95C-10939—11 - ML6984, ML7984 Series 4000 Direct

95C-10939—11 - ML6984, ML7984 Series 4000 Direct
ML6984, ML7984 Series 4000
Direct Coupled Valve Actuators
PRODUCT DATA
FEATURES
• Self-contained, motorized globe valve linkage.
• Microprocessor-based digital position sensing and
motor control for accurate positioning.
• Compact size for easy installation in confined spaces.
• NEMA 3R rain-proof cover for outdoor installation.
• Self-calibrating for valve stroke from 1/2 in. (13 mm)
to 1 in. (25 mm).
• DIP switch input configuration selection.
• LED (light-emitting diode) status indication.
• Configurable to 3-wire mode for floating models.
• 710 N 160 lbf (712 N) valve closing force.
• Usable with common transformer power supply for
multiple actuators and controllers.
• 24 Vac or 28 Vdc power supply.
• Field-addable position feedback/auxiliary switch
module available for 5-wire models.
APPLICATION
The ML6984 and ML7984 are self-contained, selfadjusting, motorized valve actuators that mount directly
onto V5011 two-way and V5013 three-way globe valves,
providing linear stem operation between 1/2 in. (13 mm)
and 1 in. (25 mm).
ML6984 is for use with low voltage SPDT Series 20, Series
60 (on-off), or SP3T Series 60 (floating) electromechanical and electronic controllers.
ML7984 is for use with Series 70 0-10 Vdc, 2-10 Vdc, 4-20
mA; electronic Series 90 “SuperMod”; and 135 ohm
modulating controllers.
Contents
Specifications ............................................................................... 2
Ordering Information ................................................................ 2
Installation .................................................................................... 3
Wiring Schematics ..................................................................... 5
Operation ....................................................................................... 9
Replacement Notes .................................................................... 10
Checkout ........................................................................................ 11
Troubleshooting .......................................................................... 12
95C-10939-11
ML6984, ML7984 SERIES 4000 DIRECT COUPLED VALVE ACTUATORS
SPECIFICATIONS
IMPORTANT
The specifications given in this publication do not
include normal manufacturing tolerances. Therefore, an individual unit may not exactly match the
listed specifications. Also, this product is tested
and calibrated under closely controlled conditions
and some minor differences in performance can
be expected if those conditions are changed.
Operating Environment:
Operating Ambient Temperature: 32° to 130° F (0° to 54°
C) measured at the actuator.
Shipping Temperature: -40° to 150° F (-40° to +65° C).
Relative Humidity: 15% to 95% up to 104° F (40° C), noncondensing atmosphere NEMA-3R/IP54 cover for outdoor installation.
Acoustic Noise: 55 dBA maximum Sound Pressure Level
at 39 in. (991.0 mm) distance.
Electrical Ratings: Power supply/consumption: 24 V
(+10%, -15%), 50/60 Hz or 28 Vdc +/- 10%, 6 VA (Running), 12 VA (Valve seating).
CE Certified
Inputs:
ML6984
- 25 mA 24 Vac (5-wire mode only)
- 500 mA (valve seating 3-wire mode)
- Minimum Signal Input Duration: 100 ms
ML7984*
- 2 -10 Vdc (1 mA); 4-20 mAdc
*May be used with 0-10 Vdc input but valve will be
closed at 2 Vdc.
Input Impedance for the ML7984:
Voltage Source - 20 KW ohm
Current Source- 237 ohm
Shipping Weight: Approx. 2.2 lb (1 kg).
Accessories/Parts:
272629A - Mounting adapter for V5045 valves.
272630D - Electronic position feedback low voltage auxiliary switch.
272822 - Resistor kit for multiple actuator Series 90 application and for ML7984 to replace the old ML784 (4-20
mA).
40003793-005 - Mounting hardware bag assembly.
Mechanical Ratings:
Stroke - Between 1/2 in. (13 mm) and 1 in. (25 mm), selfadjusting.
Bonnet - 1 3/8 in. (35 mm) for V5011/13 valves up to 3 in.
(76 mm)(DN80).
Stem Coupling - 1/4-28 UNF thread.
Stroke Timing - Nominal 63 seconds for 3/4 in. (19 mm)
stroke.
- Proportional to stroke length at 24 Vac.
Closing Force - 710 N (160 lbf) minimum at 24 Vac.
- Force varies 22 N/V (5 lbf/volt).
Performance Specifications:
Life Expectancy - (at rated load and power conditions)
50,000 full stroke cycles plus 1,000,000 repositions of
10% stem travel or 10 years, whichever occurs first.
Hysteresis - 5%
Table 1. Close-off pressure ratings of ML6984/7984 Series 4000 with Honeywell valves, psid
Type
Flare
Valve Family
1/2 in.
3/4 in.
1 in.
2 in.
2-1/2 in.
150
150
150
150
91
58
77
53
—
—
—
—
—
—
63
45
V5011F, G
150
150
150
150
91
58
33
19
V5011H, J
150
150
150
150
—
—
—
—
V5011N, V5013N
230
230
193
123
79
44
—
—
V5011A
V3350/51/60/61;
V3450/51/60/61
NPT
1-1/4 in. 1-1/2 in.
3 in.
V5011N2xxx, V5011G Steam
100
100
100
100
79
44
—
—
V5013F
150
150
150
149
91
58
—
—
*Do not exceed 100 psid with valves used in steam applications.
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 Environmental and Combustion Controls Sales Office (check white pages of your phone
directory).
2. Honeywell Customer Care
1985 Douglas Drive North
Golden Valley, Minnesota 55422-4386
3. http://customer.honeywell.com or http://customer.honeywell.ca
International Sales and Service Offices in all principal cities of the world. Manufacturing in Belgium, Canada, China,
Czech Republic, Germany, Hungary, Italy, Mexico, Netherlands, United Kingdom, and United States.
95C-10939—11
2
ML6984, ML7984 SERIES 4000 DIRECT COUPLED VALVE ACTUATORS
1/4 - 20 NUT
(2)
2.01
(51)
7/8 (22)
Knockout
4.0
(102)
4.02
(102)
1/4 - 28UNF
1.368 (34.7)
MOUNTING DIA.
7.04
(178.8)
1.53
(39)
3.2
(81)
4.57
(116)
0.80
(20.5)
4.06
(103)
2.09
(53.2) 0.27
(7)
0.78
(20)
3.09
(77.5)
0.75 (19)
NORMAL STROKE
1.65
(42)
2.20
(56)
3.22
(82)
2.71 (Yellow)
2.83 (Silver)
(68.8) (71.8)
3.07
(78)
0.39 (10)
0.19 (5) DIA.
M25485
Fig. 1. ML6984 Valve Actuator Dimensions, in. (mm).
INSTALLATION
5.
DO NOT electrically operate the actuator before
assembly to the valve because damage not apparent
to the installer may occur.
IMPORTANT
Before installing the valve, raise and lower the valve
stem to make sure that the valve stem operates
freely. Impaired stem operation can indicate that
the stem was bent by rough handling. This condition can require repair or replacement of the valve.
3 in. (76 mm) for Actuators with
mechanical auxiliary switches
Protect the stem from damage due to bending or
scratching. Damage to the stem packing may
result.
12 in. (305 mm)
Proper Use
Valves are to be installed by skilled personnel and in strict
accordance with installation instructions and local
regulations. Honeywell assumes no responsibility for
damages or injuries resulting from non-compliance with
installation instructions or standard good practice when
mounting, operating, or maintaining the valves, even if not
explicitly mentioned in the installation instructions.
Observe all safety practices when working with steam
systems.
Minimum Mounting
Clearance
M25486
Fig. 2. Minimum Mounting Clearance.
CAUTION
Short and rapid cycling/repositioning may result
in possible switch device lock-up or reduced
service life.
2.
3.
4.
1.
2.
When Installing This Product...
1.
Mounting
Read these instructions carefully. Failure to follow
them could damage the product or cause a hazardous condition.
Check ratings given in instructions and on the product to ensure the product is suitable for your application.
The installer must be a trained, experienced service
technician.
After installation is complete, check out product
operation as provided in these instructions.
3
Ensure that valve body is installed correctly, arrow
pointing in the direction of flow.
Actuator can be mounted in any position; however, it
is preferable that it is mounted above the horizontal
plane of the pipe. This minimizes the risk of damage
to the actuator in the event of condensation or valve
gland leak. When controlling steam, rotate the valve
body with the actuator beside the valve to avoid
exceeding ambient temperature limits of the actuator. For the same reason, do not mount ML Actuators
to steam valves in enclosed cabinets. For on-off control of steam in small pipe sizes, Honeywell recommends V8043J zone valves.
NOTE: NEMA 3R rainproof rating only applies to actuators mounted vertically. Cover has been treated
with UV stabilizers for outdoor applications.
95C-10939—11
ML6984, ML7984 SERIES 4000 DIRECT COUPLED VALVE ACTUATORS
Weather-proof conduit fittings approved for outdoor and wet locations must be used to maintain
NEMA 3R rating.
3.
4.
Remove stem button (Fig. 3) from valve stem.
(Optional) Snap red position indicator (metal clip)
over valve stem and position for best visibility (Fig. 3).
Indicator will self-align to the marking on yoke after
complete operating cycle. It is recommended that
this is done after actuator installation.
NOTE: Use the U-bolt supplied with the actuator. Do not
replace with stainless steel U-bolt on chilled water
valves. Condensation may cause corrosion of yoke
with SS U-bolt.
1
Remove Stem Button
NOTE: DO NOT
DAMAGE ANY
PART OF
THE STEM.
Valve Stem
DO NOT
ADJUST
Valve Stem
Position
Indicator 1
(Metal clip)
Yoke
ASSEMBLY OF POSITION INDICATOR
1 Position indicator will fit 1/4 in. - 7-1/16 in. valves.
Valve Bonnet
U-bolt
2
Yoke
M25487
Fig. 3. Preparation for Valve Assembly.
Assembly of MLx984 Actuator to the
Valve
1.
2.
3.
4.
5.
6.
The drive shaft of the MLx984 Actuator has a 1/4-28
UNF threaded hole to link with the valve stem. Slide
the yoke over the valve bonnet (Fig. 4).
Thread the MLx984 Actuator drive shaft onto the
valve stem all the way, until it is completely attached
(with no threads showing), by turning the valve actuator in a clockwise direction, as viewed from above.
Depending on the valve body, use a pin or wrench to
keep the valve stem from turning. Note that the valve
actuator is shipped with the drive shaft in the midposition.
Care should be exercised when using tools on the
valve stem during tightening (Fig. 4). DO NOT damage the threads or other parts of the stem.
Orient the conduit hole to the most desirable direction, then tighten the LOCKNUTS on the U-bolt.
Remove the plastic cover from the MLx984 by loosening the two captive screws located on the top. Drop
the Allen (Hex) type of set screw (included in the plastic bag) into the top of the shaft, hex side up.
Tighten the set screw to lock valve stem in place (Fig.
6), using a 1/8 in. Allen wrench (included).
1
THREAD ACTUATOR SHAFT TO VALVE STEM BY
ROTATING IN A CLOCKWISE DIRECTION.
2
TIGHTEN U-BOLT NUTS TO SECURE LINKAGE TO
VALVE BODY.
M25489
Fig. 5. Assembly of MLx984A to Valve.
5mm [3/16 in.] Slotted Screwdriver
or Allen Wrench
Linkage
Set Screw
Valve Stem
M25490
Fig. 6. Locking MLx984A Drive Shaft to Valve Stem.
CAUTION
For proper valve operation the valve stem must be
threaded into the actuator all the way (with no
threads showing) and locked in place with the set
screw provided.
M25488
Fig. 4. U-bolt Assembly.
95C-10939—11
4
ML6984, ML7984 SERIES 4000 DIRECT COUPLED VALVE ACTUATORS
Operation
The recommended valve actuator power source is a Safety
Extra-Low Voltage (SELV) Class II, 24 V transformer or
regulated 28 Vdc across terminals T5 and T6. Internal
circuitry provides dc power for the electronic sensing and
drive motor circuits.
Outdoor
NEMA3R
Indoor
90°
>5°
>5°
2
1
TYPICAL ELECTRONIC
CONTROLLER
L1
C
L2
H
ML6984 3
W
1
T6
R
T5
B
3
1 POWER SUPPLY PROVIDES OVERLOAD PROTECTION AND
DISCONNECT MEANS.
2 ALLOW UP TO 0.5 AMPS FOR EACH DEVICE. ACTUATORS AND
CONTROLLER CAN SHARE SAME TRANSFORMER, PROVIDED THAT THE
VA RATING OF THE TRANSFORMER IS NOT EXCEEDED AND PROPER
PHASING IS OBSERVED. DO NOT MIX A.C. AND D.C. POWER SOURCES.
M25491
Fig. 7. Mounting Positions.
3 CONTROLLER CAN BE LOW VOLTAGE SPDT SERIES 20 “ON-OFF” OR
SP3T SERIES 60 “FLOATING” (TRI-STATE) TYPE. TERMINALS R AND T5
ARE CONNECTED INSIDE THE ML6984.
M25493A
WIRING SCHEMATICS
MLx984 actuators are designed to operate from a Safety
Extra Low Voltage, Class II power source. A 7/8 in. (22 mm)
wiring hole is provided for attaching a flexible conduit
where required by local codes. When installing outdoors,
weatherproof conduit fittings approved for outdoor and
wet locations must be used.
Fig. 9. 3-Wire Control of ML6984 with Electronic
Controller.
3
TYPICAL SPDT
CONTROLLER
CAUTION
Electrical Shock or Equipment Damage Hazard.
B
NOTE: In all cases when wiring multiple actuators, the
power supply to all actuators must be connected
in a “star” fashion to reduce excessive voltage
drop. DO NOT “daisy chain” i.e. connect power to
one actuator then branch to another.
2
R
W
R
POWER SUPPLY PROVIDES OVERLOAD PROTECTION AND DISCONNECT
MEANS.
2
ALLOW UP TO 0.5 AMPS FOR EACH DEVICE. ACTUATORS AND
CONTROLLER CAN SHARE SAME TRANSFORMER, PROVIDED THAT THE
VA RATING OF THE TRANSFORMER IS NOT EXCEEDED AND PROPER
PHASING IS OBSERVED. DO NOT MIX A.C. AND D.C. POWER SOURCES.
3
CONTROLLER CAN BE LOW VOLTAGE SPDT SERIES 20 “ON-OFF” OR
SP3T SERIES 60 “FLOATING” (TRI-STATE) TYPE. TERMINALS R AND T5
M25492A
ARE CONNECTED INSIDE THE ML6984.
R
1
L2
OR
4
ML6984
W
T6
R
T5
T5
B
1
POWER SUPPLY PROVIDES OVERLOAD PROTECTION AND DISCONNECT
MEANS.
2
ALLOW UP TO 0.5 AMPS FOR EACH DEVICE. ACTUATORS AND
CONTROLLER CAN SHARE SAME TRANSFORMER, PROVIDED THAT THE
VA RATING OF THE TRANSFORMER IS NOT EXCEEDED AND PROPER
PHASING IS OBSERVED. DO NOT MIX A.C. AND D.C. POWER SOURCES.
3
CONTROLLER CAN BE LOW VOLTAGE SPDT SERIES 20 “ON-OFF” OR
SP3T SERIES 60 “FLOATING” (TRI-STATE) TYPE. TERMINALS R AND T5
ARE CONNECTED INSIDE THE ML6984.
4
MULTIPLE ACTUATORS CONTROLLED BY A COMMON CONTROLLER IN
PARALLEL MUST BE WIRED SO THAT THEY ALL TRAVEL IN THE SAME
DIRECTION. REVERSE ACTING ACTUATORS WILL NOT OPERATE
RELIABLY IN COMBINATION WITH DIRECT ACTING UNITS DUE TO
GEARBOX TOLERANCES. USE ML7984 MODULATING ACTUATORS, OR
DEDICATED CONTROLLERS, OR SEPARATE CONTROLLER OUTPUTS
M25494A
FOR EACH GROUP INSTEAD.
B
1
L1
28 VDC
T5
B
R
T5
2
T6
TYPICAL ELECTRO-MECHANICAL ML6984 3
CONTROLLER
W
T6
24 VAC
T6
B
Disconnect power supply to the actuator to prevent
electrical shock and equipment damage, or remove
and cap the air line to the actuator.
1 L1
L2
W
24 VAC
W
Can Shock Individuals or Short Equipment
Circuitry.
4
ML6984
Fig. 10. 5-Wire Control of ML6984.
Fig. 8. 3-Wire Control of ML6984 with Series 60
Controller.
5
95C-10939—11
ML6984, ML7984 SERIES 4000 DIRECT COUPLED VALVE ACTUATORS
SIGNAL
SOURCE
3 ML7984 2
3 ML7984 2
R
T6
W
T5
SIGNAL
SOURCE
R
T6
W
T5
C
C
3 ML7984 2
R
T6
W
T5
3 ML7984 2
1
R
T6
L1
L1
24 VAC
24 VAC
W
L2
L2
T5
C
OR
C
1
OR
T6
T5
3 ML7984 2
R
T6
W
T5
T6
28 VDC
ML7984
3 (SLAVE)
C
FUNCTION
1000
2-10 VDC DIRECT ACTING
1010
10-2 VDC REVERSE ACTING
R
T6
W
T5
T5
2
28 VDC
C
DIP SWITCH CONFIGURATION
ON (1)
OFF (0)
1
2
3
2
3
X000
4-20 MA DIRECT ACTING
4
ON (1)
OFF (0)
1
FUNCTION
4
DIP SWITCH CONFIGURATION
1
X010
20-4 MA REVERSE ACTING
5
4
MASTER ACTUATOR
SLAVE ACTUATOR
1
2
3
1
2
3
4
ON (1)
OFF (0)
5
4
MASTER ACTUATOR
SLAVE ACTUATOR
1
ON (1)
OFF (0)
4
1 POWER SUPPLY PROVIDES OVERLOAD PROTECTION AND
DISCONNECT MEANS.
1
POWER SUPPLY PROVIDES OVERLOAD PROTECTION AND DISCONNECT
MEANS.
2 ALLOW UP TO 0.5 AMPS FOR EACH DEVICE. ACTUATORS AND
CONTROLLER CAN SHARE SAME TRANSFORMER PROVIDING THE VA
RATING OF THE TRANSFORMER IS NOT EXCEEDED AND PROPER
PHASING IS OBSERVED. DO NOT MIX A.C. AND D.C. POWER
SOURCES.
2
ALLOW UP TO 0.5 AMPS FOR EACH DEVICE. ACTUATORS AND CONTROLLER
CAN SHARE SAME TRANSFORMER PROVIDING THE VA RATING OF THE
TRANSFORMER IS NOT EXCEEDED AND PROPER PHASING IS OBSERVED. DO
NOT MIX A.C. AND D.C. POWER SOURCES.
3
IN ML7984, "T5” AND “W” TERMINALS ARE CONNECTED INTERNALLY. DEVICE
IS COMPATIBLE WITH 3 CONDUCTOR WIRING.
4
USE CONFIGURATION DIP SWITCHES TO SELECT DEVICE FUNCTIONS: DIRECT
ACTING FUNCTION (ACTUATOR STEM MOVES DOWNWARDS WITH SIGNAL
INCREASES TO 10V/20MA) OR REVERSE ACTING FUNCTION (ACTUATOR STEM
MOVES UPWARDS WITH SIGNAL INCREASES TO 10V/20MA).
5
ALWAYS TURN POWER OFF BEFORE SETTING ANY DIP SWITCHES.
3 IN ML7984, “T5” AND “W” TERMINALS ARE CONNECTED INTERNALLY.
DEVICE IS COMPATIBLE WITH 3 CONDUCTOR WIRING.
4 USE CONFIGURATION DIP SWITCHES TO SELECT DEVICE FUNCTIONS:
DIRECT ACTING FUNCTION (ACTUATOR STEM MOVES DOWNWARDS
WITH SIGNAL INCREASES TO 10V/20MA) OR REVERSE ACTING
FUNCTION (ACTUATOR STEM MOVES UPWARDS WITH SIGNAL
INCREASES TO 10V/20MA).
M25496A
5 ALWAYS TURN POWER OFF BEFORE SETTING ANY DIP SWITCHES.
M25495A
Fig. 11. ML7984 Wiring with 10 Vdc Analog Control
Signal.
95C-10939—11
6
Fig. 12. ML7984 Wiring with 20mA Analog Control
Signal.
ML6984, ML7984 SERIES 4000 DIRECT COUPLED VALVE ACTUATORS
SINGLE
SOURCE
B
MODULATING
LIMIT
2
6
R
W
ML7984
2
3
ML7984
3
B
B
R
R
T6
W
W
T5
R
1
L1
T6
24 VAC
W
L2
T5
OR 2
2
B
ML7984
SINGLE
SOURCE
3
B
R
L1
T6
R
4
2
ML7984
T6
3
B
B
R
R
1
L1
T6
W
L2
T5
OR 2
OR
3
2
ML7984
T6
3
28 VDC
T5
T6
B
B
R
R
28 VDC
T5
W
L2
T5
W
ML7984
24 VAC
24 VAC
W
2
28 VDC
B
T5
R
T6
1
L1
T6
24 VAC
W
W
W
T5
L2
T5
OR 2
T6
FUNCTION
1001
MECHANICAL SERIES 90
DIRECT ACTING
1011
MECHANICAL SERIES 90
REVERSE ACTING
DIP SWITCH CONFIGURATION
ON (1)
OFF (0)
1
2
3
4
1
2
3
4
ON (1)
OFF (0)
RESISTOR SELECTION CHART
4
5
1
POWER SUPPLY PROVIDES OVERLOAD PROTECTION AND
DISCONNECT MEANS.
2
ALLOW UP TO 0.5 AMPS FOR EACH DEVICE. ACTUATORS AND
CONTROLLER CAN SHARE SAME TRANSFORMER PROVIDING THE
VA RATING OF THE TRANSFORMER IS NOT EXCEEDED AND PROPER
PHASING IS OBSERVED. DO NOT MIX A.C. AND D.C. POWER SOURCES.
3
DO NOT MIX M984/6 OR MODUTROL MOTORS WITH THE ML7984 IN
THE SAME CIRCUITRY.
4
USE CONFIGURATION DIP SWITCHES TO SELECT DEVICE FUNCTIONS:
DIRECT ACTING FUNCTION (ACTUATOR STEM MOVES UPWARDS WITH
SIGNAL INCREASE) OR REVERSE ACTING FUNCTION (ACTUATOR
STEM MOVES DOWNWARDS WITH SIGNAL INCREASE).
5
6
28 VDC
T5
TURN POWER OFF BEFORE SETTING ANY DIP SWITCHES. FOR
COMMON TRANSFORMER AND COMMON CONTROLLER APPLICATION,
PLEASE CONSULT THE FACTORY.
NO. OF
ACTUATORS
RESISTOR
VALUE
1
2
3
4
RESISTOR NOT REQ’D.
133 OHM
68.1 OHM
45.3 OHM
4
ALL RESISTORS
1/4 WATT
1% METAL FILM
1
POWER SUPPLY PROVIDES OVERLOAD PROTECTION AND
DISCONNECT MEANS.
2
ALLOW UP TO 0.5 AMPS FOR EACH DEVICE. ACTUATORS AND
CONTROLLER CAN SHARE SAME TRANSFORMER PROVIDING THE
VA RATING OF THE TRANSFORMER IS NOT EXCEEDED AND PROPER
PHASING IS OBSERVED. DO NOT MIX A.C. AND D.C. POWER SOURCES.
3
DO NOT MIX M984/6 OR MODUTROL MOTORS WITH THE ML7984 IN
THE SAME CIRCUITRY.
4
USE RESISTOR KIT PART NUMBER 272822.
M25498A
Fig. 14. ML7984 with Individual Transformers, Common
Controller.
MAXIMUM RESISTANCE PER CONTROL CIRCUIT OF 280 OHM.
M25497A
Fig. 13. ML7984 Wiring with Common Transformer,
Individual Controllers.
7
95C-10939—11
ML6984, ML7984 SERIES 4000 DIRECT COUPLED VALVE ACTUATORS
ELECTRONIC
SERIES 90
(W973, T775,
H775, W7100)
2
ML7984
3
2
ELECTRONIC
SERIES 90
(W973, T775,
H775, W7100)
B
R
R
ML7984
3
B
1
R
T6
L1
T6
24 VAC
W
W
T5
L2
T5
W
OR
NOTE:
POLARITY SENSITIVE,
CHECK CONNECTIONS
W to R, R to W
2
ML7984
2
3
T6
R
R
L1
T6
W
T5
ML7984
28 VDC
B
T5
R
T6
W
W
T5
L2
OR
NOTE:
POLARITY
SENSITIVE,
CHECK
CONNECTIONS
W to R,
R to W
OR
3
T5
W
W
L2
T6
R
L1
24 VAC
24 VAC
2
28 VDC
T5
1
R
W
T6
3
B
B
R
ML7984
2
ML7984
T6
3
28 VDC
T5
B
1
R
L1
T6
24 VAC
L2
T5
W
OR
T6
28 VDC
T5
FUNCTION
1101
ELECTRONIC SERIES 90
DIRECT ACTING
1111
ELECTRONIC SERIES 90
REVERSE ACTING
DIP SWITCH CONFIGURATION
FUNCTION
ON (1)
OFF (0)
1
2
3
4
4
ON (1)
OFF (0)
1
2
3
1101
ELECTRONIC SERIES 90
DIRECT ACTING
5
1111
ELECTRONIC SERIES 90
REVERSE ACTING
4
1
POWER SUPPLY PROVIDES OVERLOAD PROTECTION AND
DISCONNECT MEANS.
2
ALLOW UP TO 0.5 AMPS FOR EACH DEVICE. ACTUATORS AND
CONTROLLER CAN SHARE SAME TRANSFORMER PROVIDING THE
VA RATING OF THE TRANSFORMER IS NOT EXCEEDED AND PROPER
PHASING IS OBSERVED. DO NOT MIX A.C. AND D.C. POWER SOURCES.
3
DO NOT MIX M984/6 OR MODUTROL MOTORS WITH THE ML7984 IN
THE SAME CIRCUITRY.
4
USE CONFIGURATION DIP SWITCHES TO SELECT DEVICE FUNCTIONS:
DIRECT ACTING FUNCTION (ACTUATOR STEM MOVES UPWARDS WITH
SIGNAL INCREASES TO 10V/20MA) OR REVERSE ACTING FUNCTION
(ACTUATOR STEM MOVES DOWNWARDS WITH SIGNAL INCREASES TO
10V/20MA).
5
TURN POWER OFF BEFORE SETTING ANY DIP SWITCHES.
M25499A
Fig. 15. ML7984 with Common Transformer, Individual
Controllers.
DIP SWITCH CONFIGURATION
1
2
3
4
1
2
3
4
ON (1)
OFF (0)
4
ON (1)
OFF (0)
5
1 POWER SUPPLY PROVIDES OVERLOAD PROTECTION AND
DISCONNECT MEANS.
2
ALLOW UP TO 0.5 AMPS FOR EACH DEVICE. ACTUATORS AND
CONTROLLER CAN SHARE SAME TRANSFORMER PROVIDING THE VA
RATING OF THE TRANSFORMER IS NOT EXCEEDED AND PROPER
PHASING IS OBSERVED. DO NOT MIX A.C. AND D.C. POWER
SOURCES.
3 DO NOT MIX M984/6 OR MODUTROL MOTORS WITH THE ML7984 IN
THESAME CIRCUITRY.
4 USE CONFIGURATION DIP SWITCHES TO SELECT DEVICE FUNCTIONS:
DIRECT ACTING FUNCTION (ACTUATOR STEM MOVES UPWARDS WITH
SIGNAL INCREASES TO 10V/20MA) OR REVERSE ACTING FUNCTION
(ACTUATOR STEM MOVES DOWNWARDS WITH SIGNAL INCREASES TO
10V/20MA).
5 TURN POWER OFF BEFORE SETTING ANY DIP SWITCHES.
M25500A
Fig. 16. ML7984 with Individual Transformers, Common
Controller.
95C-10939—11
8
ML6984, ML7984 SERIES 4000 DIRECT COUPLED VALVE ACTUATORS
OPERATION
CAUTION
Disconnect power supply before beginning
Each time actuator terminals T5 and T6 are (re)powered,
the microprocessor will cycle the valve through a full stroke
to calibrate its position. Any stroke between 1/2 in. (13
mm) and 1 in. (25 mm) will be divided into 30 equal steps.
Run time is proportional to stroke length and power supply
voltage. The actuator will also slow down as the valve
closes off the seat. The LED lights when terminals T5 and
T6 are powered, and flashes when the actuator is in motion.
T5 is connected to Terminal R in ML6984 and to Terminal
W in ML7984.
NOTE: Initial calibration does not apply to ML6984
installed for 3-wire control or installed for 5-wire
control without the 272630D position feedback/auxiliary switch module. Span and start
positions will need to be set during controller setup. See ML6984 Operation 3-wire, below. ML7984
always conducts a self-calibration sequence when
(re)powering up.
installation to prevent electrical shock and
equipment damage.
All wiring must comply with applicable local
electrical codes, ordinances, and regulations.
Make certain that the voltage and frequency of the
power supply correspond to the rating of the device.
DO NOT electrically operate the MLx984 actuator
before assembly to the valve because damage not
apparent to the installer may occur.
DO NOT connect 24 Vac between any ML7984
signal input terminals. DEVICE FAILURE WILL
RESULT.
NOTE:
1.
ML7984 Operation
The microprocessor responds to the signal across the input
terminals based on the configuration DIP switch settings.
When correctly connected to the actuator, a control signal
between signal input terminals is converted to a digital run
time and compared to pulse counts from the first gear in
the gear train. When these counters are equal, the drive
motor and drive shaft are stationary.
As long as the value of the controlled medium remains at
the controller setpoint, the control loop circuit is in
balance, and the actuator does not run. When the
controller set point or controlled temperature changes, the
controller output voltage is changed, causing the counters
to differ. As the actuator moves in the direction to correct
the difference, the counters increment or decrement, and
stop the actuator when the input and gear counts agree.
At the end of the valve stroke, the actuator develops the
necessary force for positive valve close-off. The motor
stops automatically when the motor draws a
predetermined current which corresponds to a force level.
The digital counters are reset and calibrated at each end of
stroke.
Modulating actuators will automatically travel to the
position corresponding to analog input signal following the
self-calibration cycle.
2.
3.
The ML7984 must be field configured with the
DIP switches which are located beside the terminal block. See wiring diagrams for details.
Turn power off before setting any DIP switches.
There is a 1.5 second delay in actuator
response to every signal change. This occurs to
screen out electrical noise.
For proper operation, voltage on the T5 and T6
must not be less than 22 Vac or 24 Vdc during
running or force generating stages. Increase
transformer VA rating or use a model with better
regulation if voltage drops below 22 Vac when
the valve is closing off.
ML6984 Floating Operation, 5-Wire
The motor is controlled by a microprocessor. Connecting B
to R for 1/10 second or longer tells the microprocessor to
cause the actuator to drive upwards. Connecting W to R will
cause the actuator to drive downwards. For “floating”
control, the actuator will remain in the last position when
there is no connection to R.
At the end of the valve stroke, the actuator will develop the
necessary force for positive valve close-off. As forces are
developed, the current to the motor increases. The
microprocessor stops the actuator automatically when
motor current and force reaches the factory-calibrated
level.
NOTE: There must be at least 1.5 second delay between
successive floating input signals. The actuator will
ignore floating signals during calibration cycle
and does not remember any pulses sent during
this period. The controller may need to run
through its own calibration cycle before use.
ML6984 Operation, 3-Wire
ML6984 may be installed like a conventional (nonelectronic) floating actuator. The interface electronics are
powered at the same time as the motor. Pulses must be at
least 100 ms long with a delay of at least 1500 ms between
pulses. When ML6984 is not powered between terminals
T6 and T5/R, self-calibration will not occur. The controller
must drive the valve through a cycle manually to calibrate
stroke to the controller.
9
95C-10939—11
ML6984, ML7984 SERIES 4000 DIRECT COUPLED VALVE ACTUATORS
NOTE: The 272630D position feedback/auxiliary switch
module cannot be used with ML6984 3-wire
installation. The 272630D requires continuous
power.
REPLACEMENT NOTES
HEATING ONLY
1
ML6984 XL10 Controller
Compatibility
T6
24Vac
T5
C
XL10 controllers are designed to work with constant-speed
actuators. ML6984 actuators use direct current motors
which vary their speed as the valve seats or if power supply
voltage is not consistent. ML6984 actuators in 5-wire
mode offer 30 discrete positions only. To minimize
potential valve position drift, XL10 controllers should use
the 3-wire installation and be programmed for a daily valve
exercise cycle.
W
B
UP
W
DOWN
R
R
Y
ML6984
COOLING ONLY
1
T6
ML6984 On-Off Operation
24Vac
T5
C
For on-off operation, ML6984 requires a 24 Vac SPDT
contact. An interface relay such as RA889 is required to
power the anticipator heater of an electromechanical
thermostat such as T87F (See Fig. 17).
W
UP
DOWN
R
R
Y
1
B
W
ML6984
CLASS 2 TRANSFORMER. PROVIDE DISCONNECT MEANS AND
M25502
OVERLOAD PROTECTION AS REQUIRED.
1K1
1
2
L1
R
W
R
B
T5
L2
Fig. 18. ML6984 with Honeywell T87K Round™
Thermostat.
W
T6
1K
ML6984
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND
OVERLOAD PROTECTION AS REQUIRED.
2
SET HEATING ANTICIPATOR TO MATCH CURRENT DRAW OF
RELAY 1K. DO NOT ROUTE RELAY CONTACTS THROUGH
THERMOSTAT.
M25501
See Fig. 19, if connecting TH5110D or TH6110D
FocusPRO™ thermostats to ML6984. Configure the
thermostats for Series 20 operation.
THERMOSTAT WIRING TERMINALS
TH5110D
Rc
TH6110D
R
2
Y
Fig. 17. ML6984 with Honeywell T87F Round™
Thermostat.
C
If connecting the ML6984 directly to a T87F with a Series
20 sub-base, clip out the cooling anticipation resistor on
the sub-base between terminals Rc and Y. This is needed
for electrical compatibility with ML6984 but may result in
wider room temperature swings due to the loss of
anticipation.
4
W
O/B
G
3
B
W
T6
T5
R
5
ML6984
POWER TO OPEN
AND POWER TO
CLOSE
MOTOR OR VALVE
(SERIES 20)
R
1
L1
(HOT)
C
L2
1
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
2
FACTORY INSTALLED JUMPER.
3
OPTIONAL 24 VAC COMMON CONNECTION.
4
CONFIIGURE SYSTEM TYPE TO HEAT ONLY IN THE INSTALLER SETUP.
5
TERMINALS R AND T5 ARE INTERNALLY CONNECTED.
M25503
Fig. 19. ML6984 with FocusPro™ Electronic Thermostat.
95C-10939—11
10
ML6984, ML7984 SERIES 4000 DIRECT COUPLED VALVE ACTUATORS
CHECKOUT
To Replace ML784 or ML984
1.
2.
The old ML784 or ML984 actuators cannot be used
with new ML7984 valve actuators in the same circuitry, unless the old models are each powered by
their own transformer to prevent cross-talking.
The ML7984 is a direct replacement for all old
ML784 and ML984, except:
a. When replacing the old reverse acting models, the
signal input wires to the new devices no longer
need to be reversed. Just follow the terminal
polarity designations and DIP switch settings.
b. When replacing the old actuator which has an
Electronic Series 90 “Supermod” controller - e.g.:
T775, W973, H775, or W7100 - the old interface
resistor must be removed. The ML7984 Series
4000 will work directly with the controller without
the external 240 ohm resistor.
c. When replacing the old ML784 (mA model) in
multiple-actuator installations, resistor(s) will be
needed. Use Resistor Kit (part no. 272822) and
set DIP switches accordingly. See Figures 17 and
18.
To Replace ML684A
1.
2.
2.
3.
4.
6.
The ML6984 is a direct replacement for the old
ML6874 in single actuator hook-up.
For parallel, multiple ML6874 actuators applications,
an isolation relay must be used. The isolation relay
contacts should be placed in the new ML6984 actuator signal input “W” and “B” circuit.
To Replace Line Voltage Auxiliary
Switches
1.
2.
Operate an external relay, such as R8845U, using the
adjustable SPDT pilot duty output on the 272630D.
1.
3.
4.
5.
6.
7.
8.
1.
3.
4.
5.
11
Make sure the valve stem is completely screwed into
the actuator drive shaft with no threads showing
before applying power.
Make sure the valve stem is locked in place with the
set screw.
Connect 24 Vac or 28 Vdc power to T5 and T6.
Jumper R and B. The valve stem should move up.
Jumper R and W. The valve stem should move down.
For Floating operation, open R connection Valve stem
should remain in position.
Re-connect all control wiring.
Operate the system (valve, actuator, and controller)
for several cycles to ensure proper installation.
When checkout is complete, return the controller to
the desired setting.
ML6984: 3-Wire Installation
2.
If a second, independent output switch is needed, wire the
2-10 Vdc position feedback signal to an Approved,
adjustable, voltage-controlled relay.
The Device will ignore any input changes until it
has completed its repositioning relative to the
initial signal input.
272630D position feedback/auxiliary switch
module is inactive during self-calibration.
ML6984: 5-Wire Installation
9.
These accessories are no longer available. Replace the old
actuator with new model and 272630D position feedback/
auxiliary switch module.
Make sure the valve stem is completely screwed into
the actuator drive shaft with no threads showing
before applying power.
Make sure the valve stem is locked in place with the
set screw.
Make sure the Configuration DIP switches are set
correctly.
With 24 Vac or 28 Vdc power source connected to T5
and T6, actuator operation can be verified by connecting appropriate control signal (Series 70/90)
from controller to the signal input terminals (Figures
8 thru 16). For direct acting: A modulating action can
be obtained by increasing the control signal. The
actuator will travel from stem down to stem up. On
signal failure (disconnected/no signal), actuator
defaults to closed position. For reverse acting:
Decreasing controller signal will drive actuator from
full stem down to full stem up. On signal failure (disconnect/no signal), actuator defaults to open position.
Operate the system (valve, actuator, and controller)
for several cycles to ensure proper installation.
When checkout is complete, return the controller to
the desired setting.
NOTE:
2.
To Replace ML6874
2.
1.
5.
The new ML6984 is a direct replacement for the old
ML684A in single actuator or parallel multiple actuators hook-up. The old and new actuators can be
mixed in the same electrical circuit. For multiple
actuators controlled by a common controller in parallel, these actuators must be wired so that they all
travel in the same direction.
When replacing the ML684A1009 (80 lbf) with this
new ML6984 on the V5045 valve, the installed valve
adaptor (part no. 272629A) on the valve stem and
actuator assembly is still needed.
NOTE: The 272630D position feedback/auxiliary switch
module cannot be used with ML6984 3-wire
installation. The 272630D requires continuous
power.
1.
ML7984
Make sure the valve stem is completely screwed into
the actuator drive shaft with no threads showing
before applying power.
Make sure the valve stem is locked in place with the
set screw.
Connect 24 Vac to T6.
Manually override the controller to signal the actuator to open/close for a few cycles to ensure proper
installation.
When checkout is complete, return the controller to
the desired setting.
95C-10939—11
ML6984, ML7984 SERIES 4000 DIRECT COUPLED VALVE ACTUATORS
TROUBLESHOOTING
Symptom
Valve seat leaks or will not close
properly
Noisy Motor
Motor
overheats/smoke/component
burn-out
ML will not respond
Possible Causes
Actions
Wrong actuator used and/or system head pressure too
high
1) Check valve close-off rating
2) Check voltage at actuator terminals
Actuator not properly installed
Ensure valve stem is fully threaded into brass drive shaft and locked
in place with the set screw
Incorrect DIP switch settings
Check against Product Instruction Sheet
Bearing failed due to overheat
1) Check for excessive temperature and replace complete actuator
2) Use high temperature kit (43196000-001)
Brushes worn out
Check for excessive cycling and replace actuator
Current sensing circuit failed or electronic components
failed
Replace actuator. Make sure:
1) Correct actuator used
2) Properly installed
3) Do not operate actuator before mounting on valve supply
4) Proper voltage supply
LED (on):
Incorrect DIP switch settings
Check against Product Instruction Sheet
No control signal present
Check controller
Incorrect wiring connections
Check against Product Instruction Sheet
Internal time delay
Allow at least 1/2 - 1 second for the ML to respond
LED (off):
No or low power supply
Check voltage on T5 and T6 terminals
Error mode (gearbox damage)
1) Check power supply
2) Check calibration cycle
3) Valve stroke length less than 1/2 in. or greater than 1-1/4 in.
4) Reset device by a momentary disconnect of power at T5 and T6
Vdc/mA signal drops when
connected to ML
ML7984 in mA mode with voltage input
Change DIP switch setting
Signal degradation due to incompatible load impedance
Output and ML input impedance specifications
Actuator yoke corrodes
Galvanic reaction from dissimilar metals if
SS U-bolt used with aluminum yoke
Replace U-bolt with galvanized U-bolt and nuts
Floating Actuator position “drifts” Mismatch between actuator resolution
when used with building
(30 steps) and BAS controller
automation system
TYPICAL SPECIFICATIONS
Valve Actuators shall mount directly to the bonnet of the
valve, and shall be self-contained and self adjusting.
Direct coupled valve actuators shall be 24° Vac or 28° Vdc
power, available with floating or modulating control signal
inputs. Actuator shall be usable with common power
supply for multiple actuators and controllers.
1) Read actual valve position using 272630D feedback module
2) Rewire actuator for 3-wire control
3) Program daily valve reset.
Position feedback voltage/pilot duty auxiliary switch kit,
mounting adaptor, high temperature kits, and resistor kits
for multiple actuator application shall be optional
accessories for direct coupled valve actuators.
Direct coupled valve actuators shall have a minimum
performance rating of 50,000 full stroke cycles plus
1,000,000 repositions documented in the product
literature.
Direct coupled valve actuators shall be manufactured by
the same company as manufacturers of the valves.
Automation and Control Solutions
Honeywell International Inc.
1985 Douglas Drive North
Golden Valley, MN 55422
customer.honeywell.com
® U.S. Registered Trademark
© 2016 Honeywell International Inc.
95C-10939—11 M.S. Rev. 09-16
Printed in United States
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