Series 61 and Series 62

Modutrol IV™ Motors

PRODUCT DATA

FEATURES
• Directly replaces M644, M944B,E,G,H,J,K,R,S and
M945B,C,G,K,L,AD Motors.
• Oil-immersed motor and gear train for reliable
performance and long life.
• Junction box provides NEMA 3 weather protection.
• Motor and circuitry operate from 24 Vac. Models
available with factory-installed transformer, or a field-
added internal transformer.
• Quick-connect terminals standard; screw terminal
adapter available.
• Adapter bracket for matching shaft height of older
motors standard with replacement motors.
• Field-adjustable stroke (90° to 160°) models available.
• Nominal standard timing of 30 seconds for 90° stroke
and 60 seconds for 160° stroke. Other timings
available.
• Die-cast aluminum housing.
• Integral auxiliary switches available factory mounted,
or can be field added to TRADELINE® models.
• Integral spring returns motor shaft to normal position
(fully open or fully closed, depending on model) upon
APPLICATION power interruption.
• Series 62 models include electrically isolated
The Series 61 and Series 62 Modutrol IV™ Motors are three- feedback potentiometer that provides shaft position
wire spring return and non-spring return floating control indication.
motors. Use these motors with controllers that provide a • Series 62 TRADELINE models have linear feedback,
switched spdt or floating output to operate dampers or valves. configurable for slaving Series 90 Motors.
The Series 62 motors also have an internal electrically • Spring return motors can operate valve linkages from
isolated feedback potentiometer that provides indication of power end or auxiliary end shafts for normally closed
the motor shaft position and can be used for slaving Series or normally open valve applications.
90 Motors or rebalancing an external control circuit.

Contents
Aapplication .......................................................................... 1
Features ................................................................................ 1
Specifications ........................................................................ 2
Ordering Information ............................................................. 2
Installation ............................................................................. 5
Settings and Adjustments ..................................................... 8
Operation ............................................................................. 11
Checkout ............................................................................. 12
Replacement ....................................................................... 12

® U.S. Registered Trademark

Copyright © 1999 Honeywell Inc. • All Rights Reserved 63-2188-3
SERIES 61 AND SERIES 62 MODUTROL IV ™ MOTORS

TRADELINE models have auxiliary switch cams.

SPECIFICATIONS
Modutrol IV Order Number Guide:
TRADELINE® Models: See Table 1.
TRADELINE models are selected and packaged to provide
ease of stocking, ease of handling and maximum Dimensions:
replacement value. Specifications are the same as those See Fig. 1.
of standard models unless specified.
Table 1. Modutrol IV Order Number Guide.
M Motor
61 Floating Control
62 Floating Control with feedback
6 — 35 lb-in. Non-Spring Return
7 25 lb-in. Spring Return 75 lb-in. Non-Spring Return
8 60 lb-in. Spring Return 150 lb-in. Non-Spring Return
9 — 300 lb-in. Non-Spring Return
1 Single-ended Non-Spring Return
2 shaft Normally Closeda Spring Return
3 Normally Openb Spring Return
4 Dual-ended Non-Spring Return
5 shaft Normally Closeda Spring Return
6 Normally Openb Spring Return
A 0 Aux. Switches Fixed Stroke Normally Closeda
B 1 Aux. Switch
C 2 Aux. Switches
D 0 Aux. Switch Adjustable Stroke
E 1 Aux. Switch
F 2 Aux. Switches
G 0 Aux. Switch Fixed Stroke Normally Openb
H 1 Aux. Switch
J 2 Aux. Switches
K 0 Aux. Switch Adjustable Stroke
L 1 Aux. Switch
M 2 Aux. Switches

M 61 8 4 A XXXX Varies with Model

a Electrically normally closed. Shaft rotates clockwise (as viewed from the power end) with increase in control signal. Motor
drives to normally closed position when powered with control wiring not connected.
b Electrically normally open. Shaft rotates counterclockwise (as viewed from the power end) with increase in control signal.
Motor drives to normally open position when powered with control wiring not connected.

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 Home and Building Control Sales Office (check white pages of your phone directory).
2. Home and Building Control Customer Logistics
Honeywell Inc., 1885 Douglas Drive North
Minneapolis, Minnesota 55422-4386 (612) 951-1000

In Canada—Honeywell Limited/Honeywell Limitée, 155 Gordon Baker Road, North York, Ontario M2H 3N7.
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.

63-2188—3 2
 SERIES 61 AND SERIES 62 MODUTROL IV ™ MOTORS

TOP VIEW TOP VIEW OF BRACKET

4-7/8 4-1/4
(124) (107)

4-5/8
(116) 5-13/16
(148)
5-1/2
(140) 2-5/16
(58)

11/16
(17)

POWER END
1/4 13/16
(7) 3 (20) 1/4 (7)
4-1/16 (103) 1-1/2 (37)
4 4-7/8 (124)
4-1/16 (103) 5-9/16 (141)
5
4-1/16 (103)

WIRING
BOX

BASE
MOTOR

1 6-7/16
(164)

AUXILARY POWER 5-3/8 SPRING RETURN MODEL SHOWN

END END (137)
1 SOME MODELS DO NOT HAVE AN AUXILIARY
2-9/16 SHAFT. ALL OTHER DIMENSIONS ARE THE SAME.
(66)
2 FOR HIGH TORQUE (60 LB-IN.) SPRING RETURN
MODELS 8-3/4 (222); FOR LOW TORQUE (25 LB-IN.)
SPRING RETURN MODELS 8-1/4 (210);
NON-SPRING RETURN MODELS 7-5/16 (185).
9/16 (15)
2 3 FOR HIGH TORQUE (60 LB-IN.) SPRING
RETURN MODELS (SHOWN).

3/4 4 FOR LOW TORQUE (25 LB-IN.) SPRING

ADAPTER
BRACKET (19) RETURN MODELS.

5 FOR NON-SPRING RETURN MODELS. M17089

Fig. 1. Series 61 and 62 Modutrol IV Motor mounting dimensions in in. (mm).

Electrical Ratings: Auxiliary Switch Ratings:

See Table 2. See Table 3.

Table 2. Series 61 and 62 Modutrol Motor Power Table 3. Auxiliary Switch Ratings.
Consumption Ratings.
Single Contact 120V 240V
Power Consumption Ratinga (in Amps) (in Amps)

Voltage Non-Spring Spring Full Load 7.2 3.6

Internal at Return Return Locked Rotor 43.2 21.6
Transformer 50/60 Hz (VA) (W) (VA) (W) a40 VA pilot duty, 120/240 Vac on opposite contact.
No 24 17 15 21 20
Yes 24 26 20 30 25 Control Inputs:
120 26 20 30 25 Floating three-wire (Series 60): drive open, hold, drive closed.
Series 62 models include an internal, electrically isolated
208 26 20 30 25 feedback potentiometer that provides shaft position
240 27 20 34 25 indication.

3 63-2188—3
SERIES 61 AND SERIES 62 MODUTROL IV ™ MOTORS

Ambient Temperature Ratings: 220736B Internal Auxiliary Switch Kit; two switches, can be
Maximum: 150°F (66°C) at 25% duty cycle. field-installed on TRADELINE models.
Minimum: -40°F (-40°C). 220741A Screw Terminal Adapter converts the standard
quick-connect terminals to screw terminals.
Feedback Potentiometer (Series 62 Models Only): 221455A Infinitely Adjustable Crank Arm, can rotate through
TRADELINE Models (Can be shunted for slaving a Series 90 downward position and clear base of motor without
Motor): requiring use of adapter bracket.
160° Stroke: 600 ohms. 4074ERU Weatherproofing Kit provides NEMA 3 rating for
90° Stroke: 353 ohms. Modutrol IV Motors mounted in position other than upright.
All other models have potentiometer shunted to 115 ohms. 4074EZE Bag Assembly with parts that can provide CE
compliance.
Dead Weight Load On Shaft: 7617ADW Crank Arm, can rotate through downward position
Power or Auxiliary End: 200 lb (90.8 kg) maximum. and clear base of motor without requiring use of adapter
Maximum Combined Load: 300 lb (136 kg). (Dual shaft bracket.
motors only.) ES650-117 Explosion-Proof Housing encloses motor for use
in explosive atmospheres. Not for use with Q5001 (or any
Crankshaft: other valve linkages). Order separately from O-Z/Gedney
3/8 in. (9.5 mm) square. (Some models have double-ended Inc. To order, contact: O-Z/Gedney, Nelson Enclosures
shafts.) and Controls,
(918) 641-7381 or (918) 641-7374; or write to:
Stroke: O-Z/Gedney, Nelson Enclosures and Controls
Fixed Stroke Models: Available 90° or 160°. P.O. Box 471650
Adjustable Stroke Models: Available field-adjustable from 90° Tulsa, OK 74147-1650
to 160°. (See Stroke Setting procedure.) (Requires Honeywell 7617DM Coupling.)
Q100 Linkage connects Modutrol Motor to V51 Butterfly
Timing And Torque: Valve. Requires the 220738A Adapter Bracket.
See Table 4. Q181 Auxiliary Potentiometer for sequence or unison control
of 1 to 4 additional modulating (Series 90) motors.
Approvals: Q5001 Bracket and Linkage Assembly connects Modutrol
Underwriters Laboratories Inc. Listed: File No. E4436, Guide Motor to water or steam valve.
No. XAPX. Q605 Damper Linkage connects motor to damper. Includes
Canadian Standards Association Certified: General Listed file motor crank arm.
no. LR1620, guide no. 400-E. Q607 External Auxiliary Switch controls auxiliary equipment
as a function of motor position.
Accessories:
198162AA Internal Transformer; 120/208/240 Vac 50/60 Hz NOTE: Torque designation corresponds to torque rating at
primary, 24 Vac secondary. standard timing (nominally 60 seconds for 160° and
198162EA Internal Transformer; 120 Vac 50/60 Hz primary, 30 seconds for 90° except for 300 lb-in. motors that
24 Vac secondary. have timings of 2 or 4 minutes).
198162GA Internal Transformer; 220 Vac 50/60 Hz primary,
24 Vac secondary. IMPORTANT
198162JA Internal Transformer; 24 Vac 50/60 Hz primary, Never use Modutrol Motor continuously at the
24 Vac secondary (for electrical isolation). Breakaway Torque rating.
220736A Internal Auxiliary Switch Kit; one switch, can be
field-installed on TRADELINE models.

Table 4. Series 61 and 62 Modutrol Motor Timing and Torque Ratings.

Rated Torque in lb-in. (N•m)b

Nominal Timinga in sec Normal Running Torque Breakaway Torquec
90° Stroke 160° Stroke Spring Return Non-Spring Return Spring Return Non-Spring Return
15 30 — 75 (8.5) — 150 (17.0)
30 60 25 (2.8) 50 (5.7)
60 (6.8) 35 (4.0) 120 (13.6) 70 (7.9)
150 (17.0) 300 (34.0)
60 120 25 (2.8) 300 (34.0) 50 (5.7) 600 (68.0)
120 240 — —
150 (17.0) 300 (34.0)
a Timings apply to all TRADELINE models. Some OEM models are available with non-standard timing/torque.
b Torque ratings for dual-ended shaft motors are the sum of the shaft torques (power-end torque plus auxiliary-end torque).
c Breakaway torque is the maximum torque available to overcome occasional large loads such as a seized damper or valve.

63-2188—3 4
 SERIES 61 AND SERIES 62 MODUTROL IV ™ MOTORS

• Spring Return Motors are shipped from the factory in their

INSTALLATION normal position.
• Normally closed models are shipped at the limit of
When Installing this Product... counterclockwise rotation, as viewed from the power
1. Read these instructions carefully. Failure to follow them end of the motor.
could damage the product or cause a hazardous • Normally open models are shipped at the limit of
condition. clockwise rotation, as viewed from the power end of the
2. Check the ratings given in the instructions and on the motor.
product to make sure the product is suitable for your
application. NOTE: Refer to Fig. 2 for graphical representation of fully-
3. Installer must be a trained, experienced service open and fully-closed positions.
technician. VERTICAL VERTICAL
4. After installation is complete, check out product REFERENCE REFERENCE
operation as provided in these instructions. FULLY FULLY
CLOSED CLOSED
10°
10°

CAUTION 90°

Electrical Shock or Equipment Damage Hazard.

160°
Can shock individuals or short equipment
circuitry.
Disconnect all power supplies before installation. FULLY
OPEN
Motors with auxiliary switches can have more than
one disconnect.
FULLY

CAUTION 90 DEGREE STROKE

25, 35,60, AND 75 lb-in. TORQUE
OPEN
160 DEGREE STROKE
Equipment Damage Hazard. VERTICAL
Can damage the motor beyond repair. REFERENCE
Never turn the motor shaft by hand or with a wrench.
45°
Forcibly turning the motor shaft damages the gear FULLY
train and stroke limit contacts. CLOSED

IMPORTANT
90°
Always conduct a thorough checkout when
installation is complete.

Location
FULLY

CAUTION 90 DEGREE STROKE

150 AND 300 lb-in. TORQUE
OPEN
M17090

Motor Damage Hazard.

Fig. 2. Motor shaft positions at stroke limits
Deteriorating vapors and acid fumes can damage
(viewed from power end of motor).
metal parts.
Install motor in areas free of acid fumes and other
deteriorating vapors.
Adapter Bracket
In excessive salt environments, mounting base and screws The 220738A Adapter Bracket, positioned between the motor
should be zinc or cadmium plated, not stainless steel or and the equipment, raises motor shaft height by 0.75 in. (19
brass. Use the 220738A Adapter Bracket for mounting on mm) to match that of previous Modutrol® Motor models.
these surfaces.
The following applications require this bracket:
Allow enough clearance for installing accessories and • Q607 External Auxiliary Switch.
servicing the motor when selecting a location (see Fig. 1). If • Damper linkage applications require added clearance to
located outdoors, use liquid-tight conduit connectors with the allow:
junction box to provide NEMA 3 weather protection. If • Crank arm rotation through the downward position.
mounted outdoors in a position other than upright, install a • Sufficient damper linkage to reach the motor shaft.
4074ERU Weatherproofing Kit and liquid-tight connectors to • All valve linkages except the Q5001.
provide NEMA 3 protection.
NOTE: When the bracket is not used in a replacement
Mounting application, the damper linkage requires adjustment
for the new shaft position.
Use the following guidelines for proper motor mounting:
• Always install motors with the crankshaft horizontal.
To mount the motor with the bracket:
• Mounting flanges extending from motor housing base are
1. Mount the bracket to the equipment with existing or
drilled for 1/4 inch (6.4 mm) machine screws or bolts.
standard bolts.
• Non-Spring Return Motors are shipped from the factory in
2. Using the provided bolts, mount the motor to the
the closed position (at the limit of counterclockwise
bracket threaded holes. See Fig. 3.
rotation, as viewed from the power end of the motor).

5 63-2188—3
SERIES 61 AND SERIES 62 MODUTROL IV ™ MOTORS

STANDARD
BOLTS (4)
BOLTS
1 PROVIDED (4)

WIRING
BOX

MOTOR

ND
RE
WE
PO

ADAPTER
BRACKET

EQUIPMENT ND ND
BASE RE RE
WE WE
PO PO

1 No. 12 OR 1/4 in. ZINC PLATED

MACHINE SCREWS OR BOLTS

M452E NON-SPRING RETURN SPRING RETURN

Fig. 3. Mounting the motor with an adapter bracket.

For valve linkage applications (other than the Q5001): Housing an internal transformer or internal auxiliary switches
1. Mount the bracket to the linkage. requires using a junction box.
2. Position the motor on the bracket to align the motor
shaft with the linkage. Wiring
3. Attach the motor to the bracket with the four bolts
provided. See Fig. 4.
CAUTION
Damper Linkages Electrical Shock or Equipment Damage Hazard.
The motor does not include a crank arm. Order the crank arm Can shock individuals or short equipment
separately (see Accessories in the Specifications section). circuitry.
For detailed instructions on the assembly of specific linkages, Disconnect power supply before installation.
refer to the Installation Instructions packed with the linkage.
IMPORTANT
All wiring must agree with applicable codes,
CAUTION ordinances and regulations.
Equipment Damage Hazard.
Stalling a motor can damage the drive shaft. 1. Ensure that the voltage and frequency stamped on the
Ensure installation of motors and linkages allows the motor correspond with the power supply characteristics.
motor to drive through full stroke without obstruction. 2. When connecting several motors in parallel, ensure that
the power supply VA rating is large enough to provide
power to all motors used without overloading.
Valve Linkages 3. Fig. 5 shows that the motor terminals are quick-
The Q100 Linkage requires the 220738A Adapter Bracket for all connects located on top of the printed circuit board.
valve applications. Applications with the Q5001 Valve Linkage 4. To access the wiring compartment:
do not require the 220738A Adapter Bracket (see Fig. 4). a. Remove the four screws from the junction box
top.
Junction Box b. Lift off the cover.
5. Refer to Fig. 6 through 8 for typical wiring, and Fig. 9
When used with liquid-tight conduit connectors, the junction for internal auxiliary switch connections.
box provides NEMA 3 weather protection for the motor. The
junction box, standard with replacement motors, encloses the
terminals and provides knockouts for wiring conduits.

63-2188—3 6
 SERIES 61 AND SERIES 62 MODUTROL IV ™ MOTORS

Q5001 POWER WIRING

VALVE END OF BOX
LINKAGE MOTOR

MOTOR

1/4-20 UNC
1 in. LONG
VALVE MOUNTING
BOLTS

M17092

Fig. 4. Mounting the motor on a Q5001 Valve Linkage.

NOTE: Reverse motor rotation by switching wires at either ADJUSTABLE STROKE

POTENTIOMETER
the motor or the panel. Reverse rotation on the STROKE
ADJUSTMENT
Series 61 models by reversing the wires at terminals CAMS 1
W and B. Reverse rotation on the Series 62 models
Y INNER AUXILIARY
by reversing wires at terminals 1 and 2 (to correct SWITCH
the motor rotation) and reverse wires at terminals Y 2

and G (to maintain a feedback signal that G

corresponds with the shaft rotation). INNER AUXILIARY
T SWITCH CAM (BLUE)

2
POWER
1 END

R
OUTER AUXILIARY
4 SWITCH CAM (RED)

3
OUTER AUXILIARY
SWITCH

1 HIGH TORQUE (150 lb.-in., 300 lb.-in.) MODELS HAVE TWO

YELLOW ADJUSTMENT CAMS. LOW TORQUE MODELS HAVE
ONLY ONE BROWN INTERNAL STROKE ADJUSTMENT CAM.

2 SERIES 62 TERMINAL DESIGNATIONS SHOWN.

NOTE: NOT ALL FEATURES AVAILABLE ON ALL MODELS. M17094

Fig. 5. Terminals and adjustments.

7 63-2188—3
SERIES 61 AND SERIES 62 MODUTROL IV ™ MOTORS

SERIES 60 SERIES 61 NOTE: Vibration does not affect the performance of

CONTROLLER MOTOR
Modutrol IV Motors (as it did in earlier Modutrol
R R Motors). When replacing a motor that was
connected to an R927C or R9107A Relay,
W T1 Honeywell recommends performing a retrofit to
B W B remove the relay and the old motor. Replace both
with one Series 90 Modutrol IV motor (that is, do not
T2 replace the relay).

1 2 2 2 3
BLUE LEAD YELLOW LEAD
L1
(HOT)
L2 1

1 POWER SUPPLY. PROVIDE DISCONNECT MEANS

AND OVERLOAD PROTECTION AS REQUIRED. 1

2 TRANSFORMER MAY BE INTERNAL OR EXTERNAL

TO MOTOR. RED LEAD 2
M17095

Fig. 6. Series 61 motor wiring. 1 USE NEC CLASS 1 WIRING UNLESS POWER SUPPLY
MEETS CLASS 2 REQUIREMENTS. TAPE UNUSED LEADS.
ENSURE THE CURRENT DRAW OF THE EXTERNAL CIRCUIT
IS LESS THAN SWITCH CONTACT RATING.
SERIES 60 SERIES 62
MOTOR 2 ON TWO-SWITCH MOTORS, SECOND SWITCH HAS BLACK
CONTROLLER
LEADS WITH BLUE, YELLOW, AND RED TRACERS.
R R 3 YELLOW LEAD NOT PRESENT ON ALL MOTORS. M17099

1 3 Fig. 9. Auxiliary switch schematic.

B W 2

T 4

G
SETTINGS AND ADJUSTMENTS
1 2
Y
3 Adjustable Stroke
L1 On adjustable stroke motors, stroke is field-adjustable
(HOT)
L2
between 90° and 160°.
• The mechanical adjustment (cams) establishes the fully
open (clockwise, as viewed from the power end) and fully
1 POWER SUPPLY. PROVIDE DISCONNECT MEANS
AND OVERLOAD PROTECTION AS REQUIRED.
closed positions of the motor shaft.
• The electrical adjustment (trim potentiometer) matches the
2 TRANSFORMER MAY BE INTERNAL OR EXTERNAL
TO MOTOR.
feedback resistance change to the motor stroke.
• TRADELINE® motors are shipped with the stroke set at
3 FEEDBACK POTENTIOMETER. M17096 160°.
Fig. 7. Series 62 motor wiring.
CAUTION
Careless Installation Hazard.
SERIES 90 R927C OR R9107A RELAY
CONTROLLER
1 Use of excessive force while adjusting cams
L2 damages the motor.
W W R B G Y T 2 1 T L1 To avoid damaging motor end switches, set cams by
(HOT) moving only the top of the screwdriver.
R

2
CAUTION
Careless Installation Hazard.
Forcibly turning the motor shaft damages the gear
Y T G 2 1 4 3
B train and stroke limit contacts.
R
Never turn the motor shaft manually (by hand or with
a wrench).
W
Q181A
160° STROKE SERIES 62 MOTOR Before Setting Stroke
1. Remove the top cover from the motor.
1 POWER SUPPLY. PROVIDE DISCONNECT MEANS 2. Disconnect the controller from the motor.
AND OVERLOAD PROTECTION AS REQUIRED.
3. For models with an internal transformer (line voltage
2 CONNECTION REQUIRED ONLY FOR SPRING RETURN MOTORS.
M17098
motors), ensure that power (and nothing else) remains
connected to the motor.
Fig. 8. Connections to R927C or R9107A Relay.

63-2188—3 8
 SERIES 61 AND SERIES 62 MODUTROL IV ™ MOTORS

IMPORTANT 3. Insert 1/8 in. screwdriver blade into a slot on inner cam
Detach the linkage from motor before adjusting the and move the top of the screwdriver as far as possible
stroke. clockwise (viewed from the power end). See Fig. 10.
Repeat in successive cam slots until the inner cam is
Setting Stroke at 90° or 160° against the clockwise stop.
1. Adjust the trim potentiometer: 4. Drive the motor to the fully-open position as follows:
a. For 160° stroke, turn fully clockwise. a. For models with an internal transformer (line
b. For 90° stroke, turn fully counterclockwise. voltage motors), connect a jumper across
2. Drive the motor to the mid-position as follows: terminals R and 2 until the motor reaches the
a. For models with an internal transformer (line fully-open position.
voltage motors), connect a jumper across b. For models with no internal transformer (low
terminals R and 2 to drive motor open (clockwise, voltage motors), connect 24 Vac across motor
as viewed from power end), or across terminals R terminals 2 and 3 until motor reaches the fully-
and 1 to drive motor closed (counterclockwise) open position.
until motor reaches mid-position.
b. For models with no internal transformer (low NOTE: The motor should now be in the 90° position.
voltage motors), connect 24 Vac across motor
terminals 2 and 3 to drive motor open (clockwise, IMPORTANT
as viewed from the power end), or across During step 5, allow the motor to reposition after
terminals 1 and 3 to drive motor closed each move of the cam.
(counterclockwise) until motor reaches mid-
position. 5. Insert 1/8 in. screwdriver blade into a slot on inner cam
3. Insert 1/8 in. screwdriver blade into a slot on inner cam and move the top of the screwdriver slowly clockwise
and proceed as follows: (viewed from the power end). Repeat this procedure
a. For 90° stroke: Move the top of the screwdriver until the motor reaches the desired fully-open position.
as far as possible counterclockwise (viewed from
the power end). NOTE: Each click of the cam provides approximately
b. For 160° stroke: Move the top of the screwdriver 2 degrees of rotation.
as far as possible clockwise (viewed from the
power end). IMPORTANT
See Fig. 10. Repeat in successive cam slots until the If the motor turns past the desired position, do not
inner cam is against the stop. move the cam.

NOTE: For low torque motors (75 lb-in. or less), omit 6. If the motor turns past the desired position, drive the
step 4 and proceed to step 5. motor to mid-position then move the cam clockwise to
the stop and repeat steps 4 and 5.
4. Insert 1/8 in. screwdriver blade into a slot on outer cam
and proceed as follows: NOTE: Drive the motor to mid-position as follows:
a. For 90° stroke: Move the top of the screwdriver a. For models with an internal transformer (line
as far as possible clockwise (viewed from the voltage motors), connect a jumper across
power end). terminals R and 2 to drive motor open (clockwise,
b. For 160° stroke: Move the top of the screwdriver as viewed from power end), or across terminals R
as far as possible counterclockwise (viewed from and 1 to drive motor closed (counterclockwise)
the power end). until motor reaches mid-position.
See Fig. 10. Repeat in successive cam slots until the b. For models with no internal transformer (low
outer cam is against the stop. voltage motors), connect 24 Vac across motor
5. Check the motor stroke before connecting the linkage. terminals 2 and 3 to drive motor open (clockwise,
6. Reconnect the controller, replace the motor top cover as viewed from the power end), or across
and attach the linkage to the motor. terminals 1 and 3 to drive motor closed
(counterclockwise) until motor reaches mid-
Setting Stroke Between 90° and 160°
position.
7. Once the desired position is reached, set the electrical
1. Adjust the trim potentiometer fully clockwise. stroke limit:
2. Drive the motor to the mid-position as follows: a. Slowly adjust the trim potentiometer
a. For models with an internal transformer (line counterclockwise until the motor starts to move.
voltage motors), connect a jumper across b. Stop and turn the trim potentiometer 1/8 turn
terminals R and 2 to drive motor open (clockwise, clockwise.
as viewed from power end), or across terminals R
and 1 to drive motor closed (counterclockwise) NOTE: This last adjustment ensures total motor
until motor reaches mid-position. movement over the full range of the controller.
b. For models with no internal transformer (low
voltage motors), connect 24 Vac across motor 8. Check that the electrical stroke is set properly by
terminals 2 and 3 to drive motor open (clockwise, opening the W lead. The motor should not move.
as viewed from the power end), or across terminals
1 and 3 to drive motor closed (counterclockwise)
until motor reaches mid-position.

9 63-2188—3
SERIES 61 AND SERIES 62 MODUTROL IV ™ MOTORS

3
4
R
1
2
G
Y

INNER STROKE
ADJUST CAM 1

OUTER STROKE
ADJUST CAM 2 M652

Fig. 11. Attaching a shunt resistor to TRADELINE motors.

AUXILIARY
POWER END SWITCH CAMS
OF MOTOR

MOVE SCREWDRIVER AT
TOP ONLY TO ADJUST CAM.
Auxiliary Switches
Adjustable cams actuate the auxiliary switches. These cams
can be set to actuate the switches at any angle within the
1 NO. OF CAM
TORQUE CAMS COLOR motor stroke. Select switch differential of 1° or 10°.
1/8 INCH
HIGH 2 YELLOW STRAIGHT-BLADE
SCREWDRIVER
Motors with factory-added auxiliary switches are shipped in
LOW 1 BROWN the closed position (fully counterclockwise, as viewed from
CAM
the power end). Auxiliary cam default actuates the switches
2 OUTER STROKE ADJUST CAM IS ONLY
30° from fully open with a 1° differential. With the motor in the
PRESENT ON HIGH TORQUE MOTORS. M17100 closed (fully counterclockwise) position, the auxiliary switch
Fig. 10. Stroke adjustment setup for non-spring breaks contacts R-B. See Fig. 9 (or the auxiliary switch
return models. Installation Instructions) for auxiliary switch wiring.

TRADELINE Motors are shipped with auxiliary switch cams

that permit acceptance of 220736A,B Internal Auxiliary Switch
Feedback Potentiometer Configuration Kits. Refer to form 63-2228 for 220736A,B installation
(Series 62 TRADELINE® Motors Only) instructions.
Select and install one of the four shunt resistors to obtain the
appropriate feedback characteristic for your application. See Auxiliary Switch Adjustment
Specifications section for details on feedback resistance IMPORTANT
without a shunt resistor. When adjusting the auxiliary switch cams use the
• Linear feedback provides linear indication of shaft position following procedure:
with no shunt resistor. With no shunt resistor, full stroke 1. Insert 1/8 in. screwdriver blade into a slot on cam
feedback resistance is 600 ohms for 160° stroke motors and move the top of the screwdriver as far as
and 355 ohms for 90° stroke motors. possible in the required direction. See Fig. 12.
• W902 Control requires full stroke feedback resistance of 2. Repeat step 1 in successive cam slots until the cam
115 ohms. Select and attach the proper shunt resistor is in the required position.
across terminals Y and G (see Table 5 and Fig. 11). Use
the white shunt resistor for 160° stroke motors; use the Use the following procedure to obtain the desired auxiliary
green shunt resistor for 90° stroke motors. switch settings:
• Slaving a Series 90 Motor requires full stroke feedback 1. Remove the top cover from the motor to gain access to
resistance of 142 ohms. Select and attach the proper the motor terminals and auxiliary cams.
shunt resistor across terminals Y and G (see Table 5 and 2. Disconnect the controller from the motor.
Fig. 11). Use the red shunt resistor for 160° stroke motors; 3. Drive the motor to the position where the auxiliary
use the purple shunt resistor for 90° stroke motors. equipment is to be switched as follows:
a. For Non-Spring Return models without a
Table 5. Shunt Resistor Selections. transformer, connect 24 Vac to motor terminals 2
and 3 to drive motor open (clockwise as viewed
Linear W902 Slaving Series from the power end), or to terminals 1 and 3 to
Stroke Feedback Controla 90 Motor drive motor closed (counterclockwise).
90° None Green Purple b. For Non-Spring Return models with a
(174 ohms) (274 ohms) transformer, jumper across terminals R and 2 to
drive motor open (clockwise as viewed from the
160° None White Red power end), or across terminals R and 1 to drive
(143 ohms) (187 ohms) motor closed (counterclockwise).
a Note that the W902 Control is obsolete, replaced by the
W964F, which does not require a feedback signal.

63-2188—3 10
 SERIES 61 AND SERIES 62 MODUTROL IV ™ MOTORS

c. For Spring Return models, connect a jumper NOTE: Changing the differential from 1° to 10° reverses the
across motor terminals 2 and 4 to drive the motor switching action. For example, with a 10° differential,
open, or across motor terminals 1 and 4 to drive switch contacts R-B make and R-W break on a
the motor closed. counterclockwise (closed) rotation. With a 1°
4. Once Modutrol Motor reaches correct position, differential, switch contacts R-W make and R-B
disconnect the jumper. break on a counterclockwise (closed) rotation.
5. For a switch differential of 1°, check continuity of the
auxiliary switch contacts R-B and rotate the cam as
follows:
a. If the contacts are open, rotate the cam clockwise
until the R-B contacts close. OPERATION
b. If the contacts are closed, rotate the cam
counterclockwise until the R-B contacts open. Use Series 61 and Series 62 Modutrol IV Motors for standard
6. For a switch differential of 10°: Series 60 operation (drive open, hold, drive closed). Series
a. For Spring Return models, rotate the cam 62 Motors can also be used with the feedback potentiometer
approximately 180° so the slow-rise portion of the as an input to the controller.
cam actuates the switch. Then check continuity of
the auxiliary switch contacts R-B. See Table 6 for details on motor response to controller
b. For Non-Spring Return models, check continuity signals.
of the auxiliary switch contacts R-B.
7. Rotate the cam as follows: NOTE: Reverse the wires at either the motor or the
a. If the contacts are open, rotate the cam controller.
counterclockwise until the R-B contacts close.
b. If the contacts are closed, rotate the cam To reverse the rotation direction of a non-spring return motor:
clockwise until the R-B contacts open. 1. Reverse the wires at terminals 1 and 2.
8. Check for the proper differential and switching of the 2. Reverse the wires at terminals Y and G.
auxiliary equipment by driving the motor though the full
stroke in both directions.
9. Disconnect the jumper, reconnect the controller, and
replace the top cover on the motor.

MOVE SCREWDRIVER AT NOTE: CAMS ARE OFFSET

TOP ONLY TO ADJUST CAM. VERTICALLY TO PROVIDE
BETTER VIEW OF BACK CAM.
1/8 INCH
STRAIGHT-BLADE
SCREWDRIVER

RIGHT/INNER
SLOW RISE AUXILIARY
PORTION SWITCH
(APPROX.
10° DIFF.)
INNER
AUXILIARY
CAM
(BLUE)

FAST RISE
PORTION
(APPROX.
1° DIFF.)

LEFT/OUTER
AUXILIARY
SWITCH
SLOW RISE
PORTION
(APPROX.
FAST RISE OUTER 10° DIFF.)
PORTION AUXILIARY RIGH/INNER
(APPROX. CAM AUXILIARY SWITCH
1° DIFF.) (RED)
INNER AUXILIARY
CAM (BLUE)

MOTOR MOTOR LEFT/OUTER OUTER AUXILIARY

OPEN CLOSE AUXILIARY CAM (RED)
POWER SWITCH POWER END
END OF MOTOR M17101

Fig. 12. Auxiliary switch adjustment.

11 63-2188—3
SERIES 61 AND SERIES 62 MODUTROL IV ™ MOTORS

Table 6. Modutrol IV Motor Operation. 5. Return the controller to the desired setting before
leaving the job.
Motor Terminal Connection Resulting
Type Series 61 Series 62 Action

Non-Spring R-W 4-1 ccw (closed) REPLACEMENT

Return
or Spring R-B 4-2 cw (open) Damper Application
Return 1. Turn off power and remove wiring from the old motor.
Non-Spring None None stops (none) 2. Remove the crank arm from the shaft of the old motor
Return and remove the old motor.
3. Determine necessity of the mounting bracket. If the
Spring — None spring return linkage can reach the new motor shaft position and the
Return (closed) crank arm has clearance for the necessary rotation, the
bracket is not required. Use the 220738A Adapter
Bracket or the 221455A Crank Arm if the crank arm
must rotate through the bottom plane of the motor.
CHECKOUT a. If no bracket is required, mount the new motor
directly to the equipment and refer to the
After the installation and linkage adjustment, check the entire Installation, Settings and Adjustments, and the
motor and control hookup. Proper checkout ensures that: Operation and Checkout sections.
• The motor operates the load (damper or valve) properly. b. If the bracket is required, refer to the Adapter
• The motor responds properly to the controller as the input Bracket section and Fig. 3 in addition to the
varies. See Table 6. Installation, Settings and Adjustments, and the
• The auxiliary switch, if used, operates at the desired point Operation and Checkout sections.
of motor rotation. 4. Use No. 12 or 1/4 inch machine screws or bolts to
mount the new motor.
1. Inspect the motor, linkage, and valve or damper to 5. Mount damper crank arm and linkage to the new motor
ensure all mechanical connections are correct and shaft.
secure. 6. Use the Checkout procedures to test the crank arm and
linkage adjustment.
NOTE: In damper installations, the pushrod should
not extend more than a few inches past the Valve Application
ball joints.
When replacing a motor in a valve application, the linkage
type determines the necessity for the 220738A Adapter
2. Ensure that there is adequate clearance for the linkage
Bracket. With Q100, Q601 or Q618 Linkages, it is necessary
throughout the entire motor stroke without binding or
to use the 220738A to raise the motor shaft to the appropriate
striking other objects.
height. Valve applications with a Q5001 Linkage do not
3. Drive the motor fully open and fully closed. See Table 6.
require the 220738A Adapter Bracket. To operate Honeywell
V5011 two-way or V5013 three-way valves through full stroke,
NOTE: Refer to controller or system instructions for
use a 160° stroke motor.
additional checkout procedures.

4. For spring return motors, ensure that the valve or

damper returns to its normal position when power is
interrupted.

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