ML6984, ML7984 Series 4000 Direct Coupled Valve Actuators

ML6984, ML7984 Series 4000 Direct Coupled Valve Actuators
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, self-adjusting,
motorized valve actuators that mount directly onto V5011 twoway 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) electro-mechanical 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................................................................. 11
Put UPC Code Here
95C-10939-09
ML6984, ML7984 SERIES 4000 DIRECT COUPLED VALVE ACTUATORS
SPECIFICATIONS
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
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.
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.
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.
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).
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).
Specifications/CE Declaration: ML6984 and ML7984
actuators conform to the essential requirements of the Low
Voltage Directive 73/23/EEC based on the standards EN
60730-1:2000 and EN 60730-2-14:1995+A1:2001
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%
Inputs:
ML6984
- 25 mA 24 Vac (5-wire mode only)
- 500 mA (valve seating 3-wire mode)
- Minimum Signal Input Duration: 100 ms
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.
1-1/4 in.
1-1/2 in.
2 in.
2-1/2 in.
3 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
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 Automation and Control Products Sales Office (check white pages of your phone directory).
2. Honeywell Customer Care
1985 Douglas Drive North
Minneapolis, Minnesota 55422-4386
In Canada—Honeywell Limited/Honeywell Limitée, 35 Dynamic Drive, Toronto, 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.
95C-10939—09
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
Mounting
Fig. 2. Minimum Mounting Clearance.
1.
CAUTION
2.
Short and rapid cycling/repositioning may result in
possible switch device lock-up or reduced service
life.
When Installing This Product...
1.
2.
3.
4.
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.
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. Weather-proof
conduit fittings approved for outdoor and wet locations must be used to maintain NEMA 3R rating.
3
95C-10939—09
ML6984, ML7984 SERIES 4000 DIRECT COUPLED VALVE ACTUATORS
3.
4.
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.
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.
Remove Stem Button
NOTE: DO NOT
DAMAGE ANY
PART OF
THE STEM.
Valve Stem
Valve Stem
1
DO NOT
ADJUST
Position
Indicator 1
(Metal clip)
Yoke
ASSEMBLY OF POSITION INDICATOR
1 Position indicator will fit 1/4 in. - 7-1/16 in. valves.
M25487
Fig. 3. Preparation for Valve Assembly.
Valve Bonnet
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 mid-position.
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).
U-bolt
2
Yoke
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—09
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°
Typical Electronic
Controller
2
1
L1
C
L2
H
ML6984 3
1
W
T6
R
T5
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.
3
CONTROLLER CAN BE LOW VOLTAGE SPDT SERIES 20 “ON-OFF” OR
SP3T SERIES 60 “FLOATING” (TRI-STATE) TYPE. TERMINALS R AND T5
M25493
ARE CONNECTED INSIDE THE ML6984.
M25491
Fig. 7. Mounting Positions.
WIRING SCHEMATICS
Fig. 9. 3-Wire Control of ML6984 with Electronic Controller.
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.
3
4
Typical SPDT Controller
ML6984
W
B
Electrical Shock or Equipment Damage Hazard.
Can Shock Individuals or Short Equipment Circuitry.
W
L1
1
24 Vac
L2
R
W
OR
3
CONTROLLER CAN BE LOW VOLTAGE SPDT SERIES 20 “ON-OFF” OR
SP3T SERIES 60 “FLOATING” (TRI-STATE) TYPE. TERMINALS R AND T5
M25492
ARE CONNECTED INSIDE THE ML6984.
R
T5
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
M25494
FOR EACH GROUP INSTEAD.
B
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.
T6
T5
POWER SUPPLY PROVIDES OVERLOAD PROTECTION AND DISCONNECT
MEANS.
T5
2
W
T6
1
T6
POWER SUPPLY PROVIDES OVERLOAD PROTECTION AND DISCONNECT
MEANS.
1
L2
T5
R
B
3
1
L1
28 Vdc
R
B
T6
4
ML6984
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.
ML6984
R
B
Disconnect power supply to the actuator to prevent
electrical shock and equipment damage, or remove
and cap the air line to the actuator.
Typical Electro-mechanical
Controller
2
24 Vac
W
CAUTION
2
B
Fig. 10. 5-Wire Control of ML6984.
Fig. 8. 3-Wire Control of ML6984 with Series 60 Controller.
5
95C-10939—09
ML6984, ML7984 SERIES 4000 DIRECT COUPLED VALVE ACTUATORS
SIGNAL
SOURCE
3
ML7984
R
T6
W
T5
SIGNAL
SOURCE
3
2
ML7984
R
T6
W
T5
2
C
C
3
3
ML7984
R
2
1
R
1
2
T6
L1
24 Vac
T6
L1
W
24 Vac
W
ML7984
L2
T5
L2
T5
OR
C
OR
T6
C
T6
3
R
T6
W
T5
28 Vdc
T5
ML7984 2
3
1000
2-10 Vdc Direct Acting
1010
10-2 Vdc Reverse Acting
R
T6
W
T5
2
28 Vdc
T5
C
C
FUNCTION
ML7984
(SLAVE)
FUNCTION
DIP SWITCH CONFIGURATION
1
1
2
2
3
3
On (1)
Off (0)
4
On (1)
Off (0)
5
X000
4-20 mA Direct Acting
4
X010
20-4 mA 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
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.
DIP SWITCH CONFIGURATION
Master actuator
Slave actuator
1
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.
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.
M25496
M25495
Fig. 12. ML7984 Wiring with 20mA Analog Control Signal.
Fig. 11. ML7984 Wiring with 10 Vdc Analog Control Signal.
95C-10939—09
6
ML6984, ML7984 SERIES 4000 DIRECT COUPLED VALVE ACTUATORS
SINGLE
SOURCE
MODULATING
LIMIT
6
2
2
ML7984
ML7984
3
3
B
B
R
W
1
B
R
R
R
T6
W
W
T5
24 Vac
W
2
ML7984
B
B
R
R
T6
W
W
T5
SINGLE
SOURCE
B
B
R
R
T6
W
W
T5
T6
3
28 Vdc
R
R
1
L1
T6
L1
24 Vac
W
W
L2
T5
L2
OR 2
2
OR
3
ML7984
T6
28 Vdc
3
T5
B
28 Vdc
B
ML7984
T5
T6
B
2
3
24 Vac
ML7984
L2
T5
OR 2
4
2
L1
T6
1
T5
R
L1
T6
24 Vac
W
L2
T5
OR 2
T6
28 Vdc
FUNCTION
1001
Mechanical Series 90
Direct Acting
1011
Mechanical Series 90
Reverse Acting
T5
DIP SWITCH CONFIGURATION
On (1)
Off (0)
1
2
3
4
1
2
3
4
On (1)
Off (0)
RESISTOR SELECTION CHART
4
5
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.
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
DO NOT MIX M984/6 OR MODUTROL MOTORS WITH THE ML7984 IN
THE SAME CIRCUITRY.
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).
4
USE RESISTOR KIT PART NUMBER 272822.
5
TURN POWER OFF BEFORE SETTING ANY DIP SWITCHES. FOR
COMMON TRANSFORMER AND COMMON CONTROLLER APPLICATION,
PLEASE CONSULT THE FACTORY.
6
MAXIMUM RESISTANCE PER CONTROL CIRCUIT OF 280 OHM.
M25498
Fig. 14. ML7984 with Individual Transformers, Common
Controller.
M25497
Fig. 13. ML7984 Wiring with Common Transformer,
Individual Controllers.
7
95C-10939—09
ML6984, ML7984 SERIES 4000 DIRECT COUPLED VALVE ACTUATORS
ELECTRONIC
SERIES 90
(W973, T775,
H775, W7100)
2
ML7984
3
B
R
R
2
ELECTRONIC
SERIES 90
(W973, T775,
H775, W7100)
ML7984
3
B
1
R
T6
T6
L1
24 Vac
W
W
T5
L2
T5
W
OR
NOTE:
POLARITY SENSITIVE,
CHECK CONNECTIONS
W to R, R to W
2
ML7984
2
3
T5
T6
R
R
L1
T6
W
T6
28 Vdc
B
T5
R
R
T6
2
ML7984
T6
3
T5
B
28 Vdc
1
R
L1
T6
24 Vac
L2
T5
W
W
W
L2
OR
NOTE:
POLARITY
SENSITIVE,
CHECK
CONNECTIONS
W to R,
R to W
OR
3
T5
W
W
L2
T5
ML7984
L1
24 Vac
24 Vac
2
28 Vdc
1
R
W
T6
3
B
B
R
ML7984
OR
T5
T6
T5
FUNCTION
1101
Electronic Series 90
Direct Acting
1111
Electronic Series 90
Reverse Acting
On (1)
Off (0)
1
2
3
2
3
1101
Electronic Series 90
Direct Acting
4
On (1)
Off (0)
1
FUNCTION
4
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
28 Vdc
DIP SWITCH CONFIGURATION
TURN POWER OFF BEFORE SETTING ANY DIP SWITCHES.
On (1)
Off (0)
1
2
3
4
On (1)
Off (0)
1
2
3
4
5
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.
M25499
Fig. 15. ML7984 with Common Transformer, Individual
Controllers.
DIP SWITCH CONFIGURATION
M25500
Fig. 16. ML7984 with Individual Transformers, Common
Controller.
95C-10939—09
8
ML6984, ML7984 SERIES 4000 DIRECT COUPLED VALVE ACTUATORS
OPERATION
NOTE:
1.
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.
2.
3.
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 set-up. See ML6984 Operation 3-wire,
below. ML7984 always conducts a self-calibration
sequence when (re)powering up.
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.
ML7984 Operation
The microprocessor responds to the signal across the input
terminals based on the configuration DIP switch settings.
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.
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.
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.
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.
ML6984 Operation, 3-Wire
ML6984 may be installed like a conventional (non-electronic)
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, selfcalibration will not occur. The controller must drive the valve
through a cycle manually to calibrate stroke to the controller.
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 selfcalibration cycle.
NOTE: The 272630D position feedback/auxiliary switch module cannot be used with ML6984 3-wire installation.
The 272630D requires continuous power.
CAUTION
ML6984 XL10 Controller
Compatibility
Disconnect power supply before beginning
installation to prevent electrical shock and
equipment damage.
All wiring must comply with applicable local electrical
codes, ordinances, and regulations.
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.
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.
ML6984 On-Off Operation
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).
DO NOT connect 24 Vac between any ML7984 signal
input terminals. DEVICE FAILURE WILL RESULT.
9
95C-10939—09
ML6984, ML7984 SERIES 4000 DIRECT COUPLED VALVE ACTUATORS
THERMOSTAT WIRING TERMINALS
1K1
1
2
L1
W
R
R
B
TH5110D
Rc
TH6110D
R
W
2
Y
T5
L2
T6
C
4
W
O/B
G
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
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
Fig. 17. ML6984 with Honeywell T87F Round™
Thermostat.
If connecting the ML6984 directly to a T87F with a Series 20
sub-base, clip out the cooling anticipation resistor on the subbase 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.
REPLACEMENT NOTES
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.
To Replace ML784 or ML984
HEATING ONLY
1.
1
T6
24Vac
T5
C
W
B
UP
W
DOWN
2.
R
R
Y
ML6984
COOLING ONLY
1
T6
24Vac
T5
C
W
UP
DOWN
R
R
Y
1
B
W
ML6984
To Replace ML684A
CLASS 2 TRANSFORMER. PROVIDE DISCONNECT MEANS AND
M25502
OVERLOAD PROTECTION AS REQUIRED.
1.
Fig. 18. ML6984 with Honeywell T87K Round™
Thermostat.
See Fig. 19, if connecting TH5110D or TH6110D FocusPRO™
thermostats to ML6984. Configure the thermostats for Series
20 operation.
95C-10939—09
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.
2.
10
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.
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.
5.
To Replace ML6874
1.
2.
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.
NOTE:
1.
To Replace Line Voltage Auxiliary
Switches
2.
These accessories are no longer available. Replace the old
actuator with new model and 272630D position feedback/
auxiliary switch module.
1.
2.
If a second, independent output switch is needed, wire the 210 Vdc position feedback signal to an Approved, adjustable,
voltage-controlled relay.
3.
4.
5.
6.
CHECKOUT
7.
8.
ML7984
2.
3.
4.
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
Operate an external relay, such as R8845U, using the
adjustable SPDT pilot duty output on the 272630D.
1.
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.
9.
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
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
1.
2.
3.
4.
5.
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.
TROUBLESHOOTING
Symptom
Valve seat leaks or will not close
properly
Noisy Motor
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
11
95C-10939—09
ML6984, ML7984 SERIES 4000 DIRECT COUPLED VALVE ACTUATORS
Symptom
Possible Causes
Actions
Motor overheats/smoke/component Current sensing circuit failed or electronic
burn-out
components failed
ML will not respond
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 automation (30 steps) and BAS controller
system
1) Read actual valve position using 272630D feedback module
2) Rewire actuator for 3-wire control
3) Program daily valve reset.
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.
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
® U.S. Registered Trademark
© 2011 Honeywell International Inc.
95C-10939—09 K.K. Rev. 06-11
Printed in U.S.A.
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