VSI 1000-X Series User manual

SERIES 1000-X
OPERATION AND MAINTENANCE MANUAL
VER0815-2
For information on this product and other VSI products please visit our web page - www.valvesolutions.com
COMMERCIAL AND INDUSTRIAL VALVES
AND AUTOMATION
OPEN/CLOSE SERVICE ELECTRIC ACTUATORS
Publication S1000X-110

VSI Series 1000-X Electric Actuator
Operation and Maintenance Manual
2
• Actuators are equipped with an internal overheat protection device.
When the motor exceeds the temperature of 257°F (125°C), the
overheat protection device will automatically switch off the motor.
• Take proper leakage protection steps when installing actuator
and its associated wiring, and when putting it into service. Cables
connected to the actuator conduit entries must utilize proper
waterproof cable ends. Tube conduit should come from below and
up to the actuator to keep fluid from draining into the actuator.
• Confirm input voltages and signal polarity corresponds with those
shown for the actuator’s associated data.
• Only qualified service personnel who are familiar with the
installation, commissioning and operation of the actuator should
perform installation and servicing.
• All actuators have the proper wiring diagram affixed to the inside of
the Front Wiring Cover (#4); all wiring should follow these diagrams.
Do not manually operate the actuator without deenergizing
actuator with factory installed push button or by external
disconnect such as a circuit breaker.
NOTICE
• Valve Solutions, Inc is not responsible for damages incurred because
of modification, lack of proper maintenance, or improper usage of
actuators
To prevent reduced or erratic performance a single
isolated relay is required for each actuator; refer to
diagram.
NOTICE
Indicates a potentially hazardous situation which, if not
avoided, could result in injury or death
WARNING
Indicates a potential situation which, if not avoided, may
result in undesirable results or property damage
NOTICE
SAFETY INSTRUCTIONS AND WARNINGS
Safety Instructions and Warnings 2
Component Names 3
Overall Dimensions and Specifications
1005-X 4
1010-X 5
1020-X Thru 1060-X 6
1100-X Thru 1250-X 7
Electrical Wiring Connection 8
Power Supply Requirements 8
Application Requirements 9
Mounting on a Valve 10
Adjustment of Actuator 11
Operation Test 12
Maintenance and Service 12
Troubleshooting Guide 12
CONTENTS
POWER SUPPLY
INCORRECT
RELAY
POWER SUPPLY
RELAY RELAY RELAY
CORRECT

VSI Series 1000-X Electric Actuator
Operation and Maintenance Manual
3
1 Side Gear Cover 11 Worm Shaft
2 Top Wiring Cover 12 Override Socket
3 Handwheel* 13 Reducing Gear Group
4 Front Wiring Cover 14 Capacitor
5 Push Button* 15 Open Cam Lock Screw
6 Conduit Plugs 16 Close Cam Lock Screw
7 Hex Handle 17 Position Indicator
8 Hex Handle Bracket 18 SPDT Limit Switches
9 Travel Stop Nut 19 Heater
10 Travel Stop Screw 20 Position Pointer
*Optional on select sizes/models
COMPONENT NAMES
1
2
3
4
5
6
7
8
9
10
111213 161514
17
18
19
20

VSI Series 1000-X Electric Actuator
Operation and Maintenance Manual
4
S
O
32
36
Ø70
Ø70
Ø50
45°
4-M6
4-M8
Evenly Distributed
Evenly Distributed
Direct Mount Parameters
Square Shaft
Mounting Flanges
Stem Height
14 x 14
F05 F07
Height ≤32mm
113[114]
63[66] 49[48] 24
S
O
160[162]
83[82] 77[80]
125[126]
Fig. A
1005-X DIMENSIONS [1005-XL DIMENSIONS]
1005/S-X DIMENSIONS [1005/S-XL DIMENSIONS]
1005-X AND 1005-XL SPECIFICATIONS
Power Supply 24 VAC 110 VAC 220 VAC
Motor Power 10W
Rated Current 1.7A 0.24A 0.16A
Max. Current 1.9A 0.34A 0.17A
Standard Torque 443inlb/50NM
Run Time 1005-X: 17 ± 0.5 sec, 1005-XL: 21 ± 0.5 sec
Turning Angle 90° Adjustable ± 5°
Total Weight* 6.00lbs/2.72kg
Insulating Resistance 100MΩ/250VDC 100MΩ/500VDC
Overvoltage Withstanding 500VAC - 60 sec 1500VAC - 60 sec
Protection Class IP67 NEMA 4X
Installation Angle At or above the centerline of pipe. See Fig. A
Ambient Temperature -22°F to +140°F (-30°C to +60°C)
Ambient Humidity ≤95% Relative Humidity
Duty Cycle 80%
Options Hand-crank Override
*Weight may vary with selected options
OVERALL DIMENSIONS AND SPECIFICATIONS FOR 1005-X
AND 1005-XL

VSI Series 1000-X Electric Actuator
Operation and Maintenance Manual
5
Direct Mount Parameters
Square Shaft
Mounting Flanges
Stem Height
17 x 17
F05 F07
Height ≤32mm
126
71 55 24 95.5
196
100.5
129
S
O
Ø70
Ø50
4-M8
4-M6
45°
Evenly Distributed
Evenly Distributed
Ø90
32 33
S
O
Fig. A
1010-X SPECIFICATIONS
Power Supply 24 VAC 110 VAC 220 VAC
Motor Power 25W
Rated Current 2.11A 0.57A 0.35A
Max. Current 2.40A 0.81A 0.52A
Standard Torque 885inlb/100NM
Run Time 24.5 ± 0.5 sec
Turning Angle 90° Adjustable ± 5°
Total Weight* 9.10lbs/4.13kg
Insulating Resistance 100MΩ/250VDC 100MΩ/500VDC
Overvoltage Withstanding 500VAC - 60 sec 1500VAC - 60 sec
Protection Class IP67 NEMA 4X
Installation Angle At or above the centerline of pipe. See Fig. A
Ambient Temperature -22°F to +140°F (-30°C to +60°C)
Ambient Humidity ≤95% Relative Humidity
Duty Cycle 80%
Options Handwheel Override, Motor PushbuttonX
*Weight may vary with selected options
X NA on 24VAC Units
OVERALL DIMENSIONS AND SPECIFICATIONS FOR 1010-X

VSI Series 1000-X Electric Actuator
Operation and Maintenance Manual
6
158
95 63 24
121
255
134
148
45
48
Ø125
Ø102
Ø70
4-M10
Evenly Distributed
4-M8
Evenly Distributed
45°
Direct Mount Parameters
Square Shaft
Mounting Flanges
Stem Height
27 x 27
F07 F10
Height ≤45mm
Fig. A
OVERALL DIMENSIONS AND SPECIFICATIONS FOR 1020-X THRU 1060-X
1020-X/1040-X/1060-X SPECIFICATIONS
Power Model 1020-X 1040-X 1060-X
24VAC
Motor Power 40W 40W
NA
Rated Current 3.7A 6.8A
Max. Current 3.9A 7.25A
Total Weight* 19.9lbs/9.03kg 21.4lbs/9.71kg
110VAC
Motor Power 40W 90W 90W
Rated Current 0.65A 1.12A 1.18A
Max. Current 1.68A 3.41A 3.60A
Total Weight* 19.4lbs/8.80kg 20.9lbs/9.46kg 20.9lbs/9.463kg
220VAC
Motor Power 40W 90W 90W
Rated Current 0.37A 0.57A 0.60A
Max. Current 0.78A 1.78A 1.87A
Total Weight* 19.7lbs/8.91kg 21.2lbs/9.59kg 21.1lbs/9.55kg
Standard Torque 1,770inlb/200NM 3,540inlb/400NM 5,310inlb/600NM
Run Time 28.5 ± 0.5 sec 27.5 ± 0.5 sec 34.5 ± 0.5 sec
Turning Angle 90° Adjustable ± 5°
Insulating Resistance 24VAC: 100MΩ/250VDC 110/220VAC: 100MΩ/500VDC
Overvoltage Withstanding 24VAC: 500VAC - 60 sec 110/220VAC: 1500VAC - 60 sec
Protection Class IP67 NEMA 4X
Installation Angle At or above the centerline of pipe. See Fig. A
Ambient Temperature -22°F to +140°F (-30°C to +60°C)
Ambient Humidity ≤95% Relative Humidity
Duty Cycle 80%
Options Handwheel Override, Motor PushbuttonX
*Weight may vary with selected options X NA on 24VAC Units

VSI Series 1000-X Electric Actuator
Operation and Maintenance Manual
7
148
310
162
165
54
Ø135
56
130
217
87 24
Ø140
Ø102
45°
4-M10
Evenly Distributed
4-M16
Evenly Distributed
Direct Mount Parameters
Square Shaft
Mounting Flanges
Stem Height
36 x 36
F10F14
Height ≤54mm
Fig. A
1100-X/1160-X/1250-X SPECIFICATIONS
Power Model 1100-X 1160-X 1250-X
110VAC
Motor Power 120W 140W 140W
Rated Current 1.75A 1.93A 1.93A
Max. Current 3.80A 3.95A 3.95A
Total Weight* 40.8lbs/18.5kg 41.8lbs/19.0kg 41.9lbs/19.0kg
220VAC
Motor Power 140W 140W 140W
Rated Current 0.94A 0.98A 0.98A
Max. Current 2.12A 2.20A 2.20A
Total Weight* 41.2lbs/18.7kg 41.9lbs/19.0kg 42.4lbs/19.2kg
Standard Torque 8,850inlb/1,000NM 14,160inlb/1,600NM 22,125inlb/2,500NM
Run Time 26.5 ± 0.5 sec 38.5 ± 0.5 sec 63.5 ± 0.5 sec
Turning Angle 90° Adjustable ± 5°
Insulating Resistance 100MΩ/500VDC
Overvoltage Withstanding 1500VAC - 60 sec
Protection Class IP67 NEMA 4X
Installation Angle At or above the centerline of pipe. See Fig. A
Ambient Temperature -22°F to +140°F (-30°C to +60°C)
Ambient Humidity ≤95% Relative Humidity
Duty Cycle 80%
Options Handwheel Override, Motor Pushbutton
*Weight may vary with selected options
OVERALL DIMENSIONS AND SPECIFICATIONS FOR 1100-X THRU 1250-X

VSI Series 1000-X Electric Actuator
Operation and Maintenance Manual
8
The opening and closing operation of the actuator
is regulated with the travel limit switches which
interrupt the power circuit to the motor. The two
power legs and a common are needed in order to drive
the actuator open or closed. Two SPDT switches are
provided to give end of travel status indication. For
all units, except the 1005-X, a manual override push
button is included to isolate motor for manual hand
crank or wheel operation.
Y&G
GREY
BROWN
WHITE
BLACK
RED
BLUE
HEATER
OLS
CLS
C
M
PE
FULL CLOSE SIGNAL
FULL OPEN SIGNAL
COM
OPEN
CLOSE
KL
N
PUSH BUTTONTHERMAL PROTECTOR
ACTUATOR
FIELD WIRING
GND 7
6
5
4
3
2
1
Power must be removed from actuator using manual
override pushbutton, or disconnect/circuit breaker for the
1005-X, before manual operation. If manual operation is
attempted with power connected actuator handwheel or
crank may rotate and cause personnel injury.
WARNING
Models Contact Ratings
AC Voltage DC Voltage
1005-X and 1005-XL 3A/250VAC NR
1010-X thru 1250-X 15A/250VAC 0.6A/125VDC
1. Power Common
2. Close Operation (Power Hot)
3. Open Operation (Power Hot)
4. Auxiliary Contact Common
5. Auxiliary Contact Open Status
6. Auxiliary Contact Close Status
7. Chassis Ground
TERMINAL WIRING
ELECTRICAL WIRING CONNECTION
POWER SUPPLY REQUIREMENTS
• Power supply for the corresponding unit must
meet the electrical requirements for voltage and
current ratings as show in its specifications.
• The power supply tolerance shall be as follows:
Rating 24 V 110V 220V
Range 21.6V-26.4V 99V-121V 198V-242V
Frequency 60 Hz
Rating 24V 110V 220V
1005-X & 1005-XL 5A 3A 2A
1010-X 7A 5A 3A
1020-X & 1040-X 10A 7A 5A
1060-X NA 7A 5A
1100-X, 1160-X, & 1250-X 10A 7A
Circuit Breaker Fuses
Recommended fuses for circuit breakers are as
follows:
Model Transformer
1005-X & 1005-XL 50VA
1010-X 50VA
1020-X 150VA
1040-X 200VA
24VAC Transformers
Minimum recommended 120V/24V power transformer
ratings are as follows:
Care should be taken sizing and wiring 120V/24V
transformers, considering wiring transformer primaries in
series will split voltage and in parallel will split current.
~V2IN
~V1IN
~VIN TOTAL
=V1IN+V2IN
~V2OUT
~V1OUT

VSI Series 1000-X Electric Actuator
Operation and Maintenance Manual
9
APPLICATION REQUIREMENTS
•Series 1000-X units may be installed in indoor or
outdoor conditions up to IP67 or NEMA 4X
Series 1000-X units are not rated for hazardous
environments and caution should be taken to avoid
flammable and explosive environments.
WARNING
• Manual override operation and maintenance tasks
should be taken into consideration when installing
units.
• Ambient temperature should be within -22°F to
+140°F.
Installation Conditions
• Care should be taken to prevent the heat of the
working medium from raising the actuator above
its rated ambient temperature limits.
• When the temperature of the working medium
exceeds the actuator’s rated temperature limits, a
thermal coupling shall be installed to reduce heat
transfer between the medium and the actuator.
Medium temperatures above 175°F require the use of
bracket and thermal isolating coupling in lieu of direct
mounting to valve.
WARNING
Medium/Radiant Heat
• Refer to Figure 1.1 and 1.2 when connecting
conduit to Series 1000-X actuators.
• Conduit entries are ½” NPT. All entry fittings
should be sealed watertight.
• Best practice when connecting conduit to Series
1000-X actuators is to run the conduit from below
the actuator upward to prevent condensation from
conduit working into the actuator; as shown in
Figure 1.2.
Conduit and Cable Installation
• If actuator must be installed below conduit, a drip
loop or drain should be provided to allow any water
to exit the piping.
Conduit and Cable Installation (Cont.)
Waterproof
cable connector
Branch
Connector
Plastic tube
Seal Ring
Cable
Lock Nut
ø9 ~ ø11
Figure 1.1
Figure 1.2
• Refer to Figure 2 for installation of cable directly
into unit without the use of conduit.
• The outer diameter of the cable shall be Ø9mm-
Ø11mm.
• Use of cable smaller than specified may allow
water to enter the unit and damage the electronics.
• When possible, power wiring and signal wiring
should be routed through separate conduit entries;
all units have two conduit entries.
Figure 2

VSI Series 1000-X Electric Actuator
Operation and Maintenance Manual
10
MOUNTING ON A VALVE
1. NOTE: Direct mounting the actuator removes the
bracket and coupling from the mounting process,
but the remainder of the process remains the
same.
2. Rotate valve to fully closed position. Ensure that
the valve rotates freely with no obstruction.
3. Using the proper bolts attach the bracket to the
valve – tighten only loosely.
4. Apply grease or anti-seize to the valve shaft and
place the coupling onto the valve stem.
5. Using the manual override handle or handwheel,
rotate the actuator to the fully closed position so
that the position indicator displays “SHUT”.
6. Apply grease or anti-seize to the coupling at the
actuator interface.
7. Place the actuator onto the bracket, aligning the
coupling drive and actuator.
8. Attach the bracket with proper bolts and tighten
all bolts. If bolt holes are not aligned, but within
Installation of Actuator to Valve
5° alignment, rotate actuator handwheel to move
actuator into alignment.
9. Drive the actuator using the manual crank or
handwheel and confirm hat the valve rotates
without obstruction. Ensure the valve is fully open
as the actuator rotates to the full open position
• If using your own bracket or one provided by third
party supplier, ensure that the materials provided
are manufactured professionally and meet the
requirements of Figure 3.
• The coupling valve and actuator drive ends must be
absolutely coaxial to prevent damage to actuator.
• Poor locating of bolt holes in the bracket may
cause improper indexing of the valve and actuator,
preventing the actuator from fully opening or
closing the valve.
• Only tighten bolts after the actuator, bracket, and
valve have been properly aligned.
Mounting Tips
The coaxiality between axes A andBshall not exceed 0.2mm.
Figure 3 Figure 4

VSI Series 1000-X Electric Actuator
Operation and Maintenance Manual
11
ADJUSTMENT OF ACTUATOR
1. Using the manual handwheel or hand crank, drive the
valve to the fully closed position. Visually inspect the valve
disc/ball to ensure it is fully closed, but not over-rotated
close.
2. If the dome indicator does not indicate fully close remove
the top wiring cover using a screwdriver. Loosen the
center Phillips head screw holding the dome indicator and
rotate the indicator to the correct position. Re-tighten the
screw to secure the dome indicator.
3. Using a multi-meter or test indicator light test continuity
between the closed limit switch contacts, 4 and 6 on the
terminal block. If electric test equipment is not available,
listen for the audible click of the limit switches.
Switch Adjustment
4. If the contacts indicate continuity (switch activated):
a. Using a 2mm Allen wrench, rotate the closed position
regulating shaft (S) in the counterclockwise direction
until the switch deactivates.
b. Then rotate the close regulating shaft clockwise until
the switch reactivates.
5. If the contacts do not indicate continuity (switch
deactivated)
a. Using a 2mm Allen wrench, rotate the closed position
regulating shaft (S) in the clockwise direction until the
switch activates.
6. Repeat steps 1-5 for the open position, testing for
continuity between terminals 4 and 5 on the terminal
block and using the open position regulating shaft (O).
Scale plate
Dome indication
Full-open position
Full-close position
Lock screw
Opening gear
Shut position regulating shaft
Open position regulating shaft
S(Red) O(Green)
D2
D1
O
S
K1
K2
K3
K4
Open-direction  middleposition
Close-directionmiddleposition
Micro-switch
Clockwise
Stroke dog
Counter-
Clockwise Clockwise
Regulang sha
Figure 4
1. Using the manual override handle or handwheel, rotate the valve in
the closed direction until the feedback indicates a current or voltage
that correlates with fully closed as established in the controller
adjustment section. Rotate handwheel or crank in close direction
an additional 1/2 turn.
2. Loosen the lock-nut on the left side of the unit and rotate the
adjusting screw clockwise using an Allen wrench until the
screw comes into contact with the stopper, then back off ½ turn
counterclockwise. Tighten lock nut to finish close mechanical stop
adjustment.
3. Repeat steps 1-2 for the open direction.
To prevent damage,
the mechanical stops
should never be used
to limit the rotation of
the actuator. Electrical
WARNING
Figure 7
Electric Limit-Switch
(Full Close Posion)
Electric Limit-Switch
(Full Open Posion)
Mechanical Limit-Switch
for close direcon
Mechanical Limit-Switch
for open direcon
90°
2.5°
2.5°
Figure 6
Adjusng screw for
closing limit-switch
Adjusng screw for
opening limit-switch
Lock Nut
Mechanical
Limit Stopper
MECHANICAL ADJUSTMENT
limit switches are provided to set travel limits. Please refer to
section above to set travel limit.
Actuator Size Lock Nut Adjusting Screw
1005-X & 1005-XL 10mm 3mm
1010-X 13mm 4mm
1020-X to 1060-X 17mm 5mm
1100-X to 1250-X 19mm 6mm

VSI Series 1000-X Electric Actuator
Operation and Maintenance Manual
12
OPERATION TEST
1. Connect wiring per the wiring diagram – located in the front wiring cover.
2. Verify that the valve rotates to the closed position by observing the dome indicator points to the red zero “shut”.
3. Verify that the valve rotates to the open position by observing the dome indicator points to the yellow zero “open”.
4. After all adjustments mentioned above, check the alignment of the dome indicator scale and pointer. If the pointer is not
aligned properly on open and closed position adjust as needed by loosening the dome lock screw and re-tightening.
• All actuators utilize high grade molybdenum based grease for their gears. No lubrication or periodic maintenance is
required.
• If actuators are rarely cycled, periodic rotation operation should be scheduled to check if abnormal conditions are present.
MAINTENANCE AND SERVICE
TROUBLESHOOTING GUIDE
PROBLEM CAUSE REMEDY
Actuator fails to operate Power is not connected Connect power or replace circuit breaker
Manual/Auto pushbutton is not engaged Press manual/auto pushbutton on unit to
engage power
Voltage is too low Check and correct voltage
The actuator is in thermal protection mode
due to over torque situation, or ambient
temperature is too high
Remove over torque conditions. Check valve
to ensure manual movement without sticking.
Cool down ambient temperature. Ensure that
mechanical limits are not keeping actuator
from reaching electrical limits.
Defective micro-switch Replace micro-switch or Contact VSI
Defective capacitor Contact VSI
Actuator does not
feedback for open/
closed position
Defective micro-switch Replace micro-switch or Contact VSI
Improper micro-switch position Readjust the electrical limits according to
instructions
Motor continues to
operate after reaching
limit
Defective micro-switch Replace micro-switch or Contact VSI
Power is not connected correctly Recheck power connections
Improper micro-switch position Readjust the electrical limits according to
instructions
Mechanical limit is out of adjustment Readjust the mechanical limits according to
instructions
Water present inside of
actuator
Inlet power cables are not properly installed
per instructions
Recheck conduit connections
The dome indicator lens is broken Contact VSI
Housing screws are not tightened and sealed Tighten housing screws
Condensation heater not working or not
connected
Check heater connections or Contact VSI
Valve Solutions Inc, LLC
tel: [phone]
fax: [phone]
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