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Emerson Fisher 4194 Instruction Manual

1. 19 4 26 0 O RING PROPORTIONAL J BAND ADJUSTMENT KEY 25 PLASTIC a WASHER EN KEY 22 i ADJUSTABLE SET POINT SET POINT NOZZLE PIVOT ASSEMBLY BEAM SHOE ASSEMBLY KEY 17 SET POINT KEY 29 KEY 21 BEAM ASSEMBLY KEY 23 W4193 EXPLODED VIEW FLAPPER ALIGNMENT SCREW FLAPPER RETAINER CLIP E RING CAP POSITIVE FEEDBACK TUBING ASSEMBLY PROPORTIONAL BAND ADJUSTMENT KNOB SHOE ADJUSTMENT SCREWS 2225 SET POINT BIAS SPRING SET POINT ASSEMBLY SET POINT LINK 3 RELAY NOZZLE W3852 BEAM SHOE TUBING ASSEMBLY LINK 3 DISCONNECT 31 Instruction Manual 4194HS Controllers D200157X012 October 2011 Figure 19 Position of Link Number 4 Adjustment Figure 20 Proportional Band Adjustment Knob Screws Alignment LINK 4 ADJUSTMENT SCREW HEADS ADJUSTABLE SET POINT PIVOT ASSEMBLY 5 200 i m A Y Ec nmn SCREW AND WASHER SCREW WASHER KEYS 19 AND 20 KEYS 19 AND 20 lt 7 NOTES 1 SCREW INSERTED INTO THE ADJUSTABLE SET POINT PIVOT ASSEMBLY 2 SCREW INSERTED INTO THE RELAY NOZZLE TUBING ASSEMBLY W3761 W4195 Figure 21 Nozzle Flapper Alignment NOZZLE FLAPPER W3449 1 32 Instruction Manual 4194HS Controllers D200157X012 October 201 1 37 38 39 40 41 42 43 44 45 46 47 48 If the output pressure snaps
2. Note To remove the controller from the case first perform steps 1 through 7 found in the procedures for replacing the differential pressure unit Then perform steps 1 through 3 below 1 Perform the procedures required in the Note above Bleed away any process or supply pressure Disconnect piping Remove the controller and differential pressure unit from the field mounting position Remove the differential pressure unit from the controller Remove the nine screws key 38 from the case key 1 and lift out the controller assembly Install the controller assembly in the replacement case Slide the controller frame down to assure an O ring seal at the pressure connection Hold the frame in place Install and tighten the nine mounting screws Remove the blow out plug key 72 from original case and install in the replacement case ND RW Reinstall the differential pressure unit using the procedures in that portion of this section 24 Instruction Manual 4194HS Controllers D200157X012 October 201 1 8 Mount the controller as described in the Installation section 9 Connect the supply output and process pressure piping to the controller 10 Perform necessary calibration steps Gauges CAUTION Before performing this procedure be sure the replacement gauges are the correct range so the gauges are not damaged by overpressure 1 Unscrew the output gauge key 46 or the supply gauge key 47 from
3. 14 Reverse Acting Controllers 15 Principle of Operation 16 Overall 16 Remote Set Point suffix letter M 17 Auto Manual Station suffix letter E 17 Sg EE 18 Inspection and Maintenance 18 Galles uc ke ES ace SEE 25 Troubleshooting 19 Nc cM 25 Changing Controller Action 20 LiMn ell er T scs beo 25 Replacing the Differential Pressure Unit 21 Link Number2 26 Replacing Controller Parts 22 Link 3 27 Process Pressure Scale 23 Link 4 28 TE 23 Supply Tubing and Positive Feedback Case Cover 24 Tubing Assemblies 28 ae EMERSON www Fisher com Process Management 4194HS Controllers October 2011 Contents continued Proportional Band Knob Nozzle Pivot and Set Point Beam Assembly Flapper Flexure Pivot Assembly Positive Feedback Bellows Calibration After Controller Maintenance Process Zero and Span Adjustment Flapper Alignment Replacing Remote Set Point suffix letter M Parts Pivot Pivot Asse
4. 0 to 62 Inches w c mbar to 50 0 to 124 0 to 75 0 to 186 0 to 100 0 to 248 0 to 20 0 to 50 0 to 25 0 to 62 0to 50 0 to 124 0 to 75 0 to 186 0 to 100 0 to 248 1 Differential pressure ranges are in English units of measurement metric equivalents are shown here for reference only Consult your Emerson Process Management ales office for special differential pressure ranges 2 For other ranges and materials contact your Emerson Process Management sales office 3 The Barton 199 differential pressure unit may be pressured to this value after reaching the travel stop at the upper range limit without permanent zero shift or structural damage to controller components Table 4 Supply Pressure Data Output Signal Range Moti Geet supply Maximum Pressure Limit 2 1 1 If this pressure is exceeded control stability may impaired 2 If this pressure is exceeded damage to the controller may result psig Instruction Manual 4194HS Controllers D200157X012 October 201 1 Do not install operate or maintain a 4194HS differential pressure indicating controller without being fully trained and qualified in valve actuator and accessory installation operation and maintenance To avoid personal injury or property damage it is important to carefully read understand and follow all of the contents of this manual including all safety cautions and warnings If you have any questions about these i
5. 18 8 SST 2 req d 64 Machine screw fill hd 18 8 SST 4 req d 65 Feedback link ass y aluminum brass SST 71 Machine screw fill hd 18 8 SST 4 req d 72 Blowout plug 4194HS Controllers October 2011 Key 46 47 Pressure Gauge Ns GAUGE MATERIAL NEN NENNEN Dual Scale Gauge 2 0 to 2 kg cm2 11B8577X042 11B8583X032 0 to 30 psig 0 to 4kg cm2 0 to 60 psig 11 8577 052 Triple Scale Gauge 0 to 2 bar 0 to 200 11B8577X012 0 to 30 psig 0 to 4 bar 0 to 400 11B8577X022 0 to 60 psig 1 One type of pressure gauge is used for both output pressure and supply pressure indication 11B8583X012 11B8583X022 Key Description 101 Indicator ass y Note The parts listed here for key 101 are for the indicator ass y without a differential pressure unit attached Individual key numbers are listed in the Indicator Assembly subsection of this parts list Key numbers for individual assembly parts also appear in figure 30 Indicator ass y For use w o remote set pt For use w remote set pt 120 Machine screw fill hd 18 8 SST For 4194HSM and HSME only Required to mount remote set pt ass y suffix letter M to indicator ass y 2 req d 131 Machine screw fill 530400 2 req d 135 Frame manifold A03600 aluminum for 4194HS and HSM only Note Key 136 rate reset manifold is used as a positive feedback manifold in this unit 136 positive fdback manifold A03600 alu
6. Before tightening down the drive flexure set the pivot in the middle of the bushing end play Tighten down the drive flexure to hold the pivot in that position Do not kink or twist the flexure when tightening the screws Adjust the length of the pivot arm if necessary until the flexure is straight Decrease the remote set point pressure to 0 psig Connect the end of link A key 116 in figure 30 to the pivot lever arm in the same position noted in step 3 Replace the tie bar key 106 After replacing parts refer to the various maintenance calibration procedures process zero and span adjustment flapper alignment Pivot Assembly B Key 115 Refer to figure 27 for the key numbered assembly 1 2 Decrease the remote set point pressure to 0 psig Note where the links are connected Disconnect the links keys 116 and 126 from the arms of the pivot assembly key 115 Remove the two screws key 102 attaching the pivot assembly to the mounting plate key 111 Remove the pivot assembly Loosen the linearity adjustment screw on the replacement pivot assembly and set it in the same position as the adjustment on the original pivot assembly Tighten the screw Set the replacement pivot assembly on the mounting plate and attach it with two machine screws Attach the links keys 116 and 126 to the arm locations for the new pivot assembly as noted in step 2 After replacing parts refer to the various maintenance calibrati
7. Machine screw fill hd 18 8 SST 16 6380 012 18A2898X012 1P8453X0022 Controller Mounting Parts Note Part numbers are shown for recommended spares only For part numbers not shown contact your Emerson Process Management sales office Note Specify quantity of fittings required Fittings For 1 4 in tubing Connector brass Elbow brass For 3 8 in tubing Connector brass Elbow brass 53 4194HS Controllers Instruction Manual October 2011 D200157X012 Figure 26 Controller Assembly Drawings F 7 0 838 2 47 56 64 52 318 CONTROLLER COMMON PARTS 32 06 EI ie Ge 2 a 10 WT VAL D dag gl D 1 ZS GC SECTION Instruction Manual 4194HS Controllers D200157X012 October 201 1 Figure 26 Controller Assembly Drawings Continued D SKS 3 ar a a EE 2 8 Li ei 5 5 UNS Wd 222 ES X vs A7 22 WK SL 121 L L Dr TERIS LE 9 A E oc _ ON Gil DAT e Les 14 1 11 p 073 PL rT 2 E 11 JAg ll Ss 1 4 0 APPLY LUB SEALANT SECTION B B 49A0770 A NOTES
8. To switch from manual to automatic mode adjust the set point manually or with remote set point pressure to move the ball into the switching zone Turn the switch to AUTOMATIC and adjust the set point manually or with remote set point pressure to control the output When the automatic manual switch is in AUTOMATIC adjusting the loader knob has no effect on the controller output When the automatic manual switch is in MANUAL changing the set point adjustment has no effect on the controller output Prestartup Checks When performing the checks open process loop conditions must exist Refer to figure 5 for location of adjustments Note If the controller has the auto manual option suffix letter E be sure the controller is in the automatic mode before performing prestartup checks 1 Connect supply pressure to the supply pressure regulator and be sure it is delivering the proper supply pressure to the controller Provide a means of measuring the controller output pressure 2 For controllers with remote set point suffix letter M connect regulated pressure of 0 2 to 1 0 bar 3 to 15 psig or 0 4 to 2 1 6 to 30 psig to the remote set point connection at the top of the controller case 3 Loosen two screws key 6 lift off the proportional band indicator cover key 36 and set the proportional band knob between DIRECT and REVERSE 4 The process indicator should indicate the process differential pressure For example with the
9. 1 KEY 4 GASKET IS USED BETWEEN INTERNAL FRAME AND FRAME MANIFOLD 2 KEY 5 GASKET IS USED BETWEEN FRAME MANIFOLD AND POSITIVE FEEDBACK TUBING MANIFOLD 0 a 88 6 EE Bi D Ej Ge L b 2 gt Al CFA S REMOTE SET POINT OPTION VIEW C C 55 4194HS Controllers Instruction Manual October 2011 D200157X012 Figure 27 Remote Set Point Assembly lt 9 69 6 R S Cp 59 po py SHE a E gt _ fe I EON 6 2 4 Te C APPLY LUB SEALANT Instruction Manual 4194HS Controllers D200157X012 October 201 1 Figure 28 Auto Manual Station D d Es See 3 088 VIEW 311 m S ALOITTI SECTION 275 12227 293 310 ROSE 07 277 SRLS 294 292 SSN 1L Pro aba VI 38 LA O eem X 55 i 2 GA gt C T SECTION B B A 0200157 012 Instruction Manual Figure 28 Auto Manual Station Continued 4194HS Controllers October 2011 e 6 mo de 58 e Y Lager Lx TTC Sg ke Look muli MANUAL SWITCH LOADER KNOB AUTOMATIC 8 PLASTIC TUBE V 28 G E METAL BAL
10. CAUTION In the next step when the groove pin key 303 is removed the lever spring could eject the switch lever key 304 The lever spring switch lever and lever spring seat key 301 could be lost or damaged 46 Instruction Manual 4194HS Controllers D200157X012 October 201 1 When removing the groove pin hold onto the switch lever and slowly pull the switch lever from the lever assembly shaft key 297 Then remove the lever spring and lever spring seat 3 Using a 1 5 mm 1 16 inch punch push the groove pin key 303 out of the lever assembly shaft 4 Remove the switch lever key 304 lever spring key 302 and lever spring seat key 301 5 Remove the tubing assembly key 309 CAUTION In the next step when the switch body screws key 290 are removed and the assemblies are separated the switch body springs key 295 could eject themselves or cause other parts to be lost or damaged When removing the switch body screws use caution to prevent loss of or damage to the springs or other parts 6 Loosen the two screws key 290 and separate the switch body assembly key 291 from the loader assembly key 282 7 Remove the O rings keys 292 293 and 294 switch body springs key 295 and balls key 296 8 Loosen two screws key 308 Remove the closing plate key 307 and the closing plate gasket key 306 9 Pull the clip key 300 from its engagement with the shaft of the lever assembly key 297 10 Pull the leve
11. Install the replacement flexure pivot assembly with the four screws key 10 Do not tighten the screws 16 Move the flexure pivot assembly towards the relay as far as possible and tighten the four screws key 10 17 Place the input feedback beam assembly key 11 onto the flexure pivot assembly key 9 with link 4 through the square hole in the frame 18 Install the screw key 12 with the washer key 13 through the input feedback beam assembly key 11 into the pivot assembly key 9 Do not tighten the screw 19 Align flapper leveling screw number 2 with the centerline of the oblong hole in the frame as shown in figure 22 Tighten the screw key 12 Make sure link 4 does not touch the frame 20 Disconnect link number 1 from the pivot assembly and manually position the process pointer to 100 percent of the scale Refer to figure 14 for location of link 21 Adjustthe length of link number 2 by turning the adjustment screw clockwise to increase the length or counterclockwise to decrease the length so the pin on the end of the link is approximately one half of its diameter short of aligning with the hole in the input feedback beam assembly as shown figure 16 22 Connect link number 2 to the input feedback beam assembly 23 Connect link number 1 to the drive arm 34 Instruction Manual 4194HS Controllers D200157X012 October 2011 24 Adjust the proportional band between DIRECT and REVERSE Do this by aligning the ta
12. W3688 1 Figure 6 Parts and Adjustments Remote Set Point Option F 1 GUIDE MOUNTING FLEXURE 7 SCREW ADIUSTMENT SCREW PIVOT ASSEMBLY A LINKB J LINEARITY N ADJUSTMENT o C Ye 72 PIVOT ASSEMBLY B MOUNTING SCREW TIE BAR REMOTE SET POINT ZERO ADJUSTMENT SCREW ZERO ADJUSTMENT LOCKING SCREW 36A9751 C B1668 4 FRONT VIEW 10 SIDE VIEW OF SET POINT PROCESS INDICATOR ASSEMBLY DRIVE FLEXURE LOWER TRAVEL CAPSULES SIDE VIEW Instruction Manual 4194HS Controllers D200157X012 October 201 1 Adjustments Remote Set Point suffix letter M CAUTION Do not move the set point adjustment manually on controllers with remote set point Moving the set point adjustment could damage the controller If the controller is equipped with the remote set point option vary the remote set point pressure to change the set point Increase the pressure to increase the set point and decrease the pressure to decrease the set point Manual Set Point The set point adjustment changes the upper or lower switching point depending on controller action To adjust the set point open the controller cover and move the set point adjustment indicator until the desired value on the process pressure scale is below the line on the set point indicator Move the adjustment to the right to increase the set point and to the left to decrease it Changing the set point adjustment does not affect the different
13. faulty adjustment of the process indicator perform the calibration procedures These instructions are valid for either shop or field calibration if open loop conditions exist Note If the controller has the auto manual station option be sure the controller is in the automatic mode before performing calibration Note Any adjustment of the pointer span adjustment screw will require readjustment of the pointer zero adjustment screw Refer to figure 5 for location of adjustments Remove two screws key 6 and lift off the proportional band indicator cover key 36 Set the proportional band between DIRECT and REVERSE Adjust the process differential pressure to the low limit of the input range Loosen the locking screw key 331 figure 29 on the pivot assembly 1 2 3 4 Align the process pointer with the support as shown figure 15 5 6 Apply 50 percent differential pressure to the differential pressure unit 7 Adjust the process pointer by manually moving the pointer to the 50 percent mark on process scale within 2 percent and tighten the locking screw key 331 CO Adjust the process differential pressure to the low limit of the input range 9 Adjust the process pointer to the lowest limit of the input scale by loosening the zero adjustment locking screw turning the zero adjustment screw 10 Adjust the process differential pressure to the upper limit of the input span Note whether the
14. key 6 and lift off the proportional band indicator cover key 36 3 Adjust the proportional band adjustment to 5 percent direct acting WARNING In step 4 do not exceed the operating limits for the controller refer to table 3 Personal injury or equipment damage could result from overpressure 6 Repeat steps 4 and 5 until the output pressure snaps within 2 percent of set point 7 Adjust the proportional band adjustment between DIRECT and REVERSE Slowly increase the process differential pressure from zero until the output pressure snaps to supply pressure The output pressure should snap to supply pressure within 2 percent of set point Ifthe output snaps to supply pressure below 2 percent of set point adjust flapper leveling screw number 3 clockwise If the output snaps above 2 percent of set point adjust flapper leveling screw number 3 counterclockwise 8 If the output pressure snaps to supply pressure depress the flapper with a screwdriver so the output pressure snaps to zero pressure Slowly release the flapper If the output snaps to supply pressure adjust flapper leveling screw number 2 clockwise until the output does not snap to supply pressure Then adjust screw number 2 counterclockwise 1 8 of a turn at a time until the output snaps to supply pressure Repeat step 8 to recheck the adjustment of flapper leveling screw number 2 Adjust the proportional band adjustment to 5 percent reverse acting 39 41
15. locking screw Then adjust the fine zero adjustment to align the pointer and pointer assembly 6 With a regulated air supply adjust process differential pressure to 50 percent of process scale range The process pointer should be at the 50 1 0 percent position on the scale If not refer to the zero and span adjustment procedures in the Calibration section 7 Refer to the maintenance calibration and flapper alignment procedures 25 4194HS Controllers Instruction Manual October 2011 D200157X012 Figure 14 Link Locations LINK 4 ADJUSTMENT LINK 4 20 2 LINK 3 ADJUSTMENT LINK W3442 1 LINK 2 ADJUSTMENT 3 Link Number 2 Remove two screws key 6 and lift off the proportional band indicator cover key 36 Note where the link is connected Disconnect the link from process pointer assembly and from the input feedback beam assembly key 11 Remove the link Install the replacement link with the screw head nearest the process pointer as shown in figure 14 Connect the link to the process pointer assembly only and in the position noted in step 2 Adjust the set point adjustment manually or with the remote set point pressure to 100 percent of scale range Set the proportional band between DIRECT and REVERSE Disconnect link number 1 from the pivot arm and manually position the process pointer to 100 percent of the scale Adjust the length of link number 2 by turning the adjusting screw clockwis
16. may bear the CE marking to 3 ofthe Pressure Equipment Directive PED 97 23 indicate compliance with other applicable European EC It was designed and manufactured in accordance Community Directives NOTE Specialized instrument terms are defined in ANSI ISA Standard 51 1 Process Instrument Terminology 1 Consult your Emerson Process Management sales office for additional information 2 The pressure temperature limits in this document and any applicable standard or code limitation should not be exceeded 3 With Barton 199 differential pressure unit 4 Normal m hr normal cubic meters per hour m3 hr 0 C and 1 01 325 bar Scfh standard cubic feet per hour ft3 hr 60 F and 14 7 psia 5 Also for transportation and storage limits Table 3 Process Sensor Barton 199 Differential Pressure Unit Range and Pressure Ratings SAFE WORKING PRESSURE 3 DIFFERENTIAL PRESSURE 1 2 ENSE TEN HOUSING MATERIAL 2 Oto 15 0101 0 to 30 0 to gt 0 to 40 0 to 2 8 50 0 to 3 4 Stainless steel 0 to 60 0 to 4 0 to 75 0 to 5 15 Oto 1 0 to 30 0 to 2 0 to 40 0 to 2 8 Psig bar 0 to 50 0 to 3 4 0 to 60 0 to 4 0 to 75 0 to 5 15 0101 0 to 30 0 to 2 0 to 40 0 to 2 8 0 to 50 0to 3 4 0 to 60 0 to 4 0 to 75 0 to 5 0 to 20 0 to 50 0 to 25 0 to 62 0 to 50 0 to 124 Stainless steel 75 0 to 186 0 to 100 0 to 248 0 to 20 0 to 50 to 25
17. of either bearing 43 4194 Controllers Instruction Manual October 2011 D200157X012 d Set pivot A in the middle of the bushing end play e Tighten the screws that hold the drive flexure in place 5 The guide flexure should also be straight If not loosen the screw key 122 on the end of the flexure that is attached to the top of pivot A key 114 and allow the flexure to straighten itself Tighten the screw on the flexure Setting Remote Set Point Travel Stops 1 Loosen the set screw in the travel stop nut key 86 CAUTION Make sure the loose travel stop nut does not bind up on the diaphragm capsule extension when pressurizing the capsules Damage to the capsules could result 2 Full span stop Adjust remote set point pressure input to 5 percent greater than full span pressure Loosen the screws mounting the travel stop key 83 to the mounting plate Slide the travel stop until it is just touching the end of the capsule stack Tighten the travel stop mounting screws to lock it into that position 3 Zero stop Adjust set point differential pressure input to 0 percent of full span Slide the travel stop nut key 86 along the diaphragm capsule extension key 82 until it is approximately 0 4 mm 1 64 inch away from the travel stop Tighten the set screw to lock the travel stop nut in that position Aligning Remote Set Point Linkage 1 Adjust the remote set point pressure to the capsules to 50 percent of full sp
18. on the process scale range Then go to step 53 For reverse acting controllers adjust the proportional band knob to 5 percent reverse acting Adjust the set point manually or with remote set point pressure to 5 percent of the process scale range Carefully adjust the process differential pressure to 100 percent of the process scale range Then slowly decrease the process differential pressure until the output pressure snaps to supply pressure The output should snap to supply pressure with 2 percent of set point If the output pressure snaps to supply pressure below 2 percent of set point adjust flapper leveling screw number 1 counterclockwise see fiqure 5 for location of screw If the output pressure snaps to supply pressure above 2 percent of set point adjust flapper leveling screw number 1 clockwise Repeat steps 44 through 46 until the output pressure snaps to supply pressure within 2 percent of set point If the tolerance cannot be obtained with the flapper leveling screw go to step 51 Adjust the set point manually or with remote set point pressure to 95 percent of the process scale range WARNING In step 49 do not exceed the operating limits of the controller refer to table 3 Personal injury or equipment damage could result from overpressure 49 50 51 52 53 Increase the process differential pressure until the output pressure snaps to zero Then slowly decrease the process differential pressure u
19. pointer indication is above or below the upper limit of the process scale 11 Adjust the span screw as follows Clockwise to increase span for a low indication counterclockwise to decrease span for a high indication Adjust the span screw to connect one half the error 12 Repeat steps 7 through 11 until the error is eliminated 13 Refer to the flapper alignment procedure Flapper Alignment Leveling screw numbers and adjustments are shown in figure 25 Provide a means of applying process differential pressure and supply pressure to the controller and a means of measuring output pressure After flapper alignment go to the appropriate prestartup procedures 38 Instruction Manual D200157X012 Figure 25 Leveling Screws di Keen Ae 1 2024 RIF LIF 2 2 CEZ a ui ae a d 1 LA 2 1 ZA i LJ 19 id 7 2 2 4 T 4 4 ii j ei LL LOL C Ee 2 5 1 5 2 5 3 SIDE VIEW OF CONTROLLER SHOWING FLAPPER LEVELING SCREWS 4194HS Controllers October 2011 1 For controllers with manual set point move the set point adjustment to 50 percent of the scale range For controllers with remote set point suffix letter M adjust the remote set point pressure until the set point indicator is at 50 percent of the scale range 2 Remove the two screws
20. process differential pressure at 50 percent of the input span the process pointer should be at 50 1 0 percent of its span Slight adjustment of the indicator zero screw might be necessary See figure 5 for zero adjustment and locking screw location 5 If desired the accuracy can be verified at other points on the scale If the indicator is out of calibration refer to the process zero and span adjustment portion of the calibration procedure 6 Install the proportional band indicator cover key 36 and tighten two screws key 6 Startup Set the controller switching point as described in the calibration procedures If manual control valves are being used to bypass the control valve package valve actuator positioner controller slowly open the upstream and downstream manual control valves in the pipeline and close the manual bypass valve Calibration Note Some of the following procedures require that the proportional band knob be adjusted to between DIRECT and REVERSE If this is done it will be necessary to set the proportional band knob to 400 direct or reverse action before replacing the proportional band indicator cover Instruction Manual 4194HS Controllers D200157X012 October 201 1 Note If the controller has the auto manual option be sure the controller is in the automatic mode before performing calibration procedures If the prestartup checks revealed faulty adjustment of the process indicator perform the cali
21. r P d m MANUAL LOADER KNOB Em Pia iaar LGE Teac Sette tee ine OUTPUTPRESSURE gt Ce Hie TO FINAL CONTROL ELEMENT ge MANUAL POSITION RELAY B AUTO MANUAL SWITCH SUPPLY PRESSURE OUTPUT PRESSURE TO FINAL CONTROL RELAY OUTPUT PRESSURE Aker S SUPPLY PRESSURE 48A5230 A A2999 1 1 MANUAL LOADER OUTPUT PRESSURE When the auto manual switch is in the MANUAL position the output of the manual loader is channeled through the auto manual switch and becomes the output of the controller When the auto manual switch is in the AUTO position the output of the relay is channeled through the switch to become the output of the controller 4194HS Controllers Instruction Manual October 2011 D200157X012 Before the auto manual switch is operated the output of the relay must equal the output of the manual loader to avoid bumping the process Adjusting the set point varies the pressure on the left hand side of the plastic tube Adjusting the manual loader knob varies the pressure on the right hand side When the pressures are equal the metal ball is centered in the tube Pressure imbalance forces the ball to one end of the tube where it forms a seal blocking air flow through the tube Maintenance Inspection and Maintenance WARNING The following maintenance procedures require taking the controller out
22. screw fill hd 18 8 SST Plain washer 18 8 SST 2 req d Set screw hex socket 18 8 SST 2 req d Cap screw hex hd 18 8 SST 4 req d Cap screw hex hd SST 3 req d Cap screw hex hd 18 8 SST 4 req d Remote Set Point Assembly key 62 figure 27 12 13 79 52 screw hex socket 18 8 SST 2 req d Plain washer 18 8 SST 3 req d Drive flexure 530200 Instruction Manual D200157X012 Key Description 80 Diaphragm capsule 55 for remote set pt ass y 1 bar 15 psig span 09902 alloy SST 1 6 bar 24 psig 09902 alloy SST 83 Travel stop CF8 SST casting 86 Travel stop nut 530300 87 Set screw hex socket 18 8 SST 93 Union 31600 99 Plain washer 18 8 SST 102 Machine screw fill hd 18 8 SST 4 req d 103 Machine screw pan hd 18 8 SST 2 req d 104 Remote set pt tubing ass y 530400 105 Pedestal ass y SST 106 bar G10100 pl steel 107 Spring pl steel 108 Zero adj screw 530300 109 Pivot screw 530300 110 A Zero adj bracket 530400 111 Mounting plate G10100 pl steel 112 Spring washer pl steel 114 Pivot clevis ass y A plastic SST 115 Pivot clevis ass y B plastic SST 116 Connecting link ass y aluminum bronze brass 118 screw hex socket 18 8 SST 119 Guide flexure 530200 121 Drive bracket 530400 122 Machine screw fill hd SST 2 req d 123 Plain washer 18 8 SST 124 Nut Hex 18 8 SST 125 Spacer A92011 aluminum 126 Connecting link ass y aluminum bronze bras
23. the set point beam shoe key 29 did not change during this procedure relative to the set point beam assembly key 23 perform the following step step 40 replacing proportional band knob procedure 41 If the output pressure is not 0 psig decrease the process differential pressure until the output pressure snaps to zero Then slowly increase the process differential pressure until the output snaps to supply pressure The output should snap to supply pressure within 2 percent of set point 42 Install the controller assembly in the case Slide the controller frame down to assure an O ring seal at the pressure connections Hold the frame in place 43 Install and tighten the nine screws that hold the controller assembly in the case 44 Referto the flapper alignment procedure 45 Replace the proportional band cover key 36 and tighten the two screws key 6 Positive Feedback Bellows Note The following procedure requires that the controller be removed from the case Perform steps 1 through 7 in the replacing the differential pressure unit procedure Then perform steps 1 through 3 in the replacing the case and cover procedure 1 Remove the two screws key 6 and lift off the proportional band indicator cover key 36 2 Disconnect link 4 key 65 from the bellows bracket key 31 3 Remove the screw key 34 spring key 33 and bellows adjustment bracket key 32 from the bellows bracket key 31 4 Referto figure 24 for l
24. to supply pressure below 2 percent of set point adjust flapper leveling screw number 3 clockwise see figure 5 for location of screw If the output pressure snaps to supply pressure above 2 percent of set point adjust flapper leveling screw number 3 counterclockwise Repeat steps 36 and 37 until the output pressure snaps within 2 percent If the tolerance cannot be obtained with the flapper leveling screw go to step 42 Adjust the set point manually or with remote set point pressure to 95 percent of the process scale range If the output pressure is not 0 psig decrease the process differential pressure until the output pressure snaps to zero Then slowly increase the process differential pressure until the output snaps to supply pressure The output should snap to supply pressure within 2 percent of set point If the output pressure snaps to supply pressure within 2 percent of set point go to step 53 If the output pressure does not snap to supply pressure within 2 percent of set point go to step 42 If the output pressure snaps to supply pressure below 2 percent of set point adjust the set point beam shoe key 29 slightly toward the center of the nozzle pivot If the output snaps to supply pressure above 2 percent of set point adjust the set point beam shoe slightly away from the center of the pivot Repeat steps 35 through 42 until the output pressure snaps to supply pressure within 2 percent of set point at 5 and 95 percent
25. 12 Changing the Scale V W3492 DEFLECT LOWER PORTION OF THE SLOT AND LIFT THE SCALE UP AND OFF 4 To install the replacement scale bend the lower part of the slot slightly so the scale slides downward over the set point adjustment and under the process indicator 5 Install and tighten the four screws on the scale 6 Aslight zero adjustment figure 5 might be necessary so the process indicator aligns with the 0 mark on the scale This procedure is described in the zero and span adjustment portion in the calibration procedure Relay 1 Loosen the two captive screws that hold the relay key 50 in place 2 Tip the relay slightly toward the case to clear output pressure gauge and lift out the relay 3 Make sure the replacement relay has three O ring assemblies as shown in figure 13 The fourth port is for exhaust and does not require an O ring 23 4194HS Controllers Instruction Manual October 2011 D200157X012 4 Install the replacement relay making sure the tabs on the relay line up with the tab on the frame figure 13 Figure 13 Relay Features CLEAN OUT WIRE EXHAUST PORT NO O RING gt USED O RINGS RELAY RELAY gt MOUNTING TAB SCREWS W5744 5 Install and tighten the two screws that hold the relay in place Case and Cover CAUTION The case and cover are an integral unit trying to separate them will damage the hinge If the cover needs to be replaced replace the case also
26. 4194HS Controllers October 2011 Controller Parts fiqure 26 Note Part numbers are shown for recommended spares only For part numbers not shown contact your Emerson Process Management sales office Instruction Manual D200157X012 Key Description Part Number 1 Case and cover ass y 2 Nameplate A91100 aluminum 3 Frame A03600 aluminum 4 Gasket chloroprene for use between internal frame and frame manifold key 135 18 0749 012 57 Gasket chloroprene for use between frame manifold key 135 and positive feedback tubing manifold key 136 18 0742 012 6 Machine screw fill hd 18 8 SST 6 req d 7 O ring nitrile 2 req d 1 376206992 8 O ring nitrile 3 req d 16 6903 012 9 Flexure pivot ass y sapphire SST 10 Machine screw fill hd 18 8 SST 4 req d 11 Happerass y 29A9518X012 12 Cap screw hex socket 18 8 SST For flapper ass y key 11 2 req d 17 Adjustable set pt pivot ass y SST 18 Relay nozzle tubing ass y SST 19 Machine screw fill hd 18 8 SST 3 req d 20 Plain washer 18 8 SST 2 req d 21 Nozzle ass y SST 22 Washer plastic 23 Set pt beam ass y aluminum SST 24 O ring nitrile 2 req d 1E222606992 25 Proportional band knob polycarbonate 26 Retaining clip 530200 302 SST 2 E ring SST 28 Set pt beam bias spring pl steel 29 Set pt beam shoe G10100 pl steel 30 Cap screw hex socket 18 8 SST 2 req d 31 Bellows bracket A95052 aluminum 32 Bellows adj bracket G10100 pl steel 33 Be
27. 94HS Controllers Instruction Manual October 2011 D200157X012 11 Carefully adjust the process differential pressure to 100 percent of the process scale range Then slowly decrease the process differential pressure until the output pressure snaps to supply pressure The output pressure should snap to supply pressure within 2 percent of set point 12 If the output pressure snaps to supply pressure below 2 percent of set point adjust flapper leveling screw number 1 counterclockwise If the output snaps to supply pressure above 2 percent of set point adjust flapper leveling screw number 1 clockwise 13 Repeat steps 11 and 12 until the output pressure snaps within 2 percent of set point 14 Repeat steps 3 through 13 to recheck adjustments Continue to adjust flapper leveling screws 1 2 and 3 as necessary until no flapper adjustments are required 15 Setthe proportional band adjustment to 400 percent in the desired controller action Replace the proportional band indicator cover key 36 and tighten the two screws key 6 Replacing Remote Set Point suffix letter M Parts Note After replacing parts perform the various maintenance calibration procedures process zero and span adjustment flapper alignment Figure 6 shows the location of the parts Key numbers refer to figure 27 Pivot Assembly A Key 114 CAUTION Avoid bending or kinking the drive flexure during this procedure Bending or kinking the drive flexure can res
28. Instruction Manual 4194HS Controllers D200157X012 October 201 1 Fisher 4194HS Differential Pressure Indicating Controllers Contents Figure 1 Fisher 4194HS Differential Pressure EEN 2 Controller Scope 2 DESCHDUON use dde oed P E Ea 2 Specifications PIU PEE 5 Educational Services 5 Installation Mounting and Connections 5 Pipestand Mounting 6 Pressure CONNECTIONS 6 Process Pressure Connections 7 Vent REG 8 Supply Pressure 9 Remote Set Point suffix letter M Connection 9 Controller Operation 9 el En EE 11 Remote Set Point suffix letter M 11 Manual Set Point 11 Proportional Band Differential 11 Changing Controller Action 11 Switching The Auto Manual Station suffix letter E 11 Prestartup Checks 12 SET GE eS 12 ECH e e ES NERO 12 Process Indicator Zero and Span 13 Remote Set Point Zero and Span Adjustment suffix letter M 13 Setting Switching Points 14 Direct Acting Controllers
29. L e BACK VIEW COVER REMOVED SIDE VIEW COVER REMOVED Instruction Manual 4194HS Controllers October 201 1 D200157X012 Figure 29 Process and Set Point Indicator Assembly with Differential Pressure Unit We Vi af i NES ONE ON UM TTL Lue DE 7 7 eee er re e a Jnd Dal 4194HS Controllers Instruction Manual October 2011 D200157X012 Figure 30 Process and Set Point Indicator Assembly Manual Set Point ABI NIA IU P 117 oo 1 4 39 1126 Neither Emerson Emerson Process Management nor any of their affiliated entities assumes responsibility for the selection use maintenance of any product Responsibility for proper selection use and maintenance of any product remains solely with the purchaser and end user Fisher is a mark owned by one of the companies in the Emerson Process Management business division of Emerson Electric Co Emerson Process Management Emerson and the Emerson logo are trademarks and service marks of Emerson Electric Co All other marks are the property of their respective owners The contents of this publication are presented for informational purposes only and while every effort has been made to ensure their accuracy they are not to be construed as warranties or guarantees express or implied regarding the products or services described he
30. ST Tube plastic Ball SST Ball seat nitrile 2 req d Diaphragm ass y nitrile aluminum Loader ass y aluminum plastic Range spring SST Range spring cup pl steel Spring adj screw pl steel Retaining ring pl steel Loader knob plastic Machine screw rd hd 18 8 SST 2 req d Machine screw fill hd 18 8 SST 4 req d Machine screw fill hd 530200 2 req d Switch body 55 aluminum nitrile O ring nitrile O ring nitrile O ring nitrile Switch body spring A228 music wire alt desgntn 08500 pl steel 2 req d Ball SST 2 req d Lever 55 SST O ring nitrile Rocker arm A96061 aluminum 18A2878X012 18A2903X012 10853806992 11A8741X052 13A1584X012 1E2226X0032 Recommended spare parts Key 300 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 4194HS Controllers October 2011 Description Part Number Clip SST Lever spring seat SST Lever spring A228 music wire alt desgntn 08500 pl steel Groove pin SST Switch lever plastic SST Switch lever cover plate aluminum chromate Closing plate gasket chloroprene Closing plate SST Machine screw pan hd 18 8 SST 2 req d Continuous output tubing ass y SST Lithium Grease not furnished with controller Anti Seize Sealant not furnished with controller O ring nitrile 3 req d Auto Manual scale plastic Machine screw fill hd S30400 304 SST Machine screw fill hd 18 8 SST
31. al Station suffix letter E Note Fach of the following procedures requires that the controller be removed from the case Refer to steps 1 through 7 found in the procedures for replacing the differential pressure unit Then perform steps 1 through 4 of the procedure for replacing the controller case and cover Replacing the Auto Manual Station Note This procedure also permits replacement of the switch manifold O rings key 312 the auto manual tubing assembly key 138 and the frame gaskets keys 4 and 5 45 4194 Controllers Instruction Manual October 2011 D200157X012 Disassembly Refer to figures 29 and 30 for key number location 1 Loosen the screw key 316 that holds the auto manual station key 273 to the controller frame 2 Loosen the two screws keys 314 and 315 that hold the auto manual station to the auto manual tubing assembly key 138 3 Remove the auto manual station from the controller frame 4 Remove the switch manifold O rings key 312 5 Carefully loosen the nut on the relay nozzle tubing assembly key 18 figure 26 where it connects to the auto manual tubing assembly key 138 Loosen three screws keys 34 and 131 and remove the tubing assembly and body gaskets keys 4 and 5 6 Inspect the gaskets keys 4 and 5 and O rings key 312 for wear Replace if necessary Assembly 1 Install the gaskets and the tubing assembly to the frame Start but do not tighten the three screws keys 34 a
32. an 2 Set the linearity adjustment screw in the center of the slot on the lever arm of pivot clevis assembly B key 115 3 Set the length of link B key 126 in the middle of its adjustment 4 Set the length of link A key 116 so the lever arms of pivots A and B are parallel and that link A is perpendicular to them 5 To complete maintenance calibration the zero and span adjustments must be set Refer to the zero and span adjustment procedures If linearity adjustments must also be made refer to the linearity adjustment procedure 6 Replace the tie bar key 106 7 Refer to the flapper alignment procedure Remote Set Point Zero and Span Adjustment 1 Decrease the remote set point pressure to 0 psig 2 Loosen the screw on link A key 116 and adjust the length so the set point pointer points to scale zero Tighten the screw 3 Make fine zero adjustments by loosening the zero adjustment locking screw key 102 and turning the zero adjustment screw key 108 Tighten the locking screw Refer to figure 6 for location of screws 4 Apply 100 percent of the remote set point pressure input span 5 To increase the span proceed as follows a Turn the span adjustment screw clockwise Adjust span to correct one half the error 44 Instruction Manual 4194HS Controllers D200157X012 October 201 1 b To increase the span further than the adjustment will allow move both ends of link A to the right Refer to figure 6 for link l
33. and clean it if necessary 15 Lubricate key 318 and install the proportional band knob key 25 on the set point beam assembly key 23 16 Install the retaining clip key 26 on the three posts on the proportional band knob 17 Install the nozzle tubing assembly key 21 through the set point beam assembly key 23 the proportional band knob key 25 and the retaining clip key 26 into the cap aligning the nozzle with the tab on the proportional band knob shown in figure 18 18 While holding the nozzle tubing key 21 against the set point beam assembly key 23 depress the retaining clip key 26 and install the E ring key 27 into the E ring groove on the nozzle tubing assembly key 18 29 4194HS Controllers Instruction Manual October 2011 D200157X012 19 20 21 22 29 24 25 26 27 28 29 30 31 32 33 34 Inspect the O ring on the relay nozzle tubing assembly key 18 and replace it if necessary Apply a suitable lubricant key 318 to the O ring Install the relay nozzle tubing assembly key 18 into the set point beam assembly Adjust the proportional band between DIRECT and REVERSE Do this by aligning the tab on the proportional band knob with the hole in the set point beam assembly as shown in figure 20 Position the proportional band knob nozzle pivot and the set point beam assembly on frame Install the relay nozzle tubing nut loosely into frame manifold while positioning
34. and the lever assembly key 297 to preload the spring Make sure the notch of the switch lever engages the pin of the lever assembly 9 Drive in the groove pin key 303 to hold the switch lever 10 Replace the lever cover plate key 305 and attach with two screws key 288 11 Perform the assembly portion of the replacing the auto manual station procedure Replacing Auto Manual Station Loader Range Spring Diaphragm Assembly Ball Seat Tubing and Ball Disassembly Refer to figure 28 for key number location 1 Remove the auto manual station from the controller frame as described in steps 1 through 4 of the procedure for replacing the auto manual station 2 Remove tubing assembly key 309 WARNING To avoid personal injury caused by preload from the range spring key 282 turn the loader knob key 287 counterclockwise opposite to the arrow to relieve pressure on the spring 3 Loosen the four screws key 289 and separate the loader assembly key 282 and the lower loader assembly key 274 4 Remove the loader range spring key 283 range spring cup key 284 and diaphragm assembly key 281 5 Remove the tube key 278 ball seats key 280 and ball key 279 Assembly 1 Turn the loader knob key 287 counterclockwise to back the spring adjusting screw key 285 all the way out to eliminate loading the range spring 2 Position the range spring cup key 284 the range spring key 283 and the diaphragm a
35. atch the link being replaced Tighten the screw Refer to figure 27 for correct orientation of the link 3 Attach the replacement link to the two lever arms in the same position as noted in step 1 4 After replacing parts refer to the various maintenance calibration procedures process zero and span adjustment flapper alignment Link B 1 Note where link B key 126 is connected figure 27 Disconnect both ends of the link from the pivot arm and from the set point indicator assembly 42 Instruction Manual 4194HS Controllers D200157X012 October 201 1 2 Loosen the screw in the replacement link and adjust the length to match the link being replaced Tighten the screw 3 Attach both ends of the replacement link Refer to figure 28 for correct orientation of the link and position the link as noted in step 1 4 After replacing parts refer to the various maintenance calibration procedures process zero and span adjustment flapper alignment Pressure Control Block for Remote Set Point 1 Remove remote set point pressure 2 Loosen the nut on that portion of the tubing that connects the capsular element to the pressure control block key 57 3 Remove the two cap screws key 58 that hold the pressure control block to the frame key 3 and lift out the pressure control block Install the O ring key 7 on the replacement pressure control block Install the replacement pressure control block to the frame with two screws k
36. b on the proportional band knob with the hole in the set point beam assembly as shown in figure 20 Figure 22 Flapper Assembly and Leveling Screws Figure 23 Exploded View Flexure Pivot Assembly FLAPPER LEVELING FLAPPER FLEXURE PIVOT SCREW NUMBER 2 ASSEMBLY ASSEMBLY KEY 10 25 26 27 28 29 30 32 33 34 35 36 37 38 39 W4770 INPUT 1f FEEDBACK BEAM ASSEMBLY WITH LINK 4 ATTACHED OBLONG HOLE IN FRAME FLEXURE PIVOT ASSEMBLY SCREWS KEY 12 Position the proportional band knob nozzle pivot and set point beam assembly on frame Install the relay nozzle tubing nut loosely into frame manifold while positioning the nozzle in the center of the flapper as shown in figure 21 Install the washer key 20 on the screw key 19 Install the screw key 19 through the frame key 3 and into the relay nozzle tubing assembly key 18 Tighten the screw Be sure the nozzle remains centered on the flapper with the set point beam assembly slid snugly towards the relay nozzle tubing assembly Install the pivot of the set point pivot assembly key 17 in the hole in the set point beam Install washer key 20 on screw key 19 Install the screw key 19 through the frame key 3 into the set point pivot assembly key 23 Do not tighten Slide the set point pivot assembly key 17 toward the set point beam until the cone lightly contacts the set point beam and tighten the scre
37. bration procedures These procedures are valid for either shop or field calibration if open process loop conditions exist Process Indicator Zero and Span Adjustment Note Any change in process pointer span will require readjustment of the process pointer zero adjustment screw Refer to figure 5 for location of adjustments 1 Loosen two screws key 6 and lift off the proportional band indicator cover key 36 2 Set the proportional band between DIRECT and REVERSE 3 Adjust the process differential pressure to the low limit of the input range 4 Adjust the process indicator to the lowest limit of the input scale by loosening the zero adjustment locking screw and turning the zero adjustment screw 5 Adjust the process differential pressure to the upper limit of the input span Note whether the pointer indication is above or below the upper limit of the process scale 6 Adjust the span screw as follows Clockwise to increase span for a low indication counterclockwise to decrease span for a high indication Adjust the span screw to correct one half the error 7 Repeat steps 3 through 6 until the error is eliminated 8 Install the proportional band indicator cover key 36 and tighten two screws key 6 Remote Set Point Zero and Span Adjustment suffix letter M Note Any adjustment of the pointer span adjustment screw will require readjustment of the pointer zero adjustment screw Refer to figures 5 and 6 for location of a
38. cess scale range Set Point Continuously adjustable from 0 to 10025 of the scale range Steady State Air Consumption 0 to 1 4 Bar 0 to 20 Psig Output 0 1 normal m h 3 5 scfh 0 to 2 4 Bar 0 to 35 Psig Output 0 14 normal m h 5 0 scfh Delivery Capacity 4 0 to 1 4 Bar 0 to 20 Psig Output 5 6 normal m h 210 scfh 0 to 2 4 Bar 0 to 35 Psig Output 9 9 normal m h 370 scfh Exhaust Capacity 4 0 to 1 4 Bar 0 to 20 Psig Output 4 6 normal m h 170 scfh 2 4 Bar 0 to 35 Psig Output 7 0 normal m h 260 scfh Operative Ambient Temperature 150259 40 to 70 C 40 to 160 F Housing Designed to NEMA 3 weatherproof and IEC 529 IP54 specifications Hazardous Area Classification Complies with the requirements of ATEX Group Category 2 Gas and Dust Mounting Controller is mounted on a pipestand See figure 2 Approximate Weight Controller 4 5 kg 10 without the differential pressure unit Differential Pressure Unit 21 5 kg 47 Ib Total Weight 26 kg 57 Ib controller with a Barton 199 differential pressure unit 4194HS Controllers Instruction Manual October 2011 D200157X012 Table 2 Specifications continued Declaration of SEP with Sound Engineering Practice SEP and cannot Fisher Controls International LLC declares this bear the CE marking related to PED compliance product to be in compliance with Article 3 paragraph However the product
39. djustment will widen or narrow the differential gap between the two switching points by moving the position of the upper switching point Figure 7 shows the relationship between the percent of sensor range between switching points and the proportional band setting on the controller The following example illustrates how to use figure 7 Example The sensing element has a range of 30 psi The lower switching point is to be set at 10 psi and the upper switching point is to be set at 25 psi Proceed as follows e Divide the differential gap the difference between the upper and lower switching points by the sensing element range Multiply the result by 100 as shown in the following equation Differential Gap T _ l5psi Sensing Element Range 30 psi e Locate the 50 percent line on figure 7 Move along this line you intersect the curve Read the proportional band setting on the left hand axis For this example the setting is approximately 35 percent 1 Using the curve in figure 7 determine the correct proportional band setting for the desired gap expressed as a percent of the maximum input element span between the switching points 2 Set the proportional band knob to the desired setting determined in step 1 3 Adjust the set point to the lower desired switching point 4 Decrease the process differential pressure until the controller output signal switches from zero pressure to full supply pressure 4194HS Controllers Instr
40. djustments 1 Loosen two screws key 6 and lift off the proportional band indicator cover key 36 2 Setthe proportional band between DIRECT and REVERSE 3 Adjust the set point pressure to the low limit of the input range 4 Adjust the set point indicator to the lowest limit of the input scale by loosening the zero adjustment locking screw and turning the zero adjustment screw 4194HS Controllers Instruction Manual October 2011 D200157X012 5 Adjust the set point pressure to the upper limit of the input span Note whether the pointer indication is above or below the upper limit of the process scale 6 Adjust the span screw as follows Clockwise to increase span for a low indication counterclockwise to decrease span for a high indication Adjust the span screw to correct one half the error 7 Repeat steps 3 through 6 until the error is eliminated 8 Install the proportional band indicator cover key 36 and tighten two screws key 36 Setting Switching Points Direct Acting Controllers The controller output signal will switch from zero pressure to full supply pressure when increasing process differential pressure passes the upper switching point The controller output signal will not return to zero pressure until decreasing process differential pressure passes the lower switching point When adjusting the controller as described in the following steps keep in mind that e Changing the set point adjustment will move both switch
41. e O rings 2 1 Replace gauge if necessary 2 2 Repair or replace pressure regulator if necessary 2 3 Replace defective parts as necessary 2 4 Replace defective parts as necessary 2 5 Repair or replace damaged parts 2 6 If output does not change as described remove relay Replace O rings if necessary Replace relay if necessary 2 7 Make alignments and adjustments as necessary 2 8 Refer to the maintenance procedures for link adjustment 3 1 Align flapper as necessary 3 2 Adjust switching as necessary 3 3 Repair or replace faulty parts 3 4 Replace links as necessary 3 5 Replace the relay If the output still does not go to zero replace the nozzle pivot assembly 1 Loosen two screws key 6 in the proportional band indicator cover key 36 The screws do not need to removed 20 Instruction Manual 4194HS Controllers D200157X012 October 201 1 2 Liftthe proportional band indicator cover as shown in figure 11 Figure 11 Changing Controller Action W3439 3 Rotate the proportional band knob key 25 to the desired controller action 4 Install the proportional band indicator cover key 36 and tighten the two screws key 6 Replacing the Differential Pressure Unit Before performing any maintenance procedure remove the controller and differential pressure unit from the mounting position Then move the controller and differential pressure unit to a maintenance area Be sure the unit is properly su
42. e to increase length counterclockwise to decrease length so the pin on the end of the link is approximately one half of its diameter short of aligning with the hole in the input feedback beam assembly as shown in figure 16 The adjustment provides the proper tension on the link 7 Connectthe link to the input feedback beam assembly 8 Connect link number 1 to the drive arm 9 Refer to the maintenance calibration and flapper alignment procedures 26 Instruction Manual 4194HS Controllers D200157X012 October 2011 Figure 15 Process Pointer Alignment 24 4 ALIGNED ZERO ADJUSTMENT MISALIGNED ADJUSTMENT FINE ZERO LOCKING SCREW W3443 1 W3475 1 Figure 16 Link Number 2 Adjustment FLAPPER CLINCH NUT SCREW 3 W4191 W3451 1 2 OF PIN DIAMETER Link Number 3 1 Remove the two screws key 6 and lift off the proportional band indicator cover key 36 2 Note where the link is connected Disconnect link number 3 from set point adjustment assembly and the set point beam assembly key 23 27 4194HS Controllers Instruction Manual October 2011 D200157X012 3 Install the replacement link with the screw head toward set point beam assembly as shown in figure 17 and in the position as noted in step 2 Figure 17 Link Number 3 Adjustment LINK 3 ADJUSTMENT 200 2 DISCONNECT 4 Check that set point beam bias spring key 28 is correctly located in frame bore and spring seat on t
43. enance calibration Auto Manual Suffix Letter E Procedures describe disassembly and assembly of the auto manual station Controller Operation A description of prestartup startup and calibration procedures to return the controller to service Troubleshooting As an aid to troubleshooting table 5 lists some common operating faults their probable cause and suggested procedures for correcting the fault 4194HS Controllers October 2011 Table 5 Troubleshooting Chart Possible Cause 1 Output does not snap when process pointer and set point indicator are aligned 2 Controller output will not snap to full output pressure 3 Controller output will not snap to zero pressure 1 1 Flapper out of alignment 1 2 Process pointer not calibrated correctly 1 3 No supply pressure 1 4 Leak in nozzle or feedback tubing 1 5 Leak in relay O rings 2 1 Output pressure gauge not functioning 2 2 Supply pressure incorrect 2 3 Leak in positive feedback tubing 2 4 Leak in nozzle tubing assembly 2 5 Sensing element or linkage failure 2 6 Relay malfunction 2 7 Switching point has not been reached 2 8 Link 4 not adjusted correctly 3 1 Flapper out of alignment 3 2 Switching point has not been reached 3 3 Sensing element or linkage failure 3 4 Links 2 3 and 4 defective 3 5 Relay malfunction or clogged nozzle Changing Controller Action The following steps describe changing contro
44. essed as a percent of the input span between the switching points 2 Set the proportional band knob to the desired setting determined in step 1 3 Adjust the set point to the desired upper switching point 4 Increase the process differential pressure until the controller output signal switches from zero pressure to full supply pressure 5 Decrease the process differential pressure to the desired switching point at which the controller output signal switches from full supply pressure to zero pressure 6 Narrow or widen the proportional band slowly until the output signal switches from full supply pressure to zero pressure 7 Repeat steps 4 through 6 until the controller output switches at the desired points 8 Observe the process pointer when the output switches at the upper switching point The process pointer indication should be within 2 percent of the set point indication Reverse Acting Controllers The controller output signal will switch from zero pressure to full supply pressure when decreasing process differential pressure passes the lower switching point The controller output signal will not return to zero pressure until increasing process differential pressure passes the upper switching point When adjusting the controller as described in the following steps keep in mind that e Changing the set point adjustment will move both switching points equally in the direction of adjustment e Changing the proportional band a
45. et Point Capsular Element Assembly Note Remove the supply pressure gauge before trying to remove the capsular element assembly 1 Decrease the remote set point pressure to 0 psig 2 Remove the pressure connection key 93 at the pedestal assembly key 105 3 Disconnect link B key 126 from the pivot hole on set point indicator assembly 4 Remove the three mounting screws that attach the capsular element assembly to the process set point indicator assembly See figure 6 for location of screws CAUTION In the following step do not lift out the capsular element assembly by holding the capsule or the linkages These parts are easily damaged 5 Lift out the capsular element assembly by holding the plate key 111 travel stop key 83 or pedestal assembly key 105 6 Align the replacement assembly with the mounting screw holes Replace the mounting screws 7 Reconnect the process pressure connection union key 93 Apply remote set point pressure and check for leaks 8 Connect the link key 126 to the pivot hole on the set point indicator assembly 9 Replace the supply pressure gauge 0 After replacing parts refer to the various maintenance calibration procedures process zero and span adjustment flapper alignment Link A 1 Note where link A key 116 is connected figure 27 Disconnect both ends of the link from the lever arms on the two pivots 2 Loosen the screw in the replacement link and adjust the length to m
46. ey 33 and tighten the screw key 34 until the spring is compressed completely Tighten the two screws key 35 Make sure the bellows bracket key 31 is installed correctly so it does not touch the frame Replace the proportional or reset tubing assembly on the bellows base Apply the correct supply pressure and check for leaks Remove the supply pressure If the length of link 4 key 65 was not changed proceed with step 14 If the length of link 4 was changed during this procedure refer to the replacement procedures for the flapper flexure assembly Perform steps 36 through 38 of the procedures Replace link 4 on the bellows bracket Make sure the link does not touch the frame If it does repeat steps 8 through 12 to straighten the bellows bracket key 31 Refer to the flapper alignment procedures Remove the supply pressure the output measurement device and the regulated differential process pressure source Rotate the proportional band indicator cover key 36 and tighten the two screws key 6 Install the controller assembly in the case Slide the controller frame down to assure an O ring seal at the pressure connections Hold the frame in place Install and tighten the nine screws that hold the controller assembly in the case 37 4194 Controllers Instruction Manual October 2011 D200157X012 Calibration After Controller Maintenance Process Zero and Span Adjustment If the prestartup checks procedures revealed
47. ey 58 Tighten the nut that was loosened in step 2 Mou Apply the maximum value of remote set point pressure and check for leaks Remote Set Point Maintenance Calibration Note Perform all maintenance calibration procedures upon completion of maintenance If only zero and span or linearity adjustments are required use only those procedures Key numbers are referenced in figure 27 Adjustments are shown in figure 5 After maintenance calibration perform the flapper alignment procedures if directed to do so Otherwise go to the appropriate prestartup instructions in the Controller Operation section Refer to figure 6 for parts location Key numbers refer to figure 27 Remote Set Point Precalibration Procedures 1 Setthe proportional band adjustment between DIRECT and REVERSE 2 Remove the tie bar key 106 3 Apply 50 percent of full span remote set point pressure 4 The drive flexure key 79 should be straight If not proceed as follows a Loosen the screw on the adjustment arm on pivot assembly A key 114 and the screws holding the drive flexure b Setthe length of the adjustment arm so the drive flexure is parallel to the centerline of the capsules c Tighten the screw on the adjustment arm Note The adjustment arm of pivot A turns on a bushing at each end of the shaft supporting the adjustment arm In the next step position the shaft so both bushings float inside the bearings and do not rest against the end
48. fferential pressure unit procedure Then perform steps 1 through 3 found in the replacing the case and cover procedure Remove the two screws key 6 and lift off the proportional band indicator cover key 36 Disconnect link number 3 from the set point beam assembly key 23 Refer to figure 18 for location of the link Remove the set point beam bias spring key 28 Refer to figure 18 for spring location W N Remove the screw and washer keys 19 and 20 that hold the pivot assembly figure 19 to the frame and remove the pivot assembly Ul Disconnect the nut that holds relay nozzle tubing key 18 into the frame key 3 6 While holding the proportional band knob remove the screw and washer keys 19 and 20 which holds the relay nozzle tubing assembly key 18 to the frame 7 Remove the proportional band knob nozzle pivot and set point beam assembly from controller 8 Remove the relay nozzle tubing assembly key 18 from the set point beam assembly key 23 figure 18 9 Remove the E ring key 27 from the nozzle tubing assembly key 21 10 Remove the nozzle tubing assembly key 21 from the bottom of the set point beam assembly key 23 11 Remove the retaining clip key 26 12 Remove the proportional band knob key 25 from the set point beam assembly key 23 13 Inspect the nozzle pivot O ring key 24 14 Inspect the nozzle tubing assembly key 21 and replace it if necessary Inspect the nozzle orifice
49. ge Lower and Upper Range Limits See tables 3 and 4 Maximum Allowable Operating Limits See tables 3 and4 Output Signal Differential Gap Range 0 and 1 4 bar 0 and 20 psig or 0 and 2 4 bar 0 and 35 psig Action Field reversible between direct increasing differential pressure increases output pressure or reverse increasing differential pressure decreases output pressure Process Scale Standard scale is matched to the range of the sensing element Optional scales available Process Connections Standard 1 4 NPT internal stainless steel all input ranges Optional 1 2 NPT internal stainless steel Supply and Output Connections 1 4 NPT internal Supply Pressure Requirements 2 See table 4 Supply Pressure Medium Air or natural gas Air Supply pressure must be clean dry air that meets the requirements of ISA Standard 7 0 01 A maximum 40 micrometer particle size in the air system is acceptable Further filtration down to 5 micrometer particle size is recommended Lubricant content is not to exceed 1 ppm weight w w or volume v v basis Condensation in the air supply should be minimized Natural Gas Natural gas must be clean dry oil free and noncorrosive H5S content should not exceed 20 Remote Set Point Pressure Ranges 2 0 2 to 1 0 bar 3 to 15 psig or 0 4 to 2 0 bar 6 to 30 psig Continued 4194HS Controllers October 2011 Controller Adjustments Differential Gap Control 1 to 100 of pro
50. he controller assembly in the case Parts Parts Ordering Whenever corresponding with your Emerson Process Management sales office about this equipment always mention the controller serial number When ordering replacement parts refer to the 11 character part number of each required part as found in the following parts list WARNING Use only genuine Fisher replacement parts Components that are not supplied by Emerson Process Management should not under any circumstances be used in any Fisher instrument Use of components not supplied by Emerson Process Management may void your warranty might adversely affect the performance of the instrument and could cause personal injury and property damage Pa rts Kits Description Part Number peer pane pure 4190 Controller Repair Kit 4190 Controller Auto Manual Repair Kit Contains keys 4 5 7 8 24 52 R4190X00C12 Contains keys 277 278 279 281 292 293 294 298 306 312 R4190X0AM12 4190 Controller Pointer and Bracket Repair Kit 4190 Controller Auto Manual Retrofit Kit Contains pointer and bracket 55 Contains keys 138 273 312 313 314 315 316 three machine screws three washers R4190X00P12 Brass tubing R4190X00B12 SST tubing 4190 00512 4190 Controller Relay Replacement Kit Contains Relay Assembly key 50 4190 Controller Case Handle Kit 0 2 to 1 0 bar 3 to 15 psig RRELAYX83C2 Contains lever and mounting hardware R4190X00H12 0 4 to 2 0 bar 6 to 30 psig RRELAYX83D2 49
51. he process differential pressure increases in a direct acting controller the flapper moves toward the nozzle restricting flow through the nozzle and increasing nozzle pressure When this occurs relay action increases the output pressure delivery of the controller Output pressure is fed back to the positive feedback bellows The action of this bellows is a positive feedback action that moves the flapper closer to the nozzle increasing nozzle pressure which in turn increases the relay output Output pressure to the final control element switches to full supply pressure As the process differential pressure decreases approaching the lower switching point the flapper moves away from the nozzle in a direct acting controller reducing nozzle pressure Through relay action pressure to the positive feedback bellows is reduced moving the flapper farther away from the nozzle and further reducing nozzle pressure Output pressure to the final control element switches to zero Instruction Manual 4194HS Controllers D200157X012 October 201 1 The set point adjustment changes the proximity of the nozzle and flapper as does a change in process pressure except that when the set point is changed the nozzle moves with respect to the flapper The set point adjustment moves both the upper and lower switching points The proportional band knob positions the nozzle on the flapper Increasing widening the proportional band moves the nozzle away from the inpu
52. he set point beam assembly as shown in figure 18 5 Adjustthe proportional band between DIRECT and REVERSE 6 Adjust the set point adjustment manually or with the remote set point pressure to 50 percent of scale Adjust the screw on the link so the edge of the proportional band knob is parallel to the case or set point adjustment as shown in figure 5 7 Referto the maintenance calibration and flapper alignment procedures Link Number 4 1 Remove the two screws key 6 and lift off the proportional band cover key 36 2 Refer to figure 14 for location of link 4 Note where the link is connected Disconnect the link from bellows bracket assembly key 31 and the input feedback assembly key 11 3 Connect the replacement link to the input feedback assembly so the two adjusting screws on the link are nearest to the feedback bellows bracket The screw heads should face the bottom of the controller as shown in figure 19 and be positioned as noted in step 2 4 Adjust the process differential pressure to 0 percent of the process scale range Adjust the proportional band to 5 percent direct acting and adjust the set point manually or with remote set point pressure to 100 percent of scale range Controller output should be 0 psig 5 With zero pressure in the feedback bellows loosen the two adjusting screws on the link Connect the free end of the link to the bellows bracket assembly and allow the link to find its free length 6 Tighten
53. ial gap setting Proportional Band Differential Gap The proportional band knob adjusts the width of the gap between switching points Rotate the proportional band knob until the desired value is opposite the line on the proportional band indicator cover Changing Controller Action Controller action is switchable from direct to reverse or vice versa by simply loosening the screws on the proportional band indicator cover and moving the cover out so the proportional band knob can be rotated to the desired action The white portion of the adjustment enables direct controller action the black portion enables reverse controller action Switching The Auto Manual Station suffix letter E CAUTION Switching the controller between automatic and manual mode without balancing can disturb the process and cause controller cycling Refer to figure 28 if the controller has the auto manual option To switch from automatic to manual mode you must balance the manual output with the controller output Two balance methods are available to equalize the manual output with the controller output 4194HS Controllers Instruction Manual October 2011 D200157X012 To switch from automatic to manual mode carefully adjust the loader knob until the metal ball inside the plastic tube moves into the switching zone Then move the automatic manual switch to MANUAL Turn the loader knob clockwise to increase the controller output or counterclockwise to decrease it
54. ing points equally in the direction of adjustment e Changing the proportional band adjustment will widen or narrow the differential gap between the two switching points by moving the position of the lower switching point Figure 7 shows the relationship between the percent of sensor range between switching points and the proportional band setting on the controller The following example illustrates how to use figure 7 Figure 7 Curve for Determining Proportional Band Setting 2 lt lt 2 fe cc 0 10 20 30 40 50 60 70 80 90 100 A2853 1 IL SENSOR RANGE BETWEEN SWITCHING POINTS Example The sensing element has a range of 30 psi The lower switching point is to be set at 10 psi and the upper switching point is to be set at 25 psi Proceed as follows Divide the differential gap the difference between the upper and lower switching points by the sensing element range Multiply the result by 100 as shown in the following equation Differential Gap l5psi Sensing Element Range 30 psi Instruction Manual 4194HS Controllers D200157X012 October 201 1 e Locate the 50 percent line on figure 7 Move along this line until you intersect the curve Read the proportional band setting on the left hand axis For this example the setting is approximately 35 percent 1 Using the curve in figure 7 determine the correct proportional band setting for the desired gap expr
55. ld result from fire or explosion of accumulated gas The controller assembly does not form a gas tight seal and a remote vent line is recommended However a remote vent line cannot be relied upon to remove all hazardous gas Leaks may still occur Provide adequate ventilation and necessary safety measures Vent line piping should comply with local and regional codes and should be as short as possible with adequate inside diameter and few bends to reduce case pressure buildup CAUTION When installing a remote vent pipe take care not to over tighten the pipe fitting in the vent connection Excessive torque will damage the threads in the connection If a remote vent is required the vent line must be as short as possible with a minimum number of bends and elbows Vent line piping should have a minimum inside diameter of 19 mm 3 4 inches for runs up to 6 1 m 20 feet anda minimum inside diameter of 25 mm 1 inch for runs from 6 1 to 30 5 m 20 to 100 feet Instruction Manual 4194HS Controllers D200157X012 October 201 1 If a remote vent is not required the vent opening figure 3 must be protected against the entrance of any foreign material that could plug it Check the vent periodically to be certain it is not plugged Supply Pressure WARNING Personal injury or property damage may occur from an uncontrolled process if the supply medium is not clean dry oil free air or a non corrosive gas While use and regular maintenance of a filte
56. ler and differential pressure unit Also refer to the differential pressure unit instruction manual for specific information about connections and piping Instruction Manual 4194HS Controllers D200157X012 October 201 1 Figure 3 Connections 1 4 REMOTE SET POINT CONNECTION REMOTE SET POINT CONNECTION 1 2 NPT TOP VIEW 1 4 NPT OPTIONAL EXTERNAL FEEDBACK CONNECTION 1 4 NPT VENT SUPPLY PRESSURE CONTROLLER OUTPUT PRESSURE 1 4 NPT 41 1 4 2 HOLES LEFT SIDE VIEW FRONT VIEW BOTTOM VIEW NOTE 1 HIGH PRESSURE CONNECTION ON A BARTON 199 DIFFERENTIAL PRESSURE UNIT 18 5903 000 1 Supply output vent and remote set point connections 1 4 Use 1 4 3 8 inch pipe or tubing for supply output vent and remote set point piping Process pressure connections are 1 4 or 1 2 NPT optional When installing process piping from the differential pressure sensing unit in the process pipeline to the differential pressure unit attached to the controller follow accepted engineering installation and safety practices to insure the safe and accurate transmission of the process differential pressure to the differential pressure unit Install shutoff valves vents drains or seal systems as required by accepted practices Process Pressure Connections Process pressures are piped to the connections on the ends of the differential pressure unit figure 4 Refer
57. ller action from direct increasing process differential pressure produces increasing output pressure to reverse increasing process differential pressure produces decreasing output pressure or vice versa 1 1 Refer to flapper alignment procedure 1 2 Refer to the process zero and span adjustment procedures 1 3 Check supply pressure 1 4 Using a soap solution check for leaks 1 5 Using a soap solution check for leaks 2 1 Check output with external gauge 2 2 Check with external source 2 3 Using a soap solution check for leaks 2 4 Using a soap solution check for leaks 2 5 Inspect element or linkage for damaged parts 2 6 Manually cap the nozzle output by pushing the flapper toward the nozzle Output should go to supply pressure 2 7 Refer to the flapper alignment or to the setting switching points procedure 3 1 Refer to the flapper alignment procedure 3 2 Refer to the setting switching points procedure 3 3 Inspect sensing element and linkage for damaged parts Using soap solution check for leaks 3 4 Inspect links for loose screws and improper connections Ensure links are not rubbing or catching on other parts 3 5 Manually push the flapper away from the nozzle The output should go to zero Instruction Manual D200157X012 1 1 Align flapper as necessary 1 2 Adjust as necessary 1 3 Provide correct supply pressure 1 4 Repair or replace defective parts 1 5 Repair or replace defectiv
58. llows adj spring pl steel 34 Machine screw fill hd 18 8 SST 2 req d 35 Machine screw hex hd 18 8 SST 2 req d 36 Proportional band indicator cover ABS w polyester label 50 Key Description Part Number 37 Self tapping screw 18 8 SST For indicator ass y key 101 4 req d 38 Self tapping screw 18 8 SST 9 req d 39 Supply gauge tubing ass y SST 41 Plug 530300 45 Positive Feedback Tubing Assembly Stainless steel brass Note One type of pressure gauge is used for both output pressure and supply pressure indication See Key 46 47 table for part numbers See Key 46 47 table See Key 46 47 table 46 Output gauge 47 Supply gauge 48 Bellows ass y 2 req d brass 16A6953X012 532100 530400 16 6953 022 49 Bellows beam A96061 aluminum 0 2 to 1 0 bar 3 to 15 psig 0 4 to 2 0 bar 6 to 30 psig 50 Relay Assembly The relay assembly is included in the Replay Replacement kit Relay 0 2 to 1 0 bar 3 to 15 psig Relay 0 4 to 2 0 bar 6 to 30 psig 51 Relief valve cover plate A03600 aluminum 52 O ring nitrile 53 Machine screw fill hd 18 8 SST 2 req d 10853806992 56 Process and set pt indicator ass y Note The parts for key 56 are for the complete process and set pt indicator ass y Individual indicator ass y parts are listed in two subsections of this parts list the Process and Set Point Indicator Assembly key 56 subsection and the Indicator Assembly key 101 subsection Key numbers for individual i
59. mbling the pivot bracket it must be carefully aligned so it will not cause binding on the extension shaft key 331 5 Remove the pivot bracket key 320 by removing the screws and washers keys 329 and 332 6 Loosen the locking screw key 331 and slide the drive arm key 322 off the extension shaft CAUTION When removing the controller from the controller mounting plate key 327 be careful not to bend the extension shaft key 321 Remove four screws key 336 from the controller mounting plate key 328 and carefully slide the controller off the extension shaft For controller maintenance remove the controller mounting plate key 328 by removing three screws key 335 to gain access to the back of the controller For differential pressure unit maintenance loosen the set screw key 333 and remove the extension shaft 10 Remove four screws key 334 from the mounting plate key 327 to gain access to the differential pressure unit 11 For maintenance of the differential pressure unit refer to the instruction manual for the unit CO LO CAUTION When reinstalling the differential pressure unit carefully insert the extension shaft key 321 into the controller to avoid damage to controller parts 12 Follow this procedure in reverse to rejoin the controller and differential pressure unit Before returning the unit to process control perform maintenance calibration and flapper alignment procedures Refer
60. mbly Drive Flexure erg Remote Set Point Capsular Element Assembly HAKA Macr een BGM Ried EE Pressure Control Block for Remote Set Point Remote Set Point Maintenance Calibration Remote Set Point Precalibration Procedures Setting Remote Set Point Travel Stops Aligning Remote Set Point Linkage Remote Set Point Zero and Span acide ee SC DE TA ISP EQUES Introduction Scope of Manual Instruction Manual D200157X012 Remote Set Point Linearity Adjustment 45 Auto Manual Station suffixletter E 45 Replacing the Auto ManualStation 45 DISASSEIMDIY uou 46 ASSOIMDIY EE 46 Replacing the Auto Manual Station Switch Body Assembly Lever O Ring Switch Body O Ring and the Tubing Assembly 46 Disassembly 46 Assem DIY E REM 47 Replacing Auto Manual Station Loader Range Spring Diaphragm Assembly Ball Seat Tubing and Ball 48 Disassembly 48 Vets cea as 48 Replacing the Auto Manual Station Loader Valve Plug and Valve Plug Spring 49 Ki 49 Parts Ordering 49 PallS 49 Controller Parts 50 Process and Set Point Indicator A
61. minum 138 Auto manual tubing 55 Use w suffix letter E int auto manual station option for 4194HSE and HSME only SST aluminum 51 4194HS Controllers October 2011 Key 140 162 310 311 317 318 337 362 365 Description Machine screw fill hd 18 8 SST For 4194HSM and HSME only Required to mount remote set pt ass y suffix letter M to indicator ass y 2 req d Machine screw hex hd 18 8 SST Lithium Grease not furnished with controller Anti Seize Sealant not furnished with controller Silicone based lubricant not furnished with controller Lubricant silicone sealant not furnished with controller Barton 199 Differential Pressure Unit Key 337 includes the pipestand mounting bracket and three set screws square hd steel 3 8 16 x 5 8 inch Spring retaining washer SST Washer 18 8 SST Process and Set Point Indicator Assembly key 56 fiqure 29 101 319 320 321 322 323 324 325 326 327 328 329 330 331 332 333 334 335 336 Indicator 55 For use w o remote set pt For use w remote set pt Support bracket 18 8 SST Pivot bracket ass y SST Sapphire Shaft extension 18 8 SST Drive arm ass y SST steel Zero link ass y SST brass Clamp block 18 8 SST Nut 2 req d Boot nitrile Mounting plate for differential pressure unit stl zn pl Controller mounting plate stl zn pl Machine screw pan hd 18 8 SST 2 req d Machine screw fill hd 18 8 SST 2 req d Machine
62. nd 131 and the nut on the nozzle tubing assembly key 18 2 Install the three O rings key 312 and secure the auto manual station to the controller frame with the screw key 316 and to the tubing assembly key 138 with two screws keys 314 and 315 Do not tighten any screws CAUTION In the next step take care to tighten the two screws keys 314 and 315 evenly Uneven tightening could damage the tubing assembly 3 Position the auto manual station as far down on the frame and toward the scale as possible Carefully tighten the two screws keys 314 and 315 so the auto manual station contacts the three pads on the tubing assembly 4 Carefully tighten the remaining screws and nuts 5 Apply air pressure to the controller and check for leaks 6 Install the controller assembly in the case Slide the controller frame down to assure an O ring seal at the pressure connections Hold the frame in place 7 Install and tighten the nine screws that hold the controller assembly in the case 8 Refer to the flapper alignment procedure Replacing the Auto Manual Station Switch Body Assembly Lever O ring Switch Body O ring and the Tubing Assembly Disassembly Refer to figure 28 for key number locations 1 Remove the auto manual station from the controller frame as described in steps 1 through 4 of the procedure for replacing the auto manual station 2 Loosen the two screws key 288 and remove the lever cover plate key 305
63. ndicator parts also appear in figures 29 and 30 Process and set pt indicator ass y plastic aluminum stainless steel w o remote set for 4194HS and 4194HSE w remote set for 4194HSM and 4194HSME 57 Pressure control block CF8M 316 SST Casting w remote set only 1 4 18 internal process connection Recommended spare parts Instruction Manual D200157X012 Key Description 58 Cap screw hex hd SST for use w pressure control block key 57 w remote set pt 2 req d 61 Process scale aluminum for indicator ass y 0 5 psid 0 10 psid 0 15 psid 0 20 psid 0 30 psid 0 40 psid 0 50 psid 0 60 psid 0 75 psid 0 250 mbar differential 0 0 6 bar differential 0 1 4 bar differential 0 1 6 bar differential 0 2 0 bar differential 0 20 in w c differential 0 25 in w c differential 0 50 in w c differential 0 75 in w c differential 0 100 in w c differential 0 100 percent 0 10 square root 0 100 square root 62 Remote set pt ass y suffix letter M Note The parts listed for key 62 are for the complete remote set point suffix letter M assembly Individual assembly parts are listed in the Remote Set Point Assembly subsection of the parts list Key numbers for individual assembly parts also appear in figure 27 Remote set pt ass y suffix letter M for 4194HSM and HSME only N09902 alloy 0 8 bar 12 psig span 1 7 bar 24 psig span SST 0 8 bar 12 psig span 1 7 bar 24 psig span 63 Machine screw hd
64. nstructions contact your Emerson Process Management sales office before proceeding Specifications Specifications for the 4194HS controllers are listed in table 2 WARNING This product is intended for a specific range of pressure temperatures and other application specifications Applying different pressure temperature and other service conditions could result in malfunction of the product property damage or personal injury Educational Services For information on available courses for 4194HS controllers as well as a variety of other products contact Emerson Process Management Educational Services Registration P O Box 190 301 S 1st Ave Marshalltown IA 50158 2823 Phone 800 338 8158 or Phone 641 754 3771 FAX 641 754 3431 e mail education emerson com Installation Mounting and Connections WARNING To avoid personal injury or property damage from sudden release of process pressure e Always wear protective clothing gloves and eyewear when performing any installation operations to avoid personal injury e Personal injury or property damage may result from fire or explosion if natural gas is used as the supply medium and preventative measures are not taken Preventative measures may include but are not limited to one or more of the following Remote venting of the unit re evaluating the hazardous area classification ensuring adequate ventilation and the removal of any ignition sources For information
65. nt beam assembly key 23 See figure 18 If the position of the set point beam shoe key 29 figure 18 was changed relative to the set point beam assembly key 23 go to step 33 If the position of the set point beam shoe was not changed go to step 53 Connect supply pressure and a regulated process differential pressure to the controller Also provide a means of measuring controller output pressure Perform the flapper alignment procedure Then proceed as directed by the following note Note For direct acting controllers go to step 35 For reverse acting controllers go to step 44 35 For direct acting controllers adjust the proportional band knob to 5 percent direct acting Adjust the set point manually or with remote set point pressure to 5 percent of the process scale range WARNING In step 36 do not exceed the operating limits of the controller refer to table 3 Personal injury or equipment damage could result from overpressure 36 30 Slowly increase the process differential pressure from zero until the output pressure snaps to supply pressure The output pressure should snap to supply pressure within 2 percent of set point Instruction Manual 4194HS Controllers D200157X012 October 2011 Figure 18 Proportional Band Knob and Set Point Beam Details PLASTIC NOZZLE TUBING CAP ASSEMBLY KEY 18 WASHER WASHER Bes 20 E RING 4 27 SCREW 1
66. ntil the output pressure snaps to supply pressure The output should snap to supply pressure within 2 percent of set point If the output pressure snaps to supply pressure within 2 percent of set point go to step 53 If the output pressure does not snap to supply pressure within 2 percent go to step 51 If the output pressure snaps to supply pressure below 2 percent of set point adjust the set point beam shoe key 29 slightly toward the center of the nozzle pivot If the output pressure snaps to supply pressure above 2 percent of set point adjust the set point beam shoe slightly away from the center of the nozzle pivot Repeat steps 44 through 51 until the output pressure snaps to supply pressure within 2 percent of set point at 5 and 95 percent of the process scale range then go to step 53 Install the controller assembly in the case Slide the controller frame down to assure an O ring seal at the pressure connections Hold the frame in place 33 4194HS Controllers Instruction Manual October 2011 D200157X012 54 Install and tighten the nine mounting screws that hold the controller assembly in place 55 Refer to the flapper alignment procedures 56 Replace the proportional band indicator cover key 36 and tighten two screws key 6 Flapper Flexure Pivot Assembly Note The following procedure requires that the controller be removed from the case Perform steps 1 through 7 in the replacing the differential pressure unit p
67. ocation c Make fine adjustments with the span adjustment screw 6 To decrease the span proceed as follows a Turn the span adjustment screw counterclockwise Adjust span to correct one half of the error b To decrease the span further than the adjustment will allow move both ends of link A to the right Refer to figure 6 for link location c Make fine adjustments with the span adjustment screw 7 Repeat the adjustments until the zero and span indications are within 1 percent of input span 8 Check the pointer position at 50 percent of full pressure input span If the error is greater than 1 percent of input span perform the linearity adjustment procedure Remote Set Point Linearity Adjustment Adjust the linearity by rotating the linearity adjustment screw in the curved slot on the lever arm of the short pivot B key 115 Adjusting the linearity affects the zero and span 1 Adjust the set point pressure to 50 percent of input span The set point pointer should indicate the 50 percent mark on the scale 2 If the pointer indicates high loosen the linearity screw and rotate it counterclockwise in the slot If the pointer indicates low rotate the linearity screw clockwise in the slot 3 Check the zero and span as described in the zero and span adjustment procedures Make any necessary adjustment 4 Repeat steps 1 through 3 until zero span and linearity indications are within 1 percent of input span Auto Manu
68. ocations Remove two screws key 35 from the bellows assembly 5 Remove the four screws key 6 from the bellows beam key 49 and remove the bellows bracket 6 Remove the positive feedback tubing assembly key 45 from the positive feedback bellows CAUTION When removing and replacing the proportional or positive feedback bellows keep in mind that the bellows has left hand threads Overtightening could damage the threads 7 Unscrew the bellows 8 Before installing the replacement bellows coat the threads with a suitable lubricant Screw in the replacement bellows until it is finger tight against the frame key 3 9 Install the four screws key 6 through the bellows bracket key 31 into bellows beam key 49 36 Instruction Manual 4194HS Controllers D200157X012 October 2011 Figure 24 Bellows Assembly and Proportional Band Adjustment Process Scale and Proportional Band Adjustment Cover Removed FOUR SCREWS KEY 6 RESET BELLOWS PROPORTIONAL BELLOWS WASHER KEY 362 TWO SCREWS BELLOWS KEY 35 BRACKET 10 11 12 13 14 15 16 T 18 19 KEY 31 LOCKING NUT ADJUSTABLE SET POINT PIVOT ASSEMBLY KEY 17 WW LLLA Y i SA 4 ET SCREW AND e WASHER KEYS 19 AND 20 W4199 Install the two screws key 35 through the bellows bracket key 31 into the bellows Install the bellows adjustment bracket key 32 spring k
69. of service To avoid personal injury and property damage caused by uncontrolled process pressure observe the following before performing any maintenance procedures e Always wear protective clothing gloves and eyewear when performing any installation operations to avoid personal injury e Personal injury or property damage may result from fire or explosion if natural gas is used as the supply medium and preventative measures are not taken Preventative measures may include but are not limited to one or more of the following Remote venting of the unit re evaluating the hazardous area classification ensuring adequate ventilation and the removal of any ignition sources For information on remote venting of this controller refer to page 8 e Provide some temporary means of control for the process before taking the controller out of service e Shut off the supply pressure to the controller e Check with your process or safety engineer for any additional measures that must be taken to protect against process media Note Unless otherwise noted key numbers refer to figure 26 Figures 5 and 6 show the location of adjustments and major components For maintenance on the indicator assembly refer to figures 29 and 30 Parts are subject to normal wear and must be inspected and replaced as necessary Inspection and maintenance frequency depends upon the severity of the service conditions When inspection or repairs are required disassemble only th
70. on procedures process zero and span adjustment flapper alignment Drive Flexure CAUTION Avoid bending or kinking the drive flexure during this procedure Bending or kinking the drive flexure can result in product damage as well as impaired performance Disconnect the flexure key 79 from the drive bracket key 121 and from the adjustment arm of pivot assembly A Remove the screws and washers key 12 and 13 remove the flexure Set remote set point pressure at 50 percent of input span Connect the new flexure making sure it stays straight and horizontal Before tightening down the drive flexure set pivot A in the middle of the bushing end play Tighten down the drive flexure to hold the pivot in that position Do not kink or twist the flexure when tightening the screws 4 Decrease the remote set point pressure to 0 psig After replacing parts refer to the various maintenance calibration procedures process zero and span adjustment flapper alignment Tubing 1 Decrease the remote set point pressure to 0 psig 41 4194HS Controllers Instruction Manual October 2011 D200157X012 2 Disconnect the pressure connection key 93 into the pedestal assembly key 105 and the connection to the case exterior at the top of the case 3 Remove the tubing key 104 4 Install the replacement tubing and reconnect the two pressure connections 5 Apply full remote set point pressure and check for leaks Remote S
71. on remote venting of this controller refer to page 8 e Check with your process or safety engineer for any additional measures that must be taken to protect against process media e If installing into an existing application also refer to the WARNING at the beginning of the Maintenance section in this instruction manual 4194HS Controllers Instruction Manual October 2011 D200157X012 Pipestand Mounting A 4194HS controller mounts on a pipestand and must be installed with the vent opening facing down The coupling is secured to the pipestand by three set screws as shown in figure 2 Figure 2 Right Side View of Controller BARTON 199 DIFFERENTIAL PRESSURE UNIT 112 NPT PRESSURE 1 CONNECTION 1 4 NPT PRESSURE lt PIPESTAND MOUNTING BRACKET SET SCREW 3 REQ D NOTE 1 LOW PRESSURE CONNECTION ON A BARTON 199 DIFFERENTIAL PRESSURE UNIT W3635 1 Pressure Connections WARNING To avoid personal injury or property damage resulting from the sudden release of pressure do not install any system component including the differential pressure unit where service conditions could exceed the limits given in this manual or on the appropriate nameplates Use pressure relieving devices as required by government or accepted industry codes and good engineering practices Refer to figures 2 and 3 for the location of all input and output connections for the control
72. ose parts necessary to accomplish the job Figure 10 is a maintenance guide that summarizes the information available in the maintenance procedures Select the appropriate maintenance procedure and perform the numbered steps Shut off the supply pressure and process pressure before beginning maintenance The Maintenance section describes part replacement common to this type of Fisher controller Other portions of the maintenance procedures describe replacing the differential pressure unit making process zero and span and flapper alignments and other calibration and maintenance procedures When maintenance procedures including flapper alignment have been completed refer to the appropriate prestartup procedure Instruction Manual 4194HS Controllers D200157X012 October 201 1 Figure 10 Maintenance Guide eshootinq It the controller is not operating properly refer to the troubleshooting chart table 5 Then use the appropriate portions of the Maintenance section Replacing Common Controller Parts Procedures describe replacement of controller parts The procedures may be performed separately but must be followed by maintenance calibration procedures Flapper Alignment Procedures align the flapper for both direct and reverse controller action Remote Set Point Suffix Letter M Procedures describe replacement of parts in the remote set point assembly The procedures may be performed separately but must be followed by maint
73. pported before trying to separate the controller and differential pressure unit Use this procedure in reverse to connect a differential pressure unit to a controller Refer to figures 26 and 27 for key number locations 1 Isthe process under temporary control If so shut off the pressure pressure and supply pressure Carefully bleed pressure from the controller and differential pressure unit 2 Disconnect all tubing Refer to the installation procedures for process and supply tubing connections that must be disconnected when the differential pressure unit is removed from the pipestand WARNING The combined weight of the controller and differential pressure unit is approximately 26 kilograms 57 pounds Provide adequate support for the unit during removal procedures to prevent personal injury or property damage 3 Remove the controller and differential pressure unit from the mounting position Figure 2 shows the location of the set screws that connect the mounting bracket key 337 to the pipestand Move the controller and differential pressure unit to a maintenance area Be sure the unit is properly supported before trying to separate the controller and differential pressure unit 21 4194HS Controllers Instruction Manual October 2011 D200157X012 4 To separate the controller and differential pressure unit open the cover locate link number 1 key 323 and disconnect it from the drive arm key 322 CAUTION When reasse
74. r assembly from the switch body assembly key 291 and rocker key 299 11 Remove the O ring key 298 12 Inspect the O rings and the gaskets for damage or wear and replace if necessary Assembly 1 Insert the lever assembly key 297 into the switch body assembly key 291 and hold the rocker key 299 with the flats on the lever assembly shaft 2 Insert the clip key 300 in the groove of the lever assembly shaft to hold the lever assembly key 297 in the switch body assembly key 291 3 Position the closing plate gasket key 306 and the closing plate key 307 Secure with two screws key 308 Note After assembly in step 3 be sure the side of the closing plate marked OUT is visible 4 Place the balls key 296 switch body springs key 295 and O rings keys 292 293 and 294 in the switch body key 291 Note In the following step the ends of the springs must be in the counterbored spring seats before compression 5 Compress the switch body springs with the loader assembly key 282 and bolt the switch key 291 to the loader assembly using the two screws key 290 47 4194HS Controllers Instruction Manual October 2011 D200157X012 6 Reconnect the tubing assembly key 309 7 Locate the lever spring key 302 and the spring seat key 301 on the switch lever key 304 and position these parts in the opening of the loader assembly key 282 8 Push the switch lever down using the lever spring seat key 301
75. r that removes particles larger than 40 micrometers in diameter will suffice in most applications check with a Emerson Process Management field office and industry instrument air quality standards for use with corrosive gas or if you are unsure about the proper amount or method of air filtration or filter maintenance Supply pressure must be clean dry air or noncorrosive gas that meets the requirements of ISA Standard 7 0 01 A maximum 40 micrometer particle size in the air system is acceptable Further filtration down to 5 micrometer particle size is recommended Lubricant content is not to exceed 1 ppm weight w w or volume v v basis Condensation in the air supply should be minimized Alternatively natural gas may be used as the supply pressure medium Gas must be clean dry oil free and noncorrosive H5S content should not exceed 20 ppm Use a suitable supply pressure regulator to reduce the supply pressure source to 1 4 bar 20 psig for an output signal range of 0 and 1 4 bar 0 and 20 psig and to 2 4 bar 35 psig for an output signal range of 0 and 2 4 bar 0 and 35 psig Remote Set Point suffix letter M Connection If the controller has the remote set point option connect the remote set point pressure to the top of the controller case at the location shown in figure 3 Use clean dry air or noncorrosive gas If pressure is supplied to the remote set point connection with a regulator a small bleed orifice should be placed between
76. rein or their use or applicability All sales are governed by our terms and conditions which are available upon request We reserve the right to modify or improve the designs or specifications of such products at any time without notice Emerson Process Management Marshalltown lowa 50158 USA Sorocaba 18087 Brazil Chatham Kent MEA 407 UK Dubai United Arab Emirates Es Singapore 128461 Singapore Fisher Controls International LLC 1983 201 1 All Rights Reserved
77. rocedure Then perform steps 1 through 3 in the replacing the case and cover procedure Remove the two screws key 6 and lift off the proportional band indicator cover key 36 Disconnect link number 3 from the set point beam assembly key 23 Refer to figure 18 for link location Remove the set point beam bias spring key 28 refer to figure 18 for the spring location Remove the screw and washer keys 19 and 20 that holds the set point pivot assembly key 17 to the frame Remove the set point pivot assembly key 17 Disconnect the nut that holds relay nozzle tubing key 18 into the frame key 3 Mo UW B While holding the proportional band knob remove the screw and washer keys 19 and 20 figure 19 which holds the relay nozzle tubing assembly key 18 to the frame 8 Remove the proportional band knob nozzle pivot and set point beam assembly from controller 9 Disconnect link number 2 from the input feedback beam assembly key 11 shown in figure 17 Referto figure 14 for location of link 10 Disconnect link number 4 from the bellows bracket key 31 11 Remove the screws key 12 and washers key 13 from the flexure pivot assembly key 9 See figure 22 for screw location 12 Remove the input feedback beam assembly as shown in figure 23 13 Remove the four screws key 10 as shown in figure 23 that hold the flexure pivot assembly to the frame 14 Remove the flexure pivot assembly key 9 15
78. s 134 Diaphragm 55 extension A92011 aluminum 139 Machine screw fill hd 18 8 SST 3 req d 141 Adj arm 530400 311 Anti Seize Sealant not furnished with controller Indicator Assembly key 101 figure 30 37 Self tapping screw 18 8 SST 4 req d 61 Process scale aluminum See key 61 under Controller Parts 353 Machine screw pan hd 18 8 SST 4 req d 366 Controller Mounting Plate 18 8 SST 367 Support bracket ass y zinc brass 368 Link ass y SST brass 2 req d 369 Process pointer adj 55 aluminum SST brass 370 Set pt pointer ass y aluminum SST brass 371 Pivotpin 18 8 SST 2 req d 372 Washer plain 18 8 SST 4 req d 374 Pointer and bracket 55 aluminum steel Instruction Manual D200157X012 Key Description Part Number 375 Setptindicator ass y A93003 aluminum for controllers w remote set pt for controllers w o remote set pt 376 DialBracket G10080 steel 377 Dialbracket G10080 steel 378 Screw self tapping 18 8 SST 2 req d Auto Manual Station suffix letter E figure 28 138 2 3 274 275 276 271 278 279 280 281 282 283 284 285 286 287 288 289 290 291 292 293 294 295 296 297 298 299 Auto manual tubing ass y suffix letter E aluminum brass aluminum SST Auto manual station aluminum plastic Lower loader 55 aluminum Spring seat screw pl steel Valve plug spring A228 music wire alt desgntn 08500 pl steel Valve plug 18 8 S
79. ssembly 52 Remote Set Point Assembly 52 Indicator Assembly 52 Auto Manual Station suffix letter E 53 Controller Mounting 53 xni PE HL len oo ete 53 This instruction manual provides installation operating calibration maintenance and parts ordering information for the 4194HS high static pressure differential pressure indicating controllers The type number of the controller is on the nameplate Refer to figure 1 for the location of the nameplate Configurations of the controller are indicated by letter suffixes in the type number that correspond to the mode and option designated in table 1 Refer to table 1 for definition of each 4194HS type number Description The controllers described in this manual provide differential gap control with options as shown in table 1 The controller shows process differential pressure and set point on an easy to read process scale The controller output is a pneumatic signal that operates a final control element Table 1 Available Configurations Controller Internal Auto Manual Station Suffix Letter E Remote Set Point Suffix Letter M 4194HS 4194HSE 4194HSM 4194HSME 1 Reverse acting constructions are designated by an R suffix in the type number Instruction Manual D200157X012 Table 2 Specifications Available Configurations See table 1 Input Signal Sensing Element Ran
80. ssembly key 281 on the loader assembly key 282 3 Position the ball key 279 the tube key 278 and the ball seats key 280 between the ears of the loader assemblies keys 282 and 274 position the diaphragm assembly key 281 between the main halves of the loader assemblies Note The tube key 278 must be well seated in the cups of the ball seats key 280 4 Boltthe loader assembly halves together using the four screws key 289 Note Be sure that the supply and exhaust seats of the loader are correctly aligned Misalignment will impair loader performance 48 Instruction Manual 4194HS Controllers D200157X012 October 201 1 5 Attach the tubing assembly key 309 6 Perform the assembly portion in the replacing the auto manual station procedure Replacing the Auto Manual Station Loader Valve Plug and Valve Plug Spring Refer to figure 30 for key number location Loosen the spring seat screw key 275 Remove the valve plug spring key 276 and the valve plug key 277 Inspect the parts and replace as necessary 1 2 3 4 Install the valve plug spring and valve plug 5 Tighten the spring seat screw 6 Temporarily apply supply pressure and process differential pressure and check for leaks 7 Install the controller assembly in the case Slide the controller frame down to assure O ring seal at the pressure connections Hold the frame in place 8 Install and tighten the nine screws that hold t
81. t connection When the proportional band adjustment moves the nozzle across the feedback connection the controller action changes between direct and reverse On a direct acting controller changing the proportional band adjustment will widen or narrow the differential gap between the two switching points This is accomplished by changing the position of the lower switching point On a reverse acting controller changing the proportional band adjustment will widen or narrow the differential gap between the two switching points This is accomplished by changing the position of the upper switching point Remote Set Point suffix letter M The capability to adjust the controller set point from a remote location is available with all 4194HS controllers This option is designated by the suffix letter M in the type number Auto Manual Station suffix letter E Controllers with the auto manual option designated by the suffix letter E in the type number have piping on the output side of the relay as shown in figure 9 Supply pressure to the relay is also applied to the manual loader The manual loader functioning as a regulator applies pressure to one side of the plastic tube and to the auto manual switch Output pressure from the relay registers on the other side of the plastic tube as well as in the auto manual switch Figure 9 Schematic of Auto Manual Option 655 MANUAL LOADER AUTOMATIC POSITION AUTO 2 MANUAL SW ITC H y
82. the frame key 3 2 Before installing the replacement gauge coat the threads on the gauge with a suitable sealant 3 Screw the replacement gauge into the frame Links This section describes the separate replacement of four links in the controller To clarify the location of each link the links are numbered as follows Link Number 1 connects the drive arm and the process pointer Link Number 2 connects the process pointer and the input feedback beam assembly key 11 Link Number 3 connects the set point adjustment and the set point beam assembly key 23 Link Number 4 key 65 connects the input feedback beam assembly and the bellows bracket assembly key 31 Figures 5 and 14 show the location of each link Link Number 1 1 See figure 5 for the location of link number 1 Note where the link is connected Disconnect the link from the drive arm and from the process pointer assembly Remove the link Then install the replacement link 2 Attach the replacement link to the process pointer assembly and drive arm in the position noted in Step 1 3 Remove the two screws key 6 and lift off the proportional band indicator cover key 36 4 Adjust the set point manually or with remote set point pressure to 100 percent of the scale range and set the proportional band between DIRECT and REVERSE 5 The process pointer should be lined up with the pointer subassembly as shown in figure 15 If not loosen the zero adjustment
83. the nozzle in the center of the flapper as shown in figure 21 Install the screw and washer keys 19 and 20 into the relay nozzle tubing assembly key 18 as shown in figure 19 Install the screw key 19 through the frame key 3 and into the relay nozzle tubing assembly key 18 Tighten the screw Make sure the nozzle remains centered on the flapper with the set point beam assembly slid snugly towards the relay nozzle tubing assembly Install the pivot of the set point pivot assembly key 17 in the hole in the set point beam assembly key 23 Install the washer key 20 on the screw key 19 Install the screw key 19 through the frame key 3 into the set point pivot assembly key 23 Do not tighten First slide the beam assembly snugly toward the relay tubing assembly Then slide the pivot assembly key 17 toward the set point beam until the cone lightly contacts the set point beam and tighten the screw The proportional band knob should fall freely when the controller is in the upright position If it does not reposition the set point pivot assembly key 17 until the proportional band knob falls freely Tighten the nut on the relay nozzle tubing assembly key 18 and apply full supply pressure to check for leaks with the controller developing full output pressure Install the set point beam bias spring key 28 into frame bore and onto the spring seat on the set point beam assembly figure 18 Attach link number 3 to the set poi
84. the regulator and remote set point connection to prevent pressure variations due to regulator lock up Controller Operation Note Some of the following procedures require that the proportional band knob be adjusted to between DIRECT and REVERSE If this is done it will be necessary to set the proportional band knob to 400 direct or reverse action before replacing the proportional band indicator cover This section includes descriptions of adjustments and procedures for prestartup and startup Location of adjustments is shown in figures 5 and 6 To better understand the adjustments and overall operation of the controller refer to the Principle of Operation section which appears later in this manual Also refer to the schematic diagrams figures 8 and 9 4194HS Controllers October 2011 Figure 5 Location of Controller Parts and Adjustments SET POINT lt ADJUSTMENT PROCESS DRIVE ARM INDICATOR LOCKING SCREW PROPORTIONAL PIVOT BRACKET BAND INDICATOR 1 COVER DRIVE ARM d A DE S PROPORTIONAL Instruction Manual D200157X012 BAND ADJUSTMENT CONNECTING LINK 1 4 SH PROCESS gt OUTPUT ADJUSTMENT PEI ed e ie GE ZERO ADJUSTMENT t GAUGE ADJUSTMENT LOCKING SCREW 35 7374 REMOTE SET POINT SPAN ADJUSTMENT SPAN ADJUSTMENT 79 J SUPPLY PRESSURE GAUGE NOTE 1 gt ON CONTROLLERS EQUIPPED WITH REMOTE SET POINT OPTION THIS IS THE REMOTE SET POINT INDICATOR FRONT VIEW
85. the two adjusting screws on the link 7 Referto the maintenance calibration and flapper alignment procedures Supply Tubing and Positive Feedback Tubing Assemblies Note The following procedure requires that the controller be removed from the case Perform steps 1 through 7 found in the replacing the differential pressure unit procedure Then perform steps 1 through 3 found in the replacing the case and cover procedure 28 Instruction Manual 4194HS Controllers D200157X012 October 201 1 Refer to figure 26 for key number locations 1 Remove the nuts that hold the supply gauge tubing assembly key 39 or the positive feedback tubing assembly key 40 to the frame Remove the tubing 2 Install the replacement tubing assemblies 3 Apply the correct supply pressure and check for leaks Then remove pressure 4 Install the controller assembly into the case Slide the controller assembly down and make sure the O rings key 7 form a proper seal at the pressure connections Hold the frame in place 5 Install and tighten the nine self tapping screws key 38 into the frame 6 Mount the assembled controller on a pipestand as described in the Installation section 7 Connect supply output and process pressure piping to controller Proportional Band Knob Nozzle Pivot and Set Point Beam Assembly Note The following procedure requires that the controller be removed from the case Perform steps 1 through 7 found in the replacing the di
86. to the differential pressure unit instruction manual for the high and low pressure connections When installing process piping follow accepted practices to ensure accurate transmission of the process pressures to the differential pressure unit Install a three valve bypass shutoff valves vents drains or seal systems as needed in the process pressure lines If the instrument is located such that the adjacent process pressure lines will be approximately horizontal the lines should slope downward to the instrument for liquid filled lines and upward toward the instrument for gas filled lines This will minimize the possibility of air becoming trapped in the sensor with liquid filled lines or of condensate becoming trapped with gas filled lines The recommended slope is 83 millimeters per meter 1 inch per foot 4194HS Controllers Instruction Manual October 2011 D200157X012 Figure 4 Simplified Control Loop Diagram LOW PRESSURE CONNECTIONS HIGH PRESSURE CONNECTIONS SUPPLY PRESSURE LOW PRESSURE SIGNAL HIGH PRESSURE PIPING gt t EF ORIFICE PLATE NOTE 1 TO ALLOW A REAR VIEW OF THE CONTROLLER DIFFERENTIAL PRESSURE UNIT THE SCHEMATIC SHOWS PROCESS FLOW FROM RIGHT TO LEFT 22 SEE FIGURE 2 FOR LOW PRESSURE CONNECTIONS W5910 Vent Connection WARNING If a flammable gas is to be used as the supply pressure medium and the controller is in an enclosed area personal injury or property damage cou
87. to the installation procedures when reinstalling the unit Replacing Controller Parts Note Remove the controller and differential pressure unit to a maintenance area to perform the following procedures Refer to the installation procedures for process and supply tubing connections that must be disconnected when the differential pressure unit is removed from the pipestand Figure 2 shows the location of the set screws that connect the mounting bracket key 337 to the pipestand Refer to the installation procedures when reinstalling the unit 22 Instruction Manual 4194HS Controllers D200157X012 October 2011 Note Some of the following procedures require that the proportional band knob be adjusted to between DIRECT and REVERSE If this is done it will be necessary to set the proportional band knob to 400 direct or reverse action before replacing the proportional band indicator cover Process Pressure Scale CAUTION Take care not to bend the process indicator or the set point adjustment while performing the following procedure 1 Refer to figure 12 Adjust the set point adjustment manually or with the remote set point pressure to 50 percent of scale range 2 Remove four screws key 37 3 Slide the process scale key 61 so the top of the slot touches the set point adjustment Deflect the lower portion of the slot and carefully slide the scale upward and off clearing the set point adjustment as shown in figure 12 Figure
88. uction Manual October 2011 D200157X012 5 Increase the process differential pressure to the desired switching point at which the controller output signal switches from full supply pressure to zero pressure 6 Narrow or widen the proportional band slowly until the output signal switches from full supply pressure to zero pressure 7 Repeat steps 4 through 6 until the controller output switches at desired points 8 Observe the process pointer when the output switches at the lower switching point The process pointer indication should be within 2 percent of the set point indication Principle of Operation Overall Operation Refer to the schematic diagram in figure 8 Figure 8 Schematic of Fisher 4194HS Controller SET POINT POSITIVE FEEDBACK INDICATOR PROPORTIONAL BELLOWS d BELLOWS REVERSE ACTION QUADRANT PROPORTIONAL BAND ADJUSTMENT PROCESS POINTER Ne REMOTE SET POINT 75 CONNECTED HERE 5 S FEEDBACK INPUT ELEMENT MOTION FLAPPER CONNECTED HERE PIVOT DIRECT ACTION QUADRANT INPUT MOTION CONNECTING LINK FLAPPER DETAIL SN OUTPUT PRESSURE SUPPLY PRESSURE 255 p TO FINAL CONTROL E ELEMENT OUTPUT PRESSURE 2 d NOZZLE S POSITIVE FEEDBACK PRESSURE 2 T RELAY pesecc NOZZLE PRESSURE 222 SUPPLY PRESSURE B1546 2 The input element is connected to the process pointer and to the flapper by connecting links As t
89. ult in product damage as well as impaired performance 1 Decrease the remote set point pressure to 0 psig 2 Remove the tie bar key 106 3 Note where link A key 116 is connected Disconnect the link from the lever arm on the pivot assembly 4 Disconnect the drive flexure key 79 from the adjustment arm of the pivot assembly Be careful not to bend or kink the drive flexure 5 Remove the screw key 122 the washer key 123 and the nut key 124 that attach the quide flexure to the top of the pivot assembly 6 Remove the pivot screw and spring washer keys 109 and 112 and the mounting screw key 102 attaching the pivot assembly to the mounting plate Lift out the pivot assembly 7 Loosen the screw key 118 on the adjustment arm of the replacement pivot assembly and set the arm to the same length as the arm on the pivot assembly being replaced Tighten the screw 8 Toreplace the pivot assembly first put the spring washer on the screw Then install the screw through the pivot assembly into the mounting plate 9 Connect the guide flexure to the top of the new pivot assembly with the screw key 122 the washer and the nut as it was before 40 Instruction Manual 4194HS Controllers D200157X012 October 201 1 10 11 12 13 14 15 Increase the remote set point pressure to 50 percent of input span Connect the drive flexure to the arm on the new pivot assembly making sure it stays straight and horizontal
90. ws The proportional band knob should fall freely when the controller is in the upright position If it does not reposition the set point pivot assembly key 17 Tighten the relay nozzle tubing nut key 18 Apply full supply pressure and check for leaks Disconnect the supply pressure Install the set point beam bias spring key 28 into frame key 3 bore and onto spring seat on the set point beam assembly key 23 Attach link number 3 to the set point beam assembly Apply proper supply pressure to the controller and check for leaks Apply process differential pressure equal to the lower range value Adjust the proportional band to 5 percent direct acting and adjust set point to the maximum value on the process scale Controller output should be 0 psig Remove supply and differential pressure from the controller With zero pressure in both bellows loosen the two adjusting screws on link 4 and connect the link to the bellows bracket assembly allowing the link to find its free length Tighten the two adjusting screws 35 4194HS Controllers Instruction Manual October 2011 D200157X012 40 Determine the position of the set point beam shoe key 29 e f the position ofthe set point beam shoe was changed during this procedure relative to the set point beam assembly key 23 refer to the procedure for replacing proportional band knob nozzle pivot and set point beam assembly Perform steps 32 through 51 there e f the position of

Emerson Fisher 4194 Instruction Manual

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