Johnson Controls M100G User manual

FANs 121, 1628.3
Product/Technical Bulletin M100G
Issue Date 0394
© 1994 Johnson Controls, Inc. 1
Part No. 34-636-100, Rev. A
The M100G Series Motor Actuator is used in
applications where dampers or valves are to be
modulated open or closed. Typical applications
include:
●
positioning of D-1300 Series Dampers
●
opening and closing a diverting valve
●
positioning a hot water, chilled water, or steam
valve
●
controlling an inlet vane damper on a fan
●
outdoor air, return air, and exhaust dampers
●
face and bypass control
●
blade positioning for variable volume fans
Refer to damper manufacturer’s information to properly
size the damper and actuator. Return to normal
actuators are recommended for use with outdoor air
dampers.
M100G Proportional Motor Actuators
with DC/mA Control Signal Input
R81GAA-2 Interface Board
Features and Benefits
❑Output Versatility Both ends of output shaft can be used for linkage
connections for dampers and full power in both
directions
❑Load Versatility Available in torques of 25, 35, 50, 75, and
150 in·lbs (2.8, 4.0, 5.7, 8.5, and 17 N·m)
❑Travel Adjustment Located in
Top Wiring Compartment Easy field screwdriver adjustment, reduces
installation time
❑R81 Plug-in Electronic
Interface Boards Faster replacement or conversions and when
necessary, shorter service times, reduces
inventory
Figure 1: M100 Series Motor Actuator

2 M100G Product/Technical Bulletin
Operation
Use the jumper selectable, direct and reverse acting
M100G Series Motor Actuators with R81GAA-2 circuit
boards in damper and valve applications for
proportional 0 to 10 VDC or 4 to 20 mA direct or
reverse acting control signals. This unit is a
replacement for existing M100G and M100H motor
actuators.
Note: Spring return models always return
Counterclockwise (CCW) to the zero position
when power is removed.
Travel
Adjust
Span
Adjust
Zero
Adjust
Factory Installed
500 ohm Resistor
Direct
Reverse
W1
Jumpers
Jumper
Positions
9
8
10
X
+DC Input
T1
T2
Direct
Reverse
W1
Figure 2: R81GAA-2 Circuit Board
The board is factory set in direct acting mode for 4 to
20 mA. When direct acting mode is selected, there will
be a Clockwise (CW) action of the motor actuator on
signal increase. When reverse acting mode is
selected by changing the orientation of the jumpers at
W1, there will be a counterclockwise action with a
signal increase. Selecting reverse acting mode will
require calibration.
A 500 ohm resistor with quick-connect terminals is
factory installed between terminal T1 and the DC input
terminal for 4 to 20 mA operation. Use the resistor for
applications with a DC mA current controller. The
resistor must be removed for applications with a DC
voltage controller. An optional 750 ohm resistor
(RES22A-600) is available for 0 to 24 mA control or
use with a JCI N500A controller interface.
Options
The following table lists the torque rating for each
model (MXXXGYZ-2--X = Model No.):
Table 1: Torque Rating
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 (5.7 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 torque ratings listed are relative to 90 degree
actuator rotation. When used with certain linkage
arrangements, a multiplication factor results when
actuator travel is increased up to 270 degrees. See
the linkage instruction sheet for actual forces
developed.
The following table lists the input voltage options
(MXXXGYZ-2--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 (MXXXGYZ-2--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.
DS91PT-1 Potentiometer (1000 ohm) installed
on auxiliary end of M100.

M100G Product/Technical Bulletin 3
Travel and Timing
The M100G Motor Actuator travel is factory set at
90 degrees and is 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.
When using Y20 valve linkage kits, each 15 degrees of
actuator rotation results in 0.1 inch (2.54 mm) of linear
movement of the rack assembly.
Load End
It is preferable that all linkage connections be made to
the drive shaft on the load end of the actuator. The
load end is rated for up to 200 lbs dead weight. The
auxiliary end shaft drive should be limited to load
equivalents of 10 lbs dead weight.
Direction of Rotation
LOAD END
Keyway
Direction of Drive Rotation
Terminal 8 to 9 Shorted
10° (ax.)
Zero Reference
Position
Drive Shaft
Direction of Drive Rotation
Terminal 8 to 10 Shorted
Figure 3: 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 3. From this view, the CCW limit is
the zero reference.
The actuators are factory set at zero position, which is
10 degrees clockwise from vertical (see Figure 3) and
for 90 degrees clockwise travel. Direction of spring
return models is always return to the CCW zero
position.

4 M100G Product/Technical Bulletin
Dimensions
Top View
Load End Auxiliary End
Side View
1.69
43
4 Mounting Slots
0.88
22.23
5.64
143 4.88
124
4.00
102
4.81
122
0.56
14 0.27
6.76
7.28
185
0.45
12 1.50 38 1.31 33
3.31
84
4.65
118
0.29
7
0.38
10
0.03
0.76
5.81
148
1.75
45
0.16
4
4.38
111
2.50
641.25
32
4 Holes
1.27
32
0.97
25
0.51
13 5.13
130
2.56
65
Figure 4: M100 with Spring Return Dimensions
Figure 4 shows the dimensions for a standard M100
Series Motor Actuator. Allow additional space for
options such as a switch kit (two inches additional
length at auxiliary end).
Installation
Tools Needed
●screwdriver, Phillips-head (No. 1 or 2 tip)
●screwdriver, flat-blade, 1/8 inch tip
Precautions and Code Requirements
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.
●Seal wiring to return air systems to prevent
aspiration of corrosive air into the actuator.
Mounting
●Provide four 1/4 x 1 inch bolts for mounting the
motor actuator.
●Upright mounting of the motor actuator is
preferred. This is not always possible and multi-
position mounting is possible as long as the output
shaft is parallel to the floor.

M100G Product/Technical Bulletin 5
●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 to
couple the motor actuator and the controlled
device.
●Perform travel adjustments described in the
C
ommissioning Procedures section on page 9 as
required.
R81 Installation
M100X base motor actuators are provided with no
circuit boards mounted within the unit. Remove the top
cover and proceed to
Installing Boards . To replace the
electronic circuit boards in an existing M100 Motor
Actuator, proceed as follows:
Removing Boards
!
CAUTION: Disconnect the electrical power
supply before attempting to
remove wiring connections and
circuit boards to prevent possible
electrical shock or damage to the
equipment.
1. Remove the motor actuators 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.
Installing Boards
To install the circuit boards:
Terminal
Board
Terminal
Board Screws
Receptacles
Pin Terminals
Figure 5: Terminal Receptacles
1. Install the terminal board by carefully placing the
terminal receptacles onto the pin terminals. The
terminal board engages only the pin terminals on
the right hand side, just below the receptacles
shown.
2. Fasten the board in place using the screws that
are supplied with the R81 kit when installing in
M100X.
Vertical Board
Terminal
Receptacles
Pin
Terminals
Figure 6: Installing Vertical Board
3. Install the vertical board by carefully placing the
terminal receptacles onto the two sets of pin
terminals as shown in Figure 6.
Note: Properly align all pins within the receptacle.

6 M100G Product/Technical Bulletin
Bracket
Screw
Figure 7: Installing Bracket
4. Place the bracket, supplied with the motor
actuator, over the vertical board and fasten the
bracket in place with captive screw through the
terminal board as shown in Figure 7. The bracket
is provided for use with M100X base actuators.
MODEL NO.
M150 X GA-2
Base Actuator
Requires R81 Electronic Board Kit
G
This Model Contains
R81GAA-2
Electronic Board Kit
Identification
Label
Figure 8: Installing Identification Label
5. Install the adhesive backed label supplied in the
R81 kit when being applied to an M100X base
actuator.
IMPORTANT: As shown in Figure 8, 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. Install the motor actuator.
7. Make control and 24 VAC wiring connections.
8. Turn on power supply.
9. Adjust, and check operation.
Wiring
!
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 NEC and local
regulations.
Wiring
Compartment
Figure 9: Attaching Wiring Junction Box 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 9.
Note: Use an electrical box to connect the high
voltage wiring to a Y68 top mounted
transformer.
Runs less than 50 feet (15 m) long require no shielded
cable for the VDC/mA control wiring. Avoid running
low voltage control wiring in the same conduit as line
voltage or 24 VAC wiring or other conductors that
supply highly inductive loads (contactors, coils, motors,
generators, etc.).

M100G Product/Technical Bulletin 7
If the control wiring is over 50 feet (15 m) long, run in a
common conduit, or near inductive loads, we
recommend the use of shielded cable. 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. Connect the shield only at the controller.
Do not connect shield to any other point.
Controller
Power
Supply
(-)
(+)
Factory Installed
500 ohm Resistor
Transformer R81GAA-2
9810 X
+DC Input
Direct
Reverse
W1
24 VAC
T2
T1
Figure 10: Typical Single Unit Wiring Diagram
Note: The factory installed resistor is for a mA
controller and must be removed when a
DC voltage controller is used.
Note: Power the controller by a separate
transformer, other than the transformer
powering the motor actuator.
Controller
Power
Supply
(-) (+)
Transformer
R81GAA-2
9X
+DC Input
Direct
Reverse
W1
9
8
10
X
24
VAC
M100J
9
8
10
X
24
VAC M100J
T2
T1
T2
T1
Power
Supply Power
Supply
24
VAC
Factory Installed
500 ohm Resistor
10
8
T1
T2
Figure 11: Typical Parallel Wiring Diagram
A350P
Power
Supply
Transformer
R81GAA-2
9810 X
+DC Input
T2
Direct
Reverse
W1
24
VAC
Power
Supply
Transformer
24
VAC
T1
Figure 12: Wiring to A350P
Figure 12 shows an A350P powered by an external
transformer driving an M100G Motor Actuator with
DC voltage input. Note that the factory installed
resistor has been removed. When an A350P is
powered by a Y350R Power Module, the motor
actuator is powered by a separate 24 VAC supply.

8 M100G Product/Technical Bulletin
Y350R
A350P D350
L2
L1
R81GAA-2
9810 X
+DC Input
T1
Direct
Reverse
W1
Actuator One
Zero
Span
Power
Supply
Transformer
24
VAC
R81GAA-2
9810 X
+DC Input
T1
T2
Direct
Reverse
W1
Actuator Two
Power
Supply
Transformer
24
VAC
T2
Figure 13: Sequencing with A350P
Figure 13 shows an A350P sequencing M100G Motor
Actuators. Set actuator one zero adjust to minimum
(0.25 VDC) and set the span to the desired portion of
the A350P output signal that will drive the actuator
from full CCW to full CW (example 5 VDC). Set
actuator number two zero adjust to the A350P voltage
output where actuation will begin (example 5.5 VDC)
and set the span to the desired portion of the A350P
output signal that the actuator will drive from full CCW
to full CW (example 9.5 VDC).
TC-6100
Power
Supply
Transformer R81GAA-2
9810 X
+DC Input
T1
T2
Direct
Reverse
W1
Figure 14: Wiring To TC-6100
Figure 14 shows an M100G wired to a TC-6100
Cybertronic Temperature Controller. Connections one
and thirteen are used.
To connect the wires:
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 plugs.
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.
5. Connect 24 VAC to terminals T1 and T2.
Note: To avoid potential miswiring or control signal
problems, the use of separate transformers on
each M100 is required.
For further information on any
of the controllers illustrated,
reference the applicable
controller literature.
A 500 ohm resistor for 0 to 20 mA with quick-connect
terminals is factory installed between terminal T1 and
the DC input terminal. The resistor is for applications
with a DC milliampere controller. Remove the resistor
for applications with a DC voltage controller. An
optional 750 ohm resistor is available for use with an
N500 Controller.

M100G Product/Technical Bulletin 9
The input impedance of the M100G Motor Actuators is
44,000 ohms. Commissioning Procedures
Checkout Procedure
After installation and wiring are complete, make
system settings and apply power. After assembling
the linkage and motor actuator to the valve or damper,
cycle the motor actuator using the controller.
Observe at least three complete operating cycles to
see that all components are functioning correctly. Do
not stall the motor actuator with the damper or valve. If
not allowed to complete the full stroke, damage to the
motor actuator will result.
Travel Adjustment
The rotational travel is field adjustable from 65 to
270 degrees rotation by turning the travel adjustment.
Changing the travel adjustment affects the clockwise
limit of the actuator’s rotation.
1. Run the motor actuator to its CW limit by
jumpering terminals 8 and T1 (24 VAC supplied to
terminals T1 and T2).
2. Turn the travel adjustment potentiometer on the
terminal board clockwise to increase the travel and
counterclockwise to reduce the total travel.
3. For further information on travel adjustment, refer
to the damper or valve linkage instruction sheet.
Zero and Span
The “Zero” (0.25 minimum, 24 VDC maximum) and
“Span” (2 minimum 18 VDC maximum) adjustments
are field adjustable. This allows the selection of any
portion of the signal input to fully modulate the motor
actuator.
Manual Override
Use the following procedures to manually override the
motor actuator.
!
CAUTION: This procedure is for checkout of
the actuator only and not for
continuous operation of the motor
actuator.
1. Disconnect all control inputs before manually
overriding the motor actuator.
2. Connecting terminals 8 and T1 will drive the motor
actuator in the CW direction. This will override the
VDC/mA input and drive the motor to its full
adjusted travel.
3. Connecting terminals 8 and 10 will drive the motor
actuator in the CCW direction. This will override
the VDC/mA input and drive the motor to its
starting point.

10 M100G Product/Technical Bulletin
Direct Acting Mode Calibration
1. Properly set up the motor actuator for the applied
input. Use a factory installed 500 ohm resistor
between T1 and DC input for 0 to 20 mA signal.
Use a field supplied 750 ohm resistor for 0 to
24 mA and no resistor for DC voltage input.
2. Set the jumpers to direct acting position as shown
in Figure 2.
3. Apply 24 VAC to terminals T1 and T2.
4. Increase the zero adjustment to its maximum and
decrease the span adjustment to its minimum.
Note: Direction indicators for increasing each
adjustment are on the potentiometer.
5. Apply power to the controller that supplies the
DC control voltage (mA) to the motor actuator.
6. Using a DC voltmeter, adjust the controller setpoint
to produce the minimum voltage at which the
actuator will be at its desired full counterclockwise
position.
Note: The motor actuator ignores voltages below the
selected value.
7. Slowly decrease the zero adjustment until the
motor actuator begins to respond. The motor
actuator should start and run clockwise about two
angular degrees.
8. Slowly increase the zero adjustment enough to
return the motor actuator to its normal CCW
position.
9. Leave the zero adjustment set at this point.
10. Adjust the controller setpoint to produce the
maximum voltage at which the actuator will be at
its desired full CW position.
11. Slowly increase the span adjustment until there is
a slight CCW movement of the motor actuator.
The motor actuator should start and back up about
two angular degrees.
12. To be sure complete travel is achieved, the span
adjustment must be decreased just enough to
return the motor actuator to its maximum CW
travel limit.
13. Leave the span adjustment set at this point.
Repeat the preceding steps to verify achievement of
the complete control range. Perform at least three
complete operating cycles of the system before leaving
the installation.
Reverse Acting Mode Calibration
1. Properly set up the motor actuator for the applied
input. Use a factory installed 500 ohm resistor
between T1 and DC input for 0 to 20 mA signal.
Use a 750 ohm field supplied resistor for 0 to
24 mA and no resistor for DC voltage input.
2. Set the jumpers to the reverse acting mode as
shown in Figure 2.
3. Apply 24 VAC to terminals T1 and T2 and wait for
the motor actuator to travel to its full CW limit.
4. Decrease the zero and span adjustments to their
minimums.
Note: Direction indicators for increasing each
adjustment are on the potentiometer.
5. Apply power to the controller that supplies the
DC control voltage (mA) to the motor actuator.
6. Using a DC voltmeter, adjust
the controller setpoint to
produce the maximum voltage
at which the actuator will be
at its desired full CCW
position.
Note: The motor actuator ignores voltages above the
selected value.
7. Slowly increase the zero adjustment until the motor
actuator begins to respond. The motor actuator
should start and run clockwise about two angular
degrees.
8. Slowly decrease the zero
adjustment enough to return
the motor actuator to its
normal CCW position.
9. Leave the zero adjustment set at this point.
10. Adjust the controller setpoint to produce the
minimum voltage at which the actuator will be at its
desired full CW position.
Note: The motor actuator ignores voltages below the
selected value.
11. Slowly increase the span adjustment until there is
a slight CCW movement of the motor actuator.
The motor actuator should start and back up about
two angular degrees.
12.To be sure complete travel is
achieved, the span
adjustment must be decreased
just enough to return the
motor actuator to its
maximum CW travel limit.
13. Leave the span adjustment set at this point.

M100G Product/Technical Bulletin 11
Repeat the preceding steps to verify achievement of
the complete control range. Perform at least three
complete operating cycles of the system before leaving
the installation.
Troubleshooting
1. Remove the control signal.
2. Maintain isolated 24 VAC power.
3. Jumper pin 8 to T1, motor will drive CW.
4. Jumper pin 8 to pin 10, motor will drive CCW.
Take the following steps to check the proper
functioning of the motor actuator and associated
controls:
1. The voltage at terminal 10, with reference to
terminal T1, should be approximately +12 VDC
constant.
2. Be sure the actuator model selected has a range
that covers the controller voltages desired.
3. By adjusting the controller setpoint up and down,
the resulting voltage changes received by the
motor actuators should result in proportional
changes in the output voltage across terminal 8
and terminal 10. Output voltage should be
between 0 and -2 VDC (terminal 10 reference).
R
eplacement
The drive motor and gear train are immersed in oil and
sealed in a die cast case. Therefore, maintenance is
not necessary.
For replacement, contact the nearest Johnson
Controls Representative.

12 M100G Product/Technical Bulletin
S
pecifications
Product M100G
Power Requirements 24 VAC at 50/60 Hz, 25 VA spring return, 20 VA non-spring return
Rotation Timing 38 seconds for 90° travel
60 seconds for 160° travel
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
Dimensions (H x W x D) 5.64 in. x 4.38 in. x 4.94 in. (143 mm x 111 mm x 125 mm) without transformer
Shipping Weight 9 lbs (4.1 kg) without transformer
Enclosure NEMA-1
Agency Listings UL Recognized File E27734 Guide XAPX2
CSA Certified File L4573 Class 4813 02
Accessories
(Order Separately) S91DJ-1, Auxiliary switch kit with one SPDT switch
S91EJ-1, Auxiliary switch kit with two SPDT switches
S91PT-1 Auxiliary potentiometer switch kit, 1000 ohms, 1/3 watt
SEL12A-600R, Weatherproofing kit for S91
CVR83A-600R, Weather resistant cover
Q99ADN-1 or Q99AUP-1, Assembly charge for 2-way valves, 1/2 through 2 inch
Q99ADN-2 or Q99AUP-2, Assembly charge for 2-way valves, 2-1/2 inch and over
Q99ADN-3 or Q99AUP-3, Assembly charge for 3-way valves, 1/2 through 2 inch
Q99ADN-4 or Q99AUP-4, Assembly charge for 3-way valves, 2-1/2 inch and over
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, Inc. shall not be liable for damages resulting from misapplication or misuse of its products.
Controls Group
507 E. Michigan Street
P.O. Box 423
Milwaukee, WI 53201 Printed in U.S.A