R81EAA Type Plug-In Electronic Circuit Board Kit For Series M100 Motor Actuators

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1 R81EAA Type Plug-In Electronic Circuit Board Kit For Series M100 Motor Actuators Installation Sheets Manual 121 Relays and Contactors Section R Technical Bulletin R81EAA Application R81 plug-in electronic board kits are used in Series M100X base motor actuators and as a replacement or conversion board kit in an existing Series M100 motor actuator. The R81EAA kit consists 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 R81EAA economizer board kit has a changeover relay, refrigeration programming relay, adjustable minimum position potentiometer, mixed air set point adjustment, proportional band adjustment, and an actuator travel adjustment. When the R81EAA is installed in the M100 Series, the motor actuator controls outdoor air dampers (O.A.), return air dampers (R.A.), and exhaust air (E.A.) dampers to maintain proper mixed air. The motor actuator with the R81EAA installed allows economical use of outdoor air for natural cooling and reduces energy consumption by minimizing the compressor run-time. The internal changeover relay and refrigeration programming relay can be wired in various ways to provide control sequences that use available natural cooling. These cooling options must be wired with A19 temperature controls (sensible changeover) or W84 total heat controls (enthalpy changeover). A91 thermistor sensors are used for direct mixed air control or T91 thermistor room thermostats are used for ventilation only systems. All Series R81 electronic board kits are designed for use only as operating controls. An operating control is not authorized for use where its failure in any mode can result in personal injury and/or loss of property. It is the responsibility of the user to add those necessary devices that protect against undesirable system failure modes. Operation Fig. 1 -Drawing showing how to remove and/or install the R81 Plug-In Electronic Board Kit To accomplish greater energy savings, the motor actuator will be cycled by the room thermostat on a call for cooling. Johnson Controls, Inc. 1 Code No. LIT Part No , Rev. --

2 Relay A is energized by the contacts of the changeover control. (See Fig. 4.) When relay A is energized, the motor actuator will use outside air for cooling. Should the O.A. parameters rise too high for natural cooling, the contacts of the changeover control will open, changeover relay A will deenergize, and the motor actuator will return to its minimum position. Relay B is used as a refrigeration programmer when two stages of cooling are needed. The outside air changeover control energizes relay B, which switches the first stage of cooling to outside air, and the second stage of cooling becomes the first stage refrigeration when the outside conditions are low enough for natural cooling. See Fig. 5 for wiring diagram. 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.) 2. Install terminal board E by carefully placing the terminal receptacles onto the pin terminals. (See Fig. 1, 1-A.) 3. Fasten the board in place using the screws D that are supplied with the R81 kit. 4. Install vertical board C with ribbon attached cover mounted board by carefully placing the terminal receptacles onto the pin terminals. (See Fig. 1, 1-B.) 5. Place bracket B, supplied with the motor actuator, over vertical board C and fasten the bracket in place with captive screw A. (See Fig. 1, 1-C.) 6. Important: The adhesive backed label supplied in the R81 kit must be placed on the label located on the insulation barrier as shown in Figure 2. The letter on the R81 label will complete the number that identifies the Series M100 with the R81 installed. 7. Install the motor actuator. 8. Make wiring connections. Turn on power supply. Adjust, and check operation. 9. Fasten the motor actuator s cover that contains the adjustment potentiometers to the motor actuator. Make sure the ribbon connector is completely inside the cover. To remove and replace the electronic circuit boards in an existing Series M100E 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. If the existing motor actuator is installed and wired, be sure the power supply is turned off and then disconnect all wiring connections to the terminal board. 3. Loosen screw A and remove board bracket B. (See Fig. 1.) 4. Pull vertical board C straight up. Be careful not to bend or damage the pin terminals. 5. Remove the two screws D from terminal board E. Remove the terminal board by lifting straight up. Be careful not to bend or damage the pin terminals. 6. Install the replacement terminal board E by carefully placing the terminal receptacles onto the pin terminals. (See Fig. 1, 1-A.) 7. Fasten the board in place using the screws D. 8. Install vertical board C by carefully placing the terminal receptacles onto the pin terminals. (See Fig. 1, 1-B.) 9. Place bracket B, supplied with the motor actuator, over vertical board C and fasten the bracket in place with captive screw A. (See Fig. 1, 1-C.) 10. Important: The adhesive backed label supplied in the R81 kit must be placed on the label located on the insulation barrier as shown in Figure 2. The letter on the R81 label will complete the number that identifies the Series M100 with the R81 installed. 11. Make wiring connections. Turn on power supply. Adjust, and check operation. 12. Replace the motor actuator s cover. Be sure the ribbon connector is completely inside the wiring compartment. Wiring 2 R81EAA Technical Bulletin

3 Make wiring connections using copper conductors only and in accordance with the National Electrical Code and local regulations. Refer to the typical wiring diagram for selected hookup. All splices are to be made in junction boxes using approved solderless connectors, or by soldering and then taping the connections. All splicing and excess wiring must be located outside of the motor actuator wiring compartment. If desired, a standard electrical box can be added to the wiring compartment of the motor actuator. (See Fig. 3.) When more than one Series M100 motor actuator, with the R81EAA The set point for the remote sensor is located on the R81 s terminal board and has a calibrated dial that is adjustable between 40 and 90 F (5 and 30 C). Should a remote set point be desired, such as a room ventilation control, turn the set point knob counterclockwise to its limit at the low temperature end of the dial and set the temperature at the T91BCA thermostat or remote Y45BA-1 set point adjuster. Proportional Band The proportional band adjustment is located on the cover mounted circuit board. The proportional band is adjustable between 2 and 20 F (1.1 and 11 C).! CAUTION: While narrowing the proportional band is usually desirable, too narrow a proportional band may result in poor control. The proportional band must be increased if the motor actuator cannot maintain a stable position when the system is operating. Instability causes the motor actuator to oscillate (hunt). Remote Minimum Position Remote control of the outdoor air dampers is desirable where temporary additional ventilation is required. For example, a restaurant, conference room, factory, or store may need to have the air purged temporarily. The O.A. Minimum potentiometer is integral on the cover mounted circuit board for minimum position control. The addition of a Y45AA-9 will allow the building occupant to control the minimum position from a remote location. (See Fig. 6.) Night Setback During the day mode, the T26 night setback thermostat is locked out of the heating circuit. However, in the night position, the T26 thermostat, with its lower set point, will operate the heating. Also, in the night position, cooling will be entirely locked out and the O.A. damper will be closed. (Dampers close only with spring return motor actuators.) When supply power is cut to the transformer, the spring return motor actuator closes the damper. (See Fig. 7.) installed, is powered from the same 24 VAC power source, polarity must be maintained; connect all T 2 terminals to the same side of the 24 VAC supply. To avoid potential miswiring, separate transformers are recommended. When slaving motor actuators with the number 10 terminals connected together, separate transformers must be used. Never simultaneously parallel terminals 10 and T 1. If an existing 24 VAC power supply is available, Johnson Controls Y69 isolation transformer is recommended. M100J motor actuators may be slaved from the R81EAA/M100 using the X terminal and a common power supply. (See Fig. 8.) Adjustment Set Point R81EAA Technical Bulletin 3

4 Parallel Damper Actuators In certain applications, It may be possible that outside air, return air, and exhaust air dampers cannot be modulated by a single motor actuator. In this event, up to two additional M100J motor actuators can be slaved from the first Series M100 motor actuator with the R81EAA installed. This is illustrated in Fig. 8. Checkout Procedure Relay A Turn the O.A. minimum position potentiometer full counterclockwise (CCW), and energize the changeover relay. This simulates the availability of outside air for natural cooling. Adjust the set point to approximately midrange, 65 F (18 C). Next jumper sensor terminals S1 and S2. Since a negative temperature coefficient sensor is used, this will simulate a rise in mixed air temperature and the O.A. dampers will modulate open. Remove the jumper and disconnect terminal S2. This will now simulate a drop in mixed air temperature and the O.A. dampers should modulate closed. Minimum Position De-energize the changeover relay to simulate that outside air is no longer available for natural cooling. The motor actuator will rotate to the minimum position. By turning the minimum position potentiometer clockwise (CW), the minimum position should increase. The motor actuator will rotate CW. Checkout Procedure After the linkage and motor actuator have been assembled 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. Field repairs must not be made. For a replacement electronic board kit, contact the nearest Johnson Controls Commercial Systems wholesaler. Repairs and Replacement 4 R81EAA Technical Bulletin

5 R81EAA Technical Bulletin 5

6 6 R81EAA Technical Bulletin Notes

7 Notes R81EAA Technical Bulletin 7

8 Notes Controls Group 507 E. Michigan Street P.O. Box 423 Milwaukee, WI Printed in U.S.A. 8 R81EAA Technical Bulletin

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