Honeywell R7195A Operation manual

PRODUCT DATA
63-2582
® U.S. Registered Trademark
Copyright © 2002 Honeywell • All Rights Reserved
R7195A,B
Motor Positioner
APPLICATION
The R7195A,B Motor Positioner is a single channel solid state
proportioning amplifier that will accept an output signal from a
controller to position a reversing control motor with a 135-ohm
or 1000-ohm feedback slidewire. Motors with slidewires that
have resistances other than 135 ohms or 1000 ohms will be
shunted to one of these two values.
The R7195A Motor Positioner is factory-adjusted to accept a 4
to 20 mA input. The R7195B Motor Positioner is
factory-adjusted to accept input from a 135-ohm
retransmitting slidewire.
FEATURES
• Accepts 4-20 mA or 135-ohm signal to provide position
proportional control of M944 Modutrol® Motor without
balance relay and M940A,B Actionator.
• Heavy duty case.
• Mounts directly on M940 Actuator.
• Solid state design extends product life and reliability.
• Zero, span and deadband adjustments allow motor to
be field adjusted to various input ranges: i.e., split
ranging.
• Hard Manual feature allows operator to override the
controller (4-20 mA or 135-ohm input) action to open or
close fully the final control element.
• Reversing direction of motor can be accomplished by
simple wiring change of R7195.
• Output from one R7355 4-20 mA DialaTrol can operate
up to eight R7195 Positioners and associated M944 or
M940 Actuators.
• Output from one 135-ohm Series 90 Controller can
operate up to five R7195B Motor Positioners.
• Span and zero adjustment do not interact with each
other so each adjustment can be made independently
without having to readjust the other parameter.
• Can operate with motor feedback slidewire between
100 and 1000 ohms.
Contents
Application ........................................................................ 1
Features ........................................................................... 1
Specifications ................................................................... 2
Installation ........................................................................ 3
Wiring ............................................................................... 3
Operation .......................................................................... 6
Service and Troubleshooting ............................................ 7

R7195A,B MOTOR POSITIONER
63-2582 2
ORDERING INFORMATION
When purchasing replacement and modernization products from your TRADELINE® wholesaler or distributor, refer to the
TRADELINE® Catalog or price sheets for complete ordering number.
If you have additional questions, need further information, or would like to comment on our products or services, please write or
phone:
1. Your local Home and Building Control Sales Office (check white pages of your phone directory).
2. Home and Building Control Customer Relations
Honeywell, 1885 Douglas Drive North
Minneapolis, Minnesota 55422-4386
In Canada—Honeywell Limited/Honeywell Limitée, 35 Dynamic Drive, Scarborough, Ontario M1V 4Z9.
International Sales and Service Offices in all principal cities of the world. Manufacturing in Australia, Canada, Finland, France,
Germany, Japan, Mexico, Netherlands, Spain, Taiwan, United Kingdom, U.S.A.
SPECIFICATIONS
Models:
See Table 1.
Table 1. R7195A,B Models.
Operating Temperature Range:
-30°F to +150°F (-35°C to +66°C).
Slidewire Resistance:
135 ohms or 1000 ohms.
Input Range—R7195A (4-20 mA):
Adjustments:
Zero: 0.8 to 16.8 mA.
Span: 2.0 to 20.0 mA.
Deadband: 1% to 5%.
Factory Settings:
Zero: 4.0 mA input = 0% to 5% feedback potentiometer
position.
Full Scale: 20 mA = 95% to 100% feedback potentiometer
position.
Input Range—R7195B (135-ohm retransmitting slidewire
input):
Adjustments:
Zero: 0% to 80% of slidewire input.
Span: 12.5% to 125% of slidewire input.
Deadband: 1% to 5% of slidewire input.
Factory Settings:
Zero: 0% to 2% input potentiometer = 0% to 10% feedback
potentiometer position.
Full Scale: 98% input potentiometer = 90% to 100%
feedback potentiometer position.
Repositions:
1% Deadband Setting = 100 repositions.
5% Deadband Setting = 20 repositions.
Input Impedance:
R7195A: 75 ohms.
R7195B: 1 Megohm.
Dimensions:
See Fig. 1.
Weight:
R7195A: 2.7 lbs (1.2 kg).
R7195B: 3 lbs (1.4 kg).
Approvals:
Underwriters Laboratories, Inc. Listed: Type 4 Enclosure, File
Number 84572.
CSA Certified: Enclosure 4, File Number LR47125.
Model Number Operating Voltage Controller Input
R7195A1031 120 Vac, 60 Hz 4-20 mA
R7195A1056 120 Vac, 60 Hz 4-20 mA (equipped for
1000-ohm feedback
slidewire)
R7195A1064 220 Vac, 60 Hz 4-20 mA
R7195B1021 120 Vac, 60 Hz 135-ohm input

R7195A,B MOTOR POSITIONER
3 63-2582
Fig. 1. R7195A,B Motor Positioner approximate dimensions in in. (mm).
INSTALLATION
When Installing this Product…
1. Read these instructions carefully. Failure to follow them
could damage the product or cause a hazardous
condition.
2. Check the ratings given in the instructions and on the
product to make sure the product is suitable for your
application.
3. The installer must be a trained, experienced technician.
4. After installation is complete, check out product
operation as provided in these instructions.
WARNING
Electrical Shock Hazard.
Can cause serious injury or death.
Disconnect power supply before beginning installation.
More than one disconnect may be needed.
Equipment Required
To install the R7195A,B Motor Positioner, you will need:
1. Electric drill.
2. Drill bits (No. 23, No. 37).
3. Four No. 6 machine screws or four No. 6 self-tapping
screws.
4. Standard screwdriver.
5. Small adjustable wrench.
6. Center punch and hammer.
Procedure
Refer to Fig. 1 and layout of the centers of the mounting hole
locations on the mounting surface.
1. Use a center punch and hammer to mark the locations
for drilling.
2. Depending on the characteristics of the mounting
surface, drill clearance holes (No. 23 bit) for No. 6
machine screws or starting holes (No. 37 bit) for No. 6
self-tapping screws.
3. Place the positioner on the surface so that the mounting
holes are aligned with those drilled in the surface and
secure with the machine screws and nuts or self-tapping
screws, as applicable.
4. Install separate conduit for controller leads and
operating voltage leads.
WIRING
General
All wiring must comply with all applicable local electrical
codes, regulations and ordinances. When wiring more than
one motor positioner to a controller, make sure that the total
impedance of positioners and wiring is less than the output
impedance of the controller.For example, the R7355
DialTrol™ Controller can be wired to a maximum of eight
R7195A Motor Positioners. The R7355 Controller is capable
of driving a load of up to 650 ohms. See Fig. 2.
3-3/4 (95)
6-9/16
(167)
3/4 (14) NPSM (2)
7-3/8
(187)
3-1/2 (89)
3
/16 (5)
M2078
6
4-29/32 (124)
7-25/32
(198)

R7195A,B MOTOR POSITIONER
63-2582 4
Fig. 2. Multiple R7195A Motor Positioners connected to
one 4-20 mA input.
Split Range Capability
See Fig. 2 and 3. Two R7195A Motor positioners can be wired
to operate in series or can be used to split the range. One
R7195A Motor Positioner can be calibrated from 4 mA to 12
mA and the second positioner can be calibrated from 12 mA
to 20 mA. Both positioners can also operate in series with an
operating range of 4-20 mA.
More than one R7195B Motor Positioner can be connected to
a single 135-ohm input potentiometer as shown in Fig. 3. All
Wand Rmotor positioner terminals are connected in parallel
to the potentiometer. Only one motor positioner terminal Bis
connected to the input potentiometer. The R7195B Motor
Positioners may be calibrated to operate as split ranges or all
may be set to the same range. Up to five R7195B Positioners
may be connected to the one potentiometer.
Fig. 3. Multiple R7195B Motor Positioners connected to
one 135-ohm input potentiometer.
Wiring Motor Positioner to Motor Terminals
1. Refer to wiring diagrams and documentation supplied
with the motor to connect the motor positioner for
specific applications.
2. To avoid inductive interference to the internal circuitry,
separate the leads carrying line voltage from all other
leads.
3. Provide conduit protection for controller leads and
provide separate conduit for motor positioner leads from
terminals 4, 5 and 6.
4. Refer to Fig. 4, 5, 6 and 7 for examples of typical wiring
configurations.
Fig. 4. Connections to M940 Motor using separate supply voltage.
4 TO 20 mA
CONTROLLER
R7195
R7195
4-20 mA
OUTPUT
+
-
W
R
W
R
M20787
A
R7195
MOTOR
POSITIONER
BRW BRW BRW
RE-TRANSMITTING POTENTIOMETER (OR OTHER
POTENTIOMETER) USED FOR INPUT. M2078
7
1
1
R7195
MOTOR
POSITIONER
R7195
MOTOR
POSITIONER
546
GL2 L1 231BW R
G32 1
654
GROUND
GROUND
NEUTRAL
HOT
HOT
NEUTRAL
MOTOR
SUPPLY
R7195
SUPPLY
M940A MOTOR
TERMINALS TO
4-20 mA INPUT
BW R
CW
135-OHM
POTENTIOMETER
INPUT
M20789A
+-
R7195A,B
MOTOR POSITIONER

R7195A,B MOTOR POSITIONER
5 63-2582
Fig. 5. Connections to M940 Motor using common supply voltage.
Fig. 6. Connections to M944G,S Motors.
R7195A,B
MOTOR POSITIONER
546
GL2 L1 231BW R
G32 1
654
GROUND
NEUTRAL
HOT
R7195
SUPPLY
M940A MOTOR
TERMINALS TO
4-20 mA INPUT
BW R
CW
135-OHM
POTENTIOMETER
INPUT
M20790
+–
R7195A,B
MOTOR POSITIONER
546
GL2 L1 231BW R
1
L1
L2
23R
YTG
GROUND
NEUTRAL
NEUTRAL
HOT
HOT
R7195
SUPPLY
M944 G, S
LINE
VOLTAGE
MOTOR TERMINALS TO
4-20 mA INPUT
BW R
CW
135-OHM
POTENTIOMETER
INPUT
M2079
1
+–

R7195A,B MOTOR POSITIONER
63-2582 6
Fig. 7. Connections to M944B,E Modutrol® Motors.
OPERATION
Operating Principles
See Fig. 8 and 9.
When the motor positioner is connected to a reversing control
motor, proportioning controller, and power supply (as specified
in the application), the unit will operate as follows:
The controller output signal is transmitted to the balancing
bridge portion of the motor positioner. The balancing bridge
will compare the controller output to the feedback
potentiometer voltage. This compared voltage is referred to as
the error signal voltage. The balancing bridge circuit will
amplify the error signal, causing a Triac switch to fire. This will
energize a motor winding and will re-position the feedback
potentiometer until the error signal is reduced to zero.
Fig. 8. Block diagram.
R7195A,B
MOTOR POSITIONER
546
GL2 L1 231BW R
123
L1
L2
24 VAC
120 VAC
YTG
GROUND
NEUTRAL
HOT
R7195
SUPPLY
M944B, E
MODUTROL
MOTORS TERMINALS TO
4-20 mA INPUT
BW R
CW
135-OHM
POTENTIOMETER
INPUT
M2079
2
+–
SENSOR FEEDBACK
POTENTIOMETER
MOTOR
WINDINGS
INPUT FROM
CONTROLLER
BALANCING BRIDGE CIRCUIT
(COMPARES INPUT TO
FEEDBACK POTENTIOMETER)
TRIAC SWITCHES
POWER SUPPLY
ZERO CROSSING CIRCUITS (220/240 VAC)
OPTO ISOLATORS (120 VAC)
(PROVIDE RFI PROTECTION;
ALSO DRIVES TRIACS) M20793

R7195A,B MOTOR POSITIONER
7 63-2582
Fig. 9. External wiring diagram.
Heating Application # 1:
When the temperature at the sensor is above the range of the
controller, the controller output will be above the proportioning
range of the controller. For example: the controller output
signal will be less than 4 mA for a 4-20 mA range controller;
motor positioner triac Q3 will fire to drive the motor to the
closed position.
Heating Application # 2:
When the temperature at the sensor is below the range of the
controller, the controller output will be below the proportioning
range of the controller. For example: the controller output will
be greater than 20 mA for a 4-20 mA range controller. Motor
positioner triac Q4 will fire to drive the motor to the open
position.
Heating Application # 3:
When the temperature at the sensor is within the
proportioning range of the controller; Q3 triac will fire as the
sensor temperature rises above the controller setpoint to drive
the motor in the closed direction. Q4 triac will fire as the
temperature at the sensor drops below the controller setpointt
to drive the motor in the open direction.
In each case the motor will move until a new balance point is
reached such that the error voltage between the input signal
and the slidewire signal is zero.
SERVICE AND TROUBLESHOOTING
Calibration Procedure
NOTE: The R7195 Motor Positioner is calibrated at the
factory for a 4-20 mA input signal for the R7195A
and a 135-ohm potentiometer input for the R7195B.
Therefore, do not calibrate the motor positioner
unless the input signal desired is something other
than 4-20 mA (R7195A) or 135 ohms (R7195B).
To calibrate the positioner, refer to Fig. 9.
For the span and zero adjustment check, do the following:
1. Connect the input source (4-20 mA or 135-ohm
potentiometer) to terminals R, B and W.
2. Set the input to the minimum value of span. Adjust the
zero potentiometer (P3) to balance out the motor and
the minimum limit.
3. Set the input to the maximum value of span. Adjust the
span potentiometer (P1) to balance out the motor at the
maximum limit.
Deadband Adjustment
The deadband adjustment (P2) will be set at the mid position
to provide precise control of the process for most process
applications. Some processes may require deadband
adjustment to achieve stable control. Unstable process
conditions may be characterized by:
(P1) SPAN ADJUST
(P2) DEADBAND ADJUST
(P3) ZERO ADJUST
M202794
GROUND
NEUTRAL
HOT
GROUND
R7195 SUPPLY
HOT
ROTOR SWITCH
CCW
CLOSE CW OPEN
MOTOR
WINDINGS
Q4
Q3 LIMIT
SWITCHES
NEUTRAL
G
GROUND
MOTOR
SUPPLY
COMMON
4-20 mA INPUT
MOTOR
BW
R
CW
135-OHM
POTENTIOMETER INPUT
R7195A,B
MOTOR POSITIONER
546
GL2 L1 231BW R

R7195A,B MOTOR POSITIONER
63-2582 8
a. Frequent re-positioning (hunting) of the motor.
b. Oscillation of the process variable around the
setpoint.
Check for unstable process conditions during initial startup of
the process. If unstable operation occurs, increase the
deadband adjustment (P2) until the cycling rate diminishes.
Hard Manual Check
Hard Manual allows the operator to override the controller
action to open or close fully the final control element (valve,
damper, etc.).
4-20 mA—Model 7195A
Connect terminal W to terminal B to drive the motor fully open.
Disconnect terminal W or terminal R to drive the motor fully
closed.
135-ohm Potentiometer—Model R7195B
Connect terminal W to terminal R to drive the motor fully
closed. Disconnect wire from Terminal W to drive the motor
fully open.
Troubleshooting
CAUTION
Equipment Damage Hazard.
Improper procedure can damage internal circuits.
To prevent triac damage, do not attempt to short
R7195 terminals 1, 2 or 3.
Motor Checkout Procedure
1. Identify wires on terminals 1 through 6 by terminal
number; then disconnect them from the terminals.
2. Connect an ohmmeter across wires 4 and 5 (feedback
slidewire).
3. Apply rated voltage across wires 1 and 2. Observe
gradual increase or decrease in feedback resistance.
4. Apply rated voltage across wires 2 and 3. Observe
gradual increase or decrease in feedback resistance.
If the motor functions properly, continue with the
troubleshooting procedure that follows.
4-20 mA Input Applications
PRINTED WIRING BOARD
Refer to Fig. 10 and 11.
1. Connect the operating voltage leads to the appropriate
terminals and apply power (Fig. 10).
2. Set the motor at mid-range as follows:
a. Connect input source to terminals W and R, as
applicable to the motor.
b. Adjust the input source to mid-range.
3. Refer to Fig. 11, a logic diagram to help you isolate
output circuit component failures on the printed wiring
board. Please refer to the appropriate literature for your
motor.
4. The types of component failures are listed below:
a. Shorted triac switches Q3 and Q4.
b. Q3 and Q4 break over at less than rated voltage.
c. Q3 and Q4 do not fire.
d. MOV (CR12) shorts.
5. If the logic diagram does not identify your
system-related problem, the failure is not in the output
circuit and the controller should be replaced or you may
use the schematic to troubleshoot the board.
NOTE: If your motor-motor controller system runs to fully
open or fully closed position, but fails to balance with
proper input conditions, it may be necessary to
reverse either motor power connections (1 and 3) or
feedback slidewire connections (4 and 6) at the
controller.
REVERSING DIRECTION OF THE MOTOR
Motor direction may be reversed as follows:
1. Interchange motor winding connections on terminals 1
and 3.
2. Interchange feedback potentiometer connections on ter-
minals 4 and 6.
135-Ohm Input Applications
PRINTED WIRING BOARD
Refer to Fig. 10 and 11.
1. Connect the operating voltage to the appropriate
terminals and apply power.
2. Set the motor at mid-range as follows:
a. Connect input source to terminals B, W and R.
b. Adjust input source to mid-range.
3. Refer to Fig. 11, a logic diagram to help you isolate
output circuit component failures on the printed wiring
board. Please refer to the appropriate literature for your
motor.
4. Types of component failures are listed below:
a. Shorted Triac switches Q3 and Q4.
b. Q3 and Q4 break over at less than rated voltage.
c. Q3 and Q4 do not fire.
d. MOV (CR12) shorts.
5. If the logic diagram does not identify your
system-related problem, the failure is not in the output
circuit and the controller should be replaced or you may
use the schematic to troubleshoot the board.
NOTE: If your motor-motor controller system runs to fully
open or fully closed position, but fails to balance with
proper input conditions, it may be necessary to
reverse either motor power connections (1 and 3) or
feedback slidewire connections (4 and 6) at the
controller.
REVERSING DIRECTION OF THE MOTOR
Motor direction may be reversed as follows:
1. Interchange motor winding connections on terminals 1
and 3.
2. Interchange feedback potentiometer connections on
terminals 4 and 6.

R7195A,B MOTOR POSITIONER
9 63-2582
Fig. 10. Flowchart to troubleshoot output Triac switch circuits for 4-20 mA input.
REPLACE Q3.
NO
DID MOTOR
DRIVE OPEN?
IS OPERATING
VOLTAGE
120V?
TRIAC OUTPUT CIRCUIT IS OKAY.
REPLACE OR TROUBLESHOOT
PRINTED WIRING BOARD USING
SCHEMATICS.
MEASURE
AC VOLTAGE AT
TERMINALS L2 TO 1.
REPLACE Q4.
REPLACE Q4.
DID MOTOR
DRIVE AT
NORMAL
SPEED?
YES
NO
IS VOLTAGE
LESS THAN
10V?
YES
NO
REPLACE Q3,
A4, R28, R29.
YES
YES
NO
NO
YES
DID MOTOR
DRIVE OPEN?
REPLACE Q4
REPLACE Q4, A5, R31, R32.
REPLACE CR12
REPLACE Q3.
M20795
NO
YES
SHORT TERMINALS
B TO W.
CONNECT OPERATING
VOLTAGE.OPEN INPUT
FROM CONTROLLER.
MEASURE
AC VOLTAGE AT
TERMINALS 1 AND L2.
IS VOLTAGE
LESS THAN
10V?
REPLACE Q3.
YES
NO
YES
NO YES
DID MOTOR
DRIVE
CLOSE?
DID MOTOR
DRIVE AT
NORMAL
SPEED?
SHORT TERMINALS
B TO W.
IS OPERATING
VOLTAGE
120V?
NO

R7195A,B MOTOR POSITIONER
63-2582 10
Fig. 11. Flowchart to troubleshoot output Triac switch circuits for 135-ohm potentiometer input.
REPLACE Q3.
NO
DID MOTOR
DRIVE OPEN?
IS OPERATING
VOLTAGE
120V?
TRIAC OUTPUT CIRCUIT IS OKAY.
REPLACE OR TROUBLESHOOT
PRINTED WIRING BOARD USING
SCHEMATICS.
MEASURE
AC VOLTAGE AT
TERMINALS L2 TO 1.
REPLACE Q4.
REPLACE Q4.
DID MOTOR
DRIVE AT
NORMAL
SPEED?
YES
NO
IS VOLTAGE
LESS THAN
10V?
YES
NO
REPLACE Q3,
A4, R28, R29.
YES
YES
NO
NO
YES
DID MOTOR
DRIVE OPEN?
REPLACE Q4
REPLACE Q4, A5, R31, R32.
REPLACE CR12
REPLACE Q3.
M20796
NO
YES
OPEN INPUT W.
CONNECT OPERATING
VOLTAGE. SHORT R-W.
MEASURE
AC VOLTAGE AT
TERMINALS 1 AND L2.
IS VOLTAGE
LESS THAN
10V?
REPLACE Q3.
YES
NO
YES
NO YES
DID MOTOR
DRIVE
CLOSE?
DID MOTOR
DRIVE AT
NORMAL
SPEED?
SHORT TERMINALS
B TO W.
IS OPERATING
VOLTAGE
120V?
NO

11 63-2582

63-2582 G.R. 09-02 Printed in Mexico www.honeywell.com
Automation and Control Solutions
Honeywell Honeywell Limited-Honeywell Limitée
1985 Douglas Drive North 35 Dynamic Drive
Golden Valley, MN 55422 Scarborough, Ontario
M1V 4Z9
R7195A,B MOTOR POSITIONER
By using this Honeywell literature, you agree that Honeywell will have no liability for any damages arising out of your
use or modification to, the literature. You will defend and indemnify Honeywell, its affiliates and subsidiaries, from and
against any liability, cost, or damages, including attorneys’ fees, arising out of, or resulting from, any modification to the
literature by you.