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Emerson Fisher 4195K Instruction Manual

1. 43 p PS D he 40 No 57 3 39 3 SS i a O VIEW C C VIEW 4195KC CONTROLLERS 4195KC CONTROLLERS WITH ANTI RESET WINDUP SUFFIX LETTER F 56A9752 U SHT 3 111 Instruction Manual 4195K Controllers D200160X012 December 2012 Figure 7 1 Controller Assembly Drawings cont d 40 43 40 43 we TOST e 56A9752 U SHT2 y 56A9752 U SHT 3 56A9752 U SHT 2 SECTION B B SECTION B B SECTION B B VIEW B B 4195KA CONTROLLERS 4195KB CONTROLLERS 4195KC CONTROLLERS 4195KS CONTROLLERS H H 273 i S 910 N 3 312 316 138 34 131 56A9752 U SHT 4 MEME CONTROLLERS WITH AUTO MANUAL STATION SUFFIX LETTER E 112 Instruction Manual 4195K Controllers D200160X012 December 2012 Figure 7 1 Controller Assembly Drawings cont d
2. QP __ um WN 58A0708 E POSITIVE AND COMPOUND PRESSURE Remote Set Point Assembly suffix letter M key 62 figure 7 6 Key Description 12 screw hex socket 18 8 SST 2 req d 13 Plain washer 18 8 SST 3 req d 79 flexure SST 58A0710 C Key ee be J epo MA m 87 OON MIEWA 84 B E oy zn tae _ 9 um dn se 9s ia 9 s MP at 63 _ so 02 62 VACUUM Description Diaphragm capsule ass y 1 bar 12 psig span N09902 Nickel Alloy SST 2 bar 24 psig span N09902 Nickel Alloy SST Travel stop CF8 SST casting 119 4195 Controllers Instruction Manual December 2012 D200160X012 Figure 7 6 Remote Set Point Assembly 41 H8 109 04 go es VM AENEA fg ue me z T bi ESI i A soe 63 63 i PN UX 69 DE 09 E Ld A 116 rl 86 09 65 Na 2 35 Lr 01 08 H zm Li APPLY LUB SEALANT 36A6988 C Key 86 87 93 99 102 103 104 105 106 107 108 109 110 111 112 114 115 116 118 119 121
3. f 76 gt 74 qd 76 25 a 73 HI HE 56A9752 U SHT 4 VIEW H VIEW G CONTROLLERS WITH REMOTE SET POINT BOURDON TUBE SUFFIX LETTER M TRAVEL STOPS 339 56A9752 U SHT 5 56A9752 U SHT 3 VIEWM VIEWM EXTERNAL FEEDBACK FOR EXTERNAL FEEDBACK FOR 4195K BOURDON TUBE 4195K POSITIVE AND AND VACUUM PRESSURE CONTROLLERS COMPOUND PRESSURE CONTROLLERS 113 4195K Controllers December 2012 Instruction Manual D200160X012 Figure 7 2 Process and Set Point Indicator Assembly for Bourdon Tube Controllers SM 32B1532 A Process and Set Point Indicator Assembly key 56 figures 7 2 and 7 3 Key Description With capsular element assembly 101 Indicator ass y Note Individual parts are listed in the Indicator Assembly and the Capsular Element Assembly subsections of this parts list Key numbers for individual ass y parts also appear in figures 7 4 and 7 5 For use w o remote set pt For use w remote set pt 114 Key Description 113 Capsular element ass y Note Individual ass y parts for key 113 are listed in the Capsular Element Assembly subsection of this parts list Key numbers for individual ass y parts also appear in figure 7 4 127 Machine screw fill hd 18 8 SST 4 req d to attach the capsular element ass y to the indicator ass y key 101 Instruction Manual D200160X012 4195K Controllers
4. 48 Overall Operation 48 Remote Set Point Option 50 50 6 Maintenance Inspection and 51 51 Replacing Common Controller Parts 55 Replacing the Process Pressure Scale 55 Replacing the Relay 56 Replacing the Case and Cover 56 Replacing the lt 57 Replacing the Supply Gauge Proportional Reset Reset Valve and Positive Tubing Feedback lt 58 Replacing the Proportional Band Adjustment Knob Nozzle Assembly and Set Point Beam Assembly 58 Replacing the Flapper Assembly and Flapper Flexure Pivot Assembly 63 Replacing the Proportional or Reset Bellows eiennenn i PREE E MES 68 Replacing the Reset Restriction Valve 4195KB lt 70 Replacing the Rate Reset Valve Assembly 4195KC lt 71 Replacing the Anti Reset Windup suffix letter F Differential Relief Valve 72 Replacing the Anti Reset Windup suffix letter F Relief Valve Tubing Assembly 5 eres 72 Bourdon Tube Controller Maintenance and Calibration 73 Replacing the Bourdon Tube 73 Replaci
5. Pressure SCALE RANGE PART NUMBER Vacuum Pressure 150 to 0 mbar 1R0003X1632 Bar Scales 400 to 0 mbar 1R0003X0592 0 6to 0 1R0003X0602 1to0 1R0003X0612 5to0 1R0003X0322 In Scales 1000 1R0003X0332 20to0 1R0003X0342 30to0 1R0003X0192 Compound Pressure 50 to 100 mbar 1R0003X1572 150 to 250 mbar 1R0003X0632 0 2 to 0 4 1R0003X0642 Bar Scales 0 4to 0 6 1R0003X0652 0 6 to 0 8 1R0003X1582 1 to 0 6 1R0003X0662 1to 1 1R0003X1592 30 inches wc vac to 30 inches wc 1R0003X0252 5 inches Hg vac to 2 5 psig 1R0003X0352 Psiq Scales 10 inches Hg vac to 5 psig 1R0003X0362 3 15 inches Hg vac to 7 5 psig 1R0003X0262 20 inches Hg vac to 10 psig 1R0003X0372 30 inches Hg vac to 15 psig 1R0003X0272 Scale Range Part Number 150 mbar 1R0003X1562 0 to 400 mbar 1R0003X0422 0 to 0 6 1R0003X0402 Otol 1R0003X0432 02101 1R0003X1602 Oto 1 4 1R0003X1612 Oto 1 6 1R0003X0442 0to2 1R0003X1652 0 4to2 1R0003X1622 MM 0to 2 5 1R0003X0452 0to4 1R0003X0462 0to6 1R0003X0472 Oto 10 1R0003X0482 0016 1R0003X0492 Oto 25 1R0003X0572 0 to 40 1R0003X0502 0 to 60 1R0003X0512 00 100 1R0003X0522 Oto 160 1R0003X0532 010250 1R0003X0542 0 to 60 inch wc 1R0003X0202 0to5 1R0003X0212 Oto 10 1R0003X0222 31015 1R0003X0172 Oto 15 1R0003X0232 01020 1R0003X0242 6 to 30 1R0003X0182 0 to 30 1R0003X0032 Psig Scales 0 to 60 1R0003X0042 0to 100 1R0003X0052 Oto 200 1R0003X0062 0 to 300 1R0003X0072 0
6. December 2012 D200160X012 Figure 3 3 Fisher 4195KA Controller Calibration Adjustment Locations POINTER ZERO ADJUSTMENT POINTER ZERO ADJUSTMENT LOCKING SCREW REMOTE SET POINT ZERO ADJUSTMENT SUFFIX LETTER M REMOTESEEFOINE PROCESS POINTER ZERO DI MOEN SPAN ADJUSTMENT LOCKING SCREW SUFFIX LETTER M FRONT VIEW SCREW 1 SCREW 2 SCREW 3 39A1126 B PROCESS REMOTE SET POINT POINTER SPAN SPAN ADJUSTMENT ADJUSTMENT SUFFIX LETTER M 56487525 6730 SIDE VIEW OF SET POINT SIDE VIEW OF CONTROLLER PROCESS INDICATOR ASSEMBLY 20 SHOWING FLAPPER LEVELING SCREWS Instruction Manual 4195K Controllers D200160X012 December 2012 RWN o Ui Remove the two screws key 6 and lift off the proportional band indicator cover key 36 Setthe proportional band between DIRECT and REVERSE Apply process pressure equal to the process scale span lower limit The process pointer should indicate the process scale lower limit If not adjust the process pointer to the process scale lower limit by loosening the zero adjustment locking screw and turning the zero adjustment screw Tighten the zero adjustment locking screw Apply process pressure equal to the process scale span upper limit The process pointer should indicate the process scale upper limit If not adjust the span screw to correct one half of the error as follows clockwise to increase span for a low indication below the upper limit counte
7. PROCESS SPAN ADJUSTMENT Lf REMOTE SET POINT SPAN ADJUSTMENT SIDE VIEW OF SET POINT PROCESS INDICATOR ASSEMBLY SIDE VIEW OF CONTROLLER SHOWING FLAPPER LEVELING SCREWS Adjustments for 4195KS Controllers Manual Set Point The set point adjustment adjusts 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 until the pointer indicates the desired value of pressure on the process pressure scale Move the adjustment to the right to increase the set point and to the left to decrease it Adjusting the set point does not affect the differential gap setting Remote Set Point Option M CAUTION Do not move the set point manually on controllers with remote set point Doing so could damage the controller If the controller is equipped with 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 Proportional Band Differential Gap The proportional band knob adjusts width of the gap between switching points Rotate the knob until the desired value is opposite the line on the proportional band indicator cover Changing Controller Action Controller action can be switched from direct to reverse or vice versa by loosening the screws on the proportional band indicator cover and movin
8. 24 a 39 ps m 42 B oo 131 n E aD x eoue 9 F 18 SECTION D D Oa MEW CE VIEW C C A E MIS 4195KA CONTROLLERS 4195KS CONTROLLERS 109 4195 Controllers Instruction Manual December 2012 D200160X012 Figure 7 1 Controller Assembly Drawings cont d VIEW F F VIEW F F 56A9752 U SHT4 VIEW K K PROCESS CONNECTION ADAPTORS J VIEW E VIEW E 4195KB CONTROLLERS 4195KB CONTROLLERS WITH ANTI RESET WINDUP Ime G9 S SR SUFFIX LETTER F Ob SRI ia 1 A __ KH VIEW C C VIEW C C 4195KB CONTROLLERS 4195KB CONTROLLERS WITH ANTI RESET WINDUP SUFFIX LETTER F 56A9752 U SHT 2 110 Instruction Manual 4195K Controllers D200160X012 December 2012 Figure 7 1 Controller Assembly Drawings cont d 43 12 Ne pr VIEW F F 262 VIEW F F E VIEW E VIEWE 4195KC CONTROLLERS WITH 4195KC CONTROLLERS ANTI RESET WINDUP SUFFIX LETTER F
9. 293 294 298 306 312 R4190X0AM12 adj adjustment alt desgntn alternative designation 4190 Controller Auto Manual Retrofit Kit SST tubing ass y assembly Contains keys 138 273 312 313 conn s connection s 314 315 316 R4190X00512 diff differential as in process differential pressure 4190 Controller Case Handle Kit fdback feedback ore Contains lever and mounting hardware RA190X00H12 fill hd fillister head as in fillister head cap screw ext external 4190 Controller Repair Kit hd head as in machine screw head Contains keys 4 5 7 8 24 52 R4190X00C12 int internal OD outside diameter 4190 Controller Pointer and Bracket Repair Kit plo part of as in part of another assembly Contains pointer and bracket ass y pl plated as n plated steel three machine screws three washers R4190X00P12 pt point as in set point qty quantity 4190 Controller Relay Replacement Kit SST stainless steel Contains Relay Assembly includes keys 13 and 15 wl with and key 10 w o without 0 2 to 1 0 bar 3 to 15 psig RRELAYX83C2 0 4 to 2 0 bar 6 to 30 psig RRELAYX83D2 4195KBF Anti Reset Windup Retrofit Kit SST tubing Contains keys 44 and 55 R4190X00S22 105 4195K Controllers Instruction Manual December 2012 D200160X012 Controller Common Parts figure 7 1 Key Description Part Number 20 Plain washer 18 8 SST Used w key 19 2 req d Note 21 Nozzle ass y SST 22 Washer plastic 2 req d Part numbers are shown for recommend
10. 33 Anti Reset Windup suffix letter F Differential Relief Valve Calibration 35 Principle of Operation for 4195KB and KC Controllers 36 Overall Operation 36 Anti Reset Windup suffix letter F Operation e RR 39 Remote Set Point suffix letter M Operation 39 Auto Manual Station suffix letter E Operation xe bees eee ke rrr mmi 40 External Feedback Operation 41 5 4195KS Differential Gap Controllers Operating Information 42 Adjustments for 4195KS Differential Gap Controllers voee uer secre RENE ER 43 Manual Set Point 43 Remote Set Point Option M 43 Proportional Band Differential Gap 43 Changing Controller Action 43 es EMERSON www Fisher com Process Management 4195K Controllers December 2012 Instruction Manual D200160X012 Contents continued Auto Manual Switching Option E 44 Prestartup Checks 44 Startup vices tog Ret m qe tems 44 Calibration ert nem 45 Process Zero and Span Adjustment 45 Remote Set Point Zero and Span Option M 45 Setting Switching Points 46 Direct Acting Controllers 46 Reverse Acting Controllers 48 Principle of Operation
11. If necessary connect a pressure source to the process connection and adjust the process pointer to the last mark on the left side of the scale If the last scale mark is 0 bar 0 psig a pressure source is not required 9 The controller output pressure should be 0 bar 0 psig 10 Rotate the proportional band to 5 percent REVERSE 11 The controller output should be within 0 14 bar 2 psig of the supply pressure 12 If the controller output is within tolerance adjust the proportional band to 400 percent in the desired action Secure the proportional band indicator cover key 36 with the machine screws key 6 and go to the startup procedure If the controller output pressure is not within tolerance go to the 4195KB and KC calibration procedure for recalibration Startup for 4195KB and KC Controllers Perform the prestartup checks and if necessary calibrate the controller prior to this procedure o N RW Note When performing the startup procedures keep in mind that the initial settings are guidelines They will vary depending on the actual process being controlled 28 Instruction Manual 4195K Controllers D200160X012 December 2012 1 Besure the supply pressure regulator is delivering the proper supply pressure to the controller 2 For controllers with Manual set point Move the set point indicator to the desired set point Remote set point a See figure 2 5 for the location of the remote set po
12. D200160X012 December 2012 Figure 6 3 Proportional Band Adjustment and Set Point Beam Details RELAY NOZZLE TUBING RAT CAP May 18 SCREW ERING Pi KEY 19 KEY 27 RETAINING CLIP T KEY 26 O RING PROPORTIONAL BAND ADJUSTMENT KEY 25 NES PLASTIC WASHER PIVOT ASSEMBLY A 7 CS KEY 22 5 KEY 17 NS SEFPOINT NOZZLE BEAM SHOE ASSEMBLY SET POINT KEY 21 ES BEAM ASSEMBLY KEY 29 KEY 23 EXPLODED VIEW FLAPPER RETAINING CLIP E RING CAP PROPORTIONAL BAND ADJUSTMENT KNOB RM SET POINT BEAM BIAS SPRING SHOE ADJUSTMENT SCREWS SET POINT SET POINT RELAY NOZZLE BEAM ASSEMBLY BEAM SHOE TUBING ASSEMBLY ASSEMBLED VIEW CONTROLLER REMOVED FROM CASE 4194 7 While holding the proportional band adjustment knob remove the screw and washer keys 19 and 20 that hold the relay nozzle tubing assembly key 18 to the frame 8 Remove the proportional band adjustment knob relay nozzle tubing assembly and set point beam assembly from the controller 59 4195 Controllers Instruction Manual December 2012 D200160X012 9 10 11 12 13 14 15 Remove the relay nozzle tubing assembly key 18 from the set point beam assembly key 23 Remove the E ring key 27 from the nozzle assembly key 21 Remove the nozzle assembly key 21 and plastic washer key 22 from the bottom of the set point beam assembly key 23 Remove the retaining clip key 26 Rem
13. 3 Normal m3 hr Normal cubic meters per hour 0 C and 1 01325 bar absolute Scfh Standard 4 Without auto manual station With auto manual station air consumption is 0 28 normal m3 hr 10 0 Scfh for either output range 5 Also use these temperatures for transportation and storage limits cubic feet per hour 60 F and 14 7 psia Table 1 2 Available Configurations for Fisher 4195KA 4195KB 4195KC and 4195KS Controllers MODES OPTIONS Proportional Proportional Proportional Internal 2 CONTROLLER NUMERI Only Plus Reset PUE Differential Auto Manual EI PODA One Mode Two Mode Gap Controller Station ingup Three Mode F M Controllers Controllers E Controllers 4195KA X 4195 X X ELIKA 4195KAM X um 225 X 4195KAME X X m X 4195KB X 4195KBE X aoe X 2 E 4195KBF X ns des X 225 4195 X srr X X 227 412KB 4195KBM X 222 liz M X 4195KBME X ges zs X PS X 4195KBFM X de ee p X X 4195KBFME X zm X X X 4195KC X 4195 X m X P eee 4195KCF X ees dee X zs 4195KCFE X X X 225 41998C 4195KCM X See oe ee X 4195KCME X X e X 4195KCFM x nae TA X X 4195KCFME Sus X fs X X X 4195KS X 4195KSE
14. 8 Push the switch lever down using the lever spring seat key 301 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 the Loader Range Spring Diaphragm Assembly Ball Seat Tubing and Ball Refer to the Maintenance WARNING on page 51 102 Instruction Manual 4195K Controllers D200160X012 December 2012 Refer to figure 7 7 for key number locations Disassembly 1 Remove the auto manual station from the controller as described in steps 1 through 4 of the replacing the auto manual station procedure 2 Remove the tubing assembly key 309 A WARNING To avoid personal injury caused by preload from the range spring key 283 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 upper 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 s
15. Perform the appropriate calibration procedure in Section 3 4 or 5 Replacing the Switch Body Assembly Lever O Ring Switch Body O Ring and Tubing Assembly WARNING Refer to the Maintenance WARNING on page 51 Refer to figure 7 7 for key number location Disassembly 1 Remove the auto manual station from the controller as described in steps 1 through 4 of the replacing the auto manual station procedure 2 Loosen the two screws key 288 and remove the lever cover plate key 305 A WARNING The lever spring key 302 is under preload To avoid personal injury or losing parts carefully disassemble the auto manual station 3 Using a 1 16 inch 1 5 mm punch push the groove pin key 303 out toward the surface of the lever cover plate 4 Remove the switch lever key 304 lever spring key 302 and lever spring seat key 301 5 Remove the tubing assembly key 309 A WARNING The switch body springs key 295 are under preload To avoid personal injury or losing parts carefully separate the switch body assembly from the loader assembly 6 Loosen the two screws key 290 and separate the switch body assembly key 291 from the loader assembly key 282 4195 Controllers Instruction Manual December 2012 D200160X012 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 and remove the closing plate key 307 and the closing plate g
16. 10 Increase the process pressure or vacuum for a vacuum controller to the controller until the controller output pressure balances at 0 4 bar 6 psig for a 0 2 to 1 0 bar 3 to 15 psig output range or 0 8 bar 12 psig for a 0 4 to 2 0 bar 6 to 30 psig output range Turn the reset adjustment to the CLOSED 4195KB controllers or OFF 4195KC controllers position Increase the controller output pressure in small steps approximately 0 04 bar 0 5 psig by changing the process pressure to the controller or by changing the controller set point After each change in process pressure or set point the controller output pressure should quickly change and then stabilize at the new value Continue to change the controller output pressure in 0 04 bar 0 5 psi steps and check the output pressure after each step to make sure it stabilizes At some point the controller output will start to ramp upward to supply pressure with no further change to the controller input or set point Record the controller output pressure where this ramping action begins because this is the point at which the differential relief valve has relieved To obtain the differential relief valve differential setting calculate the difference between the original controller output pressure in step 7 and the controller output pressure recorded in step 10 If the differential pressure calculated in step 11 is incorrect for the application adjust the differential pressure by
17. X X E vee oo 4195KSM e et x 59 X 4195KSME zt X X X 1 Reverse acting constructions are designated by the suffix letter R added to the type number Instruction Manual 4195K Controllers D200160X012 December 2012 Table 1 3 Process Sensor Capsular Element Pressure Ratings CAPSULE CAPSULAR SPAN OPERATING RANGE OPERATING MATERIAL STANDARD RANGES Min Max Min Max LIMIT 2 0 to 150 mbar 100 mbar 160 mbar 350 mbar 350 mbar 510 mbar 0 to 400 mbar 350 mbar 700 mbar 1 bar 1 bar 1 5 bar 0 to 0 6 bar 0 35 bar 0 7 bar 1 bar 1 bar 1 5 bar 0 2 to 1 bar 0 4 bar 0 8 bar 1 bar 1 4 bar 2 bar Positive pressure Oto 1 bar 0 5 bar 1 bar 1 bar 1 4 bar 2 bar Oto 1 4 bar 0 7 bar 1 4 bar 1 bar 1 7 bar 2 5 bar Oto 1 6 bar 1 bar 2 bar 1 bar 2 4 bar 3 5 bar 0 4 to 2 bar 0 8 bar 1 6 bar 1 bar 2 bar 3 bar 0 to 2 bar 1 bar 2 bar 1 bar 2 4 bar 3 5 bar 150 to 0 mbar 85 mbar 170 mbar 350 mbar 350 mbar 510 mbar 340 to 0 mbar 170 mbar 340 mbar 480 mbar 480 mbar 724 mbar STC Ants Vacuum 400 to 0 mbar 350 mbar 700 mbar 1 bar 1 bar 1 5 bar 0 6 to 0 bar 0 35 bar 0 7 bar 1 bar 1 bar 1 5 bar 1 to 0 bar 0 5 bar 1 bar 1 bar 1 4 bar 2 bar 50 to 100 mbar 100 mbar 160 mbar 350 mbar 350 mbar 510 mbar 175 to 175 mbar 175 mbar 350 mbar 480 mbar 480 mbar 724 mbar 150 to 250 mbar 350 mbar 700 mbar 1 bar 1 bar 1 5 bar 2 d 0 2 to 0 4 bar 0 35 bar 0 7 bar 1 b
18. turning the differential relief valve adjustment screw shown in figure 4 3 Turn the screw clockwise to decrease the 35 4195 Controllers Instruction Manual December 2012 D200160X012 13 differential pressure or counterclockwise to increase the differential pressure The differential relief valve is set at the factory to relieve at approximately 0 4 bar 5 psi differential pressure Repeat steps 7 through 12 until the required differential pressure is obtained Calibration for the differential relief valve to relieve on falling controller output pressure 1 Provide a means of measuring the controller output pressure by connecting the controller output to a pressure gauge open loop conditions must exist Do not apply supply pressure at this time Setthe reset adjustment to 0 01 minutes per repeat wide open and the rate adjustment 4195KC controllers only to the OFF position Foracontroller with manual set point move the set point indicator to the mid scale mark on the process scale For a controller with remote set point adjust the remote set point pressure until the set point indicator is at the mid scale mark on the process scale Setthe proportional band to 100 percent in either the DIRECT or REVERSE action depending on the application requirements Refer to figure 4 3 for the location of the anti reset windup differential relief valve For the differential relief valve to relieve on falling control
19. 27 28 29 30 62 e following procedure steps 22 through 28 matches the process pointer motion to the set point indicator motion so the ntroller will control at set point at all positions on the process scale Setthe proportional band to 40 percent in REVERSE or DIRECT depending on the desired controller action Adjust the set point to the lower limit on the process scale Disconnect link 1 from the input element noting the hole from which it is removed for capsular input elements and tape the process pointer to the lower limit on the process scale The output pressure may be anywhere between 0 2 to 1 0 bar 3 to 15 psig for a 0 2 to 1 0 bar 3 to 15 psig output signal range or between 0 4 to 2 0 bar 6 to 30 psig for a 0 4 to 2 0 bar 6 to 30 psig output signal range If the output is not within the specified range adjust the flapper leveling screw nearest the nozzle until the output is within the range specified Record the controller output pressure Adjust the set point to the upper limit on the process scale Remove the tape and move the process pointer until the controller output equals the pressure recorded in step 24 Note the process pressure indication The process pressure indication should be within 2 percent of the upper limit on the process scale If the process pressure indication in step 26 is greater than the upper limit of the process scale by 2 percent loosen the shoe adjustment screws key 30 sho
20. 4195 Controllers Instruction Manual December 2012 D200160X012 Note Any adjustment of the process pointer span adjustment screw requires readjustment of the process pointer zero adjustment screw When checking the zero and span adjustments ensure that the Bourdon tube does not contact the optional travel stops if used key 73 and 74 A WU N Remove the two screws key 6 and lift off the proportional band indicator cover key 36 Setthe proportional band adjustment between DIRECT and REVERSE Set the reset valve 4195KB and KC controllers only to 0 01 minutes per repeat Setthe rate 4195KC controllers only to OFF Foracontroller with manual set point move the set point indicator to the mid scale mark on the process scale For a controller with remote set point adjust the remote set point pressure until the set point indicator is at the mid scale mark on the process scale Apply process pressure equal to the mid scale value of the process scale span 7 The process pointer should be aligned with the pointer subassembly as shown in figure 6 15 If not loosen the zero adjustment locking screw and adjust the zero adjustment screw to align the process pointer with the pointer subassembly Tighten the zero adjustment locking screw The process pointer should indicate mid scale 3 percent of the process scale span If not loosen the screws in link 1 and adjust the length so that the process pointer point
21. Squeeze the adjustable set point pivot assembly against the set point beam assembly Check to be sure the nozzle is still centered on the flapper and tighten the machine screw key 19 If necessary loosen both machine screws key 19 to allow slightly moving the adjustable set point pivot assembly set point beam assembly and the relay nozzle tubing assembly as a unit to center the nozzle on the flapper After centering the nozzle tighten the two machine screws Instruction Manual 4195K Controllers D200160X012 December 2012 15 Turn the proportional band adjustment knob to 5 percent DIRECT Refer to figure 6 6 to locate the locking nut on the adjustable set point pivot assembly Loosen the locking nut and back out the set screw slightly so that the set point beam assembly falls under its own weight when pivoted upward Also maintain a minimum side play between the adjustable set point pivot assembly and the nozzle tubing assembly Tighten the locking nut Figure 6 4 Proportional Band Adjustment Knob Figure 6 5 Nozzle Flapper Positioning Setting HOLE FLAPPER W3761 W3449 Figure 6 6 Adjustable Set Point Pivot Assembly Locking Nut Location LOCKING ADJUSTABLE SET POINT NUT PIVOT ASSEMBLY SW qo 8 SCREW AND WASHER SCREW AND WASHER KEYS 19 AND 20 lt 2 KEYS 19 AND 20 lt T NOTES 1 gt SCREW INSERTED INTO THE ADJUSTABLE SET POINT PIVOT ASSEMBLY 2 gt SCREW INSERTED INTO THE RELAY NOZZLE T
22. 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 Instruction Manual D200160X012 4195K Controllers December 2012 Table 1 1 Specifications Available Configurations See table 1 2 Input Signal Process Sensor Range Lower and Upper Range Limits See tables 1 3 and 1 4 Maximum Allowable Operating Limits See tables 1 3 and 1 4 Output Signal Proportional Only Proportional Plus Reset or Proportional Plus Reset Plus Rate Range 0 2 to 1 0 bar or 0 4 to 2 0 bar 3 to 15 psig or 6 to 30 psig 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 sensed process pressure increases output pressure or reverse increasing sensed process pressure decreases output pressure Process Scale Standard scale is matched to the range of the sensing element with the exception of receiver controllers Optional scales are available Process Connections Standard 1 4 NPT internal stainless steel all input ranges Optional 1 2 NPT see table 1 5 Supply and Output Connections 1 4 NPT internal Supply Pressure Requirements 2 See table 1 6 Supply Pressure Medium Air or natural gas Air Supply pressure must be clean dr
23. 120 Description Travel stop nut 30300 303 SST Set screw hex socket 18 8 SST Union 531600 316 SST Plain washer 18 8 SST Machine screw fill hd 18 8 SST 4 req d Machine screw pan hd 18 8 SST 2 req d Remote set pt tubing ass y S30400 304 SST Pedestal ass y SST Tie bar G10100 pl steel Spring pl steel Zero adj screw 530300 303 SST Pivot screw 530300 303 SST Zero adj bracket 530400 304 SST Mounting plate G10100 pl steel Spring washer pl steel Pivot clevis ass y A plastic SST Pivot clevis ass y B plastic SST Connecting link ass y aluminum bronze brass Cap screw hex socket 18 8 SST Guide flexure 30200 302 SST Drive bracket 530400 304 SST Key Description 122 Machine screw fill hd 18 8 SST 2 req d 123 Plain washer 18 8 SST 124 Hex 18 8 SST 125 Spacer A92011 aluminum 126 Connecting link aluminum bronze brass 134 Diaphragm ass y extension A92011 aluminum 139 Machine screw fill hd 18 8 SST 3 req d 141 Adj arm S30400 304 SST 311 Anti seize sealant not furnished with controller Auto Manual Station suffix letter E figure 7 7 274 Lower loader ass y aluminum 275 Spring seat screw pl steel 276 Valve plug spring K08500 pl steel 277 Valve plug 18 8 SST 278 Tube plastic 279 Ball SST 280 Ballseat nitrile 2 req d 281 Diaphragm ass nitrile aluminum 282 Loader ass y aluminum plastic 283
24. A pressure imbalance forces the ball to one end of the tube where it forms a seal blocking air flow through the tube 40 Instruction Manual 4195K Controllers D200160X012 December 2012 External Feedback Operation External feedback is available for all 4195KB controllers Controllers with this option have an external connection on the bottom of the controller case as shown in figure 2 5 This connection breaks the positive feedback reset loop inside the controller and brings it outside as shown in figure 4 9 The connection allows the positive feedback loops of two controllers primary and secondary to be tied together when the controllers are used in an override application When connected the secondary controller tracks the primary controller minimizing reset windup Figure 4 9 Schematic of External Feedback Option TO RESET TO BELLOWS NOZZLE OUTPUT d RESET VALVE RELAY Co TO PROPORTIONAL SUPPLY BELLOWS Y PRESSURE EXTERNAL FEEDBACK TO OUTPUT OF HIGH OR LOW SELECT RELAY NOZZLE PRESSURE SUPPLY PRESSURE RESET PRESSURE ERES OUTPUT PRESSURE ANN SELECT RELAY OUTPUT 47A0975 A A3342 1 41 4195K Controllers Instruction Manual December 2012 D200160X012 Section 5 4195KS Differential Gap Controllers Operating Information This section includes descriptions of adjustments and procedures for prestartup and startup Location of adjustments is shown in figures 5 1 and 5 2 To better underst
25. Instruction Manual 4195K Controllers D200160X012 December 2012 Replacing Common Controller Parts A WARNING To avoid personal injury or property damage caused by the uncontrolled release of pressure be sure any trapped process pressure is properly vented from the controller Vent any supply pressure from the controller before disassembly Replacing the Process Pressure Scale WARNING Refer to the Maintenance WARNING on page 51 CAUTION To prevent the pointer or set point indicator from rubbing on the cover or scale and producing an inaccurate indication take care not to bend the process pointer or the set point indicator while performing the following procedure Refer to figure 6 1 Figure 6 1 Changing the Scale W3492 DEFLECT LOWER PORTION OF THE SLOT AND LIFT THE SCALE UP AND OFF 1 Adjust the set point indicator either manually or with the remote set point pressure to the mid scale mark on the process scale 2 Remove the four self tapping screws key 37 3 Slide the process scale key 61 downward so that the top of the slot touches the set point indicator Deflect the lower portion of the slot outward and carefully slide the scale up and off clearing the set point indicator as shown in figure 6 1 4 To install the replacement scale deflect the lower part of the slot slightly so that the scale slides downward over the set point indicator and under the process pointer 55 4195 Controllers Instr
26. cap the nozzle and check for leaks Remove the supply pressure 10 Position the controller assembly in the case and start but do not tighten the nine mounting screws Slide the controller assembly down to assure an O ring seal at the pressure connections along the bottom of the case Hold the controller assembly in place while tightening the nine mounting screws 11 Perform the controller calibration procedures and if necessary the appropriate remote set point calibration procedure in Section 4 12 Mountthe controller as described in the Installation section 13 Connect the external piping to the controller Replacing the Rate Reset Valve Assembly 4195KC Controllers A WARNING Refer to the Maintenance WARNING on page 51 Note Read this entire procedure before removing any parts Refer to the 4195KC portion of figure 7 1 for key number locations 1 Remove the controller assembly from the case by performing steps 1 through 3 of the case and cover replacement procedure 2 Remove the two machine screws key 71 on the side of the rate reset valve assembly key 262 3 Gently pull the rate tubing assembly away from the rate reset assembly and remove the gasket key 5 from the side of the rate reset assembly 4 Unscrew the nut holding the reset tubing assembly key 43 into the rate reset valve assembly 5 Unscrew the nut holding the proportional tubing assembly key 40 into the rate reset assembly 6 For controllers wi
27. pan hd 18 8 SST 2 req d 309 Tubingassy SST 310 Lithium grease not furnished with controller 311 Anti seize sealant not furnished with controller Controller Mounting Parts Note Contact your Emerson Process Management sales office for any additional parts required for controller mounting Pipestand Mounting figure 2 2 66 Cap screw hex hd pl steel 3 req d 67 Lock washer pl steel 7 req d 68 Bracket pl steel 69 Clamp pl steel 2 req d Pipestand Mounting with Regulator figure 2 2 66 Cap screw hex hd pl steel 3 req d 67 Lockwasher pl steel 7 req d 68 Bracket pl steel 69 Clamp pl steel 2 req d 362 Capscrew hex hd pl steel 2 req d 363 Lock washer 18 8 SST 2 req d 364 Hexnut A563 pl steel 2 req d 365 Tubing fittings 2 req d See fittings subsection 122 Key Description Panel Mounting figure 2 3 66 screw hex hd pl steel 3 req d 67 Lock washer pl steel 3 req d 68 Bracket A569 pl steel 70 Machine Screw rd hd pl steel 4 req d Wall Mounting figure 2 4 66 screw pl steel 3 req d 67 Lock washer pl steel 3 req d 68 Bracket pl steel Controller Mounting Parts for Actuator With Casing Mounted Controller Spacer spool steel 3 req d Cap screw hex hd pl steel 3 req d Lock washer pl steel 5 req d Mounting bracket A569 pl steel Cap screw hex hd pl steel 2 req d Mounting bracket G10100 pl steel For 657 667 size 80
28. 51 Remove the controller assembly from the case by performing steps 1 through 3 of the case and cover replacement procedure 2 Remove the two screws key 6 and lift off the proportional band indicator cover key 36 3 Disconnect link 3 from the set point beam shoe part of the set point beam assembly key 23 Refer to figure 6 3 for the link location Remove the set point beam bias spring key 28 Refer to figure 6 3 for the spring location Remove the screw and washer keys 19 and 20 that hold the adjustable set point pivot assembly key 17 to the frame 6 Remove the adjustable set point pivot assembly key 17 7 Unscrew the nut that secures the relay nozzle tubing assembly key 18 to the frame manifold key 135 Refer to 10 11 12 13 14 15 16 17 18 19 figure 6 3 While holding the proportional band adjustment knob remove the screw and washer keys 19 and 20 that hold the relay nozzle tubing assembly key 18 to the frame Remove the proportional band adjustment knob relay nozzle tubing assembly and the set point beam assembly from the controller Disconnect link 2 from the flapper assembly key 11 Refer to figure 6 7 for the link location Disconnect link 4 from the bellows bracket key 31 Refer to figure 6 7 for the link location Remove the two cap screws key 12 from the flexure pivot assembly key 9 See figure 6 8 for screw location Remove the flapper assembly a
29. 83 For the zero stop perform the following as appropriate e Ifthe lower limit of the capsular element range is 0 bar 0 psig adjust the process pressure to 0 bar 0 psig Slide the zero travel stop nut key 86 along the diaphragm assembly extension 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 position e Ifthe lower limit of the capsular element range is other than 0 bar 0 psig adjust the process pressure to 5 percent below the capsular element range lower limit and slide the travel stop nut key 86 along the diaphragm extension until it just touches the travel stop key 83 Tighten the set screw Increase the input pressure to the capsular element range lower limit and make sure the travel stop nut is not contacting the travel stop key 83 Aligning the Capsular Element Linkage 1 Adjust the process pressure to 75 percent of the capsular element range The drive flexure key 79 should be straight and horizontal If it is not proceed as follows a Loosen the screw on the pivot adjustment arm on the long pivot clevis assembly key 78 and the two screws mounting the drive flexure b Adjust the length of the pivot adjustment arm so that the drive flexure is parallel to the centerline of the capsules Tighten the screw to set the length of the pivot adjustment arm in that position Note See figure 6 20 The adjustment arm of the long pivot cl
30. Adjusting the set point does not affect the proportional band setting 4195K Controllers Instruction Manual December 2012 D200160X012 Remote Set Point suffix letter M Adjustment CAUTION Do not manually move the set point indicator on controllers with remote set point Manually moving the set point indicator could damage the controller If the controller is equipped with remote set point suffix letter M 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 Proportional Band Adjustment PB ADJ The proportional band determines the controller output sensitivity The proportional band adjustment is marked in percentages of process pressure required to drive the controller from zero output to full output To adjust the proportional band open the controller cover and locate the proportional band adjustment PB ADJ knob Rotate the knob until the desired value is opposite the line on the proportional band indicator cover Changing Controller Action To change the controller action from direct to reverse or vice versa loosen the screws on the proportional band indicator cover Lift the cover out as shown in figure 3 2 and rotate the proportional band adjustment to the desired action Setting the proportional band to the values in the white portion of the adjustment provides direct controller action setting proportional band in the
31. December 2012 Figure 7 3 Process and Set Point Indicator Assembly for Capsular Element Controllers Positive and Compound Pressure Shown 24o WE p C 27 36 6986 Key Description With Bourdon tube 101 Indicator ass y Note Individual ass y parts for key 101 are listed the Indicator Assembly subsection of this parts list Key numbers for individual ass y parts also appear in figure 7 4 For use w o remote set pt For use w remote set pt Recommended spare parts Key Description Part Number 379 Process Tube Retainer 530400 304 SST 380 Machine screw pan hd 18 8 SST 381 Process tubing SST 382 Linkass steel SST 383 Bourdon tube See Key 383 table 384 Screw self tapping pl steel 2 req d 115 4195K Controllers December 2012 Instruction Manual D200160X012 Key 383 Bourdon Tubes BAR RANGE PSIG RANGE PART NUMBER 531600 316 SST Bourdon Tube Oto 1 6 or 0 to2 0 to 30 32B4589X012 0 to 4 or0to2 5 0 to 60 32B4589X022 0to6 00100 32B4589X032 0to 10 0 to 200 32B4589X042 01016 00300 32B4589X052 0 to 40 or 0 to 25 0 to 600 32B4589X062 0 to 60 0 to 1000 32B4589X072 0 to 100 0 to 1500 32B4589X082 0 to 160 0 to 3000 32B4589X092 0 to 250 or 0 to 300 0 to 5000 32B4589X102 Indicator Assembly key 101 figure 7 4 Key Description N
32. If installing into an existing application also refer to the WARNING at the beginning of the Maintenance section of this instruction manual Controller Mounting Orientation Mount the controller with the housing vertical as shown in figure 2 1 so the vent points down Figure 2 1 Typical Actuator Mounting FISHER 657 ACTUATOR 4195K CONTROLLER FILTER REGULATOR MOUNTING W8462 1 PLATE Pipestand Mounting Refer to figure 2 2 Pipestand mounting parts are provided to mount the controller to a 2 inch nominal pipe Attach a bracket key 68 to the controller with cap screws key 66 and lock washers key 67 Attach two clamps key 69 to the bracket and fasten the controller to the pipe 4195 Controllers Instruction Manual December 2012 D200160X012 Figure 2 2 Pipestand Mounting HEX HEAD CAP SCREW REGULATOR KEY 66 HEX HEAD CAP SCREW LOCKWASHER KEY 362 ses KEY 67 BRACKET HEX NUT KEY 68 KEY 364 LOCKWASHER KEY 363 PIPE CLAMP KEY 69 ELBOW KEY 365 VERTICAL PIPE HEX HEAD CAP SCREW KEY 362 LOCKWASHER PIPE CLAMP KEY 363 KEY 69 HEX NUT KEY 364 HEX HEAD BRACKET CAP SCREW KEY 68 KEY 66 LOCKWASHER KEY 67 ELBOW KEY 365 49A3196 A HORIZONTAL PIPE Panel Mounting Using the dimensions shown in figure 2 3 cut a hole in the panel surface Slide the controller into the hole and attach the bracket key 68 to the
33. Input element or linkage failure 6 1 Measure the output with an external pressure gauge 6 2 Check with an external source 6 3 Adjust proportional band setting to 10 Manually cap the nozzle Output should increase 6 4 Inspectthe element for alignment and loose screws 6 1 Replace the gauge if it is defective 6 2 Repair or replace the supply pressure regulator if necessary Replace the supply pressure gauge if necessary 6 3 Usea narrower proportional band setting 6 4 Repair or replace parts as necessary continued 53 4195K Controllers Instruction Manual December 2012 D200160X012 Table 6 1 Troubleshooting Chart continued Fault Possible Cause Check Correction 6 Controller will not attain full output range continued 6 5 Nozzle pressure leak 6 6 Leakin nozzle pressure tubing 6 7 Relay malfunction 6 5 Check for nozzle tubing leaks with a water bottle and soap solution with the nozzle capped by the flapper Press the nozzle cap key 23 gently to ensure the nozzle assembly is sealing Ensure the relay nozzle tubing nut key 18 is tight and the manifold screws keys 34 and 131 are tight 6 6 Using soap solution check for leaks in the nozzle tubing assembly 6 7 Manually push the flapper away from the nozzle The output pressure should be zero Cap the nozzle The output should increase rapidly to within 35 mbar 0 5 psig of the supply pressure 6 5 Tighten the relay nozzl
34. Parts voi up MeAFe ER Abbreviations Used In The Parts List Controller Common Parts Process and Set Point Indicator Indicator Assembly Capsular Element Assembly Remote Set Point Assembly suffix letter Auto Manual Station suffix letter E Controller Mounting Parts Pipestand Mounting Pipestand Mounting with Regulator W6831 NAMEPLATE Panel Wall Controller Mounting Parts for Actuator with Casing Mounted Controller Controller Mounting Parts for Actuator with Yoke Mounted Controller Regulator Mounting Parts Regulator Mounting Parts for Casing Mounted Regulator Regulator Mounting Parts for Yoke Mounted Regulator Mounting Bracket Not Required Regulator Mounting Parts for Yoke Mounted Regulator With Mounting Bracket tere T Peres 4195 Controllers Instruction Manual December 2012 D200160X012 Section 1 Introduction Scope of Manual This instruction manual provides installation operating calibration maintenance and parts ordering information for Fisher 4195KA KB KC and KS gauge pressure indicating controllers Portions of this manual apply only to specific 4195K controller confiqurations These configur
35. Range spring SST 284 Range spring cup pl steel Instruction Manual D200160X012 4195K Controllers December 2012 Figure 7 7 Auto Manual Station Assembly SECTION A A mA lovi 4 SECTION C C APPLY LUB SEALANT 48A2905 A Key Description 285 Spring adj screw pl steel 286 Retaining ring pl steel 287 Loader knob plastic 288 Machine screw rd hd 18 8 SST 2 req d 289 Machine screw fill hd 18 8 SST 4 req d 290 Machine screw fill 530200 302 SST 2 req d Recommended spare parts Key 291 292 293 294 295 296 297 SECTION B B Description Switch body ass y aluminum nitrile O ring nitrile O ring nitrile O ring nitrile Switch body spring K08500 pl steel 2 req d Ball SST 2 req d Lever ass y SST Part Number 1U2398X0032 11A8741X052 13A1584X012 121 4195K Controllers December 2012 Instruction Manual D200160X012 Key Description Part Number 298 O ring nitrile 1E222606992 299 Rocker A96061 aluminum 300 Clip SST 301 Leverspring seat SST 302 Leverspring K08500 pl steel 303 Groove pin SST 16A6380X012 304 Switch lever polycarbonate SST 305 Switch lever cover plate aluminum chromate 306 Closing plate gasket chloroprene 18A2898X012 307 Closing plate SST 308 Machine screw
36. Remote Set Point 92 Replacing Remote Set Point Assembly Parts 94 Replacing Pivot Assembly A key 114 94 Replacing Pivot Assembly B key 115 95 Replacing the Drive Flexure 95 Replacing the Remote Set Point Tubing 96 Replacing Link A 96 Replacing LinkB 96 Remote Set Point suffix letter M Maintenance Calibration 96 Precalibration Procedure 96 Aligning the Flexures 97 Setting the Travel Stops 97 Aligning the Linkage 98 Remote Set Point Zero and Span Adjustment 98 Remote Set Point Linearity Adjustment 99 Auto Manual Station suffix letter E Maintenance 100 Replacing the Auto Manual Station 100 Replacing the Switch Body Assembly Lever O Ring Switch Body O Ring Tubing Assembly 101 Replacing the Loader Range Spring Diaphragm Assembly Ball Seat Tubing and Ball 102 Replacing the Loader Valve Plug and Valve Plug Spring 103 Instruction Manual D200160X012 4195K Controllers December 2012 Figure 1 1 Fisher 4195K Gauge Pressure Controllers W5663 1 Contents continued 7 Parts Parts Ordering Parts Kits 1 LEAL Y eperIY
37. SUFFIX LETTER F ONLY CONTROLLER SHOWING 6731 FLAPPER LEVELING SCREWS 81 4195 Controllers Instruction Manual December 2012 D200160X012 15 Apply process pressure equal to the mid scale value of the process scale span The process pointer should indicate mid scale 2 percent of the process scale span If the process pointer error is 2 percent or less proceed to step 17 If the process pointer error is greater than 2 percent loosen the two Bourdon tube mounting screws key 384 figure 7 2 Also loosen the two screws keys 379 and 380 figure 7 2 holding the process tubing retainer Slide the Bourdon tube up or down and tighten the four screws loosened in step 15 Several tries may be required to determine the direction in which to move the Bourdon tube to obtain the required accuracy Return to step 5 Adjust the process pointer to within 1 percent of the mid scale mark by loosening the zero adjustment locking screw and adjusting the zero adjustment screw Tighten the zero adjustment locking screw This distributes the error over the entire process scale and keeps all points within 1 percent of the process scale span Adjust the process pressure to the lower and upper limits of the process scale span to make sure the process pointer is still within 1 percent of the lower and upper scale limits Perform the flapper alignment procedure and if necessary the appropriate remote set point calibration procedure in
38. The vent must be protected against the entrance of any foreign material that could plug it or if a remote vent is not required the vent opening in the case 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 4195K Controllers Instruction Manual December 2012 D200160X012 Section 3 4195KA Proportional Only Controllers Adjustments for 4195KA Controllers This section includes descriptions of adjustments and procedures for prestartup startup and calibration Adjustment locations are shown in figures 3 1 and 3 3 To better understand the adjustments and overall controller operation refer to the Principle of Operation section and the schematic diagrams in figures 3 4 and 3 5 Unless otherwise noted key numbers given in this section are found in figure 7 1 Figure 3 1 Fisher 4195KA Controller Adjustment Locations METAL BALL SWITCHING ZONE INDICATOR LOADER KNOB AUTO MANUAL SWITCH SET POINT INDICATOR AUTO MANUAL STATION PROCESS POINTER SUFFIX LETTER E PROPORTIONAL BAND ADJUSTMENT PROPORTIONAL BAND INDICATOR COVER OUTPUT PRESSURE GAUGE W6832 Manual Set Point Adjustment Adjust the set point by moving the set point indicator until the line on the set point indicator is over the desired value on the process pressure scale Move the indicator to the right to increase the set point and to the left to decrease it
39. Then move the automatic manual switch to MANUAL Turn the loader knob clockwise to increase the controller output or counterclockwise to decrease it To switch from manual to automatic mode adjust the set point to move the ball into the switching zone Turn the switch to AUTO and adjust the set point to control the output When the auto manual switch is in AUTO adjusting the loader knob has no effect on the controller output When the auto manual switch is in MANUAL changing the set point has no effect on the controller output Prestartup Checks for 4195KA Controllers Refer to figure 3 1 for adjustment locations and refer to figure 7 1 for key number locations When performing the checks open loop conditions must exist An open loop exists when the controller output does not affect the input pressure or other control signal to the controller Note If the controller has the auto manual station suffix letter E be sure the controller is in the automatic mode before performing the prestartup checks 1 Provide a means of measuring the controller output pressure by connecting the controller output to a pressure gauge Connect supply pressure to the supply pressure regulator and be sure it is delivering the proper supply pressure to the controller Do not exceed the normal operating pressure in table 1 6 2 Fora controller 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
40. 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 proportional bellows and to the reset bellows The action of the proportional bellows quickly counteracts the flapper movement that resulted from the process pressure change and backs the flapper away from the nozzle Figure 4 5 Fisher 4195KB Controller Schematic SET POINT INDICATOR RESET BELLOWS REVERSE ACTION QUADRANT PROPORTIONAL PROPORTIONAL BAND ADJUSTMENT FEEDBACK PROCESS POINTER LINK REMOTE SET POINT V CONNECTED HERE FEEDBACK X INPUT ELEMENT MOTION FLAPPER CONNECTED HERE PIVOT 7 DIRECT ACTION QUADRANT INPUT MOTION FLAPPER DETAIL OUTPUT PRESSURE 7 TO FINAL CONTROL ELEMENT FLAPPER NOZZLE RELAY SUPPLY PRESSURE TO RESET 3 z BELLOWS PROPORTIONAL PLUS RESET CONTROL TO NOZZLE TO OUTPUT SUPPLY PRESSURE PROPORTIONAL di BELLOWS QOO RESET PRESSURE 46A9764 C B1908 4 DIFFERENTIAL RELIEF VALVE PROPORTIONAL PLUS RESET CONTROL WITH ANTI RESET WINDUP Pressure in the reset bellows opposes the action of the proportional bellows and slowly moves the flapper closer to the nozzle The result of this interaction is that when the process pressure changes p
41. amp 100 For all other types Cap screw hex hd pl steel 2 req d Hex nut pl steel 2 req d Washer pl steel 2 req d Washer G10100 pl steel 2 req d Controller Mounting Parts for Actuator With Yoke Mounted Controller figure 2 1 Spacer spool steel 3 req d Cap screw hex hd pl steel 3 req d Lock washer pl steel 5 req d Mounting bracket steel For 1061 w switches or manual operator For all other types Spacer spool steel 2 req d Cap screw hex hd pl steel 2 req d Recommended spare parts Instruction Manual D200160X012 4195K Controllers December 2012 Regulator Mounting Parts Description Regulator Mounting Parts for Casing Mounted Regulator Cap screw hex hd pl steel 2 req d Lock washer pl steel 2 req d Cap screw hex hd pl steel 2 req d Hex nut pl steel 2 req d Mounting bracket G10100 pl steel For 657 667 size 80 amp 100 For all other types Regulator Mounting Parts for Yoke Mounted Regulator Mounting Bracket Not Required Cap screw hex hd pl steel 2 req d Lock washer pl steel 2 req d Regulator Mounting Parts for Yoke Mounted Regulator With Mounting Bracket Cap screw hex hd pl steel 2 req d Lock washer pl steel 4 req d Cap screw hex hd pl steel 2 req d Hex nut pl steel 2 req d Mounting bracket G10100 pl steel For 1061 size 30 all shaft sizes For all other types Fittings Description Note The quantity shown make up the
42. arm to the same length as the arm on the pivot assembly being replaced Attach the replacement pivot clevis assembly to the mounting plate with the two mounting screws key 102 8 Loosely connect the drive flexure to the pivot adjustment arm on the new pivot clevis assembly See figure 6 20 The adjustment arm of the long pivot clevis assembly is connected to a shaft that turns on bushings at each end of the shaft In the next step position the shaft so that both bushings float inside the bearings and do not rest against the end of either bearing UJ NJ A o N 4195 Controllers Instruction Manual December 2012 D200160X012 Figure 6 20 Cutaway of Long Pivot Clevis Assembly 10 11 12 1 gt END BUSHING a P ADJUSTMENT ARM i SHAFT 1 END BUSHING BEARING NOTE 1 gt BEFORE TIGHTENING THE DRIVE FLEXURE MOUNTING SCREWS POSITION THE SHAFT SO THE END BUSHINGS FLOAT IN THE BEARINGS 26A9784 E A5682 Apply 75 percent of the capsular element range to the capsule The drive flexure should be straight and horizontal Before tightening the drive flexure cap screws key 12 hold the pivot shaft in the middle of the bushing end play Be sure neither bushing is resting against the inside end of either bearing Tighten the drive flexure cap screws to hold the pivot shaft in position Adjust the length of the pivot adjustment arm as needed until the dri
43. as shown in figure 6 3 o Move the set point indicator to the mid scale mark on the process scale 7 Apply process pressure to position the process pointer at the mid scale mark on the process scale 8 Adjust the proportional band to 5 percent DIRECT Turn flapper leveling screw 3 the screw nearest the nozzle until the nozzle just touches the flapper 9 Adjust the proportional band to 5 percent REVERSE Turn flapper leveling screw 1 the screw nearest the nozzle until the nozzle just touches the flapper 10 Flapper leveling screws 1 and 3 should protrude the same distance from the clinch nuts A clinch nut is shown in figure 6 16 11 If leveling screw 1 protrudes further than leveling screw 3 turn the link 3 adjusting screw counterclockwise If leveling screw 3 protrudes further than leveling screw 1 turn the link 3 adjusting screw clockwise 12 Repeat steps 8 through 11 until leveling screws 1 and 3 protrude an equal distance from the clinch nuts 13 Perform the controller calibration procedures and if necessary the appropriate remote set point calibration procedure in Section 3 4 or 5 Replacing Capsular Element Controller Link 4 1 Remove the two screws key 6 and lift off the proportional band indicator cover key 36 2 Disconnect link 4 from the bellows bracket key 31 and the flapper assembly key 11 3 Connect the replacement link to the flapper assembly so that the two adjusting screws on the link are neare
44. based lubricant not furnished with controller 318 Lubricant silicone not furnished with controller 339 External feedback ass y SST tubing For controllers w Bourdon tube or vacuum capsules For controllers w positive or w compound capsules 362 Spring retaining washer SST 365 Washer 18 8 SST 1P8453X0022 Recommended spare parts Instruction Manual 4195K Controllers D200160X012 December 2012 Figure 7 1 Controller Assembly Drawings SEE VIEWH SEE VIEW G B s D qc il i5 TON Bis ww Bo 365 8 VAN E A ANNE eS 318 one lt 5 4 v 15 ne Ke 7 50 poe E02 22 ay ae 63 E Pm ES G3 3 3II cH 2 58 OOS bas 2318 SECTION B B SEE VIEW E o Bd al vee DY 49 24 4 317 2 29 zu 20 84
45. black portion provides reverse controller action Figure 3 2 Changing Controller Action on Fisher 4195KA Controllers W3439 Bourdon Tube or Capsular Element Controllers for Positive or Compound Pressure e For direct control action An increasing sensed pressure increases output pressure e Forreverse control action An increasing sensed pressure decreases output pressure Capsular Element Controllers for Vacuum Pressure For direct control action An increasing sensed vacuum increases output pressure Instruction Manual 4195K Controllers D200160X012 December 2012 For reverse control action An increasing sensed vacuum decreases output pressure After changing the action tighten the screws on the proportional band indicator cover Switching The Auto Manual Station suffix letter E Note Switching the controller between automatic and manual or manual and automatic mode without balancing the outputs can disturb the process and cause controller cycling Refer to figure 3 1 if the controller has the auto manual station suffix letter E To switch from automatic to manual mode or from manual to automatic you must first balance the manual output with the controller output Two balance methods are available to equalize the manual output with the controller output 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
46. by changing the setting to a lower value faster reset Disturb the system again Continue this procedure until the system cycles When the system cycles multiply the reset time setting by a factor of three reset setting x3 and slow down the reset by changing the reset setting to the higher value The reset is now tuned Tuning rate action For a controller with rate 4195KC controllers adjust the rate toward the higher setting until cycling occurs When the system cycles divide the rate value by a factor of three rate setting 3 and decrease the rate by changing the setting to the lower value The rate is now tuned 7 Checkthe stability of the recommended proportional band setting by introducing a disturbance and monitoring the process 8 Once stable control is attained the process pointer and set point indicator should be in line If they are aligned return the set point to the desired value If they are not readjust the set point to the desired control point and proceed with step 9 9 If the process pointer is within 5 percent of the set point indicator turn the link 3 adjustment see figure 6 13 or 6 21 for location until the process pointer aligns with the set point indicator Turn the link 3 adjustment screw clockwise to increase the process indication or counterclockwise to decrease it If the process pointer is misaligned with the set point indicator by more than 5 percent of the scale span perform the calibration procedures f
47. difference between the recorded process pressure in step 25 and the process pressure in step 26 is larger than 1 percent of the process scale span proceed with step 28 If the difference is less than 1 percent go to step 33 28 Loosen the proportional bellows screw key 35 29 If the reading recorded in step 26 is greater than in step 25 adjust the reset gain screw key 34 one half turn in clockwise If the reading recorded in step 26 is less than in step 25 adjust the gain screw key 34 one half turn out counterclockwise 30 Tighten the proportional bellows screw key 35 31 Repeat steps 25 through 30 until the difference is less than 1 percent of the process scale span 32 If 1 percent of process scale span cannot be achieved by adjusting the gain screw key 34 loosen the machine screw key 35 attaching the reset bellows and slide it to the left if the reading in step 26 is greater than in step 25 orto the right if the reading in step 26 is less than in step 25 Tighten the screw and repeat steps 25 through 31 33 Remove the supply pressure the output measurement device and the regulated process pressure source 34 Position the controller assembly in the case and start but do not tighten the nine mounting screws Slide the controller assembly down to assure an O ring seal at the pressure connections along the bottom of the case Hold the controller assembly in place while tightening the nine mounting screws 35
48. for 4195KS Controllers It is recommended that the controller switching points be set as described in the calibration procedures 44 Instruction Manual 4195K Controllers D200160X012 December 2012 If they are used slowly open the upstream and downstream manual control valves in the pipeline and close the manual bypass valve Calibration of 4195KS Controllers 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 If the prestartup checks revealed faulty adjustment of the process indicator perform the calibration procedures These procedures are valid for either shop or field calibration provided that open process loop conditions exist Note If the controller has the auto manual option be sure the controller is in the automatic mode prior to performing the calibration procedures Process Zero and Span Adjustment Note Any adjustment of the pointer span adjustment screw will require readjustment of the pointer zero adjustment screw Refer to figure 5 1 for location of adjustments Remove the two screws key 6 and lift off the proportional band indicator cover key 36 Setthe proportional band between DIRECT and REVERSE Adjust the process pressure to the low limit of the input range A
49. gaskets keys 4 and 5 Inspect the gaskets keys 4 and 5 and O rings key 312 for wear Replace if necessary Assembly 1 Install the gaskets and tubing assembly to the frame Start but do not tighten the three screws keys 34 and 131 and the nut on the relay nozzle tubing assembly key 18 Install the switch manifold 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 the two screws keys 314 and 315 Do not tighten any screws 100 Instruction Manual 4195K Controllers D200160X012 December 2012 CAUTION In the next step take care to tighten the two screws keys 314 and 315 evenly Uneven tightening could damage the tubing assembly UJ 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 that the auto manual station contacts the three pads on the tubing assembly 4 Carefully tighten the remaining screws and nuts Plug the controller output connection and apply supply pressure to the controller Check for leaks 6 Position the controller assembly in the case and start but do not tighten the nine mounting screws Slide the controller assembly down to assure an O ring seal at the pressure connections along the bottom of the case Hold the controller assembly in place while tightening the nine mounting screws
50. hold pivot assembly A in this position Do not bend or twist the flexure when tightening the screws 12 Decrease the remote set point pressure to 0 bar 0 psig 13 Connect the end of link A key 116 to the pivot lever arm in the same holes noted in step 3 14 Replace the tie bar key 106 15 Perform the remote set point maintenance calibration procedure Perform the appropriate process indicator zero and span calibration and flapper alignment procedures in Section 3 4 or 5 Replacing Pivot Assembly B Key 115 1 Decrease the remote set point pressure to 0 bar 0 psig 2 Note the holes where links A and B are connected Disconnect links A and B keys 116 and 126 from the arms of pivot assembly B key 115 3 Remove the two screws key 102 that attach pivot assembly B to the mounting plate key 111 Remove the pivot assembly 4 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 5 Setthe replacement pivot assembly on the mounting plate and attach it with the two machine screws 6 Attach links A and B keys 116 and 126 to the arms of the replacement pivot assembly in the same holes noted in step 2 7 Perform the remote set point maintenance calibration procedure Perform the appropriate process indicator zero and span calibration and flapper alignment procedures in Section 3 4 or 5 Replacing t
51. is short process pointer indication is less than the process scale upper limit disconnect link 1 from the process pointer subassembly and move the link to the lowest hole the hole nearest the pointer pivot Return to step 9 b If the span is long process pointer indication is greater than the process scale upper limit disconnect link 1 from the process pointer subassembly and move the link to the highest hole hole furthermost from the pointer pivot and return to step 9 Instruction Manual 4195K Controllers D200160X012 December 2012 Figure 6 19 Fisher 4195K Controller Calibration Adjustment Locations un m EO 10 15 20 05 x 30 auto nl PSI o POINTER ZERO ADJUSTMENT i ZU POINTER ZERO ADJUSTMENT Pd LOCKING SCREW PROCESS POINTER SPAN ADJUSTMENT ANTI RESET WINDUP RELIEF VALVE lt 2 ANTI RESET WINDUP VALVE ADJUSTING lt 2 SCREW RATE RESET REMOTE SET POINT REMOTE SET POINT RESET ADJUSTMENT ADJUSTMENT ZERO ADJUSTMENT ZEROADJUSTMENT ADJUSTMENT lt T LOCKING SCREW vasos Wess FRONT VIEW 4195KB CONTROLLERS 4195KC CONTROLLERS SCREW 1 SCREW 2 SCREW 3 PROCESS POINTER SPAN ADJUSTMENT REMOTE SET POINT SPAN ADJUSTMENT SUFFIX LETTER M SIDE VIEW OF SET POINT PROCESS INDICATOR ASSEMBLY 59A9752 S SHT 1 B NOTES D T gt AVAILABLE ON 4195KB CONTROLLERS ONLY SIDE VIEW OF 2 AVAILABLE ON 4195KB AND KC CONTROLLERS
52. key 114 and allow the flexure to straighten itself Tighten the machine screw 3 If the flexure is not horizontal loosen the two machine screws key 139 and raise or lower the pedestal assembly key 105 until the guide flexure is horizontal Retighten the machine screws key 139 and ensure the diaphragm assembly extension key 134 is centered in the upper travel stop key 83 hole 4 The drive flexure key 79 should be straight If not proceed as follows a Loosen the screw key 118 on the adjustment arm of pivot assembly A key 114 and loosen the screws holding the drive flexure b Setthe length of the adjustment arm so that the drive flexure is parallel to the centerline of the diaphragm capsule assembly key 80 c Tighten the screw key 118 on the adjustment arm Note See figure 6 20 The adjustment arm of the remote set point pivot assembly 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 of either bearing d Hold the pivot assembly A shaft in the middle of the bushing end play Be sure neither bushing is resting against the inside end of either bearing e Tighten the screws that hold the drive flexure in place Setting the Travel Stops A WARNING Refer to the Maintenance WARNING on page 51 1 Loosen the set screw key 87 in the travel stop nut key 86 97
53. keys 73 and 74 with the machine screws keys 75 and 76 Do not tighten the machine screws key 75 that secure the upper travel stop If only the upper travel stop is installed go to step 10 Otherwise proceed with step 4 4 If the operating range lower limit is 0 bar 0 psig and a lower travel stop is installed adjust the lower travel stop adjustment so it does not interfere with the Bourdon tube Tighten the lower travel stop adjustment lock nut and proceed to step 10 If the operating range lower limit is other than 0 psig elevated zero perform steps 5 through 15 5 If the process scale lower limit is other than 0 psig adjust the process pressure to 5 percent of the process scale span less than the operating range lower limit see example at the beginning of this procedure Adjust the lower travel stop adjustment shown in figure 6 18 until it touches the Bourdon tube Tighten the lower travel stop adjustment lock nut N OD Increase the process pressure to the operating range lower limit 9 The Bourdon tube should not touch the lower travel stop If it does repeat steps 5 through 8 10 Apply process pressure to the controller equal to 105 percent of the process scale span 11 Slide the upper travel stop key 73 until it touches the Bourdon tube 12 Tighten the machine screws key 75 13 Decrease the process pressure to 100 percent of the process scale span 14 The Bourdon tube should not touch the upper travel
54. link 2 from the process pointer and from the flapper assembly key 11 Remove the link 3 Install the replacement link with the screw head nearest the process pointer as shown in figure 6 13 Connect the link to the process pointer only 4 The process pointer should be aligned with the pointer subassembly as shown in figure 6 15 If not loosen the zero adjustment locking screw and adjust the process pointer zero adjustment to align the process pointer and pointer subassembly Tighten the zero adjustment locking screw 5 Move the set point indicator either manually or with the remote set point pressure to the process scale lower limit and set the proportional band to 5 percent REVERSE The nozzle should not be touching the flapper If it is adjust flapper leveling screw 1 the screw nearest the nozzle until clearance is obtained 75 4195 Controllers Instruction Manual December 2012 D200160X012 6 7 Disconnect link 1 from the Bourdon tube and manually position the process pointer to the process scale upper limit Tape the pointer in this position Adjust the length of link 2 by turning the adjusting screw clockwise to increase the length or counterclockwise to decrease the length so that the pin on the end of the link is approximately one half of its diameter short of aligning with the hole in the flapper assembly as shown in figure 6 11 This adjustment provides the proper tension on the link to eliminate lost motion 8 C
55. 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 indicator parts also appear in figures 7 2 and 7 3 Process and set pt indicator ass y w Bourdon tube sensing element Process and set pt indicator ass y w capsular element ass y 58 Cap screw hex hd SST 2 req d for use w each pressure control block key 57 59 Hex reducing nipple use only when specified 1 2 NPT external All ranges up to 0 345 bar 0 5000 psig Steel SST 60 Reducing adaptor use only when specified 1 2 NPT internal All ranges up to 0 345 bar 0 5000 psig Steel SST 61 Process scale aluminum For indicator ass y key 101 107 4195K Controllers December 2012 Instruction Manual D200160X012 Key Description 62 Remote set pt suffix letter M Note The part numbers listed for key 62 are for the complete remote set point suffix letter M ass y Individual assembly parts are listed in the Remote Set Point Assembly subsection of the parts list Key numbers for individual ass y parts also appear in figure 7 6 N09902 Nickel 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 64 Machine screw fill hd 18 8 SST 4 req d to attach process and set pt indicator ass y key 56 to frame 65 Feedback link ass y aluminum brass SST 71 Machine screw fill hd 18 8 SST For all 4195
56. open loop conditions must exist Do not apply supply pressure at this time Note 4195KB and KC controllers with anti reset windup suffix letter F are supplied with two O rings key 52 valve cover key 51 and two machine screws key 53 Use these parts in the next step 1 For controllers with anti reset windup suffix letter F record the direction of the arrow on the anti reset windup relief valve key 55 Remove the relief valve and install the two O rings key 52 and valve cover key 51 supplied with the controller Secure the valve cover with the two machine screws key 53 provided 2 If necessary remove the two machine screws key 6 and lift off the proportional band indicator cover key 36 3 If the controller has the external feedback option available with the 4195KB only connect the controller output to the external feedback connection See figure 2 5 for the location of the output and external feedback connections 4 Provide regulated supply pressure to the controller Do not exceed the normal operating pressure in table 1 6 5 For a controller with manual set point move the set point indicator to the mid scale mark on the process scale For a controller with remote set point suffix letter M adjust the remote set point pressure until the set point indicator is at the mid scale mark on the process scale 6 Setthe reset adjustment to 0 01 minutes per repeat If the controller has rate 4195KC controllers
57. page 51 CAUTION Before performing this procedure be sure the replacement gauges are the correct range so that they are not damaged by overpressure 1 Unscrew the output pressure gauge or the supply pressure gauge key 46 from the frame key 3 2 Before installing the replacement gauge coat the threads on the gauge with a sealant such as key 311 or equivalent 3 Screw the replacement gauge into the frame 4 Apply the correct supply pressure and check for leaks with the nozzle capped for full output pressure 4195 Controllers Instruction Manual December 2012 D200160X012 Replacing the Supply Gauge Proportional Reset Reset Valve and Positive Feedback Tubing Assemblies A WARNING Refer to the Maintenance WARNING on page 51 1 Remove the controller assembly from the case by performing steps 1 through 3 of the case and cover replacement procedure 2 Unscrew the nuts at each end of the tubing assembly Remove the tubing assembly 3 Install the replacement tubing assembly 4 Setthe reset adjustment to 0 01 4195KB and KC controllers and set the rate adjustment to OFF 4195KC controllers 5 Apply the correct supply pressure and check for leaks with the nozzle capped for full output pressure Then remove the supply pressure 6 Position the controller assembly in the case and start but do not tighten the nine mounting screws Slide the controller assembly down to assure an O ring seal at the pressure connecti
58. psig controller output signal range or a 0 4 to 2 0 bar 6 to 30 psig remote set point pressure range for a 0 4 to 2 0 bar 6 to 30 psig controller output signal range If pressure is supplied to the remote set point connection with a regulator a small bleed orifice should be placed between the regulator and remote set point connection to prevent pressure variations due to regulator lock up External Feedback Pressure Connection 4195KB Controllers Only When a secondary controller in an override application has this option reset windup is minimized in the secondary controller Connect the external feedback connection of the secondary controller to the output of the customer supplied high or low select relay see figures 2 5 and 4 9 Figure 2 5 Connection Locations 5 16 UNC 28 3 HOLES MOUNTING FRONT VIEW REAR VIEW 14 18 NPT 1 4 18 NPT CONTROLLER SUPPLY PRESSURE OUTPUT CONNECTION CONNECTION pow S n 2 56 i gt D 31 1 4 NPT gt 1 22 REMOTE SET POINT CONNECTION NPT VENT CONNECTION 1 4 NPT 4 HOLES BOTTOM VIEW TOP VIEW NOTES 1 4 18 NPT PROCESS CONNECTION MARKED A FOR ALL BOURDON TUBE CONTROLLERS AND FOR THOSE CAPSULAR mm ELEMENT CONTROLLERS USED IN VACUUM PRESSURE APPLICATIONS INCH 2 1 4 18 NPT PROCESS CONNECTION MARKED B FOR CAPSULAR ELEMENT CONTROLLERS USED IN POSITIVE AND COMPOUND PRESSURE APPLICATIONS 35 FOR THE
59. ring seal at the pressure connections along the bottom of the case Hold the controller assembly in place while tightening the nine mounting screws 18 Perform the controller calibration procedures and if necessary the appropriate remote set point calibration procedure in Section 4 19 Mountthe controller as described in the Installation section 20 Connectthe external piping to the controller Replacing the Anti Reset Windup suffix letter F Differential Relief Valve A WARNING Refer to the Maintenance WARNING on page 51 Refer to the 4195KB or 4195KC suffix letter F portion of figure 7 1 for key number locations 1 Loosen the two mounting screws in the differential relief valve key 55 and remove the relief valve 2 Inspect the O rings on the replacement relief valve Apply a suitable lubricant to the O rings 3 Install the replacement relief valve into the controller frame keeping in mind that e When the arrow points up the valve relieves with decreasing output pressure e When the arrow points down the valve relieves with increasing output pressure 4 Tighten the two screws that hold the relief valve to the frame 5 The relief valve differential pressure is factory set at 0 3 bar 5 psig Maximum differential pressure is 0 5 bar 7 psig minimum differential pressure is 0 14 bar 2 psig If a different differential pressure setting is desired refer to the anti reset windup valve calibration procedure in Section 4 R
60. the controller assembly in the case and start but do not tighten the nine mounting screws Slide the controller assembly down to assure an O ring seal at the pressure connections along the bottom of the case Hold the controller assembly in place while tightening the nine mounting screws 67 4195 Controllers Instruction Manual December 2012 D200160X012 51 Perform the controller calibration procedures and if necessary the appropriate remote set point calibration procedure in Section 3 4 or 5 52 Mount the controller as described in the Installation section 53 Connectthe external piping to the controller Replacing the Proportional Reset or Positive Feedback Bellows A WARNING Refer to the Maintenance WARNING on page 51 Refer to figure 6 12 unless otherwise noted 1 Remove the controller assembly from the case by performing steps 1 through 3 of the case and cover replacement procedure Remove the two screws key 6 and lift off the proportional band indicator cover key 36 Disconnect link 4 key 65 from the bellows bracket key 31 Remove the two machine screws key 35 and washer key 362 from the bellows assemblies Remove the four machine screws key 6 from the bellows beam key 49 and remove the bellows bracket key 31 num A WN Remove the proportional tubing assembly key 40 from the proportional bellows the reset tubing assembly key 43 from the reset bellows or the positive feedback
61. the process pointer until it aligns with the left hand edge of the set point indicator as shown in figure 4 4 The controller output should be within 0 14 bar 2 psig of the supply pressure If the controller does not perform as indicated in steps 14 through 19 the flapper is not correctly aligned This may occur because the output was not sufficiently stabilized in steps 9 through 13 Repeat steps 8 through 19 34 Instruction Manual 4195K Controllers D200160X012 December 2012 21 22 23 When the flapper is correctly aligned set the proportional band to 400 percent in the desired controller action and replace the proportional band indicator cover If link 1 was disconnected reconnect link 1 to the input element using the same hole noted in step 8 Remove supply pressure If the controller has the external feedback option disconnect the outside tubing which connects the external feedback connection to the output connection 24 For controllers with anti reset windup suffix letter F remove the two machine screws valve cover and two O rings installed in step 1 of this procedure Install the anti reset windup relief valve key 55 with the arrow pointing in the direction recorded in step 1 Anti Reset Windup suffix letter F Differential Relief Valve Calibration Calibration for the differential relief valve to relieve on rising controller output pressure 1 Provide a means of measuring the controller output pressu
62. the screw nearest the nozzle Repeat steps 4 through 9 until the controller output remains in tolerance without further leveling screw adjustments If link 1 was disconnected remove the tape and reconnect link 1 to the input element Instruction Manual 4195K Controllers D200160X012 December 2012 12 Setthe proportional band to 400 percent in the desired controller action and replace the proportional band indicator cover Principle of Operation for 4195KA Controllers Overall Operation Refer to the schematic diagram in figure 3 4 Figure 3 4 Fisher 4195KA Controller Schematic SET POINT INDICATOR RESET BELLOWS VENTED REVERSE ACTION MN PROPORTIONAL QUADRANT PROPORTIONAL BELLOWS BAND ADJUSTMENT FEEDBACK PROCESS POINTER LINK REMOTE SET SY CONNECTED HERE INPUT ELEMENT CONNECTED HERE FEEDBACK MOTION NI FLAPPER PIVOT DIRECT ACTION INPUT E QUADRANT MOTION FLAPPER DETAIL CONNECTING LINK OUTPUT PRESSURE TO FINAL CONTROL ELEMENT FLAPPER SUPPLY PRESSURE NOZZLE RELAY OUTPUT PRESSURE PROPORTIONAL PRESSURE NOZZLE PRESSURE 46A9764 A B1489 2 SUPPLY PRESSURE The input element is connected to the process pointer and to the flapper by connecting links As the process pressure increases in a direct acting controller the flapper moves toward the nozzle restricting flow through the nozzle and increasing nozz
63. to 74 Instruction Manual 4195K Controllers D200160X012 December 2012 the bottom hole the hole nearest the pointer pivot If the process pointer has too much travel move the link to the top hole the hole furthest from the pointer pivot 4 Move the set point Indicator either manually or with remote set point pressure to the mid scale mark on the process scale and set the proportional band between DIRECT and REVERSE 5 The process pointer should be aligned with the pointer subassembly as shown in figure 6 15 If not loosen the zero adjustment locking screw and adjust the process pointer zero adjustment to align the process pointer and pointer subassembly Tighten the zero adjustment locking screw Figure 6 15 Process Pointer Alignment ALIGNED ZERO ADJUSTMENT MISALIGNED FINE ZERO LOCKING SCREW ADJUSTMENT W3443 1 W3475 1 6 Apply process pressure equal to the mid scale value of the process scale span The process pointer should indicate mid scale 3 percent of the process scale span If not loosen the two screws in link 1 and move the process pointer to the mid scale mark on the process scale Tighten the screws 7 Perform the controller calibration procedures and if necessary the appropriate remote set point calibration procedure in Section 3 4 or 5 Replacing Bourdon Tube Controller Link 2 1 Remove the two screws key 6 and lift off the proportional band indicator cover key 36 2 Disconnect
64. tubing 8 Controller remains at zero output 8 1 Gauge not functioning 8 2 Sensor or linkage failure 8 3 Flapper misalignment 8 4 Relay malfunction 8 5 Nozzle pressure leak 8 1 Verify that the supply pressure is at its correct value and that the controller output is zero 8 2 Vary the process pressure and observe the flapper for movement Inspect the sensor and linkage for damage 8 3 Vary the process pressure and verify that the nozzle can be capped by the flapper 8 4 Check for air at the nozzle Cap the nozzle and see if the controller output increases to within 0 03 bar 0 5 psig of supply pressure 8 5 Check for nozzle tubing leaks with a water bottle and soap solution with the nozzle capped by the flapper Press the nozzle cap key 23 gently to ensure the nozzle assembly is sealing Ensure the relay nozzle tubing nut key 18 is tight and the manifold screws keys 34 and 131 are tight 8 1 Replace gauges as necessary 8 2 Repair or replace parts as necessary 8 3 Perform flapper alignment procedures 8 4 Clean outthe relay primary orifice with the cleanout wire attached to the relay to ensure the orifice is not clogged If the problem persists replace the relay 8 5 Tighten the relay nozzle tubing nut key 18 Tighten the manifold screws keys 34 and 131 Replace the nozzle assembly key 21 O ring key 24 or set point beam assembly key 23 as necessary if leaking 54
65. 00 750 1000 0 1300 1500 to 1500 1100 1500 0 1950 2250 0 to 3000 2200 3000 0 3900 4500 0 to 5000 3700 5000 0 6000 7000 1 Minimum or maximum span or any span in between may be positioned anywhere within the operating range For example if a 0 to 2 bar 0 to 30 psig sensing element is used and the minimum span of 1 bar 15 psig is set the process indication can be calibrated to a range of 1 to 0 bar 30 inch Hg to 0 psig 0 to 1 bar 0 to 15 psig 1 to 2 bar 15 to 30 psig 2 to 3 bar 27 to 42 psig or any value between the operating range minimum and maximum values 2 Travel stops should be used when the maximum or minimum process pressure will be 5 over or under the calibrated range For example a 0 to 2 bar 0 to 30 psig sensing element is calibrated for 0 7 to 2 bar 10 to 30 psig the desired range The minimum expected pressure is 0 psig and the maximum expected pressure is 2 8 bar 40 psig Travel stops must be used to prevent excessive overtravel and undertravel since the maximum allowable overpressure and underpressure is higher than 5 of the 1 4 bar 20 psig span which is 70 mbar 1 psig 3 Bourdon tube without travel stops may be pressured to this value without permanent zero shift 4 Bourdon tube with travel stops set may be pressured to this value without permanent zero shift Table 1 5 Optional Process Connections INPUT RANGE CONNECTION Bar Psig Size Material Steel or Upto Upto 1
66. 00160X012 December 2012 20 Align flapper leveling screw number 2 with the centerline of the oblong hole in the frame as shown in figure 6 8 Tighten the cap screws key 12 Note The following procedure steps 21 through 23 adjusts link 2 to ensure that it will always be in tension to eliminate possible instability due to lost motion 21 Disconnect link 1 from the input element noting the hole location if the controller has a capsular input element and manually position the process pointer to the process scale upper limit Tape the pointer in this position 22 Adjustthe length of link 2 by turning the adjustment screw shown in figure 6 10 clockwise to increase the length or counterclockwise to decrease the length so that the pin on the end of the link is approximately one half of its diameter short of aligning with the hole in the flapper assembly as shown in figure 6 11 Figure 6 10 Link 2 and 4 Adjustment Locations LINK 4 LINK 4 ADJUSTMENT LINK 2 LINK 2 ADJUSTMENT LINK 3 W3442 1 65 4195 Controllers Instruction Manual December 2012 D200160X012 Figure 6 11 Link 2 Adjustment 23 24 25 26 27 28 29 30 31 32 33 66 LEVELING SCREW NUMBER 1 CONNECTING TAB ON FLAPPER ASSEMBLY 1 2 OF PIN Waaa DIAMETER Connect link 2 to the flapper assembly Set the proportional band between DIRECT and REVERSE Do this by aligning the tab on the proportional band ad
67. 1 and 4 3 for adjustment locations Note Any change to the process pointer span adjustment will require readjustment of the process pointer zero adjustment 1 Remove the two screws key 6 and lift off the proportional band indicator cover key 36 2 Setthe proportional band between DIRECT and REVERSE 3 Apply process pressure equal to the process scale span lower limit 30 Instruction Manual 4195K Controllers December 2012 D200160X012 Figure 4 3 Fisher 4195KB and KC Controller Calibration Adjustment Locations POINTER ZERO ADJUSTMENT POINTER ZERO ADJUSTMENT LOCKING SCREW PROCESS POINTER SPAN ADJUSTMENT ANTI RESET WINDUP RELIEF VALVE SUFFIX LETTER F ANTI RESET WINDUP VALVE ADJUSTING SCREW SUFFIX LETTER F REMOTE SET POINT REMOTE SET POINT RESET ZERO ADJUSTMENT ZERO ADJUSTMENT ADJUSTMENT SUFFIXLETTERM LOCKING SCREW RATE RESET SUFFIX LETTER M ADJUSTMENT ADJUSTMENT W6833 FRONT VI EW W3599 1 2 4195KC CONTROLLERS 4195KB CONTROLLERS SCREW 1 SCREW 2 SCREW 3 PROCESS REMOTE SET POINT POINTER SPAN SPAN ADJUSTMENT ADJUSTMENT SUFFIX LETTER M SIDE VIEW OF SET POINT PROCESS INDICATOR ASSEMBLY 59A9752 S SHT 1 SIDE VIEW OF 39A1126 8 CONTROLLER SHOWING A6731 FLAPPER LEVELING SCREWS 31 4195 Controllers Instruction Manual December 2012 D200160X012 4 The process pointer should indicate the process scale lower limit If not adjust the process pointer
68. 2NPTexternal 0 to 400 0 to 5000 or W 1 2 NPT W stainless internal steel to 400 to to 5000 to k 1 010600 Oto 10 000 1 2 NPT internal Stainless steel 0 to 400 to 0 to 5000 to 010600 Oto 10 000 1 2 NPT external Stainless steel Table 1 6 Supply Pressure Data Output Range Signal Supply Pressure Pressure Limit 2 0 2to 1 0 14 2 8 0 4to 2 0 24 2 8 3to15 20 40 Psig 6to 30 35 40 1 Ifthis pressure is exceeded 2 Ifthis pressure is exceeded control may be impaired damage to the controller may result Instruction Manual 4195K Controllers D200160X012 December 2012 Section 2 Installation To avoid personal injury or property damage resulting from the sudden release of pressure e Always wear protective clothing gloves and eyewear when performing any installation operations e Personal injury or property damage may result from fire or explosion if natural gas is used as the supply medium and preventive measures are not taken Preventive 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 14 e Check with your process or safety engineer for any additional measures that must be taken to protect against process media e
69. 4195 Controllers Instruction Manual December 2012 D200160X012 CAUTION Make sure the loose travel stop nut does not bind on the diaphragm capsule extension key 134 when pressurizing the capsules key 80 Damage to the capsules may result 2 Full span stop Adjust the remote set point pressure to 2 1 2 percent of span greater than the remote set point input range upper limit Loosen the two screws keys 139 and 140 that secure the travel stop key 83 to the mounting plate key 111 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 position 3 Zero Stop Adjust the remote set point pressure to 2 1 2 percent of span less than the remote set point input range lower limit Slide the travel stop nut key 86 along the diaphragm capsule extension key 134 until it is just touching the travel stop key 83 Tighten the set screw key 87 to lock the travel stop nut in position Aligning the Linkage A WARNING Refer to the Maintenance WARNING on page 51 1 Adjust the remote set point pressure to 50 percent of the remote set point input range Set the linearity adjustment screw in the center of the slot on the lever arm of pivot clevis assembly B key 115 See figure 6 23 for the linearity adjustment location Set the length of link A key 116 so the lever arms of pivot assembly A and pivot assembly B are parallel and link A is perpendic
70. 5KC controllers only SST aluminum 138 Auto manual tubing ass y Use w suffix letter E auto manual station only SST aluminum 140 Machine screw fill hd 18 8 SST Used to attach remote set pt ass y suffix letter M to indicator ass y key 56 162 Machine screw hex hd 18 8 SST Used to attach the reset valve 4195KB or rate reset valve 4195KC to the frame For 4195KB and KC controllers only 262 Rate reset valve ass y for 4195KC controllers only Brass bellows 0 2 to 1 0 bar 3 to 15 psig 0 4 to 2 0 bar 6 to 30 psig SST bellows 0 2 to 1 0 bar 3 to 15 psig 0 4 to 2 0 bar 6 to 30 psig 273 Auto manual station suffix letter E Note The part number listed for key 273 is for the complete auto manual station suffix letter E Individual ass y parts are listed the Auto Manual Station subsection of the parts list Key numbers for individual ass y parts also appear in figure 7 7 310 Lithium grease not furnished with controller 311 Anti seize sealant not furnished with controller 312 O ring nitrile For all types w suffix letter E auto manual station 3 req d 313 Auto Manual Scale plastic For all types w suffix letter E auto manual station 314 Machine screw fill hd 18 8 SST For all types w suffix letter E auto manual station 315 Machine screw fill hd 18 8 SST For all types w suffix letter E auto manual station 316 Machine screw SST For all types w suffix letter E auto manual station 317 Silicone
71. 8 SST For flapper ass y key 11 2 req d 44 Relief valve tubing ass y SST For 4195KBF KBFE KBFM 17 Adjustable set pt pivot ass y SST and KBFME only 18 Relay nozzle tubing SST For 4195KCF KCFE KCFM 19 Machine screw fill hd 18 8 SST and KCFME only 1 req d to attach adjustable set pt pivot 5 key 17 to frame 45 Positive Feedback Tubing Assembly SST For 4195KC controllers req d to attach relay nozzle tubing ass y key 18 to frame 106 For 4195KS controllers only Recommended spare parts Instruction Manual 4195K Controllers D200160X012 December 2012 Key Description Part Number Key 46 Pressure ANGE GAUGE MATERIAL Brass SST Note Dual Scale Gauge One type of pressure gauge is used for both output pressure and supply 0 to 30 psig 1188577 042 1188583 032 pressure indication 0 to 2 kg cm 0 to 60 psig M Oto 4 kg cm2 11B8577X052 Triple Scale Gauge 46 Pressure gauge 2 req d See Key 46 table 0 to 30 psig 48 Bellows ass y 2 req d 0 to 200 kPa 11B8577X012 11B8583X012 Brass 16A6953X012 0 to 2 bar SST 16A6953X022 0 to 60 psig 49 Bellows beam A96061 aluminum 0 to 400 kPa 11B8577X022 11B8583X022 0 2 to 1 0 bar 3 to 15 psig 0 to 4 bar 0 4 to 2 0 bar 6 to 30 psig 1 One type of pressure gauge is used for both output pressure and supply pressure indication 5 Relief valve cover plate A03600 aluminum 52 O ring nitrile 1C853806992
72. A2999 1 When the auto manual switch is in the MANUAL position the manual loader output is channeled through the auto manual switch and becomes the controller output When the auto manual switch is in the AUTO position the relay output is channeled through the switch to become the controller output Before the auto manual switch is operated the relay output must equal the manual loader output 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 and it is held in place by a small magnet A pressure imbalance forces the ball to one end of the tube where it forms a seal blocking air flow through the tube 24 Instruction Manual 4195K Controllers D200160X012 December 2012 Section 4 4195KB Proportional Plus Reset Controllers and 4195KC Proportional Plus Reset Plus Rate Controllers Adjustments for 4195KB and KC Controllers This section includes descriptions of adjustments and procedures for prestartup startup and calibration Adjustment locations are shown in figures 4 1 and 4 3 To better understand the adjustments and overall controller operation refer to the Principle of Operation section and to the schematic diagrams in figures 4 5 through 4 9 Unless otherwise noted key numbers given in this section are found in figure 7 1 Fig
73. EXTERNAL FEEDBACK CONNECTIONS 4195KB CONTROLLERS ONLY EITHER THE A OR B CONNECTION IS USED DEPENDING ON THE LOCATION OF THE PROCESS CONNECTION 46A9765 A A2892 4 13 4195 Controllers Instruction Manual December 2012 D200160X012 Vent Personal injury or property damage could result from fire or explosion of accumulated gas or from contact with hazardous gas if a flammable or hazardous gas is used as the supply pressure medium Because the controller case and cover assembly do not form a gas tight seal when the assembly is enclosed a remote vent line adequate ventilation and necessary safety measures should be used to prevent the accumulation of flammable or hazardous gas However a remote vent pipe alone cannot be relied upon to remove all flammable or hazardous gas 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 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 meters 20 feet and a minimum inside diameter of 25 mm 1 inch for runs from 6 1 to 30 5 meters 20 to 100 feet
74. Instruction Manual D200160X012 4195K Controllers December 2012 Fisher 4195KA KB KC and KS Gauge Pressure Controllers Contents 1 Introduction Scope Description vasos ere ee Specifications Educational Services 2 Installation Controller Mounting Orientation Pipestand Mounting Panel Mounting Wall Mounting Actuator Mounting Pressure Connections Process Pressure Connection Supply Pressure Connection Remote Set Point suffix letter M Pressure Connection External Feedback Pressure Connection 4195KB Controllers Only Oe oat ee le 3 4195KA Proportional Only Controllers Adjustments for 4195KA Controllers Manual Set Point Adjustment Remote Set Point suffix letter M Adjustment Proportional Band Adjustment PB ADJ Changing Controller Action Switching The Auto Manual Station suffix letter E Prestartup Checks for 4195KA Controllers Startup for 4195KA Controllers Calibration of 4195KA Controllers General Calibration Instr
75. JUSTMENT LINEARITY LINK 2 LINK 3 ADJUSTMENT SCREW LINK 2 ADJUSTMENT LINK 3 ADJUSTMENT Replacing Capsular Element Controller Link 1 1 Remove the two screws key 6 and lift off the proportional band indicator cover key 36 2 Note the hole position of link 1 and disconnect the link from the short pivot clevis assembly and from the process pointer Remove the link 3 Attach the replacement link in the same holes noted in step 2 to the process pointer and the short pivot clevis assembly If you do not know in which hole in the process pointer the link was connected place it in the middle hole If during the process indicator zero and span calibration the pointer will not travel the full scale even after full span adjustment move the link to the bottom hole the hole nearest the pointer pivot If the process pointer has too much travel move the link to the top hole the hole furthermost from the pointer pivot 4 Move the set point indicator either manually or with remote set point pressure to the mid scale mark on the process scale and set the proportional band between DIRECT and REVERSE 5 The process pointer should be aligned with the pointer subassembly as shown in figure 6 15 If not loosen the zero adjustment locking screw and adjust the process pointer zero adjustment to align the process pointer and pointer subassembly Tighten the zero adjustment locking screw 6 Apply process pressure equal to the mid scale v
76. KA and KS controllers 4 req d For all 4195KC controllers 6 req d 72 Blowout plug silicone Note Key numbers 73 through 76 are only for use with a 4195K controller with a Bourdon tube element Travel stops are required when the calibration starting point is greater than 0 psig Use only when specified 73 Uppertravel stop G10100 steel Use only when specified See Note above 74 Lower travel stop G10100 steel Use only when specified See Note above 75 Machine screw fill hd 18 8 SST Use only when specified See Note above If only upper travel stop installed none req d If both upper and lower travel stop installed 2 req d to mount upper travel stop 76 Machine screw fill hd 18 8 SST Use only when specified See Note above If only upper travel stop installed 2 req d to mount upper travel stop If both upper and lower travel stop installed 2 req d to mount lower travel stop 120 Machine screw fill hd 18 8 SST 2 req d to attach remote set pt ass y suffix letter M to indicator ass y base plate 127 Machine screw fill hd 18 8 SST 4 req d 131 Machine screw fill hd 530400 304 SST 2 req d to attach rate reset manifold key 136 to frame manifold key 135 108 Key Description Part Number 135 Framemanifold A03600 aluminum For all types except w suffix letter E auto manual station 136 Rate reset manifold A03600 aluminum For all types except 4195KC controllers 137 Rate tubing for 419
77. OINT FEEDBACK LINK NS CONNECTED HERE 7 FEEDBACK INPUT ELEMENT MOTION FLAPPER CONNECTED HERE PIVOT CONNECTIN INPUT MOTION LINK FLAPPER DETAIL OUTPUT PRESSURE TOFINALCONTROL d ELEMENT FLAPPER SUPPLY PRESSURE NOZZLE J RELAY Ed OUTPUT PRESSURE P y SUPPLY POSITIVE FEEDBACK PRESSURE PRESSURE NOZZLE PRESSURE As the process 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 further away from the nozzle and further reducing nozzle pressure Output pressure to the final control element switches to zero 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 input 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 swi
78. Operation The capability to adjust the controller set point from a remote location is available with all 4195KA controllers This option is designated by the letter M in the type number A control pressure is applied to the capsular element within the remote set point assembly The expansion and contraction of the capsule moves the set point adjustment via a connecting linkage Increasing the control pressure to the capsule increases the set point setting and decreasing the control pressure reduces the set point setting Auto Manual Station suffix letter E Operation A controller with the auto manual station designated by the suffix letter E in the type number has piping on the output side of the relay as shown in figure 3 5 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 3 5 Fisher 4195KA Auto Manual Station Schematic AUTOMATIC POSITION AUTO MANUAL a MANUAL LOADER SWITCH 7s MANUAL LOADER KNOB OUTPUT PRESSURE TO FINAL CONTROL lt ELEMENT MANUAL POSITION B ES AUTO MANUAL i SWITCH SUPPLY PRESSURE OUTPUT PRESSURE RELAY OUTPUT PRESSURE TO FINAL CONTROL SUPPLY PRESSURE ELEMENT MANUAL LOADER OUTPUT PRESSURE 48A5230 A
79. Perform the controller calibration procedures and if necessary the appropriate remote set point calibration procedure in Section 3 4 or 5 36 Mount the controller as described in the Installation section 37 Connectthe external piping to the controller Replacing the Reset Restriction Valve 4195KB Controllers WARNING Refer to the Maintenance WARNING on page 51 Refer to the 4195KB controller portion of figure 7 1 for key number locations 1 Remove the controller assembly from the case by performing steps 1 through 3 of the case and cover replacement procedure 2 Remove the reset valve tubing assembly key 42 from the reset restriction valve key 54 3 Remove the reset tubing assembly key 43 from the reset restriction valve 70 Instruction Manual 4195K Controllers D200160X012 December 2012 4 For controllers with anti reset windup suffix letter F remove the relief valve tubing assembly key 44 from the reset restriction valve 5 Remove the screw key 162 that fastens the reset restriction valve to the frame 6 Install the replacement reset restriction valve and secure it with the screw removed in step 5 7 Install the reset valve tubing assembly key 42 the reset tubing assembly key 43 and for controllers with anti reset windup the relief tubing assembly key 44 Tighten all connections 8 Setthe reset adjustment to 0 01 minutes per repeat 9 Apply the proper supply pressure to the controller
80. STMENT LINK 4 LINK 2 ADJUSTMENT W5745 Replacing Bourdon Tube Controller Links Figure 6 14 Disconnecting Link 1 from the Bourdon Tube W5747 A WARNING Refer to the Maintenance WARNING on page 51 This section describes the separate replacement of four links in the controller Figure 6 13 shows the location of each link To clarify the location of each link the links are numbered as follows e Link 1 connects the Bourdon tube and the process pointer e Link 2 connects the process pointer and the flapper assembly key 11 e Link 3 connects the set point indicator and the set point beam assembly key 23 Replacing Bourdon Tube Controller Link 1 Link 4 key 65 connects the flapper assembly and the bellows bracket key 31 1 Remove the two screws key 6 and lift off the proportional band indicator cover key 36 2 Note the hole position of link 1 in the process pointer As shown in figure 6 14 disconnect the link from the Bourdon tube and from the process pointer Adjust the length of the replacement link to the same length as the link being replaced 3 Attach the replacement link to the original holes in the process pointer and the Bourdon tube If you do not know in which hole in the process pointer the link was connected place it in the middle hole If during the process indicator zero and span calibration the pointer will not travel the full scale even after full span adjustment move the link
81. Section 3 4 or 5 Capsular Element Controller Maintenance and Calibration Replacing the Capsular Element Assembly A WARNING Refer to the Maintenance WARNING on page 51 Refer to figure 7 5 for key number locations unless noted otherwise WwW N A Remove process pressure from the controller Note the hole location and disconnect link 1 key 90 from the process pointer Disconnect the process pressure connection union key 93 from the pedestal assembly key 81 Use two 5 16 inch hex wrenches Remove the four machine screws key 127 in figure 7 3 that attach the capsular element assembly to the indicator assembly key 101 in figure 7 3 CAUTION In the following step do not lift out the capsular element assembly by holding the capsular element or linkages These parts may be damaged N en Ui Lift out the capsular element assembly by holding the tie bar key 97 mounting plate key 77 travel stop key 83 or pedestal assembly key 81 Position the replacement capsular element assembly over the mounting screw holes Install and tighten the mounting screws key 127 in figure 7 3 Reconnect link 1 key 90 to the process pointer in the same hole noted in step 2 Reconnect the process pressure connection union key 93 Apply process pressure to the controller and check for leaks Perform the capsular element maintenance calibration procedure in this section Pe
82. The process pointer should indicate the process scale upper limit 1 percent of the process scale span 14 If the error is greater than 1 percent repeat steps through 13 Remote Set Point suffix letter M Zero and Span Calibration Refer to figures 4 1 and 4 3 for adjustment locations Refer to figure 7 1 for key number locations Note Any adjustment of the remote set point span adjustment screw requires readjustment of the remote set point zero adjustment screw Remove the two screws key 6 and lift off the proportional band indicator cover key 36 Setthe proportional band between DIRECT and REVERSE Apply remote set point pressure equal to the lower range limit Theset point indicator should indicate the process scale lower limit If not loosen the remote set point zero adjustment locking screw and adjust the remote set point zero adjustment screw until the set point indicator aligns with the process scale lower limit Tighten the zero adjustment locking screw vI Apply remote set point pressure equal to the upper range limit 6 The set point indicator should indicate the process scale upper limit If not adjust the remote set point span adjustment screw to correct one half the error as follows clockwise to increase span for a low indication counterclockwise to decease span for a high indication 7 Repeat steps 3 through 6 until the error is eliminated 8 Adjust the remote set point pressure
83. UBING ASSEMBLY W4195 61 4195 Controllers Instruction Manual December 2012 D200160X012 16 17 18 19 20 21 Atthe frame manifold key 135 tighten the nut that secures the tubing from the relay nozzle tubing assembly key 18 Apply full supply pressure with the nozzle capped and check for leaks Remove supply pressure Install the set point beam bias spring key 28 into the frame bore and onto the spring seat on the set point beam assembly Attach link 3 to the set point beam shoe as shown in figure 6 3 For controllers with reset or rate adjustment 4195KB or 4195KC controllers turn the reset adjustment to the CLOSED 4195KB or OFF 4195KC position Set the rate adjustment to the OFF position The controller output must be 0 bar 0 psig To be sure the controller output is 0 bar 0 psig remove supply pressure set the reset adjustment to 0 01 minutes per repeat and wait 30 seconds then turn the reset adjustment to the CLOSED position 4195KB or to the OFF position 4195KC Apply the correct supply pressure refer to table 1 6 to the controller and provide an accurate means of measuring the controller output pressure Perform the appropriate process indicator zero and span calibration procedure and if necessary the remote set point zero and span calibration procedure in Section 3 4 or 5 When calibration is complete continue with step 22 below Note Th co 22 23 24 25 26
84. Used w key 51 2 req d 53 Machine screw fill hd 18 8 SST Used w key 51 2 req d 4195KA KB and KS controllers 4195KC controllers 7 req d 54 Reset restriction valve 4195KB controllers only 55 Differential relief valve For all 4195KB and KC controllers w suffix letter F anti reset windup 57 Pressure control block CF8M 316 SST Casting 1 4 18 NPT Internal Process Connection 1 reqd for all types w o remote set pt and w o ext fdback except none required for units with Bourdon tube isolator 2 req d for all types w remote set pt and w o ext fdback except 1 req d for units with Bourdon tube isolator 2 req d for all types w ext fdback and w o remote set pt except 1 req d for units with Bourdon tube isolator 3 req d for all types w ext fdback and w remote set pt except 2 req d for units with Bourdon tube isolator 1 2 14 NPT External Process Connection For all types w o remote set pt and w o ext fdbck 1 req d Pressure control block CF8M 316 SST Casting 1 4 18 NPT Internal Process Connection 1 req d for all types w o remote set pt and w o ext fdback except none required for units with Bourdon tube isolator For all types w remote set pt and w o ext fdbck For all types w ext fdback and w o remote set pt For all types w ext fdback and w remote set pt Recommended spare parts Key Description 56 Process and set pt indicator ass y w sensing element Note Individual indicator ass y parts are listed in two subsections
85. acket key 31 and into the proportional bellows Do not tighten 12 Place the washer key 362 on the second machine screw key 35 and start the screw through the bellows bracket key 31 into the reset bellows Do not tighten 13 Compress the bellows and start the four machine screws key 6 through the bellows bracket key 31 into the bellows beam key 49 but do not tighten 14 Be sure that the bellows bracket is aligned such that it does not rub on the frame at any point and tighten the screws keys 6 and 35 15 Install the proportional reset or positive feedback tubing assembly on the bellows base 16 Fora 4195KB or KC controller set the reset adjustment for 0 01 minutes per repeat For a 4195KC controller set the rate adjustment to OFF 17 Apply the correct supply pressure with the nozzle capped and check for leaks Remove the supply pressure 18 Reconnect link 4 key 65 to the bellows bracket Be sure that the link does not contact the frame If it does loosen the four screws key 6 that attach the bellows bracket to the bellows beam and reposition the bellows bracket to provide clearance Be sure the bellows bracket does not rub on the frame then tighten the screws 19 Lift link 4 out of the hole in the bellows bracket key 31 and ensure it drops back into the hole under its own weight If not perform steps 35 through 41 of the flapper assembly and flapper flexure pivot assembly replacement procedures 20 If the cont
86. adjust the remote set point pressure until the set point indicator is at the mid scale mark on the process scale A U 6 Apply process pressure equal to the mid scale value of the process scale span 7 The process pointer should be aligned with the pointer subassembly as shown in figure 6 15 If not loosen the zero adjustment locking screw and adjust the zero adjustment screw to align the process pointer with the pointer subassembly Tighten the zero adjustment locking screw 8 The process pointer should indicate mid scale 3 percent of the process scale span If not loosen the screw on either link 1 or link 5 and adjust the length so that the process pointer points to the mid scale mark on the process scale Tighten the screw 9 Apply process pressure equal to the process scale lower limit 10 The process pointer should indicate the process scale lower limit If not loosen the zero adjustment locking screw and adjust the zero adjustment screw until the process pointer indicates the lower limit Tighten the zero adjustment locking screw 11 Apply process pressure equal to the process scale upper limit 12 The process pointer should indicate the process scale upper limit If not proceed as follows a Ifthe pointer indicates less than the process scale upper limit rotate the pointer span adjustment clockwise to increase the span Adjust the span adjustment screw to correct for one half of the error 91 4195 Controller
87. ale span 6 To increase the span proceed as follows a Turn the remote set point span adjustment screw clockwise b To increase the span further than the adjustment screw allows move both ends of link A key 116 to the right c Make fine adjustments with the remote set point span adjustment screw To decrease the span proceed as follows a Turn the remote set point span adjustment screw counterclockwise b To decrease the span further than the adjustment screw allows move both ends of link A key 116 to the left c Make fine adjustments with the remote set point span adjustment screw Repeat the adjustments until the upper and lower indications are aligned with the upper and lower limits on the process scale Adjust the remote set point pressure for 50 percent of the remote set point input range The set point indicator should indicate mid scale 2 percent of the process scale span If the error is within 2 percent proceed to step 11 If the error is greater than 2 percent of the scale span proceed to the remote set point linearity adjustment procedure Adjust the set point indicator to mid scale 1 percent of the process scale span by loosening the zero adjustment locking screw and turning the zero adjustment screw Tighten the locking screw Adjust the remote set point pressure to the upper and lower limits of the remote set point input range and make sure the set point indicator is still within 1 p
88. alue of the process scale span The process pointer should indicate mid scale 3 percent of the process scale span If not loosen the screw in link 1 or link 5 and move the pointer to the mid scale mark on the process scale Tighten the screw 7 Perform the controller calibration procedures and if necessary the appropriate remote set point calibration procedure in Section 3 4 or 5 Replacing Capsular Element Controller Link 2 1 Remove the two screws key 6 and lift off the proportional band indicator cover key 36 2 Disconnect link 2 from the process pointer and from the flapper assembly key 11 Remove the link 3 Install the replacement link with the screw head nearest the process pointer as shown in figure 6 21 Connect the link to the process pointer only 4 The process pointer should be lined up with the pointer subassembly as shown in figure 6 15 If not loosen the zero adjustment locking screw and adjust the process pointer zero adjustment to align the pointer with the process pointer subassembly Tighten the zero adjustment locking screw 86 Instruction Manual 4195K Controllers D200160X012 December 2012 5 Move the set point indicator manually or with remote set point pressure to the process scale lower limit and set the proportional band at 5 percent REVERSE The nozzle should not be touching the flapper If it is adjust flapper leveling screw 1 the screw nearest the nozzle until clearance is obtained 6 No
89. an in between may be positioned anywhere within the operating range For example if a 0 to 350 mbar 0 to 5 psig sensing element is used and the minimum span of 1 75 mbar 2 5 psig is set the process indication can be calibrated to a range of 340 mbar to 203 mbar 10 inch Hg to 6 inch Hg 0 to 172 mbar 0 to 2 5 psig 172 to 345 mbar 2 5 to 5 psig 305 to 480 mbar 4 5 to 7 psig or any value between minimum and maximum values of operating range 2 Capsules with the travel stops set may be pressured to this value without permanent zero shi t 4195K Controllers Instruction Manual December 2012 D200160X012 Table 1 4 Process Sensor Bourdon Tube Pressure Ratings and Materials OPERATING RANGE BOURDON TUBES E gt STANDARD Minimum Maximum Minimum Maximum LIMITS MATERIAL Bar Oto 1 6 1 2 1 3 3 3 Oto 2 5 2 4 1 6 6 6 0to4 2 4 1 6 6 6 0to6 3 5 7 1 10 11 0 to 10 7 14 1 20 22 0 0 16 10 20 1 30 33 Metric units 0to25 20 40 0 60 66 531600 316 SST 0 to 40 20 40 0 60 66 0 to 60 55 70 0 90 103 to 100 76 100 0 135 155 to 160 160 200 0 270 310 0 to 300 250 350 0 420 482 STANDARD Psig Psig Psig Inch Hg Psig Psig MATERIAL 0 to 30 15 30 30 42 48 0 to 60 30 60 30 84 96 to 100 50 100 30 140 160 0 to 200 100 200 30 280 320 a 0 to 300 150 300 30 420 480 U S units 0 to 600 300 600 0 840 960 531600 316 SST to 10
90. and ind cover ABS w polyester label to the frame 37 Self tapping screw 18 8 SST 4 req d to mount bellows bracket 4 req d to attach process scale key 61 key 31 to bellows beam key 49 to process scale bracket key 376 2 req d to attach process scale brackets keys 376 377 to frame 38 Self tapping screw 18 8 SST 7 O Ring nitrile Used to attach frame inside case 9 req d Used between frame and case at conns process pressure 39 Supply gauge tubing SST either 1 4 18 NPT internal or 1 2 14 NPT external output 40 Proportional tubing ass y SST and supply remote set point and external feedback For 4195KA or KB controllers 3 req d w o remote set pt and w o ext fdback For 4195KC controllers 4 req d w remote set pt or ext fdback 5 req d w remote set pt and ext fdback 1C376206992 41 Plug 530300 303 SST 8 O Ring nitrile For all 4195KA KB and KS controllers 1 req d Used between frame and case on For 4195KC KCM KCE and KCME 2 req d mounting bosses extending from the frame For 4195KCF KCFM KCFE and through the back of the case 3 req d 16A6903X012 KCFME 1 req d 9 Flexure pivot ass y sapphire SST 42 Reset valve tubing ass y SST 10 Machine screw fill hd 18 8 SST For 4195KB controllers w o ext feedback SST Used to attach the flexure pivot ass y 43 Reset tubing SST key 9 to the frame 4 req d For all 4195KB controllers 11 Flapper ass y 29A9518X012 For all 4195KC controllers 12 Machine screw hex socket 18
91. and the adjustments and overall operation of the controller refer to the Principle of Operation section and the schematic diagrams figures 5 4 and 5 5 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 Figure 5 1 Fisher 4195KS Controller Parts and Adjustments Locations SET POINT ADJUSTMENT PROCESS INDICATOR PROPORTIONAL BAND INDICATOR COVER TIEBAR PROPORTIONAL LINK 5 BAND ADJUSTMENT LONG PIVOT LINK 1 BOURDON lt ASSEMBLY TUBE TT CONNECTING INDICATOR LINK SHORT ZERO INDICATOR PIVOT ADJUSTMENT ZERO ADJUSTMENT ASSEMBLY ZERO ADJUSTMENT ADJUSTMENT LOCKING SCREW LINEARITY LOCKING SCREW PROCESS ADJUSTMENT SPAN ADJUSTMENT SPAN ADJUSTMENT OUTPUT PRESSURE GAUGE SUPPLY CAPSULAR ELEMENT PROCESS SENSOR PRESSURE GAUGE NOTE 15 SENSING ELEMENT CAN ALSO BE A CAPSULAR ELEMENT C0528 1 42 BI METAL STRIP FOR FRONT VIEW OF CONTROLLER WITH BOURDON TUBE PROCESS SENSOR TEMPERATURE COMPENSATION Instruction Manual 4195K Controllers D200160X012 December 2012 Figure 5 1 Fisher 4195KS Controller Parts and Adjustments Locations continued SCREW 1 SCREW 2 SCREW 3
92. ar 1 bar 1 5 bar 0 4 to 0 6 bar 0 5 bar 1 bar 1 bar 1 4 bar 2 bar N09902 0 6 to 0 8 bar 0 7 bar 1 4 bar 1 bar 1 7 bar 2 5 bar 1 to 0 6 bar 1 bar 2 bar 1 bar 2 4 bar 3 5 bar 1to 1 bar 1 bar 2 bar 1 bar 2 4 bar 3 5 bar 0 to 60 inch wc 40 inch wc 60 inch wc 10 inch Hg 5 psig 7 5 psig O0to5 psig 2 5 psig 5 psig 14 inch Hg 7 psig 10 5 psig Oto 10 psig 5 psig 10 psig 30 inch Hg 15 psig 22 5 psig ot 3to 15 psig 6 psig 12 psig 30 inch Hg 20 psig 30 psig Positive pressure ot 15 psig 7 5 psig 15 psig 30 inch Hg 20 psig 30 psig 0 to 20 psig 10 psig 20 psig 30 inch Hg 25 psig 37 5 psig 6 to 30 psig 12 psig 24 psig 30 inch Hg 30 psig 45 psig 0 to 30 psig 15 psig 30 psig 30 inch Hg 35 psig 52 5 psig U S unit 5 to 0 inch Hg 2 5inchHg 5inch Hg 10 inch Hg 5 psig 7 5 psig DUI Mondo 10 to 0 inch Hg 5 inch Hg 10inchHg 14inchHg 7psig 10 5 psig 20 to 0 inch Hg 10 inch Hg 20 inch Hg 30 inch Hg 15 psig 22 5 psig 30 to 0 inch Hg 15 inch Hg 30 inch Hg 30 inch Hg 20 psig 30 psig 30 to 30 inch wc 40 inch wc 60 inch wc 10 inch Hg 5 psig 7 5 psig 5 inch Hg to 2 5 psig 2 5 psig 5 psig 14inch Hg 7 psig 10 5 psig 10 inch Hg to 5 psig 5 psig 10 psig 30 inch Hg 15 psig 22 5 psig Compound 2 15 inch Hg to 7 5 psig 7 5 psig 15 psig 30 inch Hg 20 psig 30 psig 20 inch Hg to 10 psig 10 psig 20 psig 30 inch Hg 25 psig 37 5 psig 30 inch Hg to 15 psig 15 psig 30 psig 30 inch Hg 35 psig 52 5 psig 1 Minimum or maximum span or any sp
93. ase and cover are an integral unit attempting to separate them will damage the hinge If the cover needs to be replaced replace the case also 1 Remove the external piping and fittings from the controller NJ Remove the controller from its mounting to a maintenance area Remove the nine screws key 38 from the case and cover assembly key 1 and lift out the controller assembly If the controller has remote set point suffix letter M use a screwdriver or appropriate tool to deflect the case slightly at the remote set point connection to remove the controller assembly Inspect the O rings around the external piping connections and replace as necessary UJ A Position the controller assembly in the replacement case and cover 5 Start the nine mounting screws but do not tighten Slide the controller assembly down to assure an O ring seal at the pressure connections along the bottom of the case Hold the controller assembly in place while tightening the nine mounting screws Remove the blow out plug key 72 from the original case and install it in the replacement case o N 8 Perform the controller calibration procedures and if necessary the appropriate remote set point calibration procedure in Section 3 4 or 5 Mount the controller as described in the Installation section 10 Connect the external piping to the controller Replacing the Gauges A WARNING Refer to the Maintenance WARNING on
94. asket key 306 9 Pull the clip key 300 from its engagement with the lever assembly shaft key 297 10 Pull the lever 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 gaskets for damage or wear 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 assembly 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 body assembly key 291 to the loader assembly with the two screws key 290 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
95. ations are indicated by letter suffixes in the type number that correspond to the mode and option designated in table 1 2 The specific controller type number with letter suffixes is located on the nameplate shown in figure 1 1 Refer to table 1 2 for the definition of each 4195K type number Do not install operate or maintain a 4195K 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 the contents of this manual including all safety cautions and warnings If you have any questions about these instructions contact your Emerson Process Management sales office before proceeding Description The controllers described in this manual provide gauge pressure control with the options as shown in table 1 2 e 4195KA Proportional only control e 4195KB Proportional plus reset control e 4195KC Proportional plus reset plus rate control e 4195KS Differential gap control These controllers show process pressure and set point on an easy to read process scale The controller output is a pneumatic signal that operates a final control element Specifications Specifications for 4195KA KB KC and KS controllers are listed in table 1 1 Educational Services For information on available courses for 4195KA 4195KB 4195KC and 4195KS gauge pressure indicating controllers
96. bar 6 to 30 psig to the remote set point connection at the top of the controller case Remove the two machine screws key 6 and lift off the proportional band indicator cover key 36 Adjust the set point a minimum of 20 percent of input span above the process pointer Adjust the proportional band for 5 percent DIRECT If necessary connect a pressure source to the process connection and adjust the process pointer to the last mark on the left side of the scale If the last scale mark is 0 psig a pressure source is not required Dum KR W 4195 Controllers Instruction Manual December 2012 D200160X012 7 The controller output pressure should be 0 bar 0 psig 8 Rotate the proportional band to 5 percent REVERSE 9 The controller output should be within 0 14 bar 2 psig of the supply pressure 10 If the controller output is within tolerance adjust the proportional band to 400 percent in the desired action secure the proportional band indicator cover key 36 with the machine screws key 6 and go to the startup procedure If the controller output pressure is not within tolerance go to the 4195KA calibration procedure for recalibration Startup for 4195KA Controllers Perform the prestartup checks and if necessary calibrate the controller prior to this procedure Note When performing the startup procedures keep in mind that the initial settings are guidelines They will vary depending on the actual process being con
97. ch step to make sure it stabilizes At some point the controller output will start to ramp downward to 0 bar 0 psig with no further change to the controller input or set point Record the controller output pressure where this ramping action begins because this is the point at which the differential relief valve has relieved To obtain the differential relief valve differential setting calculate the difference between the original controller output pressure in step 7 and the controller output pressure recorded in step 10 If the differential pressure calculated in step 11 is incorrect for the application adjust the differential pressure by turning the differential relief valve adjustment screw shown in figure 4 3 Turn the screw clockwise to decrease the differential pressure or counterclockwise to increase the differential pressure The differential relief valve is set at the factory to relieve at approximately 0 4 bar 5 psi differential pressure Repeat steps 7 through 12 until the required differential pressure is obtained Principle of Operation for 4195KB and KC Controllers Overall Operation Refer to the schematic diagram in figure 4 5 for 4195KB controllers or to the schematic diagram in figure 4 6 for 4195KC controllers 36 Instruction Manual 4195K Controllers D200160X012 December 2012 The input element is connected to the process pointer and to the flapper by connecting links As the process pressure increases in
98. d 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 Figure 5 5 Fisher 4195KS Auto Manual Schematic AUTOMATIC POSITION x MANUAL LOADER 7 SS us AUTO MANUAL SWITCH MANUAL ae LOADER KNOB OUTPUT PRESSURE TO FINAL CONTROL ELEMENT POSITION tj A AUTO MANUAL SUPPLY SWITCH PRESSURE OUTPUT PRESSURE TO FINAL CONTROL RELAY OUTPUT PRESSURE SUPPLY PRESSURE MANUAL LOADER OUTPUT PRESSURE ELEMENT 48A5230 A A2999 1 50 Instruction Manual 4195K Controllers D200160X012 December 2012 Section 6 Maintenance Controller parts are subject to normal wear and must be inspected and replaced as necessary The frequency of inspection and parts replacement depends upon the severity of the service conditions When inspection or repairs are required disassemble only those parts necessary to accomplish the job Inspection and Maintenance A WARNING The following maintenance procedures require taking the controller out of service To avoid personal injury and property damage caused by uncontrolled process pressure observe the following before performing any maintenance procedure
99. djust the process pointer to the lowest limit of the input scale by loosening the zero adjustment locking screw and turning the zero adjustment screw Adjust the process 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 7 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 8 Repeat steps 4 through 7 until the error is eliminated 9 Install the proportional band indicator cover key 36 and tighten the two4 screws key 6 o Remote Set Point Zero and Span Adjustment Option M Note Any adjustment of the pointer span adjustment screw will require readjustment of the pointer zero adjustment screw 45 4195K Controllers Instruction Manual December 2012 D200160X012 Refer to figures 5 1 and 5 2 for location of adjustments Remove the two screws key 6 and lift off the proportional band indicator cover key 36 Setthe proportional band between DIRECT and REVERSE Adjust the process pressure to the low limit of the input range A turning the zero adjustment screw o Adjust the process 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 Adjust the process pointer to t
100. e Note the number of instruments being supplied by the regulator 1 3 Note if the pointer is bent 1 4 Inspectthe element for loose screws and damaged flexures links or pivots Using a soap solution check the sensing element for leaks 1 5 Check for links that are bent or not connected properly flexures bent or broken pivots broken 1 6 By changing the process set point and observing the output verify that the output will change at about the same rate in both directions 1 7 The minimum relief valve setting is dependent on the loop dynamics and the controller settings If under normal load changes the relief valve opens instability can occur Check by observing the controller reaction to aset point or load change under closed loop conditions 1 1 Ifstable control cannot be attained and all other elements of the loop are functionally correct examine other possible causes related to the controller 1 2 Correct as necessary One regulator per instrument is recommended 1 3 Bend pointer to provide clearance 1 4 Repair or replace parts as necessary 1 5 Replace or repair as necessary 1 6 Ifthe output changes quickly in one direction and sluggishly in the other replace the relay 1 7 If the differential relief valve appears to be set too low refer to the section of this instruction manual that covers the anti reset windup option 2 Controlling off set point as reflected by process and set point indica
101. e screw in the replacement link B and adjust the length to match the link being replaced Tighten the screw 3 Refer to figure 6 23 for the correct link orientation Attach the replacement link B to the pivot arm and to the set point indicator in the same holes as noted in step 1 4 Perform the remote set point maintenance calibration procedure Perform the appropriate process indicator zero and span calibration and flapper alignment procedures in Section 3 4 or 5 Remote Set Point suffix letter M Maintenance Calibration Refer to figure 6 23 for parts and adjustment locations Refer to figures 7 1 and 7 6 for key number locations Precalibration Procedure A WARNING Refer to the Maintenance WARNING on page 51 96 Instruction Manual 4195K Controllers D200160X012 December 2012 1 Remove the two screws key 6 and lift off the proportional band indicator cover key 36 2 Setthe proportional band adjustment between DIRECT and REVERSE 3 Remove the two screws key 103 and remove the tie bar key 106 from the remote set point assembly Aligning the Flexures WARNING Refer to the Maintenance WARNING on page 51 1 Apply remote set point pressure equal to 50 percent of the remote set point pressure range 2 The quide flexure key 119 should be straight and horizontal If not straighten the flexure by loosening the machine screw key 122 on the end of the flexure that is attached to the top of the pivot assembly A
102. e span adjustment can be made by moving both ends of link 5 up or down a If the span is short process pointer indication is less than the process scale upper limit disconnect both ends of link 5 move the link down one set of holes and return to step 6 b If the span is long process pointer indication is greater than the process scale upper limit disconnect both ends of link 5 move the link up one set of holes and return to step 6 16 Apply process pressure equal to the mid scale value of the process scale span The process pointer should indicate mid scale 2 percent of the scale span If the process pointer error is 2 percent or less proceed to step 17 If the process pointer error exceeds 2 percent the linearity can be improved with the linearity adjustment See figure 6 22 for the linearity adjustment screw location a If the error at mid scale is high process pointer is to the right side of the mid scale mark loosen the linearity adjustment screw and slide it upward in the curved slot Tighten the screw and return to step 6 b If the error at mid scale is low process pointer is to the left side of the mid scale mark loosen the linearity adjustment screw and slide it downward in the curved slot Tighten the screw and return to step 6 17 Adjust the process pointer to within 1 percent of the mid scale mark by loosening the zero adjustment locking screw and adjusting the zero adjustment screw Tighten the zero adjustmen
103. e 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 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 Principle of Operation Overall Operation Refer to the schematic diagram in figure 5 4 48 Instruction Manual 4195K Controllers D200160X012 December 2012 The input element is connected to the process pointer and to the flapper by connecting links As the process pressure increases in a direct acting controller This movement restricts the flow through the nozzle and increases nozzle pressure When this occurs relay action increases the output pressure delivery of the controller Output pressure is fed backto 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 Figure 5 4 Fisher 4195KS Controller Schematic POSITIVE FEEDBACK SET POINT BELLOWS INDICATOR PROPORTIONAL BELLOWS VENTED REVERSE ACTION QUADRANT PROPORTIONAL BAND ADJUSTMENT PROCESS POINTER REMOTE SET P
104. e tubing nut key 18 Tighten the manifold screws keys 34 and 131 Replace the nozzle assembly key 21 O ring key 24 or set point beam assembly key 23 as necessary if leaking 6 6 Replace faulty parts as necessary Clean out the relay primary orifice with the cleanout wire attached to the relay to ensure the orifice is not clogged 6 7 If the output does not change as described remove the relay Replace the O rings if necessary Replace relay if necessary 7 Controller remains at full output 7 1 Supply pressure too high 7 2 Output gauge not functioning 7 3 Sensor or linkage failure 7 4 Flapper mis alignment 7 5 Relay failure or restriction in nozzle passage 7 1 Check with an external pressure gauge 7 2 Reduce supply pressure to 0 bar 0 psig to see if output gauge responds 7 3 Vary the process pressure and observe the flapper for movement Inspect the sensor and linkage for damage 7 4 Vary the process pressure and verify that the nozzle can be uncapped by the flapper 7 5 Loosen the relay nozzle tubing nut key 18 with full supply pressure 7 1 Supply pressure regulator or gauge may have to be replaced 7 2 If output gauge does not respond replace it 7 3 Repair or replace parts as necessary 7 4 Perform flapper alignment procedures 7 5 Ifthe output pressure remains atthe supply pressure replace the relay If the output pressure moves to 0 bar 0 psig clean or replace nozzle or nozzle
105. ed spares only For part numbers not shown contact your Emerson Process Management sales 23 Set pt beam aluminum SST 24 O ring nitrile 1 req d for nozzle tubing ass y key 18 1 req d for nozzle ass y key 21 1E222606992 Note 25 Proportional band knob polycarbonate Figure 7 1 shows key numbers for the common construction of all 26 Retaining clip 530200 302 SST controller types Figure 7 1 continues over several pages Be sure to 27 E ing SST check all pages of figure 7 1 to find the common key numbers 28 Set pt beam bias spring pl steel 29 Set pt beam shoe G10100 pl steel 30 Machine screw 18 8 SST Key Description Part Number Used w key 29 2 req d 1 Case and cover ass y 31 Bellows bracket A95052 aluminum For use w o remote set pt For use w remote set pt 32 Bellows adj bracket G10100 pl steel 2 Nameplate A91100 aluminum 33 Bellows adj spring pl steel 3 Frame A03600 aluminum 34 Machine screw fill hd 18 8 SST 4 Frame gasket chloroprene Used to attach frame manifold key 135 to For use between frame and frame frame and for reset gain adjustment 2 req d manifold key 135 18A0749X012 35 Machine screw hex hd 18 8 SST 5 Gasket chloroprene Used to attach bellows bracket key 31 4195KA KB and KS 1 req d to each bellows key 48 2 req d 4195KC 2 req d 18A0742X012 6 Machine screw fill hd 18 8 SST 9 req d 36 Proportional band indicator cover 2 req d to mount the prop b
106. edure in Section 3 4 or 5 Replacing the Process Drive Flexure 1 84 Set the process pressure to 75 percent of the capsular element range Instruction Manual 4195K Controllers D200160X012 December 2012 2 Remove the tie bar key 97 from the capsular element assembly by removing the mounting screws key 103 3 Using an Allen wrench remove the cap screws and washers keys 12 and 13 to disconnect the drive flexure key 79 from the drive bracket assembly key 84 and from the pivot adjustment arm of the long pivot clevis assembly key 78 Remove the drive flexure 4 Loosely connect the replacement drive flexure making sure it is straight and horizontal Note See figure 6 20 The adjustment arm of the long pivot clevis assembly is connected to a shaft that turns on bushings at each end of the shaft In the next step position the shaft so that both bushings float inside the bearings and do not rest against the end of either bearing 5 Before tightening the drive flexure cap screws key 12 hold the pivot shaft in the middle of the bushing end play Be sure neither bushing is resting against the inside end of either bearing Tighten the drive flexure cap screws to hold the pivot shaft in position Take care not to kink or twist the flexure when tightening the screws 6 Perform the capsular element maintenance calibration procedure in this section Perform the controller calibration procedures and if necessary the appr
107. elationship 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 5 3 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 Locate the 50 percent line on figure 5 3 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 Differential Gap 15 psi x 100 x 100 50 Sensing Element Range 30 psi 1 Using the curve in figure 5 3 determine the correct proportional band setting for the desired gap expressed as a percent of the maximum input element span between the switching points Set the proportional band knob to the desired setting determined in step 1 Adjust the set point to the desired lower switching point Decrease the process pressure until the controller output signal switches from zero pressure to full supply pressure BR WN Increase the process pressure to the desired switching point at which the controller output signal switches from full supply pressur
108. en the remote set point zero adjustment locking screw and adjust the remote set point zero adjustment screw to correct for half the error at mid scale Tighten the zero adjustment locking screw Apply remote set point pressure equal to the lower and upper range limits and make sure the set point indicator is within 1 percent If necessary perform the process indicator zero and span calibration procedure in this section Otherwise perform the flapper alignment procedure in this section Flapper Alignment Note Pe rform the process indicator zero and span calibration procedure and for controllers with remote set point suffix letter M the remote set point zero and span calibration procedure before the flapper alignment Flapper leveling screw numbers and adjustments are shown in figure 3 3 Key number locations are shown in figure 7 1 Provide a means of measuring the controller output pressure by connecting the controller output to a pressure gauge open loop conditions must exist Provide a regulated supply pressure to the controller Do not exceed the normal op 1 erating pressure in table 1 6 After performing the flapper alignment procedure go to the startup procedure Fora controller with manual set point move the set point indicator to the mid scale mark on the process scale For a controller with remote set point suffix letter M adjust the remote set point pressure until the set point indicator is at the m
109. ent 4195KC to the OFF position The controller output must be 0 bar 0 psig To be sure the controller outputis at 0 bar 0 psig remove supply pressure set the reset adjustment to 0 01 minutes per repeat and wait 30 seconds then turn the reset adjustment to the CLOSED 4195KB or OFF 4195KC position 5 Adjust the proportional band to 5 percent REVERSE and move the set point indicator to the process scale upper limit 6 Disconnect link 1 from the Bourdon tube and move the process pointer to the process scale lower limit Tape the process pointer in this position 7 Apply the correct supply pressure to the controller The output of the controller should be within 0 14 bar 2 psig of the supply pressure If not adjust flapper leveling screw 1 the screw nearest the nozzle until the output is within 0 14 bar 2 psig of supply pressure 8 Loosen the two adjusting screws on link 4 Connect the free end of the link to the bellows bracket and allow the link to find its free length 9 Tighten the two adjusting screws on the link 10 Raise link 4 out of the hole in the bellows bracket key 31 and ensure that it drops back into the hole under its own weight If not repeat steps 8 and 9 11 Fora controller with reset adjust the reset adjustment to 0 01 minutes per repeat The rate adjustment 4195KC should remain in the OFF position 12 The controller output should be within 0 14 bar 2 psig of the supply pressure If not adju
110. eplacing the Anti Reset Windup suffix letter F Relief Valve Tubing Assembly A WARNING Refer to the Maintenance WARNING on page 51 Refer to the 4195KB or 4195KC suffix letter F portion of figure 7 1 for key number locations 1 Remove the controller assembly from the case by performing steps 1 through 3 of the case and cover replacement procedure 2 Loosen the nuts at both ends of the relief valve tubing key 44 and remove the tubing 3 Install the replacement relief valve tubing and tighten the tubing nuts at both ends 4 Apply the proper supply pressure to the controller cap the nozzle and check for leaks Remove the supply pressure 72 Instruction Manual 4195K Controllers D200160X012 December 2012 5 Position the controller assembly in the case and start but do not tighten the nine mounting screws Slide the controller assembly down to assure an O ring seal at the pressure connections along the bottom of the case Hold the controller assembly in place while tightening the nine mounting screws 6 Perform the controller calibration procedures and if necessary the appropriate remote set point calibration procedure in Section 4 7 Mount the controller as described in the Installation section 8 Connect the external piping to the controller Bourdon Tube Controller Maintenance and Calibration Replacing the Bourdon Tube A WARNING Refer to the Maintenance WARNING on page 51 Refer to figure 7 2 for key number l
111. er output does not affect the input pressure or other control signal to the controller Note If the controller has the auto manual station suffix letter E be sure the controller is in the automatic mode before performing prestartup checks If the controller has the external feedback option connect the controller output connection to the external feedback connection see figure 2 5 Adjust the controller for full output pressure and with the RESET knob adjusted to 0 01 minutes repeat verify the tubing connections do not leak Disconnect after completing the prestartup checks 1 Provide a means of measuring the controller output pressure by connecting the controller output to a pressure gauge Connect supply pressure to the supply pressure regulator and be sure it is delivering the proper supply pressure to the controller Do not exceed the normal operating pressure in table 1 6 2 Foracontroller 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 bar 6to 30 psig to the remote set point connection at the top of the controller case Remove the two machine screws key 6 and lift off the proportional band indicator cover key 36 Adjust the set point a minimum of 20 percent of input span above the process pointer Turn the reset adjustment to 0 01 minutes per repeat Turn the rate adjustment to OFF 4195KC controllers Adjust the proportional band for 5 percent DIRECT
112. ercent at the lower and upper limits of the process scale Perform the appropriate flapper alignment procedure and if necessary the process indicator zero and span calibration procedure in Section 3 4 or 5 Remote Set Point Linearity Adjustment A WARNING Refer to the Maintenance WARNING on page 51 Adjust the linearity by loosening and repositioning the linearity adjustment screw in the curved slot on the lever arm of pivot assembly B key 115 Adjusting the linearity affects the zero and span adjustment 1 Adjust the remote set point pressure to 50 percent of the remote set point input range The set point indicator should indicate mid scale 1 percent of the process scale span If not make fine adjustments by loosening the zero adjustment locking screw and turning the zero adjustment screw Adjust the remote set point pressure to 0 percent of the remote set point input range and note the indicator position relative to the process scale lower limit 99 4195 Controllers Instruction Manual December 2012 D200160X012 Adjust the remote set point pressure to 100 percent of the remote set point input range and note the indicator position relative to the process scale upper limit Ifthe greatest misalignment is positive the set point indicator is to the right of the process scale limits loosen the linearity screw and move it clockwise in the slot If the misalignment is negative move the linearity screw cou
113. erent actuator types Attach the mounting bracket to the actuator yoke with cap screws lock washers and spacer spools Attach the controller to the bracket with cap screws lock washers and spacer spools On some designs the mounting bracket is attached to the actuator casing rather than to the yoke 4195 Controllers Instruction Manual December 2012 D200160X012 Pressure Connections A WARNING To avoid personal injury or property damage resulting from the sudden release of pressure do not install any system component where service conditions could exceed the limits given in this manual Use pressure relieving devices as required by government or accepted industry codes and good engineering practices Refer to figure 2 5 for pressure connection locations Supply output remote set point external feedback and vent connections are 1 4 NPT internal Process pressure connections are 1 4 or 1 2 NPT optional Use 1 4 inch or 3 8 inch pipe or tubing for supply output remote set point and external feedback connections Process Pressure Connection The connection marked A on the bottom of the case is the process input for all Bourdon tube controllers and those capsular element controllers used in vacuum pressure applications The connection marked B is the process input for capsular element controllers used in positive pressure and compound pressure applications See figure 2 5 for the location of the A and B connections When instal
114. evis assembly is connected to a shaft that turns on bushings at each end of the shaft In the next step position the shaft so that both bushings float inside the bearings and do not rest against the end of either bearing 90 c Before retightening the drive flexure screws hold the long pivot clevis assembly shaft in the middle of the bushing end play Be sure neither bushing is resting against the inside end of either bearing d Tighten the drive flexure screws to hold the pivot clevis assembly shaft in position Setthe linearity adjustment screw on the short pivot clevis assembly so the two arms of the short pivot clevis assembly are parallel The linearity adjustment screw should be near the center of its slot Make certain that the process pointer and pointer subassembly are aligned as shown in figure 6 15 If not loosen the zero adjustment locking screw and adjust the process pointer zero adjustment screw to align the process pointer and pointer subassembly Tighten the zero adjustment locking screw Adjust the process pressure to 50 percent of the capsular element range Instruction Manual 4195K Controllers D200160X012 December 2012 5 Loosen the screw on link 5 key 88 and adjust the link length so that the pivot arms of the short pivot clevis assembly key 89 and the long pivot clevis assembly key 78 are parallel Tighten the screw 6 Complete the maintenance calibration by performing the zero and span adjust
115. ew key 102 and tighten Connect the guide flexure key 119 to the top of the replacement pivot assembly with the screw key 122 washer key 123 and nut key 124 as it was before The guide flexure should be straight and horizontal as shown in figure 6 23 If not loosen the screws key 122 and retighten to eliminate any bowing Loosen the screws key 139 and raise or lower the pedestal assembly key 105 to get the link horizontal Retighten the screws key 139 and ensure the diaphragm assembly extension key 134 is centered in the upper travel stop key 83 hole Instruction Manual 4195K Controllers D200160X012 December 2012 10 Apply remote set point pressure equal to 50 percent of the remote set point input range Note See figure 6 20 The adjustment arm of the remote set point pivot assembly 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 of either bearing 11 Connect the drive flexure key 79 to the arm on the replacement pivot assembly making sure it stays straight and vertical Adjust the length of the pivot arm if necessary until the flexure is vertical Before tightening the drive flexure screws hold the pivot assembly shaft in the middle of the bushing end play Be sure neither bushing is resting against the inside end of either bearing Tighten the drive flexure screws to
116. fitting for one end of the tubing or hose Specify quantity of fittings required Fittings for 3 8 inch tubing casing or yoke mounted controller with regulator Connector brass 2 req d Elbow brass 2 req d Fittings for 3 8 inch tubing pipestand mounted controller with regulator Elbow brass 2 req d Fittings for 3 8 inch tubing all controllers without regulator Connector brass 1 req d Elbow brass 1 req d Fittings for 1 2 inch synthetic rubber hose all controllers w or w o regulator Connector 316 SST Elbow 316 SST Swivel 316 SST 2 req d 123 4195 Controllers Instruction Manual December 2012 D200160X012 Neither Emerson Emerson Process Management nor any of their affiliated entities assumes responsibility for the selection use or 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 unit 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 ser
117. g the cover out so the proportional band knob can be rotated to the desired action 43 4195 Controllers Instruction Manual December 2012 D200160X012 The white portion of the adjustment enables direct controller action the black portion enables reverse controller action Auto Manual Switching Option E Refer to figure 5 5 if the controller has the auto manual option Two balance methods are available to equalize the manual output with the controller pressure 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 The move the automatic manual switch to MANUAL Turn the loader knob clockwise to increase the controller output or counter clockwise to decrease it 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 the 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 Note Switching the controller between automatic and manual or manual and automatic mode without balancing the outputs can disturb the process and cause controller cycling Prestar
118. groove on the nozzle assembly key 21 Ensure that all three tabs of the E ring are engaged Inspect the O ring on the relay nozzle tubing assembly key 18 and if necessary replace it Apply a suitable lubricant to the O ring Install the relay nozzle tubing assembly key 18 into the set point beam assembly Setthe proportional band adjustment between DIRECT and REVERSE Do this by aligning the tab on the proportional band adjustment knob with the hole in the set point beam assembly as shown in figure 6 4 Position the proportional band adjustment knob relay nozzle tubing assembly and the set point beam assembly on the frame Screw the relay nozzle tubing nut loosely into the frame manifold Insert the machine screw with plain washer keys 19 and 20 through the frame and start it into the relay nozzle tubing assembly key 18 but do not tighten Centerthe nozzle on the flapper as shown in figure 6 5 while squeezing the set point beam assembly firmly against the relay nozzle tubing assembly With the nozzle centered on the flapper tighten the machine screw key 19 Ensure that the nozzle is still centered on the flapper Insert the pivot of the adjustable set point pivot assembly key 17 into the hole in the set point beam assembly key 23 Insert the screw with washer keys 19 and 20 through the frame key 3 and start it into the adjustable set point pivot assembly key 17 but do not tighten
119. gure 4 8 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 4 8 Fisher 4195KB and KC Auto Manual Station Schematic x MANUAL LOADER Bc Sx UM AUTOMATIC e 3 POSITION AUTO MANUAL SWITCH MANUAL LOADER KNOB OUTPUT PRESSURE TO FINAL CONTROL ELEMENT MANUAL POSITION tj x AUTO MANUAL SWITCH SUPPLY PRESSURE RIA OUTPUT PRESSURE RELAY OUTPUT PRESSURE TO FINAL CONTROL ELEMENT j SUPPLY PRESSURE 9 j MANUAL LOADER OUTPUT PRESSURE 48A5230 A A2999 1 When the auto manual switch is in the MANUAL position the manual loader output is channeled through the auto manual switch and becomes the controller output When the auto manual switch is the AUTO position the relay output is channeled through the switch to become the controller output Before the auto manual switch is operated the relay output must equal the manual loader output 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 and it is held in place by a small magnet
120. h nut is shown in figure 6 16 Figure 6 16 Flapper leveling Screw and Clinch Nut CLINCH FLAPPER LEVELING NUT SCREW 11 76 Wa4191 1 If leveling screw 1 protrudes further than leveling screw 3 turn the link 3 adjusting screw counterclockwise If leveling screw 3 protrudes further than leveling screw 1 turn the link 3 adjusting screw clockwise Instruction Manual 4195K Controllers D200160X012 December 2012 12 Repeat steps 8 through 11 until leveling screws 1 and 3 protrude an equal distance from the clinch nuts 13 Perform the controller calibration procedures and if necessary the appropriate remote set point calibration procedure in Section 3 4 or 5 Replacing Bourdon Tube Controller Link 4 1 Remove the two screws key 6 and lift off the proportional band indicator cover key 36 2 Disconnect link 4 from the bellows bracket key 31 and the flapper assembly key 11 3 Connect the replacement link to the flapper assembly so that the two adjusting screws on the link are nearest to the bellows bracket key 31 and so that the screw heads are facing the bottom of the controller as shown in figure 6 17 Figure 6 17 Position of Link 4 Adjustment Screws BELLOWS BRACKET LINK 4 ADJUSTMENT KEY 31 SCREW HEADS g mm TIT 4195 4 For controllers with reset 4195KB or reset and rate adjustments 4195 turn the reset adjustment to the CLOSED 4195KB or OFF 4195KC position Turn the rate adjustm
121. he supply pressure be shut off before beginning maintenance The maintenance procedures section describes part replacement common to 4195KA KB KC and KS controllers After completing the maintenance procedures perform the appropriate calibration procedures Unless otherwise noted calibration procedures for the 4195KA controller are in Section 3 calibration procedures for the 4195KB and KC controller are in Section 4 and calibration procedures for the 4195KS controller are in Section 5 If difficulty is encountered performing the calibration procedures in Section 3 4 or 5 refer to the calibration procedures in this section Troubleshooting As an aid to troubleshooting table 6 1 lists some common operating faults their probable cause and suggests procedures for correcting the faults 51 4195K Controllers Instruction Manual December 2012 D200160X012 Table 6 1 Troubleshooting Chart Fault Possible Cause Check Correction 1 Process wanders or cycles about set point 1 1 Proportional band and reset settings 1 2 Supply pressure varying 1 3 Process pointer rubbing on cover or scale 1 4 Input element failure 1 5 Linkage failure 1 6 Relay malfunction 1 7 Anti reset windup differential relief valve set too low suffix letter F only 1 1 Referto the startup procedures for controller settings 1 2 Monitor the supply pressure with an external gauge Ensure that itis set correctly and does not fluctuat
122. he Drive Flexure 1 Using an Allen wrench remove the cap screws key 12 and washers key 13 to disconnect the drive flexure key 79 from the drive bracket key 121 and from the adjustment arm of pivot assembly A Remove the drive flexure 2 Setthe remote set point pressure to 50 percent of the remote set point input range Note See figure 6 20 The adjustment arm of the remote set point pivot assembly 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 of either bearing 3 Connect the new drive flexure making sure it stays straight and vertical Adjust the length of the pivot arm if necessary until the drive flexure is straight Before tightening the drive flexure screws hold the pivot assembly A 95 4195 Controllers Instruction Manual December 2012 D200160X012 shaft in the middle of the bushing end play Be sure neither bushing is resting against the inside end of either bearing Tighten the drive flexure screws to hold the pivot shaft in this position Do not bend or twist the flexure when tightening the screws 4 Decrease the remote set point pressure to 0 bar 0 psig 5 Perform the remote set point maintenance calibration procedure Perform the appropriate process indicator zero and span calibration and flapper alignment procedure in Section 3 4 or 5 Replacing the Remote Set Po
123. he lowest limit of the input scale by loosening the zero adjustment locking screw and 7 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 8 Repeat steps 4 through 7 until the error is eliminated 9 Install the proportional band indicator cover key 36 and tighten the two screws key 6 Figure 5 2 Fisher 4195KS Controller Parts and Adjustments Locations Remote Set Point Option SCREW DRIVE FLEXURE LOWER TRAVEL ei ADJUSTMENT SCREW in E ASSEMBLY A LINK B sil D sth 1 MOUNTING TIEBAR SCREW CAPSULE REMOTE SET POINT ZERO ADJUSTMENT SCREW ZERO ADJUSTMENT LOCKING SCREW esc FRONT VIEW SIDE VIEW Setting Switching Points Direct Acting Controllers The controller output signal will switch from zero pressure to full supply pressure when increasing process pressure passes the upper switching point 46 Instruction Manual 4195K Controllers D200160X012 December 2012 The controller output signal will not return to zero pressure until decreasing process pressure passes the lower switching point When making adjustments as described in the following steps keep in mind that Changing the set point adjustment will move both switching points equally in the direction of adjustment Changing the proportional band adjust
124. id scale mark on the process scale Apply process pressure equal to the mid scale value of the process scale span If pressure is not available to pressure the input element to the mid scale value an alternate method is to disconnect link number 1 at the input element and tape the process pointer at the mid scale mark on the process scale If the controller has a capsular input element note the hole from which link number 1 was removed for proper replacement This method should only be used if pressure is not available to pressure the input element to the mid scale value Remove the two machine screws key 6 and lift off the proportional band indicator cover key 36 4 Adjustthe proportional band between DIRECT and REVERSE 5 The controller output should be 0 62 0 007 bar 9 0 10 psig for a 0 2 to 1 0 bar 3 to 15 psig output or 1 2 0 01 bar 18 0 2 psig for a 0 4 to 2 0 bar 6 to 30 psig output If not adjust flapper leveling screw 2 the screw nearest the nozzle until the output is within tolerance 6 Setthe proportional band to 30 percent DIRECT The controller output should be 0 62 0 02 bar 9 0 25 psig or 1 2 0 04 bar 18 0 5 psig If not adjust flapper leveling screw 3 the screw nearest the nozzle 8 Setthe proportional band to 30 percent REVERSE 9 The controller output should be 0 62 0 02 bar 9 0 25 psig or 1 2 0 04 bar 18 0 5 psig If not adjust flapper 10 11 22 leveling screw 1
125. ig Output 10 4 normal m3 hr 350 scfh Operative Ambient Temperature Limits 2 5 40 to 71 C 40 to 160 F Exhaust Capacity 0 2 to 1 0 Bar 3 to 15 Psig Output 4 6 normal m3 hr 186 scfh 0 4 to 2 0 Bar 6 to 30 Psig Output 7 0 normal m3 hr 295 scfh Hazardous Area Classification Complies with the requirements of ATEX Group II Category 2 Gas and Dust x u2 ap continued 4195K Controllers December 2012 Instruction Manual D200160X012 Table 1 1 Specifications continued Housing Designed to NEMA 3 Weatherproof and IEC 529 IP54 Specifications Mounting Controller can be mounted on actuator panel wall or pipestand Approximate 4 5 kg 10 po Weight unds Declaration of SEP Fisher Controls International LLC declares this product to be in compliance with Article 3 paragraph of the Pressure Equipment Directive PED 97 23 EC It was designed and manufactured in accordance with Sound Engineering Practice SEP and cannot bear the CE marking related to PED compliance However the product may bear the CE marking to indicate compliance with other applicable EC Directives NOTE Specialized instrument terms are defined in ANSI ISA Standard 51 1 Process Instrument Terminology 1 Consult your Emerson sales office for additional information 2 The pressure temperature limits in this document and any applicable standard or code limitation should not be exceeded
126. in this manual Instruction Manual 4195K Controllers D200160X012 December 2012 General Calibration Instructions Note If the controller has the auto manual station suffix letter E be sure the controller is in the automatic mode before performing calibration If the prestartup checks or startup reveal faulty controller operation perform the calibration described in this section These instructions are valid for either shop or field calibration provided that open process loop conditions exist Unless otherwise noted key numbers are found in figure 7 1 Do not use the gauges supplied with the controller during calibration Monitor process pressure supply pressure controller output pressure and if applicable remote set point pressure with external gauges Process Indicator Zero and Span Calibration Before starting this procedure Provide a regulated process pressure to the controller and a means of measurement external to the controller Provide a means of measuring the controller output pressure by connecting the controller output to a pressure gauge open loop conditions must exist Provide a regulated supply pressure to the controller Do not exceed the normal operating pressure in table 1 6 Refer to figures 3 1 and 3 3 for adjustment locations Note Any change to the process pointer span adjustment will require readjustment of the process pointer zero adjustment 4195K Controllers Instruction Manual
127. increase the set point and decrease the pressure to decrease the set point Proportional Band Adjustment PB ADJ The proportional band determines the controller output sensitivity The proportional band adjustment is marked in percentages of process pressure required to drive the controller from zero output to full output To adjust the proportional band open the controller cover and locate the proportional band adjustment PB ADJ knob Rotate the knob until the desired value is opposite the line on the proportional band indicator cover Changing Controller Action To change the controller action from direct to reverse or vice versa loosen the screws on the proportional band indicator cover Lift the cover out as shown in figure 4 2 and rotate the proportional band adjustment to the desired action Setting the proportional band to the values in the white portion of the adjustment provides direct controller action setting proportional band in the black portion provides reverse controller action Figure 4 2 Changing Controller Action on Fisher 4195KB and KC Controllers W3439 26 Instruction Manual 4195K Controllers D200160X012 December 2012 Bourdon Tube or Capsular Element Controllers for Positive or Compound Pressure For direct control action An increasing sensed pressure increases output pressure For reverse control action An increasing sensed pressure decreases output pressure Capsular Element Controllers for Vac
128. ing widening the proportional band moves the nozzle to a position on the flapper where less input and more feedback motion occurs which decreases the gain of the controller Decreasing narrowing the proportional band moves the nozzle toward a position where more input and less feedback motion occurs which increases the gain The controller action is changed from direct to reverse by turning the proportional band adjustment to position the nozzle on the flapper quadrant to a point where the direction of the flapper motion versus input motion is reversed as shown in the flapper detail of figure 4 5 or 4 6 With the controller in the reverse acting mode an increase in process pressure causes a decrease in output pressure 38 Instruction Manual 4195K Controllers D200160X012 December 2012 A 4195KC controller also has a rate valve as shown in figures 4 6 and 4 7 This valve is an adjustable restriction that momentarily increases the controller gain to accelerate the corrective action for slow pressure systems A proportional plus reset plus rate controller responds to a change in process pressure as follows First the rate action delays the proportional action just long enough to allow the controller to respond to the change quickly with high gain but not long enough for the high gain to cause instability e Then the low gain provided by the proportional action keeps the system stable Finally reset action slowly increases the gain and ret
129. int Tubing 1 Decrease the remote set point pressure to 0 bar 0 psig 2 Using two 5 16 inch open end wrenches disconnect the pressure connection union key 93 from 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 Replacing Link A This procedure describes link A key 116 replacement in the remote set point assembly Figure 6 23 shows the link location 1 Note the holes where link A is connected Disconnect link A key 116 from the lever arms on pivot assembly A and pivot assembly B 2 Loosen the screw in the replacement link A and adjust the length to match the link being replaced Tighten the screw 3 Refer to figure 6 23 for the correct link orientation Attach the replacement link A to the two lever arms in the same holes noted in step 1 4 Perform the remote set point maintenance calibration procedure Perform the appropriate process indicator zero and span calibration and flapper alignment procedures in Section 3 4 or 5 Replacing Link B This procedure describes link B key 126 replacement in the remote set point assembly Figure 6 23 shows the link location 1 Note the holes where link B is connected Disconnect link B key 126 from the pivot arm and from the set point indicator 2 Loosen th
130. int connection Connect an adjustable pressure source to the remote set point connection b Adjust the pressure source until the set point indicator reaches the desired set point Remember Increasing the remote set point pressure increases the set point 3 Setthe reset adjustment to 0 05 minutes per repeat for fast processes Set it to 0 5 minutes per repeat for slow processes For controllers with rate set the rate adjustment to OFF 4 Setthe proportional band to 100 percent for fast processes For slow processes calculate the proportional band percentage from the equation below 200 x Allowable Overshoot Pressure Span For example 200 x 0 14 bar EE RR Eu 2 1 5 If the controller is used in conjunction with control valve return the control valve to service by slowly opening the upstream and downstream manual control valves in the pipeline Close the manual bypass valve if one is used 6 Tune the various controller actions Tuning proportional action Create a load upset by momentarily changing the set point Check for system cycling If the system does not cycle lower the proportional band setting thus raising the gain and disturb the system again by changing the set point Continue this procedure until the system cycles At this point double the proportional band setting proportional band setting x2 Tuning reset action Disturb the system If the system does not cycle speed up the reset
131. justment knob with the hole in the set point beam assembly as shown in figure 6 4 Position the proportional band adjustment knob nozzle assembly and set point beam assembly and nozzle tubing assembly on the frame and screw the relay nozzle tubing assembly nut loosely into the frame manifold key 135 Insert the machine screw with washer keys 19 and 20 through the frame and start it into the relay nozzle tubing assembly key 18 but do not tighten Center the nozzle on the flapper as shown in figure 6 5 while squeezing the set point beam assembly firmly against the relay nozzle tubing assembly With the nozzle centered on the flapper tighten the machine screw key 19 Ensure that the nozzle is still centered on the flapper Insert the pivot of the adjustable set point pivot assembly key 17 into the hole in the set point beam assembly key 23 Insert the screw with washer keys 19 and 20 through the frame key 3 and start it into the adjustable set point pivot assembly key 17 but do not tighten Squeeze the adjustable set point pivot assembly against the set point beam assembly Check to be sure the nozzle is still centered on the flapper and tighten the machine screw key 19 If necessary loosen both machine screws key 19 to allow slightly moving the adjustable set point pivot assembly set point beam assembly and the relay nozzle tubing assembly as a unit to center the nozzle on the flapper After centering the nozzle tigh
132. kinking the drive flexure during the following procedures Bending or kinking the drive flexure can result in product damage as well as impaired performance Figure 6 23 shows the parts and adjustment locations Refer to figure 7 6 for key number locations Replacing Pivot Assembly A Key 114 Dn uU A W N N Decrease the remote set point pressure to 0 bar 0 psig Remove the two screws key 103 and remove the tie bar key 106 Note where link A is connected Disconnect link A key 116 from the lever arm on pivot assembly A key 114 Disconnect the drive flexure key 79 from the adjustment arm of pivot assembly A Be careful not to bend or kink the drive flexure Remove the screw key 122 washer key 123 and nut key 124 that attach the quide flexure key 119 to the top of the pivot assembly 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 key 111 Lift out pivot assembly A Loosen the adjustment 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 Toreplace the pivot assembly first put the spring washer key 112 on the screw key 109 Then insert the screw through the replacement pivot assembly and into the mounting plate and tighten Install the mounting scr
133. le pressure When this occurs relay action increases the output pressure delivery of the controller Output pressure is fed back to the proportional bellows The action of the proportional bellows counteracts the flapper movement that resulted from the process pressure change and backs the flapper away from the nozzle until equilibrium is reached Moving the set point indicator changes the distance between 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 proportional band adjustment positions the nozzle on the flapper Increasing widening the proportional band moves the nozzle to a position on the flapper where less input and more feedback motion occurs which decreases the gain of the controller Decreasing narrowing the proportional band moves the nozzle toward a position where more input and less feedback motion occurs which increases the gain The controller action is changed from direct to reverse by turning the proportional band adjustment to position the nozzle on the flapper quadrant to a point where the direction of the flapper motion versus input motion is reversed as shown in the flapper detail of figure 3 4 With the controller in the reverse acting mode an increase in process pressure causes a decrease in output pressure 23 4195 Controllers Instruction Manual December 2012 D200160X012 Remote Set Point suffix letter M
134. ler output pressure install the valve so the arrow on the valve points up To change the direction of the arrow loosen the two mounting screws pull the valve out and reinstall the valve with the arrow pointing up Tighten the two mounting screws Provide a regulated supply pressure to the controller Do not exceed the normal operating pressure in table 1 6 Note Because of the high controller gain with the reset adjustment at 0 01 minutes per repeat the controller output will not balance perfectly in the following step If the controller output is stable for approximately 5 seconds it is adequately balanced 7 Increase the process pressure or vacuum for a vacuum controller to the controller until the controller output pressure balances at 0 8 bar 12 psig for a 0 2 to 1 0 bar 3 to 15 psig output range or 1 6 bar 24 psig for a 0 4 to 2 0 bar 6 to 30 psig output range Turn the reset adjustment to the CLOSED 4195KB controllers or OFF 4195KC controllers position 9 Decrease the controller output pressure in small steps approximately 0 04 bar 0 5 psig by changing the process 13 pressure to the controller or by changing the controller set point After each change in controller process pressure or set point the controller output pressure should quickly change and then stabilize at the new value Continue to change the controller output pressure in 0 04 bar 0 5 psi steps and check the output pressure after ea
135. ling process piping follow accepted practices to ensure accurate transmission of the process pressure to the controller Install a three valve bypass shutoff valves vents drains or seal systems as needed in the process pressure lines If necessary install a needle valve in a process pressure sensing line to dampen pulsations If the instrument is located such that the adjacent process pressure lines are approximately horizontal the lines should slope downward to the instrument for liquid filled lines and upward toward the instrument for gas filled lines This reduces the possibility of air becoming trapped in the sensor with liquid filled lines or of condensation becoming trapped in gas filled lines The recommended slope is 83 millimeters per m 1 inch per foot If the controller is being used in conjunction with a control valve to control pipeline pressure connect the process pressure line in a straight section of pipe approximately 10 pipe diameters away from the valve and also away from bends elbows and areas of abnormal fluid velocities For pressure reducing service the process pressure line must be connected downstream of the control valve For pressure relief service the process pressure line must be connected upstream of the control valve Supply Pressure Connection A WARNING Severe personal injury or property damage may occur if the instrument air supply is not clean dry and oil free or noncorrosive gas While use and regular
136. ly stable at any value within the output range If not adjust flapper leveling screw 1 the screw nearest the nozzle until the output is relatively stable 13 Repeat steps 9 through 12 until the controller output remains relatively stable without further flapper leveling screw adjustment Note Steps 14 through 20 check the flapper alignment 14 15 Set the proportional band to 30 percent DIRECT Apply process pressure to the input element or if link 1 was disconnected remove the tape from the process pointer and move the pointer until it aligns with the right hand edge of the set point indicator as shown in figure 4 4 The controller output should be within 0 14 bar 2 psig of the supply pressure Figure 4 4 Alignment of the Process Pointer with the Set Point Indicator 17 18 20 RIGHT HAND EDGE LEFT HAND EDGE W4039 W4038 Apply process pressure to the input element or if disconnected move the process pointer until it aligns with the left hand edge of the set point indicator as shown in figure 4 4 The controller output pressure should go to 0 bar 0 psig Set the proportional band to 30 percent REVERSE Apply process pressure to the input element or if disconnected move the process pointer until it aligns with the right hand edge of the set point indicator as shown in figure 4 4 The controller output should be 0 bar 0 psig Apply process pressure to the input element or if disconnected move
137. maintenance of a filter that removes particles larger than 40 micrometers in diameter will suffice in most applications check with an 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 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 must be clean dry oil free and noncorrosive H2S content should not exceed 20 ppm Instruction Manual 4195K Controllers D200160X012 December 2012 Use a suitable supply pressure regulator to reduce the supply pressure source to the normal operating supply pressure shown in table 1 6 Connect supply pressure to the SUPPLY connection on the bottom of the case shown in figure 2 5 Remote Set Point suffix letter M Pressure Connection If the controller has remote set point suffix letter M connect the remote set point pressure to the top of the controller case at the location shown in figure 2 5 Use clean dry air or noncorrosive gas Use a 0 2 to 1 0 bar 3 to 15 psig remote set point pressure range for a 0 2 to 1 0 bar 3 to 15
138. ment will widen or narrow the differential gap between the two switching points by moving the position of the lower switching point Figure 5 3 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 5 3 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 AUN o 7 Sensing Element Range 30 psi 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 15 psi x100 x 100 50 Locate the 50 percent line on figure 5 3 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 Using the curve in figure 5 3 determine the correct proportional band setting for the desired gap expressed as a percent of the input span between the switching points Setthe proportional band knob to the desired setting determined in step 1 Adjust the set point to the desired upper switching point Increase the process pressure until the controller output signal switches from zero pressure to full supply pressure Decrease the process
139. ments in the following procedure Capsular Element Controller Zero and Span Adjustment Note For routine zero and span calibration refer to the appropriate procedures in Section 3 4 or 5 Use the following maintenance zero and span adjustment procedure only if difficulty is encountered with the routine procedure or if nonlinearity occurs Provide a means of applying process pressure to the sensing element and a regulated supply pressure adjusted to the normal operating pressure see table 1 6 Plug the controller output or connect it to a gauge Monitoring the controller output is not necessary However the flapper should not contact the nozzle at any time while performing this procedure If it does adjust flapper screw 2 the one nearest the nozzle to provide clearance Refer to figure 6 19 for the adjustment locations Refer to figure 7 1 for the key number locations Note Any adjustment of the process pointer span adjustment screw requires readjustment of the process pointer zero adjustment screw Remove the two machine screws key 6 and lift off the proportional band indicator cover key 36 Set the proportional band between DIRECT and REVERSE Adjustthe reset 4195KB and KC controllers only to 0 01 minutes per repeat Adjust the rate 4195KC controllers only to OFF Fora controller with manual set point move the set point indicator to the mid scale mark on the process scale For a controller with remote set point
140. nd REVERSE 6 The process pointer should be aligned with the pointer subassembly as shown in figure 6 15 If not loosen the zero adjustment locking screw and adjust the process pointer zero adjustment to align the process pointer and pointer subassembly Tighten the zero adjustment locking screw 7 Apply process pressure equal to the mid scale value of the process scale span The process pointer should indicate the mid scale 3 percent of the scale span If not loosen the screw in link 1 or link 5 and move the process pointer to the mid scale mark of the process scale span Tighten the screw 8 Perform the controller calibration procedures and if necessary the appropriate remote set point calibration procedure in Section 3 4 or 5 Capsular Element Controller Maintenance Calibration A WARNING Refer to the Maintenance WARNING on page 51 88 4195K Controllers Instruction Manual December 2012 D200160X012 Precalibration Procedure 1 Remove the two machine screws key 6 and lift off the proportional band indicator cover key 36 2 Setthe proportional band adjustment between DIRECT and REVERSE 3 Remove the two screws key 103 and remove the tie bar key 97 from the capsular element assembly Aligning the Drive Bracket Assembly Refer to figures 6 22 and 7 5 1 With an Allen wrench loosen the set screw in the hex nut of the drive bracket assembly key 84 2 Loosen the screw key 98 that holds the guide flex
141. nd link 4 as shown in figure 6 9 Remove the four machine screws key 10 shown in figure 6 9 that hold the flexure pivot assembly to the frame Remove the flexure pivot assembly key 9 Install the replacement flexure pivot assembly with the four screws key 10 Do not tighten the screws With the controller in the upright position move the flexure pivot assembly down as far as possible and tighten the four screws key 10 Place the flapper assembly key 11 on the flexure pivot assembly key 9 with link 4 through the hole in the frame Position the flapper assembly key 11 on the flexure pivot assembly key 9 and start the cap screws key 12 that hold the flapper assembly to the flexure pivot assembly Do not tighten the screws 63 4195 Controllers Instruction Manual December 2012 D200160X012 Figure 6 7 Bellows Assembly and Proportional Band Adjustment Process Scale and Proportional Band Indicator Cover Removed PROPORTIONAL KEY 31 a ADJUSTABLE SET POINT PIVOT ASSEMBLY KEY 17 ana SCREW AND WASHER So Rs KEYS 19 AND 20 AD N LINK 4 W4199 LINK 2 Figure 6 8 Leveling Screw Alignment Figure 6 9 Exploded View of Flexure Pivot Assembly FLAPPER LEVELING SCREW NUMBER2 FLAPPER ASSEMBLY FOUR FLEXURE PIVOT SCREWS ASSEMBLY FLAPPER KEY 10 KEY 9 ASSEMBLY AND LINK 4 OBLONG HOLE IN FRAME FLEXURE PIVOT ASSEMBLY SCREWS KEY 12 wares WA4770 64 Instruction Manual 4195K Controllers D2
142. ng Bourdon Tube Controller Links 74 Replacing Link 1 74 Replacing Link2 75 Replacing Link3 76 Replacing Link4 77 Bourdon Tube Travel Stop Installation and Adjustment 78 Bourdon Tube Controller Calibration Zero and Span Adjustment 79 Capsular Element Controller Maintenance and Calibration 82 Replacing the Capsular Element lt lt 82 Replacing Capsular Element Parts 83 Replacing the Long Pivot Assembly 83 Replacing the Short Pivot Assembly 84 Replacing the Process Drive Flexure 84 Replacing the Process Tubing 85 Replacing Capsular Element Controller Links 85 Replacing Link 1 86 Replacing Link2 86 Replacing Link3 87 Replacing Link 4 87 Replacing Link 5 88 Capsular Element Controller Maintenance Calibration 88 Precalibration Procedure 89 Aligning the Drive Bracket Assembly 89 Setting the Travel Stops 89 Aligning the Linkage 90 Capsular Element Controller Zero and Span Adjustment 91 Remote Set Point suffix letter M Maintenance 92 Replacing the
143. nk 4 out of the hole in the bellows bracket key 31 and ensure that it drops back into the hole under its own weight If not repeat steps 8 and 9 11 Fora controller with reset adjust the reset adjustment to 0 01 minutes per repeat The rate adjustment 4195KC should remain in the OFF position 12 The controller output should be within 0 14 bar 2 psig of the supply pressure If not adjust flapper leveling screw 1 the screw nearest the nozzle until the output is within 0 14 bar 2 psig of supply pressure 13 Remove the tape from the process pointer and connect link 1 to the pivot arm 14 Perform the controller calibration procedures and if necessary the appropriate remote set point calibration procedure in Section 3 4 or 5 Replacing Capsular Element Controller Link 5 1 Remove the two screws key 6 and lift off the proportional band indicator cover key 36 2 Note the location of the connection holes and disconnect both ends of link 5 key 88 from the lever arms of the two pivot assemblies Refer to figure 6 22 for parts locations 3 Loosen the adjustment screw on the replacement link and adjust the length to match the original link Tighten the adjustment screw 4 Attach the replacement link to the two lever arms in the same holes noted in step 2 5 Move the set point indicator either manually or with remote set point pressure to the mid scale mark on the process scale and set the proportional band between DIRECT a
144. nterclockwise in the slot If the misalignment is greater than 1 percent of the process scale span at the lower and upper limits with one positive and the other negative perform the remote set point zero and span adjustment procedure to correct a span error Repeat steps 1 through 4 until lower middle and upper indications are within 1 percent of the process scale markings Auto Manual Station suffix letter E Maintenance Replacing the Auto Manual Station A WARNING Refer to the Maintenance WARNING on page 51 Refer to figures 7 1 and 7 7 for key number locations 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 Disassembly 1 Remove the controller assembly from the case by performing steps 1 through 3 of the case and cover replacement procedure Loosen the screw key 316 that holds the auto manual station key 273 to the controller frame Loosen the two screws keys 314 and 315 that hold the auto manual station to the auto manual tubing assembly key 138 4 Remove the auto manual station from the controller frame 5 Remove the switch manifold O rings key 312 6 Carefully loosen the nut on the relay nozzle tubing assembly key 18 where it connects to the auto manual tubing 7 assembly key 138 Loosen three screws keys 34 and 131 and remove the tubing assembly and frame
145. ocations Refer to figure 6 13 for a detailed photograph of the Bourdon tube controller link locations and adjustments 1 Disconnect link 1 key 382 from the Bourdon tube key 383 as shown in figure 6 14 2 Unscrew the tubing nut from the Bourdon tube to allow for Bourdon tube removal 3 Remove the self tapping screws key 384 that fasten the Bourdon tube key 383 to the indicator assembly key 101 4 With care separate the Bourdon tube key 383 from the process tubing assembly key 381 and lift out the Bourdon tube 5 Carefully place the replacement Bourdon tube in position and start the two self tapping screws Connect the process tubing assembly then tighten the self tapping screws to secure the Bourdon tube 6 Apply process pressure equal to the process scale upper limit and check for leaks Remove process pressure 7 Connect link 1 to the Bourdon tube 8 With the process pressure at 0 percent the process pointer should indicate 0 percent on the process scale If not loosen the two screws on link 1 and adjust the length of link 1 to position the process pointer at 0 percent Tighten the screws 9 Perform the controller calibration procedures and if necessary the appropriate remote set point calibration procedure in Section 3 4 or 5 73 4195K Controllers December 2012 Instruction Manual D200160X012 Figure 6 13 Bourdon Tube Controller Link Locations and Adjustments COURSE ZERO ADJUSTMENT LINK 4 ADJU
146. onnect link 2 to the flapper assembly 9 Remove the tape from the process pointer and reconnect link 1 to the Bourdon tube 10 Perform the controller calibration procedures and if necessary the appropriate remote set point calibration procedure in Section 3 4 or 5 Replacing Bourdon Tube Controller Link 3 N Oo Remove the two screws key 6 and lift off the proportional band indicator cover key 36 Disconnect link 3 from the set point indicator and the set point beam assembly key 23 Adjust the replacement link to the same length as the link removed Install the replacement link with the screw head toward the set point beam assembly as shown in figure 6 13 Check that the set point beam bias spring key 28 is correctly located in the frame bore and the spring seat on the set point beam assembly as shown in figure 6 3 Move the set point indicator to the mid scale mark on the process scale Apply process pressure to position the process pointer at the mid scale mark on the process scale 8 Adjust the proportional band to 5 percent DIRECT Turn flapper leveling screw 3 the screw nearest the nozzle until the nozzle just touches the flapper Adjust the proportional band to 5 percent REVERSE Turn flapper leveling screw 1 the screw nearest the nozzle until the nozzle just touches the flapper Happer leveling screws 1 and 3 should protrude the same distance from the clinch nuts A clinc
147. ons along the bottom of the case Hold the controller assembly in place while tightening the nine mounting screws 7 Perform the controller calibration procedures and if necessary the appropriate remote set point calibration procedure in Section 3 4 or 5 8 Mount the controller as described in the Installation section 9 Connect the external piping to the controller Replacing the Proportional Band Adjustment Knob Nozzle Assembly and Set Point Beam Assembly A WARNING Refer to the Maintenance WARNING on page 51 Figure 6 3 shows the parts locations for the proportional band adjustment and set point beam Unless otherwise noted refer to this figure while performing the following procedures Disassembly 1 Remove the controller assembly from the case by performing steps 1 through 3 of the case and cover replacement procedure 2 Remove the two machine screws key 6 and lift off the proportional band indicator cover key 36 See figure 7 1 for parts location 3 Disconnect link 3 from the set point beam shoe part of the set point beam assembly key 23 4 Remove the set point beam bias spring key 28 5 Remove the screw and washer keys 19 and 20 that hold the adjustable set point pivot assembly key 17 to the frame and remove the pivot assembly 6 Unscrew the nut that secures the relay nozzle tubing assembly key 18 to the frame manifold key 135 58 Instruction Manual 4195K Controllers
148. opriate remote set point calibration procedure in Section 3 4 or 5 Replacing the Process Tubing 1 Remove process pressure from the controller 2 Using two open end 5 16 inch wrenches disconnect the process tubing keys 91 or 92 at the pedestal assembly key 81 and at the bottom of controller case Remove the tubing 3 Install the replacement tubing and tighten all connections Check for leaks 4 Perform the controller calibration procedures and if necessary the appropriate remote set point calibration procedure in Section 3 4 or 5 Replacing Capsular Element Controller Links A WARNING Refer to the Maintenance WARNING on page 51 This section describes the separate replacement of five links in the controller Figure 6 21 shows the location of each link To clarify the location of each link the links are numbered as follows Link 1 connects the short pivot clevis assembly and the process pointer Link 2 connects the process pointer and the flapper assembly key 11 Link 3 connects the set point indicator and the set point beam assembly key 23 Link 4 key 65 connects the flapper assembly and the bellows bracket key 31 Link 5 key 88 in figure 7 5 connects the short pivot clevis assembly key 89 and the long pivot clevis assembly key 78 85 4195 Controllers Instruction Manual December 2012 D200160X012 Figure 6 21 Capsular Element Controller Link Locations and Adjustments LINK 4 LINK 4 AD
149. or 4195KB and KC controllers 29 4195 Controllers Instruction Manual December 2012 D200160X012 Calibration of 4195KB and KC Controllers To avoid personal injury or property damage resulting from the sudden release of pressure do not exceed the operating limits given in this manual General Calibration Instructions Note If the controller has the auto manual station suffix letter E be sure the controller is in the automatic mode before performing calibration If the prestartup checks or startup reveal faulty controller operation perform the calibration described in this section These instructions are valid for either shop or field calibration provided that open loop conditions exist Unless otherwise noted key numbers are found in figure 7 1 Do not use the gauges supplied with the controller during calibration Monitor process pressure supply pressure controller output pressure and if applicable remote set point pressure with external gauges Process Indicator Zero and Span Calibration Before starting this procedure e Provide a regulated process pressure to the controller and a means of measurement external to the controller Provide a means of measuring the controller output pressure by connecting the controller output to a pressure gauge open loop conditions must exist Provide a regulated supply pressure to the controller Do not exceed the normal operating pressure in table 1 6 Refer to figures 4
150. ote Key numbers 37 61 376 377 and 378 are not included as part of the indicator assembly key 101 If replacing the indicator assembly and these parts are required order them separately 37 Self tapping screw 18 8 SST 4 req d to attach process scale key 61 to process scale bracket key 376 61 Process scale aluminum 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 See Key 61 tables Figure 7 4 Indicator Assembly 39A1126 H 116 Key 368 369 370 371 372 374 375 376 377 378 Description Link ass y 18 8 SST 2 req d Process pointer adj ass y aluminum SST brass Set pt pointer ass y aluminum SST brass Pivot pin 530200 302 SST 2 req d Washer plain 18 8 SST 4 req d Pointer and bracket ass y aluminum steel Set pt indicator ass y A93003 aluminum For controllers w remote set pt For controllers w o remote set pt Dial Bracket G10080 steel Dial bracket G10080 steel Screw self tapping 18 8 SST 2 req d Instruction Manual D200160X012 4195K Controllers December 2012 Key 61 Process Scale Positive Pressure Key 61 Process Scale All Controllers Scale Range Part Number to 100 1R0003X1042 0 to 10 Square Root 1R0003X1172 0 to 100 Square Root 1R0003X1292 Key 61 Process Scale Vacuum and Compound
151. ove the proportional band adjustment knob key 25 and plastic washer from the set point beam assembly key 23 Inspect the nozzle assembly key 21 and if necessary replace it Inspect the nozzle orifice and if necessary clean it Also inspect the plastic washers and if necessary replace them Inspect the nozzle assembly O ring key 24 and if necessary replace it Assembly 1 Apply a suitable lubricant such as key 318 or equivalent to the set point beam assembly then position a plastic washer key 22 and the proportional band adjustment knob key 25 on the set point beam assembly key 23 as shown in figure 6 3 2 Position the retaining clip key 26 on the three posts on the proportional band adjustment knob 3 Place the second plastic washer on the nozzle assembly Apply a suitable lubricant such as key 317 or equivalent to 60 the nozzle assembly O ring Insert the nozzle assembly key 21 through the set point beam assembly key 23 the plastic washer key 22 the proportional band adjustment knob key 25 and the retaining clip key 26 into the cap Align the nozzle with the tab on the proportional band adjustment knob shown in figure 6 4 make sure the proportional band adjustment knob engages the flats on the nozzle assembly While holding the nozzle assembly 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
152. pressure to the desired switching point at which the controller output signal switches from full supply pressure to zero pressure Narrow or widen the proportional band slowly until the output signal switches from full supply pressure to zero pressure Repeat steps 4 through 6 until the controller output switches at the desired points Figure 5 3 Curve for Determining Proportional Band Setting PROPORTIONAL BAND SETTING 10 20 30 40 50 60 70 80 90 100 SENSOR RANGE BETWEEN SWITCHING POINTS A2853 1 47 4195 Controllers Instruction Manual December 2012 D200160X012 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 pressure passes the lower switching point The controller output signal will not return to zero pressure until increasing process pressure passes the upper switching point When making adjustments 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 adjustment will widen or narrow the differential gap between the two switching points by moving the position of the lower switching point Figure 5 3 shows the r
153. pring adjustment screw key 285 all the way out to eliminate loading the range spring 2 Position the range spring cup key 284 range spring key 283 and the diaphragm assembly key 281 on the upper 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 5 Attach the tubing assembly key 309 6 Perform the assembly portion of the replacing the auto manual station procedure Replacing the Loader Valve Plug and Valve Plug Spring A WARNING Refer to the Maintenance WARNING on page 51 103 4195 Controllers Instruction Manual December 2012 D200160X012 Refer to figure 7 7 for key number location 1 o DUN KRW Remove the controller assembly from the case by performing steps 1 through 3 of the case and cover replacement procedure 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 Install the val
154. rclockwise to decrease span for a high indication above the upper limit 7 Repeat steps 3 through 6 until the error is eliminated 8 Apply process pressure equal to the mid scale value of the process scale span The process pointer should indicate 10 11 12 13 14 the mid scale mark 2 percent of span If the error is greater than 2 percent refer to the Maintenance section and perform the appropriate zero and span adjustment procedure for a Bourdon tube or capsular element controller Adjust the process pointer to within 1 percent of the mid scale mark by loosening the locking screw and turning the zero adjustment screw This distributes the error over the entire scale span and brings all points within 1 percent of the process input span Apply process pressure equal to the process scale span lower limit The process pointer should indicate the process scale lower limit 1 percent of the scale span Apply process pressure equal to the process scale span upper limit The process pointer should indicate the process scale upper limit 1 percent of the scale span If the error is greater than 1 percent repeat steps 3 through 13 Remote Set Point suffix letter M Zero and Span Calibration Refer to figures 3 1 and 3 3 for adjustment locations Refer to figure 7 1 for key number locations Note Any adjustment of the remote set point span adjustment screw requires readjustment of the remote set point zero adjustment scre
155. re by connecting the controller output to a pressure gauge open loop conditions must exist Do not apply supply pressure at this time Setthe reset adjustment to 0 01 minutes per repeat wide open and the rate adjustment 4195KC controllers only to the OFF position Foracontroller with manual set point move the set point indicator to the mid scale mark on the process scale For a controller with remote set point adjust the remote set point pressure until the set point indicator is at the mid scale mark on the process scale Setthe proportional band to 100 percent in either the DIRECT or REVERSE action depending on the application requirements Refer to figure 4 3 for the location of the anti reset windup differential relief valve For the differential relief valve to relieve on rising controller output pressure install the valve so the arrow on the valve points down To change the direction of the arrow loosen the two mounting screws pull the valve out and reinstall the valve with the arrow pointing down Tighten the two mounting screws Provide a regulated supply pressure to the controller Do not exceed the normal operating pressure in table 1 6 Note Because of the high controller gain with the reset adjustment at 0 01 minutes per repeat the controller output will not balance perfectly in the following step If the controller output is stable for approximately 5 seconds it is adequately balanced VE 8 9
156. rear of the controller using three cap screws key 66 and lock washers key 67 Tighten the screws key 70 to seat the case snugly and evenly against the panel surface Instruction Manual 4195K Controllers D200160X012 December 2012 Figure 2 3 Panel Mounting HEX HEAD 13 CAP SCREW KEY 66 BRACKET 2 68 2 43 84 ROUND geil n i 63 i MACHINE 12 06 2 49 SCREW hava KEY 70 14 TOP VIEW PAN 036R SSS 236 REAR VIEW 231 mm eu DIMENSIONS OF INCH pos PANEL CUTOUT Wall Mounting Using the dimensions in figure 2 4 drill holes in the wall to align with the four holes in the bracket key 68 If the tubing is to run through the wall drill a hole in the wall large enough to accept the tubing Mount the controller to the bracket using three cap screws key 66 and lock washers key 67 Attach the bracket to the wall using suitable screws or bolts Figure 2 4 Wall Mounting HEX HEAD CAP SCREW KEY 66 TOP VIEW LOCKWASHER 1 67 13 2 43 0 50 13 0 50 68 REAR VIEW mm SLE INCH Actuator Mounting Refer to figure 2 1 A controller specified for mounting on a control valve actuator is mounted at the factory If the controller is ordered separately for installation on a control valve actuator mount the unit as described in this section Mounting parts vary for diff
157. ressure set the reset adjustment to 0 01 minutes per repeat and wait 30 seconds then turn the reset adjustment to the CLOSED 4195KB or OFF 4195KC position 36 Apply the correct supply pressure refer to table 1 6 to the controller and provide an accurate means of measuring the controller output pressure 37 Adjustthe proportional band to 5 percent REVERSE and adjust the set point to the process scale upper limit 38 With link 1 disconnected tape the process pointer at the process scale lower limit The output pressure should be within 0 14 bar 2 psig of the supply pressure If not adjust flapper leveling screw 1 the screw nearest the nozzle until the output is within 0 14 bar 2 psig of supply pressure 39 Loosen the two adjustment screws on link 4 shown in figure 6 10 and connect the link to the bellows bracket key 31 allowing the link to find its free length 40 Tighten the two adjusting screws on link 4 41 Liftlink 4 out of the hole in the bellows bracket key 31 and ensure it drops back into the hole under its own weight If not repeat steps 39 and 40 42 Adjust the proportional band to 40 percent REVERSE or DIRECT depending on the desired controller action 43 Adjust the set point to the process scale lower limit 44 Tape the process pointer at the process scale lower limit The output pressure may be anywhere between 0 2 to 1 0 bar 3 and 15 psig for a 0 2 to 1 0 bar 3 to 15 psig output signal range or bet
158. rform the controller calibration procedures and if necessary the appropriate remote set point calibration procedure in Section 3 4 or 5 Instruction Manual 4195K Controllers D200160X012 December 2012 Replacing Capsular Element Parts WARNING Refer to the Maintenance WARNING on page 51 CAUTION Avoid bending or kinking the drive flexure during the following procedures Bending or kinking the drive flexure can result in product damage as well as impaired performance Refer to figure 7 5 for capsular element key number locations Refer to figure 6 19 for adjustment locations and refer to figure 7 4 for indicator assembly without process sensing element part locations Replacing the Long Pivot Assembly 1 Remove process pressure from the controller Remove the tie bar key 97 from the capsular element assembly by removing the mounting screws key 103 Note the hole position of link 5 key 88 and disconnect the link from the pivot adjustment arm on the long pivot clevis assembly key 78 Using an Allen wrench remove the cap screw and washer keys 12 and 13 that attach the drive flexure key 79 to the pivot adjustment arm of the long pivot clevis assembly Take care not to bend or kink the drive flexure 5 Remove the two screws key 102 attaching the long pivot clevis assembly to the mounting plate key 77 Loosen the screw on the pivot adjustment arm of the replacement pivot clevis assembly and adjust the
159. roller is a proportional only 4195KA or KS controller go to step 33 If the controller has reset 4195KB or KC controller continue with step 21 Note The following procedure steps 21 through 32 adjusts the reset gain of the controller to minimize steady state offset 21 22 23 Apply the correct supply pressure refer to table 1 6 to the controller and provide an accurate means of measuring the controller output pressure Also provide a means of applying regulated process pressure Adjust the proportional band to 100 percent DIRECT Adjust the set point to the mid scale mark on the process scale 69 4195 Controllers Instruction Manual December 2012 D200160X012 24 Adjustthe reset adjustment to 0 01 minutes per repeat For a 4195KC controller set the rate adjustment to OFF 25 ncrease the process pressure until the output pressure stabilizes at 0 2 bar 3 psig for a 0 2 to 1 0 bar 3 to 15 psig output or 0 4 bar 6 psig for a 0 4 to 2 0 bar 6 to 30 psig output Record the process pressure reading Note When the reset valve is at 0 01 the controller is very sensitive to any process pressure change Only small process pressure changes may be necessary 26 Very slowly increase the process pressure until the output pressure stabilizes at 1 0 bar 15 psig for a 0 2 to 1 0 bar 3 to 15 psig output or 2 0 bar 30 psig for a 0 4 to 2 0 bar 6 to 30 psig output Record the process pressure reading 27 If the
160. roportional action temporarily reduces the gain of the controller for improved stability The process pressure then slowly returns to set point as pressure in both bellows equalizes via the reset action Moving the set point indicator changes the distance between 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 37 4195K Controllers Instruction Manual December 2012 D200160X012 Figure 4 6 Fisher 4195KC Controller Schematic EATUR RESET BELLOWS REVERSE ACTION QUADRANT PROPORTIONAL PROCESS POINTER REMOTE SET POINT CONNECTED HERE INPUT ELEMENT CONNECTED HERE CONNECTING LINK SUPPLY PRESSURE PAX OUTPUT PRESSURE NOZZLE PRESSURE RESET PRESSURE INN PROPORTIONAL PRESSURE 46A9764 B 0593 3 FLAPPER NOZZLE PROPORTIONAL BAND ADJUSTMENT FEEDBACK LINK MOTION FLAPPER PIVOT DIRECT ACTION QUADRANT INPUT MOTION FLAPPER DETAIL OUTPUT PRESSURE g Padi TO FINAL CONTROL ELEMENT 7 RELAY V VA SUPPLY PRESSURE RATE VALVE RESET VALVE PROPORTIONAL PLUS RESET PLUS RATE CONTROL TO TO RESET TO BELLOWS PROPORTIONAL NOZZIE BELLOWS 4 OUTPUT DIFFERENTIAL RELIEF VALVE RELAY PRESSURE PROPORTIONAL PLUS RESET PLUS RATE CONTROL WITH ANTI RESET WINDUP The proportional band adjustment positions the nozzle on the flapper Increas
161. s Before performing any maintenance operations e Always wear protective clothing gloves and eyewear 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 Personal injury or property damage may result from fire or explosion if natural gas is used as the supply pressure medium and preventive measures are not taken Preventive measures may include but are not limited to one or more of the following Remote venting of the unit re evaluation 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 14 e Disconnect any operating lines providing supply air pressure a process input signal or other pressure source to the controller 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 figures 7 1 through 7 7 Figures 3 1 and 3 3 show adjustment locations for 4195KA controllers figures 4 1 and 4 3 show adjustment locations for 4195KB and KC controllers and figures 5 1 and 5 2 show adjustment locations for 4195KS controllers For maintenance on the indicator assembly refer to figures 7 2 7 3 and 7 4 Select the appropriate maintenance procedure and perform the numbered steps Each procedure requires that t
162. s reflected by process and set point indicators Note Some offset is inherent with proportional only controllers 4195KA controllers The amount of offset is a function of the proportional band setting 2 7 Reset valve leaks 2 8 Leak remote set point system 2 9 Input element overpressured 2 7 Hold the input constant and adjust the output to 1 0 bar 15 psig for a 0 2 to 1 0 bar 3 to 15 psig output or 2 0 bar 30 psig fora 0 4 to 2 0 bar 6 to 30 psig output Close the reset valve If the controller output varies as the reset valve is closed and no leaks were found in the rest of the feedback system Step 2 6 the reset valve is leaking 2 8 Adjust remote set point pressure to 1 0 bar 15 psig Using soap solution check for leaks in the remote set point and tubing assembly 2 9 Check for zero shift 2 7 Replace the reset valve 4195KB controllers or the rate reset valve 4195KC controllers 2 8 Repair or replace parts as necessary 2 9 Replace input element and adjust travel stops of applicable 3 Controlling off set point but not reflected by process and set point indicators 3 1 Controller is out of calibration 3 1 Referto the process indicator remote set point if applicable and flapper alignment procedures 3 1 Adjust as necessary 4 Noreset action 4195KB and 4195KC controllers 4 1 Reset valve is plugged 4 2 Reset pressure leak 4 3 Tubing leak 4 1 Turn the reset valve
163. s Instruction Manual December 2012 D200160X012 b If the pointer indicates greater than the process scale upper limit rotate the pointer span adjustment counterclockwise to decrease the span Adjust the span adjustment screw to correct for one half of the error 13 Repeat steps 9 through 12 until the zero and span indications are within 1 percent of the scale limits with no further adjustment If proper span is achieved proceed to step 16 If the span adjustment screw is adjusted to its limit and the span is still too short or too long proceed with step 14 14 Within the process pointer subassembly there are three holes for the connection of link 1 Use procedure a or b below to make the coarse span adjustment with link 1 a If the span is short process pointer indication is less than the process scale upper limit disconnect link 1 from the process pointer subassembly move the link to the lowest hole the hole nearest the pointer pivot and return to step 9 If the link is already in the lowest hole proceed to step 15 b If the span is long process pointer indication is greater than the process scale upper limit disconnect link 1 from the process pointer subassembly move the link to the highest hole the hole furthermost from the pointer pivot and return to step 9 If the link is already in the highest hole proceed to step 15 15 Ateither end of link 5 there are four holes in which the link may be connected A coars
164. s to the mid scale mark on the process scale Tighten the screws 9 Apply process pressure equal to the process scale lower limit 11 12 80 The process pointer should indicate the process scale lower limit If not loosen the zero adjustment locking screw and adjust the zero adjustment screw until the process pointer indicates the lower limit Tighten the zero adjustment locking screw Apply process pressure equal to the process scale upper limit The pointer should indicate the process scale upper limit If not proceed as follows a If the pointer indicates less than the process scale upper limit rotate the pointer span adjustment clockwise to increase the span Adjust the span adjustment screw to correct for half of the error b If the pointer indicates greater than the process scale upper limit rotate the pointer span adjustment counterclockwise to decrease the span Adjust the span adjustment screw to correct for half of the error Repeat steps 9 through 12 until the zero and span indications are within 1 percent of the scale limits with no further adjustment If proper span is achieved proceed to step 15 If the span adjustment screw is adjusted to its limit and the span is still too short or too long proceed with step 14 Within the process pointer subassembly there are three holes for the connection of link 1 Use procedure a or b below to make the coarse span adjustment with link 1 a If the span
165. st flapper leveling screw 1 the screw nearest the nozzle until the output is within 0 14 bar 2 psig of supply pressure 77 4195 Controllers Instruction Manual December 2012 D200160X012 13 Remove the tape from the process pointer and connect link 1 to the Bourdon tube 14 Perform the controller calibration procedures and if necessary the appropriate remote set point calibration procedure in Section 3 4 or 5 Bourdon Tube Travel Stop Installation and Adjustment A WARNING Refer to the Maintenance WARNING on page 51 Note The process indicator should be calibrated before installing or adjusting travel stops Refer to the appropriate process indicator zero and span calibration procedure in Section 3 4 or 5 Refer to figure 6 18 for adjustment locations and figure 7 1 for key number locations The lower travel stop is necessary only if the operating range lower limit is greater than 0 bar or 0 psig elevated zero For example The process scale limits may be 0 to 300 psig but the range of operation is 150 to 300 psig In this example the elevated zero is 150 psig and the lower travel stop would be adjusted for 5 percent of the process scale span less than 150 psig 150 0 05 X 300 135 psig 1 Remove the two screws key 6 and lift off the proportional band indicator cover key 36 2 Setthe proportional band between DIRECT and REVERSE 3 Install the upper travel stop key 73 or upper and lower travel stops
166. st to the bellows bracket key 31 and so that the screw heads are facing the bottom of the controller as shown in figure 6 21 4 For controllers with reset 4195KB controllers or reset and rate adjustments 4195KC controllers turn the reset adjustment to the CLOSED 4195KB or OFF 4195KC position Turn the rate adjustment 4195KC to the OFF position 87 4195 Controllers Instruction Manual December 2012 D200160X012 The controller output must be 0 bar 0 psig To be sure the controller output is at 0 bar 0 psig remove supply pressure set the reset adjustment to 0 01 minutes per repeat and wait 30 seconds then turn the reset adjustment to the CLOSED 4195KB or OFF 4195KC position 5 Adjust the proportional band to 5 percent REVERSE and move the set point indicator to the process scale upper limit 6 Disconnect link 1 from the pivot arm Tape the process pointer to the process scale lower limit the last mark on the left side of the scale 7 Apply the correct supply pressure to the controller The output of the controller should be within 0 14 bar 2 psig of supply pressure If not adjust flapper leveling screw 1 the screw nearest the nozzle until the output is within 0 14 bar 2 psig of supply pressure 8 Loosen the two adjusting screws on link 4 Connect the free end of the link to the bellows bracket and allow the link to find its free length 9 Tighten the two adjusting screws on the link 10 Raise li
167. stop If it does repeat steps 10 through 13 15 Adjust the proportional band to 400 percent in the desired action and install the proportional band indicator cover key 36 Tighten the two screws key 6 78 Instruction Manual 4195K Controllers D200160X012 December 2012 Figure 6 18 Bourdon Tube Controller Travel Stop Adjustment LOWER TRAVEL STOP ADJUSTMENT LOCK NUT MOUNTING SCREW KEY 76 MOUNTING SCREWS KEY 75 LOOSEN THESE SCREWS TO ADJUST UPPER TRAVEL STOP MOUNTING SCREW KEY 76 UPPER TRAVEL STOP KEY 73 LOWER TRAVEL STOP LOWER TRAVEL KEY 74 STOP ADJUSTMENT 56A9752 U SHT 4 A6945 Bourdon Tube Controller Calibration Zero and Span Adjustment A WARNING Refer to the Maintenance WARNING on page 51 Note For routine zero and span calibration refer to the appropriate procedures in Section 3 4 or 5 Use the following maintenance zero and span adjustment procedure only if difficulty is encountered with the routine procedure or if nonlinearity occurs Refer to figure 6 19 for location of adjustments and figure 7 1 for key number locations Provide a means of applying process pressure to the Bourdon tube and a regulated supply pressure adjusted to the normal operating pressure see table 1 6 For 4195KA and KS controllers connect the controller output to an accurate gauge For 4195KB and KC controllers a gauge is not necessary and the controller output connection may be plugged 79
168. t locking screw This distributes the error over the entire process scale and keeps all points within 1 percent of the process scale span 18 Adjustthe process pressure to the lower and upper limits of the scale span to make sure the process pointer is still within 1 percent of the lower and upper scale limits 19 Perform the flapper alignment procedure and if necessary the appropriate remote set point calibration procedure in Section 3 4 or 5 Remote Set Point suffix letter M Maintenance Replacing the Remote Set Point Assembly A WARNING Refer to the Maintenance WARNING on page 51 92 Instruction Manual 4195K Controllers December 2012 D200160X012 Use the following procedures to replace the remote set point assembly Figure 6 23 shows the part locations Refer to figure 7 6 for key number locations Figure 6 23 Remote Set Point suffix letter M Parts and Adjustment Locations GUIDE FLEXURE MOUNTING SCREW DRIVE FLEXURE ADJUSTMENT SCREW LOWER TRAVEL PIVOT ASSEMBLY A LINK B LINEARITY ADJUSTMENT CN PIVOT L ASSEMBLY B H MOUNTING NNN m TIE BAR SCREW CAPSULES D REMOTE SET POINT ZERO ADJUSTMENT SCREW ZERO ADJUSTMENT LOCKING SCREW FRONT VIEW SIDE VIEW 36A9751 C B1668 4 Note Remove the supply pressure gauge before attempting to remove the capsular element assembly Decrease the remote set point pressure to 0 bar 0 psig Remove the supply press
169. tching points This is accomplished by moving 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 by moving the position of the upper switching point 49 4195 Controllers Instruction Manual December 2012 D200160X012 Remote Set Point Option M The capability to adjust the controller set point from a remote location is available with all 4195KS controllers This option is designated by the letter M in the type number Auto Manual Option Controllers with the auto manual option designated by the letter E in the type number have piping on the output side of the relay as shown in figure 5 5 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 When the auto manual switch is in the MANUAL position the manual loader output 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 relay output is channeled through the switch to become the output of the controller Before the auto manual switch is operated the relay output must equal the manual loader output to avoi
170. te the hole position and disconnect link 1 from the short pivot clevis assembly Manually position the process pointer to the process scale upper limit and tape the process pointer in this position 7 Adjust the length of link 2 by turning the adjusting screw clockwise to increase the length or counterclockwise to decrease the length so that the pin on the end of the link is approximately one half of its diameter short of aligning with the hole in the flapper assembly as shown in figure 6 11 This adjustment provides the proper tension on the link to eliminate lost motion 8 Connect link 2 to the flapper assembly 9 Remove the tape from the process pointer and reconnect link 1 to the hole in the short pivot clevis assembly noted in step 6 10 Perform the controller calibration procedures and if necessary the appropriate remote set point calibration procedure in Section 3 4 or 5 Replacing Capsular Element Controller Link 3 Remove the two screws key 6 and lift off the proportional band indicator cover key 36 Disconnect link 3 from the set point indicator and the set point beam assembly key 23 Adjust the replacement link to the same length as the link removed Install the replacement link with the screw head toward the set point beam assembly as shown in figure 6 21 N Check that the set point beam bias spring key 28 is correctly located in the frame bore and the spring seat on the set point beam assembly
171. teel 98 Machine screw fill hd 18 8 SST Used to attach the guide flexure p o drive bracket ass y to mounting plate 99 Plain washer 18 8 SST 118 Key Description 102 Machine screw fill hd 18 8 SST For mounting the short pivot clevis ass y key 89 and the long pivot clevis ass y key 78 to the mounting plate key 77 4 req d 103 Machine screw pan hd 18 8 SST For mounting tie bar key 97 to pedestal ass ies key 81 and to travel stop key 83 2 req d 130 Diaphragm ass y extension A96061 aluminum See key 80 table to determine if required 132 Diaphragm ass y extension A96061 aluminum See key 80 table to determine if required 133 Diaphragm ass y extension A96061 aluminum See key 80 table to determine if required 139 Machine screw fill hd 18 8 SST 2 req d to mount each pedestal ass y key 81 4 req d Relay figure 6 2 Relay Assembly includes keys 13 and 15 0 2 to 1 0 bar 3 to 15 psig 0 4 to 2 0 bar 6 to 30 psig 10 Relay mounting screw 18 8 SST 2 req d 13 O ring nitrile 15 O ring nitrile 2 req d Note The above relay parts are included in the 4190 Relay Replacement Kit Instruction Manual D200160X012 4195K Controllers December 2012 Figure 7 5 Capsular Element Assembly 30 n 7 48 i 86 C aa ee Cu ee 7 62 VIEW A A n 84 Oz 8 e I3 z ERIS 997 68
172. ten the two machine screws Turn the proportional band adjustment knob to 5 percent DIRECT Refer to figure 6 6 to locate the locking nut on the adjustable set point pivot assembly Loosen the locking nut and back out the set screw slightly so that the set point beam assembly falls under its own weight when pivoted upward Also maintain a minimum side play between the adjustable set point pivot assembly and the nozzle tubing assembly Tighten the locking nut At the frame manifold key 135 tighten the nut that secures the tubing from the relay nozzle tubing assembly key 18 Apply full supply pressure with the nozzle capped to obtain maximum output pressure and check for leaks Remove supply pressure Install the set point beam bias spring key 28 into the frame bore and onto the spring seat on the set point beam assembly as shown in figure 6 3 Instruction Manual 4195K Controllers D200160X012 December 2012 34 Attach link 3 to the set point beam shoe as shown in figure 6 3 Note The following procedure steps 35 through 41 adjusts link 4 so it will always be in compression to eliminate possible instability due to lost motion 35 For controllers with reset and rate adjustments 4195KB or 4195KC controllers remove the supply pressure then turn the reset adjustment to the CLOSED 4195KB or OFF 4195KC position The controller output must be 0 bar 0 psig To be sure the controller output is 0 bar 0 psig remove supply p
173. th anti reset windup suffix letter F unscrew the nut holding the relief tubing assembly key 44 into the rate reset assembly 7 While holding the rate reset valve assembly remove the machine screw key 162 from the frame 8 Remove the rate reset valve assembly from the frame 9 Inspect and if necessary replace the gasket key 5 10 To install the replacement rate reset valve assembly position the assembly on the frame key 3 and secure it with the mounting screw key 162 11 Position the gasket key 5 on the rate reset valve assembly Hold the gasket in place while installing the rate tubing assembly key 137 on the valve assembly using the two machine screws key 71 12 Insert the reset tubing assembly key 43 into the rate reset valve assembly and tighten the nut 13 Insert the proportional tubing assembly key 40 into the rate reset valve assembly and tighten the nut 71 4195 Controllers Instruction Manual December 2012 D200160X012 14 For controllers with anti reset windup suffix letter F insert the relief tubing assembly key 44 into the rate reset valve assembly and tighten the nut 15 Set the reset to 0 01 minutes per repeat and the rate to OFF 16 Apply the proper supply pressure to the controller and check for leaks Remove the supply pressure 17 Position the controller assembly in the case and start but do not tighten the nine mounting screws Slide the controller assembly down to assure an O
174. that secure the travel stop key 83 to the mounting plate key 77 Slide the travel stop until it is just touching the end of the 89 4195 Controllers Instruction Manual December 2012 D200160X012 capsule stack Tighten the travel stop mounting screws to lock it into position Decrease the input pressure to 100 percent of the capsular element range and make sure the capsule stack is not contacting the travel stop key 83 For positive or compound pressure with a two capsule stack loosen the set screw key 87 in the travel stop nut key 86 between the travel stop key 83 and the capsule stack Slide the nut along the diaphragm capsule extension key 130 until it just touches the travel stop key 83 Tighten the set screw to lock the travel stop nut in position Decrease the input pressure to 100 percent of the capsular element range and make sure the travel stop nut is not contacting the travel stop key 83 e For vacuum pressure loosen the set screw key 87 in the travel stop nut key 86 on the end of the diaphragm capsule extension key 132 or 133 The nut is located on the opposite side of the travel stop key 83 from the capsule Slide the nut along the diaphragm capsule extension until it just touches the travel stop key 83 Tighten the set screw to lock the travel stop nut in position Decrease the vacuum to 100 percent of the capsular element range and make sure the travel stop nut is not contacting the travel stop key
175. through its range several times to remove any restrictions 4 2 Adjust the output to 1 0 bar 15 psig for a 0 2 to 1 0 bar 3 to 15 psig output or 2 0 bar 30 psig fora 0 4 to 2 0 bar 6 to 30 psig output Close the reset valve If the output varies and no leaks were found in the rest of the feedback system see Step 2 6 the reset valve is leaking 4 3 With reset valve positioned at 01 minute repeat put 1 0 bar 15 psig to the output port Using soap solution check for leaks in the reset bellows and attached tubing assembly 4 1 If reset action returns no further action is necessary If not replace the reset valve 4195KB controllers or rate reset valve 4195KC controllers 4 2 Replace the reset valve 4195KB controllers or the rate reset valve 4195KC controllers 4 3 Repair or replace parts as necessary 5 Abnormal control point shift when proportional band is changed Note Control point shift is inherent when changing proportional band in proportional only controllers 4195KA controllers 5 1 Flapperis out of alignment 5 2 Flapperis dirty or pitted 5 1 Referto flapper alignment procedure 5 2 Inspectthe flapper 5 1 Align flapper as necessary 5 2 Clean or replace flapper as necessary 6 Controller will not attain full output range 6 1 Output pressure gauge not functioning 6 2 Supply pressure not correct 6 3 Proportional band setting too wide 4195KA controllers only 6 4
176. to 600 1R0003X0082 0 to 1000 1R0003X0092 0 to 1500 1R0003X0102 0 to 3000 1R0003X0112 0 to 5000 1R0003X0122 0 to 200 1R0003X0922 0 to 400 1R0003X0932 0 to 700 1R0003X0942 0 to 1400 1R0003X0702 0 to 2000 1R0003X0952 0 to 4000 1R0003X0962 0 to 7000 1R0003X0972 0 to 10 000 1R0003X0712 0 to 20 000 1R0003X0982 0 to 35 000 1R0003X0992 117 4195K Controllers December 2012 Instruction Manual D200160X012 Capsular Element Assembly key 113 figure 7 5 Key Description 12 Capscrew hex socket 18 8 SST 2 req d 13 Plain washer 18 8 SST 2 req d 77 Mounting plate G10100 pl steel 78 Long pivot clevis ass y plastic SST 79 Driveflexure S30200 302 SST 80 Diaphragm capsule 81 Pedestal assembly SST 82 Diaphragm ass y extension A96061 aluminum See key 80 table to determine if required 83 Travelstop CF8 SST casting 84 Drive bracket SST 86 Travel stop nut 530300 303 SST See key 80 table for quantity 87 Set screw 18 8 SST 1 req d for drive bracket ass y key 84 1 req d for each travel stop nut key 86 88 Connecting link ass y aluminum bronze brass 89 Short pivot clevis plastic SST 90 Connecting link ass y aluminum bronze brass 91 Process tubing ass y 530400 304 SST positive and compound capsule only 92 Process tubing ass y 530400 304 SST vacuum capsule only 93 Union S31600 316 SST 97 Tiebar G10100 pl s
177. to the mid range value 9 Make sure the set point indicator is within 1 percent of the mid scale mark and if so proceed to step 12 If the set point indicator is not within 1 percent but is within 2 percent of the mid scale mark proceed with step 10 If the set point indicator is not within 2 percent proceed to the remote set point zero and span adjustment procedure in the Maintenance section 32 Instruction Manual 4195K Controllers D200160X012 December 2012 10 Loosen the remote set point zero adjustment locking screw and adjust the remote set point zero adjustment screw to correct for half the error at mid scale Tighten the zero adjustment locking screw 11 Apply remote set point pressure equal to the lower and upper range limits and make sure the set point indicator is within 1 percent 12 If necessary perform the process indicator zero and span calibration procedure in this section Otherwise perform the flapper alignment procedure in this section Flapper Alignment Note Perform the process indicator zero and span calibration procedure and for controllers with remote set point suffix letter M the remote set point zero and span calibration procedure before the flapper alignment Flapper leveling screw numbers and adjustments are shown in figure 4 3 Key number locations are shown in figure 7 1 Provide a means of measuring the controller output pressure by connecting the controller output to a pressure gauge
178. to the process scale lower limit by loosening the zero adjustment locking screw and turning the zero adjustment screw Tighten the zero adjustment locking screw 5 Apply process pressure equal to the process scale span upper limit 6 The process pointer should indicate the process scale upper limit If not adjust the process pointer span screw to correct one half the error as follows clockwise to increase span for a low indication below the upper limit counterclockwise to decrease span for a high indication above the upper limit 7 Repeat steps 3 through 6 until the error is eliminated 8 Apply process pressure equal to the mid scale value on the process scale span The process pointer should indicate the mid scale mark 2 percent of span If the error is greater than 2 percent refer to the Maintenance section and perform the appropriate zero and span adjustment procedure for Bourdon tube or capsular element controllers 9 Adjust the process pointer to within 1 percent of the mid scale mark by loosening the zero adjustment locking screw and turning the zero adjustment screw This distributes the error over the entire scale range and brings all points within 1 percent of the process scale span 10 Apply process pressure equal to the process scale lower limit 11 The process pointer should indicate the process scale lower limit 1 percent of the scale span 12 Apply process pressure equal to the process scale upper limit 13
179. tors Note Some offset is inherent with proportional only controllers 4195KA controllers The amount of offset is a function of the proportional band setting 2 1 Supply pressure not set correctly 2 2 Flapper not aligned 2 3 Leak in input element tubing assembly 2 4 Indicators out of calibration 2 5 Linkage not connected correctly 2 6 Leak in feedback system 2 1 Check with an external source 2 2 Refer to the flapper alignment procedure 2 3 Using soap solution check the input element and tubing for leaks 2 4 Refer to the process indicator and remote set if applicable zero and span calibration procedures in this manual 2 5 Inspect for loose screws and damaged flexures links or pivots 2 6 Open the reset valve to 0 1 minute repeat Adjust output pressure to 1 4 bar 20 psig Using soap solution check for leaks in the proportional and reset bellows in the tubing that connects these bellows 2 1 Reset the supply pressure if necessary If the condition occurs again the regulator should be rebuilt or replaced 2 2 Align the flapper as necessary 2 3 Repair or replace parts as necessary 2 4 Adjust as necessary 2 5 Repair or replace parts as necessary 2 6 Repair as necessary 52 continued Instruction Manual 4195K Controllers D200160X012 December 2012 Table 6 1 Troubleshooting Chart continued Fault Possible Cause Check Correction 2 Controlling off set point a
180. trolled 1 Be sure the supply pressure regulator is delivering the proper supply pressure to the controller 2 For controllers with Manual set point Move the set point adjustment to the desired set point Remote set point a See figure 2 5 for the location of the remote set point connection Connect an adjustable pressure source to the remote set point connection b Adjust the pressure source until the set point indicator reaches the desired set point Remember Increasing the remote set point pressure increases the set point 3 Setthe proportional band adjustment to 100 percent for fast processes For slow processes calculate the proportional band percentage from the equation below 200 x Allowable Overshoot P B KS Pressure Span For example 200 x 0 14 bar _ 13 2 1 bar 4 Create a load upset by momentarily changing the set point Check for system cycling If the system does not cycle lower the proportional band setting thus raising the gain and disturb the system again by changing the set point Continue this procedure until the system cycles At this point double the proportional band setting proportional band setting x2 5 Check the stability of the recommended proportional band setting by introducing a disturbance and monitoring the process Calibration of 4195KA Controllers To avoid personal injury or property damage resulting from the sudden release of pressure do not exceed the operating limits given
181. tubing assembly key 45 from the positive feedback bellows depending on which bellows is to be replaced 7 Remove the four machine screws key 71 from the bellows beam and remove the bellows beam from the frame Figure 6 12 Bellows Assembly Bellows Bracket and Bellows Beam Location FOUR SCREWS KEY 6 RESET BELLOWS WASHER J lt 362 PROPORTIONAL 35 gt RESET d BELLOWS BRACKET KEY 31 Boe A yy thas DANN Poen NN INS 68 Instruction Manual 4195K Controllers D200160X012 December 2012 CAUTION When removing and replacing the proportional reset or positive feedback bellows keep in mind that the bellows has left hand threads Overtightening could damage the threads Note Both bellows need not be removed if only one requires replacement 8 Unscrew the bellows assembly key 48 If the bellows assembly cannot be removed by hand thread a machine screw key 35 into the bellows until tight then loosen the bellows assembly by applying clockwise torque to the machine screw Before installing the replacement bellows coat the threads with a suitable lubricant such as key 310 Screw in the replacement bellows until it is finger tight against the frame key 3 10 Reinstall the bellows beam key 49 and tighten the machine screws key 71 11 Position the bellows bracket key 31 over the bellows Insert a machine screw key 35 through the bellows br
182. tup Checks for 4195KS Controllers When performing the checks open loop conditions must exist Refer to figure 5 1 for location of adjustments Note If the controller has the auto manual option option E be sure the controller is in the automatic mode prior to 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 option M connect regulated pressure of 0 2 to 1 0 bar 3 to 15 psig or 0 4 to 2 1 bar 6to 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 cover key 36 and set the proportional band knob between DIRECT and REVERSE 4 The process indicator should indicate the process pressure For example with the process pressure at 50 percent of the input span the process pointer should be 50 percent 1 percent of its span Slight adjustment of the indicator zero screw may be necessary See figure 5 1 for zero adjustment and locking screw location 5 If desired the accuracy can be verified at other points on the scale If the indicator appears to be out of calibration refer to the process zero and span adjustment portion of the calibration procedure 6 Install the proportional band cover and install two screws key 6 Startup
183. turn the rate adjustment to OFF 8 Apply process pressure equal to the mid scale value of the process scale span If pressure is not available to pressure the input element to mid scale value an alternate method is to disconnect link number 1 at the input element and tape the process pointer at mid scale mark on the process scale If the controller has a capsular input element note the hole where link number 1 is connected to the input element then disconnect link 1 This method should only be used if pressure is not available to pressure the input element to the mid scale value N Note Because of the high controller gain the controller output will not remain stable in steps 9 through 13 The controller output gauge is adequate to check the output pressure during this procedure 33 4195 Controllers Instruction Manual December 2012 D200160X012 Setthe proportional band between DIRECT and REVERSE The controller output should be relatively stable at any value within the output range If not adjust flapper leveling screw 2 the screw nearest the nozzle until the output is relatively stable 11 Setthe proportional band to 30 percent DIRECT The controller output should be relatively stable at any value within the output range If not adjust flapper leveling screw 3 the screw nearest the nozzle until the output is relatively stable 12 Setthe proportional band to 30 percent REVERSE The controller output should be relative
184. uction Manual December 2012 D200160X012 5 Secure the scale with the four self tapping screws key 37 6 If the controller has remote set point suffix letter M perform the appropriate remote set point zero and span calibration procedure in Section 3 4 or 5 7 Perform the appropriate process indicator zero and span calibration and the flapper alignment procedures in Section 3 4 or 5 Replacing the Relay Refer to the Maintenance WARNING on page 51 1 Loosen the two captive screws that hold the relay key 50 in place 2 Tip the relay slightly toward the side of the case to clear the output pressure gauge key 46 and lift out the relay 3 Make sure the replacement relay has three O rings keys 13 and 15 installed as shown in figure 6 2 The fourth port is for exhaust and does not require an O ring 4 Install the replacement relay making sure the tab on the relay shown in figure 6 2 aligns with the tab on the frame 5 Tighten the two screws that hold the relay in place Figure 6 2 Relay Construction CLEAN OUT WIRE EXHAUST PORT NO O RING USED O RINGS KEY 15 O RING KEY 13 RELAY TAB RELAY MOUNTING SCREWS KEY 10 W5744 6 Perform the appropriate flapper alignment procedure in Section 3 4 or 5 Replacing the Case and Cover A WARNING Refer to the Maintenance WARNING on page 51 56 Instruction Manual 4195K Controllers D200160X012 December 2012 CAUTION The c
185. uctions Process Indicator Zero and Span Calibration Remote Set Point suffix letter M Zero and Span Calibration Flapper Alignment Principle of Operation for 4195KA Controllers Overall Operation Remote Set Point suffix letter M Operation esee Auto Manual Station suffix letter E Operation 4 4195KB Proportional Plus Reset Controllers and 4195KC Proportional Plus Reset Plus Rate Controllers Adjustments for 4195KB and KC Controllers 25 Manual Set Point Adjustment 25 Remote Set Point suffix letter M Adjustment 26 Proportional Band Adjustment PB ADJ 26 Changing Controller Action 26 Reset Adjustment 27 Rate Adjustment 27 Anti Reset Windup suffix letter F Adjustment cceeee eee eeee 27 Switching the Auto Manual Station suffix letter E 27 Prestartup Checks for 4195KB and KC Controllers ael ceart eaa a iena 28 Startup for 4195KB and KC Controllers 28 Calibration of 4195KB and KC Controllers 30 General Calibration Instructions 30 Process Indicator Zero and Span Calibration 30 Remote Set Point suffix letter M Zero and Span Calibration 32 Flapper Alignment
186. ular to them Setthe length of link B key 126 so the set point indicator indicates mid scale on the process scale span NJ UJ A Replace the tie bar key 106 and install the two screws key 103 Remote Set Point Zero and Span Adjustment A WARNING Refer to the Maintenance WARNING on page 51 Note For routine remote set point zero and span calibration refer to the appropriate procedures in Section 3 4 or 5 Use the following maintenance remote set point zero and span adjustment procedures only if difficulty is encountered with the routine procedure or nonlinearity occurs Refer to figures 6 19 and 6 23 for adjustment locations Instruction Manual 4195K Controllers D200160X012 December 2012 1 Decrease the remote set point pressure to 0 percent of the remote set point input range Theset point indicator should indicate the lower limit of the process scale span If not loosen the adjustment screw on link A key 116 and adjust the length so the set point indicator points to the lower limit of the process scale Tighten the screw 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 23 for the screw locations 4 Apply remote set point pressure equal to 100 percent of the remote set point input range 5 The set point indicator should indicate the upper limit of the process sc
187. ure 4 1 Fisher 4195KB and KC Controller Adjustment Locations METAL BALL SWITCHING m un MANUAL 7 i e MC ZONE 1 i INDICATOR LOADER KNOB A 5 T A T 0 25 40 AUTO MANUAL il SWITCH SET POINT INDICATOR PROCESS POINTER AUTO MANUAL STATION SUFFIX LETTER E PROPORTIONAL BAND ADJUSTMENT ANTI RESET WINDUP DIFFERENTIAL RELIEF VALVE SUFFIX LETTER F RESET SUPPLY RESET ADJUSTMENT ADJUSTMENT PRESSURE GAUGE ADJUSTMENT OUTPUT PRESSURE GAUGE W3599 1 TYPICAL ADJUSTMENTS 4195KC RESET AND RATE ADJUSTMENTS 4195KB SHOWN W6833 Manual Set Point Adjustment Adjust the set point by opening the controller cover and moving the set point indicator until the line on the set point indicator is over the desired value on the process pressure scale Move the indicator to the right to increase the set point and to the left to decrease it Adjusting the set point does not affect the proportional band setting 25 4195K Controllers Instruction Manual December 2012 D200160X012 Remote Set Point suffix letter M Adjustment CAUTION Do not manually move the set point indicator on a controller with remote set point Manually moving the set point indicator could damage the controller If the controller is equipped with remote set point suffix letter M vary the remote set point pressure to change the set point Increase the pressure to
188. ure gauge Remove the pressure connection key 93 at the pedestal assembly key 105 Use two 5 16 inch wrenches Disconnect link B key 126 from the connection hole on the set point indicator Remove the three mounting screws keys 120 and 140 that attach the remote set point assembly to the process set point indicator assembly Figure 6 23 shows the mounting screw locations CAUTION In the following step do not lift out the remote set point assembly by holding the capsular element or linkages These parts may be damaged 93 4195 Controllers Instruction Manual December 2012 D200160X012 o N Lift out the remote set point assembly by holding the tie bar key 106 mounting plate key 111 travel stop key 83 or pedestal assembly key 105 Align the replacement assembly with the mounting screw holes Replace the mounting screws Reconnect the remote set point pressure connection union key 93 Apply full remote set point pressure and check for leaks Connect link B key 126 to the connecting hole on the set point indicator Replace the supply pressure gauge Perform the remote set point maintenance calibration procedure Perform the appropriate process indicator zero and span calibration and flapper alignment procedure in Section 3 4 or 5 Replacing Remote Set Point Assembly Parts A WARNING Refer to the Maintenance WARNING on page 51 CAUTION Avoid bending or
189. ure to the tab on the mounting plate key 77 The guide flexure location is shown in figure 6 22 Figure 6 22 Process Input Capsular Element Assembly Part and Adjustment Locations Positive and Compound Pressure Element Shown DRIVE GUIDE FLEXURE TRAVEL FLEXURE TRAVEL Bcc STOP STOP NUT A 7 Ha AL ie Cel i C E J v DIAPHRAGM VIEW A A ASSEMBLY PRIVE LONG EXTENSI N BRACKET PIVOT Pic LINK 5 1 LINEARITY LINKI ADJUSTMENT a PIVOT STOP NUT VIEW A A 58A0708 E 3 Apply process pressure equal to 75 percent of the capsular element range 4 Slide the drive bracket assembly key 84 along the diaphragm capsule extension key 82 until the guide flexure is aligned with the center of the long pivot clevis assembly key 78 5 Tighten the machine screw key 98 and the set screw in the hex nut to fasten the drive bracket assembly in that position Setting the Capsular Element Travel Stops 1 For the full span stop Apply process pressure equal to 5 percent greater than capsular element range Then perform the following as appropriate For positive or compound pressure with a three capsule stack loosen the machine screws key 139
190. urns the process pressure toward the set point Figure 4 7 Reset Rate Schematic RELAY OUTPUT PRESSURE RESET PROPORTIONAL BELLOWS BELLOWS 19A5000 A A3237 2 Anti Reset Windup suffix letter F Operation Anti reset windup is available on all 4195KB and KC controllers and is designated by the letter F in the type number The differential relief valve operates when the difference between the proportional bellows pressure and the reset bellows pressure reaches a predetermined value Anti reset windup reduces overshoot of the process pressure that can result from a large or prolonged deviation from set point Remote Set Point suffix letter M Operation The capability to adjust the controller set point from a remote location is available with all 4195KB and KC controllers This option is designated by the letter M in the type number A control pressure is applied to the capsular element within the remote set point assembly The expansion and contraction of the capsule moves the set point indicator via connecting linkage Increasing the control pressure to the capsule increases the set point setting and decreasing the control pressure reduces the set point setting 39 4195 Controllers Instruction Manual December 2012 D200160X012 Auto Manual Station suffix letter E Operation A controller with the auto manual station designated by the suffix letter E in the type number has piping on the output side of the relay as shown in fi
191. utomatic and manual or manual and automatic mode without balancing the outputs can disturb the process and cause controller cycling Refer to figure 4 1 if the controller has the auto manual station suffix letter E To switch from automatic to manual mode or from manual to automatic you must first balance the manual output with the controller output Two balance methods are available to equalize the manual output with the controller output 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 27 4195 Controllers Instruction Manual December 2012 D200160X012 To switch from manual to automatic mode adjust the set point to move the ball into the switching zone Turn the switch to AUTO and adjust the set point to control the output When the automatic manual switch is in AUTO adjusting the loader knob has no effect on the controller output When the automatic manual switch is in MANUAL changing the set point has no effect on the controller output Prestartup Checks for 4195KB and KC Controllers Refer to figure 4 1 for adjustment locations and refer to figure 7 1 for key number locations When performing the checks open loop conditions must exist An open loop exists when the controll
192. uum Pressure e For direct control action An increasing sensed vacuum increases output pressure Forreverse control action An increasing sensed vacuum decreases output pressure After changing the action tighten the screws on the proportional band indicator cover Reset Adjustment To adjust reset open the controller cover and locate the RESET adjustment Rotate the adjustment clockwise to decrease the minutes per repeat or counterclockwise to increase the minutes per repeat Increasing the minutes per repeat provides a slower reset action Rate Adjustment To adjust rate open the controller cover and locate the RATE adjustment Rotate the adjustment clockwise to decrease the minutes less rate action or counterclockwise to increase the minutes more rate action Anti Reset Windup suffix letter F Adjustment If the arrow on the relief valve points toward the bottom of the controller case as shown in figure 4 1 the valve opens with increasing controller output pressure If the arrow points in the opposite direction the relief valve opens with decreasing controller output pressure Differential relief pressure is factory set at 0 3 bar 5 psig Maximum relief pressure is 0 5 bar 7 psig The minimum is 0 1 bar 2 psig Turn the adjusting screw counterclockwise to increase differential relief pressure clockwise to decrease it Switching the Auto Manual Station suffix letter E Note Switching the controller between a
193. ve flexure is horizontal Take care not to kink or twist the flexure when tightening the screws Connect the left hand end of link 5 key 88 to the pivot adjustment arm in the hole position noted in step 3 Replace the tie bar key 97 Perform the capsular element maintenance calibration procedure in this section Perform the controller calibration procedures and if necessary perform the appropriate remote set point calibration procedure in Section 3 4 or 5 Replacing the Short Pivot Assembly 1 Remove process pressure from the controller Note the hole positions of links 1 and 5 keys 88 and 90 and disconnect the links from the short pivot clevis assembly key 89 Also note the screw position of the linearity adjustment for later reference Remove the two machine screws key 102 attaching the short pivot clevis assembly key 89 to the mounting plate key 77 and remove the pivot clevis assembly Setthe linearity adjustment screw in the replacement pivot assembly to approximately the same location as noted in step 2 Position the replacement short pivot clevis assembly on the mounting plate and attach it with the two machine screws Attach links 1 and 5 keys 88 and 90 in the same hole position as noted in step 2 Perform the capsular element maintenance calibration procedures in this section Perform the controller calibration procedures and if necessary the appropriate remote set point calibration proc
194. ve plug spring and valve plug Tighten the spring seat screw Temporarily apply supply pressure and process pressure and check for leaks Position the controller assembly in the case and start but do not tighten the nine mounting screws Slide the controller assembly down to assure an O ring seal at the pressure connections along the bottom of the case Hold the controller assembly in place while tightening the nine mounting screws Mount the controller as described in the Installation section Connect the external piping to the controller 104 Instruction Manual 4195K Controllers D200160X012 December 2012 Section 7 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 A 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 may void your warranty might adversely affect the performance of the instrument and could cause personal injury and property damage Parts Kits Parts List Description Part Number 4190 Controller Auto Manual Repair Kit Abbreviations Used In Parts List Contains keys 277 278 279 281 292
195. vices described herein 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 i Chatham Kent ME4 4QZ UK s Dubai United Arab Emirates es Singapore 128461 Singapore www Fisher com EMERSON Dr aS maement 1983 2013 Fisher Controls International LLC All rights reserved Frocess IV ement
196. w 1 Remove the two screws key 6 and lift off the proportional band indicator cover key 36 2 Set the proportional band between DIRECT and REVERSE 3 Apply remote set point pressure equal to the lower range limit 4 The set point indicator should indicate the process scale lower limit If not loosen the remote set point zero Cc adjustment locking screw and adjust the remote set point zero adjustment screw until the set point indicator aligns with the process scale lower limit Tighten the zero adjustment locking screw Apply remote set point pressure equal to the upper range limit Theset point indicator should indicate the process scale upper limit If not adjust the remote set point span adjustment screw to correct one half the error as follows clockwise to increase span for a low indication counterclockwise to decrease span for a high indication 7 Repeat steps 3 through 6 until the error is eliminated 8 Apply remote set point pressure equal to the mid range value 21 4195 Controllers Instruction Manual December 2012 D200160X012 Make sure the set point indicator is within 1 percent of the mid scale mark and if so proceed to step 12 If the set point indicator is not within 1 percent but is within 2 percent of the mid scale mark then proceed with step 10 If the set point indicator is not within 2 percent proceed to the remote set point calibration procedure in the Maintenance section Loos
197. ween 0 4 to 2 0 bar 6 and 30 psig for a 0 4 to 2 0 bar 6 to 30 psig output signal range If the output is not within the specified range adjust the flapper leveling screw nearest the nozzle until the output is within the range specified Record the controller output pressure 45 Adjust the set point to the process scale upper limit 46 Remove the tape and move the process pointer until the controller output equals the pressure recorded in step 44 Note the process pressure indication 47 The process pressure indication should be within 2 percent of the process scale upper limit If the process pressure indication in step 46 is greater than the process scale upper limit by 2 percent loosen the shoe adjustment screws key 30 shown in figure 6 3 and move the set point beam shoe key 29 slightly away from the center of the flapper assembly If the process pressure indication in step 46 is less than the process scale upper limit by 2 percent loosen the shoe adjustment screws key 30 shown in figure 6 3 and move the set point beam shoe key 29 slightly toward the center of the flapper assembly 48 Repeat steps 43 through 47 until the error is less than 2 percent of the process scale span at the process scale upper limit 49 Remove the tape from the process pointer and reconnect link 1 to the input element If the controller has a capsular input element be sure to reconnect link 1 in the same hole noted in step 21 50 Position
198. wn in figure 6 3 and move the set point beam shoe key 29 slightly away from the center of the flapper assembly If the process pressure indication in step 26 is less than the upper limit of the process scale by 2 percent loosen the shoe adjustment screws key 30 shown in figure 6 3 and move the set point beam shoe key 29 slightly toward the center of the flapper assembly Repeat steps 23 through 27 until the error is less than 2 percent of process scale span at the upper limit of the process scale Remove the tape from the process pointer and reconnect link 1 to the input element If the controller has a capsular input element be sure to reconnect link 1 in the same hole noted in step 24 Position the controller assembly in the case and start but do not tighten the nine mounting screws Slide the controller assembly down to assure an O ring seal at the pressure connections along the bottom of the case Hold the controller assembly in place while tightening the nine mounting screws Instruction Manual 4195K Controllers D200160X012 December 2012 31 32 33 Perform the controller calibration procedures and if necessary the appropriate remote set point calibration procedure in Section 3 4 or 5 Mount the controller as described in the Installation section Connect the external piping to the controller Replacing the Flapper Assembly and Flapper Flexure Pivot Assembly A WARNING Refer to the Maintenance WARNING on page
199. y 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 H2S content should not exceed 20 ppm Remote Set Point Pressure Ranges 0 2 to 1 0 bar or 0 4 to 2 0 bar 3to 15 psig or 6 to 30 psig Controller Adjustments Proportional Band 5 to 500 of process input span Reset Adjustable from 0 01 to more than 74 minutes per repeat from 100 to less than 0 0135 repeats per minute Rate Adjustable from 0 to 20 minutes Differential Gap Controllers Adjustable from 5 to 100 of process scale range Set Point Adjustable from 0 to 100 of the scale span Controller Performance Repeatability 0 4 of output span Dead Band Less than 0 4 of process scale span Typical Frequency Response 1 5 hertz and 90 degree phase shift with 3 05 m 10 feet of 6 4 mm 1 4 inch tubing and 1639 cm 100 cubic inch volume Steady State Air Consumption 3 4 0 2 to 1 0 Bar 3 to 15 Psig Output 0 1 normal m3 hr 3 5 scfh 0 4 to 2 0 Bar 6 to 30 Psig Output 0 14 normal m3 hr 5 0 scfh Delivery Capacity 3 0 2 to 1 0 Bar 3 to 15 Psig Output 5 9 normal m hr 240 scfh 0 4 to 2 0 Bar 6 to 30 Ps

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