Honeywell Automobile Parts ML6195 User Manual

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  
 
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.  
63-2537—1  
3
 
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.  
63-2537—1  
4
 
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.  
63-2537—1  
5
 
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.  
63-2537—1  
6
 
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  
7
 
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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