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VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin Code No. LIT-977325 Issued May 2018 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 1 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 2 VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin 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 Bulletin 3 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. 4 VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin 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 Bulletin 5 A OPEN N.O. (VOLTAGE FREE) B RED RED C BLUE D BLUE N.C. AUX OPEN 1 Neutral Open 120 VAC Close For Heater Only Blue Red O C Motor N Yellow or Black Close BLUE 3 RED 4 BLUE 5 RED 6 YELLOW 9 Open Ground Ground COM 2 7 8 N.O. COM OVERRIDE SW YELLOW N.O. COM HEATER RED BLUE N.C. N.O. N.C. OPEN GREEN CAM RED CAM N.C. N.O. CLOSE N.C. N.O. COM COM AUX CLOSE FIG:977319_Fig2 CLOSE N.O. (VOLTAGE FREE) Figure 1: Typical Wiring Diagram of VA-9070 Series Two-Position Electric Rotary Actuator 6 VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin 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 Bulletin 7 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. Actuator B Op en Op en Field Wiring DPDT Switch Live Correct Wiring SPDT Switch Neutral Live FIG: wir_crrct_incrrct Op en Field Wiring Neutral e os Cl Motor Motor Motor Motor Actuator B Actuator A e os Cl e os Cl e os Cl Op en Actuator A Incorrect Wiring Figure 3: Correct and Incorrect Wiring Schematics 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. 8 VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin 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. Figure 4: Setting the Travel Limit Switches 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. VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin 9 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. 10 VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin If the fault indication lights illuminate during autocalibration, then the autocalibration sequence could not be successfully completed. Refer to the troubleshooting section for more information. No other operating modes can be entered during autocalibration, and entering autocalibration mode overrides any previous mode of operation. Accessories External Feedback Potentiometer for Actuators without Servos FIG:ptntmtr Potentiometers for external feedback are available for field installation on VA9072, VA-9073, VA-9074, VA-9075, VA-9076, VA-9077, and VA-9078 actuators. Figure 5: Potentiometer for VA-907x Series Actuators IMPORTANT: In special instances where dual potentiometers are required (such as when a servo is installed and an external feedback potentiometer is also required), you must make modifications to the switch plate - including locating, drilling, and tapping two new mounting holes. Consult the local Johnson Controls representative for instructions. VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin 11 Contents of the Feedback Potentiometer Kit • one potentiometer assembly • two No. 6 cross-drive pan-head screws • two No. 6 internal lock washers • one 10-point terminal strip • one terminal strip marker for auxiliary switches and/or feedback potentiometer • one small wiring diagram sticker for the additional potentiometer Tools Required For terminal wiring: 3/16 in. (5 mm) blade screwdriver For potentiometer mounting screws: No. 2 Phillips screwdriver Installation Procedure 1. Install the potentiometer next to the camshaft, use the two threaded holes provided. 2. Mount the potentiometer in the correct orientation with its gear centered so that it meshes with the potentiometer drive gear. FIG:instl_ptntmtr 3. Push the assembly towards the cam to mesh the potentiometer gears, and tighten the mounting screws. Figure 6: Installing the Feedback Potentiometer 4. Move the wiring from the six-point strip to the new terminal strip, reconnecting the wiring in the same positions. 12 VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin 5. Wire the potentiometer to the terminal strip using the small stick-on wiring diagram provided. 6. Adhere the wiring diagram sticker to the inside of the cover. 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 remain engaged with the drive gear throughout full actuator travel. Troubleshooting Procedures Actuator Troubleshooting See Table 1 for actuator troubleshooting information. Table 1: Actuator Troubleshooting Chart (Part 1 of 2) Problem Possible Cause Solution Actuator does not operate. Override is engaged. Push handwheel in all the way. Wiring is incorrect. Check wiring and power supply. Actuator motor has reached its thermal shutdown temperature Allow time to cool. Actuator operates in reverse directions. Field wiring is reversed. Rewire field wiring. Actuator does not fully close valve or open valve Limit switches trip. Readjust travel limit switches. Mechanical travel stop is stopping actuator. Adjust mechanical travel stops. Valve torque requirement is higher than actuator output. Manually override out of seat; try angle seating or larger actuator. Optional torque switches activating Valve torque exceeds actuator torque rating - consult factory Voltage power supply is low. Check power source Override pin is corroded or damaged. Clean and check for smooth operation of the override switch pin. Override switch is damaged. Replace switch. Engaging override handwheel does not shut off motor. VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin 13 Table 1: Actuator Troubleshooting Chart (Part 2 of 2) Problem Possible Cause Solution Disengaging override handwheel does not restart motor. Not completely disengaged. Push handwheel in as far as possible so that no yellow shows. Override pin is damaged and/or does not trigger switch. Replace override pin. Incorrect wiring of override switch. Check wiring. Motor runs but worm and gear segment do not run. Worm gear segment is not meshing with worm. Remove switch plate and inspect; adjust travel stops to prevent problem. Pin/Key on Worm/Motor drive gear sheared. Replace Pin/Key on drive gear. Corrosion inside actuator. Condensation forming. Test heater wiring; should have constant power. Water leaking in. Check all seals and possible water entry through conduit. Servo Troubleshooting Refer to the actuator manual before adjusting or replacing any actuator components. Before testing or acting on any possible issues, check for any active faults. WARNING: Risk of electric shock Turn off all power and lockout/tag out service panel before installing or modifying any electrical wiring. Table 2: Servo Troubleshooting Chart 14 Problem Possible Cause Solution Servo NXT does not turn on when power is applied Fuse is blown Verify and replace fuse Servo NXT is incorrectly wired Verify wire connections against the wiring diagram Servo NXT is not receiving power Test the Input Power connection with a multimeter or oscilloscope Power is not correct Check the provided power against the voltage listed for the Servo NXT and actuator Actuator moves back and forth near setpoint (hunting) Deadband is too narrow Increase the deadband setting Excessive noise on the signal lines Use an oscilloscope to test for the presence of EMI. Utilize EMI reducing techniques to mitigate the issue. Servo NXT not responding to command signal Servo NXT in local mode If local control is being used, ensure the local control station is not active or is set to remote mode. Servo NXT in manual or autocalibration mode Check the indicators for manual or autocalibration mode Servo NXT is incorrectly wired Verify wire connections against the wiring diagram VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin Problem Possible Cause Solution Cmd Signal Fault Command signal does not match input setting Adjust the input setting to match the command signal used Servo NXT is incorrectly wired Verify wire connections against the wiring diagram Servo NXT is not receiving the command signal Test the Input Command connection with a multimeter or oscilloscope Both limit switches engaged Adjust actuator cams Servo NXT is incorrectly wired Verify wire connections against the wiring diagram Travel limit switch failure Test the switches to ensure that they change states when engaged. Hand wheel is engaged Disengage (push in) hand wheel Servo NXT is incorrectly wired Verify wire connections against the wiring diagram Hand wheel switch failure Test the switch to ensure that it is changing states when engaged. Potentiometer outside of travel range Operate the actuator to the fully open and fully closed position, and adjust the potentiometer position as needed. Servo NXT is incorrectly wired Verify wire connections against the wiring diagram Torque switch setting enabled with no torque switches connected Disable torque switch settings Torque switch or switches engaged Check the valve and/or actuator for obstructions. Servo NXT is incorrectly wired Verify wire connections against the wiring diagram Torque switch failure Test the switches to ensure that they change states when engaged. Operational torque is exceeding the torque rating of the actuator Check the valve and/or actuator for obstructions. Measure the torque required to rotate the valve and verify against the rated torque Servo NXT is incorrectly wired Verify wire connections against the wiring diagram Fault occurring during calibration Operate the actuator to the fully open and fully closed position, and correct any faults that occur Servo NXT is incorrectly wired Verify wire connections against the wiring diagram Limit switch fault Hand wheel fault FB pot fault Torque switch fault Motor stall fault Fault condition during autocalibration Some flash codes indicate a warning condition. In a warning condition (such as the indication of an invalid calibration), the servo recovers automatically. In this case, default calibration automatically loads. This means the servo will operate, but it may not be a perfect match to the actuator. If this happens, recalibrate the servo as soon as possible. VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin 15 To recalibrate the servo, 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. Note: If you detect error codes 3, 5, 6, or 7, contact your Johnson Controls representative for further information. Table 3: Green LED Warning and Information Flash Codes 16 Code Description Meaning 1 Normal Operation The actuator detects no errors and operates normally. 2 Control Signal Calibration Error If this error occurs, add or remove jumpers for the input type. 3 Feedback Potentiometer Error An invalid feedback potentiometer calibration is detected. To ensure a valid feedback calibration, ensure that these conditions exist. The upper limit calibration is greater than the lower limit calibration. The difference between the upper and lower limits is at least 3 volts. The feedback potentiometer is not wired backwards. 4 Calibration in Process The green LED flashes rapidly during this operation. 5 Reverse Acting Warning This warning indicates that the servo is configured to operate in the Reverse Acting Mode. 6 Split Range 0 to 50% Warning This warning indicates that the servo is configured to operate in the Split Range 0 to 50% range mode. 7 Split Range 50 to 100% Warning This warning indicates that the servo is configured to operate in the Split Range 50 to 100% range mode. 8 Calibration in Process During a calibration, the LED flashes rapidly at one-half second intervals. When the calibration is complete, the LED resumes with the Normal Operation flash code (Code 1) unless another warning is still pending. VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin Red LED A flashing red LED indicates a fault condition that prevents the actuator from operating. Correct the fault condition to allow the actuator to resume operating. If you detect error Code 16, contact your Johnson Controls representative for further information. Table 4: Red LED Warning and Information Flash Codes Code Description Meaning 9 Handwheel Is Engaged (Pulled Outward) When the handwheel is engaged, the servo can only be operated manually. This error also occurs if the handwheel switch is incorrectly connected to the servo. 10 Command Signal Failure When the servo is configured to operate in the 0 to 20 mA mode, an input greater than 20 mA triggers an error. When the handwheel is configured to run in 4 to 20 mA operating mode, an input less than 4 mA or greater than 20 mA triggers an error. The Command Signal is not checked in the 0 to 10 V mode. 11 Feedback Potentiometer Failure If the feedback potentiometer cannot be detected, or if in the fully closed or fully open position and the feedback potentiometer is at the end of its travel, an error is detected. 12 Open and Close Limit Switch Failure When both the open and close limit switches are open-circuited at the same time, an error is detected. 13 Open Torque Limit Reached The open torque limit switch has been tripped or the open torque limit switch is incorrectly connected to the servo. 14 Close Torque Limit Reached The close torque limit switch has been tripped or the close torque limit switch is incorrectly connected to the servo. 15 Feedback Potentiometer Wired in Reverse This check is made only during the servo autocalibration. The feedback potentiometer is wired in reverse when, at the completion of the calibration, the feedback potentiometer value at the fully open position is less than the value at the fully closed position. To clear the error, turn off the power to the servo, correct the feedback potentiometer wiring, turn on the power to the servo, and complete the autocalibration. 16 General Servo Failure If after cycling the power to the servo, this error persists, contact your local Johnson Controls representative for assistance. 17 Calibration Error This flash code is displayed after a failed calibration for 3 seconds. See Code 2 and Code 3 in Table 3 for more information. VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin 17 Disassembly and Assembly General Information VA-9070 Series actuators are differentiated into four groups, according to size: • VA-9072 actuators • VA-9075 actuators • VA-9076, VA-9077, and VA-9078 actuators • VA-907A and VA-907B actuators Tools Required Table 5: Basic Tools Common to All Actuators Item Tool Terminal Connections, Cam Adjustment Screwdriver, 3 to 4 Tip Blade All Switches, Terminal Strip, Torque Switch Plate Screwdriver, No. 1 Phillips Switch Plate Screws, Capacitor Screwdriver, No. 2 Phillips Servo Trimmer Potentiometers Screwdriver, Blade for Trim Potentiometers Table 6: Basic Tools for VA-9072 Actuators Item Tool Mounting Nuts Wrench, 1/2 in. (13 mm) Cover Captivated Cap Screws Hex Key, 1/4 in. (6 mm) Travel Stop Adjusting Studs Hex Wrench, 1/8 in. (3 mm) Travel Stop Jam Nuts Wrench, 7/16 in. (11 mm) Motor Mount Socket Flat-Head Cap Screw Hex Key, 3/32 in. (2 mm) Motor Mount Socket-Head Cap Screw Hex Key, 9/64 in. (4 mm) Table 7: Basic Tools for VA-9075 Actuators Item Tool Mounting Nuts (Small Pattern), Travel Stop Jam Nuts Wrench, 1/2 in. (13 mm) Mounting Nuts (Large Pattern) Wrench, 3/4 in. (19 mm) Cover Captivated Cap Screws Hex Key, 5/16 in. (8 mm) Travel Stop Adjusting Studs Hex Key, 3/16 in. (5 mm) Motor Mount Socket-Head Cap Screw Hex Key, 5/32 in. (4 mm) Table 8: Basic Tools for VA-9076, VA-9077, VA-9078, VA-907A, and VA-907B Actuators 18 Item Tool Mounting Nuts, Travel Stop Jam Nuts Wrench, 3/4 in. (19 mm) Cover Captivated Cap Screws Hex Key, 3/8 in. (10 mm) Travel Stop Adjusting Studs Wrench, 3/4 in. (19 mm) [15/16 in. (8 mm) for VA907A and VA-907B] Motor Mount Socket-Head Shoulder Bolt Hex Key, 5/32 in. (4 mm) Motor Mount Socket-Head Cap Screws Hex Key, 3/16 in. (5 mm) VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin Procedure for VA-9072 Actuators 1. Disconnect all power to the actuator and remove the cover. See Figure 7. Figure 7: Two-Position Actuator with Cover Removed 2. Disconnect the motor wires from the main terminal block (motor close, motor open, and neutral). VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin 19 3. Remove the switch plate by unscrewing the seven Phillips mounting screws. The switch plate should lift out as an assembly with the camshaft attached. See Figure 7 and Figure 8. Figure 8: Removing the Switch Plate (Two-Position Actuator) 20 VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin 4. Disassemble the switch plate. See Figure 9. Figure 9: Disassemble the Switch Plate (Modulating Actuator) VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin 21 FIG:rmv_mtr Figure 10: Removing the Motor 5. Disconnect the motor leads that run to the capacitor (plug-in connectors), and then unscrew the three mounting screws (two lower and one upper). See Figure 10. 6. Vertically remove the gear motor out of the actuator. See Figure 10. Do not misplace the alignment pin. 22 VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin Figure 11: Disassembling the Actuator 7. To remove the worm shaft spur gear, remove the spring pin using a 3/32 in. (2 mm) punch, then slide the gear off the end of the worm shaft. See Figure 11. 8. To remove the output drive worm gear, back off both mechanical travel stops. Manually override the worm gear until it disengages the worm. Remove the retaining ring and thrust washer, then lift the output drive worm gear out of its bushing. See Figure 11. 9. Remove the capacitor. See Figure 10. Note: A spring pin holds the handwheel in place. Further disassembly of the actuator requires special tools and procedures and is not covered in this document. The reassembly procedure is the opposite of the disassembly procedure. VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin 23 Procedure for VA-9075, VA-9076, VA-9077, VA-9078, VA-907A, and VA-907B Actuators 1. Disconnect all power to the actuator and remove the cover. See Figure 12. Figure 12: Two-Position Actuator with Cover Removed 2. Remove the field wiring and the internal motor wiring from the terminal strips. See Figure 13. Figure 13: Removing the Switch Plate (Two Position Actuator) 24 VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin 3. Remove the switch plate by unscrewing the seven Phillips-head mounting screws and then pull up on the switch plate to remove it. See Figure 14. Figure 14: Two-Position Actuator with Switch Plate Removed VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin 25 Figure 15: Removing the Motor 4. Disconnect the motor leads that run to the capacitor. See Figure 15. 5. Unscrew the mounting screws. See Figure 15. Note: The VA-9072 Series Actuator has two lower mounting screws and one upper mounting screw. The VA-9075 Series Actuators have four lower mounting screws and one upper mounting screw. The VA-9076 through VA-907B Series Actuators have four lower mounting screws, one upper mounting screw, and one lower locating screw. 6. Remove the motor vertically out of the actuator. See Figure 15. Note: Do not misplace the alignment pin. 26 VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin Figure 16: Disassembling the Actuator 7. Remove the bowed E-clip retainer and slide the worm shaft spur gear off the end of the worm shaft. See Figure 16. Note: The VA-9075 Series Actuators use a drive gear with pin and retaining ring. 8. Back off both mechanical travel stops. Note: This is not needed on the VA-9076 through VA-907B Series Actuators. 9. Manually override the worm gear until it disengages the worm. Note: This is not needed on the VA-7076 through VA-907B Series Actuators. 10. Remove the seal and retaining ring, then lift the output drive worm gear out of its bushing. See Figure 16. Further disassembly of the actuator requires special tools and procedures and is not covered in this document. The reassembly procedure is the opposite of the disassembly procedure. VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin 27 Appendix A Table 9: VA-9072 Two-Position Actuator Callouts Callout 28 Description Callout Description 1 Indicator Cover Screws 38 Manual Override Shaft Hub 2 Lockwasher 39 Manual Override Sleeve 3 Position Indicator Cover 40 O-Ring 4 O-Ring 41 O-Ring 5 Cover Fastening Screws 42 Retaining Ring 6 Cover 43 Handwheel 7 O-Ring 44 Spring Pin 8 Position Indicator 45 Manual Override Bushing 9 Cam Assembly 46 Thrust Washer 10 Limit Switch Screw 47 Thrust Roller Bearing 11 Limit Switch Bracket 48 Disc Spring 12 Main Open/Closed Limit Switches 49 Worm 13 Limit Switch Insulator 50 Spring Pin 14 Switch Plate, Fixed 51 Retaining Ring 15 Heater Bracket Screw 52 Thrust Washer 16 Heater Mounting Bracket 53 Base 17 Heater 54 Conduit Plug 18 Override Switch 55 Name Tag 19 Override Switch Insulator 56 Bushing 20 Override Switch Screw 57 Drive Gear Pin 21 Override Switch Trigger Pin 58 Drive Gear 22 Torque Switch Cover 59 Terminal Strip 23 Switch Plate Ball Bearing 60 Capacitor 24 Retaining Ring 61 Gearmotor 25 Coupler 62 Lock Washer 26 Worm Wheel 63 Motor Cap Screw 27 Spring Pin 64 Wire Entry Guard 28 O-Ring 65 Dowel Pin 29 O-Ring 66 Motor Screw 30 Nylon Flat Washer 67 Ground Terminal Washer 31 Travel Stop Nut 68 Ground Terminal Screw 32 Travel Stop Spacer 69 Switch Plate Mounting Screw 33 Travel Stop Bolt 70 Removable Switch Plate 34 Worm Shaft 71 Terminal Strip Marker 35 Override Drive Pin 72 Terminal Strip 36 Spring Plunger 73 Terminal Block Screw 37 Manual Override Shaft Hub 74 Aux Open/Closed Limit Switches VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin Figure 17: VA-9072 Two-Position Actuators, Exploded View VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin 29 VA-9075 Actuator Table 10: VA-9075 Two-Position Actuator Callouts Callout 30 Description Callout Description 1 Indicator Cover Screws 39 Manual Override Shaft Hub 2 Lockwasher 40 Spring Plunger 3 Position Indicator Cover 41 Manual Override Shaft Stub 4 O-Ring 42 Manual Override Sleeve 5 Cover Fastening Screw 43 O-Ring 6 Cover 44 O-Ring 7 O-Ring 45 Retaining Ring 8 Position Indicator 46 Handwheel 9 Cam Assembly 47 Spring Pin 10 Switch Plate Mounting Screw 48 Manual Override Bushing 11 Switch Plate 49 Thrust Washer 12 Limit Switch Screw 50 Thrust Roller Bearing 13 Limit Switch Bracket 51 Thrust Washer 14 Main Open/Closed Limit Switches 52 Disc Spring 15 Limit Switch Insulator 53 Disc Spring 16 Heater Bracket Screw 54 Worm 17 Heater Mounting Bracket 55 Spring Pin 18 Heater 56 Retaining Ring 19 Override Switch Trigger Pin 57 Thrust Washer 20 Override Switch 58 Base 21 Override Switch Insulator 59 Conduit Plug 22 Override Switch Screw 60 Name Tag 23 Switch Plate Ball Bearing 61 Bushing 24 Retaining Ring 62 Gear Spacer 25 Coupler 63 Drive Gear 26 Worm Wheel 64 Spring Pin 27 O-Ring 65 Retaining Ring 28 Terminal Strip 66 Gear Motor 29 Capacitor 67 Lock Washer 30 Spring Pin 68 Motor Cap Screw 31 O-Ring 69 Dowel Pin 32 Nylon Flat Washer 70 Wire Entry Guard 33 Travel Stop Nut 71 Terminal Strip Marker 34 Travel Stop Spacer 72 Terminal Strip 35 Travel Stop Bolt 73 Terminal Block Screw 36 Worm Shaft 74 Ground Terminal Washer 37 Override Drive Pin 75 Ground Terminal Screw 38 Spring Pin 76 Torque Switch Cover 77 Aux Open/Closed Limit Switches VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin VA-9075 Actuator Figure 18: VA-9075 Actuator VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin 31 VA-9076, VA-9077 and VA-9078 Actuators Table 11: VA-9076, VA-9077 and VA-9078 Two-Position Actuator Callouts 32 Callout Description Callout Description 1 Indicator Cover Screws 39 Spring Pin 2 Lockwasher 40 Spring Plunger 3 Position Indicator Cover 41 Manual Override Shaft 4 O-Ring 42 Manual Override Sleeve 5 Cover Fastening Screw 43 O-Ring 6 Cover 44 O-Ring 7 O-Ring 45 Retaining Ring 8 Position Indicator 46 Spring Pin 9 Cam Assembly 47 Handwheel 10 Limit Switch Screw 48 Manual Override Bushing 11 Limit Switch Bracket 49 Thrust Washer 12 Main Open/Closed Limit Switches 50 Thrust Roller Bearing 13 Limit Switch Insulator 51 Thrust Washer 14 Heater Bracket Screw 52 Spherical Washer 15 Heater Mounting Bracket 53 Disc Spring 16 Heater 54 Worm 17 Override Switch Trigger Pin 55 Spring Pin 18 Override Switch 56 Retaining Ring 19 Override Switch Insulator 57 Thrust Washer 20 Override Switch Screw 58 Base 21 Ground Terminal Screw 59 Conduit Plug 22 Ground Terminal Washer 60 Name Tag 23 Switch Plate Ball Bearing 61 Bushing 24 Retaining Ring 62 Drive Gear Key 25 Coupler 63 Drive Gear 26 Worm Wheel 64 Retaining Ring 27 O-Ring 65 Gear Motor 28 Capacitor 66 Dowel Pin 29 Terminal Pin 67 Lock Washer 30 Spring Pin 68 Motor Cap Screw 31 O-Ring 69 Motor Shoulder Screw 32 Nylon Flat Washer 70 Wire Entry Guard 33 Travel Stop Nut 71 Terminal Strip Marker 34 Travel Stop Spacer 72 Terminal Strip 35 Travel Stop Bolt 73 Terminal Block Screw 36 Worm Shaft 74 Switch Plate 37 Override Drive Pin 75 Switch Plate Mounting Screw 38 Manual Override Shaft Hub 76 Torque Switch Cover 77 Aux Open/Closed Limit Switches VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin Figure 19: VA-9076, VA-9077, and VA-9078 Two-Position Actuators, Exploded View VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin 33 VA-907A and VA-907B Actuators Table 12: VA-907Aand VA-907B Two-Position Actuator Callouts Callout Description Callout Description 1 Cover Fastening Screw 37 Spring Pin 2 Cover 38 Handwheel 3 O-Ring 39 Manual Override Bushing 4 Limit Switch Screw 40 Thrust Washer 5 Flat Insulation Washer 41 Thrust Roller Bearing 6 Main Open/Closed Limit Switches 42 Thrust Washer 7 Aux Open/Closed Limit Switches 43 Spherical Washer 8 Switch Spacer 44 Disc Spring 9 Limit Switch Insulator 45 Worm 10 Torque Switch Assembly 46 Spring Pin 11 Override Switch Trigger Pin 47 Retaining Ring 12 Heater Bracket Screw 48 Thrust Washer 13 Heater Mounting Bracket 49 Base 14 Heater 50 Conduit Plug 15 Override Switch 51 Name Tag 16 Override Switch Insulator 52 Bushing 17 Override Switch Screw 53 Drive Gear Key 18 Switch Plate Ball Bearing 54 Drive Gear 19 Retaining Ring 55 Retaining Ring 20 Coupler 56 Gear Motor 21 Worm Wheel 57 Dowel Pin 22 O-Ring 58 Lock Washer 23 Capacitor 59 Motor Cap Screw 24 Terminal Strip 60 Motor Shoulder Screw 25 Spring Pin 61 Wire Entry Guard 26 Set Screw 62 Terminal Strip Marker 27 Worm Shaft 63 Terminal Strip 28 Override Drive Pin 64 Terminal Block Screw 29 Manual Override Shaft Hub 65 Switch Plate 30 Spring Pin 66 Terminal Strip Marker 31 Spring Plunger 67 Terminal Strip 32 Manual Override Shaft Stub 68 Terminal Block Screw 33 Manual Override Sleeve 69 Cam Assembly 34 O-Ring 70 Bushing 35 O-Ring 36 Retaining Ring VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin 34 Figure 20: VA-907A and VA-907B Two-Position Actuators, Exploded View VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin 35 Table 13: VA-907A and VA-907B 3:1 Gear Box Callout Description 1 Fastening Screw 2 Position Indicator Plate 3 Position Indicator Gasket 4 Actuator/Gear Box Gasket 5 Dowel Pin 6 O-Ring 7 Washer, Flat, Nylon 8 Nut, Hex 9 Bolt, Hex, Hd 10 Cover 11 Washer, Conical 12 Actuator/Gear Box Fastening Screw 13 Output Gear Bearing 14 Idler/Input Gear Bearing 15 Cover Gasket 16 Input Gear 17 Output Gear 18 Idler Gear 19 Cover 20 Lock Washer 21 Base Fastening Screw VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin 36 Figure 21: VA-907A and VA-907B 3:1 Gear Box, Exploded View VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin 37 Appendix B Table 14: Actuator Codes and Valve Assembly Actuator Suffix Electric Modulating Models Electric Two-Position Models Johnson Controls Actuator Only Code Number Johnson Controls VF Series Butterfly Valve Assembly Actuator Suffix Johnson Controls Actuator Only Code Number Johnson Controls VF Series Butterfly Valve Assembly Actuator Suffix VA-9072-01 -702 VA-9072-02 -722 VA-9075-01 -703 VA-9075-02 -723 VA-9075-01 -704 VA-9075-02 -724 -705 VA-9075-02 -725 VA-9076-01 -706 VA-9076-02 -726 VA-9077-01 -707 VA-9077-02 -727 VA-9078-01 -708 VA-9078-02 -728 VA-907A-01 -907 VA-907A-02 -927 VA-907B-01 -908 VA-907B-02 -928 Building Technologies & Solutions 507 E. Michigan Street, Milwaukee, WI 53202 Metasys® and Johnson Controls® are registered trademarks of Johnson Controls All other marks herein are the marks of their respective owners. © 2014 Johnson Controls 38 VA-9070 Series Electric Rotary Actuators for Two-Position and Modulating Service Technical Bulletin Published in U.S.A. www.johnsoncontrols.com ">
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