Valve and Actuator Manual 977
Actuators and Positioners Product Information Section
Technical Bulletin VA-9000
Issue Date 0398
VA-9000 Series Electric Rotary Actuators
Commissioning Procedures
Overview
Page
3
•
Circuit Board Specifications
3
•
Typical Wiring Diagram
3
Installation and Commissioning Procedures
5
•
Valve Installation
5
•
Valve Actuator Installation
5
•
Limit Switch Cam Adjustments
6
•
Micro-Travel Cam Adjustments
7
•
Manual Operation of the Valve Actuator
8
Circuit Board Commissioning
11
•
Tools Required
11
•
Preliminary Checks
11
•
Setting the Actuator Feedback Potentiometer
12
•
DC Power Supply Test
14
•
Initial Settings
14
•
Calibration
15
•
Circuit Board Checkout
16
© 1998 Johnson Controls, Inc.
Code No. LIT-977335
1
2 VA-9000 Series Electric Rotary Actuators Commissioning Procedures Technical Bulletin
Overview
Circuit Board
Specifications
The following specifications apply to the circuit board used in VA-9000
Series Electric Rotary Actuators manufactured after January, 1995:
Power Requirements --- Single Phase, 115 VAC + 10%, 50/60 Hz,
Fused; Internal DC Power Supply + 15 VDC, 2.4 VA, Fused
Input Signal --- 4 to 20 mA DC
Input Impedance --- 249 ohms
Sensitivity --- + 0.6% of Total Input Signal Span for 30 Seconds of
Actuator Shaft Travel Time
Deadband --- 0.1 to 10% of Total Signal Span
Zero Adjustment --- 50% of Span at Low Signal End
Span Adjustment --- 50% of Span Range
Ambient Operating Temperature Limits --- 0 to 140°F (-18 to 60°C)
Typical Wiring
Diagram
T h e rm a l
S w itch
O p tio n a l
HTR
Blue/Ye llow
B lu e /Y e llo w
T h e rm a l
O ve rlo a d
S w itch
Ye llo w
M
R
N e u tra l
A .C . V o lta g e
(+ )
(-)
C ircu it
B o a rd
D e ad
B an d
Sp an
Z e ro
L in e
In p u t
Com m and
S ig n a l
TB
1
2
3
4
5
6
7
8
9
10
11
12
B la ck
S W .2
Red
S W .1
B lue/R ed
B lu e /O ra n g e
Pu rple
C
Brake
(O ptio na l)
B
0% C W
F ee dback
Potentio m e ter
100% C C W
T w ist an d run in a
sepa rate b undle.
Figure 1: Typical Wiring Schematic for 4 to 20 mA DC Control of
a VA-900x-01 Series Modulating Electric Rotary Actuator
VA-9000 Series Electric Rotary Actuators Commissioning Procedures Technical Bulletin
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4 VA-9000 Series Electric Rotary Actuators Commissioning Procedures Technical Bulletin
Installation and
Commissioning Procedures
Valve
Installation
Install the valve in the proper manner, following the procedures
outlined in the VF Series Butterfly Valves 2 Through 20 in., Two-Way and
Three-Way Product/Technical Bulletin (LIT-977205P).
Valve Actuator
Installation
1.
Before installing the valve actuator, manually operate it to its open
position.
2.
Remove any mechanical position stops if present, taking care not to
damage the valve. Also, be careful not to remove any other parts of
the valve.
3.
If the actuator is supplied separately from the valve body, the actuator
will be shipped in the open position. Take care to maintain the
alignment between the actuator and valve shafts. If the shafts are not
aligned, repeat Step 1 to properly align them.
4.
Mount the actuator to the valve body. Whenever possible, the
actuator should be parallel to the pipe run.
5.
Cycle the actuator with the mounting bolts loose enough to allow the
unit to center itself.
6.
Tighten all mounting bolts and nuts evenly, taking care to center the
actuator on the valve stem.
7.
On models with a declutching knob, loosen the socket set screw and
remove the manual knob.
8.
Remove the hex-head bolts located above the flange of the actuator,
then remove the cover.
9.
Wire the actuator using No. 18 AWG wire or larger. If the actuator is
of a special design, a wiring diagram will be furnished with it. If not,
follow the wiring diagram included in Figure 1.
The wiring diagram illustrates the circuit conditions for the valve in
the open position. Wiring must be performed in accordance with all
applicable local and national electrical code requirements.
10. Run the actuator several times from one extreme position to the other
and check for proper operation. If the actuator travel is not correct,
adjust the limit switch cams as outlined in the Limit Switch Cam
Adjustments section which follows.
VA-9000 Series Electric Rotary Actuators Commissioning Procedures Technical Bulletin
5
11. Install the actuator cover and tighten all flange bolts.
12. On models with a declutching knob, re-install the knob previously
removed and tighten the socket set screw. The valve and actuator
assembly is now ready for service.
Limit Switch
Cam
Adjustments
If limit switch cam adjustments are required, refer to Figure 2 and proceed
as follows:
P ivo t S cre w o n
S w itch "B "
P ivo t S cre w o n
S w itch "A "
A ctu a to r
S h a ft
S e t S cre w o n
C a m "B "
S e t S cre w o n
M icro -A d ju stm e n t
C a m "A "
S e t S cre w o n
C a m "A "
S e t S cre w o n
M icro -A d ju stm e n t
C a m "B "
S w itch R o lle rs
Figure 2: Adjusting the Limit Switch Cams
Setting Open
Travel
1.
Loosen the set screw on cam “A” just enough so that the screw
maintains a finger-tight grip on the actuator shaft.
2.
Rotate cam “A” clockwise away from switch “A.”
3.
Manually operate the valve to the proper open position.
4.
Rotate cam “A” counterclockwise against the switch roller on
switch “A” until the switch clicks once.
5.
Tighten the set screw on cam “A” and test the unit for proper travel.
If travel is not correct, repeat Steps 1 through 4, or proceed to the
Micro-Travel Cam Adjustments section which follows.
6 VA-9000 Series Electric Rotary Actuators Commissioning Procedures Technical Bulletin
Setting Closed
Travel
1.
Loosen the set screw on cam “B” just enough so that the screw
maintains a finger-tight grip on the actuator shaft.
2.
Rotate cam “B” counterclockwise away from switch “B.”
3.
Manually operate the valve to the proper closed position.
4.
Rotate cam “B” clockwise against the switch roller on switch “B”
until the switch clicks once.
5.
Tighten the set screw on cam “B” and test the unit for proper travel.
If travel is not correct, repeat Steps 1 through 4, or proceed to the
Micro-Travel Cam Adjustments section which follows.
Micro-Travel
Cam
Adjustments
If the limit switch cam adjustment procedures do not provide the
necessary travel control, the micro-travel cams can be adjusted as follows:
Setting Open
Travel
1.
Loosen the pivot screw on switch “A” and the set screw on
micro-adjustment cam “A.”
2.
In the event of actuator undertravel, rotate micro-adjustment
cam “A” to swing switch “A” outward from the cam post. In the
event of actuator overtravel, rotate micro-adjustment cam “A” to
swing switch “A” into the cam post.
3.
Tighten the pivot screw on switch “A” and the set screw on
micro-adjustment cam “A.”
1.
Loosen the pivot screw on switch “B” and the set screw on
micro-adjustment cam “B.”
2.
In the event of actuator undertravel, rotate micro-adjustment
cam “B” to swing switch “B” outward from the cam post. In the
event of actuator overtravel, rotate micro-adjustment cam “B” to
swing switch “B” into the cam post.
3.
Tighten the pivot screw on switch “B” and the set screw on
micro-adjustment cam “B.”
Setting Closed
Travel
Install the actuator cover and tighten all flange bolts. On models with a
declutching knob, re-install the knob previously removed and tighten the
socket set screw. The valve and actuator assembly is now ready for
service.
VA-9000 Series Electric Rotary Actuators Commissioning Procedures Technical Bulletin
7
Manual
Operation of the
Valve Actuator
1.
Referring to Figure 3, pull the declutching knob all the way up and
hold.
Ope
n
Valve Actuators
Featuring a
Declutching
Knob
C lo s e d
Figure 3: Manual Operation of a
Valve Actuator Featuring a Declutching Knob
2.
Insert an open-ended wrench beneath the declutching knob and onto
the shaft.
3.
Applying a gentle rocking motion, use the wrench to rotate the shaft
to the desired position.
Note: During manual operation of the valve actuator, avoid turning
the shaft beyond the normal open/closed travel range.
4.
Once the shaft is in the desired position, remove the wrench and
allow the declutching knob to snap back into its original position.
5.
Once the declutching knob is in its original position, the valve
actuator will automatically re-engage and the power supply will be
restored for normal operation.
8 VA-9000 Series Electric Rotary Actuators Commissioning Procedures Technical Bulletin
Valve Actuators
Featuring a
Handwheel
1.
Depress and rotate the handwheel slowly until it drops into position
and the gears engage.
2.
Turn the handwheel in the desired direction and, using the markings
on the handwheel as a reference, check the position by the indicator
on the output shaft.
Note: During manual operation of the valve actuator, avoid turning
the shaft beyond the normal open/closed travel range.
3.
Once the shaft is in the desired position, return the handwheel to its
raised position. Doing so will reset the cutoff switch, in order to
restore power to the valve actuator for normal operation.
Note: The cutoff switch is designed to prevent unexpected operation
of the valve actuator when it is being manually positioned.
VA-9000 Series Electric Rotary Actuators Commissioning Procedures Technical Bulletin
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10 VA-9000 Series Electric Rotary Actuators Commissioning Procedures Technical Bulletin
Circuit Board Commissioning
Tools Required
•
Electronic Multimeter
•
Signal Source (4 to 20 mA DC)
•
1/8 in. Blade Screwdriver
Preliminary
Checks
!
CAUTION: Do not apply power to the actuator or circuit board
until the following preliminary visual, mechanical,
and electrical checks are made.
Also, the following preliminary checks must be
performed before the actuator is mounted to the
valve. Damage to the unit could result if these checks
are not performed before mounting.
1.
Verify that the electrical power source meets the requirements.
2.
Verify that the limit switches are set properly.
3.
Check the wiring diagram to determine whether the Open/Extend or
Close/Retract limit switch will be tripped at the minimum command
signal. (The standard setting is for the Close/Retract limit switch.)
4.
Referring to Figures 5 and 6, verify that the wire connected to
terminal 1 goes to the minimum command signal limit switch, and
that the wire connected to terminal 2 goes to the maximum command
signal limit switch.
5.
Referring to Figure 5, verify that the actuator feedback potentiometer
wires are properly connected. Also check for 20 ohms of resistance
between the blue/red wire and terminal 10 or 12 and the blue/orange
wire and terminal 11 (slider), at the minimum command signal
position.
6.
Check that the low-voltage signal wires are separated in a different
bundle from the power AC voltage wires.
7.
Check that the low-voltage signal wires shield is connected to the
signal source common ground.
Note: Be aware that the actuator limit switches and feedback
potentiometer are factory set, and should only be adjusted when
absolutely necessary.
VA-9000 Series Electric Rotary Actuators Commissioning Procedures Technical Bulletin
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Setting the
Actuator
Feedback
Potentiometer
M o unting
B ra cke t
O utput Sh aft
Active
Are a
Body
R e taining
Nut
P in ion
0%
2
3
1
100%
N on -Active
Are a
Figure 4: Feedback Potentiometer
1.
Disconnect the power to the actuator.
2.
Loosen the retaining nut on the actuator feedback potentiometer
mounting bracket until the potentiometer can be freely rotated to the
desired position.
3.
Manually operate the actuator, bypassing the circuit board. Run the
actuator in the direction of the minimum command signal position,
taking note of the direction of the output shaft rotation of the
feedback potentiometer.
The actuator can be run electrically, bypassing the circuit board.
Recheck that the power is disconnected. Referring to Figure 5,
disconnect wires L, 1, and 2 at the terminal block of the circuit board.
Then connect the wires as illustrated in Figure 6. Restore the power
to the unit and run the actuator until it is stopped by the minimum
command signal limit switch.
4.
Disconnect the power again.
5.
Referring to Figure 5, disconnect feedback potentiometer wires 10
and 11 at the terminal block.
6.
Set the electronic multimeter to measure 1000 ohms, and connect the
meter leads to wires 10 and 11.
7.
If the output shaft pinion of the feedback potentiometer rotated
clockwise while the actuator was moving in the minimum command
signal position, adjust the resistive output of the potentiometer for
20 ohms by turning the body of the potentiometer counterclockwise.
If the output shaft pinion of the feedback potentiometer rotated
counterclockwise while the actuator was moving in the minimum
command signal position, adjust the resistive output of the
potentiometer for 20 ohms by turning the body of the potentiometer
clockwise.
8.
Tighten the retaining nut to secure the potentiometer.
12 VA-9000 Series Electric Rotary Actuators Commissioning Procedures Technical Bulletin
-15V
+ 15V
TA
D eadband
TP3
M AX
M IN
F e edback
Potentio m eter
C om m and
Sign al
S upply
L
M IN
LS
P ow er
MAX
M
N
Figure 5: Circuit Board Layout
N eutral
M axim um S ig nal
Lim it S w itch
A C Line
V oltage
M
L
M inim um S ignal
Lim it S witch
Figure 6: Limit Switch Wiring Schematic
VA-9000 Series Electric Rotary Actuators Commissioning Procedures Technical Bulletin
13
9.
With the voltmeter leads temporarily connected to the feedback
potentiometer, restore power to the actuator.
10. Run the actuator in the direction of the maximum command signal
position, while noting the meter display. The potentiometer
resistance should increase gradually from 20 ohms to the maximum
value of the potentiometer. If the resistance exceeds the maximum
value and goes into the non-active area of the potentiometer before
the maximum command signal limit switch stops the actuator, the
limit switch will need to be reset.
11. Reconnect the feedback potentiometer wires to the terminal block.
DC Power
Supply Test
1.
Disconnect the power to the actuator.
2.
Referring to Figure 5, disconnect wires 1 and 2 at the terminal block
of the circuit board.
3.
Check that the disconnected wires are not touching any metallic parts,
then restore the power to the unit.
4.
Set the electronic multimeter in the DC volts mode, in order to
measure the specified voltages.
5.
Referring to Figure 5, locate the test points on the circuit board. With
terminal 9 as common, check for:
a.
+15 VDC + 0.6 VDC at test point +15V
b.
-15 VDC + 0.6 VDC at capacitor C3
In both instances, the correct voltage values must be present
for proper operation. If not, replace the circuit board; order
VA-9420-601 separately.
Initial Settings
1.
Disconnect the power to the actuator.
2.
Referring to Figure 5, verify that the actuator feedback potentiometer
is properly connected to the terminal block.
3.
Check or set the proper jumper. If the command signal fails, the
jumper setting will determine the position of the actuator:
a.
Jumper J3: Maximum signal position, power to terminal 1.
b.
Jumper J1: Maximum signal position, power to terminal 2.
c.
Jumper J2: Fail in place, no output power.
d.
No jumper: Zero command signal position, no output power.
14 VA-9000 Series Electric Rotary Actuators Commissioning Procedures Technical Bulletin
Deadband
Potentiometer
Feedback Zero
Potentiometer
Feedback Span
Potentiometer
4.
Furnish power to the actuator.
5.
Locate the test point near the deadband potentiometer.
6.
With terminal 9 as common, turn the deadband potentiometer P1 until
the voltage at the test point is 50 mV DC. To obtain this reading, it
takes approximately three counterclockwise turns from the fully
clockwise position.
7.
With terminal 9 as common, adjust the zero potentiometer P3
until the voltage at test point TP3 is approximately 1.0 VDC for a
4 mA DC or 1 VDC command signal.
8.
For a 0 mA DC or 0 VDC command signal, adjust the TP3 voltage at
zero and do not install a jumper at the J1J2J3 location.
9.
Run the actuator to the maximum command signal position.
10. Remove the input signal.
11. With terminal 9 as common, adjust span potentiometer P2 until
the voltage on test point TA is approximately 5.85 VDC for a
4 to 20 mA DC or 1 to 5 VDC command signal. If the zero or span
voltages cannot be obtained, check the DC power supply.
12. Turn the power off and reconnect all of the wires on the terminal
block of the circuit board.
Calibration
Span Adjustment
1.
Check all of the parameters outlined on the previous pages before
attempting to calibrate.
2.
Furnish power to the actuator.
3.
Apply the maximum input command signal. The actuator should run
until the maximum command signal limit switch is tripped, stopping
the actuator. If the actuator stops before the limit switch trips,
manually or electrically run the actuator bypassing the circuit board
until the maximum command signal limit switch is tripped.
4.
If the green LED light is on, turn span potentiometer P2 clockwise
until the light turns off. If the green light is already off, turn span
potentiometer P2 counterclockwise until the light turns on, then
clockwise until it turns off again. Doing so tests for proper operation.
5.
Recheck the span adjustment by changing the command signal.
VA-9000 Series Electric Rotary Actuators Commissioning Procedures Technical Bulletin
15
Zero Adjustment
6.
Apply the minimum input command signal. The actuator should run
until the minimum command signal limit switch is tripped, stopping
the actuator. If the actuator stops before the limit switch trips,
manually or electrically run the actuator bypassing the circuit board
until the minimum command signal limit switch is tripped.
7.
If the red LED light is on, turn zero potentiometer P3 clockwise until
the light turns off. If the red light is already off, turn zero
potentiometer P3 counterclockwise until the light turns on, then
clockwise until it turns off again. Doing so tests for proper operation.
8.
Recheck the zero adjustment by changing the command signal.
Deadband
Adjustment
9.
Apply 50% of the input command signal.
Circuit Board
Checkout
1.
Check the operation of the circuit board by applying the input
command signal to terminals 8 and 9. Install the positive input wire
on terminal 8 and the negative input wire on terminal 9, using the
electronic multimeter to monitor the input signal.
2.
Gradually adjust the input signal in small increments until the
maximum signal position is reached. The actuator must move
proportionally, and a “null” must be attained at each increment with
both LED lights off. When the maximum signal position is reached,
the limit switch of the actuator must trip just as the green LED light
turns off.
3.
Gradually adjust the input signal in small increments until the
minimum signal position is reached. The actuator must move
proportionally, and a “null” must be attained at each increment with
both LED lights off. When the minimum signal position is reached,
the limit switch of the actuator must trip just as the red LED light
turns off.
4.
If the above checkout procedure is not successful, replace the circuit
board; order VA-9420-601 separately.
Controls Group
507 E. Michigan Street
P.O. Box 423
Milwaukee, WI 53201
10. The actuator should run until the controller stops it at the middle
position. If the actuator overshoots, turn deadband potentiometer P1
counterclockwise in small increments until the actuator stops. Both
LED lights should be off when this “null” condition is reached.
FAN 977
Valve and Actuator Manual
Printed in U.S.A.
16 VA-9000 Series Electric Rotary Actuators Commissioning Procedures Technical Bulletin