Six-way 270° Control Valve and Actuator

Application Guide Code No. LIT-12013209

Issued March 2019

Highlights
• The first of its kind and a unique solution
within the HVAC industry.
• The actuator is the only solution in the
HVAC industry for use with either single wire,
dual wire analog proportional control or dual
wire 24VAC thermostat on/off control.
• Use of the Johnson Controls Six-Way
270° control valve saves considerable energy,
material and labor.

Figure 1: Six-way 270° Control Valve and

VA-9905 Actuator

Contents
Highlights   1
Overview   2
Typical applications   2
Design considerations   3
Benefits   5
Selection   8
Actuator ordering codes   8
Valves ordering codes   8
Accessories ordering codes   8
Actuator technical specifications   9
Valve technical specifications   10

Six-Way 270° Valve & Actuator Application Guide

1
Overview
The 270° Six-way Control Valve and Actuator is the easiest and most efficient way to control heating and cooling
operational modes. The system consists of a single valve and actuator instead of up to four valves and four actuators
or one change over valve and two valves with three actuators. This reduces wired installation requirements and results
in savings on setup and maintenance. The 270° Six-way Control Valve and Actuator uses one coil for heating and
cooling operational modes and eliminates the need for a change over valve to switch to the correct operational mode
circuit. This system simplifies the installation process and results in material and energy cost savings with a true close-
off to isolate heating and cooling circuits. A true close-off eliminates the possibility of cross flows that occur in complex
systems due to miswiring or imperfect software setup in the BAS.

The 270° Six-way Control Valve and Actuator also means that you can use a two-pipe terminal unit instead of a four-
pipe; further reducing operational and maintenance costs without decreasing the unit’s efficiency. The 270° Six-way
Control Valve and Actuator is an optimal solution to manage heating and cooling hydronic circuits and reduce the cost
of the terminal unit. The use of one coil and a two-pipe circuit in the terminal unit saves money and also offers the
following advantages:

• Increases performance by up to 34% in heating mode and 28% in cooling mode.

• Achieves a high temperature Delta T in the hot water circuit because the coil is typically sized for the cooling load.
This significantly reduces flow rates and boiler temperatures for less pumping, increased boiler efficiency, and lower
energy costs.
• The elimination of a coil results in lower initial, distribution, and total costs, and reduces hot water pumping. For some
applications, a lower water temperature also reduces the hot water heater size like those found in larger buildings,
offering further cost savings.
• Lower energy costs due to improved boiler and pumping efficiencies of between 12% and 15%.
• The 270° Six-way control valve represents an easier solution than traditional setups.

Typical applications
Figure 2: Terminal unit applications

Six-Way 270° Valve & Actuator Application Guide

2
Design considerations
The 270° Six-way Control Valve and Actuator is suitable for any terminal unit application where there is a desire to
save costs. The following figure shows three of the most common terminal application types in the market; chilled
beams, fan coils, and direct outside air supply (DOAS) units. The following section describes common, traditional, and
new six-way configurations and the advantages and considerations of each.

Figure 3: Three valves common setup - 2 two-way modulating valves and a three-way two-position valve

Advantages: The system uses a more complex set of contacts, relays, and end switches to ensure water flow in case
of power outage.

Considerations: This system is only on/off flow control. It takes the three-way valve between 25 seconds and 90
seconds to change position. The hot water (HW) and chilled water (CHW) are open to each other during this time.
This action causes a crossflow and pressure differential that reduces the overall efficiency of the system.

Six-Way 270° Valve & Actuator Application Guide

3
 Figure 4: Four valves traditional setup - 2 two-way modulating valves and 2 two-way two-position valves

Advantages: The system uses a more complex set of contacts, relays, and end switches to ensure water flow in case
of power outage and that valves are in the correct open or closed position.

Considerations: This system is only on/off flow control and is a more costly design due to the extra two-way valve,
end-switches, relays, and wiring. The possibility of reversed wiring polarity and reversed software configurations
increases. This situation could lead to cross-flow and could significantly reduce the overall efficiency of the system.”

Figure 5: Six-way modulating valve solution

Six-Way 270° Valve & Actuator Application Guide

4
Advantages: This system uses a less complex setup and provides all the benefits of the four two-way valve solution
but at a lower first cost. The chance of failure decreases due to fewer parts and a less complex controls setup.

Considerations: Both CHW and HW must run the same water solution or treatment. There is also estimated to be a
coils worth of cold water or hot water which transfers into the opposite system. The unit is furnished with a non-spring
return actuator; in the event of power failure, the unit remains in its last position and chilled water could run through
the chilled beam and create condensation.

Fixed Flow Control Considerations

You may need to control the total amount of flow differential between the HW and CHW flows through the use of a
single coil. A fixed flow controller is responsible for maintaining flow regardless of changes in differential pressure.
When a low differential pressure condition occurs, the rubber bladder opens and increases the flow of water through
the system based on the required gallons per minute (GPM). As differential pressure increases the rubber bladder
gets smaller and increases pressure to maintain the required GPM. Typical fixed flow is 0.5 GPM on the heating side
and 2 GPM on the cooling side in a chilled beam application. Johnson Controls offers a range of fixed flow controller
types.
Figure 6: Fixed flow controller type

The following figure illustrates that it is possible to incur more flow than required without the use of a flow controller.
The bold line in the graph is designed pressure. If the system experiences an increase in pressure it is likely the
system will receive more flow which can force heating and cooling loops out of balance. Meanwhile if the system
experiences low pressure it is also possible that heating and cooling loops can become imbalanced. In a low pressure
condition, even if the valve is 100 % open it is not certain the required flow pressure will be achieved. It is best
practice to use a flow control device.
Figure 7: Pressure minus a flow control device

Six-Way 270° Valve & Actuator Application Guide

5
Benefits
The benefits of converting from a traditional setup to one that uses a 270° Six-way Control Valve and Actuator are
many. The following examples illustrate more savings, the following figure demonstrates the relationship between
thermal efficiency and return water temperature. The use of the 270° Six-way Control Valve and Actuator single
coil configuration can significantly reduce boiler water temperature. A typical four-pipe boiler runs at an average of
180°F with a less than 87% efficiency rating. Whereas, a typical two-pipe boiler runs at an average 130°F with an
approximate efficiency of 95% or better.
The transition from a four-pipe to a two-pipe coil system can result in real energy cost savings.

Figure 8: Thermal efficiency curves

The following table illustrates a real life total cost differential between a traditional four-pipe setup and three different
examples of two-pipe configurations. The two-pipe savings options include the use of a six-way valve and illustrate
options to either drop a coil row, adjust water temperature or downsize a unit. The cost savings are noteworthy and
significant. Average savings run between 19% and 46%. This is just one example of how switching from a traditional
setup to a six-way setup can save on the mechanical components of the terminal unit. Beyond the mechanical
savings, users can expect to save between 5% and 10% on energy costs.

Table 1: Typical fan coil savings model

Hot Chilled
water water
Pipe Cost Coil Unit CLG HTG Max
Option configuration (list $) Savings % rows size BTU BTU (F°) (F°) watts
Base
Four pipe $4,916 Base 4 10 22,342 45,518 180/140 45/55 310
Four-pipe system
Option 1 w/six-way
Two pipe $3,848 Over base - 28% 3 10 22,342 43,498 145/105 45/55 310
Drop coil row
Option 2 w/six-way
Two pipe $4,122 Over base - 19% 4 10 22,585 46,498 140/100 47/57 310
Adjust water temps
Option 3 w/six-way
Two pipe $3,357 Over base - 46% 4 8 21,505 43,035 140/100 45/55 233
Unit down size

Six-Way 270° Valve & Actuator Application Guide

6
 Figure 9: 270° Six-way Control Valve vs. competitors 90° control angle and
resolution of flow

The 270° Six-way Control Valve solution provides distinct advantages over a competitors 90° valve:
1) Greater control angle for true modulation of chilled or hot water flow when under proportional control. The 90°
valves essentially can only provide on/off control.
2) Much higher resolution of control via two dedicated analog control inputs. One dedicated to the hot water side of
the valve and the other to the chilled water side of the valve. The entire 0-10V, 2-10V or 4-20mA signal of each wire
controls fine modulation of cold water and hot water flow. The 90° valves generally use a single wire actuation which
cannot provide the same level of control.
3) The Johnson Controls 270° also is configurable for 24VAC thermostat on/off control which allows use with a
standard two wire thermostat.
4) Lastly, the Johnson Controls 270° is also configurable for single wire analog proportional control. The advantage
here is that the 270° valve provides a much greater control angle, 60° vs the industry 25°-30°.

Typical cooling sequence

When a cooling signal occurs, the chilled water 270° Six-way Control Valve begins to modulate open. As the demand
for cooling increases, the chilled water side of the valve continues to open until the discharge fan coil air temperature
reaches 52°F (11ºC). As there is an ongoing call for cooling, the fan modulates toward the maximum cooling fan
airflow. The chilled water increases flow through the 270° Six-way Control Valve as the valve continues to modulate
open for 52°F (11ºC) discharge air temperature. This process continues until the fan reaches the cooling maximum
airflow and the chilled water side of the 270° Six-way Control Valve reaches maximum flow. When the cooling
demand decreases, the sequence begins to reverse.

Deadband
When no demand for either heating or cooling in the space, the fan coil runs at minimum airflow. The 270° Six-way
Control Valve remains in the off or zero flow position.

Typical heating sequence

When a heating signal occurs, the hot water valve begins to modulate open. As the demand for heating increases,
the hot water side of the 270° Six-way Control Valve continues to modulate open as the fan begins to modulate
from deadband towards the maximum heating fan airflow. This process continues until the fan reaches the heating
maximum airflow and the hot water side of the 270° Six-way Control Valve reaches maximum flow. When the heating
demand decreases, the sequence begins to reverse.
Six-Way 270° Valve & Actuator Application Guide

7
Benefits
VA9905 Series Electric Non-Spring Return Actuator

2 analog inputs, 1 analog input and 2 Configurable, programmable or conventional field controllers and
24VAC inputs thermostats. Improves control and precision.
Microprocessor-controlled brushless Provides constant runtime independent of torque and increases lifecycle
DC motor by reducing wear.
Mode configuration switches Permits input signal range selection plus type of control.
Integral cables with colored and Simplifies installation and field wiring.
numbered conductors
Optional integral 1/2 in. (13 mm) Simplify installation and field wiring.
threaded conduit connectors
Plenum-rated models Enables use in other environmental air spaces (plenums) in accordance
with section 300.22(C) of the National Electric Code.
Small footprint Allows application in smaller spaces.
Position Indicator Handle and Manual Allows intuitive indication of valve position and manual shut off.
override
NEMA5/IP54 enclosure Enhances the range of application environments.
Underwriters Laboratories Inc.® (UL), Provides internationally recognized regulatory agency approvals.
CE Mark, and RCM Compliance
Manufactured under International Ensures quality.
Standards Organization (ISO) 9001
quality control standards
100,000 cycles and 2.5 million Ensures reliability over time.
repositions
5-Year warranty Protects consumer investment.

VG1600 Series 270° Six-Way Ball Valves

National Pipe Thread (NPT), British Provides the right valve for a broad range of applications, reduce
Standard Pipe Parallel (BSPP) and installation time while reducing the need for adapters, and increase
Sweat Union Fittings system reliability.
Forged brass body Provides PN16 (300 psi) static pressure rating.
350kPa (50 psi) closeoff pressure Provides tight shutoff.
rating
Ethylene Propylene Diene Monomer Provides a leak-free seal; the packing has been tested and is leak-free
(EPDM) double O-ring stem seal after 100,000 cycles in iron-oxide contaminated water.
Graphite-Reinforced Includes 15% graphite-reinforced ball seats, providing better wear
Polytetrafluoroethylene (PTFE) seats resistance.
Maintenance – free design Performs without failure in excess of 100,000 full stroke cycles in iron-
oxide contaminated water.
Wide selection of styles for a variety Offers various valve configurations with just one valve size.
of applications
Factory- mounted VA9905 Series Reduces installation time, thus reducing overall installation cost
Electric Actuator

Six-Way 270° Valve & Actuator Application Guide

8
Selection
Actuator ordering codes
Code number Name Description
VA9905-KGA-1 Multi-input actuator 5 N·m furnished with 2x0(2)...10V, 1 x Europe/Asia
0(2)... 10V Analog Inputs, 2 x 24V Inputs
VA9905-KGA-2 Multi-input actuator 5 N·m furnished with 2x0(2)...10V, 1 x North America
0(2)... 10V Analog Inputs, 2 x 24V Inputs

Note: Optional 0(4)...20mA control with field furnished 500 ohm 1/4” resistor for proportional control

Valve ordering codes

Code number Name Description
VG1611AF ½ in. BSPP external threads Europe/Asia
VG1641AF ½ in. NPT internal threads North America
VG1671AF ½ in. BSPP external threads and 6x sweat union fitting North America
VG1611BL ¾ in. BSPP external threads Europe/Asia
VG1641BL ¾ in. NPT internal threads North America
VG1671BL ¾ in. BSPP male and 6x sweat union fittings North America

Accessory ordering codes

Code number Name Description
VG1600-01 ½ in. Mounting bracket Europe/North America/Asia
VG1600-02 ½ in. Flow disk kit (2 x flow disk sets and 2 x ring nut) Europe/North America/Asia
VG1600-03 ½ in. Insulation shell Europe/North America/Asia
VG1600-04 ½ in. Sweat union fitting kits (6x sweat union fitting) North America
VG1600-05 ¾ in. Flow disk kit (2 x flow disk sets + 2 x ring nut) Europe/North America/Asia
VG1600-06 ¾ in. Insulation shell Europe/North America/Asia
VG1600-07 ¾ in. Sweat union fitting kits (6x sweat union fitting) North America

Six-Way 270° Valve & Actuator Application Guide

9
Actuator technical specifications
Product description VA9905-KGA-1: Multi-Input signal mode, VA9905-KGA-2: Multi-Input signal mode
Power requirements AC 24 V ±20% at 50/60 Hz, Class 2 (North America) or SELV (Europe), 4.7 VA Running;
DC 24 V ±10% Class 2 (North America) or SELV (Europe), 1.4 W Running.
Transformer sizing ≥6 VA
requirements
Input signal/adjustments 0 (2) to 10 VDC or 0 (4) to 20 mA with field furnished 500 ohm 1/4 W resistor for
proportional control or 24VAC dual wire on/off control.
Control impedance 100K ohm DC, 4.7k ohm AC
Rotation rate 1.5° per second
Cycles 100,000 full stroke cycles; 2.5 million repositions.
Audible noise <35 dBA at 1 m (0.03 in.)
Electrical connections -1 halogen-free -2 plenum-rated
1.2 m (48 in.) halogen free cable with 3.05 m (120 in.) UL 444 type CMP plenum
0.82 mm² (18 AWG) conductors and rated cable with 0.75 mm² (19 AWG cable)
6 mm (0.25 in.) ferrule ends conductors and 6 mm (0.25 in.) ferrule ends
Conduit connections 13 mm NPSM (1/2 in.) threaded conduit connectors with M9300-100 conduit.
Ambient conditions Operating: 0 to 60°C (32 to 140°F), 90% RH, noncondensing.
Storage: -40 to 85°C (-40 to 185°F), 95% RH, noncondensing.
Enclosure IP54/NEMA 5
Dimensions Width: 89 mm (3.5 in.), Height: 74 mm (2.9 in.), Length: 170 mm (6.6 in.)
Shipping weight 0.8 kg (1.75 lb)
Compliance United States: UL Listed, CCN XAPX, File E27734; to UL 60730-1: Automatic Electrical
Controls for Household and Similar Use, Part 1; and UL 60730-2-14: Part 2, Particular
Requirements for Electric Actuators. Plenum Rated (UL 2043). Suitable for use in Other
Environmental Air Space (Plenum) in accordance with section 300.22 (c) of the NEC.
Canada: UL Listed, CCN XAPX7, File E27734; to CAN/CSA E60730-1:02: Automatic
Electrical Controls for Household and Similar Use, Part 1; and CAN/CSA-E60730-2-14,
Particular Requirements for Electric Actuators.

Europe: Johnson Controls declares that this product is in compliance with the essential
requirements and other relevant provisions of the EMC Directive.
IEC 60730-1: Automatic Electrical Controls for Household and Similar Use, Part 1:
General Requirements and IEC 60730-2-14, Automatic Electrical Controls for Household
and Similar Use; Part 2: Particular Requirements for Electric Actuators.

Australia and New Zealand: RCM—Australia/NZ Emissions Compliant

The performance specifications are nominal and conform to acceptable industry standard. For application at conditions beyond
these specifications, consult the local Johnson Controls office. Johnson Controls shall not be liable for damages resulting from
misapplication or misuse of its products.

Six-Way 270° Valve & Actuator Application Guide

10
Valve technical specifications
VG16x1AF VG16x1BL
Total operation angle 270°
Sequence 1 0...>90°
Deadband >90…<180°
Sequence 2 >180…270°
Characteristic curve Linear
ID 10.5 mm 15 mm
Fluid type Water, glycol solutions (max 50%) for HVAC applications
Fluid temperature 5 to 95°C (41 to 203°F)
Nominal pressure PN16 (232 psi)
Close off pressure 350 kPa (50 psi)
Max. differential pressure 240 kPa (35 psi)
Rangeability 100:1
Max. Kv (Cv) 2.3 (2.7) 1/2 in. pipe size 4.5 (5.2) 3/4 in. pipe size
Body Brass CW 617N (UNI EN 12420)
End connection Brass CW 617N (UNI EN 12420)
Balls Brass chrome plated
Stems Brass chrome plated
Ball seat PTFE 15% graphite filled
O-ring EPDM PEROX
Ring nut Brass CW 614N (UNI EN 12164 – UNI EN 12168)
Connections Valve Body with Male 1/2 in. BSPP Valve Body with Male 3/4 in. BSPP
Thread (external) Thread (external)
Valve Body with Female 1/2 in. NPT Valve Body with Female 3/4 in. NPT
Thread (internal) Thread (internal)
1/2 in. Sweat Union Fitting kit 3/4 in. Sweat Union Fitting kit
Shipping weight VG1611AF: 0.7 kg (1.55 lb) VG1611BL: 1.4 kg (3.01 lb)
VG1641AF: 0.8 kg (1.85 lb) VG1641BL: 1.7 kg (3.69 lb)
VG1671AF: 1.0 kg (2.20 lb) VG1671BL: 1.9 kg (4.13 lb)
Flow coefficient Flow control disk
Leakage rate A, 100,000 cycles in iron-oxide contaminated water and air-bubble-tight (EN 12266-1)
Water quality Iron-oxide contaminated water (900 ppm)
Maintenance Maintenance free
Warranty Minimum 5 years

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 shall not be liable for damages resulting from
misapplication or misuse of its products.

This product can expose you to chemicals including lead, which is known
to the State of California to cause cancer, birth defects, or other
reproductive harm. For more information, go to www.P65Warnings.ca.gov.

WARNING: BRASS MAY CONTAIN LEAD

To fulfill our obligations towards Article 33, in accordance to the European REACH Regulation No 1907/2006 EC, we hereby inform you that
this article contains the following Substances of Very High Concern mentioned on the Candidate list:
• Lead

Johnson Controls® is a registered trademark of Johnson Controls.

All other marks herein are the marks of their respective owners. © 2019 Johnson Controls.

Six-Way 270° Valve & Actuator Application Guide

11