Johnson Controls M100C Series User manual

Installation Sheets Manual 121
Motor Actuators Section M
Technical Bulletin M100C
Issue Date 0493
© 1993 Johnson Controls, Inc. 1
Part No. 34-636-70
Rev—
Figure 1: M100
The M100C Series Motor Actuator is used in damper and valve
applications where proportional control from a digital controller is
required.
The M100C has the capability of communicating with Metasys
AHU/UNT or DSC1000 controllers depending on the position of the 8-pin
DIP switch. Other functions that are user programmable include master or
slave configuration, direct or reverse acting mode, the address to which the
actuator will respond and the linear or S-curve response characteristic.
M100C Series of Motor Actuators with
Proportional Digital Control Signal Input and
R81C Interface Board
Applications

2 M Motor Actuators—M100C Series of Motor Actuators
The following table lists the torque rating for each model
(MXXXCYZ—where X = Model No.):
Table 1: Torque Ratings
MODEL DESCRIPTION
M110 25 in·lb (2.8 N·m) Torque with Spring Return
M120 35 in·lb (4.0 N·m) Torque, Non-Spring Return
M130 50 in·lb (5.6 N·m) Torque with Spring Return
M140 75 in·lb (8.5 N·m) Torque, Non-Spring Return
M150 150 in·lb (17 N·m) Torque, Non-Spring Return
The following table lists the input voltage options available
(MXXXCYZ—where Y = Power Source Option):
Table 2: Input Voltage Options
OPTION DESCRIPTION
A120 VAC
D240 VAC
G24 VAC
H24 VAC 1:1 Isolation
The following table lists the factory mounted accessories available
(MXXXCYZ—where Z = Accessory Option):
Table 3: Factory Mounted Accessories
OPTION DESCRIPTION
ANo auxiliary switch
BOne SPDT switch S91DJ-1 installed on auxiliary end of M100
CTwo SPDT switches S91EJ-1 installed on auxiliary end of M100
DS91 Potentiometer (1000 ohm) installed on auxiliary end of M100
M100C Actuators receive and interpret digital commands from a
controller for accurate positioning of the output shaft. The M100CAA-2 is
a dual direct and reverse action model replacing the M100CAA-1 (direct
acting only) and M100DAA-1 (reverse acting only) models.
The M100C Motor Actuator travel is factory set at 90 degrees and is field
adjustable from 65 to 270 degrees.
The timing of the actuator is 38 seconds for 90 degree rotation and
60 seconds for 160 degree rotation.
Torque
Power Source
Factory Mounted
Accessories
Control Input
Travel and Timing

MMotor Actuators—M100C Series of Motor Actuators 3
LOAD END
10°(AX)
Direction of
Drive Rotation
COM to CCW Shorted
Drive Shaft
Y20A1-15
Keyway Zero Reference
Position
Direction of Drive
Rotation COM to CW Shorted
Figure 2: Direction of Rotation
All reference to the direction of rotation is when viewing the load end as
stamped on the actuator housing shown in Figure 2. From this view, the
Counterclockwise (CCW) limit is the zero reference.
The actuators are factory set at zero position which is 10 degree Clockwise
(CW) from vertical (see Figure 2) and for 90 degree clockwise travel.
When using Y20 linkage kits, each 15 degrees of actuator rotation results
in 0.1 inch (2.54 mm) of linear movement of the rack assembly.
1.69
43
4 Mounting Slots
.875
22.23
5.64
143 4.88
124
4.00
102
4.81
122
.56
14 .266
6.76
7.28
185
.45
12 1.50 38
1.31
33
3.31
84
4.65
118
.29
7
.38
10
.03
.76
5.81
148
1.75
45
.16
4
4.38
111
2.50
641.25
32
4 Holes
1.27
32
.97
25
.51
13
5.13
130
2.56
65
Top View
Load End Auxiliary End
Side View
M100PB13.drw
Figure 3: M100 with Spring Return Dimensions
Figure 3 shows the dimensions for a standard M100 Series Motor
Actuator. Additional space is to be allowed for options such as a switch
kit (two inches additional length at auxiliary end).
Direction of
Rotation
Dimensions

4 M Motor Actuators—M100C Series of Motor Actuators

MMotor Actuators—M100C Series of Motor Actuators 5
Installation Procedures
•screwdriver, Phillips-head (No. 1 or 2)
•screwdriver, flat-blade, 1/8 inch tip
Note: All series M100 motor actuators are for use only as operating controls.
Where an operating control failure would result in personal injury
and/or loss of property, it is the responsibility of the user to add
devices (safety, limit controls) or systems (alarm, supervisory systems)
that protect against and/or warn of control failure.
•Follow NEC and local electrical codes.
•Disconnect all power supplies.
•Observe the following ranges and limitations:
Power Requirements 24 VAC at 50/60 Hz, 25 VA spring return, 20 VA non-spring return
Ambient Operating
Conditions -40° to 125°F (-40° to 52°C), 90% RH non-spring return
-35° to 125°F (-37° to 52°C), 90% RH spring return
Ambient Storage
Conditions -40° to 125°F (-40° to 52°C), 90% RH
•Do not install the motor actuator in atmospheres with explosive vapors
or escaping gases, or where vapors having deteriorating properties
might attack the actuator’s metal parts.
•Wiring into return air systems should be sealed to prevent aspiration of
corrosive air into the actuator.
Upright mounting of the motor actuator is required.
When mounting on a valve, do not mount below the horizontal plane of
the valve piping to prevent damage to the motor actuator if the valve leaks
or develops condensation.
Valve medium temperatures above 250°F (121°C) are permissible only if
the maximum ambient temperature at the motor actuator is less than
105°F (41°C).
Locate the motor actuator where the shaft and wiring terminals are accessible.
Follow installation procedures for the linkage kit used to couple the motor
actuator and the controlled device.
When not utilizing a damper or valve linkage kit, use four 1/4 x 1 inch
bolts for mounting the motor actuator.
Perform travel adjustments described in the Travel Adjustment section as required.
Tools Needed
Precautions and
Code
Requirements
Mounting

6 M Motor Actuators—M100C Series of Motor Actuators
To install the R81 board kit in a Series M100X base motor actuator or
remove and/or replace the electronic circuit boards in an existing Series
M100 motor actuator, proceed as follows:
!
CAUTION: Disconnect the electrical power supply before
attempting to remove the wiring connections and the
boards to prevent possible electrical shock or damage
to the equipment.
1. Remove the motor actuator’s top cover by loosening the two cover
screws.
2. Verify that power is removed from the unit and disconnect all wiring
connections to the terminal board.
3. Loosen the bracket screw and remove the bracket.
4. Pull the vertical board straight upward. Be careful not to bend or
damage the pin terminals.
5. Remove the two screws from the terminal board.
6. Remove the terminal board by grasping the receptacles and lifting
straight upward being careful not to bend or damage the pin terminals.
1. Install terminal board by carefully placing the terminal receptacles onto
the pin terminals.
Terminal
Board
Terminal
Board Screws
Receptacles
Pin Terminals
M100C01
Figure 4: Terminal Receptacles
R81 Circuit Boards
Removing Boards
Installing Boards

MMotor Actuators—M100C Series of Motor Actuators 7
2. Fasten the terminal board in place using the terminal board screws that
are supplied with the R81 kit.
Vertical Board
with Attached Cover
M100C02
Terminal
Receptacles
Pin
Terminals
Figure 5: Installing Vertical Board
3. Install the vertical board (includes ribbon cable attached to the cover
mounted board) by carefully placing the terminal receptacles onto the
pin terminals as shown in Figure 5.
Note: Align all pins within the receptacle.
Bracket
M100C03
Figure 6: Installing Bracket

8 M Motor Actuators—M100C Series of Motor Actuators
4. Place the bracket supplied with the motor actuator over vertical board
and fasten the bracket in place with captive screw as shown in
Figure 6.
MODEL NO.
M150 X GA-1
Base Actuator
Requires R81 Electronic Board Kit
C
This Model Contains
R81CAA-2
Electronic Board Kit
Identification
Label
M100C04
Figure 7: Installing Identification Label
5. Install the adhesive backed label supplied in the R81 kit.
IMPORTANT:As shown in Figure 7, locate the label on the insulation
barrier. The letter on the R81 label will complete the
number that identifies the Series M100 with the R81
installed.
6. Configure the switch settings as required by installation specifications
and shown in the Calibration Procedures section.
7. Install the motor actuator if it is not already mounted.
8. Make control and 24 VAC wiring connections as shown in the Control
Wiring section.
9. Turn on power supply.
10. Cycle the motor actuator using the Y199 tester or controller to check
operation.

MMotor Actuators—M100C Series of Motor Actuators 9
!
CAUTION: Disconnect the electrical power supply before wiring
the motor actuator to avoid possible electrical shock
or damage to the equipment. Always disconnect the
24 VAC power supply before attempting to make any
wiring connections.
Make all wiring connections using copper conductors only. Wire in
accordance with National Electric Code and local regulations.
M100C05
Wiring
Compartment
Figure 8: Wiring Junction Box Attached to M100
Make all splices in junction boxes using approved solderless connectors,
or by soldering and then taping the connections. Locate all splicing and
excess wiring outside the motor actuator wiring compartment. If desired,
add a standard electrical box to the wiring compartment of the motor
actuator as shown in Figure 8.
Runs less than 50 feet (15 m) long require no shielded cable. Avoid
running low voltage control wiring in the same conduit pipe as line voltage
wiring or other conductors that supply highly inductive loads (contactors,
coils, motors, generators, etc.).
If the control wiring is over 50 feet (15 m) long, run in a common conduit,
or near inductive loads, the use of shielded cable is recommended. Use 22
AWG gauge, Beldfoil 8761 or equivalent for runs up to 250 feet (76 m).
For 250 feet (76 m) to 500 feet (152 m) runs, use 18 AWG gauge Beldfoil
8760 or equivalent.
Control Wiring

10 M Motor Actuators—M100C Series of Motor Actuators
24 VAC
Power
Supply
CW
CCW
COM
BUS
T2
T1
M100C
Level 1 Bus or
Zone Bus
from Controller
Tape off the shield
end at the motor
actuator. Connect
the shield only at
the controller.
M100C06
Figure 9: Typical Single Unit Wiring Diagram
Connect the shield only at the controller. Do not connect shield to any
other point.
20
21
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
C500AAC-1
Power
Supply
CW
CCW
COM
BUS
T2
T1
CA-3
CW
CCW
COM
BUS
T2
T1
CA-1
CW
CCW
COM
BUS
T2
T1
HMA-2
CW
CCW
COM
BUS
T2
T1
CA-4
CW
CCW
COM
BUS
T2
T1
CA-2
Power
Supply
Power
Supply
TE-1
TE-2
TE-3
TE-4
AFS-1
AFS-2
TC-1
HT-1
HT-2
Power
Supply
Power
Supply
Power
Supply
Power
Supply
Power
Supply
TZ-9
TZ-6
TZ-4
TZ-5
TZ-7
TZ-3
TZ-2
12 3 45
OFF
ADDRESS 23
12 345
OFF
ADDRESS 24
12 345
OFF
ADDRESS 20
12 34 5
OFF
ADDRESS 14
45 678
OFF
ADDRESS 17
TZ-1
*
**
**
**
**
**
*Shield is connected to Common ofthe controller.
**Loose ends of the shield are to be taped off as
required. Do not connect to ground.
Figure 10: Typical Parallel Wiring Diagram All Master Actuators
Figure 10 shows a typical wiring diagram for a parallel system with all
motor actuators set as master. Each motor actuator has a separate address.

MMotor Actuators—M100C Series of Motor Actuators 11
20
21
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
C500AAC-1
Power
Supply
CW
CCW
COM
BUS
T2
T1
CA-1
CW
CCW
COM
BUS
T2
T1
CA-4
CW
CCW
COM
BUS
T2
T1
CA-2
Power
Supply
Power
Supply
TE-1
TE-2
TE-3
TE-4
AFS-1
AFS-2
TC-1
HT-1
HT-2
Power
Supply
Power
Supply
Power
Supply
TZ-4
TZ-5
TZ-6
TZ-3
TZ-2
45 678
OFF
ADDRESS 17
TZ-1
*
**
**
**
*Shield is connected to Common ofthe controller.
**Loose ends of the shield are to be taped off as
required. Do not connectto ground.
Slave
Master
45 678
OFF
ADDRESS 17
Slave
45 678
OFF
ADDRESS 17
Figure 11: Typical Parallel Wiring Diagram All Master Actuators
Figure 11 shows a typical wiring diagram for a parallel system with one
motor actuator set as master and the others as slaves. Each motor actuator
has the same address.
To wire the motor actuator:
1. Loosen the two screws securing the top cover and remove the top
cover for access to the wiring terminals.
2. Use a hammer and punch to drive out one of the access hole covers.
3. Install the conduit connector to the motor actuator and secure using the
conduit nut provided with the connector.
4. Connect the controller to the terminals located in the wiring
compartment as shown in Figures 9 and 10.
5. Connect 24 VAC to terminals T1 and T2.
Note: To avoid potential miswiring and electrical problems, the use of
separate transformers for each M100 is required.
Note: For further information on any of the controllers illustrated,
reference the applicable controller literature.

12 M Motor Actuators—M100C Series of Motor Actuators

MMotor Actuators—M100C Series of Motor Actuators 13
Calibration Procedures
M100C09
COMTI
CW
CCW
BUS
T2
12 3
OFF
4 5 678
Figure 12: Digital Circuit Board
Make field adjustments using the 8-position DIP switch located on the
cover-mounted circuit board as shown in Figure 12. The position of these
switches specifies the operating parameters as shown in Table 4.
Table 4: Switch Settings
SWITCH NUMBER ON FUNCTION OFF FUNCTION
1Master Slave
2Linear S-curve
3Direct Acting Reverse Acting
4L1 Bus Zone Bus
5Address Selection* Address Selection*
6Address Selection* Address Selection*
7Address Selection* Address Selection*
8Address Selection* Address Selection*
*Refer to Master/Slave section (page 14) for complete address selection options.
!
CAUTION: Disconnect the electrical power supply before
attempting to adjust the switch settings.
Switch Settings

14 M Motor Actuators—M100C Series of Motor Actuators
When using multiple dampers and/or valves for similar functions, set the
actuators to respond to the same controller address. This requires that one
actuator be set as the master and the remaining actuators at that address be
set as slaves.
Note: Select only one master actuator for each address. Set single
actuators not involved in slaving as master except when connected
to the Metasys System.
Both the master and slave actuators receive commands from the controller,
but only the master actuator has continuous 2-way communication with
the controller. The slave actuators send response messages back to the
controller only if an error occurs at the slave.
Use Switch 1 to select whether the actuator will respond as a master or
slave. Positioning the switch to OFF sets the actuator for master operation
and positioning the switch ON sets the actuator for slave operation.
Valves and dampers with non-linear flow characteristics have the greatest
amount of flow occurring in the early portion of travel. The S-curve
switch setting allows the actuator to respond in a non-linear manner. The
actuators travel in relation to the input command is smaller during the
initial 20% of command, increases during the mid 60% of command, and
then decreases during the final 20% of the command.
Figure 13: Linear Characteristics
Master/Slave
Linear/S-Curve Flow
Characteristics
0%
0%
100%
Controller Command 100%
20%
40%
60%
80%
20% 40% 60% 80% 0%
0%
100%
Controller Command 100%
20%
40%
60%
80%
20% 40% 60% 80%
m100C09

MMotor Actuators—M100C Series of Motor Actuators 15
Figure 14: S-Curve Characteristics
Use Switch 2 to select the response. Positioning the switch to OFF sets
the actuator for linear operation as shown in Figure 13. Positioning the
switch to ON sets the actuator for S-curve operation as shown in
Figure 14.
The M100C is factory calibrated for direct action where a 0 to 100%
command input will provide a CW shaft output (0% = full CCW and
100% = full CW) as viewed from the load end. Switch 3 is set to OFF.
Reverse action where a 0 to 100% command input will provide a CCW
shaft output (100% = full CCW and 0% = full CW) as viewed from the
load end is field selected. Change Switch 3 to ON.
C500 Controllers use the L1 Bus. AHU Controllers use the Zone Bus. Set
Switch 4 to the OFF position to allow the actuator to communicate with a
C500 Controller and to ON to communicate with an AHU Controller.
An address is a numeric code that precedes a controller’s command to a
controlled device. The controlled device will respond only to a command
preceded by its assigned address code number.
The positioning of Switches 5, 6, 7, and 8 provides address information to
the controller. The switches are each positioned such that the sum of their
individual values provides the desired address value.
Configure multiple actuators with a separate address when each one
performs a different function. When they all perform the same function,
set one unit as the master, with the remaining units on that address set as
slaves.
0%
0%
100%
Controller Command 100%
20%
40%
60%
80%
20% 40% 60% 80%
20% Command = 10%
Actuator Rotation
80% Command = 90%
Actuator Rotation
0%
0%
100%
Controller Command 100%
20%
40%
60%
80%
20% 40% 60% 80%
20% Command = 90%
Actuator Rotation
80% Command= 10%
Actuator Rotation
M100C10
Direct/Reverse
Action
L1/Zone Bus
Address Selection

16 M Motor Actuators—M100C Series of Motor Actuators
C500 Controllers are factory programmed for specific applications.
Different models of C500 Controllers may use the same address number
for different functions. For example; the Single Zone C500A Controller
uses Address 17 for the full range heating actuator, but the Three Loop
C500B Controller uses Address 17 for controlling a cooling actuator.
Therefore, before positioning the address switches, refer to the specific
C500 Controller technical bulletin to find the address values that
correspond to the exact motor actuator functions desired.
M100C12
45 678
OFF
Address 10
45 67 8
OFF
Address 11
4 5 678
OFF
Address 12
45 6 78
OFF
Address 13
45 678
OFF
Address 14
45 678
OFF
Address 15
45 6 7 8
OFF
Address 16
4 567 8
OFF
Address 17
45 678
OFF
Address 20
45 678
OFF
Address 21
45 6 7 8
OFF
Address 22
4 567 8
OFF
Address 23
45 678
OFF
Address 24
45 6 7 8
OFF
Address 25
4 567 8
OFF
Address 26
45 67 8
OFF
Address 27
Figure 15: C500 Address Switch Settings
Table 5: C500 Address Switch Values
SWITCH NUMBER ON VALUE OFF VALUE
5010
604
702
801
When selecting L1 Bus, add an additional value of 10 to the total of the
switch settings. For example: to select L1 Address 15, set Switches 6
and 8 OFF and Switches 5 and 7 ON (15 = 0 + 4 + 0 + 1 from the switch
settings and +10 because of L1 Bus selection). Using the switches, any L1
address from 10 to 27 is selectable with the exception of Addresses 18 and
19 that are not available.
C500 Controller
Address Selection

MMotor Actuators—M100C Series of Motor Actuators 17
Full range operation is when the motor actuator will rotate proportionally
through its full travel during 100% of the output command.
When proportional sequencing multiple dampers or valves in applications,
use the Low/High Sequence feature. The low sequence actuator rotates
proportionally through its full travel during the first 50% of the C500
output command. If the demand increases, the high sequence actuator
rotates proportionally through its full travel as the output command
increases from 50% to 100% as shown in Table 6.
Table 6: Full Range or Low/High Sequence Chart
OPERATION C500 CONTROLLER
COMMAND DIRECT ACTION ROTATION REVERSE ACTION ROTATION
0 0 100
Full Range 50 50 50
100 100 0
0 0 100
Low Sequence 50 100 0
100 100 0
0 0 100
High Sequence 50 0 100
100 100 0
Note: The Low/High Sequence feature is available only on some C500
Controllers and is not available on any of the AHU Controllers.
The addresses used by the AHU Controller are 20 through 25. Make the
address assignment during the HVAC PROconfiguration process for
analog outputs. Refer to the HVAC PRO User’s Manual (FAN 637) for
details.
!
CAUTION: The phone jack connector on the terminal board is for
easy, single-point connection of the HVAC PRO
service device (laptop PC). Do not connect any other
device at the phone jack. Connection of another
device at the phone jack may result in damage to the
equipment or wiring.
Full Range or
Low/High Sequence
AHU Controller
Address Selection

18 M Motor Actuators—M100C Series of Motor Actuators
M100C13
45 678
OFF
Address 20
45 6 7 8
OFF
Address 21
4 567 8
OFF
Address 22
45 6 7 8
OFF
Address 23
45 6 7 8
OFF
Address 24
45 67 8
OFF
Address 25
Figure 16: AHU Address Switch Settings
Table 7: AHU Address Switch Values
SWITCH NUMBER ON VALUE OFF VALUE
50—
604
702
801
For selection of Zone Bus, switch 5 must be ON and an additional value
of 20 added to the total of the switch settings. For example: to select L1
Address 25, set Switches 6 and 8 OFF and Switches 5 and 7 ON
(25 = 0 + 4 + 0 + 1 from the switch settings and +20 because of Zone Bus
selection). Usingthe switches, select anyZone address between 20 and 27
although only 20 through 25 are addressable by the AHU Controller.
The M100C is adjustable from 65 to 270 degrees of rotation.
Travel Adjustment The controller sends position commands to the actuator ranging from
0 to 100%. The actuator responds to these commands only over its
selected range of travel.
0%
(CCW)
0%
100%
(CW)
Reverse
Action
Direct
Action
Controller Command 100%
M100C13

MMotor Actuators—M100C Series of Motor Actuators 19
Figure 17: Full Range Rotation
For example: If a direct acting actuator has its travel set at 120 degrees, a
50% command from the controller would position the actuator at 60
degrees of rotation.
A 100% command would position the actuator at 120 degrees of rotation.
For reverse acting actuators with a travel set at 120 degrees rotation, the
50% command positions the motor actuator at 60 degrees rotation and a
command of 100% positions the actuator at 0 degrees of rotation.
The travel adjustment potentiometer mounted on the terminal board
enables positioning of the M100 motor actuator within the range of 65 and
270 degrees rotation. Changing the travel adjustment effects the
Clockwise (CW) rotation limit. Turning the adjustment CW increases the
total travel, and CCW reduces the total travel. To make the adjustments,
use the following procedure or refer to the instructions provided with the
appropriate valve or damper linkage.
1. The travel adjustment potentiometer should be set fully CCW.
2. Remove all control wires.
!
CAUTION: Always turn power off before attempting to make any
wiring changes or connections.
3. Apply 24 VAC between T1 and T2.
4. Jumper terminals COM and CW to drive the motor to the fully CW
position.
5. Slowly rotate the travel adjustment potentiometer CW to increase
motor rotation until the corresponding valve or damper is in the
desired position.
6. Remove the jumper from terminals COM and CW to allow the motor
to return to the full CCW position.
7. Repeat Steps 4 through 6 to provide proper stroking.
8. Make sure that the power is off, and connect the control wires.

20 M Motor Actuators—M100C Series of Motor Actuators
Troubleshooting Procedures
A Y199 tester is required to drive the M100C Motor Actuator when not
connected to the controller.
After installation and wiring are complete, make system settings and apply
power. Cycle the motor actuator using the controller after assembling the
linkage and motor actuator to the valve or damper.
The drive motor and gear train are immersed in oil and sealed in a die cast
case. Therefore, maintenance is not necessary.
Make no field repairs except for replacement of R81 plug-in electronic
board kits. For repair parts or replacement, contact the nearest Johnson
Controls Commercial Systems wholesaler or Systems and Services
Division branch office.
Check Out
Replacement
Controls Group FAN 121
507 E. Michigan Street Installation Sheets Manual
P.O. Box 423 Printed in U.S.A.
Milwaukee, WI 53201