Honeywell Automobile Parts ML6131 User Manual

ML6131  
Direct Coupled Actuator  
PRODUCT DATA  
FEATURES  
Mounts directly on damper shaft.  
6 lb-in. torque.  
Selectable 45°, 60°, and 90° stroke in either clockwise  
(cw) or counterclockwise (ccw) directions.  
15 second timing model suitable for use with pressure  
independent VAV systems.  
Magnetic coupling typically provides a maximum of  
18 lb-in. stall torque eliminating the need for  
mechanical stops or limit switch adjustments.  
Two field-addable auxiliary switches.  
Field-addable auxiliary feedback potentiometer.  
Models available with 0° to 30° minimum position  
adjustment in cw or ccw directions.  
Compatible for use with Honeywell W7620 Terminal  
Unit Controller.  
Can be used with the Commercial Zone Damper in the  
W7600 Commercial Zone System.  
APPLICATION  
Manual declutch on some models.  
The ML6131 Direct Coupled Actuator (DCA) is used to control  
dampers in applications such as variable air volume (VAV)  
terminal units. It is suitable for use with single pole double  
throw (spdt) floating thermostats or two-position control  
systems.  
Contents  
®
® U.S. Registered Trademark  
Copyright © 2000 Honeywell Inc. • All Rights Reserved  
63- 2498- 2  
 
   
ML6131 DIRECT COUPLED ACTUATOR  
2-7/8 (73)  
1-11/16  
CAUTION  
Actuator Damage Hazard.  
(42)  
Deteriorating vapors and acid fumes can damage  
the actuator metal parts.  
Install actuator in areas free of acid fumes and  
deteriorating vapors.  
1 (25)  
1/8  
(3)  
OPTIONAL  
AUXILIARY  
SWITCH  
Location  
4-7/8  
(123)  
Choose a location for the actuator that allows enough  
clearance for mounting accessories and for servicing.  
CW  
COM  
CCW  
4-1/4  
(108)  
Mounting  
These actuators are designed to open a damper or valve by  
driving the shaft in either the clockwise (cw)  
or  
counterclockwise (ccw) direction. The actuator has a  
mounting tab on the bottom that secures it to a damper box or  
valve linkage. When mounted correctly, this tab allows the  
actuator to float without rotating relative to the shaft. The tab is  
sized for 1/4 in. self-tapping sheet metal screws (not  
included).  
11/16  
(18)  
7/8  
(22)  
1-5/16  
(33)  
3-3/8 (86)  
2-1/2 (64)  
M18016  
CAUTION  
Tightly securing mounting tab to damper housing  
can damage actuator.  
Fig. 1. Approximate dimensions of ML6131  
Direct Coupled Actuator in in. (mm).  
Equipment Damage Hazard.  
Once mounted, the actuator must be allowed to float;  
do not fully tighten the screw.  
INSTALLATION  
These actuators are shipped in the fully clockwise 90° position  
as viewed from the end of the damper shaft.  
When Installing this Product...  
1.  
Read these instructions carefully. Failure to follow them  
could damage the product or cause a hazardous  
condition.  
CAUTION  
2.  
Check the ratings given in the instructions and on the  
product to make sure the product is suitable for your  
application.  
Equipment Damage Hazard.  
Mounting actuator unevenly with damper housing  
can damage actuator.  
Mount actuator flush with damper housing or add  
spacer between mounting tab and damper box  
housing (see Fig. 2).  
3.  
4.  
Installer must be a trained, experienced service  
technician.  
After installation is complete, check out product  
operation as provided in these instructions.  
IMPORTANT  
All wiring must agree with applicable codes,  
DAMPER  
SHAFT  
ADD SPACER BETWEEN  
DAMPER BOX AND TAB  
ordinances and regulations.  
ML6131  
WARNING  
Explosion Hazard.  
A spark from the actuator or attached accessories  
can result in serious injury or death.  
Install the actuator in areas free of escaping gas and  
other explosive vapors.  
VAV BOX HOUSING  
M4449  
CAUTION  
Fig. 2. Mounting actuator to VAV box when  
actuator is not flush with box.  
Electrical Shock or Equipment Damage Hazard.  
Can shock individuals or short equipment  
circuitry.  
Disconnect all power supplies before installation.  
Actuators with auxiliary switches can have more than  
one disconnect.  
3
63-2498—2  
 
     
ML6131 DIRECT COUPLED ACTUATOR  
Preparation  
Before mounting the actuator onto the shaft, determine the  
following:  
1.  
2.  
Size of the shaft (3/8 in. to 1/2 in.).  
Direction the shaft rotates to open the device (cw or  
3.  
Degrees of actuator stroke for opening device (45°, 60°,  
or 90°).  
DIRMECLT6C1O3U1PLED ACTUATOR  
If the shaft is 3/8 in. round or square, use part number 201391  
Shaft Adapter provided inside the bag assembly shipped with  
the actuator. Place the adapter opposite the setscrews  
MANUAL  
DECLUTCH  
LEVER  
ML6131  
M17611  
TYPE A DAMPER  
Fig. 5. Location of manual declutch lever.  
COOLING  
AIR FLOW  
Installation  
After determining the direction of the shaft rotation (cw or  
ccw), install the device. For valve linkage mounting, refer to  
the instructions shipped with the linkage. For damper  
mounting, proceed as follows:  
CW TO OPEN, CCW TO CLOSE  
TYPE B DAMPER  
1.  
Place the actuator onto the damper shaft.  
COOLING  
AIR FLOW  
CAUTION  
Equipment Damage Hazard.  
Improper range stop selection can damage  
light-duty dampers.  
CCW TO OPEN, CW TO CLOSE  
M2067A  
Fig. 3. Determining direction damper  
shaft rotates when opening.  
Be sure to select the proper range stop.  
2.  
If the angle of the damper opening is either 45° or 60°,  
close the actuator using the manual declutch:  
a. Disengage the hub using the declutch lever; see  
Manual Operation (Declutch) section.  
SHAFT ADAPTER  
b. Rotate the hub until the actuator gear train passes  
the proper 45° or 60° setting. (Do not insert the pin  
until after the actuator passes this point.)  
c. Release the declutch lever.  
NOTE: Dampers with 90° stroke do not require the  
range stop pin.  
M2064  
3.  
Insert the range stop pin into the appropriate (cw or  
ccw) 45° or 60° slot. The range stop pin is clipped into  
its final position only after the pin passes through both  
actuator plates (see Fig. 6). The range stop pin should  
snap into position and not be removable manually  
(see Fig. 7).  
Fig. 4. Using shaft adapter for 3/8 in. shafts.  
Manual Operation (Declutch)  
IMPORTANT  
Do not fully tighten the mounting screw; the actuator  
CAUTION  
must be allowed to float.  
Personal Injury and Product Damage Hazard.  
Do not use manual declutch without supporting  
the load.  
4.  
5.  
With the actuator placed in its final position, secure the  
mounting tab to the damper box with a sheet metal  
screw.  
Position the damper in the open position and securely  
tighten the Allen screws into the damper shaft.  
Support load independent of actuator immediately  
prior to and while using manual declutch lever.  
Manual declutch capability is available on some actuators.  
Use the manual declutch lever to manually adjust the actuator  
setting. Fig. 5 shows the location of the manual declutch lever.  
To operate, push the lever in the direction of the arrow on the  
lever cover.  
63-24982  
4
 
     
ML6131 DIRECT COUPLED ACTUATOR  
1.  
2.  
Determine the direction of the desired closing rotation.  
Move the actuator to the position fully opposite the  
desired closing rotation (if cw closing rotation is desired,  
move the actuator to the full ccw position).  
RANGE STOP PIN  
3.  
Determine the correct hole for the setscrew using Fig. 8  
and the results of step 1.  
ACTUATOR PLATES  
THIS SETSCREW  
CORRESPONDS WITH  
CLOSING IN THE  
CW DIRECTION  
THIS SETSCREW  
CORRESPONDS WITH  
CLOSING IN THE  
CCW DIRECTION  
60  
60  
45  
60  
45  
CW  
60  
45  
COM  
CCW  
45  
M10247  
Fig. 8. Setscrew location for ML6131.  
CAUTION  
Equipment Damage Hazard.  
Improper hub positioning or hole selection can  
permanently damage the device.  
Avoid backdriving the actuator with the setscrew.  
M10246A  
Fig. 6. Range stop pin properly inserted.  
4.  
Remove the red cap from the desired hole. Leave the  
other cap in position. The caps ensure that dust and  
other impurities do not enter the gear train through  
unused holes.  
SCREWDRIVER  
5.  
6.  
Thread the locknut fully onto the 1/4 in. setscrew.  
Insert the setscrew into the desired hole, turning  
clockwise until resistance is encountered or the locknut  
contacts the housing.  
7.  
8.  
If resistance is met before the setscrew is fully inserted,  
stop and review the initial setup procedures as detailed  
in steps 1 through 3.  
Determine the angle of minimum position required for  
the application. With the setscrew fully inserted, the  
minimum position is 30°. With the setscrew fully out, the  
minimum position is 0°.  
M2065  
Fig. 7. Lifting a range stop pin out of its slot.  
9.  
Using the conversion of approximately 1.7 angular  
degrees of shaft rotation per turn of the setscrew, back  
the screw out of the housing and stop slightly short of  
the calculated position. This allows the setscrew to be  
set accurately while taking air flow measurements.  
Minimum Position Setscrew  
Certain ML6131 models are equipped with two tapped holes  
located in the plastic housing at the top of the actuator. These  
holes can be used with the minimum position setscrew and  
locknut inside the 4074ENJ Bag Assembly (see Fig. 6). The  
setscrew provides for a 0° to 30° minimum position  
adjustment.  
IMPORTANT  
After initiating step 10, the setscrew cannot be  
turned into the housing without returning the actuator  
to the fully open position (as determined in step 1).  
The actuator follows the setscrew without damaging  
the housing only when backed out of the housing  
(turned ccw).  
NOTE: Before starting operation, note that the 1/4 in.  
minimum position setscrew limits closing motion,  
while the range stop pin limits opening motion.  
5
63-24982  
 
     
ML6131 DIRECT COUPLED ACTUATOR  
10.  
11.  
Rotate the actuator to minimum position using the  
manual declutch; see Manual Operation (Declutch)  
section.  
With the actuator at minimum position, adjust the  
position more accurately using air flow measurements.  
The 201052A, B and C Auxiliary Switches are field-addable.  
For mounting instructions, see form 63-2218, provided with  
the device.  
IMPORTANT  
When operating an ML6131 from a two-position  
controller, a 201052B Auxiliary Switch is required for  
proper operation. See Fig. 10.  
IMPORTANT  
— After each adjustment, ensure the actuator is  
completely stopped before proceeding with the next  
adjustment.  
NOTE: See Fig. 11 for the 201052B Auxiliary Switch wiring.  
— To reduce the minimum position, turn out the  
setscrew (ccw). The actuator then drives toward the  
closed position.  
— Turning the setscrew in (cw) damages the actuator  
housing.  
2
ML6131  
EXTERNAL  
SWITCH  
R8222  
RED COM  
BLUE CW  
— If the device is too far closed, return to step 1.  
12.  
When proper air flow is achieved, loosen the locknut  
from the setscrew until it contacts the actuator housing,  
then turn it an additional 1/8 turn to lock the setscrew in  
place.  
WHITE CCW  
T87F  
1
L1  
(HOT)  
W
Y
L2  
R
IMPORTANT  
Run an entire check of the operation after completing  
this procedure.  
1
2
POWER SUPPLY. PROVIDE DISCONNECT MEANS  
AND OVERLOAD PROTECTION AS REQUIRED.  
AUXILIARY SWITCHES ARE REQUIRED TO TURN  
OFF THE MOTOR AT EACH END OF THE STROKE.  
Wiring  
M17613  
Fig. 9. ML6131 used with T87F in heating-only  
or cooling-only application.  
CAUTION  
Electrical Shock or Equipment Damage Hazard.  
Can shock individuals or short equipment  
circuitry.  
ML6131  
L1  
201052B  
(HOT)  
RED COM  
BLUE CW  
Disconnect all power supplies before installation.  
Actuators with auxiliary switches can have more than  
one disconnect.  
SPDT  
CONTROL  
L2  
2
1
ON/OFF  
CONTROL  
WHITE CCW  
3
4
All wiring must comply with local electrical codes, ordinances  
and regulations. Voltage and frequency of the transformer  
used with the actuator must correspond with the  
characteristics of both the power supply and the actuator.  
Screw terminals are provided for easy hookup. See Fig. 9 for  
typical wiring.  
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD  
PROTECTION AS REQUIRED.  
2
3
SET SWITCH TO CLOSE WHEN STROKE REACHES FULL CW POSITION.  
SET SWITCH TO CLOSE WHEN STROKE REACHES FULL CCW POSITION.  
ON-OFF CONTROL REQUIRES AN R8222 SPDT RELAY IN PLACE OF THE  
4
Auxiliary Switches  
SPDT CONTROL.  
M17612  
The 201052A, B or C Auxiliary Switch is used in conjunction  
with the actuator. It allows for control of equipment external to  
the actuator (for example, electric reheat coils and fan) at an  
adjustable point in the stroke (0° to 90°) of the actuator.  
Fig. 10. 201052B Auxiliary Switch wiring.  
63-24982  
6
 
   
ML6131 DIRECT COUPLED ACTUATOR  
Auxiliary Potentiometers  
AUXILIARY POTENTIOMETER  
The 200976 Auxiliary Potentiometer mounts on the face of  
certain ML6131A actuators as shown in Fig. 11. The  
potentiometer shaft has a slipping collar, which means that if  
one of the two limits of the potentiometer is exceeded, the  
collar will continue to rotate, causing no damage to the  
potentiometer itself. To mount the potentiometer on the  
actuator:  
MOTOR  
RB  
RW  
POSITION  
RESISTANCE  
RESISTANCE  
FULLY CW  
24V (COM-CW)  
500 OR  
2000 OHMS  
0 OHMS  
500 OR  
2000 OHMS  
FULLY CCW  
24V (COM-CCW)  
0 OHMS  
1.  
2.  
3.  
Turn the potentiometer to align the shaft key with the  
slot in the potentiometer drive.  
AUXILIARY POTENTIOMETER LEADS  
MOTOR  
Tilt the potentiometer slightly so the key faces down  
toward the slot.  
Insert the potentiometer into the slot, and push down so  
the potentiometer is flush with the actuator body and the  
bracket is aligned over the screw hole.  
Insert the screw provided into the hole and fasten  
securely.  
ROTATION  
RW OHMS  
INCREASE  
DECREASE  
RB OHMS  
DECREASE  
INCREASE  
CCW  
CW  
4.  
IMPORTANT  
Failure to follow the calibration procedures can result  
in improper resistance values at desired stroke.  
60  
To Calibrate the 200976A,C:  
60  
45  
IMPORTANT  
Remove the range stop pins and minimum position  
45  
setscrews prior to calibration.  
CW  
1.  
2.  
3.  
Drive the actuator fully closed (0°) to fully open (90°)  
and back again to the fully closed position. This must be  
done to receive the correct resistance readings at the  
appropriate degree of stroke.  
Check the resistance values of the potentiometer with  
an ohmmeter at intervals in the stroke while referring to  
the table in Fig. 11 and resistance information provided  
in the Specifications section.  
COM  
CCW  
R
B
W
Replace the range stop pins and/or the minimum  
position setscrews using the appropriate procedures.  
FIELD-ADDABLE AUXILIARY POTENTIOMETER  
M10251B  
Fig. 11. ML6131 with field-addable potentiometer.  
7
63-24982  
 
 
ML6131 DIRECT COUPLED ACTUATOR  
OPERATION  
CHECKOUT  
To check out the ML6131, determine the direction the damper  
shaft moves to open the damper (cw or ccw). See Fig. 3:  
VAV Systems  
1.  
2.  
3.  
VAV systems control the temperature within a space by  
varying the volume of supply air. Air is delivered to the space  
at a fixed temperature. The volume of supply air is controlled  
by the space thermostat modulating the supply air damper.  
When full heating and cooling flexibility is required in a zone, it  
is handled by temperature air system, or with reheat capability  
in the air terminal units. As individual zones shut down, the  
total air flow in the system is regulated by a central duct static  
pressure controller. The fan system is sized to handle an  
average peak load, not the sum of the individual peaks. As  
each zone peaks at a different time of day, extra air is  
Place 24 Vac across the appropriate COM and CW or  
COM and CCW terminals to energize the actuator. The  
ML6131 should begin to open the damper.  
If the actuator does not run, switch the 24 Vac across  
the opposite COM and CW or COM and CCW terminals  
to determine if the damper will begin to close.  
If the actuator does not run in either direction, replace  
the ML6131.  
In the event the ML6131 is used with a spdt floating wall  
thermostat (pressure dependent systems):  
1.  
2.  
borrowed from the off-peak zones. This transfer of air from  
low-load to high-load zones occurs only in true VAV systems.  
Adjust the setpoint of the thermostat to call for cooling.  
Observe the operation of the actuator; if the device is  
closed, it should begin to open.  
3.  
4.  
5.  
In pressure independent systems, individual zone airflow  
sensors are used to maintain the zone air flow rate regardless  
of fluctuation in the total system pressure.  
If not, adjust the setpoint of the thermostat higher to  
determine if the wiring is correct.  
If no movement is observed, check for the presence of  
24 volts.  
If using the T641 Thermostat, check that 24 volts are  
present between terminals C and Y during a call for  
cooling. With proper wiring and 24 volts present, the  
actuator should operate correctly.  
Pressure independent systems, when used with controllers  
such as the W7620, can react faster to changes in air flow  
demand. Therefore, these systems can use the faster  
15 second ML6131 models.  
6.  
If not, replace the actuator.  
Parallel Actuators  
NOTE: When the ML6131 is used with electronic  
control systems such as the W7620, override  
the control system by programming the  
controller to open/close the zone damper as  
appropriate.  
IMPORTANT  
Over time, parallel-driving actuators can become out  
of sync with each other. Normally, driving all  
actuators to the fully-open or fully-closed position  
puts them back in sync.  
Using Fig. 9, parallel the CW, COM and CCW terminals. Make  
certain the total connected load does not exceed the current  
capacity of the controller or thermostat.  
Home and Building Control  
Honeywell Inc.  
Honeywell Plaza  
Home and Building Control  
Honeywell Limited-Honeywell Limitée  
155 Gordon Baker Road  
North York, Ontario  
P.O. Box 524  
Minneapolis, MN 55408-0524  
M2H 3N7  
Printed in U.S.A. on recycled  
paper containing at least 10%  
post-consumer paper fibers.  
63-24982 B.B. Rev. 6-00  
 
   

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