Honeywell ML6185 User manual

1 63-2483—2G.R. • Rev. 4-95 • ©Honeywell Inc. 1995
ML6185
Spring Return
Direct CoupledActuator
The ML6185 Spring Return Direct Coupled
RotaryActuatorisafloatingcontrolmotorthatcan
be used with controls that provide switched or
floating single pole double throw (spdt) control
output to operate dampers in heating, ventilation,
and air conditioning (HVAC) applications.
■Mounts directly on horizontal 3/8 in., 1/2 in., and
5/8 in. round and square damper shafts by using the
appropriate insert. Most models are shipped with 1/
2 in. insert.
■Provides 50 lb-in. running and spring return torque.
■Magneticcouplingeliminatestheneedformechani-
cal stops or limit switch adjustments by limiting
stall torque to 130 lb-in. maximum.
■95°stroke provides necessary compression of rub-
ber/neoprene gaskets commonly used on 90°low
leakage dampers.
■88 second synchronous timing can eliminate need
forfeedbackpositionindicationinclosed-looptem-
perature control applications.
■Removablesplinedoutputhubpermitspremounting
ofthehubonthedampershaft,providinginstallation
flexibility.
■Reversible mounting allows actuator to be used for
either clockwise (cw) or counterclockwise (ccw)
spring rotation.
■Designedforbothsingle-pointandthree-pointmount-
ing, providing installation flexibility.
■Availablewithorwithoutatime-outfeature.Models
without the time-out feature are designed to be used
withintelligent building management system and/or
controller.
■Standard models have two 8 mm x 12 mm long set
screws for securing the damper shaft. Actuator
models are available for various shaft sizes that will
allowthedampershafttooperatecentered inside the
output hub.
■Standard one-meter cable with color-coded lead-
wires allows external wire connections with 1/2 in.
conduit connectors.
■Can mount two or more actuators on one damper
shaft to increase output torque for use on dampers
larger than 16 square feet.
63-2483-2
CONTENTS
Specifications .................................................2
Ordering Information.....................................2
Installation .....................................................4
Operation .......................................................9
Checkout.......................................................11

63-2483—2 2
ML6185
SPECIFICATIONS • ORDERING INFORMATION
Specifications
MODELS: ML6185 Spring Return Direct Coupled Rotary
Actuators.
ML6185A:MediumTorque(50lb-in.)DirectCoupled
Rotary Actuator without auxiliary switches and
without time-out function.
ML6185C:MediumTorque(50lb-in.)DirectCoupled
Rotary Actuator with two line voltage rated aux-
iliary switches, without time-out function.
ML6185D:MediumTorque(50lb-in.)DirectCoupled
Rotary Actuator without auxiliary switches and
with time-out function.
ML6185F:MediumTorque(50lb-in.)DirectCoupled
Rotary Actuator with two line voltage auxiliary
switches and time-out function.
ELECTRICAL RATINGS:
Power Input: 24 Vac ±20%, 50/60 Hz.
Power Consumption:
ML6185A-C: 12 VA maximum at 24 Vac.
ML6185D,F: 12 VA maximum at 24 Vac.
AuxiliarySwitchRatings:120,240Vac:3AFL,18ALR,
1A pilot duty.
Control: Standard models include nonplenum UL/
CSA rated, 30V, 60°C, 20 gauge cable.
Auxiliary Switch: UL/CSA rated 300V 90°C, 18
gauge.
TORQUE RATINGS (at Rated Voltages):
Lift and Hold: 50 lb-in. (6 N•m).
Breakaway Minimum: 50 lb-in. (6 N•m).
Stall Minimum: 50 lb-in. (6 N•m) spring return.
Stall Driving Maximum: 130 lb-in. (15 N•m).
ACTUATOR STROKE: 95°Nominal ±2°, mechanically
limited.
ACTUATOR TIMING at 90°Stroke:
88 +/- 2 seconds synchronous at 60 Hz from 0°F to
140°F;
106 +/- 2 seconds at 50 Hz;
100 seconds at -30°F.
Spring Wind Timing (Upon Power Restoration Only):
100 seconds nominal at 60 Hz, 120 seconds at 50 Hz.
Spring Return Timing:
10 seconds minimum per 90°at 72°F no load;
30 seconds maximum per 90°at 72°F at rated load;
5 minutes maximum at -30°F at rated load.
AMBIENT TEMPERATURE RANGE: -30°F to +140°F
(-35°C to +60°C).
STORAGE TEMPERATURE: -30°F to 150°F (-35°C to
65°C).
HUMIDITY: 5 to 95 percent relative humidity, noncondensing.
MOUNTING: Mounts directly on horizontal 3/8 in. to
5/8 in. (12 to 16 mm) round or square damper shaft.
Minimumshaftlengthrequired:3.5in.(76mm)whenthe
shaft attachment is made on the side of the actuator
opposite the duct; 0.65 in. (16 mm) when the hub is
mountedontheshaftbeforetheactuatorisinstalled.Most
actuators are shipped with specifically sized hubs. Some
models contain an assembly with assorted hub inserts.
Mounting bracket is included with most models.
DIMENSIONS: See Fig. 1.
Ordering Information
When purchasing replacement and modernization products from your TRADELINE®wholesaler or distributor, refer to the TRADELINE®
Catalog or price sheets for complete ordering number, or specify:
1. Model number.
2. Application.
If you have additional questions, need further information, or would like to comment on our products or services, please write or phone:
1. Your local Honeywell Home and Building Control Sales Office (check white pages of your phone directory).
2. Home and Building Control Customer Logistics
Honeywell Inc., 1885 Douglas Drive North,
Minneapolis, Minnesota 55422-4386 [phone]
In Canada—Honeywell Limited/Limitée, 740 Ellesmere Road, Scarborough, Ontario M1P 2V9. International Sales and Service
offices in all principal cities of the world.

3 63-2483—2
ML6185
SPECIFICATIONS
Fig. 1—Approximate dimensions of ML6185 Spring Return Direct Coupled Actuator and mounting
bracket in in. (mm).
M8257
135
o
± 15
o
1-3/32
(28)
1-13/32
(36)
5/16
(8)
13/32
(10)
10-13/32 (264)
3/4 (19)
1-5/8 (41)
1-13/32 (36)
4-13/32 (112)
3/8
(10)
CLEARANCE
REQUIRED
FOR SPLINED
HUB MOUNTING
1-5/32 (29)
3-1/2
(89)
13/64 (5)
MOUNTING BRACKET
1/2 (13)
1-9/32
(32)
3-15/16 (100)
23/32
(18)
8-9/32 (210)
3-29/32
(99)
1-21/32
(42)
1-5/8
(41)
3-29/32
(99)
3-1/16
(79)
1-17/32 (39) 6-25/32 (173)

63-2483—2 4
ML6185
SPECIFICATIONS • INSTALLATION
DEVICE WEIGHT: 4.0 lb (1.82 kg).
NOISE RATING: (Driving only) 45 dBA maximum at
0.9m.
SPRING ROTATION: Clockwise (cw); counterclockwise
(ccw) by reverse mounting.
POSITION INDICATOR: Mounted on actuator hub.
ACTUATOR DESIGN LIFE:
Full Stroke Cycles: 60,000.
Repositions: 1,500,000.
Spring Return Cycles: 7,500.
APPROVALS:
UL94-5V: (Enclosure) Plenum rating.
UL873: (Line voltage auxiliary switches).
CSA: FILE NUMBER E4436, Guide Number XAPX.
ENVIRONMENTALPROTECTIONRATINGS:NEMA1
standard with damper shaft in horizontal position.
MOUNTINGTAB:ForusewithUniversalmountingbracket.
ACCESSORIES:
205820A 3-Point Mounting Kit.
205830A Crank-Arm Accessory.
205753 Hub Sleeve, 3/8 in.
205758 Hub Sleeve, 5/8 in.
Installation
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 and description given in this specifi-
cationtomakesuretheproductissuitableforyourapplication.
3. Installer must be a trained, experienced service
technician.
4. After installation is complete, check out product op-
eration as provided in these instructions.
CAUTION
1. Disconnectpowerbefore installationtoprevent
electrical shock or equipment damage.
2. Never turn motor output hub by hand or with a
wrench.
3. Do not install actuator in areas with acid fumes
or other deteriorating vapors that might attack
the metal parts of the actuator.
4. Do not install actuator in areas with escaping
gas or other explosive vapors that could be
ignited by a spark from the actuator or attached
accessories.
LOCATION
Installtheactuatorinanylocationfree from acidfumesor
otherdeterioratingvaporsthatmightattackthemetalpartsof
theactuator.Makesurethelocationisnotsubjecttoescaping
gas or other explosive vapors that could accidentally be
ignited by a spark from the actuator or its attached parts.
Install the actuator in a location that allows enough clear-
ance for mounting accessories and for servicing.
MOUNTING
The ML6185 Direct Coupled Actuator is designed to
operate a damper by driving the damper shaft either
cw or ccw depending on damper design. All
actuators are shipped in the fully closed position.
The ML6185 Direct Coupled Actuator is designed for
single-pointmountingwhenusinganadapterbracket.Single-
pointmountingistypicallyusedwhentheactuatorismounted
on the damper frame.
A mounting bracket (see Fig. 1) is provided with some
models to aid in installing the actuator. The bracket can be
bent to any shape to support the actuator at the correct
height.
TheML6185DirectCoupledActuatorcanalsobethree-
point mounted using the two front gear housing slots and
the adapter bracket. Secure two screws through the two
front gear housing slots and position the adapter bracket to
securetherearoftheactuator.Threepointmountingisused
for foot mounting the actuator or internally mounting the
actuator in the duct, when direct shaft coupling is not
possible.
CAUTION
Do not use the actuator as a shaft bearing. The
actuator must be used only to supply rotational
torque. To prevent damage to the actuator, avoid
any side loads to the actuator output coupling
bearings.
PREPARATION
Before installing the ML6185 on the damper shaft,
determine the opening direction of the damper shaft to
determine the correct spring return rotation and correctly
connect the wiring. The ML6185 can be mounted to pro-
vide clockwise or counterclockwise spring return. Reverse
the actuator, if necessary, to provide the desired spring
action.
INSTALLATION
Installing the Actuator and Mounting Bracket (Single
Point Mounting)
When the direction of the damper shaft rotation is deter-
mined (either cw or ccw ), proceed as follows:
1. Place the ML6185 Direct Coupled Actuator 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. 2) and adjust it
tosupporttheactuatoratthe correctheight.Markthescrew
holes for installing the mounting bracket on the damper
housing.

5 63-2483—2
ML6185
INSTALLATION
4. Remove the mounting bracket and actuator.
5. Drillorcenterpunchthestartingholesforthemount-
ing bracket screws (or use no. 10 self-tapping sheet metal
screws).
Fig. 2—Installing mounting bracket on ML6185
Direct Coupled Actuator.
6. Place the actuator and mounting bracket back into
position over the damper shaft and install the mounting
bracket screws.
7. Tightenthe two 8mmx 12mmlong setscrewsfirmly
against the damper shaft (maximum tightening torque is
100 lb-in.).
Installing the Actuator for Three-Point Mounting
The ML6185 Direct Coupled Actuator is designed with
removable hub sleeves to accommodate specific damper
shaftsizes.Propersleeveselectionisnecessarywhenthree-
point mounting is used to avoid excessive strain on the
output gear. Most ML6185 Actuators are shipped with a
1/2in.hub sleeve.Forfielduse,severalhub sleevesizesare
available. See the Accessories listing in the Specifications
section. Shaft sizes are stamped on the sleeves.
The ML6185 Direct Coupled Actuator can be mounted
directly on the motor shaft with the actuator in any position
when the actuator housing is parallel with the damper
housing or frame. (See Fig. 7.)
The ML6185 Direct Coupled Actuator has a reversible
output hub. The hub is factory mounted on the top of the
actuator gear housing. When attaching to damper shafts
less than 3.5 in. (76 mm) long, or for ease of mounting, the
outputhub can bemounted to theinside of theactuator gear
housing. See Fig. 3. Be careful when removing the retain-
ing ring that secures the output hub to the actuator housing.
Use a flatheaded screwdriver to pry the ring loose.
60
30
90
M9386
.500
.500
30
30
0
60
60 90
M7228
1
6
4
5
2
3
DETENT
INSERT
INDICATOR
DETENTS
Fig. 3—Mounting hub to inside of actuator.

63-2483—2 6
ML6185
INSTALLATION
Other possible mounting configurations and standard
connections are shown in Fig. 4 through 7.
30
30
0
60
60 90
M7230A
INDICATOR
DETENTS
1
1COUNTER CLOCKWISE SPRING ROTATION ARROW
Fig. 4—ML6185 Actuator mounted for counterclockwise spring rotation with the output hub inside the
actuator. (NOTE: NEMA rating applies only with damper shaft in the horizontal position.)

7 63-2483—2
ML6185
INSTALLATION
Fig. 5—Standard direct coupled mounting of ML6185 to a damper with counterclockwise spring rotation.
.500
.500
30
30
60
60 90
M7229

63-2483—2 8
ML6185
INSTALLATION
Fig. 6—ML6185 Actuator standard electrical
connection.
.500
.500
30
30
60
60 90
M7231
MOUNTING
BRACKET
TO JUNCTION
BOX (UP TO
3 FT. AWAY)
Fig. 7—ML6185 Actuator can be mounted in
any position. (NOTE: NEMA rating applies only
with damper shaft in the horizontal position.)
WIRING
CAUTION
Disconnect power supply before wiring to prevent
electrical shock or equipment damage.
All wiring must comply with local electrical codes,
ordinances and regulations. The ML6185 is designed for
use with a Class 2 power supply. Voltage and frequency of
the transformer used must correspond with the characteris-
tics of the motor and those of the power supply. See Fig. 8
for a typical wiring connection.
The ML6185 has an aluminum die cast housing with
two integral cast bosses on the end of the device, tapped for
1/2 in. conduit fittings. Some models are shipped with a
water seal in the conduit opening. When conduit is needed,
remove the seal before routing the cable.
ML6185 models with Factory-mounted Auxiliary
Switches (See Fig. 9)
ML6185C,F models have two nonadjustable line volt-
age rated spdt auxiliary switches with switches factory set
to make common to normally open at 12°and 82°rotation
from the counterclockwise stop. See Fig. 9.
IMPORTANT: Actuators driving in parallel may not be
synchronized with each other. In normal operation, if
all actuators are driven to the fully open or fully closed
position, the actuators will again be synchronized.
Fig. 8—ML6185 typical wiring diagram.
M9384
30
0
60
500
500
90 60
30
L1
(HOT)
L2
1
1
2
2
MOTOR
OPTIONAL
TIME OUT
POWER
SUPPLY
SPRING
CONTROL
24 VAC
OPEN
BLUE
CLOSE
YELLOW
24 HOT
RED
24 GND
BLACK
ML6185
M7224
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
TIME OUT FUNCTION AVAILABLE WITH ML6185D,F MODELS.
WHITE/RED
WHITE/BLUE
WHITE/YELLOW
BLACK/RED
BLACK/BLUE
BLACK/YELLOW
AUX. SWITCHES
3A 120 VAC
12°
82°
M7227A
Fig. 9—ML6185C,F wiring for auxiliary
switches.

9 63-2483—2
ML6185
INSTALLATION • OPERATION
Connecting ML6185 Actuators in Parallel
ML6185 Actuators can be stacked on one damper shaft
to increase the output torque required to drive dampers
larger than 16 square feet.
To make sure proper phasing occurs, connect all four
leadwires (red, black, yellow and blue) in parallel. The
number of actuators that may be wired in parallel is depen-
dent on the transformer VA rating. Make certain that the
connected load does not exceed the current capacity of the
controller/thermostat. See Fig. 10 and 11.
Fig. 11—Common transformer with one
controller output and two actuators.
Fig. 10—Common transformer with two
controller outputs and two actuators.
four distinct positions where the indicator can be placed.
The indicator can be removed (by first removing the output
hub) to provide proper damper orientation. The indicator
canbe indexed toshow cw or ccw openor closed, using the
detents that are 90°apart. See Fig. 12. If the spring return
position is the open position, rotate the indicator until it
points to 90 on the scale. If the spring return position is the
closedposition, rotate the indicator untilit pointsto zeroon
the scale. A detent can be felt at both stops; the detents
maintain the indicator position.
The ML6185D and ML6185F models provide a time-
out function that removes power from the actuator sub-
motor if the actuator remains in one position (closed, open
or any intermediate position) for longer than a nominal 100
seconds. This time-out function helps to extend actuator
life.
IMPORTANT: The ML6185 was designed to provide 7500
springreturns;therefore,theactuatorcanbeunpowered
daily for night shutdown control. However, rapidly
cycling the actuator by removing control voltagewill
lead to premature spring failure.
Operation
L1
(HOT)
L2
1
1
BLUE
YELLOW
RED
BLACK
ML6185
BLUE
YELLOW
RED
BLACK
ML6185
M7225A
POWER SUPPLY. PROVIDE DISCONNECT MEANS
AND OVERLOAD PROTECTION AS REQUIRED.
CONTROLLER
CONTROLLER
RB
W
RB
W
L1
(HOT)
L2
1
1
BLUE
YELLOW
RED
BLACK
ML6185
BLUE
YELLOW
RED
BLACK
ML6185
M7226A
POWER SUPPLY. PROVIDE DISCONNECT MEANS
AND OVERLOAD PROTECTION AS REQUIRED.
CONTROLLER
RB
W
The ML6185 Direct Coupled Actuator is designed to be
used in ventilating and air conditioning installations to
operate dampers, ventilation flaps and louvers requiring up
to 50 lb-in. torque. If the power fails, the actuator will
spring return to the starting position. The actuator is de-
signedfor reversible mounting.Arrowsare moldedintothe
covers to show the spring return direction. The larger cover
showsacounterclockwise(ccw)springrotation;thesmaller
cover shows a clockwise (cw) spring rotation.
TheML6185 DirectCoupled Actuator is operated by an
spdt floating controller. When using an spdt floating con-
troller, the actuator will be driven toward its fully open
position when the controller makes R to B and toward the
fully closed position when the controller makes R to W. It
stops when neither contact is made.
IMPORTANT: The ML6185 is designed to respond to
instantaneous contact closures from a DDC Con-
troller. Be careful not to short cycle the actuator.
Unstabledampercontrolmaycauseprematureactua-
tor failure.
The actuator has a position indicator to depict shaft
position. As the indicator moves with the shaft, it gives an
angular representation of the damper position. There are

63-2483—2 10
ML6185
OPERATION
Fig. 12—ML6185 indicator start positions.
30
30
60
60 90
00
30
30
60
60 90
00
30
30
60
60 90
00
30
30
60
60 90
00
FULLY COUNTERCLOCKWISE SPRING RETURN INDICATOR START POSITIONS
FULLY CLOCKWISE SPRING RETURN INDICATOR START POSITIONS
DRIVE CLOCKWISE TO CLOSE
(REVERSE ACTING)
DRIVE COUNTERCLOCKWISE
TO CLOSE (REVERSE ACTING) DRIVE COUNTERCLOCKWISE
TO OPEN (DIRECT ACTING)
DRIVE CLOCKWISE TO OPEN
(DIRECT ACTING)
M7235
DETENT IN INSERT DETENT IN INSERT
DETENT IN INSERT DETENT IN INSERT
POINTER AT 90°
POINTER AT 90°
POINTER AT 0°
POINTER AT 0°
M7235B

11 63-2483—2
ML6185
CHECKOUT
Checkout
The ML6185 Direct Coupled Actuator can be checked
out either directly or by using a controller.
IMPORTANT: When power is interrupted, the actuator
returnstothenormalstartingpositionusingthespring
mechanism. When power is restored, the controller
input will not operate the actuator until the spring is
fully wound and locked. The spring windingprocess
takes approximately 100 seconds, depending on the
numberofdegreesofspringreturnremainingatpower
interrupt(i.e.,10 ° ofspring returnremainingtakes10
seconds). (If the actuator is not in the closed position,
it will run to the closed position as the spring is
winding.) Once the spring is locked in its fully wound
position,theactuator respondstoinputstothered-to-
blue or red-to-yellow leadwires.
DIRECT CHECKOUT
1. Mountthe actuatorfor the requiredapplication (either
cw or ccw rotation to open the damper).
2. Checkthedamperpositionandmakesurethat24Vacis
present on the red and black leadwires.
3. Make sure the actuator spring is fully wound and
locked by applying power for at least 100 seconds.
4. Connect 24 Vac to the appropriate leadwires (red to
blue or red to yellow) to move the damper to the opposite
position. The ML6185 should drive the damper.
5. If the actuator does not run, verify that the actuator is
properly installed for either cw or ccw rotation.
6. If the actuator operates in the opposite direction than
desired, reverse the blue and yellow leadwires.
7. If the actuator is correctly installed and still does not
run, replace the actuator.
CONTROLLER CHECKOUT
1. Adjustthesetpointofthe controllertocallforcooling.
Observe the actuator.
2. If the damper is closed, it should begin to open.
3. Ifthe damper remainsclosed,move thesetpointof the
controller farther below the room temperature.
4. If the damper still does not move, check for the
presence of 24 Vac in the input.
5. Make sure the actuator spring is fully wound by
applying power for at least 100 seconds.
6. If24Vacispresentandtheactuatordoesnotoperate,
reverse the controller leadwires to determine if the device
was miswired.
7. Ifthewiringiscorrectand24Vacispresentontheinput
terminals but the actuator does not run, replace the actuator.

63-2483—2 12
Home and Building Control Home and Building Control Helping You Control Your World
Honeywell Inc. Honeywell Limited—Honeywell Limitée
1985 Douglas Drive North 740 Ellesmere Road
Golden Valley, MN 55422 Scarborough, Ontario
M1P 2V9
Printed in U.S.A.
QUALITY IS KEY