Johnson Controls M9200 Series User manual

FANs 268.1, 1628.3, 977
Product/Technical Bulletin M9200
Issue Date 0599
© 1999 Johnson Controls, Inc. 1
Part No. 34-636-461, Rev. D www.johnsoncontrols.com
Code No. LIT-2681071
M9200 Series Electric Spring Return Actuator
The M9200 Series is a direct-mount, spring return line
of electric actuators that operates on 24 VAC or VDC
power and is available for use with on/off, floating,
proportional, or resistive controllers. These
bi-directional actuators do not require a damper
linkage, and are easily installed on a round shaft up to
3/4 in. (20 mm) diameter or a square shaft up to 5/8 in.
(16 mm). They can also be mounted to valves using
one of the M9000-5xx Valve Linkage Kits.
The M9200 models deliver 140 lb·in (16 N·m) of
torque. The angle of rotation is mechanically adjustable
from 30 to 90°. Integral auxiliary switches are available
to indicate end-stop position or to perform switching
functions at any angle within the selected rotation
range. Position feedback is available through switches,
a potentiometer, or a 0 (2) to 10 VDC signal.
Figure 1: M9200 Series Spring Return Actuator
Features and Benefits
❑Bi-directional, Fail-safe
Spring Return Allows selectable rotation/spring return direction
simplifying installation
❑Four Control Input Types Meets the needs of most applications
❑Wide Range Resistive Input Interfaces to 3-wire resistive controllers from
100 to 10,000 ohms
❑Zero and Span Adjustment
on Proportional Models Allows sequential operation of dampers from a
single input signal of 0 (2) to 10 VDC or
0 (4) to 20 mA
❑On/Off Control Provides simple, 2-wire control for low-cost
applications
❑Electronic Stall Detection Provides higher reliability by deactivating the
actuator when a stall condition is detected
❑Output Position Feedback Provides simple, closed-loop control with
accurate position sensing (standard on
proportional and resistive models, optional on
floating models)
❑Calibration Output on
Proportional Models Increases speed and accuracy of zero and
span adjustments over the entire range without
waiting for mechanical rotation
❑Manual Override Allows manual positioning when the actuator is not
powered; simplifies setup and field adjustments
❑NPT Conduit Adaptor
(Included) Meets electrical code requirements

2 M9200 Series Electric Spring Return Actuator Product/Technical Bulletin
A
pplication Overview
IMPORTANT: This device is not designed or
intended to be used in or near
environments where explosive vapors
or gases could be present, or
environments where substances
corrosive to the device’s internal
components could be present.
M9200 actuators are designed to position air dampers
and valves in HVAC systems. Applications include:
•positioning return air, exhaust, or outdoor air
dampers
•controlling face and bypass dampers
•positioning blades for variable volume fans
•positioning valves used with an M9000-5xx Valve
Linkage
Refer to the manufacturer’s information to properly size
the damper, valve, and/or actuator.
O
peration
IMPORTANT: All M9200 Series actuators are
designed for use only in
conjunction with operating controls.
Where an operating control failure
would result in personal injury
and/or loss of property, it is the
responsibility of the installer to add
safety devices or alarm systems
that protect against, and/or warn of,
control failure.
M9200 actuators operate on 24 VAC at 50/60 Hz
or 24 VDC. They use a DC motor with stall detection
circuitry that operates throughout the entire stroke. The
proportional and resistive actuators employ noise
filtering techniques on the control signal to eliminate
response to spurious noise.
Rotation is mechanically limited to 93° by integral
end-stops. The position of the actuator is visually
indicated from 0 to 90° on the cover. An anti-rotation
bracket prevents lateral movement of the actuator.
The damper position can be set manually with the
manual override feature in the event of a power failure.
I
nstallation
Parts Included
•M9216 actuator
•NPT conduit adaptor (two included for actuators
with switches or a feedback potentiometer)
•anti-rotation bracket
•two No. 12-24 sheet metal screws
•5 mm manual crank
Tools Required
•1/4 in. (7 mm) and 1/8 in. (3 mm) flat-blade
screwdrivers
•Phillips No. 2 screwdriver
•center punch
•adjustable wrench or 7 mm and 10 mm nut drivers
•needle-nose pliers
•DVM or M9000-200 Commissioning Tool (for
models with zero and span potentiometers)

M9200 Series Electric Spring Return Actuator Product/Technical Bulletin 3
D
imensions
1.88
48
2.13
54
3.13
79
4.88
124
5.75
Anti-rotation Bracket
Dimensions
5 mm Hex
Manual Crank
9.47
241 6.34
161
0.35
9
4.57
116 0.15
3.8
3.47
88
1.83
46.5 1.52
38.7
2.15
54.6
7.32
186
1.97
50
0.37 to 0.8
9.4 to 20
0.37 to 0.63
9.4 to 16
Shaft
Dimensions
Shaft
Dimensions
Cover
Removal
0
30
60
90
0
30
60
90
Figure 2: Actuator, Anti-rotation Bracket, and Manual Crank Dimensions, in. (mm)
S
pring Return Direction
The actuator is factory set to spring return in a
Counterclockwise (CCW) direction.
Clockwise (CW)
To change the spring return direction to Clockwise
(CW), refer to Figure 3 and proceed as follows:
1. Turn the actuator over, release the locking clip
with a flat-blade screwdriver, and remove it from
the coupler.
2. Remove coupler and sleeve from the front of the
actuator, and slide the sleeve off of the coupler.
Groove for the
Locking Clip
Smooth Half
of Sleeve
Locking
Clip
Limit
Stop
Position
Indicator
Splines
Tab
Coupler
Back of
the Actuator
Widest Gap in
Sleeve Teeth
Figure 3: Changing the Spring Return Direction
3. Insert the sleeve into the back of the actuator with
the smooth half of the sleeve inserted first.
Note: Make sure the widest gap in the sleeve teeth
align with the two guide marks on the back of
the actuator. (See Figure 4.)
IMPORTANT: When the sleeve is changed from
the front of the actuator to the
back, the actuator’s drive direction
is also reversed.
Splines on
Sleeve
CCW Spring Return DirectionCW Spring Return Direction
Guide Marks
Front
0
0
90
90
30
30
60
60
Guide Marks
Back
Triangle on Each Scale (for Scale Selection)
Wide Gaps in Sleeve Teeth Smooth Side of Sleeve
Figure 4: Location of Guide Marks
4. Align the tab on the coupler with the wide gap in
the sleeve teeth, and insert the coupler into the
front of the actuator.
5. Replace the locking clip to secure the coupler and
sleeve in the actuator.
6. Fill in the triangle on the actuator cover with a
marking pen to indicate the scale being used.

4 M9200 Series Electric Spring Return Actuator Product/Technical Bulletin
Counterclockwise
To set the actuator to spring return in a CCW direction,
refer to Figure 3 and proceed as follows:
1. Turn the actuator over, release the locking clip with
a flat-blade screwdriver, and remove it from the
coupler.
2. Remove the coupler from the front of the actuator,
and the sleeve from the back of the actuator.
3. Insert the sleeve into the front of the actuator with
the smooth half of the sleeve inserted first.
Note: Make sure the widest gap in the sleeve teeth
align with the two guide marks on the front of
the actuator.
4. Repeat Steps 4, 5, and 6 of the previous section.
M
ounting
IMPORTANT: Make sure the space between the
back of the actuator and mounting
surface is at least 5/32 in. (4 mm).
M9200 actuators can be mounted in any convenient
orientation. They can be installed on a shaft that is
3/8 to 3/4 in. (9.5 to 19 mm) round or a 3/8 to 5/8 in.
(9.5 to 16 mm) square, 3 in. (76 mm) or longer. If the
shaft is less than 3 in. (76 mm) long, install an
extension recommended by the damper or valve
manufacturer. For 1 in. (25.4 mm) outside diameter
shafts, use the M9000-154 1 in. Jackshaft Coupler.
To mount the actuator, proceed as follows:
!
CAUTION: Equipment Damage Hazard.
The tab on the anti-rotation
bracket must fit midpoint in the
actuator slot to prevent actuator
binding and premature wear.
1. Refer to the “A” Dimensions in Table 1 and
Figure 5 to ensure the anti-rotation bracket tab fits
midway in the actuator slot.
Table 1: Shaft Sizes and Distances from
the Anti-rotation Bracket to Shaft Center
Shaft Diameter 5/8 in. 1/2 in. 3/8 in.
“A” Dimensions 8-1/4 in. 8-5/16 in. 8-3/8 in.
(See Figure 5.) 209 mm 211 mm 213 mm
0
U-bolt
with
Clamp
Nuts (2)
Anti-rotation
Bracket
Note: “A” is the distance from the center of
the holes in the anti-rotation bracket to
the center of the shaft. (See Table 1.)
Shaft
Center
A
Manual
Crank
Inserted in
the Override
Gear
Coupler
Position
Indicator
Figure 5: Mounting Positions
2. Bend or cut the anti-rotation bracket to fit the
damper frame or duct as shown in Figure 6.
No. 12-24 Sheet
Metal Screws (2)
Slot for Bracket
Anti-rotation Bracket
Damper
Frame
Anti-rotation
Bracket Tab
Cover Screw
Figure 6: Anti-rotation Bracket Positions
3. Attach the anti-rotation bracket to the damper or
duct with a 1/4 in. flat-blade screwdriver, using the
two No. 12-24 sheet metal screws provided.
IMPORTANT: Do not overtighten the sheet metal
screws, or the mounting surface
can be stripped.
4. Slide the actuator onto the damper shaft,
positioning the anti-rotation bracket tab into the slot
at the bottom of the actuator. (See Figure 5.)
5. Insert the manual crank. Push it in firmly, and turn
it CW 4 or 5 turns (position indicator is at the
3 to 5° mark on the actuator scale). Turn the
manual crank 1/4 turn CCW to lock this position.
6. Close the damper tightly.

M9200 Series Electric Spring Return Actuator Product/Technical Bulletin 5
7. Keeping the actuator flat, evenly hand tighten each
clamp nut onto the U-bolt. Use a 10 mm nut driver
or adjustable wrench to finish securing the U-bolt
to the damper shaft.
8. Turn the manual crank CW to release the spring,
and remove the manual crank. (The actuator will
spring return to its starting position.)
9. Verify that the actuator rotates freely throughout
the range. (This can be done by applying a full
stroke control signal or reinserting the manual
crank and turning it CW to rotate the coupler to the
fully open position.)
R
otation Range
The actuator is factory set for 0 to 93° rotation. The
rotation range is changed by repositioning the coupler
and adjusting the rotation limiters. This can be done by
using an input signal or the manual crank.
To change the rotation range using the manual crank:
1. Push the manual crank into the manual override
gear firmly, and wind in a CW direction until the
position indicator reaches the 45° position.
IMPORTANT: Turn the manual crank in a
CW direction only, unless locking a
new position.
2. Lock this position by winding the manual crank
1/4 turn CCW or until a slight resistance is felt.
3. Use a 7 mm nut driver to loosen the screws on the
rotation limiter. (See Figure 7.)
Note: Rotation limiters are shown
factory set in the fully down
position for 90° rotation.
0
30
60
90
0
30
Limit Stop
Screws
(2 on Each
Limiter)
Rotation
Limiters (2)
0
10
30
20
(Increments
correspond
to those on
the opposite
side.)
Figure 7: Rotation Limiters
4. Slide the rotation limiter to the desired position,
and retighten the screws to a maximum of
30 lb·in (3.4 N·m).
Examples of rotation limiter adjustments:
For a range of 30°, adjust both limiters fully up.
•To set a rotation range of 45°, adjust
one rotation limiter to 30° and the other to 15°.
•To set a range of 60°, adjust one limiter to 30°,
and leave the other at 0°.
5. Reinsert the manual crank into the manual
override gear.
6. Repeat Steps 2 through 5 to set the rotation range
for the second rotation limiter.
7. Release the manual crank spring lock by winding it
1/4 turn in a CW direction.
8. Remove the manual crank, and return it to its
original position on the actuator cover.
Note: When changing the rotation range on models
with auxiliary switches, one or both switches
may need to be adjusted. (See
Auxiliary
Switches
section.)
Feedback Signal
The feedback signal will vary with a change to the
rotation range. The resistance feedback is reduced
corresponding to the reduced rotation range for the
AGD and AGE models.
For the HGA, HGC, JGA, and JGC models, a change
to the rotation range changes the feedback signal and
the operating range proportionally. (See Figure 8.)
90°
90°
0.0V
2.0V
10.0V
8.7V 7.3V 6.0V 4.7V 3.3V
10.0V
8.3V 6.7V 5.0V 3.3V 1.7V
75°
75°
60° 60°45°
45° 30°
30°
15°
15°
0°
0°
Rotation Range
2-10V
Feedback
0-10V
Feedback
Direct
Acting
1000
Ω
135
Ω
113
Ω
667
Ω
90
Ω
45
Ω
167
Ω
Ω
Ω
0
0
833
Ω
68
Ω
23
Ω
0-135 ohms
Feedback
0-1000 ohms
Feedback
Ω
500 333
Ω
Direct or
Reverse
Acting
2-10V
Feedback
Reverse
Acting
0-10V
Feedback 0.0V 1.7V 3.3V 5.0V 6.7V 8.3V 10.0V
10.0V8.7V
7.3V
6.0V4.7V
3.3V
2.0V
Rotation Limiter
Adjustment
Rotation Limiter
Adjustment
Note: 0-135 ohms feedback is available on AGD models and
0-1000 ohms feedback on AGE models.
0-10V or 2-10V is available on HGA, HGC, JGA, JGC models.
Figure 8: Nominal Feedback Signal Relative to
Rotation Range

6 M9200 Series Electric Spring Return Actuator Product/Technical Bulletin
W
iring
!
CAUTION: Equipment Damage Hazard.
Disconnect all power supplies
before wiring connections are
made, or prior to performing
maintenance. Check all wiring
connections before applying
power to the system.
Short-circuited or improperly
connected wires will result in
permanent damage to the
equipment.
IMPORTANT: Make all wiring connections in
accordance with the National
Electrical Code and local regulations.
Because of the actuator’s movement
during operation, wire strain reliefs
must be provided.
Refer to Figure 9 for the applicable M9200 actuator.
Terminal Block 1
24 VAC
24 VDC
CW CCW
COM
Floating Control
Models: AGA, AGC, AGD, and AGE
On/Off Control
24 VAC
24 VDC
0-20mA
0-10V
0-10V
~
+
Proportional Control
Models: HGA and HGC
24V +
+
+
+
1 2 3 4
1 2 3 4
1 2 3 4 5 6
^
-~
+
Resistive Input Control
Models: JGA and JGC
+
+
^
-
1 2 3 4 5 6
COM
^
-
CCW CW
+
On/Off Control
Models: BGA and BGC
CW
*
1 2 3
*
24 VAC
24 VDC
^
-
~
+
~
+~ +
1 = Common
2 = Power
3 = Calibration Out
4 = Current Input
5 = Voltage Input
6 = Feedback Output
100-10k ohms
0-10V
24V
~
+
^
-
Terminal Block 2
CW
0% 100%
11 12 13
Feedback
Potentiometer
Models: AGD = 0-135 ohms
AGE = 0-1000 ohms
NC NO NO NC
21 22 23 24 25 26
Switch S1
10° Switch S2 80°
Auxiliary Switches
(Shown Factory Set)
Models: AGC, BGC,
HGC, and JGC
Note: Terminals 3 and 4 function as
CCW and CW references when
the Resistive models are in the
DA mode, but as CW and CCW
references when these models
are in the RA mode.
* CW rotation for the On/Off models when the coupler is
inserted in the front of the actuator, but CCW rotation
when it is inserted in the back of the actuator.
~
+
^
-
COM CW
COM
Figure 9: Wiring for M9200 Models
IMPORTANT: There is a 25-second delay before
the actuator (except the BGA and
BGC models) responds after power
is applied.
Do not switch 24 VAC from CW to
CCW (or CCW to CW) in less than
0.5 seconds.

M9200 Series Electric Spring Return Actuator Product/Technical Bulletin 7
Options
Wiring is made through the conduit openings or
through the conduit adaptor, which converts the
opening for a threaded NPT conduit fitting.
Through the Conduit Openings
Depending on the M9200 model selected, one or both
conduit openings are used. Refer to Figure 10 and
proceed as follows:
1. Loosen the cover screw with a No. 2 Phillips
screwdriver, and remove the actuator cover.
2. Push the plastic plug out of the conduit opening
with fingertip.
Plugs
(Conduit Openings)
Cover
Screw
Figure 10: Location of the Conduit Openings
3. Puncture a hole through the center of the plug with
a Phillips screwdriver, and reinsert the plug into the
conduit opening.
4. Insert the cable wires through the hole in the
conduit plug, and connect to the terminal block
using the wiring diagrams in Figure 9.
5. Replace the actuator cover, and retighten the
cover screw.
With the Conduit Adaptor (M9000-100 included)
Refer to Figure 11 and proceed as follows:
1. Push the plastic plug out of the conduit opening
with fingertip.
2. Slide the capture nut into the slot located inside of
the conduit opening. (See Figure 11.)
Capture
Nut
Figure 11: Capture Nut
3. Insert the conduit adaptor into the conduit opening,
and hand tighten by turning in a CW direction as
shown in Figure 12.
Conduit
Opening
Conduit Adaptor
Conduit Fitting
(Not Provided)
Figure 12: Conduit Adaptor Wiring
IMPORTANT: Use flexible metallic conduit or its
equivalent with the fitting. Do not
overtighten the conduit adaptor into
the actuator to avoid damaging the
actuator housing.
4. Insert the conduit fitting (not provided) into the
adaptor, and hand tighten in a CW direction.
(See Figure 12.)
5. Insert the cable wires through the conduit adaptor
assembly, and connect to the terminal block using
the wiring diagrams in Figure 9.
6. Tighten the clamp on the conduit fitting.

8 M9200 Series Electric Spring Return Actuator Product/Technical Bulletin
C
alibration
Jumper Settings
Floating (AGA, AGC, AGD, and AGE) and on/off (BGA
and BGC) models do not have jumper settings.
Resistive (JGA and JGC) models are factory set for
direct acting with Jumper W1 in the DA position.
Proportional (HGA and HGC) models are factory set
with Jumper W1 in the DA position, Jumper W2 in the
0 to 10 VDC or 0 to 20 mA position, and Jumper W3
in the fixed position. (See Figure 13.)
Zero Potentiometer
Span Potentiometer
Adjustable
Fixed
Jumper W3
Factory Set
Term inal Block 2
Feedback
Potentiometer
(See Figure 9.)
(CCW) RA
(CW) DA
Jumper W1
Factory Set
Jumper W2
1 2 3 4 5 6
Factory Set
Voltage Input
0-10 VDC 2-10 VDC
Current Input
0-20 mA 4-20 mA
Feedback Ouput
0-10 VDC 2-10 VDC
(1) Common
(2) Power
(3) Calibration Output
(4) Current Input
(5) Voltage Input
(6) Feedback Output
Direct Acting (DA)
Reverse Acting (RA)
Rotation Direction
with Increasing Signal
Terminal
Block 1
Figure 13: Calibrating M9216 Proportional Models
Direction of Action
Drive direction is dependent on the position of Jumper
W1 and the spring return direction as shown in Table
2. To change the spring return direction, see the
Spring Return Direction section.
Table 2: Settings for Direction of Action
Location of
Jumper W1/
Direction of
Spring
Return
Drive
Direction with
a Minimum
Input Signal
Drive
Direction with
a Maximum
Input Signal
DA/CCW CCW CW
RA/CCW CW CCW
DA/CW CW CCW
RA/CW CCW CW
To set an actuator for reverse acting, proceed as
follows for the appropriate model:
Proportional (HGA and HGC) and Resistive
(JGA and JGC) Models
1. Move Jumper W1 from the factory set DA position
to the RA position. (See Figure 14.)
2. Apply power and then a control signal to the
actuator to verify proper operation. (See Table 2.)
Note: HGA and HGC models may require
potentiometer settings. Proceed to the
Potentiometer Settings section.
Floating (AGA, AGC, AGD, and AGE) Models
For floating models, reverse the control wiring
connections from Terminals 3 and 4 to Terminals 4
and 3. (See Figure 9,
Terminal Block 1 .)
On/Off (BGA and BGC) Models
RA is selected by changing the actuator coupler for
on/off operation. (See the
Spring Return Direction
section.)

M9200 Series Electric Spring Return Actuator Product/Technical Bulletin 9
Potentiometer Settings
IMPORTANT: Both zero and span potentiometers
must be adjusted to ensure full
actuator travel and complete
calibration.
The HGA and HGC models have two potentiometers,
zero and span. These potentiometers do not require
adjustment when Jumper W3 is in the fixed position
(factory set). When Jumper W3 is in the adjustable
(ADJ) position, proceed as follows:
Use either Terminals 3 and 5 or Terminals 3 and 4,
a control signal, and a voltmeter. The zero and span
potentiometers can be adjusted as follows without
waiting for the actuator to drive to the final position.
Adjusting the Zero and Span
1. Verify that Jumper W2 is in the 0 to 10 VDC
position, and place Jumper W3 in the adjustable
(ADJ) position. (See Figure 13.)
2. Provide 24 VAC or 24 VDC power to Terminal 1
(Common) and Terminal 2.
3. Connect the Common from the controller to
Terminal 1, and either a voltage signal to
Terminal 5 or a current signal to Terminal 4.
4. Connect Terminals 1 and 3 to a voltmeter to
monitor the calibration output.
5. Use a 1/8 in. (3 mm) flat-blade screwdriver to turn
the zero potentiometer fully CW and the span
potentiometer fully CCW.
6. Apply the minimum (zero point) control signal
required for positioning the actuator at the
minimum position.
7. Monitor DC calibration output. To adjust the zero
potentiometer, turn it CCW until the voltmeter
displays 0 volts or slightly less (-0.1 volt).
8. Adjust the control signal to the maximum voltage
desired to cause full rotation. (Signals greater than
10 volts have no further effect.)
9. Monitor calibration output at Terminals 1 and 3.
Adjust the span potentiometer CW to increase the
calibration output to 10 volts.
10. Verify that the actuator is properly calibrated by
adjusting the control signal to the minimum and
maximum levels.
Example for a zero of 3 VDC and a span of 5 VDC:
a. Apply a 3-volt control signal to the actuator,
and turn the zero potentiometer CCW until the
calibration output at Terminal 3 is 0 volts.
b. Apply maximum voltage. (In this case, it is
8 VDC, which results in a span of 5 volts.)
c. Monitor calibration output at Terminal 3, and
adjust the span potentiometer CW until
10 volts is reached.
Note: Mechanical movement is not immediate due to
a delay in the actuator’s response to the
control signal.

10 M9200 Series Electric Spring Return Actuator Product/Technical Bulletin
A
uxiliary Switches
The M9216-xxC models have built-in auxiliary switches
which can be set for any angle between 0 and 90°
(factory set for 10 and 80°) using either an input signal
or the manual crank. (Refer to the
Specifications
section for auxiliary switch ratings.)
The following procedures serve as examples to
change the position of the auxiliary switch angles.
Adjusting Switch Cam S1
To change the angle of Switch Cam S1 to 20°:
1. Insert the manual crank into the manual override
gear.
2. Push in and turn the manual crank CW. Using the
0 to 90° nodule guides, rotate the coupler until the
position indicator is at 20°.
3. Rotate Switch Cam S1 CCW, aligning the edge of
the switch cam with the switch plunger until the
plunger rises. (See Figure 14.)
Position
Indicator
Switch
Plunger
Manual
Crank
CCW
90°
Nodule Guides
(10° Increments)
Edge of
Switch Cam S1
Edge of
Switch Cam S2
0°
CCW
Figure 14: Switch Cam Angle Settings
Note: The normally closed contact closes, and the
normally open contact opens. (See Figure 9
,
Terminal Block 2, Auxiliary Switches
.)
Adjusting Switch Cam S2
To change the angle of Switch Cam S2 to 70°:
1. Push in and turn the manual crank CW. Using the
0 to 90° nodule guides, rotate the coupler until the
position indicator is at 70°.
2. Rotate Switch Cam S2 CCW, aligning the edge of
the switch cam with the switch plunger until the
plunger rises. (See Figure 14.)
Note: The normally closed contact opens, and the
normally open contact closes. (See Figure 9
,
Terminal Block 2, Auxiliary Switches
.)
3. Turn the manual crank CW to release the spring,
and remove it. (The actuator will spring return the
coupler to the 0° position.)
4. Replace the actuator cover, and return the manual
crank to its original position on the actuator cover.
R
eplacement and Repair
Field repairs must not be made. To order, refer to
the
Ordering Information section for the desired
product code number, and contact the nearest
Johnson Controls representative.