ML6195, ML6295 Spring Return
Direct Coupled Actuators
PRODUCT DATA
FEATURES
•
Brushless DC motor achieves sophisticated control of
speed, torque and braking.
•
•
Provides 142 lb-in. (16 N•m) torque.
Mounts directly on 3/8 in. to 1 in. (9 to 25 mm) round
and 1/4 in. to 3/4 in. (6 to 18 mm) square shafts.
•
•
•
Self-centering shaft coupling minimizes installation
time.
Spring return direction is field-selectable to simplify
installation.
Manual override permits unpowered positioning to
simplify installation and troubleshooting. Deactivation
of interlock is manual or automatic when power is
restored.
•
•
Highly-visible position indicator facilitates setup,
checkout and troubleshooting.
APPLICATION
Rugged, lightweight all-metal alloy housing provides
durability.
The ML6195 Spring Return Direct Coupled Actuator (DCA) is a
floating control motor. Use with controls that provide switched or
floating single-pole, double-throw (spdt) (Series 60) control
output to operate dampers or valves in heating, ventilation, and
air conditioning (HVAC) applications. For hydronic valve
applications, a complete line of brackets and linkages are
available for mounting Honeywell DCAs on globe valves and on
Honeywell ball valves. The ML6295 includes an internal,
electrically isolated feedback potentiometer. This potentiometer
provides indication of the shaft coupling position and can be
used for rebalancing an external control circuit.
•
•
•
Integral conduit connection.
Integral adjustable range-stop.
Models available with two fully adjustable line voltage
auxiliary switches.
Contents
Application........................................................................... 1
Features .............................................................................. 1
Specifications ...................................................................... 2
Ordering Information ........................................................... 2
Installation ........................................................................... 3
Operation ............................................................................ 6
Checkout ............................................................................. 7
129-235
® U.S. Registered Trademark
63-2537-1
Rev. 1, 10/97
Copyright © 1997 Honeywell Inc.
•
All Rights Reserved
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ML6195, ML6295 SPRING RETURN DIRECT COUPLED ACTUATORS
4
(100)
MIN.
95°
1-1/8
(28)
11-13/16
(300)
7-3/4
(197)
9
(230)
1/4 (7)
MIN.
5/32 (4)
1-11/32
(34)
1-11/32
(34)
2-1/2
(63) MIN.
17/32
(14)
3-3/8 (85)
25/32
(20)
3/4
(20)
MAX.
3-15/16 (100)
1-23/32 (30)
11/32 (10)
OPENING FOR 3/8 INCH
FLEX CONDUIT (2 PLACES)
M12444A
Fig. 1. Approximate dimensions of the ML6195/ML6295 Spring Return
Direct Coupled Actuator and mounting bracket in in. (mm).
INSTALLATION
WARNING
Installing the actuator near explosive vapors
could result in serious injury or death.
A spark from the actuator or attached accessories
could ignite escaping gas or explosive vapors.
Install actuator in areas free of escaping gas and
other explosive vapors.
When Installing this Product…
1. Read these instructions carefully. Failure to follow them
could damage the product or cause a hazardous
condition.
2. Check the ratings given in the instructions and on the
product to make sure the product is suitable for your
application.
CAUTION
3. Installer must be a trained, experienced service
Failure to disconnect power before installation can
result in electrical shock or equipment damage.
Disconnect all power supplies before installation.
Motors with auxiliary switches may have more than
one disconnect to de-energize the device.
technician.
4. After the installation is complete, check out the product
operation as provided in these instructions.
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ML6195, ML6295 SPRING RETURN DIRECT COUPLED ACTUATORS
Measure shaft length
CAUTION
If the shaft is less than three inches in length, the shaft coupling
must be located between the damper/valve and actuator
housing. If the shaft length is more than three inches, the shaft
coupling may be located on either side of the actuator housing.
Deteriorating vapors and acid fumes
can damage the actuator.
Install actuator in areas free of acid fumes and other
deteriorating vapors that can attack the metal parts of
the actuator.
If the coupling must be moved from one side of the actuator
to the reverse, follow these instructions (see Fig. 3):
1. Remove the position indicator from the shaft coupling
and set it aside for later use.
Location
Install the actuator in a location that allows enough clearance
for mounting accessories and for servicing.
2. Remove the retainer clip from the shaft coupling and
set it aside for later use.
3. Remove the shaft coupling from one side of the actuator.
4. Replace the shaft coupling on the opposite side of the
actuator aligning it with the mark on the housing.
5. Replace the retainer clip on the shaft coupling using the
inner groove of the coupling.
Refer to Warnings and Cautions (above) for locations to avoid.
Mounting
The ML6195/ML6295 DCA has a self-centering shaft coupling
to accommodate specific shaft lengths, sizes, and shapes.
Proper actuator location and means of actuator rotation preven-
tion are necessary to avoid excessive strain on the output gear.
6. Replace the position indicator on the shaft coupling.
If the shaft coupling is located between the actuator housing
and damper/valve, the position indicator holder must be
attached to the other side of the actuator. If this is necessary,
perform the following (see Fig 4):
The ML6195/ML6295 DCA operates a damper or hydronic
valve by driving the shaft either cw or ccw, depending on the
design. All actuators are shipped with a 5° preload on the
spring. When power is applied to the actuator, the preload is
released and the actuator spring-returns 5° for tight closeoff.
1. Slide the position indicator holder onto the shaft
coupling near the retainer clip and rotate it until it snaps
into place.
2. Place the position indicator on the holder.
The ML6195/ML6295 DCA is designed for single-point
mounting. Single-point mounting is typically used when the
actuator is mounted on a damper frame. A mounting bracket
(see Fig. 1) is provided for installing the actuator.
CAUTION
Avoid damage to the damper or actuator.
Do not allow the mounting bracket to bind or clamp
the actuator to the duct.
Use the mounting bracket only to prevent the actuator
housing from rotating.
Preparation
Before installing the ML6195/ML6295 on the shaft, determine
the opening direction of the damper or valve for correct spring
return rotation and wiring connections. The ML6195/ML6295
can be mounted to provide clockwise or counterclockwise
spring return.
M12441
Fig. 3. Mounting shaft coupling to opposite side of actuator.
Determine appropriate mounting orientation
See Fig. 2 for mounting orientation.
CW TO OPEN
CW TO CLOSE
(FAIL-SAFE
POSITION)
CCW TO CLOSE
(FAIL-SAFE
POSITION)
CCW TO OPEN
M12443
M12440
Fig. 2. ML6195/ML6295 Spring Return Direct Coupled
Actuator mounting orientation.
Fig. 4. Adding position indicator holder.
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ML6195, ML6295 SPRING RETURN DIRECT COUPLED ACTUATORS
4. Remove the mounting bracket and actuator.
5. Drill or center punch the starting holes for the mounting
bracket screws (or use no.10 self-tapping sheet metal
screws).
CAUTION
Manually turning the shaft coupling
can damage the actuator.
6. Turn the damper blades to the desired normal position,
Never turn motor shaft coupling by hand or with a
wrench.
usually the closed position.
7. Place the actuator and mounting bracket back into
position over the damper shaft and install the mounting
bracket screws.
8. Tighten the shaft coupling set screw firmly by applying
7.5 lb-ft (10 N•m) of torque with a 13/32 in. (10mm)
wrench.
Range Stop Adjustment
The ML6195/ML6295 has an adjustable range stop feature.
When the rotational mounting of the shaft coupling is
changed, the actuator drives less than the full 95° stroke. The
stroke is adjustable in 5° increments and once adjusted, the
actuator drives until the shaft coupling reaches the
mechanical stop, which is a part of the housing. The stop
causes the motor to disengage and the shaft coupling drives
no farther. When the actuator returns, it stops at the fail-safe
position which is set as follows:
1. Remove the position indicator; and if applicable, the
holder, and set aside for later use.
NOTE: If possible, leave the position indicator attached
to the shaft coupling to aid in future steps.
2. Remove the retainer clip from the shaft coupling and
set it aside for later use.
3. Remove the shaft coupling from the actuator.
4. Rotate the shaft coupling to the desired fail-safe position.
5. Install the shaft coupling at this position.
NOTE: The location of the shaft coupling determines
the number of degrees of travel.
Example: Setting the shaft coupling at an approximate
fail-safe position of 20° (as indicated on the
housing), limits the stroke to 70°.
IMPORTANT
M12442
If the 5° preload was not released, see the Mounting
section, the fail-safe position moves 5° when power
is applied, increasing the stroke 5°.
Fig. 5. Mounting bracket installation.
6. Replace the retainer clip on the shaft coupling using the
inner groove of the shaft coupling.
7. If necessary, replace the holder and position indicator
on the shaft coupling.
CAUTION
Using the actuator as a shaft bearing will damage
the device, reducing the functional life span.
In applications with side loads to the actuator shaft
coupling, a different coupling (such as the one
supplied with the foot mount kit) must be used.
Installation
Installing Actuator and Mounting Bracket
(Single Point Damper Mounting)
Wiring
NOTE: For valve mounting, see the literature accompanying
the mounting equipment or bracket.
CAUTION
Prevent electrical shock or equipment damage.
With the direction of the damper shaft rotation determined
(either cw or ccw), proceed as follows:
Disconnect all power supplies before wiring.
1. Place the ML6195/ML6295 DCA over the damper shaft.
2. Position the actuator for best access to the actuator
damper shaft locking screw.
3. Install the mounting bracket (see Fig. 5). Mark the screw
holes for installing the mounting bracket on the damper
housing.
All wiring must comply with local electrical codes, ordinances
and regulations. The ML6195/ML6295 is designed for use
with a Class 2 power supply. Voltage and frequency of the
transformer used must correspond with the characteristics of
the motor and the power supply. See Fig. 6 and 7 for typical
wiring connections.
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ML6195, ML6295 SPRING RETURN DIRECT COUPLED ACTUATORS
SERIES 60 CONTROL
(FLOATING)
ML6195 ACTUATOR
Manual Override
6 VIOLET
The actuator can be operated with no power present. Use this
feature during installation or to move and lock the damper or
valve shaft position when there is no power.
B = CW
7 ORANGE
W = CCW
1
To operate the manual override:
1 RED
L1
(HOT)
T2
T1
1. If the power is on, turn it off.
24 VAC
2 BLACK
L2
2. Insert the supplied key (Allen wrench) as shown in Fig. 8.
3. Rotate the key in the direction indicated on the cover.
4. Once the desired position is reached, hold the key to
prevent the spring return from moving the actuator.
5. With the key held in place, use a screwdriver to turn the
gear train lock pin in the indicated direction.
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS
AND OVERLOADPROTECTION AS REQUIRED.
M12445
Fig. 6. ML6195 typical wiring diagram.
NOTE: No more than 1/8 turn of the lock pin is
required to engage the lock; a slight click is
heard and the pin resists further rotation.
SERIES 60 CONTROL ML6295 ACTUATOR
(FLOATING)
6 VIOLET
B = CW
S1 GREEN/RED
S2 GREEN/BLUE
AUX
SWITCH
A
7 ORANGE
W = CCW
S3 GREEN/PINK
S4 BLACK/RED
6. Remove the key without rotating it further.
AUX
SWITCH
B
1
1 RED
L1
S5 BLACK/BLUE
S6 BLACK/PINK
GND GREEN
T2
T1
To release the manual override with no power present:
1. Insert the supplied key.
(HOT)
24 VAC
2 BLACK
L2
OPEN
2. Turn the key 1/4 turn in the direction indicated on the
cover.
3. Remove the key without engaging the gear train lock pin.
4. The spring will return the actuator to the fail-safe position.
INTERNAL
FEEDBACK
POT
P2 WHITE/BLUE
P3 WHITE/PINK
P1 WHITE/RED
1000 OHMS
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS
AND OVERLOADPROTECTION AS REQUIRED.
M12446
Once power is restored, the actuator will return to normal
automated control.
Fig. 7. ML6295 typical wiring diagram.
95°
OPERATION
The ML6195/ML6295 DCA is designed for use in HVAC
installations to operate dampers, ventilation flaps, louvers and
valves requiring up to 142 lb-in. (16 N•m) of torque. If the
power fails, the actuator spring returns it to the fail-safe
position. The actuator is designed for reversible mounting. The
housing is asymmetrical to indicate the spring return direction
(see Fig. 2). The actuator drives from -5° to 90° (as indicated
on the label) and spring returns back to -5°.
The ML6195/ML6295 DCA is operated by an spdt floating
(Series 60) controller (see Fig. 6 and Fig. 7). The actuator
drives toward its fully open position when the controller
makes T2 to B. When the controller makes T2 to W, the
actuator drives toward its fully closed position. It stops when
neither contact is made.
"CLICK"
The actuator has a position indicator to show shaft position.
As the indicator moves with the shaft, it is an angular
representation of the shaft position; and it can be placed in
numerous distinct positions. Remove the indicator by simply
pulling it from the coupling. It can then be rotated and
repositioned at 5° increments using the two sets of three pins
on the coupling.
ROTATING
LOCKING IN PLACE
M12447A
Fig. 8. Manual override of ML6195/ML6295
Spring Return Direct Coupled Actuators.
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ML6195, ML6295 SPRING RETURN DIRECT COUPLED ACTUATORS
Auxiliary Switches (ML6295C only)
CHECKOUT
The ML6295C models have line voltage, fully adjustable
auxiliary switches. The switch setting interval (or differential) is
5°.
To perform a checkout of the ML6195/ML6295 DCA, proceed
as follows:
1. Check the damper or valve position and make sure that
24 Vac is present on the red and black leadwires.
2. Connect 24 Vac to the appropriate leadwires (red to
violet or red to orange) to move the damper or valve to
the opposite position. The ML6195/ML6295 should
drive the damper or valve.
3. If the actuator does not run, verify that the actuator is
properly installed for either cw or ccw rotation.
4. If the actuator operates in the opposite direction than
desired, reverse the violet and orange leadwires.
5. If the actuator is correctly installed and still does not
run, replace the actuator.
The switches are set as follows:
1. If the power is on, turn it off; the actuator will spring
return to the 0° position.
IMPORTANT
If the shaft coupling has been adjusted according to
the Range Stop Adjustment instructions, the position
indicator must also be adjusted to indicate 0 at the
fail-safe position. If this is not done, the position
indicator will not correspond to the auxiliary switch
adjustment settings, as shown on the label.
2. Use a flat blade screwdriver to turn the switch
adjustment dials to the desired settings.
NOTE: The numerical indication on the dials corresonds to
the location of the shaft coupling at which a signal
will be given by the switch (see Fig. 9).
Once power is restored, the actuator will return to normal
automated control.
10
20
30
A
40
AUX
SWITCH
ADD
70
90
80
70
20
30
40
B
50
60
-5° 0° 10° 20° 30°
0° 10° 20° 30°
60° 70° 80° 90°
60° 70° 80° 90°
M11699
Fig. 9. Actuator rotary range and auxiliiary switch
signal locations.
63-2537—1
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Home and Building Control
Honeywell Inc.
Honeywell Plaza
P.O. Box 524
Minneapolis MN 55408-0524
Home and Building Control
Honeywell Limited-Honeywell Limitée
155 Gordon Baker Road
North York, Ontario
Honeywell Asia Pacific Inc.
Room 3213-3225
Sun Hung Kai Centre
No. 30 Harbour Road
Wanchai
M2H 3N7
Hong Kong
Honeywell Latin American Division
Miami Lakes Headquarters
14505 Commerce Way Suite 500
Miami Lakes FL 33016
Honeywell Europe S.A.
3 Avenue du Bourget
1140 Brussels
Belgium
Helping You Control Your World®
Printed in U.S.A. on recycled
paper containing at least 10%
63-2537—1 B.B. Rev. 10-97
post-consumer paper fibers.
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