Installation Instructions VA-3100

Issue Date August 15, 2002

VA-3100 Series
Electric Valve Actuators

Installation
Table 1: Special Tools Needed
O
.K
.
Actuator/Valve Recommended Actuator
Part Mounting Tools
3/4 in. Wrench for Valves with
3/8 in. Stem O
.K
.
1 in. Wrench for Valves with
Packing Nut Figure 1: Proper Yoke Orientation
1/2 in. Stem
1-1/4 in. Wrench to Remove Old • Protect the actuator from dripping water that could
Packing Nut enter the actuator housing and damage the
mechanism or motor.
Yoke Adaptor 1-3/4 in. Wrench
• Do not cover the actuator with insulating material.
11/16 in. Wrench for Valves with
3/8 in. Stem • Allow sufficient clearance to remove the actuator
Stem Extender (as illustrated in Figure 3).
7/8 in. Wrench for Valves with
1/2 in. Stem • Pipe the valve with the flow in the direction of the
Two 9/16 in. Wrenches for Valves arrow on the valve body, so that the plug seats
with 3/8 in. Stem against the flow.
Stem Nut
3/4 in. Wrench for Valves with
!
1/2 in. Stem
CAUTION: Risk of Equipment Damage.
Actuator and Valve Disconnect all power supplies before wiring
Stem Coupling 5 mm Allen Wrench connections are made or prior to performing
Assembly Screws maintenance. Check all wiring connections before
Adjustable-Face, Pin-Style applying power to the system. Short-circuited or
improperly connected wires will result in permanent
Yoke Nut Spanner Wrench with Circle
damage to the equipment.
Diameter to 3 in.

Pre-Installation Details
Before installing a VA-3100 Series Electric Valve
Actuator onto a VG2000 Series Cast Iron Flanged
Globe Valve, please note the following:
• Mount the valve in an upright position, in a
conveniently accessible location. When mounted
horizontally, orient the yoke so that the yoke
supports are positioned vertically, one above the
other (as illustrated in Figure 1).

© 2002 Johnson Controls, Inc. 1

Part No. 14-1233-5, Rev. A [Link]
 D Table 2: Parts Included
N
E I
K Item Part Details
M
Motor
J Operation Limit
A Factory Set; Do Not Adjust
Switches S1
G and S2
Auxiliary

Hub 13 20 25 35 42
For Accessory Usage;
B B Switches S3
Two Adjustable Switch Cams
and S4
Position Indicator for On/Off
(Floating) Control Models;
Feedback
C Integrated Element of
Potentiometer
Resistance Balance Bridge for
Proportional Control Models
S1 S2 C D Gear Drives the Actuator Stem
Electronic Plug-In Module for
E
Positioner Proportional Control
L A F H For Connection of Motor and
Limit Switches; Also Input
Figure 2: VA-3100 Series F Terminal Strip
Signal Connection on
Electric Valve Actuator with Cover Removed Proportional Control Models
(View Looking Down)
For Auxiliary Switches S3 and
S4; Also Feedback
G Terminal Strip
Potentiometer for On/Off
(Floating) Control Models
Conduit
H For Motor Input
Connector
Conduit
I For Auxiliary Switches
Connector
To Feedback Potentiometer
Adjustment
J and Auxiliary Switches S3 and
Transfer Bolt
S4
K Square Shaft For Manual Crank
L Switch S7 For Line Voltage Interruption
Must Remain Parallel to
M Transfer Arm
Feedback Arm
Transmits Transfer Bolt
N Feedback Arm Position to Feedback
Potentiometer

Note: On actuators featuring auxiliary switches, field

adjust the switches to any position using the integral
auxiliary switch cam adjusting wrench.

On actuators featuring a feedback potentiometer, the

potentiometer provides position indication. Field adjust
the potentiometer on its friction clutch shaft using a
3/16 in. blade screwdriver. Measure the nominal
potentiometer resistance between Terminals 10 and
11 (as illustrated in Figure 5) when the actuator is
positioned fully down.

2 VA-3100 Series Electric Valve Actuators Installation Instructions

Dimensions

6-9/32
(160)
3-15/16 7-5/16 x 6-17/32
(100) (186 x 166)

6-3/32
(155)

12-3/32
* All VA-3100-xGC Series Electric Actuators (307)
are shipped from the factory for proper
mounting to the VG2000 Series Cast Iron
Flanged Globe Valve with the valve stem in
the fully down position. Before mounting
the actuator onto the valve, verify that
a 1/8 in. (3 mm) gap exists between the 4-9/16
gear and the transfer arm (as viewed from (116)*
the side of the actuator).

2-1/8
(54)

Figure 3: VA-3100 Series

Electric Valve Actuator Dimensions, in. (mm)

VA-3100 Series Electric Valve Actuators Installation Instructions 3

Mounting
6. Remove the actuator and valve stem coupling
assembly from the actuator, without rotating the
Actuator actuator stem.
7. Mount the actuator and yoke nut onto the yoke
adaptor, making sure that the side of the yoke nut
Actuator Yoke with the small lip and standoff is facing downward.
Actuator
Stem
Actuator and Valve Stem
8. Thread the yoke nut onto the yoke adaptor, and
Coupling Assembly tighten to a torque of 20 lb·ft (27.2 N·m).
(Includes Two Clamping Pieces,
Yoke Nut Two Screws, and Two Nuts) 9. Unscrew the stem extender to the point where it
barely touches the actuator stem, being careful not
to apply any force to the actuator stem.
Yoke Adaptor
10. Secure the position of the stem extender by
tightening the stem nut to a torque of 9 lb·ft (12.2
Stem Extender N·m).
Stem Nut 11. Secure the actuator stem to the stem extender
Packing Nut Round with using the two clamping pieces, two screws, and
Flat Ends two nuts of the actuator and valve stem coupling
Valve Stem
assembly. Position the actuator stem so that its
flats are parallel to the actuator yoke. The
Valve
Packing Box clamping assembly is designed to securely hold
the actuator stem without rotating.
Valve When properly aligned, the actuator stem and
stem extender fit perfectly into the cutouts on the
inside of the clamping pieces. The clamping
Figure 4: Exploded View of Actuator Mounting assembly straddles the actuator yoke and rides
along the yoke without rotating. Tighten the
To field mount a VA-3100 Series Electric Valve two clamping assembly screws to a torque of
Actuator onto a VG2000 Series Cast Iron Flanged 4 lb·ft (5.4 N·m). When properly installed, the
Globe Valve, refer to Figure 4 and proceed as follows: clamping assembly prevents any rotation of the
1. Remove the hex packing nut from the valve and actuator stem when the valve is at the end of its
discard. stroke.
Note: The hex packing nut is found only on 12. Drive the valve to the fully down position using the
VG2000 Series Cast Iron Flanged Globe Valves that manual crank (refer to the Manual Operation
are ordered as valve bodies only, not as complete section for more details).
actuator and valve assemblies. 13. Verify that the gap between the gear and the
2. Thread the yoke adaptor onto the packing box, transfer arm (as viewed from the side of the
and tighten to a torque of 25 lb·ft (34 N·m). actuator) is approximately 1/8 in. (3 mm). Refer to
Figure 2 for parts identification. If a 1/8 in. (3 mm)
3. Push the valve stem fully down into the valve gap exists, proceed directly to the Setup and
body. Adjustments section. If the gap is less than 1/8 in.
(3 mm), refer to Figure 4 and proceed as follows:
4. Thread the replacement packing nut (round with
flat ends) included with the mounting kit onto the a. Raise the actuator stem using the manual
packing box, and tighten to a torque of 4 lb·ft crank, until a 1/8 in. (3 mm) gap exists between
(5.4 N·m). the gear and the transfer arm.
5. Thread the stem nut and the appropriate stem b. Remove the actuator and valve stem coupling
extender onto the valve stem and down to the assembly.
packing nut, without tightening either securely in c. Push the valve stem fully down.
place. (In the VA-3100-500 Mounting Kit, the
2-1/4 in. length stem extender is for 2-1/2 in. d. Loosen the stem nut and adjust the stem
valves, and the 2-1/2 in. length stem extender is extender until it just touches the actuator stem.
for 3 and 4 in. valves.) e. Repeat Steps 10 and 11.

4 VA-3100 Series Electric Valve Actuators Installation Instructions

Wiring

Motor

S1 S2

S7

Retract
S3 S4

19 20 1 2 3 17 16 4 5 6 7 8 9 10 11 12

Down Up
Common
Auxiliary Switches and Potentiometer
(VA-3100-AGC Only)

24 VAC
Power

Figure 5: VA-3100-AGx Wiring Diagram for On/Off (Floating) Control

Motor

S1 S2

S7

Electronic Positioner
B A2 A1 O E P Y U

S3 S4

19 20 B O E Y 4 5 6 7 8 9

+ – – +
+
24 VAC 0 to 0 to
Power 10 VDC 10 VDC
Input Output

Figure 6: VA-3100-HGC Wiring Diagram for Proportional Control

VA-3100 Series Electric Valve Actuators Installation Instructions 5

Setup and Adjustments
4. Insert the end of the manual hand crank with the
Power Disconnect square socket, and gently press the crank inward
Manually switch off the electrical supply using the red to engage the friction clutch.
power disconnect button located on the underside of
the actuator. Refer to Figures 7 and 8 for more details. Note: The square shaft lies approximately 1/2 in.
(13 mm) below the surface of the actuator cover.
When inserting the manual hand crank, insert it
straight down (not at an angle).
3/16in. (5mm)
5. Observe the position indicator on the side of the
actuator yoke while turning the manual hand crank
clockwise or counterclockwise to achieve the
desired valve position.
Motor
6. Remove the manual hand crank, and return it to its
storage location on the actuator cover.
Figure 7: Height of Power Switch (Off Position) 7. Depress the red power disconnect button to the
when Motor Common is Interrupted position illustrated in Figure 8, to restore power to
the actuator.

VA-3100-AGA Electric Valve Actuator

1/16in. (2mm) No adjustments are required on the VA-3100-AGA
Electric Valve Actuator.

VA-3100-AGC Electric Valve Actuator

To adjust the potentiometer on the VA-3100-AGC
Motor
Electric Valve Actuator, proceed as follows:
1. Check that the red power switch is depressed to
Figure 8: Height of Power Switch (On Position) the On position (as illustrated in Figure 8), and
when Motor Common is Connected apply power to Terminals 1 and 2 (as illustrated in
Figure 5) to drive the valve stem fully down.
! Note: Do not drive the actuator unless it is mounted
CAUTION: Risk of Equipment Damage. on a valve.
Disconnect all power supplies before wiring 2. Adjust the transfer bolt (as illustrated in Figure 9);
connections are made or prior to performing the transfer bolt position at its center should
maintenance. Check all wiring connections before correspond to the nominal valve stroke.
applying power to the system. Short-circuited or A 2-1/2 in. valve has a nominal valve stroke of
improperly connected wires will result in permanent 3/4 in. (19 mm), a 3 or 4 in. valve has a stroke of
damage to the equipment. 1-1/8 in. (29 mm), a 5 in. valve has a stroke of
1-3/8 in. (35 mm), and a 6 in. valve has a stroke of
Manual Operation 1-1/2 in. (38 mm).
Manually operate the VA-3100 Series Electric Valve 3. Connect an ohmmeter to Terminals 10 and 12 (as
Actuator as follows: illustrated in Figure 5) and read the resistance.
Using a 3/16 in. blade screwdriver, adjust the
1. Depress the red power disconnect button to the potentiometer for 0 ohms.
motor interrupt position as illustrated in Figure 7.
4. Apply 24 VAC power to Terminals 1 and 3 (as
2. Locate the manual hand crank that is stored on illustrated in Figure 5) to drive the valve stem fully
the outside of the actuator cover. up.
3. Remove the plastic plug from the top of the
actuator cover.

6 VA-3100 Series Electric Valve Actuators Installation Instructions

Note: When the valve reaches the end of stroke, the VA-3100-HGC Electric Valve Actuator
ohmmeter should read a nominal end resistance of To adjust the span and starting point
1,900 to 2,000 ohms. If the resistance is too low or if potentiometers on the VA-3100-HGC Electric Valve
the maximum resistance occurs before the valve Actuator, proceed as follows:
reaches the end of stroke, adjust the transfer bolt (as
illustrated in Figure 9). The transfer bolt position, at its 1. Refer to Figure 2 to locate the electronic positioner
center, should correspond to the nominal valve stroke and feedback potentiometer.
in millimeters. 2. Refer to Figure 10 to locate the action mode
switch and compensating potentiometer on the
Hub 13 20 25 35 42 inward side of the electronic positioner circuit
board. Also, locate the span and starting point
potentiometers on the outward side of the
electronic positioner circuit board.
Transfer Bolt
Compensating Potentiometer

D.A.
20 % 100 0 % 100
Span Starting Point
Figure 9: Adjusting the Transfer Bolt

R.A.
(Scaled in Millimeters) View Facing Outward
View Facing Inward
From the Motors
5. Repeat Steps 1 through 4 until the required Toward the Motors
ohmmeter readings are obtained.
D.A. = Direct Acting Action Mode Switch
To adjust the auxiliary switches on the R.A. = Reverse Acting
VA-3100-AGC Electric Valve Actuator, proceed as Figure 10: Electronic Positioner Circuit Board
follows:
3. Move the action mode switch toward the valve to
1. Refer to Figure 2 to locate the auxiliary switches. the Reverse Acting (R.A.) position. In the R.A.
2. Locate the auxiliary switch cam adjusting wrench position, the actuator travels up as the input signal
that is stored on the inside of the actuator cover. increases.

3. Loosen the cam holding screw using a 3/16 in. 4. Turn the span potentiometer to 100% using a
blade screwdriver. 3/16 in. blade screwdriver.

4. Adjust the actuator to the desired down position 5. Turn the starting point potentiometer to 0% using a
where the inner auxiliary switch is to be tripped. 3/16 in. blade screwdriver.

5. Adjust the inner cam using the auxiliary switch 6. Adjust the transfer bolt (as illustrated in Figure 9);
cam adjusting wrench, so that it just trips the inner the transfer bolt position at its center should
auxiliary switch. correspond to the nominal valve stroke.
A 2-1/2 in. valve has a nominal valve stroke of
6. Adjust the actuator to the desired up position 3/4 in. (19 mm), a 3 or 4 in. valve has a stroke of
where the outer auxiliary switch is to be tripped. 1-1/8 in. (29 mm), a 5 in. valve has a stroke of
7. Adjust the outer cam using the auxiliary switch 1-3/8 in. (35 mm), and a 6 in. valve has a stroke of
cam adjusting wrench, so that it just trips the outer 1-1/2 in. (38 mm).
auxiliary switch. 7. Apply 24 VAC power to Terminals B and O (as
8. Tighten the cam holding screw using a 3/16 in. illustrated in Figure 6).
blade screwdriver after the desired position is 8. Connect a voltmeter to Terminals Y and O (as
obtained. illustrated in Figure 6) to monitor feedback voltage.
9. Reinstall the actuator cover, making sure that the The voltmeter should be on the 10 V range or set
access hole for the manual hand crank aligns with for auto.
the square drive. 9. Adjust the compensating potentiometer (located
on the inward side of the circuit board as
illustrated in Figure 10) to the center of its rotation
range.

VA-3100 Series Electric Valve Actuators Installation Instructions 7

10. Apply a 10 VDC input voltage to the actuator; the 16. Input the desired maximum control signal to the
input signal is on Terminal E, and the input signal actuator. Once the valve stops, slowly adjust the
common is on Terminal O (as illustrated in span potentiometer (as illustrated in Figure 10) in
Figure 6). The actuator should travel to the fully up small increments until the valve actuator no longer
position. strokes. The valve should be in the fully maximum
position.
11. Adjust the feedback potentiometer (as illustrated in
Figure 2) so that the voltmeter indicates a 17. Reapply the minimum control signal and the
maximum output voltage of 9.5 VDC. maximum control signal, and check the valve for
proper operation.
12. Decrease the input signal across
Terminals O and E to 0 VDC. The actuator should To adjust the auxiliary switches on the
travel to the fully down position at which point the VA-3100-HGC Electric Valve Actuator, proceed as
voltmeter on Terminals O and Y should read follows:
0.5 VDC. If the voltmeter reads something other
1. Refer to Figure 2 to locate the auxiliary switches.
than 0.5 VDC, adjust the compensating
potentiometer to obtain a reading of 0.5 VDC. 2. Locate the auxiliary switch cam adjusting wrench
that is stored on the inside of the actuator cover.
Note: Adjust the transfer bolt if the adjustment range
is not sufficient (as illustrated in Figure 9). If the 3. Loosen the cam holding screw using a 3/16 in.
voltage span is too high, move the transfer bolt in the blade screwdriver.
direction of larger strokes; if the voltage span is too
low, move the transfer bolt in the direction of smaller 4. Adjust the actuator to the desired down position
strokes. The transfer arm must remain parallel to the where the inner auxiliary switch is to be tripped.
feedback arm. 5. Adjust the inner cam using the auxiliary switch
13. Repeat Steps 9 through 12 until the required cam adjusting wrench, so that it just trips the inner
voltages are obtained. auxiliary switch.

Note: Use the action mode switch and the span and 6. Adjust the actuator to the desired up position
starting point potentiometers (illustrated in Figure 10) where the outer auxiliary switch is to be tripped.
to obtain the desired actuator action and input range. 7. Adjust the outer cam using the auxiliary switch
14. Set the action mode switch (as illustrated in cam adjusting wrench, so that it just trips the outer
Figure 10) to the desired direction. In the direct auxiliary switch.
acting mode, the actuator extends down as the 8. Tighten the cam holding screw using a 3/16 in.
control signal increases; in the reverse acting blade screwdriver after the desired position is
mode, the actuator will retract up as the control obtained.
signal increases.
9. Reinstall the actuator cover, making sure that the
Note: Use calibration values that are somewhat less access hole for the manual hand crank aligns with
than application values for the controller to have the square drive.
sufficient overtravel (to account for valve seat wear
over time). Below are examples of recommended Repairs and Replacement
calibration values:
If the VA-3100 Series Electric Valve Actuator fails to
Application Value Calibration Value operate within its specifications, unit replacement is
required. For a replacement VA-3100 Actuator, contact
0 to 10 VDC 1 to 9 VDC the nearest Johnson Controls representative.
0 to 5 VDC 1 to 4 VDC
5 to 10 VDC 6 to 9 VDC

15. Input the desired minimum control signal to the

actuator, and slowly adjust the starting point
potentiometer (as illustrated in Figure 10) in small
increments until the valve actuator no longer
strokes. The valve should be in the fully minimum
position.

8 VA-3100 Series Electric Valve Actuators Installation Instructions

Troubleshooting
Table 3: Symptoms and Suggested Remedies
Symptom Suggested Remedy
Actuator does not drive. 1. Confirm that a 24 VAC power source is available at the actuator.
2. Confirm that the red power disconnect button is in the On position.
Transfer bolt has come 1. Drive the valve to the fully down position using the manual crank, and verify that a 1/8 in.
out of the feedback arm. (3 mm) gap exists between the gear and the transfer arm (as viewed from the side of the
actuator). Refer to Steps 12 and 13 in the Mounting section for more details.
2. Install the actuator onto the valve body before operating the actuator. Refer to the
Installation section for more details.
3. Reinstall the actuator and valve stem coupling assembly properly. Refer to Step 11 in the
Mounting section for more details.

Technical Specifications
Product VA-3100 Series Electric Valve Actuators
Force Output 675 lb (3,000 N)
Power Requirements On/Off (Floating) 20 to 28 VAC, 60 Hz;
Control Models 16 VA Minimum
Proportional 20 to 28 VAC, 60 Hz;
Control Models 18 VA Minimum
Input Signal On/Off (Floating) 20 to 28 VAC, 60 Hz
Control Models
Proportional 0 to 10 VDC
Control Models
Input Impedance Proportional 5,600 ohms
Control Models
Only
Feedback Signal VA-3100-AGC Only 0 to 2,000 ohms
VA-3100-HGC Only Approximately 9 VDC Span (0.5 VDC with Valve Stem Fully Down;
9.5 VDC with Valve Stem Fully Up)
Switch Contact Rating 5 A, 24 VAC
Maximum Stroke 1-21/32 in. (42 mm)
Nominal Timing for 92 Seconds
1 in. Stroke
Ambient Operating On/Off (Floating) 14 to 140°F (-10 to 60°C)
Temperature Limits Control Models
(Limited by the Actuator) Proportional 14 to 122°F (-10 to 50°C)
Control Models
Agency Compliance UL 873 Listed, File E27734, CCN XAPX;
cUL C22.2 No. 24-93 Listed, File E27734, CCN XAPX7
Enclosure Rating NEMA 3/3R, IP 54
Shipping Weight 9.7 lb (4.4 kg)
The performance specifications are nominal and conform to acceptable industry standards. For application at conditions beyond these
specifications, consult the local Johnson Controls office. Johnson Controls, Inc. shall not be liable for damages resulting from misapplication or
misuse of its products.

Controls Group
507 E. Michigan Street
P.O. Box 423 Printed in U.S.A.
Milwaukee, WI 53201 [Link]

VA-3100 Series Electric Valve Actuators Installation Instructions 9