VG1000 Series Forged Brass Ball Valves Installation Instructions1 Refer to the QuickLIT website for the most up-to-date version of this document.ApplicationsThe 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. InstallationInstall VG1000 Series Ball Valves with the actuator at or above the centerline of the horizontal piping, as shown in Figure1.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, Figure6 through Figure11).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:mntposFigure 1: Mounting Positions for Chilled Water and Condensing Atmosphere ApplicationsVG1000 Series Forged Brass Ball ValvesInstallation InstructionsPart No. 14-1201-5, Rev. XIssued December 2018*1412015RevX*14-1201-5 Rev. XVG1000 Series Forged Brass Ball Valves Installation Instructions2For 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 Series Electric Non-Spring Return Actuators Installation Instructions (Part No. 34-636-1220)•M9102-AGA-3S and M9104-xGA-3S Series Electric Non-Spring Return Actuators 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 Valve Actuators 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)•M9000-551Ball Valve Linkage Kit Installation Instructions (PartNo.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 PortB 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 Instructions3VG1841 and VG1845 Series Three-Way Ball Valves have a different port configuration from VG1644 Series Three-Way valves. See Figure2, Figure3, and Figure4 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:VGAtoCPort ACoilPort CCommonPort B BypassFigure 2: VG1841 or VG1845 Series Three-Way Ball Valve (Port A Connected to Port C)Port ACoilPort CCommonPort B BypassFIG:vgBtoCFigure 3: VG1841 or VG1845 Series Three-Way Ball Valve (Port B Connected to Port C)CommonPortNormallyOpen PortNormallyClosed PortFIG:vg1644ccwFigure 4: Top View of VG1644 Series Three-Way Ball Valve (Actuator Fully VG1000 Series Forged Brass Ball Valves Installation Instructions4Press Valve InstallationVG1000 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 InstallationWhen 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 Port A 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 Figure5 for details. Figure 5: Sweat Valve InstallationUse only low meltingtemperature soft solder.Place a wet rag around the neck of the valve.FIG:sv_instVG1000 Series Forged Brass Ball Valves Installation Instructions5See Figure6 for dimension drawings of the Non-Spring Return VA9104 Series Actuated VG1241, VG1245, VG1841, and VG1845 Series NPT End Connection Ball Valves. See Table1 and Table2 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)11.Port A must always be connected to the coil.A (Without Thermal Barrier)A (With Thermal Barrier)BCDEFG1/2 (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)11.Port A must always be connected to the coil.ABCDEFG1/2 (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 Valvewith NPT End Connections Dimensions, in. (mm)2-13/16(71)3-1/2 (89)Clearance RequiredPort MarkingLocationsFIGVA9104X_dims6-1/2(153.5)DAVG1000 Series Forged Brass Ball Valves Installation Instructions6See Figure7 for dimension drawings of the Spring Return VA9203 Series Actuated VG1241, VG1245, VG1841, and VG1845 Series NPT End Connection Ball Valves. See Table3 and Table4 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)11.Port A must always be connected to the coil.A (Without Thermal Barrier)A (With Thermal Barrier)BCDEFG1/2 (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)11.Port A must always be connected to the coil.ABCDEFG1/2 (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 MarkingLocationsFIG:VA9203X_dimsthbr2-7/8(73)3-1/4(82)AD3-1/2 (89)Clearance RequiredVG1000 Series Forged Brass Ball Valves Installation Instructions7See Figure8 for dimensions of the Non-Spring Return VA9300 Actuated VG1241, VG1245, VG1841, and VG1845 Series Ball Valve with Optional M9000-561 Thermal Barrier. See Table5 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)BCDEFG1/2 (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)BDA3-1/2 in. (89 mm)COptional Thermal BarrierOptional Thermal BarrierFIG:Thermal BarrierBPort MarkingLocationsVG1000 Series Forged Brass Ball Valves Installation Instructions8See Figure9 for dimensions of the Non-Spring Return VA9300 Actuated VG1241, VG1245, VG1841, and VG1845 Series Ball Valve with Optional M9000-561 Thermal Barrier and M9300-2 Switch Kit. See Table6 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)BCDEFG1/2 (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)BDFIG:Thermal BarrierCBPort MarkingLocationsVG1000 Series Forged Brass Ball Valves Installation Instructions9See Figure10 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. SeeTable7 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 Size in. (DN)11.Port A must always be connected to the coil.Valve StyleA (With Thermal Barrier)A (Without Thermal Barrier)BCDEFG1-1/4 (DN32)All9-17/64 (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)All9-15/16 (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-way9-31/32 (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/A3-way7-7/8 (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)AB3-1/2 (89)Clearance RequiredGCFBCEPort MarkingLocationsDNext >