Johnson Controls VG1000 Series User manual

VG1000 Series Forged Brass Ball Valves Installation Instructions
1
Refer to the QuickLIT website for the most up-to-date version of this document.
Applications
The VG1000 Series Ball Valves are designed to regulate the flow of hot or chilled water (and for some models, low
pressure steam) in response to the demand of a controller in HVAC systems.
Installation
Install VG1000 Series Ball Valves with the actuator at or above the centerline of the horizontal piping, as shown in
Figure 1.
To minimize heat transfer in steam applications, wrap the valve and piping with insulation. Allow sufficient
clearance to remove the actuator (as illustrated in the dimension drawings, Figure 6 through Figure 11).
When mounting the actuator in the field (before installation), use an adjustable wrench to manually rotate the valve
stem several times. This rotation breaks the torque that may have built up during long-term storage.
For the valve to move in the proper direction, wire the input lines to the electric actuator correctly.
IMPORTANT: Use the VG1000 Series Valves as an operating control. Where failure or malfunction of the
VG1000 Series Valve 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 VG1000 Series Valve.
IMPORTANT: In steam applications, install the valve with the stem horizontal to the piping. Failure to follow
these guidelines may shorten the life of the actuator.
FIG:mntpos
Figure 1: Mounting Positions for Chilled Water and Condensing Atmosphere Applications
VG1000 Series Forged Brass Ball Valves
Installation Instructions
Part No. 14-1201-5, Rev. X
Issued December 2018
*1412015RevX*
14-1201-5 Rev. X

VG1000 Series Forged Brass Ball Valves Installation Instructions
2
For more detailed installation information about the specific equipment used, refer to the appropriate document
from the following list:
•VA9104-xGA-2S Series Electric Non-Spring Return Valve Actuators Installation Instructions
(Part No. 14-1336-15)
• VA9104-xGA-3S Series Electric Non-Spring Return Valve Actuators Installation Instructions
(Part No. 14-1336-23)
• M9102-AGA-2S and M9104-xGA-2S SeriesElectric Non-Spring ReturnActuators Installation Instructions (Part
No. 34-636-1220)
• M9102-AGA-3S and M9104-xGA-3S SeriesElectric Non-Spring ReturnActuators Installation Instructions (Part
No. 34-636-1433)
• VA9300 Series Electric Non-Spring Return Valve Actuators Installation Instructions
(Part No. 34-636-2421)
• VA9203-AGx-2Z Series On/Off and Floating Point Electric Spring Return Valve Actuators Installation
Instructions (Part No. 14-1380-8)
• VA9203-Bxx-2 Series On/Off Spring Return Valve Actuators Installation Instructions
(Part No. 14-1380-16)
• VA9203-GGx-2Z Series Proportional Spring Return Valve Actuators Installation Instructions
(Part No. 14-1380-24)
• VA9208-AGx-x Series On/Off and Floating Point Electric Spring Return ValveActuators Installation Instructions
(Part No. 14-1379-5)
• VA9208-Bxx-x Series On/Off Spring Return Valve Actuators Installation Instructions
(Part No. 14-1379-13)
• VA9208-GGx-x Series Proportional Spring Return Valve Actuators Installation Instructions
(Part No. 14-1379-21)
• M9000-560 Ball Valve Linkage Kit and M9000-561 Thermal Barrier Installation Instructions
(Part No. 34-636-2227)
• M9000-342 Series Weather Shield Enclosures Installation Instructions (Part No. 34-636-2499)
• M9000-551 Ball Valve Linkage Kit Installation Instructions (Part No. 34-636-1816)
Note: To avoid excessive wear or drive time on the motor for VA9104 and M9104 models, use a controller or
software that provides a time-out function to remove the signal at the end of rotation (stall). The IGx and GGx
models have an auto shutoff to avoid excessive wear or drive time on the motor.
On models with the flow-characterizing disk, the disk is located in Port A. Port A must be the inlet. On three-way
models, use Port A as the coil inlet and Port B as the bypass inlet.
IMPORTANT: Take care to prevent foreign material such as weld slag, thread burrs, metal chips, and scale
from entering the piping system. This debris can damage or severely impede the operation of the valve by
embedding itself in the seats, scoring the valve, and ultimately resulting in seat leakage. If the debris becomes
embedded in the seats, subsequent flushing and filtering of the piping system with the valve installed does not
remedy the problem.

VG1000 Series Forged Brass Ball Valves Installation Instructions
3
VG1841 and VG1845 Series Three-Way Ball Valves have a different port configuration from VG1644 Series Three-
Way valves. See Figure 2, Figure 3, and Figure 4 for details.
Contact your local Johnson Controls® representative for compatibility concerns before using VG1000 Series Ball
Valves to control the flow of fluids other than those outlined in the Technical Specifications table in this document.
IMPORTANT: Protect the actuator from dripping water, condensation, and other moisture. Water or moisture
could result in an electrical short, which may damage or affect the operation of the actuator.
IMPORTANT: Do not cover the actuator with thermal insulating material. High ambient temperatures may
damage the actuator, and a hot water pipe, steam pipe, or other heat source may overheat it.
FIG:VGAtoC
Port A
Coil
Port C
Common
Port B Bypass
Figure 2: VG1841 or VG1845 Series Three-
Way Ball Valve (Port A Connected to Port C)
Port A
Coil
Port C
Common
Port B Bypass
FIG:vgBtoC
Figure 3: VG1841 or VG1845 Series Three-
Way Ball Valve (Port B Connected to Port C)
Common
Port
Normally
Open Port Normally
Closed Port
FIG:vg1644ccw
Figure 4: Top View of VG1644 Series Three-
Way Ball Valve (Actuator Fully

VG1000 Series Forged Brass Ball Valves Installation Instructions
4
Press Valve Installation
VG1000 press end connection valves are installed using RIDGID® press tools.Always refer to the operator’s
manual supplied with the RIDGID press tool that is used to make the valve end connections. The manual should
provide proper instructions for the safe operation of the tool, proper crimping procedures, and methods of
inspecting the finished connection. If you use a battery-operated press tool, ensure its proper operation by fully
charging the unit. To avoid damage to the integral O-ring, never use sealant or pipe dope with a press connection.
Always inspect the end connections of the valve before making the connection. The end connection should not be
deformed, and the internal, integral O-ring must be in place for a proper seal.
Sweat Valve Installation
When soft soldering sweat ball valves, be sure to use a low temperature solder with a melting point that does not
exceed 450°F (232°C). For lead-free RoHS compliance, a 96.5% tin/3.5% silver solder is recommended. Never
install the actuator on the valve until you have completed the soldering operation and the valve body has cooled.
Before soldering, minimize the risk of damage to the ball seals by positioning the ball so that PortA is fully open.
When soldering, always apply a wet rag around the valve’s neck and cover as much of the valve body with the rag
as possible. Direct the tip of the flame away from the valve and always heat the copper tubing directly, but never
the valve body. Solder Port A first, then the remaining ports. These steps provide maximum protection to the
internal valve components. See Figure 5 for details.
Figure 5: Sweat Valve Installation
Use only low meltin
g
temperature soft solder.
Place a wet rag around
the neck of the valve.
FIG:sv_ins
t

VG1000 Series Forged Brass Ball Valves Installation Instructions
5
See Figure 6 for dimension drawings of the Non-Spring Return VA9104 Series Actuated VG1241, VG1245,
VG1841, and VG1845 Series NPT End Connection Ball Valves. See Table 1 and Table 2 for specific model linkage
dimensions.
Table 1: VA9104 or M9104 Actuated VG1241, VG1245, VG1841, and VG1845 Series Ball Valve with
Optional M9000-551 Linkage Dimensions, in. (mm)
Valve Size,
in. (DN)1
1. Port A must always be connected to the coil.
A
(Without
Thermal
Barrier)
A
(With
Thermal
Barrier)
BC D E F G
1/2 (DN15) 3-7/8
(98) 5-11/32 (135) 21/32 (17) 1-7/32 (31) 5-7/64 (129) 2-33/64 (64) 11/32 (9) 1-1/4 (32)
3/4 (DN20) 3-7/8
(98) 5-11/32 (135) 21/32 (17) 1-7/32 (31) 5-7/32 (133) 2-51/64 (71) 11/32 (9) 1-13/32 (36)
1 (DN25) 3-11/16
(100) 5-27/64 (137) 3/4 (19) 1-19/64 (33) 5-9/16 (141) 3-13/32 (87) 11/32 (9) 1-11/16 (43)
Table 2: VA9104 Actuated VG1275 and VG1875 Series Ball Valve with Sweat End Connections and VA9104
Actuated VG1295 and VG1895 Series Ball Valves with Press End Connections Dimensions,
in. (mm)
Valve Size,
in. (DN)1
1. Port A must always be connected to the coil.
ABC D EFG
1/2 (DN15) 3-7/8 (98) 21/32 (17) 1-7/32 (31) 5-45/64 (145) 3-25/32 (96) 11/32 (9) 2-13/16 (55)
3/4 (DN20) 3-7/8 (98) 21/32 (17) 1-7/32 (31) 5-57/64 (150) 4-3/32 (104) 11/32 (9) 2-15/32 (62)
1 (DN25) 3-15/16 (100) 3/4 (19) 1-19/64 (33) 6-1/8 (156) 4-21/32 (118) 11/32 (9) 2-27/32 (72)
Figure 6: VA9104 Actuated VG1241, VG1245, VG1841, and VG1845 Series Ball Valve
with NPT End Connections Dimensions, in. (mm)
2-13/16
(71)
3-1/2 (89)
Clearance Required
Port Marking
Locations
FIGVA9104X_dims
6-1/2
(153.5)
D
A

VG1000 Series Forged Brass Ball Valves Installation Instructions
6
See Figure 7 for dimension drawings of the Spring Return VA9203 Series Actuated VG1241, VG1245, VG1841,
and VG1845 Series NPT End Connection Ball Valves. See Table 3 and Table 4 for specific model linkage
dimensions.
Table 3: VA9203 Actuated VG1241, VG1245, VG1841, and VG1845 Series Ball Valve with NPT End
Connections Dimensions, in. (mm)
Valve Size,
in. (DN)1
1. Port A must always be connected to the coil.
A
(Without
Thermal
Barrier)
A
(With
Thermal
Barrier)
BCDEFG
1/2 (DN15) 4-1/4
(108) 6 (152) 21/32 (17) 1-7/32 (31) 6-23/32 (171) 2-33/64 (64) 11/32 (9) 1-1/4 (32)
3/4 (DN20) 4-1/4
(108) 6 (152) 21/32 (17) 1-7/32 (31) 6-7/8 (175) 2-51/64 (71) 11/32 (9) 1-13/32 (36)
1 (DN25) 4-9/32
(109) 6-1/16 (154) 3/4 (19) 1-19/64 (33) 7-7/64 (181) 3-13/32 (87) 11/32 (9) 1-45/64 (43)
Table 4: VA9203 Actuated VG1271, VG1275, VG1871, and VG1875 Series Sweat Ball Valve and VA9203
Actuated VG1291, VG1295, VG1891, and VG1895 Series Press Ball Valve Dimensions, in. (mm)
Valve Size,
in. (DN)1
1. Port A must always be connected to the coil.
ABC D EFG
1/2 (DN15) 4-5/8 (117) 21/32 (17) 1-7/32 (31) 7-13/64 (183) 3-25/32 (96) 11/32 (9) 1-1/4 (32)
3/4 (DN20) 4-5/8 (117) 21/32 (17) 1-7/32 (31) 7-3/4 (197) 4-3/32 (104) 11/32 (9) 1-13/32 (36)
1 (DN25) 4-11/16 (119) 3/4 (19) 1-19/64 (33) 8-3/16 (208) 4-41/64 (118) 11/32 (9) 1-45/64 (43)
Figure 7: Spring Return VA9203 Actuated VG1241, VG1245, VG1841, and VG1845 Series Ball Valve with
Optional M9000-561 Thermal Barrier Installed Dimensions, in. (mm)
Port Marking
Locations
FIG:VA9203X_dimsthbr
2-7/8
(73)
3-1/4
(82)
A
D
3-1/2 (89)
Clearance Required

VG1000 Series Forged Brass Ball Valves Installation Instructions
7
See Figure 8 for dimensions of the Non-Spring Return VA9300 Actuated VG1241, VG1245, VG1841, and VG1845
Series Ball Valve with Optional M9000-561 Thermal Barrier. See Table 5 for specific model linkage dimensions.
Table 5: VA9300 Actuated VG1241, VG1245, VG1841, and VG1845 Series Ball Valve with Optional
M9000-561 Thermal Barrier Dimensions, in. (mm)
Valve
Size, in.
(DN)
A (With
Thermal
Barrier)
A (Without
Thermal
Barrier)
BC D EFG
1/2
(DN15) 5-3/4 (146) 4-3/8 (111) 21/32 (17) 1-7/32 (31) 6-13/32 (163) 2-33/64 (64) 11/32 (9) 1-1/4 (32)
3/4
(DN20) 5-3/4 (146) 4-3/8 (111) 21/32 (17) 1-7/32 (31) 6-13/32 (163) 2-51/64 (71) 11/32 (9) 1-13/32 (36)
1
(DN25) 5-13/16 (148) 4-7/16 (113) 3/4 (19) 1-5/16 (33) 6-13/32 (163) 3-13/32 (87) 11/32 (9) 1-45/64 (43)
1-1/4
(DN32) 6-1/4 (159) 4-7/8 (124) 1-1/32 (26) 1-23/32 (44) 6-13/32 (163) 3-15/16 (100) 11/32 (9) 1-31/32 (50)
1-1/2
(DN40) 6-13/32 (163) 5-1/32 (128) 1-1/8 (29) 1-7/8 (48) 6-13/32 (163) 4-21/64 (110) 11/32 (9) 2-11/64 (55)
2
(DN50) 6-5/8 (168) 5-1/4 (133) 1-15/32 (37) 2-1/16 (53) 6-13/32 (163) 4-27/32 (123) 11/32 (9) 2-27/64 (62)
Figure 8: Non-Spring Return VA9300 Actuated VG1241, VG1245, VG1841, and VG1845 Series Ball
Valve with Optional M9000-561 Thermal Barrier Dimensions, in. (mm)
B
D
A
3-1/2 in. (89 mm)
C
Optional
Thermal
Barrier
Optional
Thermal
Barrier
FIG:Thermal Barrier
B
Port Marking
Locations

VG1000 Series Forged Brass Ball Valves Installation Instructions
8
See Figure 9 for dimensions of the Non-Spring Return VA9300 Actuated VG1241, VG1245, VG1841, and VG1845
Series Ball Valve with Optional M9000-561Thermal Barrier and M9300-2 Switch Kit. See Table 6 for specific model
linkage dimensions.
Table 6: VA9300 Actuated VG1241, VG1245, VG1841, and VG1845 Series Ball Valve with Optional
M9000-561 Thermal Barrier and M9300-2 Switch Kit Dimensions, in. (mm)
Valve
Size, in.
(DN)
A (With
Thermal
Barrier)
A (Without
Thermal
Barrier)
BCDEFG
1/2
(DN15) 6-3/25
(155.7) 4-3/4 (120.7) 21/32 (17) 1-7/32 (31) 6-21/32 (169) 2-33/64 (64) 11/32 (9) 1-1/4 (32)
3/4
(DN20) 6-3/25
(155.7) 4-3/4 (120.7) 21/32 (17) 1-7/32 (31) 6-21/32 (169) 2-51/64 (71) 11/32 (9) 1-13/32 (36)
1
(DN25) 6-1/5
(157.7) 4-21/25 (122.7) 3/4 (19) 1-5/16 (33) 6-21/32 (169) 3-13/32 (87) 11/32 (9) 1-45/64 (43)
1-1/4
(DN32) 6-16/25
(168.7) 5-1/4 (133.7) 1-1/32 (26) 1-23/32 (44) 6-21/32 (169) 3-15/16 (100) 11/32 (9) 1-31/32 (50)
1-1/2
(DN40) 6-4/5
(172.7) 5-3/7 (137.7) 1-1/8 (29) 1-7/8 (48) 6-21/32 (169) 4-21/64 (110) 11/32 (9) 2-11/64 (55)
2
(DN50) 6
(177.2) 5-5/8 (142.7) 1-15/32 (37) 2-1/16 (53) 6-21/32
(169) 4-27/32 (123) 11/32 (9) 2-27/64 (62)
Figure 9: Non-Spring Return VA9300 Actuated VG1241, VG1245, VG1841, and VG1845 Series Ball
Valve with Optional M9000-561 Thermal Barrier and M9300-2 Switch Kit Dimensions, in. (mm)
B
D
FIG:Thermal Barrier
C
B
Port Marking
Locations

VG1000 Series Forged Brass Ball Valves Installation Instructions
9
See Figure 10 for dimension drawings of the Spring Return VA9208 Actuated VG1241, VG1245, VG1841, and
VG1845 Series NPT End Connection Ball Valves with M9000-561 Thermal Barrier. See Table 7 for specific model
linkage dimensions.
Table 7: VA9208 Actuated VG1241, VG1245, VG1841, and VG1845 Series Ball Valve with Optional
M9000-561 Thermal Barrier Installed Dimensions, in. (mm)
Valve
Sizein.
(DN)1
1. Port A must always be connected to the coil.
Valve
Style A (With
Thermal
Barrier)
A
(Without
Thermal
Barrier)
BCDEFG
1-1/4
(DN32) All 9-17/64
(235) 7-11/16 (195) 1-1/32 (26) 1-23/32 (44) 7-1/4 (184) 3-15/16 (100) 11/32 (9) 1-31/32 (50)
1-1/2
(DN40) All 9-15/16
(240) 7-7/8 (200) 1-9/64 (29) 1-57/64 (48) 7-7/16 (189) 4-21/64 (110) 11/32 (9) 2-11/64 (55)
2
(DN50) 2-way 9-31/32
(244) 8-1/32 (204) 1-15/32 (37) 2-1/8 (54) 7-11/16 (195) 4-27/32 (123) 11/32 (9) N/A
3-way 7-7/8
(200) 2-27/64 (62)
Figure 10: Spring Return VA9208 Actuated VG1241, VG1245, VG1841, and VG1845 Series Ball Valve with
Optional M9000-561 Thermal Barrier Installed Dimensions, in. (mm)
3-29/32
(99)
A
B
3-1/2 (89)
Clearance Required
G
C
F
B
C
E
Port Marking
Locations
D

VG1000 Series Forged Brass Ball Valves Installation Instructions
10
Piping
Port C
Port
B
Port A
Port BPort A
VG184x Three-Way Valve
Return
Supply
Typical Three-Way Ball Valve Application
Typical Two-Way Ball Valve Application
VG124x Two-Way Valve
Return
Supply
Note
:
Mount the valve downstream from the coil to minimize heat transfer to the actuator.
FIG:VG1000_typpip
Figure 11: Typical VG1000 Piping