1. Introduction
This manual provides detailed instructions for the installation, operation, and maintenance of the Johnson Controls V-9012-1 E/P Solenoid Relay. This device is designed to convert an electrical signal into a pneumatic output, controlling air pressure based on a 12 VDC input. Please read this manual thoroughly before attempting any installation or operation to ensure safe and efficient use of the product.
2. Safety Information
Adherence to safety precautions is crucial for preventing injury and damage to the equipment. Always follow local codes and regulations.
- Qualified Personnel: Installation and servicing must be performed by qualified and experienced personnel only.
- Electrical Safety: Disconnect all power to the device and associated equipment before performing any wiring or maintenance. Ensure proper grounding.
- Pneumatic Safety: Depressurize all pneumatic lines before making or breaking connections. Wear appropriate personal protective equipment.
- Environmental Conditions: Do not expose the device to conditions outside its specified operating range (temperature, humidity, pressure).
3. Product Overview
The Johnson Controls V-9012-1 is an Electro-Pneumatic (E/P) Solenoid Relay that converts a 12 VDC electrical input into a pneumatic control signal. It is commonly used in industrial applications to manage air pressure for actuators or other pneumatic devices.
3.1. Key Features
- 12 VDC Input for electrical control.
- Solenoid Valve functionality for precise pneumatic regulation.
- Relay operation for switching pneumatic states.
- Maximum input current of 50 mA.
3.2. Components and Labeling
Refer to the image below for a visual representation of the V-9012-1 Solenoid Valve Relay and its key labeled components.
Figure 1: Johnson Controls V-9012-1 E/P Solenoid Relay
The image displays the Johnson Controls V-9012-1 E/P Solenoid Relay. Key labels visible on the device include:
- V-9012-1 E/P SOLENOID RELAY: Identifies the model and type of device.
- PAT 4,770,200 and PAT 4,804,009: Patent numbers associated with the product.
- BO TERM. 1 (RED): Indicates the first electrical terminal, typically for the positive 12 VDC input.
- 12 V.D.C. INPUT (50 mA. MAX.): Specifies the required input voltage and maximum current.
- BO TERM. 2 (BLK) RESISTOR: Indicates the second electrical terminal, typically for the negative connection, and notes the presence of a resistor.
- SUPPLY: The inlet port for the pneumatic supply pressure.
- ACTUATOR: The outlet port for the controlled pneumatic pressure to the actuator.
- +12 V.D.C. PRESS.: Indicates that a +12 VDC input results in a 'PRESS' (pressure) state.
- 0 V.D.C. HOLD: Indicates that 0 VDC input results in a 'HOLD' state.
- -12 V.D.C. EXHAUST: Indicates that a -12 VDC input results in an 'EXHAUST' state.
4. Setup and Installation
Proper installation is critical for the correct functioning of the V-9012-1 Solenoid Relay.
4.1. Pre-Installation Checks
- Verify that the power supply matches the device's requirements (12 VDC).
- Inspect the device for any visible damage from shipping.
- Ensure all necessary tools and fittings are available.
4.2. Mounting
Mount the solenoid relay securely in a location that is free from excessive vibration, moisture, and extreme temperatures. Ensure adequate space for wiring and pneumatic connections.
4.3. Wiring Instructions
Follow these steps for electrical connections:
- Ensure the power source is completely disconnected.
- Connect the positive (+) 12 VDC power supply wire to BO TERM. 1 (RED).
- Connect the negative (-) 12 VDC power supply wire to BO TERM. 2 (BLK). Note that this terminal includes a resistor.
- Verify all connections are secure and properly insulated.
4.4. Pneumatic Connections
Follow these steps for pneumatic connections:
- Connect the main pneumatic supply line to the port labeled SUPPLY. Ensure the supply pressure is within the device's specified operating range.
- Connect the line leading to the pneumatic actuator or controlled device to the port labeled ACTUATOR.
- Check all pneumatic connections for leaks after pressurizing the system.
5. Operation
The V-9012-1 Solenoid Relay operates based on the applied electrical input voltage, controlling the pneumatic output to the actuator.
- +12 VDC Input: When a positive 12 VDC is applied to the input terminals, the relay will enter a 'PRESS' state, allowing supply pressure to flow to the actuator.
- 0 VDC Input: When 0 VDC (no voltage) is applied, the relay will enter a 'HOLD' state, maintaining the current pneumatic output.
- -12 VDC Input: When a negative 12 VDC is applied, the relay will enter an 'EXHAUST' state, releasing pressure from the actuator.
Ensure that the control system provides the correct voltage signals for the desired pneumatic response.
6. Maintenance
The Johnson Controls V-9012-1 Solenoid Relay is designed for reliable operation with minimal maintenance. However, periodic checks can help ensure longevity and optimal performance.
- Routine Inspection: Periodically inspect the device for any signs of wear, corrosion, or damage to the housing, wiring, and pneumatic connections.
- Cleaning: Keep the exterior of the device clean and free from dust and debris. Do not use harsh chemicals or abrasive cleaners.
- Connection Integrity: Verify that all electrical and pneumatic connections remain tight and secure.
- Professional Service: For internal issues or complex repairs, contact a qualified service technician or Johnson Controls support. Do not attempt to disassemble the unit.
7. Troubleshooting
This section provides solutions to common issues that may arise during the operation of the V-9012-1 Solenoid Relay.
| Problem | Possible Cause | Solution |
|---|---|---|
| Device does not respond to electrical input. | No power, incorrect voltage, loose wiring, internal fault. | Check 12 VDC power supply. Verify wiring connections to Terminals 1 and 2. Ensure correct polarity. If problem persists, contact support. |
| Pneumatic output is incorrect or inconsistent. | Insufficient supply pressure, clogged lines, leaks in pneumatic connections, internal valve issue. | Check pneumatic supply pressure. Inspect lines for obstructions or leaks. Ensure correct electrical input for desired pneumatic state. |
| Device is overheating. | Excessive current, improper ventilation, continuous operation beyond duty cycle. | Verify input current does not exceed 50 mA. Ensure adequate airflow around the device. Review application for duty cycle requirements. |
8. Specifications
Technical specifications for the Johnson Controls V-9012-1 E/P Solenoid Relay:
| Parameter | Value |
|---|---|
| Model Number | V-9012-1 |
| Function | E/P Solenoid Relay |
| Input Voltage | 12 VDC |
| Max Input Current | 50 mA |
| Pneumatic States | Press (+12 VDC), Hold (0 VDC), Exhaust (-12 VDC) |
| Manufacturer | JOHNSON CONTROLS |
| Item Weight | 6.4 ounces |
| Date First Available | July 5, 2012 |
9. Warranty and Support
For information regarding product warranty, technical support, or service, please contact Johnson Controls directly through their official website or customer service channels. Keep your purchase receipt and product model number readily available when seeking support.
