shaft. Verify the wiring is connected correctly (Figure 5 and Figure 6). Motor Overheats Incorrect voltage? Use a meter to verify that the voltage is correct. Valve torque too high? Replace the actuator with a larger actuator. High working frequency? Check the duty cycle. Motor stem or bearing binding? Inspect the stem and bearing and replace any binding parts. Occasional On/Off Actuator Failure Simultaneous input power on/off? Verify that the selection switch is set to normal. Vibration When Valve Is Closed Motor brake spring fatigued or Teflon worn? Replace the spring or Teflon coated parts that are worn. Repair Information If the VA-908x actuator fails to operate within its specifications, replace the unit. For a replacement controller, contact the nearest Johnson Controls representative. Lubrication The enclosed gearbox of the actuator was lubricated at the factory with high-temperature lubricant sufficient for use for up to 2 years. Storage Store the actuator in a clean and dry place protected from excess moisture, dust, weather, and extreme vibration. 14 VA-908x Series Electric Rotary Actuators for Two-Position and Modulating Service Installation Instructions
Technical Specifications Table 4: VA-908x Series Electric Rotary Actuators Technical Specifications Product Codes Non-Spring Return VA-9087-01 Proportional VA-9087-02 On/Off (Floating) VA-9088-01 Proportional VA-9088-02 On/Off (Floating) Power Requirements VA-9087 120 VAC, 50/60 Hz, 180 W 3.2 A running current 12.0 A starting current 10.0 A locked rotor/stall current VA-9088 120 VAC, 50/60 Hz, 220 W 4.0 A running current 14.0 A starting current 10.0 A locked rotor/stall current Torque VA-9087 8850 lb in (1000 N m) VA-9088 13275 lb in (1500 N m) Rotation Time for 90 of Travel 46 seconds at 60 Hz, 55 seconds at 50 Hz Duty Cycle VA-908x-02 30% VA-908x-01 75% Input Signal VA-908x-02 120 VAC, 50/60 Hz VA-908x-01 Switch Selectable: 2 to 10 VDC, 4 to 20 ma, 1 to 5 VDC Switch Selectable direct or reverse action with increasing signal Switch Selectable position on loss of control signal Feedback Signal VA-908x-01 Switch Selectable 2 to 10 VDC, 4 to 20 ma Ambient Operating Temperature Range -21 to 148 F (-30 to 65 C) Agency Listings CSA CE Mark Building Efficiency 507 E. Michigan Street, Milwaukee, WI 53202 Metasys and Johnson Controls are registered trademarks of Johnson Controls, Inc. All other marks herein are the marks of their respective owners. 2009 Johnson Controls, Inc. VA-908x Series Electric Rotary Actuators for Two-Position and Modulating Service Installation Instructions 15 Published in U.S.A. www.johnsoncontrols.com