Honeywell Automobile Parts ML6194 User Manual

ML6194, ML6294  
Non-Spring Return  
Direct Coupled Actuators  
PRODUCT DATA  
FEATURES  
Mount directly on 1/2 in. to 3/4 in. (13 to 19 mm) round  
or square shaft. Mount on 1 in. (26 mm) round shafts  
with appropriate insert. All models shipped with 1 in.  
insert.  
300 lb-in. (34 N•m) torque.  
Magnetic coupling eliminates need for mechanical  
stops or limit switch adjustments by limiting stall  
torque, which is dependent on temperature. Nominal  
stall torque at room temperature of 68°F (20°C) is 410  
lb-in.  
95° stroke provides necessary compression of  
rubber/neoprene gaskets commonly used on 90° low  
leakage dampers.  
Declutch feature allows manual adjustment.  
165 second synchronous timing can eliminate need for  
feedback position indication in closed-loop  
temperature control applications.  
Both single-point and three-point mounting  
compatibility to allow installation flexibility.  
APPLICATION  
Models available with or without time-out feature.  
The ML6194 and ML6294 Non-Spring Return Direct Coupled  
Actuators (DCA) provide floating single-pole, double-throw  
(spdt) control of dampers or valves in heating, ventilating, and  
air conditioning (HVAC) applications. The ML6294 has an  
internal, electrically isolated feedback potentiometer that can  
be used to provide indication of motor output hub position or  
slave a Series 90 actuator.  
Contents  
Ordering Information ........................................................  
2
® U.S. Registered Trademark  
© 2004 Honeywell International Inc.  
All Rights Reserved  
63-2511—1  
 
   
ML6194, ML6294 NON-SPRING RETURN DIRECT COUPLED ACTUATORS  
Minimum shaft length required is 2.5 in. (64 mm).  
Mounting bracket included with all models.  
Dimensions: See Fig. 2.  
All actuators shipped with 1 in. (26 mm) hub insert. See  
Accessories section for additional hub sizes.  
4 (102)  
3-3/32 (79)  
7/16 (11)  
1-17/32  
(39)  
9/32 (7)  
3 PLACES  
1
1-1/4  
(32)  
8-7/16  
(215)  
7-11/16  
(196)  
1/2  
(12)  
36  
(914)  
1-29/32  
(48)  
13/32 (10)  
5/8 (17)  
3-5/32  
(80)  
1/4 (6)  
1/8 (3)  
1/4 (6)  
2
(51)  
1 (25)  
3/4  
(19)  
7/8 (22)  
1/2  
(13)  
1/2 (13)  
15/16  
(24)  
1-11/16 (43)  
2-1/2 (63)  
1/2 (13)  
3-5/16 (84)  
4-1/2 (114)  
1
REMOVABLE RETAINING RING FOR  
HUB SLEEVE REMOVAL.  
5 (127)  
M11270A  
6 (152)  
Fig. 2. Approximate dimensions of ML6194/ML6294 Non-Spring Return DCA and mounting bracket in in. (mm).  
3
63-2511—1  
 
ML6194, ML6294 NON-SPRING RETURN DIRECT COUPLED ACTUATORS  
Device Weight: 3.0 lb (1.36 kg).  
CAUTION  
Wrong location or improper operation will damage  
the actuator.  
1. Deteriorating vapors and acid fumes can damage  
actuator metal parts.  
2. Install actuator in areas free of acid fumes and other  
deteriorating vapors.  
Noise Rating: 45 dBA maximum at 1 meter.  
Position Indicator: Mounted on actuator hub.  
Actuator Design Life: Full Stroke Cycles: 50,000.  
Repositions: 1,500,000 minimum.  
Equipment Damage Hazard.  
3. Turning motor output hub by hand or wrench can  
damage internal gears.  
4. Ensure declutch button is depressed while manually  
Approvals:  
Underwriter’s Laboratories Inc. Component Recognized:  
UL873, File No. E4436; Guide No. XAPX.  
CSA Listed: File Number LR95329-17.  
Meets UL94-5V plenum requirements.  
turning hub.  
Mounting  
Environment Protection Rating: IP54 standard with shaft in  
The ML6194/ML6294 Non-Spring Return DCA is designed  
with removable hub inserts to accommodate specific shaft  
sizes. Proper insert selection is necessary to avoid excessive  
strain on output gear. All ML6194/ML6294 Actuators are  
shipped with a one-inch hub insert. For field use, two hub  
insert sizes are available (see Accessories section). A  
mounting bracket (see Fig. 2 and 3) is provided with all  
models to aid in installing actuator. The bracket can be bent to  
any shape to allow the bracket tab to be centered in actuator  
slot.  
horizontal position.  
Accessories:  
205843B Hub Insert, 1 in. round, with retaining ring.  
205856B Hub Insert, 3/4 in., round or square, with retaining  
ring.  
205849A Hub Insert, 5/8 in., round or square, with set screws.  
205820A Three-point Mounting Kit.  
205846 Crank-Arm Accessory.  
205860 Remote Minimum Position Potentiometer.  
205860A Remote Minimum Position Potentiometer, NEMA IV  
rated.  
The ML6194/ML6294 Non-Spring Return DCA is designed for  
single-point mounting when using a mounting bracket.  
Single-point mounting is typically used when actuator is  
mounted on a shaft.  
INSTALLATION  
The ML6194/ML6294 Non-Spring Return DCA can also be  
three-point mounted using three-point mounting kit (see  
Accessories section). Three-point mounting is used for foot  
mounting actuator or internally mounting actuator in the duct  
when direct shaft coupling is not possible.  
When Installing this Product...  
1. Read instructions carefully. Failure to follow them could  
damage the product or cause a hazardous condition.  
2. Check ratings and descriptions given in specifications to  
make sure product is suitable for your application.  
3. Installer must be a trained, experienced service  
technician.  
The ML6194/ML6294 Non-Spring Return DCA can be  
mounted directly on the shaft with the actuator in any position.  
4. After installation is complete, check out product  
operation as provided in these instructions.  
CAUTION  
Actuator and Damper Damage Hazard.  
Mounting bracket binding or clamping actuator to  
duct can damage actuator.  
WARNING  
Explosion or Fire Hazard.  
Use mounting bracket only to prevent actuator  
housing from rotating.  
Can cause severe injury, death or property  
damage.  
A spark from the actuator or attached accessories  
could ignite escaping gas or vapors. Install actuator in  
areas free of escaping gas and other explosive  
vapors.  
NOTE: Install mounting bracket so that mounting bracket tab  
is centered in actuator slot.  
Changing Hub Inserts.  
Change hub insert sizes by removing retaining ring and lifting  
hub insert from actuator. Put new insert in place and replace  
retaining ring. See Fig. 4. Be careful when removing the  
retaining ring that secures the output hub to actuator housing.  
Use a flathead screwdriver to pry ring loose.  
WARNING  
Electrical Shock or Equipment Damage Hazard.  
Can cause severe injury, death or property  
damage.  
Disconnect power supply before installation. Actuators  
with auxiliary switches can have more than one  
disconnect.  
63-2511—1  
4
 
 
ML6194, ML6294 NON-SPRING RETURN DIRECT COUPLED ACTUATORS  
RETAINING  
RING  
60  
30  
90  
0
6
30  
0
HUB  
INSERTS  
DECLUTCH  
BUTTON  
ACTUATOR  
SLOT  
1
1
INSTALL MOUNTING BRACKET SO THAT MOUNTING  
BRACKET TAB IS CENTERED IN ACTUATOR SLOT.  
M11271A  
DECLUTCH  
BUTTON  
M11272A  
Fig. 3. Installing mounting bracket on ML6194/ML6294  
Non-Spring Return DCA.  
A typical actuator mechanical connection is shown in Fig. 5;  
see Fig. 6 through 13 for wiring diagrams.  
Fig. 4. Changing hub inserts.  
Installation  
CAUTION  
Using actuator as shaft bearing can damage  
actuator.  
Use actuator only to supply rotational torque. Avoid  
any side loads to actuator output coupling bearings.  
Actuator Damage Hazard.  
Installing Actuator and Mounting Bracket  
(Single-Point Mounting)  
1. Place ML6194/ML6294 Non-Spring Return DCA over  
shaft.  
2. Position actuator for best access to actuator shaft  
locking screw.  
Preparation  
3. Install mounting bracket (see Fig. 2) and adjust it to  
center mounting bracket tab in actuator slot. Mark screw  
holes for installing mounting bracket on housing.  
4. Remove mounting bracket and actuator.  
5. Drill mounting holes for screws (screws not provided).  
6. Place actuator and mounting bracket back into position  
over shaft and install mounting bracket screws.  
Before installing actuator on shaft, determine opening  
direction of shaft to correctly connect wiring.  
7. Move shaft either fully clockwise  
counterclockwise  
8. Fully depress and hold declutch button while moving  
actuator hub either fully clockwise or fully  
to match shaft. Release  
or fully  
.
counterclockwise  
declutch button.  
9. Tighten the two set screws firmly (80 to 100 lb-in.)  
against shaft.  
5
63-2511—1  
 
ML6194, ML6294 NON-SPRING RETURN DIRECT COUPLED ACTUATORS  
transformer used must correspond with characteristics of  
motor and those of power supply. See Fig. 5 for standard  
mechanical connection. See Fig. 6 through 9 for typical wiring  
diagrams.  
ML6194A,C  
CONTROLLER  
B
BLUE  
MOTOR  
W
YELLOW  
0
6
0
3
0
9
1
0
6
L1  
(HOT)  
24 VAC  
T2  
0
3
0
L2  
BLACK  
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD  
PROTECTION AS REQUIRED.  
M11283A  
Fig. 6. ML6194A,C typical wiring diagram.  
ML6194D,F  
CONTROLLER  
B
BLUE  
MOTOR  
W
YELLOW  
TIME OUT  
T2  
RED  
1
2
L1  
(HOT)  
24 VAC  
T1  
L2  
BLACK  
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD  
PROTECTION AS REQUIRED.  
TO JUNCTION  
BOX (UP TO  
3 FT AWAY)  
2
TIME-OUT FUNCTION AVAILABLE WITH ML6194D,F MODELS.  
M11282A  
MOUNTING  
BRACKET  
Fig. 7. ML6194D,F typical wiring diagram.  
M11273A  
Fig. 5. ML6194/ML6294 Actuator standard  
mechanical connection.  
ML6294A,C  
CONTROLLER  
B
BLUE  
MOTOR  
W
WIRING  
1
YELLOW  
L1  
(HOT)  
24 VAC  
T1 BLACK  
L2  
TAN  
WARNING  
Can cause severe injury, death or property  
2
GREEN (CLOSED)  
ORANGE (OPEN)  
Electrical Shock Hazard.  
damage.  
1
2
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD  
PROTECTION AS REQUIRED.  
Disconnect power supply before installation. Actuators  
with auxiliary switches can have more than one  
disconnect.  
M11281A  
500 OHM POTENTIOMETER.  
Fig. 8. ML6294A,C typical wiring diagram.  
All wiring must comply with local electrical codes, ordinances  
and regulations. The ML6194/ML6294 are designed for use  
with a Class 2 power supply. Voltage and frequency of  
63-2511—1  
6
 
 
ML6194, ML6294 NON-SPRING RETURN DIRECT COUPLED ACTUATORS  
ML6194A,C  
ML6294A,C  
ML6294  
CONTROLLER  
B
CONTROLLER  
BLUE  
MOTOR  
BLUE  
W
YELLOW  
1
YELLOW  
L1  
(HOT)  
2
1
TIME OUT  
T2  
BLACK  
L1  
(HOT)  
RED  
T1  
L2  
24 VAC  
L2  
BLACK  
ML6194A,C  
ML6294A,C  
TAN  
3
GREEN (CLOSED)  
ORANGE (OPEN)  
CONTROLLER  
BLUE  
YELLOW  
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND  
OVERLOAD PROTECTION AS REQUIRED.  
2
3
TIME-OUT FUNCTION AVAILABLE WITH ML6294D,F MODELS.  
BLACK  
M11277A  
M11280A  
500 OHM POTENTIOMETER.  
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS  
AND OVERLOAD PROTECTION AS REQUIRED.  
Fig. 9. ML6294D,F typical wiring diagram.  
Fig. 11. Common transformer with two controller outputs  
and two ML6194A,C or ML6294A,C Actuators.  
The ML6194/ML6294 has a plastic housing with two tapped  
holes for 1/2 in. (13 mm) conduit fittings.  
ML6194 and ML6294 Models with Factory-  
mounted Auxiliary Switches (see Fig. 10)  
ML6194D,F  
ML6294D,F  
CONTROLLER  
ML6194C,F and ML6294C,F models have two nonadjustable  
low voltage rated spdt auxiliary switches that are factory set to  
make common to normally open at 12° and 82° rotation from  
closed (counterclockwise). See Fig. 10.  
BLUE  
YELLOW  
RED  
1
L1  
(HOT)  
BLACK  
L2  
COMMON  
ML6194D,F  
ML6294D,F  
WHITE/RED  
12  
NO  
WHITE/BLUE  
CONTROLLER  
INTERNAL  
AUXILIARY  
SWITCH  
NC  
WHITE/YELLOW  
BLACK/RED  
BLUE  
COMMON  
YELLOW  
82  
3A, 24 VAC  
NO  
NC  
BLACK/BLUE  
RED  
BLACK/YELLOW  
M7877A  
BLACK  
SWITCHES SHOWN AT ACTUATOR (CCW)  
CLOSED POSITION.  
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS  
AND OVERLOAD PROTECTION AS REQUIRED.  
M11278A  
Fig. 10. ML6194C,F and ML6294 Actuator wiring for  
auxiliary switches.  
Fig. 12. Common transformer with two controller outputs  
and two ML6194D,F or ML6294D,F Actuators.  
ML6194 and ML6294 Wiring for Common  
Transformer  
OPERATION  
Fig. 11 through 13 show typical wiring for ML6194 and  
ML6294 Non-Spring Return DCA using a common  
transformer.  
The ML6194 and ML6294 Non-Spring Return DCA are  
designed to be used in ventilating and air conditioning  
installations to operate dampers, ventilation flaps, and louvers  
requiring up to 300 lb-in. torque.  
The ML6194 and ML6294 Non-Spring Return DCA are  
operated by an spdt floating controller. When using an spdt  
floating controller, actuator is driven toward fully open  
(clockwise) position when controller makes B contact and  
toward fully closed (counterclockwise) position when  
controller makes W contact. It stops when neither contact is  
made.  
7
63-2511—1  
 
 
ML6194, ML6294 NON-SPRING RETURN DIRECT COUPLED ACTUATORS  
3. Apply 24 Vac control signal to blue (B) lead with respect  
to black (T1) lead. The actuator should drive shaft open  
(clockwise ).  
ML6194A,C  
ML6294A,C  
CONTROLLER  
4. Apply 24 Vac control signal to yellow (W) lead with  
BLUE  
respect to black (T1) lead. The actuator should drive  
YELLOW  
shaft closed (counterclockwise  
).  
1
5. If 24 Vac control signal is removed, actuator should  
L1  
(HOT)  
stop.  
BLACK  
L2  
TROUBLESHOOTING  
ML6194A,C  
ML6294A,C  
If actuator does not drive, travel full stroke, or operate properly  
during checkout, perform following troubleshooting procedure  
before replacing actuator:  
BLUE  
YELLOW  
1. Check actuator label to make sure proper power and  
control signal requirements are met.  
BLACK  
2. When actuator should be driving, check for 24 Vac at  
actuator wires:  
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS  
AND OVERLOAD PROTECTION AS REQUIRED.  
M11279A  
a. Black (T1) and yellow (W) or blue (B).  
b. Black (T1) and red (T2).  
3. If voltage is not present or is low, check power supply  
Fig. 13. Common transformer with one controller output  
and two ML6194A,C or ML6294A,C Actuators.  
and controller.  
4. If actuator does not drive in correct direction when a  
control signal is applied, reverse yellow and blue wires.  
5. Remove power and fully depress and hold down  
disengage button while trying to turn shaft  
IMPORTANT  
ML6194/ML6294 Actuators can operate with a DDC  
Controller that emulates an spdt break-before-make  
switch. Do not short-cycle actuator. Short-cycling  
actuator can cause premature failure.  
clockwise  
and counterclockwise  
. If shaft  
turns freely through 90° stroke, and actuator is installed  
correctly, replace actuator.  
The actuator has a position indicator to show shaft position.  
As the indicator moves with the shaft, it gives an angular  
representation of shaft position. The indicator can be rotated  
to show open or closed position.  
6. If shaft does not turn freely for full 90° stroke, check for  
any binding and verify that actuator is loose on its  
mounting bracket to prevent binding. If necessary,  
adjust mounting bracket to prevent binding.  
7. If no binding is present, remove actuator and turn shaft  
ML6194D,F and ML6294D,F models provide a time-out  
feature that removes power from actuator submotor if the  
actuator receives the same signal or no call from controller for  
longer than a nominal five minutes. This time-out feature  
helps to extend actuator life.  
clockwise  
and counterclockwise  
. If shaft  
does not turn freely, repair or replace damper.  
8. If shaft turns freely, fully depress and hold down  
disengage button and turn actuator hub  
clockwise  
and counterclockwise  
. If actuator  
hub does not turn, replace actuator.  
9. If actuator and shaft turn freely, remount actuator  
following instructions in Installation section. Make sure  
actuator does not bind. Also, make sure that shaft and  
CHECKOUT  
Use following procedure to check out ML6194 and ML6294  
Non-Spring Return DCA:  
actuator are at the same clockwise  
or  
counterclockwise end stop when assembled.  
Hook up wires and repeat checkout. If necessary,  
troubleshoot again.  
1. Check that actuator position indicator and shaft position  
agree.  
2. If actuator has a time-out feature, apply 24 Vac to black  
(T1) and red (T2) leads (see Fig. 7 or 9).  
Automation and Control Solutions  
Honeywell International Inc.  
1985 Douglas Drive North  
Golden Valley, MN 55422  
Honeywell Limited-Honeywell Limitée  
35 Dynamic Drive  
Scarborough, Ontario  
M1V 4Z9  
63-2511—1 G.R. Rev. 06-04  
 
   

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