R81CAA, R81DAA Type Digital Interface Plug-in Circuit Board Kit For Series M100 Motor Actuators

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1 R81CAA, R81DAA Type Digital Interface Plug-in Circuit Board Kit For Series M100 Motor Actuators Installation Sheets Manual 121 Relays and Contactors Section R Technical Bulletin R81CAA Application R81 digital interface plug-in circuit board kits are used in Series M100X base motor actuators, and as replacement or conversion board kits in existing Series M100 motor actuators. The R81CAA and R81DAA kits consist of a vertical plug-in board, a terminal board with travel and set point adjustment, top cover with a circuit board and ribbon attachment, mounting screws and an identification label. The R81CAA (direct acting) and R81DAA (reverse acting) receive and interpret commands from the C500 controller to accurately position their output shafts. The R81CAA provides CW action of the motor actuator on an increase in command from the C500. The R81DAA will provide a CCW action on an increase in the C500 command. These circuit board kits have return communication, sending position response messages back to the controller. All Series R81C/D electronic board kits are designed 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 installer to add devices (safety, limit controls) or systems (alarm, supervisory systems) that protect against, or warn of, control failure. Installation To install the R81 board kit in a Series M100X base motor actuator, proceed as follows: 1. Remove the motor actuator s top cover by loosening the two cover screws. The old cover will be replaced with the new cover supplied in the R81 kit. terminal receptacle onto the pin terminals. (See Fig. 1, 1-A.) 3. Fasten the board in place using the terminal board screws that are supplied with the R81 kit. 2. Install the terminal board by carefully placing the Johnson Controls, Inc. 1 Code No. LIT Part No , Rev. --

2 4. Install the vertical board, with ribbon attached cover, by carefully placing the terminal receptacles onto the pin terminals. (See Fig. 1, 1-B.)! CAUTION: Be sure that all the pins are aligned correctly within the receptacle. 5. Place the bracket, supplied with the motor actuator, over the vertical panel and fasten the bracket in place with the captive screw. (See Fig. 1, 1-C.) 6. Important: The adhesive backed label supplied in the R81 kit must be placed over the label located on the insulation barrier as shown in Fig. 2. The letter on the R81 label will complete the number that identifies the Series M100 with the R81 installed. This new label will identify the correct M100 model number for any future service. 7. Install the motor actuator. 8. Make wiring connections. Turn On the power supply. Adjust and check operation. 9. Fasten the motor actuator s cover. Make sure the ribbon connector is completely inside the cover. Do not overtighten the cover screws. Replacement Installation To remove and replace the electronic boards in an existing Series M100C/D motor actuator, proceed as follows:! CAUTION: Disconnect the electrical power supply before attempting to remove the wiring connections and the boards to avoid possible electrical shock or damage to the equipment. 1. Remove the motor actuator s top cover by loosening the two cover screws. 2. If the existing motor actuator is installed and wired, be sure 2 R81CAA/R81DAA Technical Bulletin the power supply is turned Off and then disconnect all wiring connections to the terminal board. 3. Loosen the bracket screw and remove the bracket. (See Fig. 1.) 4. Pull the vertical board straight up. Be careful not to bend or damage the pin terminals. 5. Remove the two screws from the terminal board. Remove the terminal board by lifting straight up. Be careful not to bend or damage the pin terminals. 6. Install the replacement terminal board by carefully placing the terminal receptacle onto the pin terminals. (See Fig. 1, 1-A.) 7. Fasten the board in place using the two terminal board screws. 8. Install the vertical board by carefully placing the terminal receptacles onto the pin terminals. (See Fig. 1, 1-B.)! CAUTION: Be sure that all the pins are aligned correctly within the receptacle. 9. Place bracket, supplied with the motor actuator, over the vertical board and fasten the bracket in place with its captive screw. (See Fig. 1, 1-C.) 10. Important: The adhesive backed label supplied with the kit must be placed over the label located on the insulation barrier as shown in Fig. 2. The letter on the R81 label will complete the number which identifies the Series M100 with the R81 installed. This new label will identify the correct M100 model number for any future service. 11. Make wiring connections. Turn on the power supply. Adjust and check operation. 12. Replace the motor actuator s cover. Be sure the ribbon connector is completely inside the wiring compartment. Do not overtighten the cover screws. Address Selection * 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 C500 controller uses address number 17 for the full range heating actuator, but the three loop C500 controller uses address 17 for controlling a cooling actuator.) Therefore, before positioning address switches 1 through 4, consult the specific C500 application bulletin for the motor actuator functions that correspond to the address switch positions listed in Table 1. Remove the cover of the motor actuator, taking care not to damage the ribbon cable that connects the cover to the internal circuit boards of the actuator. Five numbered slide switches and a push-pull switch are located in the cover of the motor actuator. Switches 1 through 4 are used to select the address that designates the function which the actuator will perform. Switch 5 is used to select master or slave actuator operation. The push-pull switch is used to set

3 the actuator for linear or S-curve characteristic. * An address is a numeric code which 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. Use the following information to select M100C and M100D address numbers. If multiple dampers or valves are used to perform similar (Note: Only one master actuator may be selected for each address). Both the master actuator and the slave actuators receive commands from the C500 controller. However, only the master actuator has continuous two-way communication with the controller. Slave actuators receive commands from the controller but only send response messages back to the controller if an error occurs at the slave. Use switch number 5 to select whether the actuator will respond as a master or slave. Positioning the switch to the right sets the actuator for master operation. The left switch position sets the actuator for slave operation. Linear or S-Curve Characteristics Valves and dampers with nonlinear flow characteristics have the greatest amount of flow occurring in the early portion of stem travel. The S-curve feature allows the actuator to respond in a non-linear manner. The actuator s travel in relation to input commands is smaller during the initial 20% of command, increases during the mid 60% of command, then decreases during the final 20% of command. functions, multiple actuators can be set to respond to the same controller address. One of the actuators is set to act as the master actuator, with the remaining actuators set to act as slave actuators. R81CAA/R81DAA Technical Bulletin 3

4 To select whether the actuator will operate with an S-curve or linear characteristic, use the push-pull switch located at the bottom right of the switch panel. Pull the switch up for an S-curve characteristic; push the switch down for a linear characteristic. Full Range or Low/High Sequence When Full Range is selected, the motor actuator rotates in direct proportion to the C500 controller s command output. As the command output of the C500 controller increases from 0 to 100%, the M100C motor actuator rotates from 0 to 100% of its travel. The M100D motor actuator is reverse acting. At a 0% controller command the M100D s rotation is at 100% of its travel and a 100% command corresponds to 0% travel. (See Fig. 5.) The Low/High sequence feature (not available on all C500 controller models) is used in applications where multiple dampers or valves must be proportionally sequenced. The low sequence actuator proportionately rotates through its full travel during the first 50% of the output command from the C500 controller. If the demand increases, the high sequence motor actuator proportionately rotates through its full travel as the C500 s output command increases from 50% to 100% (See Chart.) Wiring! CAUTION: Disconnect all power supplies to the system before wiring the M100C/D motor actuator to avoid damage to equipment or possible electrical shock. Make wiring connections using copper conductors only and in accordance with the National Electrical Code and local regulations. Connect the motor actuator to the digital communications bus using shielded cable only. Use Belden No. 22 gauge, Beldfoil 8761 for runs up to 200 ft. (60m). For runs to 500 ft. (150m), use Belden No. 18 gauge Beldfoil Digital bus wiring must not be run in the same conduit as line voltage wiring or other conductors that switch highly inductive loads such as contactors, coils, motors, generators, etc. Shielded bus wiring and non-switching Class II voltages (less than 30 VAC, 100 VA) can be run in the same conduit. Shielded cable that is branched (multidropped) from the Level 1 bus to controlled devices must have its shield spliced to the shield of the Level 1 bus. The Level 1 bus shield must be connected to common at the C500 controller. Isolate and tape the Level 1 bus shield at the motor actuator. Do not connect the shield to any other point. All splices are to be made in junction boxes using approved solderless connectors, or by 4 R81CAA/R81DAA Technical Bulletin

5 soldering, then taping, the connections. If desired, a standard electrical box can be added to the wiring compartment of the motor actuator. (See Fig. 6.) Make the wiring connections as shown in the typical wiring hookups in Fig. 7, using 1/4 in. female quick connects. Connect the Level 1 bus to the motor actuator terminals marked Bus and Common. Connect the 24 VAC power supply to the terminals marked T1 and T2. (See Fig. 7.) Note: All M100C and M100D Series motor actuators must be powered using separate transformers. Use a 24 VAC, minimum 40 VA, step-down transformer at each actuator (Y65 Series Transformer). Direction of Rotation Reference to the direction of rotation is made when viewing the load end of the motor actuator. From this view, the CCW limit is the zero reference. Travel Adjustment The rotational travel is adjustable from 65 to 270 rotation. Changing the travel adjustment effects the CW limit of the actuator s rotation. Run the motor actuator to its CW limit by jumpering terminals COM to CW (24 VAC must be supplied to terminals T1 and T2). Turn the adjustment potentiometer clockwise to increase the total travel, or turn the potentiometer counterclockwise to reduce the total travel. (See Fig. 2.) Note: The C500 Controller sends position commands to the motor actuator ranging from 0 to 100%. The actuator responds to these commands only over their selected range of travel. For example, if an M100C R81CAA/R81DAA Technical Bulletin 5

6 actuator has its travel set at 120, a 50% command from the C500 would position the actuator at 60 of rotation. A 100% command would position the actuator at 120 of rotation. (For M100D motor actuators with a travel set at 120, the 50% command will position the motor actuator at 60 and a command of 100% will position the motor actuator at 0.) Checkout Procedure Before leaving the installation, cycle the motor actuator using the Y199 service module (see the Y199 Service Module Bulletin and the application s specific C500 Controller Bulletin for instructions). Observe at least three complete operating cycles to see that all components are functioning correctly. The motor actuator should not be stalled by the damper or valve. The motor actuator may be damaged if it is not allowed to complete its full stroke. Repairs and Replacement Field repairs must not be made. For a replacement digital electronics board kit, contact the nearest Johnson Controls Commercial Systems wholesaler or Systems and Services Division branch office. 6 R81CAA/R81DAA Technical Bulletin

7 Notes R81CAA/R81DAA Technical Bulletin 7

8 Notes Controls Group 507 E. Michigan Street P.O. Box 423 Milwaukee, WI Printed in U.S.A. 8 R81CAA/R81DAA Technical Bulletin

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