Honeywell ML7999A Operation manual

PRODUCT DATA
65-0239-2
® U.S. Registered Trademark
Copyright © 2003 Honeywell International Inc.
All Rights Reserved
ML7999A
Universal Parallel-Positioning Actuator
APPLICATION
ML7999A Universal Parallel-Positioning Actuator provides
100 lb-in. torque, pulse-width-modulating (PWM) control of
combustion air dampers, butterfly gas valves, oil modulation
valves, and flue gas recirculation systems. The actuator
includes a precision feedback potentiometer and integral
power supply capable of direct line voltage connection. The
ML7999A Actuator is part of the ControLinks™ Control
System, and must be used with the R7999 ControLinks™
Controller.
FEATURES
• Universal power supply input.
• Password protected with an eight-digit hexadecimal
identification signal.
• 100 lb-in. (11.3 Nm) torque.
• Includes integral position feedback potentiometer.
• Separate wiring compartment between line voltage
power wiring and low voltage control.
• Direct coupling shaft interface mounting.
• Couples directly to a 1/2 in. (13 mm) shaft with no
additional parts required.
• Couples directly to 5/16 in. (8 mm) and 3/8 in. (9 mm)
shafts using available self-centering shaft reduction
accessories.
• Shaft coupler assembly available for shafts larger than
1/2 in.
• Bracket Accessory Kit available for mounting to
Honeywell V51 Butterfly Gas Valves.
• Visual indication of actuator position.
Contents
Application ........................................................................ 1
Features ........................................................................... 1
Specifications ................................................................... 2
Ordering Information ........................................................ 2
Installation ........................................................................ 3
Wiring ............................................................................... 4
Operation .......................................................................... 5
Checkout And Troubleshooting ........................................ 5

ML7999A UNIVERSAL PARALLEL-POSITIONING ACTUATOR
65-0239—2 2
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.
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 Automation and Control Products Sales Office (check white pages of your phone directory).
2. Honeywell Customer Care
1885 Douglas Drive North
Minneapolis, Minnesota 55422-4386
In Canada—Honeywell Limited/Honeywell Limitée, 35 Dynamic Drive, Scarborough, Ontario M1V 4Z9.
International Sales and Service Offices in all principal cities of the world. Manufacturing in Australia, Canada, Finland, France,
Germany, Japan, Mexico, Netherlands, Spain, Taiwan, United Kingdom, U.S.A.
SPECIFICATIONS
Model:
ML7999A Universal Parallel-Positioning Actuator. Medium
torque electronic actuator with a precision feedback
potentiometer and integral power supply capable of direct
line voltage connection.
Dimensions: See Fig. 1.
Electrical Ratings:
Power Input: 100 to 240 Vac +10% -15%, 50/60 Hz.
Maximum Power Consumption: 15 VA.
IMPORTANT
Device must be hardwired.
Temperature Range:
Ambient: -40°F to +140°F (-40°C to +60°C).
Storage: -40°F to +150°F (-40°C to +66°C).
Humidity Range (at 95°F [35°C]): 5 to 95 percent relative
humidity, noncondensing.
Vibration: 0.0 to 0.5g continuous (V2 level).
Control Signal (at 5 mA current):
Drive Clockwise: Minimum 4.25 Vdc differential between
DR1-DR2.
Drive Counterclockwise: Maximum -4.25 Vdc differential
between DR1-DR2.
NOTE: Actuator does not respond until the 8-digit ID signal
from the R7999 is passed via DR1-DR2.
Actuator Stroke: 95° nominal ± 3°, mechanically limited.
Output Hub Position Accuracy: ±0.1°.
Torque Ratings at Rated Voltages:
Lift and Hold Minimum: 100 lb-in. (11.3 Nm).
Breakaway Minimum: 100 lb-in. (11.3 Nm).
Stall Minimum: 100 lb-in. (11.3 Nm).
Stall Maximum: 150 lb-in. (17 Nm).
Actuator Design Life (at 100 lb-in.):
Full-Stroke Cycles: 100,000 minimum.
Repositions: 2,000,000 minimum.
Feedback Potentiometer: Total Resistance:
5000 ohms ±10%.
Actuator Timing (90° Travel):
Standard: 24 to 30 seconds.
Derated Cold-Start Timing (from -40°F to -20°F
(-40°C to -29°¡C): 150 seconds maximum.
Noise Rating: 55 dBA maximum at 1m during normal
operation.
Mounting:
Mounts directly on 1/2 in. (13 mm) round or square shaft.
With proper accessories, mounts to 5/16 in. and 3/8 in.
(8 mm, 10 mm) round or square shafts; 9/16 in., 5/8 in.,
and 3/4 in.
(14 mm, 16 mm, and 19 mm) round shafts.
IMPORTANT
Tighten hub setscrews to a torque of
60 lb-in. ±10 lb-in.
Position Indicator: Visible with cover on device.
Approvals:
Underwriters Laboratories Inc.: File No.
FM Approved.
CSA Approved.
CE Approved.
Enclosure: NEMA2/IP50.
Accessories:
201391 Shaft Adapter for 3/8 in. round or square shaft.
32003167-001 Shaft Adapter for 5/16 in. round or square
shaft.
32003168-001 Shaft Adapter for 3/4 in. diameter round shaft.
32003168-002 Shaft Adapter for 5/8 in. diameter round shaft.
32003168-003 Shaft Adapter for 9/16 in. diameter round shaft.
32003396-001 V51 Mounting Bracket for 1-1/2 in. and
2 in. valves.
32003396-002 V51 Mounting Bracket for 2-1/2 in., 3 in. and
4 in. valves.
32002935-001 ML7999 NEMA3/IP54 Weatherproof Kit.

ML7999A UNIVERSAL PARALLEL-POSITIONING ACTUATOR
3 65-0239—2
Fig. 1. ML7999 dimensions in in. (mm).
Fig. 2. V5197A Firing Rate Gas Valve, with
mounting bracket (included) and ML7999 Actuator
(not supplied), dimensions in in. (mm).
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 given in the instructions and on the
product to make sure the product is suitable for your
application.
3. Installer must be a trained, experienced service
technician.
4. After installation is complete, check out product
operation as provided in these instructions.
WARNING
Fire or Explosion Hazard.
Can cause property damage, severe personal
injury, or death.
Tighten the hub setscrews to a torque of
60 lb-in. (7 N•m).
WARNING
Electrical Shock Hazard.
Can Cause serious injury or death.
Disconnect power supply before installation.
Location
CAUTION
Actuator Damage Hazard.
Deteriorating vapors and acid fumes can damage
the actuator metal parts.
Install actuator in areas free of acid fumes and other
deteriorating vapors.
Mounting ML7999 Actuator
The actuator mounts on a 1/2 in. round or square shaft. For
shafts smaller than 1/2 in, self-centering adapters are
available for 5/16 in. and 3/8 in. shafts. For shafts larger than
1/2 in., adapters are available for 5/8 in., 3/4 in., and 9/16 in.
CAUTION
Equipment Damage Hazard.
Lateral forces on actuator hub will damage
actuator.
Ensure actuator is mounted with shaft centered in
actuator hub.
1. Place the actuator over the shaft, see Fig. 3.
2. Position and seat the actuator.
3. Rotate the shaft to match the actuator position.
4. Install the mounting bracket accessory (not included),
if needed. See Fig. 4.
5. Partially tighten hub setscrews to ensure actuator
seats firmly against mounting bracket with shaft
centered in hub.
6. Tighten the anti-rotation bolt to the torque
recommendation for the selected bolt/nut.
7. Tighten the hub setscrews against the shaft to a torque
of 60 lb-in.
4 (102) 7/8 (22)
1-7/8 (47)
1/2
(13)
3-1/2 (89)
1-5/8
(41)
5-1/2
(140)
6
(
153)
M16466
1/4-28
unF
1
0-5/16
(277)
4-27/32 (123) 6-7/16 (165)
2-1/2 (64)
7-1/8
(181
)
3-25/3
2
(96)
M17528

ML7999A UNIVERSAL PARALLEL-POSITIONING ACTUATOR
65-0239—2 4
Mounting the ML7999 Actuator on V5197A
Firing Rate Gas Valve. (Fig. 2)
WARNING
Explosion Hazard and Electrical Shock Hazard.
Can cause severe injury, death or property
damage.
1. Turn off gas supply before starting installation.
2. Disconnect power supply for valve actuator before
beginning installation and wiring. More than one
disconnection can be involved.
1. Attach the mounting bracket for the ML7999 Actuator
(supplied with the V5197 Valve) in the position that best
suits the valve location, access space and wiring
requirements.
2. Place the short end of the V5197 valve drive stem in the
top of the V5197 Valve drive so that the rectangular
portion of the drive stem is inside the valve drive.
3. Mount the ML7999 Actuator on the V5197 Valve and
secure the actuator to the mounting bracket with the
supplied screws.
4. Wire the ML7999 Actuator per the instructions in the
Wiring section.
5. Restore power to the system.
Fig. 3. Mounting ML7999.
Fig. 4. Mounting ML7999 with mounting
bracket accessory.
WIRING
WARNING
Electrical Shock Hazard.
Can cause severe injury or death.
Disconnect power supply before installation.
All wiring must comply with local electrical codes, ordinances
and regulations. The ML7999 is designed for used with a
Class 2 power supply for low voltage. Voltage and frequency
of the transformer must correspond with the characteristics of
both the actuator and the power supply.
Earth Ground
Earth ground is required for proper operation of the
ControLinks™ system. Earth ground provides a connection
between the subbase and the control panel of the equipment.
The earth ground must be capable of conducting enough
current to blow the fuse or breaker in the event of an internal
short.
1. Use wide straps or brackets to provide minimum length,
maximum surface area ground conductors. If a leadwire
must be used, use 14 AWG copper wire.
2. Make sure that mechanically tightened joints along the
ground path are free of nonconductive coatings and
protected against corrosion on mating surfaces.
Shield Ground
Connect the shield ground of the ML7999 Actuator(s),
Remote Reset, Manual Potentiometer, Controller 4-to-20 mA
and Auxiliary 4-to-20 mA inputs to the earth ground strip
provided in the Q7999 Universal Subbase. Connect the shield
at the controller end only. See Fig. 6.
Preparation
Use OEM-supplied 1/2 in. conduit connectors in the low- and
line- voltage base openings; the motor has separate line- and
low-voltage wiring compartments. Use Belden 9535,
5-conductor, 100% shield coverage, 300V, 80°C (UL2464,
CSA PCC FT4), or equivalent for low voltage wiring.
Wiring Procedures
IMPORTANT
Device must be hardwired.
1. Remove the cover from the actuator.
2. Pull back the snap-locks while opening the low-voltage
compartment. See Fig. 5.
3. Wire the low-voltage circuit to the R7999. See Fig. 6 for
typical wiring connections.
4. Close the low-voltage compartment.
5. Wire the line-voltage circuit. See Fig. 6 for typical wiring
connections.
6. Replace the cover on the actuator.
M16467A
LOCK WASHER OR
CAPTIVE NUT
(NOT PROVIDED)
M16468A
LOCK WASHER OR
CAPTIVE NUT
(NOT PROVIDED)

ML7999A UNIVERSAL PARALLEL-POSITIONING ACTUATOR
5 65-0239—2
Fig. 5. Opening ML7999 low-voltage wiring compartment.
Fig. 6. Typical ML7999 wiring.
OPERATION
Table 1. On-Board LED Indications.
Actuator Setup
After the password (ID signal) has been written to the
ML7999, the actuator stroke will have to be determined for the
fuel, air and FGR, if used. The auto seek open/closed function
can be used to find the actuator end strokes. It is important, if
you use the auto seek open/closed function, that you move off
the mechanical end stops of the actuator by a minimum of
five degrees. See Fig. 7.
Fig. 7. Mechanical end stop changes for auto seek open/
closed function.
CHECKOUT AND TROUBLESHOOTING
Checkout
Refer to the R7999 literature (form 66-1120) for system
checkout.
Troubleshooting
If the actuator does not operate properly during Checkout,
perform the following troubleshooting steps. Perform these
steps before replacing the actuator:
1. Check the actuator label to make sure the power and
control signal requirements are correct for the
application.
2. Check for the presence of 120-240 Vac at the actuator
(L1) and (L2) connections when the actuator should be
driving. If the voltage is not present or is low, check the
power supply.
3. Ensure actuator stroke matches stroke of damper or
valve.
a. Remove the cover.
b. Press the button labeled CW. The actuator should
drive the device clockwise.
c. Press the button labeled CCW. The actuator should
drive the device counterclockwise.
4. If the actuator operates properly, check the controller for
proper output signals.
5. If the actuator does not drive, remove power, disconnect
the actuator hub, and try to turn the shaft clockwise and
counterclockwise. If the shaft turns freely throughout the
90-degree stroke and the actuator is installed properly,
replace the actuator.
6. If the shaft does not turn freely for the full 90 degrees,
check for binding. If necessary, adjust mounting to
prevent binding.
7. If the device shaft does not turn freely, fix or replace the
device.
M16470
LINE VOLTAG
E
WIRING
LOW
VOLTAGE
WIRING
GND
L2
L1
DR1
DR2
CW
S
CCW
L2
L1
ML7999
R7999
M16469
1/2 IN.MAXIMUM
TERMINATE WIRE SHIELD AT THE CONTROLLER (R7999).
SEE FIGURE 5 FOR ACTUATORWIRING.
1
2
1 2
G
LED Online Configured Meaning Notes
Fast Blink No Yes Awaiting ID signal. Responds only to ID signal.
Slow Blink Yes Yes ID signal recognized. Monitors signals for operation or offline commands.
Steady On No No Actuator has failed. Return actuator to factory.
ACTUATOR MECHANICAL OPEN/CLOSED FIXED STOP
S
M1966
6
ACTUATOR MECHANICAL OPEN/CLOSED FIXED STOP
S
MOVED MINIMUM OF 5 DEGREES

ML7999A UNIVERSAL PARALLEL-POSITIONING ACTUATOR
65-0239—2 6
8. If the device shaft turns, reconnect the actuator and
wiring and drive the actuator hub clockwise and
counterclockwise. If the actuator does not drive, replace
the actuator.
9. If the actuator and device shaft turn freely, remount the
actuator to the device according to instructions in the
Installation section. Make sure the actuator does not
bind and that the actuator and device are both at the
same clockwise or counterclockwise end stop when
assembled. Hook up the wires and repeat the Checkout
procedures. Troubleshoot if necessary.

7 65-0239—2

65-0239—2 G.R. Rev. 10-03 www.honeywell.com
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post-consumer paper fibers.
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