Direct Coupled Actuators
APPLICATION
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.
ML6194, ML6294
Non-Spring Return
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.
• Models available with or without time-out feature.
® U.S. Registered Trademark
© 2004 Honeywell International Inc.
All Rights Reserved
Contents
Application ........................................................................ 1
Features ........................................................................... 1
Specifications ................................................................... 2
Ordering Information ........................................................ 2
Installation ........................................................................ 4
Wiring ............................................................................... 6
Operation .......................................................................... 7
Checkout .......................................................................... 8
Troubleshooting ................................................................ 8
63-2511—1
ML6194, ML6294 NON-SPRING RETURN DIRECT COUPLED ACTUATORS
SPECIFICATIONS
Models:
ML6194/ML6294 Non-Spring Return DCA:
ML6194A/ML6294A: High Torque (300 lb-in.) DCA without
auxiliary switches or time-out feature.
ML6194C/ML6294C: High Torque (300 lb-in.) DCA with two
low voltage rated auxiliary switches and without time-out
feature.
ML6194D/ML6294D: High Torque (300 lb-in.) DCA without
auxiliary switches and with time-out feature.
ML6194F/ML6294F: High Torque (300 lb-in.) DCA with two
low voltage rated auxiliary switches and with time-out
feature.
Electrical Ratings:
Power Input: 24 Vac, ± 20%, 50 or 60 Hz.
Power Consumption:
ML6194A,C/ML6294A,C: 5 VA at 24 Vac.
ML6194D,F/ML6294D,F: 6 VA at 24 Vac.
Auxiliary Switch Ratings: 24 Vac, 3 AFL, 18 ALR, 1A Pilot
Duty.
Feedback Resistor (ML6294 only): 500 ohm linear
potentiometer.
Cable Ratings:
Control: Standard models include nonplenum UL/CSA rated,
30V, 140¡F (60¡C), 20 gauge cable.
Auxiliary Switch: UL/CSA rated 300V, 194°F (90°C), 18 gauge
cable.
Conduit Fittings: Plastic housing has two tapped holes for
1/2 in. (13 mm) conduit fittings.
Controller Type:
Floating, spdt.
500
480
460
440
420
400
380
360
340
TORQUE-LB. IN
320
300
280
260
240
220
-50 -25
Voltage Requirements at Cold Temperatures: At -40°F to
-20°F (-40°C to -29°C), minimum voltage is 24 Vac, +20%,
-0%.
Actuator Stroke: 95° nominal ±3°, mechanically limited.
Actuator Timing at 90° Stroke:
165 ±3 seconds synchronous at 60 Hz from -4°F to +140°F
(-20°C to +60°C).
200 ±3 seconds synchronous at 50 Hz from -4°F to +140°F
(-20°C to +60°C).
Non-synchronous below -4°F (-20°C).
MAXIMUM TORQUE
MINIMUM TORQUE
0
50
25
TEMPERATURE F
75 100
Fig. 1. Minimum and maximum torque
versus temperature.
125
150
M11266A
Torque Ratings at Rated Voltages:
Lift, hold, and breakaway ratings are temperature dependent;
Ambient Temperature Range: -40°F to +140°F (-40°C to
+60°C).
from 250 lb in. to 350 lb-in. (28 N•m to 40 N•m). See Fig. 1.
Stall Maximum: Temperature dependent; 365 lb-in. to 495 lb
in. (41 N•m to 56 N•m). See Fig. 1.
Torque Derating at 24 ±20% Vac: See Fig. 1.
Storage Temperature Range: -30°F to +150°F (-35°C to
+65°C).
Humidity: 5 to 95 percent relative humidity, noncondensing.
Mounting:
Mounts directly on 1/2 in. to 3/4 in. (13 mm to 19 mm) round or
square and 1 in. (26 mm) round shaft, using appropriate
hub insert.
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.
63-2511—1 2
ML6194, ML6294 NON-SPRING RETURN DIRECT COUPLED ACTUATORS
Minimum shaft length required is 2.5 in. (64 mm).
Mounting bracket included with all models.
All actuators shipped with 1 in. (26 mm) hub insert. See
Accessories section for additional hub sizes.
4 (102)
3-3/32 (79)
1-17/32
(39)
9/32 (7)
3 PLACES
7/16 (11)
1-1/4
(32)
7-11/16
(196)
8-7/16
(215)
Dimensions: See Fig. 2.
1
3-5/32
(80)
1-29/32
(48)
2
(51)
15/16
(24)
1 REMOVABLE RETAINING RING FOR
HUB SLEEVE REMOVAL.
1/2
(12)
1/4 (6)
36
(914)
4-1/2 (114)
6 (152)
13/32 (10)
1/4 (6)
1/8 (3)
1/2 (13)
2-1/2 (63)
3-5/16 (84)
5 (127)
5/8 (17)
1/2
(13)
1/2 (13)1-11/16 (43)
3/4
(19)
7/8 (22)
M11270A
1 (25)
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).
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.
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.
Environment Protection Rating: IP54 standard with shaft in
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.
INSTALLATION
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.
4. After installation is complete, check out product
operation as provided in these instructions.
WARNING
Explosion or Fire Hazard.
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.
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.
CAUTION
Equipment Damage Hazard.
Wrong location or improper operation will damage
the actuator.
1. Deteriorating vapors and acid fumes can damage
2. Install actuator in areas free of acid fumes and other
3. Turning motor output hub by hand or wrench can
4. Ensure declutch button is depressed while manually
Mounting
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.
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.
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.
The ML6194/ML6294 Non-Spring Return DCA can be
mounted directly on the shaft with the actuator in any position.
CAUTION
Actuator and Damper Damage Hazard.
Mounting bracket binding or clamping actuator to
duct can damage actuator.
Use mounting bracket only to prevent actuator
housing from rotating.
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.
actuator metal parts.
deteriorating vapors.
damage internal gears.
turning hub.
63-2511—1 4
A
DECLUTCH
BUTTON
ACTUATOR
SLOT
ML6194, ML6294 NON-SPRING RETURN DIRECT COUPLED ACTUATORS
RETAINING
RING
60
30
90
0
6
30
0
HUB
INSERTS
1
1
INSTALL MOUNTING BRACKET SO THAT MOUNTING
BRACKET TAB IS CENTERED IN ACTUATOR SLOT.
M11271
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.
CAUTION
Actuator Damage Hazard.
Using actuator as shaft bearing can damage
actuator.
Use actuator only to supply rotational torque. Avoid
any side loads to actuator output coupling bearings.
Preparation
Before installing actuator on shaft, determine opening
direction of shaft to correctly connect wiring.
DECLUTCH
BUTTON
M11272A
Fig. 4. Changing hub inserts.
Installation
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.
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.
7. Move shaft either fully clockwise or fully
counterclockwise .
8. Fully depress and hold declutch button while moving
actuator hub either fully clockwise or fully
counterclockwise to match shaft. Release
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
A
A
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.
MOUNTING
BRACKET
CONTROLLER
0
6
0
3
0
9
0
6
0
3
0
1
L1
(HOT)
L2
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
24 VAC
B
BLUE
W
YELLOW
T2
BLACK
ML6194A,C
MOTOR
M11283
Fig. 6. ML6194A,C typical wiring diagram.
ML6194D,F
MOTOR
TIME OUT
2
M11282
TO JUNCTION
BOX (UP TO
3 FT AWAY)
M11273A
CONTROLLER
1
L1
(HOT)
L2
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
2
TIME-OUT FUNCTION AVAILABLE WITH ML6194D,F MODELS.
24 VAC
B
BLUE
W
YELLOW
T2
RED
T1
BLACK
Fig. 7. ML6194D,F typical wiring diagram.
Fig. 5. ML6194/ML6294 Actuator standard
mechanical connection.
WIRING
WARNING
Electrical Shock Hazard.
Can cause severe injury, death or property
damage.
Disconnect power supply before installation. Actuators
with auxiliary switches can have more than one
disconnect.
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
CONTROLLER
1
L1
(HOT)
L2
1
2
24 VAC
T1
GREEN (CLOSED)
ORANGE (OPEN)
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
500 OHM POTENTIOMETER.
BLACK
B
BLUE
W
YELLOW
TAN
ML6294A,C
MOTOR
2
Fig. 8. ML6294A,C typical wiring diagram.
M11281A
63-2511—1 6
ML6194, ML6294 NON-SPRING RETURN DIRECT COUPLED ACTUATORS
A
CONTROLLER
1
L1
(HOT)
L2
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND
OVERLOAD PROTECTION AS REQUIRED.
2
TIME-OUT FUNCTION AVAILABLE WITH ML6294D,F MODELS.
3
500 OHM POTENTIOMETER.
24 VAC
GREEN (CLOSED)
ORANGE (OPEN)
B
BLUE
W
YELLOW
T2
RED
T1
BLACK
TAN
ML6294
TIME OUT
MOTOR
2
3
M11280A
Fig. 9. ML6294D,F typical wiring diagram.
The ML6194/ML6294 has a plastic housing with two tapped
holes for 1/2 in. (13 mm) conduit fittings.
ML6194 and ML6294 Models with Factorymounted Auxiliary Switches (see Fig. 10)
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.
COMMON
12
INTERNAL
UXILIARY
SWITCH
3A, 24 VAC
82
SWITCHES SHOWN AT ACTUATOR (CCW)
CLOSED POSITION.
NO
NC
COMMON
NO
NC
WHITE/RED
WHITE/BLUE
WHITE/YELLOW
BLACK/RED
BLACK/BLUE
BLACK/YELLOW
M7877A
Fig. 10. ML6194C,F and ML6294 Actuator wiring for
auxiliary switches.
ML6194 and ML6294 Wiring for Common Transformer
Fig. 11 through 13 show typical wiring for ML6194 and
ML6294 Non-Spring Return DCA using a common
transformer.
ML6194A,C
ML6294A,C
CONTROLLER
1
L1
(HOT)
L2
CONTROLLER
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS
AND OVERLOAD PROTECTION AS REQUIRED.
BLUE
YELLOW
BLACK
ML6194A,C
ML6294A,C
BLUE
YELLOW
BLACK
M11277A
Fig. 11. Common transformer with two controller outputs
and two ML6194A,C or ML6294A,C Actuators.
ML6194D,F
ML6294D,F
CONTROLLER
1
L1
(HOT)
L2
CONTROLLER
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS
AND OVERLOAD PROTECTION AS REQUIRED.
BLUE
YELLOW
RED
BLACK
ML6194D,F
ML6294D,F
BLUE
YELLOW
RED
BLACK
M11278A
Fig. 12. Common transformer with two controller outputs
and two ML6194D,F or ML6294D,F Actuators.
OPERATION
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
A
3. Apply 24 Vac control signal to blue (B) lead with respect
to black (T1) lead. The actuator should drive shaft open
(clockwise ).
4. Apply 24 Vac control signal to yellow (W) lead with
respect to black (T1) lead. The actuator should drive
shaft closed (counterclockwise ).
5. If 24 Vac control signal is removed, actuator should
stop.
L1
(HOT)
L2
ML6194A,C
CONTROLLER
1
ML6294A,C
BLUE
YELLOW
BLACK
ML6194A,C
ML6294A,C
BLUE
YELLOW
BLACK
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS
AND OVERLOAD PROTECTION AS REQUIRED.
M11279
Fig. 13. Common transformer with one controller output
and two ML6194A,C or ML6294A,C Actuators.
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.
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.
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.
CHECKOUT
Use following procedure to check out ML6194 and ML6294
Non-Spring Return DCA:
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).
TROUBLESHOOTING
If actuator does not drive, travel full stroke, or operate properly
during checkout, perform following troubleshooting procedure
before replacing actuator:
1. Check actuator label to make sure proper power and
control signal requirements are met.
2. When actuator should be driving, check for 24 Vac at
actuator wires:
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
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
clockwise and counterclockwise . If shaft
turns freely through 90° stroke, and actuator is installed
correctly, replace actuator.
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
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
actuator are at the same clockwise or
counterclockwise end stop when assembled.
Hook up wires and repeat checkout. If necessary,
troubleshoot again.
Automation and Control Solutions
Honeywell International Inc. Honeywell Limited-Honeywell Limitée
1985 Douglas Drive North 35 Dynamic Drive
Golden Valley, MN 55422 Scarborough, Ontario
63-2511—1 G.R. Rev. 06-04 www.honeywell.com
M1V 4Z9
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