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Emerson Fisher 4194 Instruction Manual

1. GAUGE MATERIAL RANGE Brass SST Dual Scale Gauge 0 to 30 psig Oto 2 kg cm2 11B8577X042 11 8583 032 0 to 60 psig 622 0 to 4 kg cm2 11B8577X052 Triple Scale Gauge 0 to 30 psig 0 to 200 kpa 11B8577X012 11 8583 012 0 to 2 bar 0 to 60 psig 0 to 400 kpa 11B8577X022 11B858X022 0 to 4 bar 1 One type of pressure gauge is used for both output pressure and supply pressure indication Key Description Part Number Note Keys 51 52 and 53 are required for all controller types These parts are included separately with controllers with the anti reset windup option suffix letter F These parts must be used when removing the differential relief valve key 55 to perform the flapper alignment procedure for 4194HB and HC controllers 51 Relief valve cover plate A03600 aluminum 52 O ring nitrile 2 req d 53 Machine screw fill hd 18 8 SST For 4194HA and HB controllers 2 req d For 4194HC controllers 5 req d 54 Reset restriction valve For 4194HB controllers 55 Differential relief valve For all 4194H controllers w suffix letter F anti reset windup option 10853806992 56 Process and set pt indicator ass y Note The part numbers listed below are for the complete process and set pt indicator ass y The complete process and set pt indicator 5 includes the indicator ass y key 101 and parts such as the support bracket key 319 and the pivot bracket ass y key 320 Individual indicator
2. SECTION B B SUFFIX C CF VIEW E VIEWE SUFFIX C SUFFIX CF oh VIEW VIEW SUFFIX SUFFIX CF 56A9752 V Sht 3 85 4194HA HB HC Controllers September 2014 Instruction Manual D200156X012 Figure 6 1 Controller Assembly Drawings Continued t TU e 05 10 140 56A9752 V Sht 4 VIEW H SUFFIX M 86 56A9752 V Sht 5 VIEW M EXTERNAL FEEDBACK ASSY Instruction Manual D200156X012 4194HA HB HC Controllers September 2014 Figure 6 2 Process and Set Point Indicator Assembly with Differential Pressure Unit oe e r3 a e e 215 081 TDP IL 38A4986 C Process and Set Point Indicator Assembly key 56 figure 6 2 Key Description 101 Indicator ass y For use w o remote set pt For use w remote set pt 319 Support bracket 18 8 SST 320 Pivot bracket ass y SST Sapphire 321 Shaft extension 18 8 SST 322 Drive
3. Controllers Instruction Manual September 2014 D200156X012 Figure 6 5 Auto Manual Station TOP VIEW E 14 222 BETA P y Am bU PSS AII lt gt e 21171 Z 7 7 XZ SECTION B B Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 Figure 6 5 Auto Manual Station Continued METAL BALL PLASTIC TUBE LOADER KNOB AUTOMATIC MANUAL SWITCH SWITCHING ZONE INDICATION 56A9752 D 54 SIDE VIEW COVER REMOVED BACK VIEW COVER REMOVED Key Description Part Number Key Description Part Number 291 Switch body aluminum nitrile 295 Switch body spring K08500 pl steel 2 req d 292 O ring nitrile 1U2398X0032 296 Ball SST 2 req d 293 O ring nitrile 11A8741X052 297 Lever ass y SST 298 O ring nitrile 1E222606992 294 O ring nitrile 13A1584X012 299 Rocker A96061 aluminum Recommended spare parts 91 4194 HB Controllers Instruction Manual September 2014 D200156X012 Key Description Part Number Controller Mounting Parts 300 Clip SST 301 Leverspring seat SST 302 Leverspring K08500 pl steel Note 303 Groove pin SST 16A6380X012 Contact your Emerson Process Management sales office for any 304 Switchlever polycarbonate SST additional parts required for controller mounting 305 Switch lever cover plate aluminum chromate 306 Closing plate gasket c
4. e Ifthe process indicator error at mid range is greater than 2 percent loosen the two screws in the drive arm key 322 figure 6 2 and lengthen or shorten the drive arm approximately 6 3 mm 1 4 inch Then repeat steps 6 through 11 After adjusting the process indicator to 1 percent at the low mid range and upper scale limits proceed with step 12 Perform the flapper alignment procedure Install the proportional band indicator cover key 36 and tighten the two screws key 6 Remote Set Point suffix letter M Zero and Span Adjustment Refer to figure 3 1 for location of adjustments Refer to figures 6 1 and 6 2 for key number locations Note Any adjustment of the set point span adjustment screw will require readjustment of the set point zero adjustment screw Refer to figure 3 1 Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 1 Remove two screws key 6 and lift off the proportional band indicator cover key 36 2 Setthe proportional band between DIRECT and REVERSE 3 Adjust the set point pressure to the low limit of the set point input range Note the position of the set point indicator Loosen the set point zero adjustment locking screw and adjust the zero adjustment screw figure 3 1 until the set point indicator aligns with the lowest scale limit When the set point indicator is properly aligned with the low scale limit tighten the zero adjustment locking screw 4 Adjust the set
5. 4194 HB Controllers Instruction Manual September 2014 D200156X012 Anti Reset Windup Valve suffix letter F Calibration Calibration for the anti reset windup valve to relieve on rising controller output pressure 1 Plug the controller output connection or connectit to a pressure gauge if desired open loop conditions must exist 2 Set the reset adjustment to 0 01 minute per repeat wide open and the rate adjustment 4194HC controllers only to the OFF position 3 Fora controller with manual set point move the set point indicator to 50 percent of the scale range For a controller with remote set point adjust the remote set point pressure until the set point indicator is at 50 percent of the scale range 4 Adjust the proportional band to 100 percent in either the DIRECT or REVERSE action depending on the application requirements 5 Refer to figure 3 1 for the location of the anti reset windup valve For the anti reset windup valve to relieve on rising controller output pressure install the valve so the arrow on the valve points down If you must change the direction of the arrow loosen the two mounting screws pull the valve out and reinstall with the arrow direction reversed Tighten the two mounting screws 6 Turnon the supply pressure to the recommended value shown in table 1 4 Note Because of the high controller gain with the reset adjustment at 0 01 minute per repeat the controller output will not balance
6. Adjust the process differential pressure to 50 percent of the input range If pressure is not available to pressure the differential pressure unit to 50 percent of range an alternate method is to disconnect link 1 at the drive arm and tape the process indicator at 50 percent of the input range This method should only be used if pressure is not available to pressure the differential pressure unit to 50 percent Note In ad steps 8 through 12 the controller output will not stabilize because of the high controller gain The controller output gauge is equate to check the output pressure during this procedure Set the proportional band between DIRECT and REVERSE Adjust flapper leveling screw number 2 until the controller output is relatively stable at any value within the output range Adjust the proportional band to 20 percent DIRECT direct action Adjust flapper leveling screw number 3 until the controller output is relatively stable at any value within the output range Adjust the proportional band to 20 percent REVERSE reverse action Adjust flapper leveling screw number 1 until the controller output is relatively stable at any value within the output range Repeat steps 8 through 11 until the controller output remains relatively stable with no adjustments of the flapper leveling screws Note Steps 13 through 19 check the flapper alignment 13 14 16 17 66 Adjust the proportional band to 100 per
7. 4 1 Reset valve is plugged 4 2 Reset pressure leak 4 3 Tubing leak 4 1 Turn the reset valve through its range several times to remove any restrictions 4 2 Adjust the output to 1 0 bar 15 psig for 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 Close the reset valve If the output varies and no leaks were found in the rest of the feedback system see Step 2 7 the reset valve is leaking 4 3 With reset valve positioned at 0 01 MIN 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 4194HB or rate reset valve 4194HC 4 2 Replace the reset valve if necessary 4 3 Repair or replace parts as necessary 5 Abnormal control point shift when proportional band is changed 5 1 Flapper is dirty or pitted 5 2 Flapper is out of alignment 5 1 Inspect the flapper 5 2 Refer to flapper alignment procedures 5 1 Clean or replace flapper as necessary 5 2 Align 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 4194HA controllers only 6 4 Differential pressure unit or linkage failure 6 5 Leak in nozzle pressure tubin
8. 0 8 bar 12 psig span 1 7 bar 24 psig span 64 Machine screw fill hd 8 8 SST 4 req d 65 Feedback link ass y aluminum brass SST 71 Machine screw fill hd 18 8 SST For 4194HA HB controllers 4 req d For 4194HC controllers 2 req d 72 Blowout plug silicone 81 4194HA HB HC Controllers Instruction Manual September 2014 D200156X012 Key Description Part Number Key Description Part Number 262 Rate reset valve ass y 101 Indicator ass y For 4194HC controllers only Brass bellows 0 2 to 1 0 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 Note 0 4 to 2 0 bar 6 to 30 psig The part numbers listed here for key 101 are for the complete indicator 264 Set screw hex socket 530300 303 SST 55 Individual assembly parts are listed in the Indicator Assembly key For 4194HC controllers only 2 req d 101 subsection of the parts list Key numbers for individual assembly parts also appear in figure 6 4 265 Rate Scratch Valve 530300 303 SST For 4194HC controllers only 266 CoverPlate steel For 4194HC controllers only 268 Spring washer pl steel For use w o remote set pt For 4194HC controllers only 2 req d For use w remote set pt 269 Spring For 4194HC controllers only 1 req d 120 Machine screw fill hd 18 8 SST 270 Bellows base gasket chloroprene Required to mount remote set pt ass y For 4194HC controllers only 1 req d 28 0741 012 suffix letter to indicator
9. Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 7 Adjust the length of link 2 by turning the adjusting screw see figure 5 7 clockwise to increase length counterclockwise to decrease length so the pin on the end of the link is approximately one half of its diameter short of engaging with the hole in the flapper assembly as shown in figure 5 9 This adjustment provides the proper tension on the link to eliminate lost motion 8 Remove the tape from the process indicator 9 Connect link 2 to the input feedback beam assembly 10 Connect link 1 to the drive arm 11 Perform the controller calibration procedure and if necessary the appropriate remote set point calibration procedure in Section 3 or 4 Figure 5 7 Link Number 2 Adjustment CLINCH NUT FLAPPER LEVELING LEVELING SCREW NUMBER 1 W4191 lt 1 2 OF PIN DIAMETER W3451 Link 3 Note SCREW 3 CONNECTING TAB ON INPUT FEEDBACK ASSEMBLY Before performing the following link 3 maintenance steps disconnect supply pressure from the controller The link 3 procedure provides a non pressurized alignment of the flapper before calibration The following steps provide initial alignment between link 3 and the flapper 1 Remove the two screws key 6 and lift off the proportional band indicator cover key 36 2 Note where the link is connected Disconnect link 3 from set point adjustment assembly and the
10. NOZZLE PRESSURE WWW RESET PRESSURE SELECT RELAY OUTPUT 47A0975 A A3342 1 36 Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 Section 5 Maintenance Inspection and Maintenance Controller parts are subject to normal wear and must be inspected and replaced as necessary Inspection and maintenance frequency depends on the severity of service conditions When inspection or repairs are require disassemble only those parts necessary to accomplish the job Figure 5 1 is a maintenance guide which summarizes the information available in the maintenance procedures 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 procedures e Always wear protective clothing gloves and eyewear when performing any maintenance operations to avoid personal injury 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 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
11. W3635 1 Figure 2 2 Connections 1 4 NPT REMOTE SET POINT CONNECTION REMOTE SET POINT CONNECTION PUN TOP VIEW H 1 4 OPTIONAL EXTERNAL FEEDBACK CONNECTION SUPPLY PRESSURE H 14 NPT CONTROLLER 2 HOLES OUTPUT PRESSURE 114 lt VIEW IN LEFT SIDE VIEW BOTTOM VIEW NOTE 15 HIGH PRESSURE CONNECTION ON A BARTON 199 DIFFERENTIAL PRESSURE UNIT 18A5903 B 000 1 4194 HB Controllers Instruction Manual September 2014 D200156X012 Process Pressure Connections Process pressures are piped to the connections on the ends of the differential pressure unit figure 2 3 Refer to the differential pressure unit instruction manual for the high and low pressure connections Figure 2 3 Simplified Control Loop Diagram LOW 2 gt PRESSURE CONNECTIONS HIGH PRESSURE CONNECTIONS SUPPLY PRESSURE LOW PRESSURE SIGNAL HIGH PRESSURE PIPING S ORIFICE PLATE NOTE 1 gt ALLOW A REAR VIEW OF THE CONTROLLER DIFFERENTIAL PRESSURE UNIT THE SCHEMATIC SHOWS PROCESS FLOW FROM RIGHT TO LEFT 2 gt SEE FIGURE 2 1 FOR LOW PRESSURE CONNECTIONS W5910 When installing process piping follow accepted practices to ensure accurate transmission of the process pressures to the differential pressure unit Install a three valve bypass shutoff valves vents drains or seal systems as needed in the process pressure lines If
12. key 10 as shown in figure 5 14 holding the flexure pivot assembly to the frame 15 Remove the flexure pivot assembly key 9 16 Install the replacement flexure pivot assembly with the four screws key 10 Do not tighten the screws 17 Move the flexure pivot assembly towards the relay as far as possible and tighten the four screws key 10 18 Place the input feedback beam assembly key 11 onto the flexure pivot assembly key 9 with link 4 through the square hole in the frame 19 Install the screw key 12 with the washer key 13 through the input feedback beam assembly key 11 into the flexure pivot assembly key 9 Do not tighten the screw 20 Align flapper leveling screw number 2 with the centerline of the oblong hole in the frame as shown in figure 5 13 Tighten the screw key 12 Make sure link 4 does not touch the frame Note The following procedure steps 22 through 24 adjusts link 2 so it will always be in tension This eliminates possible instability due to lost motion 21 56 Disconnect link 1 figure 3 1 from the drive arm pivot assembly and manually position the process indicator to 100 percent of the scale Tape the indicator in position Instruction Manual 4194HA HB HC Controllers 200156 012 September 2014 Figure 5 12 Position of Link Number 4 Adjustment Figure 5 13 Flapper Assembly and Leveling Screws Screws INPUT ADJUSTABLE SET POINT FEEDBACK PIVOT ASSEMBLY FLAPPER LEVELING FLAPPER BEAM
13. 0 01 minutes per repeat Turn the rate adjustment to OFF Adjust the proportional band knob to 5 percent DIRECT direct action DU A If necessary connect a pressure source to the differential pressure unit and adjust the process indicator to the last scale mark on the left side of the scale If the last scale mark is 0 psig a pressure source is not required 9 The controller output pressure should be 0 psig 10 Rotate the proportional band to 5 percent REVERSE reverse action 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 adjustment to 400 percent in the desired action secure the proportional band indicator cover key 36 with the two machine screws key 6 and go to the startup procedure If the controller output pressure is not within tolerance go to the calibration procedure for 4194HB and HC controllers for recalibration Startup for 4194HB and HC Controllers Calibrate the controller prior to this procedure Note When performing the startup procedure keep in mind the initial settings are guidelines They will vary depending on the actual process being controlled 1 Be sure the supply pressure regulator is delivering the proper supply pressure to the controller 2 Move the set point adjustment to the desired set point 3 Set the reset adjustment to 0 05 minutes per repeat for fast proce
14. Connections WARNING 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 11 e Check with your process or safety engineer for any additional measures that must be taken to protect against process media e Ifinstalling 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 Pipestand Mounting 4194 controller mounts on a pipestand Install with the vent opening facing down Secure the mounting coupling to the pipestand by three set screws as shown in figure 2 1 Pressure Connections A WARNING To avoid personal injury or property damage resulting from the sudden release of pressure do not install any system component including the differential p
15. Install the replacement tubing assemblies Set the reset adjustment to 0 01 4194HB and HC controllers and set the rate adjustment to OFF 4194HC controllers Apply the correct supply pressure and check for leaks Then remove pressure Install the controller assembly into the case Slide the controller assembly down and make sure the O rings key 7 form a proper seal at the pressure connections Hold the frame in place Install and tighten the nine self tapping screws key 38 into the frame Perform the process indicator zero and span adjustment and flapper alignment procedure in the Maintenance Calibration section Mount the assembled controller on a pipestand as described in the Installation section Connect supply output and process differential pressure piping to controller differential pressure unit 51 4194 HB Controllers Instruction Manual September 2014 D200156X012 Replacing the Proportional Band Adjustment Knob Nozzle Assembly and Set Point Beam Assembly Note Before starting the following procedure remove the controller from the case Perform steps 1 through 7 of the Replacing the Differential Pressure Unit procedure Then perform steps 1 and 2 of the Replacing the Case and Cover procedure Key numbers refer to figure 6 1 Disassembly 1 Perform the procedures required in the Note above 2 Remove the two screws key 6 and lift off the proportional band indicator cover ke
16. Psig bar ct o 68 9 1000 Stainless steel 10 75 172 2500 Steel to 40 414 6000 Steel Inches w c mbar 68 9 1000 Stainless steel to 25 to 50 0 to 124 to 75 0 to 186 to 100 0 to 248 0 to 50 to 62 172 2500 Steel erg COO S 2 ooooooo000000 to 20 0to 50 to 25 0to 62 to 50 0 to 124 to 75 0 to 186 to 100 0 to 248 414 6000 Steel 1 Differential pressure ranges are in English units of measurement metric equivalents are shown here for reference only Consult your Emerson Process Management sales office for special differential pressure ranges 2 The Barton 199 differential pressure unit may be pressured to this value without permanent zero shift or structural damage to controller components Table 1 4 Supply Pressure Requirements Maximum Pressure to Prevent Output Signal Range Normal Operating Supply Pressure 1 Internal Damage 2 0 2to 1 0 1 4 2 8 par 0 4to 2 0 24 2 8 31015 20 40 Psig 6to30 35 1 If this pressure is exceeded control stability may be impaired 2 If this pressure is exceeded damage to the controller may result 4194 HB Controllers Instruction Manual September 2014 D200156X012 Section 2 Installation Mounting and
17. SCREW NUMBER 2 ASSEMBLY SCREW AND WASHER A ass KEYS 19 AND 20 lt 2 OBLONG HOLE NOTES IN FRAME screw INSERTED INTO THE ADJUSTABLE SET POINT PIVOT ASSEMBLY FLEXURE PIVOT 2 gt scREW INSERTED INTO THE RELAY NOZZLE TUBING ASSEMBLY Wao ASSEMBLY SCREWS KEY 12 W4195 Figure 5 14 Exploded View Flexure Pivot Assembly FOUR FLEXURE PIVOT SCREWS ASSEMBLY KEY 10 KEY 9 INPUT FEEDBACK BEAM ASSEMBLY WITH LINK 4 ATTACHED 4198 22 Adjust the length of link 2 by turning the adjustment screw clockwise to increase the length counterclockwise to decrease the length so the pin on the end of the link is approximately one half of its diameter short of aligning with the hole in the input feedback beam assembly as shown in figure 5 7 23 Connect link 2 to the input feedback beam assembly 24 Connect link 1 to the drive arm 25 Adjust the proportional band between DIRECT and REVERSE Do this by aligning the tab on the proportional band knob with the hole in the set point beam assembly as shown in figure 5 10 57 4194 HB Controllers Instruction Manual September 2014 D200156X012 26 Position the proportional band knob nozzle pivot and set point beam assembly on frame Install the relay nozzle tubing nut loosely into frame manifold while positioning the nozzle in the center of the flapper as shown in figure 5 11 27 Install the washer key 20 on th
18. adjustments is shown in figure 3 1 To better understand the adjustments and overall operation of the controller refer to the principle of operation and the schematic diagrams figures 4 2 through 4 6 Unless otherwise noted key numbers given in this section be found in figure 6 1 When placing the controller into operation use the following procedure for adjustment Refer to figure 3 1 for locations of adjustments Manual Set Point Adjustment To adjust the set point open the controller cover and move the set point indicator until the indicator is at the desired value on the process differential pressure scale Move the adjustment 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 If the controller is equipped with the optional external or internal set point adjustment turn the adjustment knob clockwise to increase the process set point and counterclockwise to decrease the process set point Remote Set Point suffix letter M Adjustment CAUTION Do not manually move the set point indicator on a controller with remote set point Doing so could damage the controller If the controller is equipped with the remote set point option vary the remote set point pressure to change the set point Increase the pressure to increase the set point and decrease the pressure to decrease the set point Proportional Band Adjustment PB ADJ Locat
19. and 9 until flapper leveling screws 1 and 3 protrude an equal distance from the clinch nuts 11 Perform the pressurized maintenance calibration and flapper alignment procedures Link 4 1 Remove the two screws key 6 and lift off the proportional band cover key 36 2 Refer to figure 5 5 for location of link 4 Note where the link is connected Disconnect the link from bellows bracket assembly key 31 and the input feedback assembly key 11 3 Connect the replacement link to the input feedback assembly so the two adjusting screws on the link are nearest to the feedback bellows bracket The screw heads should face the bottom of the controller as shown in figure 5 12 and be positioned as noted in step 2 50 Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 For controllers with reset 4194HB controllers or rate and reset 4194HC controllers disconnect the supply pressure and then adjust the rate 4194HC controllers only to OFF The controller output pressure must be 0 bar Adjust the reset to 0 01 minutes per repeat and wait 30 seconds Then turn the reset adjustment to the CLOSED 4194HB controllers or OFF 4194HC controllers position The controller output must be 0 bar To be sure the controller output is at 0 bar remove supply pressure set the reset adjustment to 0 01 minutes per repeat and wait 30 seconds then turn the the reset adjustment to the CLOSED 4194HB controllers or OFF 4194HC c
20. and cover 45 Refer to the process indicator zero and span adjustment and flapper alignment procedures in the Maintenance section 58 Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 Replacing the Proportional or Reset Bellows Note Before starting the following procedure remove the controller from the case Perform steps 1 through 7 of the Replacing the Differential Pressure Unit procedure Then perform steps 1 and 2 of the Replacing the Case and Cover procedure Perform the procedures required in the Note above 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 figure 5 15 and washer key 362 from the bellows assemblies Q N Remove the four machine screws key 6 figure 5 15 from the bellows beam key 49 Then remove the bellows bracket key 31 6 Remove the proportional tubing assembly key 40 from the proportional bellows and or remove the reset tubing assembly key 43 from the reset bellows depending on which bellows are to be replaced 7 Remove the four machine screws key 71 from the bellows beam and remove the bellows beam from the frame key 3 CAUTION When removing and replacing the proportional or reset bellows keep in mind the bellows has left hand threads Overtightening could damage the threads Note Do not
21. c For 4194HA controllers 0 6 0 1 bar 9 1 psig for a 0 2 to 1 3 to 15 psi output or 1 2 0 1 bar 18 2 psig for a 0 4 to 2 bar 6 to 30 psi output d For 4194HB and HC controllers 0 0 bar 0 psig If necessary adjust flapper leveling screw number 2 to obtain the required output pressure 9 Adjust the process differential pressure to the differential pressure unit to 0 percent of the process differential pressure scale range 10 Adjust the process indicator to 0 percent on the process scale by loosening the zero adjustment locking screw and turning the zero adjustment screw Tighten the zero adjustment locking screw 11 Adjust the process differential pressure to 100 percent of the scale range 12 Note whether the process indicator is above or below 100 percent on the process scale 13 Adjust the process indicator span adjustment as follows clockwise to increase the span for a low indication and counterclockwise to decrease the span for a high indication To avoid overcorrection only correct for approximately one half of the error with the span adjustment screw 14 Repeat steps 9 through 13 until the process indicator is aligned with the process scale at the 0 percent and at the 100 percent marks If the span adjustment screw is adjusted to its limit and the span is still too short or too long proceed with step 15 If proper span is achieved proceed to step 16 15 Within the process indicator subassembly the
22. controller output pressure should quickly change then stabilize at the new value Continue to affect the controller output pressure in 0 5 psi steps and check the output pressure after each step to make sure that it stabilizes At some point the controller output will start to ramp downward to 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 anti reset windup valve has relieved To obtain the anti reset windup 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 the differential can be adjusted by turning the anti reset windup valve adjustment screw see figure 3 1 Turning the screw clockwise will decrease the differential pressure Turning the screw counterclockwise will increase the differential pressure The anti reset windup valve is factory set at approximately 5 psi differential pressure Repeat steps 7 through 12 until the required differential pressure is obtained Remote Set Point suffix letter M Maintenance A WARNING Refer to the Maintenance WARNING at the beginning of this section 68 Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 Remote Set Point Assembly Re
23. 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 4Failure of differential pressure unit 1 5 Linkage failure 1 6 Relay malfunction 1 7 Differential relief valve settoo low 1 1 Refer to the Start up section for controller settings 1 2 Monitor the supply pressure with an external gauge Ensure that it is set correctly and does not fluctuate Note the number of instruments being supplied by the regulator 1 3 Note if the pointer is bent 1 4 Inspect the differential pressure unit Using a soap solution check for leaks Refer to the differential pressure unit instruction manual 1 5 Check for links bent or not connected properly or pivots broken 1 6 By changing the process differential pressure in the sensor and observing the output verify that the output will move at about the same speed 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 a set point or load change under closed loop conditions 1 1 If stable 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 recomme
24. exceed the operating limits given in this manual General Calibration Instructions Note If the controller has the auto manual option be sure the controller is in the automatic mode before performing calibration 25 4194 HB Controllers Instruction Manual September 2014 D200156X012 Ifthe prestartup checks or startup reveal faulty controller operation perform the calibration described in this section These instructions are valid for either shop field calibration if open process loop conditions exist Unless otherwise noted key numbers refer to figure 6 1 Process Indicator Zero and Span Calibration Provide a regulated process differential pressure to the differential pressure unit Also plug the controller output connection and provide a regulated supply pressure to the controller Do not exceed the normal operating pressure in table 1 4 Refer to figure 3 1 for location of adjustments Note Any adjustment of the process indicator span adjustment screw requires readjustment of the process indicator zero adjustment screw 1 Remove the two machine screws key 6 and lift off the proportional band indicator cover key 36 2 Set the proportional band adjustment between DIRECT and REVERSE 3 Adjust the process differential pressure until the input to the differential pressure unit is equal to the lowest limit of the scale range 4 If necessary adjust the process indicator to the lowest limit of the pro
25. flexure during this procedure Bending or kinking the drive flexure can result in product damage and impaired performance 1 Disconnect the flexure key 79 from the drive bracket key 121 and from the adjustment arm of pivot assembly A Remove the screws and washers key 12 and 13 remove the flexure 2 Set remote set point pressure at 50 percent of input span Note The adjustment arm of the pivot assembly 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 flexure making sure it stays straight and horizontal Before tightening down the drive flexure set pivot A in the middle of the bushing end play Tighten down the drive flexure to hold the pivot in that position Do not kink or twist the flexure when tightening the screws 4 Decrease the remote set point pressure to 0 psig 5 After replacing parts refer to the various maintenance calibration procedures process zero and span adjustment flapper alignment Remote Set Point Tubing 1 Decrease the remote set point pressure to 0 psig 2 Disconnect the pressure connection key 93 into the pedestal assembly key 105 and the connection to the case exterior at the top of the case 3 Remove the tubing key 104 4 Install the replacement tubing and reconnect the two pressure connections 5 Apply full r
26. key 285 all the way out to eliminate loading the range spring 2 Position the range spring cup key 284 the range spring key 283 and the diaphragm assembly key 281 on the loader assembly key 282 77 4194 HB Controllers Instruction Manual September 2014 D200156X012 3 Position the ball key 279 the tube key 278 and the ball seats key 280 between the ears of 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 Bolt the loader assembly halves together using the four screws key 289 Note Be sure 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 in the replacing the auto manual station procedure Replacing the Auto Manual Station Loader Valve Plug and Valve Plug Spring Refer to figure 6 5 for key number location Loosen the spring seat screw key 275 Remove the valve plug spring key 276 and the valve plug key 277 Inspect the parts and replace as necessary Install the valve plug spring and valve plug Tighten the spring seat screw Temporarily apply supply pressure and process differential pressure and check for leaks Oo uU P N Install the controller assembly in
27. manual apply only to specific 4194HA HB and HC controller configurations These configurations 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 figure 1 1 Refer to table 1 2 for the definition of each 4194H controller type number Figure 1 1 Fisher 4194H Differential Pressure Controller eo 0 TERN Y 100 W5908 Do not install operate or maintain a 4194HA HB or HC 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 4194 HB Controllers Instruction Manual September 2014 D200156X012 Description The controllers described in this manual provide differential control with options as shown in table 1 2 e 4194HA controllers Proportional only control e 4194HB controllers Proportional plus reset control e 4194HC controllers Proportional plus reset plus rate control 4194HA HB or HC controllers show process differential pressure and set point on an easy to read pro
28. point pressure to the upper limit of the input span Note whether the indication is above or below the upper limit of the process scale 5 Adjustthe 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 6 Repeat steps 3 through 5 until the error is eliminated 7 Adjust the remote set point pressure to 50 percent of the remote set point range 8 Make sure the remote set point indicator is within 1 percent of the mid scale mark and if so proceed to step 10 If the set point indicator is not within 1 percent but is within 2 percent of the mid scale mark then proceed with step 9 If the set point indicator is not within 2 percent proceed to the remote set point calibration in Section 5 9 Loosen the zero adjustment locking screw and adjust the zero screw to correct for one half the error Tighten the locking screw 10 Adjust the remote set point pressure to the lower and upper range limits and make sure the set point indicator is within 1 percent 11 Install the proportional band indicator cover and tighten the two screws 12 If necessary proceed to the process indicator zero and span calibration procedure in this section Otherwise proceed to the flapper alignment procedure in this section Flapper Alignment Note Perform the process indicator zero and span calibration procedure and if necessary th
29. 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 of direct acting controllers 3 Setthe proportional band adjustment to 100 percent for fast processes For slow processes calculate the proportional band percentage from the equation below Proportional Band 200 x Allowable Overshoot Adjustment Pressure Span For example 200 x 2Psig _ gt 4 Create load upset by momentarily changing the set point Check 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 X 2 Calibration for 4194HA 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 option be sure the controller is in the automatic mode before performing calibration If the prestartup checks revealed faulty controller operation perform the calibration described in this section These instructions are valid for either shop or field calibration provided open process loop conditions exist Unle
30. screws 12 Decrease the remote set point pressure to 0 psig 13 Connect the end of link A key 116 in figure 6 3 to the pivot lever arm in the same position noted in step 3 14 Replace the tie bar key 106 15 After replacing parts refer to the various maintenance calibration procedures process zero and span adjustment flapper alignment Pivot Assembly B Key 115 Refer to figure 6 3 for the key number locations 1 Decrease the remote set point to 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 machine screws key 102 attaching pivot assembly B to the mounting plate key 111 Remove pivot assembly B 4 Loosen the linearity adjustment screw on replacement pivot assembly B and set it in the same position as the adjustment on original pivot assembly B Tighten the screw 5 Set replacement pivot assembly B on the mounting plate and attach it with the two machine screws 70 Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 6 Attach links A and B keys 116 and 126 to the arms of the replacement pivot assembly B in the positions noted in step 2 7 Perform the remote set point maintenance calibration procedure in this section Also perform the appropriate controller calibration procedure in Section 3 4 Drive Flexure CAUTION Avoid bending or kinking the drive
31. set point indicator aligns with the lowest scale limit Properly align the set point indicator with the low scale limit Tighten the zero adjustment locking screw 4 Adjust the remote set point pressure to the upper limit of the input span Note whether the indication is above or below the upper limit of the process scale 5 Adjust the span screw figure 3 1 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 6 Repeat steps 3 through 5 until the error is eliminated 7 Adjust the remote set point pressure to 50 percent of the remote set point range 8 Make sure the remote set point indicator is within 2 percent of the mid scale mark then proceed with step 9 If the set point indicator is not within 2 percent proceed to the Remote Set Point Maintenance Calibration procedure in Section 5 9 Loosen the zero adjustment locking screw Adjust the zero screw to correct for half the error 10 Adjust the remote set point pressure to the lower and upper range limits Make sure the set point indicator is within t1 percent 11 Install the proportional band indicator cover key 36 and tighten two screws key 6 12 If necessary proceed to the process indicator zero and span calibration procedure in this section Otherwise proceed to the flapper alignment procedure in this section Flapper Alignment Note Perform t
32. the instrument is located such that the adjacent process pressure lines will be approximately horizontal the lines should slope downward to the instrument for liquid filled lines and upward toward the instrument for gas filled lines This will reduce the chance of air becoming trapped in the sensor with liquid filled lines or of condensate becoming trapped with gas filled lines The recommended slope is 83 millimeters per meter 1 inch per foot Supply Pressure WARNING Severe personal injury or property damage may occur if the instrument supply medium is not clean dry air or oil free noncorrosive gas While use and regular maintenance of a filter that removes particles larger than 40 micrometer 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 10 Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 Supply pressure must be clean dry air or noncorrosive gas that meets the requirements of ISA 7 0 01 Amaximum 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
33. 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 See figure 3 1 for the location of the flapper leveling screws Adjust the set point to the maximum value on the process scale Remove the tape and move the process indicator until the controller output equals the pressure recorded in step 21 If the process differential pressure indication in step 23 is greater than the maximum scale value by 2 percent loosen the shoe adjustment screws key 30 and move the set point beam shoe key 29 slightly down from the center of the flapper assembly see figure 5 9 If the process differential pressure indication in step 27 is at least 2 percent less than the maximum scale value move the set point beam shoe key 29 slightly upward toward the center of the flapper assembly Repeat steps 20 through 24 until the error is less than 2 percent of process scale span at the maximum process scale value Reattach link 1 to the drive arm Install the controller assembly in the case and cover Refer to the flapper alignment procedures Replace the proportional band indicator cover key 36 and tighten two screws key 6 55 4194 HB Controllers Instruction Manual September 2014 D200156X012 Replacing the Flapper Assembly and Flexure Pivot Assembly Note Before starting the following procedure remov
34. 00664 NOZZLE PRESSURE RESET PRESSURE INN PROPORTIONAL PRESSURE 46A9764 B 0593 3 NOZZLE FEEDBACK MOTION FLAPPER DIRECT ACTION PIVOT QUADRANT INPUT MOTION FLAPPER DETAIL OUTPUT PRESSURE g d TO FINAL CONTROL ELEMENT RELAY PRESSURE RATE VALVE RESET VALVI PROPORTIONAL PLUS RESET PLUS RATE CONTROL TO RESET TO BELLOWs NOZZLE PROPORTIONAL BELLOWS OUTPUT SSN DIFFERENTIAL RELAY RELIEF VALVE SUPPLY PRESSURE RATE VALVE RESET VALVE PROPORTIONAL PLUS RESET PLUS RATE CONTROL WITH ANTI RESET WINDUP The controller action is changed from DIRECT to REVERSE by turning the proportional band adjustment knob to position the nozzle on the flapper quadrant to a point where the direction of the flapper motion versus input motion is reversed see flapper detail in figure 4 2 With the controller in the reverse acting mode an increase in process differential pressure causes a decrease in output pressure 4194 controller also has rate valve figure 4 4 which 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 differential pressure as follows e 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 lon
35. 2 Differential pressure unit or linkage failure 8 3 Mechanical alignment 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 differential pressure and observe the flapper Inspect the sensor and linkages for damage Refer to the differential pressure unit instruction manual 8 3 Move the set point and verify that the nozzle can be capped by the flapper If not inspect linkages and flexures for damage 8 4 With the supply pressure on check for a low flow of air at the nozzle output When capped the output pressure should build rapidly The relay should open and pass a large flow of air through the OUTPUT nipple 8 5 Check for nozzle tubing leaks with a soap solution with the nozzle capped by the flapper Press on the nozzle cap gently to ensure the nozzle O ring is sealing Ensure the relay nozzle tubing nut 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 Repair or replace parts as necessary 8 4 Press the cleanout wire on the relay If the problem persists replace the relay 8 5 Tighten the relay nozzle tubing nut tighten manifold screws keys 34 and 131 or replace nozzle assembly O ring or set point beam assembly as appropriate Changing Controller Action The following steps d
36. 3 and slow down the reset by changing the setting to the higher value The reset is now tuned e Tuning rate action For a controller with rate 4194HC controllers adjust the rate toward the lowest setting until cycling occurs When the system cycles multiply the rate value by a factor of three reset time X 3 and slow down the rate by changing the setting to the higher value The rate is now tuned Checkthe stability of the recommended proportional band setting by introducing a disturbance and monitoring the process Once stable control is attained the process indicator and set point adjustment 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 on the process scale and proceed with step 9 If the process indicator is within 5 percent of the set point indicator turn the link 3 adjustment see figure 5 3 for location until the process indicator 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 indicator is misaligned with the set point adjustment by more than 5 percent of the scale span perform the calibration procedure for 4194HB HC controllers Calibration for 4194HB and HC Controllers WARNING To avoid personal injury or property damage resulting from the sudden release of pressure do not
37. 4 0 Bar 6 to 30 Psig Output 0 28 m3 hr 10 0 scfh Delivery Capacity 0 2 to 1 0 Bar 3 to 15 Psig Output 6 4 m3 h 240 scfh 0 4 to 2 0 Bar 6 to 30 Psig Output 9 4 m3 h 370 scfh Exhaust Capacity 0 2 to 1 0 Bar 3 to 15 Psig Output 5 0 m3 h 186 scfh 0 4 to 2 0 Bar 6 to 30 Psig Output 7 9 m3 h 295 scfh Operative Ambient Temperature Limits 4 40 to 70 C 40 to 160 F 4194HA HB Controllers September 2014 Instruction Manual D200156X012 Table 1 1 Specifications continued Hazardous Area Classification Complies with the requirements of ATEX Group II Category 2 Gas and Dust x u2 ap Housing Designed to NEMA 3 and IEC 529 IP54 specifications Mounting Controller is mounted on a pipestand See figure 2 1 Approximate Weight Controller 4 5 kg 10 Ib without the differential pressure unit Differential Pressure Unit 21 5 kg 47 Ib Total Weight controller and differential pressure unit 26 kg 57 Ib with a Barton 199 Differential Pressure Unit Declaration of SEP Fisher Controls International LLC declares this product to be in compliance with Article 3 paragraph 3 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 applica
38. 4 2 Schematic of Operation for Fisher 4194HB Controller SET POINT INDICATOR REVERSE ACTION QUADRANT RESET BELLOWS PROPORTIONAL PROCESS INDICATOR BELLOWS PROPORTIONAL NC IZ BAND ADJUSTMENT FEEDBACK S i LINK REMOTE SET POINT A CONNECTED HERE FEEDBACK S MOTION INPUT ELEMENT A ine FLAPPER CONNECTED HERE SENN w DIRECT ACTION PIVOT CONNECTING QUADRANT LINK N 2 INPUT MOTION 2 lt FLAPPER DETAIL AN AY hy BEAM Sy 4 NA 2 OUTPUT PRESSURE N gt a TO FINAL CONTROL SS 9 Sj ELEMENT FLAPPER V NA gt lt v P NOZZLE 5 RELAY 7 SUPPLY PRESSURE lt TO RESET PROPORTIONAL PLUS RESET CONTROL NOZZLE s a OUTPUT SUPPLY PRESSURE PROPORTIONAL y BE BELLOWS OUTPUT PRESSURE 292251 NOZZLE PRESSURE RESET PRESSURE RELAY 46A9764 C B1908 4 32 SUPPLY PRESSURE DIFFERENTIAL RELIEF VALVE PROPORTIONAL PLUS RESET CONTROL WITH ANTI RESET WINDUP Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 Figure 4 3 Schematic of Operation for Fisher 4194HC Controller SET POINT INDICATOR RESET BELLOWS REVERSE ACTION QUADRANT PROPORTIONAL 2 BELLOWS PROPORTIONAL PROCESS INDICATOR ie BAND ADJUSTMENT ae LINK REMOTE SET POINT CONNECTED HERE INPUT ELEMENT CONNECTED HERE CONNECTING LINK BEAM FLAPPER SUPPLY PRESSURE INN OUTPUT PRESSURE
39. 55 2 req d 271 Bellows ass y 135 Frame manifold 03600 aluminum For 4194HC controllers only For alltypes except w suffix letter E Brass bellows int auto man station option 0 2 to 1 0 bar 3 to 15 psig and 0 4 to 2 0 bar 6 to 30 psig 18A0738X012 136 lt manifold A03600 aluminum SST bellows For all types except 4194HC controllers 0 2 to 1 0 bar 3 to 15 psig and rate reset valve 0 4 to 2 0 bar 6 to 30 psig 18A0738X022 137 Ratetubing SST For 4194HC controllers only 272 Rate Reset Body 233520 zinc die casting 138 tubing 55 SST aluminum For 4194HC controllers only Use w suffix letter E int auto manual station option only 310 Lithium grease not furnished with controller 140 Machine screw fill hd 18 8 SST 311 Anti seize sealant not furnished with controller Required to mount the remote set pt ass y 317 Silicone based lubricant not furnished with controller suffix letter M to indicator ass y 2 req d 318 Lubricant silicone not furnished with controller 162 Machine screw hex hd 18 8 SST For 4194HB HC controllers only 337 Barton 199 Differential Pressure Unit 163 Knob plastic Key 337 includes the pipestand For 4194HB controllers reset restriction mounting bracket and three set valve key 54 screws square hd steel 3 8 16 x 5 8 inch For 4194HC controllers rate reset valve key 262 2 req d 339 External feedback ass y SST tubing 171 0 ni
40. 6X012 Figure 5 9 Proportional Band Knob and Set Point Beam Details PLASTIC WASHER NOZZLE TUBING ASSEMBLY KEY 18 WASHER 20 SCREW Cop lt KEY 19 E RING 27 26 O RING PROPORTIONAL BAND ADJUSTMENT SEO hie NACL vm N ADJUSTABLE lt POINT SET POINT SET POINT BEAR SHOE NOZE PIVOT ASSEMBLY BEAM ASSEMBLY KEY 29 EM KEY 17 KEY 23 w4193 EXPLODED VIEW FLAPPER ALIGNMENT SCREW FLAPPER RETAINER CLIP E RING CAP POSITIVE FEEDBACK TUBING ASSEMBLY PROPORTIONAL BAND ADJUSTMENT KNOB SHOE ADJUSTMENT SCREWS SET POINT BIAS SPRING SET POINT BEAM ASSEMBLY RELAY NOZZLE SET POINT LINK 3 BEAM SHOE TUBING ASSEMBLY W3852 LINK 3 DISCONNECT 54 Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 Figure 5 10 Proportional Band Adjustment Knob Figure 5 11 Nozzle Flapper Alignment Alignment 20 2 22 23 24 25 26 27 28 29 HOLE FLAPPER NOZZLE W3761 W3449 1 TOP VIEW Adjust the set point to the minimum value on the process scale Disconnect link 1 from the drive arm and tape the process indicator to the minimum scale value Record the controller output pressure Output pressure reading can be anywhere from 0 2 to 1 0 bar 3 to 15 psig for a 0 2 to 1 0 bar to 15 psig output signal range or 0 4 to 2 0 bar 6 to 30 psig for a 0 4 to 2
41. 8 8 SST 4 req d 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 368 Linkass y 18 8 SST 2 req d 369 Process indicator adj ass y aluminum SST brass 370 Setptindicator 55 aluminum SST brass 371 Pivot pin 530200 302 SST 2 req d 372 Washer plain 18 8 SST 4 req d 374 Pointer and bracket aluminum steel 375 Set pt indicator ass y A93003 aluminum for controllers w remote set pt for controllers w o remote set pt 376 Dial bracket G10080 steel 377 Dial bracket G10080 steel 378 Screw self tapping 18 8 SST 2 req d Recommended spare parts 4 i G78 Auto Manual Station suffix letter E figure 6 5 Key Description Part Number 273 Auto manual station 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 18A2878X012 278 Tube plastic 279 Ball SST 280 Ballseat nitrile 2 req d 281 Diaphragm ass y nitrile aluminum 282 Loaderass y aluminum plastic 283 Rangespring SST 284 Range spring cup pl steel 285 Spring adj screw pl steel 286 Retaining ring pl steel 18A2903X012 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 hd 530200 302 557 2 req d 1K318838992 4194 HB
42. 9 Attach link 3 to the set point beam assembly key 23 See figure 5 9 Tighten the nut on the relay nozzle tubing assembly key 18 Apply full supply pressure with the nozzle capped and check for leaks For controllers with reset or rate 4194HB or 4194HC controllers disconnect the supply pressure Then adjust the reset adjustment to the CLOSED 4194HB or OFF 4194HC position and adjust the rate adjustment to the OFF position Controller output pressure must be 0 bar 0 psig Set the reset adjustment to 0 01 minutes per repeat and wait 30 seconds Then turn the reset adjustment to the CLOSED position 4194HB or to the OFF position 4194HC Connect supply pressure and a regulated process differential pressure to the controller Also provide a means of measuring controller output pressure Perform the appropriate process indicator zero and span calibration procedure and if necessary the remote set point calibration procedure in Section 3 or 4 When calibration is complete continue with step 19 below Note The following procedure steps 19 through 29 matches the process indicator motion to the set point indicator motion so the controller will control at set point at all positions on the process scale 19 Adjust the proportional band to 40 percent DIRECT or REVERSE direct or reverse action depending on the desired controller action 53 4194HA HB Controllers Instruction Manual September 2014 D20015
43. Cap screw hex socket 18 8 SST For flapper ass y key 11 1 req d Plain washer key 13 not req d 17 Adjustable set pt pivot ass y SST 18 Relay nozzle tubing ass y SST 19 Machine screw fill hd 18 8 SST 3 req d 20 Plain washer carbon steel pl 2 req d 21 Nozzle ass y SST 22 Washer plastic 2 req d 23 Set pt beam ass y aluminum SST 25 Proportional band knob polycarbonate 26 Retaining clip S30200 302 SST 27 E ring SST 28 Set pt beam bias spring pl steel 29 Set pt beam shoe G10100 pl steel 30 Machine screw 18 8 SST 2 req d 31 Bellows bracket A95052 aluminum 32 Bellows adj bracket G10100 pl steel 33 Bellows adj spring pl steel 34 Machine screw fill hd 18 8 SST 2 req d 80 One type of pressure gauge is used for both output pressure and supply pressure indication See Key 46 47 table for part numbers 46 47 48 49 50 Output pressure See Key 46 47 table Supply pressure gauge See Key 46 47 table Bellows 2 req d Output ranges 0 2 to 1 0 bar 3 to 15 psig 0 4 to 2 0 bar 6 to 30 psig Brass 16A6953X012 SST 1646953 022 Bellows beam 96061 aluminum 0 2 to 1 0 bar 3 to 15 psig 0 4 to 2 0 bar 6 to 30 psig Relay ass y Relay 0 2 to 1 0 bar 3 to 15 psig Relay 0 4 to 2 0 bar 6 to 30 psig Recommended spare parts Instruction Manual D200156X012 4194HA HB HC Controllers September 2014 Key 46 47 Pressure Gauge 1
44. G SCREW MISALIGNED ADJUSTMENT W3443 1 W3475 1 Link 2 Note Before performing the following link 2 maintenance steps disconnect supply pressure from the controller 1 Remove two screws key 6 and lift off the proportional band indicator cover key 36 2 Note where the link is connected Disconnect the link from process indicator assembly and from the input feedback beam assembly key 11 Remove the link 3 Install the replacement link with the screw head nearest the process indicator as shown in figure 5 5 Connect the link to the process indicator assembly only and in the position noted in step 2 4 The process indicator should be lined up with the indicator subassembly as shown in figure 5 11 If not loosen the zero adjustment locking screw and adjust the process indicator zero adjustment to align to the process and indicator subassembly 5 Adjust the set point adjustment manually or with the remote set point pressure to 100 percent of scale range Set the proportional band between DIRECT and REVERSE Disconnect link 1 from the drive arm and position the process indicator to 100 percent of the scale Tape the indicator in place 6 Move the set point adjustment either manually or with the remote set point pressure to 0 percent on the scale Set the proportional band at 5 percent REVERSE reverse action The nozzle should not be touching the flapper If it is adjust flapper leveling screw number 1 until clearance is obtained 48
45. HB Controllers September 2014 Instruction Manual D200156X012 Figure 6 1 Controller Assembly Drawings Continued 49A0770 A SECTION B B APPLY LUB ADHESIVE NOTES FEEDBACK TUBING MANIFOLD VIEW C C SUFFIX B 56A9752 V Sht 2 iZ m i LU 3 Z ZZ M 54 42 43 VIEW F F VIEW E SUFFIX B 1 gt KEY 4 GASKET IS USED BETWEEN INTERNAL FRAME AND FRAME MANIFOLD 2 gt KEY 5 GASKET IS USED BETWEEN FRAME MANIFOLD AND POSITIVE o 9 5 T S int VIEW SUFFIX BF VIEWE SUFFIX BF 40 a pe SECTION B B SUFFIX A n SECTION B B SUFFIX B 84 Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 Figure 6 1 Controller Assembly Drawings Continued
46. IEW E 4194HC CONTROLLERS and two machine screws key 53 figure 6 1 VIEW E 4194HB CONTROLLERS or VIEW E 4194HC CONTROLLERS Use these parts in the next step 1 For4194HB and HC controllers with the anti reset windup option suffix letter F remove the differential relief valve key 55 figure 6 1 VIEW E 4194HB CONTROLLERS OPTION F or VIEW E 4194HC CONTROLLERS OPTION F Install the two O rings key 52 and valve cover key 51 provided with the controller Secure the valve cover over the two O rings with the two machine screws key 53 also provided 65 4194 HB Controllers Instruction Manual September 2014 D200156X012 Fora controller with manual set point move the set point adjustment to 50 percent of the scale range For a controller with remote set point adjust the remote set point pressure until the set point indicator is at 50 percent of the scale range Remove the two machine screws key 6 and lift off the proportional band indicator cover key 36 Adjust the reset adjustment to 0 01 minute per repeat Ifthe controller has rate 4194HC controllers turn the rate adjustment to OFF If the controller has the external feedback option available with 4194HB controllers only shut off the supply pressure connect the controller output to the external feedback connection and turn on the supply pressure See figure 2 2 for the location of the output and external feedback connections
47. Instruction Manual D200156X012 4194HA HB HC Controllers September 2014 Fisher 4194 HB and HC Differential Pressure Indicating Controllers Contents 1 Introduction Scope Description lee ARRA ea wee YA Specifications Educational Services 2 Installation Mounting and Connections Controller Mounting Orientation Pipestand Mounting Pressure Connections Process Pressure Connections Supply Pressure Vent Connection Remote Set Point suffix letter M Connection External Feedback Connection 4194HB Controllers only 3 4194HA Proportional Only Controllers Adjustments for 4194HA 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 4194HA Controllers Startup for 4194HA Controllers Calibration for 4194HA Controllers General Calibration Instructions Process Indicator Zero and Span Calibration aa aus Remote Set Point suffix
48. Perform steps 1 through 7 of the Replacing the Differential Pressure Unit procedure Then perform steps 1 and 2 of the Replacing the Case and Cover procedure 62 Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 Refer to figure 6 1 4194 or 4194HC controllers suffix letter F for key number locations Perform the procedures required in the Note above Loosen the nuts at both ends of the relief valve tubing key 44 and remove the tubing Install the replacement relief valve tubing and tighten the tubing nuts at both ends Apply the proper supply pressure to the controller Check for leaks Install the controller assembly in the case and cover Perform the process zero and span adjustment procedure and the flapper alignment procedure gu WU N Calibration After Controller Maintenance A WARNING To avoid personal injury or property damage resulting from the sudden release of pressure do not exceed the operating limits given in this manual Process Indicator Zero and Span Calibration Note For routine zero and span calibration refer to the appropriate procedures in Section 3 or 4 Use the following maintenance zero and span procedure only if difficulty is encountered with the routine procedure or if nonlinearity occurs Refer to figure 3 1 for location of adjustments and figure 6 1 for key number locations Provide a regulated process differential pressure to the differential pres
49. Pressure Control Block for Remote sua 50 SetPoint eI AE e pre en ead 72 Replacing the Supply Proportional Reset Remote Set Point Maintenance Calibration 72 Reset Valve and Relief Tubing Remote Set Point Precalibration Procedures 72 Assemblies 51 Setting Remote Set Point Travel Stops 73 Replacing the Proportional Band Adjustment Aligning Remote Set Point Linkage 73 Knob Nozzle Assembly and Set Point Remote Set Point Zero and Span Beam Assembly 52 Adjustment 73 Replacing the Flapper Assembly and Remote Set Point Linearity Adjustment 74 Flexure Pivot Assembly 56 Replacing Auto Manual Station Replacing the Proportional or Reset suffix letter Parts 75 Bellows 59 Disassembly of the Auto Manual Station 75 Replacing the Reset Restriction Valve Assembly of the Auto Manual Station 75 4194HB 61 Replacing the Auto Manual Station Switch Replacing the Rate Reset Valve Assembly Body Assembly Lever O Ring Switch 4194HC Controllers 61 Body O Ring and the Tubing Assembly 76 Replacing the Differential Relief Valve Replacing the Auto Manual Station Switch Assembly suffix letter F 62 Range Spring Diaphragm Assembly Replacing the Relief Valve Tubing Ball Seat Tubing
50. SS FEEDBACK CONNECTED HERE SA MOTION i FLAPPER INPUT ELEMENT NI Y DIRECT ACTION CONNECTED a QUADRANT XS INPUT MOTION CONNECTING 2 N LINK DETAIL row gt OUTPUT PRESSURE SW TO FINAL CONTROL FLAPPER ELEMENT 2 SUPPLY PRESSURE Ge NOZZLE 5 KAYA OUTPUT PRESSURE RELAY J NOZZLE PRESSURE SUPPLY Ir PRESSURE 20 Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 The process differential pressure input element is connected to the process indicator and to the flapper by connecting links As the process differential pressure increases in a direct acting controller the flapper moves toward the nozzle restricting flow through the nozzle and increasing nozzle pressure When this occurs relay action increases the output pressure delivery of the controller Output pressure is fed back to the proportional bellows The action of the proportional bellows counteracts the flapper movement that resulted from the process differential pressure change and backs the flapper away from the nozzle until equilibrium is reached The set point adjustment changes the distance between the nozzle and flapper as does a change in process differential pressure except that when the set point is changed the nozzle moves with respect to the flapper The proportional band adjustment knob positions the nozzle on the flapper Increasing widening the proportional band mov
51. SST For 4194HA or HB controllers For 4194HC controllers 1 dendi suena 41 Plug 530300 303 SST For use w or w o int set pt and For all 4194HA controllers 1 req d w o remote or ext set pt For all 4194HB controllers w ext For use w remote set pt and w o feedback 1 req 4 except int or ext set pt 4194HBF HBFM HBFE and 2 Nameplate A91100 aluminum KBFME not required 3 Frame A03600 aluminum For 4194HC HCM HCE and CME 2 req d 4 Gasket chloroprene For 4194HCF HCFM HCFE for use between internal frame and HCEME 1 req d and frame manifold key 135 18A0749X012 42 Reset valve tubing SST 5 Gasket chloroprene For all4194HB controllers for use between frame manifold key 135 and positive feedback 43 Reset tubing ass y SST tubing manifold key 136 18A0742X012 For all4194HB controllers 6 Machine screw fill hd 18 8 SST 6 req d For all4194HC controllers 7 nitrile For all types w either 44 Relief valve tubing ass y SST 1 4 18 NPT internal process connection or FOFATSAEIBE HBFE 1 2 14 NPT external process connection and HBFME only wo remotesetot i reddi For 4194HCF HCFE HCFM w remote set pt 2 req d and HCFME only w ext fdback and w o remote set pt 2 req d w ext fdback and w remote set pt 3 req d 10376206992 8 O Ring nitrile 3 req d 16A6903X012 9 Flexure pivot 55 sapphire SST 10 Machine screw fill hd 18 8 SST 4 req d Not 11 ass y 29A9518X012 12
52. SST casting 86 Travel stop nut 530300 303 557 87 Set screw hex socket 18 8 SST 93 Union 531600 316 557 99 Plain washer 18 8 SST 102 Machine screw pan hd 18 8 SST 4 req d 103 Machine screw pan hd 18 8 SST 2 req d 104 Remote set pt tubing 530400 304 SST 88 105 106 107 108 109 110 111 112 114 115 116 118 119 121 122 123 124 125 126 134 139 141 311 Description 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 530200 302 SST Drive bracket 30400 304 SST Machine screw fill hd 18 8 SST 2 req d Plain washer 18 8 SST Nut Hex 18 8 SST Spacer A92011 aluminum Connecting link ass y aluminum bronze brass Diaphragm ass y extension A92011 aluminum Machine screw fill hd 18 8 SST 3 req d Adj arm 530400 304 SST Anti seize sealant not furnished with controller Instruction Manual D200156X012 4194HA HB HC Controllers September 2014 Figure 6 4 Process and Set Point Indicator Assembly Manual Set Point 39A1126 H Indicator Assembly key 101 figure 6 4 Key Description 37 Self tapping screw 1
53. all 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 To switch from manual to automatic mode adjust the set point manually or with remote set point pressure to move the ball into the switching zone Turn the switch to AUTOMATIC and adjust the set point manually or with remote set point pressure to control the output When the automatic manual switch is in AUTOMATIC adjusting the loader knob has no effect on the controller output When the automatic manual switch is in MANUAL changing the set point adjustment has no effect on the controller output Prestartup Checks for 4194HA Controllers Refer to figure 3 1 for location of adjustments and refer to figure 6 1 for location of key numbers 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 option suffix letter E be sure the controller is in the automatic mode before performing the prestartup checks 4194 HB Controllers Instruction Manual September 2014 D200156X012 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 outp
54. and Ball 77 Assembly suffix letter F 62 Replacing the Auto Manual Station Loader Calibration After Controller Maintenance 63 Valve Plug and Valve Plug Spring 78 Process Indicator Zero and Span 6 Parts Calibration 63 Parts Ils oretenus 79 Flapper Alignment 64 Parts Ordering 79 4194HA Proportional Only Controllers 65 Abbreviations Used In Parts List 79 4194 Proportional Plus Reset and Controller Parts 79 4194HC Proportional Plus Reset Process and Set Point Indicator Assembly 87 Plus Rate Controllers 65 Remote Set Point Assembly 88 Anti Reset Windup Valve suffix letter F Indicator Assembly 89 Calibration 67 Auto Manual Station suffix letter E 89 Remote Set Point suffix letter M Controller Mounting Parts 92 Maintenance 68 FIELITIGS node e p i mel e onn esc ht ete 92 Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 Section 1 Introduction Scope of Manual This instruction manual provides installation operating calibration maintenance and parts ordering information for the 4194HA HB and HC high static pressure differential pressure indicating controllers Portions of this
55. ap solution check for leaks in the proportional and reset bellows in the tubing that connects these bellows 2 8 Adjust output to 1 0 bar 15 psig fora 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 Close the reset valve If the controller output varies as reset valve is closed and no leaks were found in the rest of the feedback system Step 2 7 the reset valve is leaking 2 9 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 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 Adjust as necessary 2 4 Repair or replace parts as necessary 2 5 Adjust as necessary 2 6 Repair or replace parts as necessary 2 7 Repair as necessary 2 8 Replace the reset valve 2 9 Repair or replace parts as necessary Continued 39 4194HA HB Controllers September 2014 Instruction Manual D200156X012 Table 5 1 Troubleshooting Chart Continued Fault Possible Cause Check Correction 3 Controlling off set point but not reflected by process and set point indicators 3 1 Out of calibration 3 1 Refer to the calibration and flapper alignment procedures 3 1 Adjust as necessary 4 No reset action 4194HB and 4194HC controllers
56. arm ass y SST steel 323 Zero link ass y SST brass Recommended spare parts Key 324 325 326 327 328 329 330 331 332 333 334 335 336 025 J 9 mr mr aaa Part Number Description Clamp block 18 8 55 ut 2 req d Boot nitrile ounting plate for differential pressure unit stl zn pl Controller mounting plate stl zn pl achine screw pan hd 18 8 SST 2 req d 18A4999X012 achine screw fill hd 18 8 SST 2 req d achine screw fill hd 18 8 SST Plain washer 18 8 SST 2 req d Set screw hex socket 18 8 SST 2 req d Cap screw hex hd 18 8 SST 4 req d Cap screw hex hd SST 3 req d Cap screw hex hd 18 8 SST 4 req d 87 4194HA HB HC Controllers September 2014 Instruction Manual D200156X012 Figure 6 3 Remote Set Point Assembly WS M Z N gt 19 n lo m qe ya 7 Q Or 7 9 APPLY LUB SEALANT 36A6988 C Remote Set Point Assembly key 62 figure 6 3 Key Description 12 Cap screw hex socket 18 8 SST 2 req d 13 Plain washer 18 8 SST 3 req d 79 Drive flexure SST 80 Diaphragm capsule for 4194HAM HBRM HBFME HBM and HBME 1 req d for use in remote set pt ass y key 62 N09902 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 83 Travel stop CF8
57. ass y parts are listed in two subsections of this parts list the Process and Set Point Indicator Assembly key 56 subsection and the Indicator Assembly key 101 subsection Key numbers for individual indicator parts also appear in figure 6 2 Process and set pt indicator ass y plastic aluminum stainless steel w o remote set for 4194HS and 4194HSE w remote set for 4194HSM and 4194HSME Recommended spare parts Key Description 57 Pressure control block CF8M 316 SST Casting 1 req d for remote set pt 1 req d for ext fdback 58 Cap screw hex hd SST Maximum qty req d 6 61 Process scale aluminum For indicator ass y 0 5 psid 0 10 psid 0 15 psid 0 20 psid 0 30 psid 0 40 psid 0 50 psid 0 60 psid 0 75 psid 0 250 mbar differential 0 0 6 bar differential 0 1 4 bar differential 0 1 6 bar differential 0 2 0 bar differential 0 20 in w c differential 0 25 in w c differential 0 50 in w c differential 0 75 in w c differential 0 100 in w c differential 0 100 percent 0 10 square root 0 100 square root 62 Remote set pt ass y suffix letter Note The part numbers listed for key 62 are for the complete remote set point suffix letter M assembly Individual assembly parts are listed in the Remote Set Point Assembly subsection of the parts list Key numbers for individual assembly parts also appear in figure 6 3 Remote set pt ass y suffix letter N09902 0 8 bar 12 psig span 1 7 bar 24 psig span SST
58. at and wait 30 seconds Then turn the reset adjustment to CLOSED 4194HB or OFF 4194HC position 36 Apply proper supply pressure to the controller and provide an accurate means of measuring the controller output pressure 37 Adjust the proportional band to 5 percent REVERSE reverse action and adjust the set point to the maximum value on the process scale 38 With link 1 still disconnected tape the process indicator at the minimum process scale value the last mark on the left side of the scale The output pressure should be within 0 07 bar 2 psig of the supply pressure If not adjust flapper leveling screw number 1 until the output is within 0 14 bar 2 psig of supply pressure 39 Loosen the two adjustment screws on link 4 see figure 5 5 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 see figure 5 5 41 Raise 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 repeat steps 39 and 40 42 Perform steps 20 through 26 in the maintenance procedure for the proportional band adjustment knob nozzle assembly and set point beam assembly 43 Remove the tape from the process indicator and reconnect link 1 to the drive arm For 4194HB and 4194HC controllers controllers with reset turn the reset adjustment to 0 01 44 Install the controller assembly in the case
59. ble EC Directives NOTE Specialized instrument terms are defined in ANSI ISA Standard 51 1 Process Instrument Terminology 1 With Barton 199 differential pressure unit For ranges other than those listed in table 1 3 contact your Emerson Process Management sales office 2 Consult your Emerson Process Management sales office for additional information 3 Normal m3 hr normal cubic meters per hour 0 C and 1 01325 bar absolute Scfh standard cubic feet per hour 60 F and 14 7 psia 4 Also for transportation and storage limits Table 1 2 Available Configurations MODES OPTIONS CONTROLLER ProportionalOnl Proportional Plus Proportional Plus Anti Reset Remote Set Internal Auto P y Reset Reset Plus Rate Windup Point Manual Station 4194HA X 4194HAE X x 4194 x x 4194HAME x X x 4194HB X 4194HBE X x 4194HBF x X 4194HBFE X X x 1998 4194HBM x X 4194HBME X X X 4194HBFM X X X 4194HBFME X X X X 4194HC X 4194HCE X x 4194HCF x x 4194HCFE x x x 4194 X X 4194HCME X X x 4194HCFM x x x 4194HCFME X X X x 1 Reverse acting constructions are designated by an R added to the type number Instruction Manual D200156X012 4194HA HB HC Controllers September 2014 Table 1 3 Process Sensor Barton 199 Range and Pressure Ratings DIFFERENTIAL PRESSURE RANGE 1 SAFE WORKING PRESSURE 2 HOUSING Bar Psig MATERIAL
60. cent DIRECT direct action Apply pressure to the differential pressure unit or if link 1 was disconnected remove the tape from the process indicator and move the indicator until it aligns with the right hand edge of the set point indicator as shown in figure 5 1 Controller output should be within 0 14 bar 2 psig of the supply pressure Pressure the differential pressure unit or if disconnected move the process indicator to the left hand edge of the set point indicator as shown in figure 5 1 Controller output pressure should go to 0 psig Adjust the proportional band to 100 percent REVERSE reverse action Pressure the differential pressure unit or if disconnected move the process indicator to align with the right hand edge of the set point indicator The controller output should be 0 psig Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 18 19 20 21 22 Pressure the differential pressure unit or if disconnected position the process indicator to align with the left hand edge of the set point indicator The controller output should be within 0 14 bar 2 psig of supply pressure If the controller does not perform as indicated in steps 13 through 18 the flapper is not correctly aligned This may occur because the output was not sufficiently stabilized in steps 8 through 12 Repeat steps 7 through 18 Set the proportional band to 400 percent in the desired controller action R
61. cess scale The controller output is a pneumatic signal that operates a final control element Specifications Specifications for 4194HA HB and HC controllers are listed in table 1 1 Educational Services For information on available courses for 4194HA 4194HB and 4194HC controllers as well as a variety of other products contact Emerson Process Management Educational Services Registration Phone 1 641 754 3771 or 1 800 338 8158 e mail education emerson com http www emersonprocess com education Instruction Manual D200156X012 4194HA HB HC Controllers September 2014 Table 1 1 Specifications Available Configurations See table 1 2 Input Signal Differential Pressure Sensing Element Range Differential Pressure Range See table 1 3 Maximum Safe Working Pressure See table 1 3 Output Signal Proportional Only Proportional Plus Reset or Proportional Plus Reset Plus Rate Range 0 2 to 1 0 bar 3 to 15 psig or 0 4 to 2 0 bar 6 to 30 psig Action Field reversible between direct increasing differential pressure increases output pressure or reverse 1 increasing differential pressure decreases output pressure Process Scale Standard scale is matched to the range of the differential pressure sensing element Linear square root and optional scales 2 available Process Connections To Differential Pressure Unit Standard 1 4 NPT internal stainless steel all input ranges Optional 1 2 NPT in
62. cess scale by loosening the zero adjustment locking screw and turning the zero adjustment screw 5 Adjust the process differential pressure until the input to the differential pressure unit is equal to the highest limit of the scale range 6 Note whether the process indicator is above or below the upper limit of the process scale 7 Adjust the process indicator span adjustment screw as follows Clockwise to increase the span for a low indication counterclockwise to decrease the span for a high indication Adjust the span adjustment screw to correct for approximately one half the error 8 Repeat steps 3 through 7 until the error is eliminated 9 Adjust the process differential pressure until the input to the differential pressure unit is equal to 50 percent of the process scale range The process indicator should point to the 50 percent process scale mark within 2 percent of Span e Ifthe error is greater than 2 percent perform the appropriate maintenance calibration procedure in the Maintenance section e Ifthe error is less than 2 percent but more than 1 percent proceed with step 10 10 Adjust the process indicator to within 1 percent of the 50 percent 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 input span 11 Adjust the process differential pressure to 0 percent
63. e length of the adjustment arm so the drive flexure is parallel to the centerline of the capsules c Tighten the screw on the adjustment arm 72 Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 Note The adjustment arm of pivot A turns on a bushing at each end of the shaft supporting the adjustment arm In the next step position the shaft so both bushings float inside the bearings and do not rest against the end of either bearing d Set pivot A in the middle of the bushing end play e Tighten the screws holding the drive flexure in place 5 The guide flexure should also be straight If not loosen the screw key 122 on the end of the flexure attached to the top of pivot A key 114 Allow the flexure to straighten itself Tighten the screw on the flexure Setting Remote Set Point Travel Stops 1 Loosen the set screw key 87 in the lower travel stop nut key 86 CAUTION Make sure the loose travel stop nut does not bind up on the diaphragm capsule extension when pressurizing the capsules Damage to the capsules could result 2 Upper range stop Adjust the remote set pressure to 2 1 2 percent of span greater than the upper range limit Loosen the two screws keys 139 and 140 mounting the travel stop key 83 to the mounting plate Slide the travel stop until it is just touching the end of the capsule stack Tighten the travel stop mounting screws keys 139 and 140 to lock it into that positio
64. e range by loosening the zero adjustment locking screw and turning the zero adjustment screw Tighten the locking screw 11 Adjust the remote set point pressure to the upper and lower limits of the remote set point range and make sure the set point indicator is still within 1 percent at the 0 percent and at the 100 percent process scale marks 12 Perform the appropriate flapper alignment procedure and if necessary the process pointer zero and span calibration procedure in Section 3 or 4 Remote Set Point Linearity Adjustment Adjust the linearity 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 range The set point indicator should indicate the 50 1 percent mark on the scale If not make fine adjustments by loosening the zero adjustment locking screw and turning the zero adjustment screw 2 Adjust the remote set point pressure to 0 percent and note the indicator position relative to the process scale 0 percent marking 3 Adjust the remote set point pressure to 100 percent and note the indicator position relative to the process scale 100 percent marking 4 If the greatest misalignment is positive the set point indicator is to the right of the process scale markings loosen the linearity screw and move it clockwise i
65. e remote set point calibration procedure before the flapper alignment Flapper leveling screw numbers and adjustments are shown in figure 3 1 Provide a means of applying supply pressure to the controller Also provide an accurate means of measuring output pressure Apply process differential pressure to the differential pressure unit Refer to figures 2 1 and 2 2 for the differential pressure unit connections 1 Fora controller with manual set point move the set point indicator to 50 percent of the scale range For a controller with remote set point suffix letter M adjust the remote set point pressure until the set point indicator is at 50 percent of the scale range 2 Apply differential pressure equal to 50 percent of the input range Note If a pressure source is not available to pressure the input element differential pressure unit to 50 percent of range an alternate method is to disconnect link 1 at the drive arm and tape the process indicator at 50 percent of the input range Note the hole from which link 1 was removed for proper replacement 4194 HB Controllers Instruction Manual September 2014 D200156X012 This method should only be used if pressure is not available to drive the differential pressure unit to 50 percent 3 Remove the two machine screws key 6 and lift off the proportional band indicator cover key 36 Adjust the proportional band adjustment between DIRECT and REVERSE 4 The controller o
66. e screw key 19 28 Install the screw key 19 through the frame key 3 and into the relay nozzle tubing assembly key 18 Tighten the screw Be sure the nozzle remains centered on the flapper with the set point beam assembly slid snugly towards the relay nozzle tubing assembly 29 Install washer key 20 on screw key 19 30 Install the screw key 19 through the frame key 3 into the set point pivot assembly key 23 Do not tighten 31 Slide the set point pivot assembly key 17 toward the set point beam until the cone lightly contacts the set point beam and tighten the screws The proportional band knob should fall freely when the controller is in the upright position If it does not reposition the set point pivot assembly key 17 32 Tighten the relay nozzle tubing nut key 18 Apply full supply pressure and check for leaks Disconnect the supply pressure 33 Install the set point beam bias spring key 28 into frame key 3 bore and onto spring seat on the set point beam assembly key 23 34 Attach link 3 to the set point beam assembly Note The following procedure steps 35 through 45 adjusts link 4 so it will always be in compression to eliminate possible instability due to lost motion 35 For controllers with reset or rate adjustments 4194HB or 4194HC controllers disconnect the supply pressure and adjust the rate to OFF Controller output must be 0 bar 0 psig Set the reset adjustment to 0 01 minutes per repe
67. e the controller from the case Perform steps 1 through 7 of the Replacing the Differential Pressure Unit procedure Then perform steps 1 and 2 of the Replacing the Case and Cover procedure CON A N Perform the procedures required in the Note above Remove the two screws and lift off the proportional band indicator cover Disconnect link 3 from the set point beam shoe Refer to figure 5 9 for link location Remove the set point beam bias spring Refer to figure 5 9 for the spring location Remove the screw and washer keys 19 and 20 figure 5 12 holding the set point pivot assembly to the frame Remove the set point pivot assembly Disconnect the nut holding the relay nozzle tubing key 18 figure 5 9 into the frame While holding the proportional band knob remove the screw and washer keys 19 and 20 figure 5 12 which holds the relay nozzle tubing assembly key 18 to the frame manifold key 135 9 Remove the proportional band knob nozzle pivot relay nozzle tubing assembly and set point beam assembly from controller 10 Disconnect link 2 from the input feedback beam assembly key 11 shown in figure 5 7 11 Disconnect link 4 from the bellows bracket key 31 12 Remove the two screws key 12 that hold the flexure pivot assembly key 9 to the input feedback beam assembly See figure 5 13 for screw location 13 Remove the input feedback beam assembly as shown in figure 5 14 14 Remove the four screws
68. e the proportional band adjustment Rotate the adjustment until the desired value is beneath the PB ADJ white indicator mark Adjusting the proportional band has a minimal effect on the set point Changing Controller Action Switch controller action from direct to reverse or vice versa by simply loosening the screws on the proportional band indicator cover and pulling the cover outward so the proportional band adjustment can be rotated to the desired action figure 5 2 22 Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 The white portion of the adjustment produces direct controller action The black portion produces reverse controller action After changing the action tighten the screws on the proportional band indicator cover Reset suffix letter B Adjustment 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 suffix letter C Adjustment Locate the rate adjustment Rotate the adjustment clockwise to decrease the minutes faster rate action or counterclockwise to increase the minutes slower rate action Anti Reset Windup suffix letter F Adjustment If the arrow on the relief valve points toward the top of the controller case as shown in figure 3 1 the valve opens when output pressure falls If the arrow points in the opposite d
69. efer to figure 3 1 for location of adjustments and to figure 6 1 for location of key numbers 23 4194 HB Controllers Instruction Manual September 2014 D200156X012 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 Ifthe controller has the auto manual option 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 figure 2 2 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 4 2 For a controller with remote set point suffix letter M connect regulated pressure of 0 2 to 1 0 bar or 0 4 to 2 1 bar 3 to 15 psig or 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 indicator Turn the reset adjustment to
70. emote set point pressure and check for leaks LinkA 1 Note where link A key 116 is connected figure 6 3 Disconnect both ends of the link from the lever arms on the two pivots 2 Loosen the screw in the replacement link and adjust the length to match the link being replaced Tighten the screw Refer to figure 6 3 for correct orientation of the link 3 Attach the replacement link to the two lever arms in the same position as noted in step 1 4 After replacing parts refer to the various maintenance calibration procedures process zero and span adjustment flapper alignment 71 4194 HB Controllers Instruction Manual September 2014 D200156X012 Link B 1 Note where link B key 126 15 connected figure 6 3 Disconnect both ends of the link from the pivot arm and from the set point indicator assembly 2 Loosen the screw the replacement link and adjust the length to match the link being replaced Tighten the screw 3 Attach both ends of the replacement link Refer to figure 6 3 for correct orientation of the link and position the link as noted instep 1 4 After replacing parts refer to the various maintenance calibration procedures process zero and span adjustment flapper alignment Pressure Control Block for Remote Set Point 1 Remove remote set point pressure 2 Loosen the nut on that portion of the tubing connecting the capsular element to the pressure control block key 57 3 Remove the t
71. emove 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 ofthe rate reset assembly 4 Remove the nut holding the reset tubing assembly key 43 into the rate reset valve assembly 5 Remove the nut holding the proportional tubing assembly key 40 into the rate reset assembly 6 Remove the nut holding the relief tubing assembly key 44 option F only 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 insert the assembly into its position on the frame key 3 11 Insert the valve assembly mounting screw key 162 into the valve assembly and tighten 12 Insert the gasket key 5 and hold it in place while installing the two machine screws key 71 holding the rate tubing assembly key 137 to the valve assembly and tighten the screws 13 Insert the reset tubing assembly key 43 into the rate reset valve assembly and tighten the nut 14 Insert the proportional tubing assembly key 40 into the rate reset valve assembly and tighten the nut 15 Insert the relief tubing assembly key 44 option F only into the rate reset valve assembly and tigh
72. eplace the proportional band indicator cover key 36 and install the two machine screws key 6 If link 1 was disconnected reconnect link 1 to the drive arm using the same hole connections If the controller has the external feedback option disconnect the outside tubing which connects the external feedback connection to the output connection For 4194HB and HC controllers with the anti reset windup option suffix letter F remove the two machine screws key 53 valve cover key 51 and two O rings key 52 installed in step 1 of this procedure Install the differential relief valve key 55 Anti Reset Windup Valve suffix letter F Calibration Calibration for the anti reset windup valve to relieve on rising controller output pressure 1 Plug the controller output connection or connect it to a pressure gauge if desired open loop conditions must exist Setthe reset adjustment to 0 01 minute per repeat wide open and the rate adjustment 4194HC controllers only to the OFF position Foracontroller with manual set point move the set point to 50 percent of the scale range For a controller with remote set point adjust the remote set point pressure until the set point indicator is at 50 percent of the scale range Adjust the proportional band to 100 percent DIRECT or REVERSE depending on the application requirements Referto figure 3 1 or figure 6 1 VIEW E SUFFIX BF for the location of the anti reset windup valve Fo
73. es LEFT HAND EDGE Controller output pressure should to 0 psig Adjust the proportional band to 100 percent reverse action Pressure the differential pressure unit or if disconnected move the process indicator to align with the right hand edge of the set point indicator The controller output should be 0 psig Pressure the differential pressure unit or if disconnected position the process indicator to align with the left hand edge of the set point indicator The controller output should be within 0 14 bar 2 psig of supply pressure Ifthe controller does not perform as indicated in steps 13 through 18 the flapper is not correctly aligned This may occur because the output was not sufficiently stabilized in steps 8 through 12 Repeat steps 7 through 18 Set the proportional band to 400 percent in the desired controller action Replace the proportional band indicator cover key 36 and install the two machine screws key 6 If link 1 was disconnected reconnect link 1 to the drive arm using the same hole connections If the controller has the external feedback option disconnect the outside tubing which connects the external feedback connection to the output connection For 4194HB and HC controllers with the anti reset windup option suffix letter F remove the two machine screws key 53 valve cover key 51 and two O rings key 52 installed in step 1 of this procedure Install the differential relief valve key 55 29
74. es 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 knob to position the nozzle on the flapper quadrant to a point where the direction of the flapper motion versus input motion is reversed see flapper detail in figure 5 11 With the controller in the reverse acting mode an increase in process differential pressure causes a decrease in output pressure Remote Set Point Option suffix letter M The capability to adjust the controller set point from a remote location is available with all 4194H controllers This option is designated by the suffix 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 Option suffix letter E Controllers with the auto manual option designated by the suffix letter E in the type number have piping on the output side of the relay as shown in figure 4 5 Supp
75. escribe changing controller action from direct increasing process differential pressure produces increasing output pressure to reverse increasing process differential pressure produces decreasing output pressure or vice versa 1 Loosen two screws key 6 in the proportional band indicator cover key 36 Do not remove the screws 2 Lift the proportional band indicator cover as shown in figure 5 2 3 Rotate the proportional band knob key 25 to the desired controller action 4 Install the proportional band indicator cover key 36 and tighten the two screws key 6 41 4194 HB Controllers Instruction Manual September 2014 D200156X012 Figure 5 2 Changing Controller Action W3439 Replacing the Differential Pressure Unit WARNING Refer to the Maintenance WARNING at the beginning of this section Before performing any maintenance operations e Shutoffthe supply pressure to the controller e Disconnect any operating lines providing supply air pressure a process input signal or other pressure source to the controller Refer to figures 6 1 and 6 2 for key number locations Use this procedure in reverse to connect a differential pressure unit to a controller 1 Is the process under temporary control If so shut off the process differential pressure to the differential pressure unit Also shut off the supply pressure to the controller Carefully bleed pressure from the controller and differential
76. ey 102 and tighten 9 Connect the guide flexure key 119 to the top of the replacement pivot assembly with the machine screw key 122 washer key 127 and nut key 124 as it was before The guide flexure should be straight and horizontal as shown in figure 3 2 If not loosen the machine screws key 122 and retighten to eliminate bowing Loosen the machine screws key 139 and raise or lower the pedestal assembly key 105 to get the link horizontal Retighten the machine screws key 139 and ensure the capsular element assembly extension key 134 is centered in the upper travel stop key 83 hole 10 Increase the remote set point pressure to 50 percent of input span Note The adjustment arm of the remote set point pivot assembly 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 new 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 down the drive flexure key 79 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 down the drive flexure to hold pivot assembly A in that position Do not bend or twist the flexure when tightening the
77. free and noncorrosive H2S content should not exceed 20 ppm Use a suitable supply pressure regulator to reduce the supply pressure source to 1 4 bar 20 psig for an output signal range of 0 2 to 1 0 bar 3 to 15 psig and to 2 4 bar 35 psig for an output signal range of 0 4 to 2 0 bar 6 to 30 psig Vent Connection WARNING Personal injury or property damage could result from fire or explosion of accumulated gas 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 fitting in the vent connection Excessive torque will damage the threads in the connection If a remote vent is required the vent line must be as short possible with a minimum number of bends and elbows Vent line piping should have a minimum inside diameter of 19 mm 3 4 inches for runs up to 6 1 m 20 feet anda minimum i
78. g 6 6 Relay malfunction 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 Inspect the linkages for misalignment loose screws and damaged links or pivots Using soap solution check for leaks Refer to the differential pressure unit instruction manual 6 5 Using soap solution check for leaks in the nozzle tubing assembly 6 6 Manually push the flapper away from the nozzle The output pressure should be zero Cap the nozzle The output should increase rapidly to within 0 03 bar 0 5 psig of the supply pressure 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 Use a narrower proportional band setting 6 4 Repair as necessary 6 5 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 6 If the output does not change as described remove the relay Replace 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 Differential pressure unit or linkage failure 7 4 Mechanical alignment 7 1 Check with an external pressure gauge 7 2 Vary supp
79. g enough for the high gain to cause instability 33 4194 HB Controllers Instruction Manual September 2014 D200156X012 e Then the low gain provided by the proportional action keeps the system stable Finally reset action slowly increases the gain and returns the process differential pressure toward the set point Figure 4 4 Schematic of Reset Rate Option RELAY OUTPUT PRESSURE RESET RATE VALVE VALVE RESET PROPORTIONAL BELLOWS BELLOWS 19A5000 A A3237 2 Anti Reset Windup Option suffix letter F Anti reset windup is available for all4194HB and HC 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 differential pressure that can result from a large or prolonged deviation from set point such as at process startup Remote Set Point Option suffix letter M The capability to adjust the controller set point from a remote location is available for all 4194H controllers With this option 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 connecting linkage Increasing the control pressure to the capsule increases the set point setting and decreasing the control pressure reduces t
80. he correct range so the gauges are not damaged by overpressure 1 Unscrew the output gauge key 46 or the supply gauge key 47 from the frame key 3 2 Before installing the replacement gauge coat the threads on the gauge with a suitable sealant 3 Screw the replacement gauge into the frame 4 Apply the correct supply pressure and check for leaks with the nozzle capped for full output pressure Replacing the Links This section describes the separate replacement of four links in the controller To clarify the location of each link the links are numbered as follows e Link 1 connects the drive arm and the process indicator e Link 2 connects the process indicator and the input feedback beam assembly key 11 e Link 3 connects the set point adjustment and the set point beam assembly key 23 Link 4 key 65 connects the input feedback beam assembly and the bellows bracket assembly key 31 Figure 5 5 show the location of each link 46 Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 Figure 5 5 Link Locations LINK 4 ADJUSTMENT LINK 4 LINK 2 LINK 3 ADJUSTMENT LINK 2 ADJUSTMENT LINK 3 W3442 1 Link 1 Note Before performing the following link 1 maintenance steps disconnect supply pressure from the controller 1 Note where the link is connected Disconnect the link from the drive arm and from the process indicator assembly Remove the link Then install the replacemen
81. he process indicator zero and span calibration procedure and if necessary the remote set point calibration procedure before the flapper alignment If the controller has the external feedback option connect the external feedback connection to the controller output connection 27 4194 HB Controllers Instruction Manual September 2014 D200156X012 Flapper leveling screw numbers and adjustments are shown in figure 3 1 Provide a regulated process differential pressure to the differential pressure unit Also plug the controller output connection and provide a regulated supply pressure to the controller Do not exceed the normal operating pressure in table 1 4 Note 4194HB and HC controllers with the anti reset windup option suffix letter F are supplied with two O rings key 52 figure 6 1 CONTROLLER COMMON PARTS valve cover key 51 figure 6 1 VIEW E 4194 controllers or VIEW E 4194HC controllers and two machine screws key 53 figure 6 1 VIEW E 4194HB controllers or VIEW E 4194HC controllers Use these parts in the next step 1 For4194HB and HC controllers with the anti reset windup option suffix letter F remove the differential relief valve key 55 figure 6 1 VIEW E 4194HB controllers Option F or VIEW E 4194HC controllers Option F Install the two O rings key 52 and valve cover key 51 provided with the controller Secure the valve cover over the two O rings with the two machine screws key 53 also pro
82. he set point setting This option is designated by the suffix letter M in the type number Auto Manual Station Option suffix letter E A controller with the auto manual option suffix letter E has piping on the output side of the relay as shown in figure 4 5 Supply pressure to the relay is also applied to the manual loader The manual loader functioning as a regulator 34 Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 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 the MANUAL position the output of the manual loader is channeled through the auto manual switch and becomes the output of the controller When the auto manual switch is in the AUTO position the output of the relay is channeled through the switch to become the output of the controller Figure 4 5 Schematic of Auto Manual Option AUTOMATIC POSITION MANUAL LOADER Pa a MANUAL LOADER E KNOB AUTO MANUAL SWITCH OUTPUT PRESSURE TO FINAL CONTROL ELEMENT MANUAL VE POSITION 8 i3 AUTO MANUAL SUPPLY PRESSURE SWITCH ES OUTPUT PRESSURE RELAY OUTPUT PRESSURE ELEMENT SUPPLY PRESSURE MANUAL LOADER OUTPUT PRESSURE 48A5230 A A2999 1 Before the auto manual switch is operated the output of the re
83. hloroprene 18A2898X012 Note 307 plate SST Specify quantity of fittings required 308 Machine screw hd 18 8 SST 2 req d 309 Tubing 55 SST 310 Lithium grease not furnished with controller 311 Anti seize sealant notfurnished with controller Fitti ngs 312 O ring nitrile 3 req d 1P8453X0022 313 Auto Manual Scale polycarbonate For 1 4 NPT tubing Connector brass 314 Machine screw fill hd 18 8 SST Elbow brass 315 Machine screw fill hd 18 8 SST For 3 8 NPT tubing Connector brass 316 Machine screw SST Elbow brass Recommended spare parts 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 services described herein or their use or app
84. ing Itthe controller is not operating properly refer to the troubleshooting chart table 5 1 Then use the appropriate portions of the Maintenance section Replacing Common Controller Parts Procedures describe replacement of controller parts The procedures may be performed separately but must be followed by maintenance calibration procedures Remote Set point Suffix Letter M Procedures describes replacement of parts in the remote set point assembly The procedures may be performed separately but must be followed by maintenance calibration procedures for this section Auto Manual Suffix Letter E Procedures describe disassembly and assembly of the auto manual station Controller Operation Controller Operation Controller Operation 4194HA Proportional Only 4194HB Proportional Plus 4194HC Proportional Plus Controllers Reset Controllers Reset Plus Rate Controllers A description of prestartup startup A description of prestartup startup A description of prestartup startup and calibration procedures to return and calibration procedures to return and calibration procedures to return the controller to service the controller to service the controller to service 38 Instruction Manual D200156X012 4194HA HB HC Controllers September 2014 Table 5 1 Troubleshooting Chart Fault Possible Cause Check Correction 1 Process wanders or
85. irection the valve opens when output pressure rises Turn the adjusting screw counterclockwise to increase differential relief pressure clockwise to decrease it Differential relief pressure is factory set at 0 3 bar 5 psi Maximum differential relief pressure is 0 5 bar 7 psi The minimum is 0 1 bar 2 psi Switching the Auto Manual Station suffix letter E Note Switching the controller between automatic and manual mode without balancing can disturb the process and cause controller cycling Refer to figure 6 5 if the controller has the auto manual station option Two balance methods are used to equalize the manual output pressure with the controller output 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 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 slide the set point indicator to move the ball into the switching zone Turn the switch to AUTO and move the set point indicator 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 adjustment has no effect on the controller output Prestartup Checks for 4194HB and HC Controllers R
86. key 328 and carefully slide the controller off the extension shaft 8 For controller maintenance remove the controller mounting plate key 328 by removing three screws key 335 to gain access to the back of the controller 9 For differential pressure unit maintenance loosen the set screw key 333 and remove the extension shaft 10 Remove four screws key 334 from the mounting plate key 327 to gain access to the differential pressure unit 11 For maintenance of the differential pressure unit refer to the instruction manual for the unit CAUTION When reinstalling the differential pressure unit carefully insert the extension shaft key 321 into the controller to avoid damage to controller parts When reassembling the pivot bracket it must be carefully aligned so that it will not cause binding on the extension shaft key 331 12 Follow this procedure in reverse to rejoin the controller and differential pressure unit Before returning the unit to process control perform maintenance calibration and flapper alignment procedures Refer to the installation procedures when reinstalling the unit Replacing Controller Parts A WARNING Refer to the Maintenance WARNING at the beginning of this section To avoid personal injury or property damage caused by the uncontrolled release of pressure be sure any trapped pressure is properly vented from the differential pressure unit Vent any supply pressure from the controller befo
87. l damage the hinge If the cover needs to be replaced replace the case also Note To remove the controller from the case first perform steps 1 through 7 of the Replacing the Differential Unit procedure Then continue on with step 1 below 1 Perform the procedure required in the Note above to remove the differential pressure unit from the controller 2 Open the controller case and remove the nine screws key 38 from the case and cover assembly key 1 If the controller has remote set point suffix letter M pry the case slightly to remove the frame key 3 Inspect the O rings and replace as necessary Install the controller assembly in the replacement case Slide the controller frame down to assure an O ring seal at the pressure connection Hold the frame in place Install and tighten the nine mounting screws nu Remove the blow out plug key 72 from original case and install it in the replacement case 45 4194 HB Controllers Instruction Manual September 2014 D200156X012 7 Reinstall the differential pressure unit using the proper procedures 8 Mount the controller as described in the Installation section 9 Connect the supply pressure and output piping to the controller Connect the process differential pressure to the differential pressure unit 10 Perform necessary calibration steps Replacing the Gauges CAUTION Before performing this procedure be sure the replacement gauges are t
88. lay must equal the output of the manual loader to avoid bumping the process Adjusting the set point varies the pressure on the left hand side of the plastic tube Adjusting the manual loader knob varies the pressure on the right hand side of the plastic tube When the pressures are equal the metal ball is centered in the tube and itis held in place by a small magnet Pressure imbalance forces the ball to one end of the tube where it forms a seal blocking air flow through the tube External Feedback Option External feedback is available for all 4194HB controllers Controllers with this option have an external connection on the bottom of the controller case figure 2 2 This connection breaks the positive feedback reset loop inside the controller and brings it outside figure 4 6 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 reset pressure tracks the primary controller output pressure minimizing reset windup in the secondary controller 35 4194HA HB Controllers September 2014 Instruction Manual D200156X012 Figure 4 6 Schematic of External Feedback Option TO RESET TO BELLOWS NOZZLE OUTPUT RESET VALVE RELAY TOPROPORTIONAL BM SUPPLY PRESSURE EXTERNAL FEEDBACK TO OUTPUT SUPPLY PRESSURE OFHIGH OR LOW SELECT RELAY 2284 OUTPUT PRESSURE
89. ler output pressure install the valve so the arrow on the valve points up If you must change the direction of the arrow loosen the two mounting screws pull the valve out and reinstall with the arrow direction reversed Tighten the two mounting screws 6 Turn on the supply pressure to the recommended value shown in table 1 4 Note Because of the high controller gain with the reset adjustment at 0 01 minute 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 differential pressure input to the differential pressure unit until the controller output pressure balances at 12 psig fora to 15 psig output range or 24 psig for a 6 to 30 psig output range 8 Turn the reset adjustment to the CLOSED 4194HB controllers or OFF 4194HC controllers position 9 Decrease the controller output pressure in small steps approximately 0 5 psig by changing the input to the differential pressure unit or by changing the controller set point After each change in differential pressure unit input or set point the controller output pressure should quickly change then stabilize at the new value 10 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 downward to 0 psig
90. letter Zero and Span Adjustment Flapper Alignment Principle of Operation for 4194HA Controllers Overall Operation Remote Set Point Option suffix letter Auto Manual Station Option suffix letter E 4 4194HB Proportional Plus Reset Controllers and 4194HC Proportional Plus Reset Plus Rate Controllers Adjustments for 4194HB and HC Controllers 22 Manual Set Point Adjustment 22 Remote Set Point suffix letter M Adjustment 22 Proportional Band Adjustment PB ADJ 22 Changing Controller Action 22 Reset suffix letter B Adjustment 23 Rate suffix letter C Adjustment 23 Anti Reset Windup suffix letter F Adjustment 23 Switching the Auto Manual Station suffix letter E 23 Prestartup Checks for 4194HB and HC Controllers 23 Startup for 4194HB and HC Controllers 24 Calibration for 4194HB and HC Controllers 25 General Calibration Instructions 25 Process Indicator Zero and Span Calibration wea erre Res 26 Remote Set Point suffix letter M Zero and Span Calibration 27 Flapper Alignment 27 Anti Reset Windup Valve suffix letter F Calibration 30 Principle of Operatio
91. licability All sales are governed by our terms and conditions which are available upon request We reserve the right to modify or improve the designs or specifications of such products at any time without notice Emerson Process Management Marshalltown lowa 50158 USA Sorocaba 18087 Brazil Chatham Kent ME4 4QZ UK Dubai United Arab Emirates gt Singapore 128461 Singapore www Fisher com EMERSON Dr gt an Process Management 1985 2014 Fisher Controls International LLC All rights reserved
92. ly pressure to see if output gauge responds 7 3 Vary the process differential pressure and observe the flapper Inspect the linkages for damage Refer to the differential pressure unit instruction manual 7 4 Move the set point and verify that the nozzle is uncapped by the flapper If not inspect linkages for damage 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 Repair or replace parts as necessary 40 Continued Instruction Manual D200156X012 4194HA HB HC Controllers September 2014 Table 5 1 Troubleshooting Chart Continued Fault Possible Cause Check Correction 7 Controller remains at full output continued 7 5 Relay failure or restriction in nozzle passage 7 6 Flapper misaligned 7 5 Manually move flapper 1 6 mm 1 16 inch from the nozzle 7 6 Manually push the flapper away from the nozzle Controller output should go to 0 psig 7 5 If the output pressure remains at the supply pressure remove the controller case and cover assembly and test again with the relay nozzle tubing nut loose If the output is 0 bar 0 psig clean or replace the nozzle assembly If the output remains at supply pressure replace the relay 7 6 Perform the flapper alignment procedure 8 Controller remains at zero output 8 1 Gauge not functioning 8
93. ly 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 output of the manual loader is channeled through the auto manual switch and becomes the output of the controller When the auto manual switch is in the AUTO position the output of the relay is channeled through the switch to become the output of the controller Before the auto manual switch is operated the output of the relay must equal the output of the manual loader to avoid bumping the process Adjusting the set point varies the pressure on the left hand side of the plastic tube Adjusting the manual loader knob varies the pressure on the right hand side When the pressures are equal the metal 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 21 4194 HB Controllers Instruction Manual September 2014 D200156X012 Section 4 4194HB Proportional Plus Reset Controllers And 4194HC Proportional Plus Reset Plus Rate Controllers Adjustments for 4194HB and HC Controllers This section includes descriptions of adjustments and procedures for prestartup and startup Location of
94. machine screws 3 washers 4194HBF and 4194HCF Anti Reset Windup Retrofit Kits Contains keys 44 55 Brass tubing 4194HBF SST tubing 4194HBF Part Number R4190X0AM12 R4190X00S12 R4190X00H12 R4190X00C12 4190 00 12 R4190X00B22 4190 00522 Parts List Abbreviations Used In Parts List adj ass y fdback fill hd ext hd int OD adjustment assembly feedback fillister head as in fillister head cap screw external head as in machine screw head internal outside diameter plated as in plated steel point as in set point quantity stainless steel with without Controller Parts figure 6 1 Key Description Note Part Number Figure 6 1 shows key numbers for the common construction of all controller types Figure 6 1 continues over several pages Be sure to check all pages of figure 6 1 to find the common key numbers 79 4194HA HB HC Controllers Instruction Manual September 2014 D200156X012 Key Description Part Number Key Description Part Number 35 Machine screw hex hd 18 8 SST 2 req d 36 Proportional band indicator cover ABS w polyester label Note 37 Self tapping screw 18 8 SST Part numbers are shown for recommended spares only For part For indicator ass y key 101 4 req d numbers not shown contact your Emerson Process Management sales 38 Self tapping screw 18 8 SST 9 req d office 39 Supply gauge tubing SST 40 Proportional tubing ass y
95. n 3 Zero Stop Adjust the remote set point pressure to 2 1 2 percent of span less than the lower range limit Slide the travel stop nut key 86 along the diaphragm assembly 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 that position Aligning Remote Set Point Linkage 1 Adjust the remote set point pressure to 50 percent of the remote set point range 2 Set the linearity adjustment screw in the center of the slot on the lever arm of pivot assembly B key 115 See figure 3 2 for the location of the linearity adjustment 3 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 perpendicular to them 4 Set the length of link B key 126 so the set point indicator indicates 50 percent of the process scale range 5 Replace the tie bar key 106 by installing the two screws key 103 through the tie bar and into the travel stop and support Remote Set Point Zero and Span Adjustment Note For routine remote set point zero and span adjustment see the appropriate procedure in Section 3 or 4 Use the following maintenance procedures only if difficulty or nonlinearity occurs or if directed by another procedure 73 4194 HB Controllers Instruction Manual September 2014 D200156X012 1 Decrease remote set point pressure to the lower range limit 2 Loosen the adjustmen
96. n for 4194HB and Controllers 31 Overall Operation 31 Anti Reset Windup Option suffix letter F 34 Remote Set Point Option suffix letter M 34 Auto Manual Station Option suffix letter E 34 External Feedback Option 35 5 Maintenance Inspection and Maintenance 37 Troubleshooting 37 Changing Controller Action 41 Replacing the Differential Pressure Unit 42 es EMERSON www Fisher com Dr hananamoant Process Management 4194HA HB Controllers Instruction Manual September 2014 D200156X012 Replacing Controller 43 Remote Set Point Assembly Replacing the Process Differential Replacement 69 Pressure Scale 44 Replacing Remote Set Point Parts 69 Replacing the Relay 44 Pivot Assembly A Key 114 69 Replacing the Case and Cover 45 Pivot Assembly B Key 115 70 Replacing the Gauges 46 Drive Flexure 71 Replacing the Links 46 Remote Set Point Tubing 71 LINK RIRs 47 LINK A cee 71 Lihk2 ead 48 LINK BY 72 od 49
97. n the slot If the misalignment is negative move the linearity screw counterclockwise in the slot 5 If misalignment is greater than 1 percent of the process scale span at the 0 and 100 percent markings with one positive and the other negative perform the remote set point zero and span adjustment procedure to correct a span error 74 Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 6 Repeat steps 1 through 4 until lower middle and upper indications are within 1 percent of the process scale markings Replacing Auto Manual Station suffix letter E Parts Disassembly of the Auto Manual Station Note This procedure also permits replacement of the switch manifold O rings key 312 the auto manual tubing assembly key 138 and the frame gaskets keys 4 and 5 Note Before starting the following procedure remove the controller from the case Perform steps 1 through 7 of the Replacing the Differential Pressure Unit procedure Then perform steps 1 and 2 of the Replacing the Case and Cover procedure Refer to figures 6 5 and 6 4 for key number location 1 Perform the procedures referenced in the note above 2 Loosen the screw key 316 holding the auto manual station key 273 to the controller frame 3 Loosen the two screws keys 314 and 315 holding the auto manual station to the auto manual tubing assembly key 138 4 Remove the auto manual station from the controller frame 5 Remove
98. nded 1 3 Bend pointer to provide clearance 1 4 Replace the differential unit as necessary 1 5 Replace or repair as necessary 1 6 If the output moves fast 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 indicators 2 1 Supply pressure not set correctly 2 2 Flapper not aligned Note Some offset is inherent with proportional only controllers 4194HA controllers The amount of offset is a function of the proportional band setting 2 3 Linkage not aligned correctly 2 4 Leak in differential pressure unit or tubing 2 5 Indicators out of calibration 2 6 Linkage not connected correctly 2 7 Leak in feedback system 2 8 Reset valve leaks 2 9 Leak in remote set point system 2 1 Check with an external source 2 2 Refer to the Flapper alignment procedure 2 3 Refer to the Maintenance Calibration section 2 4 Using soap solution check for leaks Refer to the differential pressure unit instruction manual 2 5 Refer to the process and remote set if applicable zero and span adjustment procedure 2 6 Inspect for loose screws links or pivots 2 7 Open the reset valve to 01 minute repeat Adjust output pressure to 1 4 bar 20 psig Using so
99. nge to the differential pressure input Record the controller output pressure where this ramping action begins because this is the point at which the anti reset windup valve has relieved Toobtain the anti reset windup valve differential setting calculate the difference between the original controller output pressure in step 7 and the controller output pressure recorded in step 10 67 4194 HB Controllers Instruction Manual September 2014 D200156X012 12 13 If the differential pressure calculated in step 11 is incorrect for the application the differential can be adjusted by turning the anti reset windup valve adjustment screw see figure 3 1 Turning the screw clockwise will decrease the differential pressure Turning the screw counterclockwise will increase the differential pressure The anti reset windup valve is set at the Fisher factory at approximately 5 psi differential pressure Repeat steps 7 through 12 until the required differential pressure is obtained Calibration for the anti reset windup valve to relieve on falling controller output pressure 1 Plug the controller output connection or connect it to a pressure gauge if desired open loop conditions must exist Set the reset adjustment to 0 01 minute per repeat wide open and the rate adjustment 4194HC controllers only to the OFF position Fora controller with manual set point move the set point to 50 percent of the scale range For a co
100. nside diameter of 25 mm 1 inch for runs from 6 1 to 30 5 m 20 to 100 feet If a remote vent is not required the vent opening figure 2 2 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 Remote Set Point suffix letter M Connection If the controller has the remote set point option connect the remote set point pressure to the top of the controller case at the location shown in figure 2 2 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 Connections 4194HB 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 figure 2 2 11 4194 HB Controllers Instruction Manual September 2014 D200156X012 Section 3 4194HA Proportional Only Controllers Adjustments for 4194HA Controllers Note Some of the following procedures require adjusting the proportional band knob 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 pr
101. nt beam assembly on frame Install the relay nozzle tubing nut loosely into frame manifold while positioning the nozzle in the center of the flapper as shown in figure 5 11 Secure the set point pivot assembly key 17 to the frame as shown in figure 5 9 Install the screw and washer keys 19 and 20 through the frame key 3 into the set point pivot bracket Do not tighten Secure the relay nozzle tubing assembly key 18 to the frame as shown in figure 5 9 Install the screw and washer keys 19 and 20 through the frame key 3 and into the relay nozzle tubing pivot bracket Tighten both this screw and the screw installed in step 9 Make sure the nozzle remains centered on the flapper with the set point beam assembly resting snugly down on the relay nozzle tubing assembly Tighten the nut on the relay nozzle tubing assembly key 18 and apply full supply pressure to check for leaks with the controller developing full output pressure Turn the proportional band adjustment knob to 5 percent direct action Loosen the locking nut figure 5 9 on the adjustable set point pivot assembly and back the set screw out slightly so the set point beam assembly falls under its own weight when pivoted upward with minimum set point beam sideplay between the pivots Tighten the locking nut Install the set point beam bias spring key 28 into the bore of the frame key 3 and onto the spring seat on the set point beam assembly see figure 5
102. nt to the right to increase the set point and to the left to decrease it 13 4194 HB Controllers Instruction Manual September 2014 D200156X012 Remote Set Point suffix letter M Adjustment CAUTION Do not manually move the set point indicator on controllers with remote set point Moving the set point indicator could damage the controller Ifthe controller is equipped with the remote set point option figure 3 2 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 Figure 3 2 Parts and Adjustments Remote Set Point Option MOUNTING SCREW DRIVE FLEXURE ADJUSTMENT LOWER TRAVEL SCREW ASSEMBLY V LINKB 2 ASSEMBLY B MOUNTING TIEBAR SCREW CAPSULES REMOTE SET POINT ZERO ADJUSTMENT SCREW ZERO ADJUSTMENT LOCKING SCREW FRONT VIEW SIDE VIEW 36A9751 C B1668 4 Proportional Band Adjustment PB ADJ The proportional band adjustment determines the output sensitivity of the controller The proportional band knob is marked in percentages of process differential pressure required to drive the controller from zero output to full output For example a typical 4194H unit offers 0 2 to 1 0 bar 3 to 15 psig output Furthermore this controller comes equipped with a differential pressure unit capable of sensing a process pressure differential ranging from 0
103. ntroller with remote set point adjust the remote set point pressure until the set point indicator is at 50 percent of the scale range Adjust the proportional band to 100 percent DIRECT or REVERSE depending on the application requirements Refer to figure 3 1 for the location of the anti reset windup valve For the anti reset windup valve to relieve on falling controller output pressure install the valve so the arrow on the valve points up If you must change the direction of the arrow loosen the two mounting screws pull the valve out and reinstall with the arrow direction reversed Tighten the two mounting screws Turn on the supply pressure to the recommended value shown in table 1 4 Note Because of the high controller gain with the reset adjustment at 0 01 minute 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 13 Increase the process differential pressure input to the differential pressure unit until the controller output pressure balances at 12 psig for a3 to 15 psig output range or 24 psig for a 6 to 30 psig output range Turn the reset adjustment to the CLOSED 4194HB controllers or OFF 4194HC controllers position Decrease the differential pressure until controller output pressure changes in small steps approximately 0 5 psig After each change in differential pressure input the
104. ocking screw Adjust the process differential pressure to the lower limit of the input span Note the position of the process indicator If necessary adjust the process indicator to the lowest limit of the input scale by loosening the zero adjustment locking screw and turning the zero adjustment screw Adjust the process differential pressure to the upper limit of the input span Note whether the process indication is above or below the upper limit of the process scale Adjust the span screw as follows Clockwise to increase span for a low indication or counterclockwise to decrease span for a high indication Adjust the span screw to correct one half the error Repeat steps 6 through 9 until the error is eliminated Adjust the process differential pressure to 50 percent of the input range The process indicator should point to the mid scale value within 1 percent of the input span If the process indicator does not point to the proper value select the appropriate instructions below e Ifthe process indicator error at mid range is greater than 1 percent but not greater than 2 percent turn the zero adjustment screw to bring the process indicator within 1 percent at mid range Then check the process indicator accuracy at the lower and upper scale limits to verify it is within 1 percent of the input span After adjusting the process indicator to 1 percent at the low mid range and upper scale limits proceed with step 12
105. of the scale range 12 The process indicator should indicate a zero scale reading 1 percent of the scale span 13 Adjust the process differential pressure to 100 percent of the scale range 14 The process indicator should point to the full scale reading 1 percent of the process scale span 26 Instruction Manual 4194HA HB Controllers D200156X012 September 2014 15 If the error is greater than 1 percent repeat steps 3 through 14 16 Perform the flapper alignment procedure Remote Set Point suffix letter M Zero and Span Calibration Refer to figure 3 1 for location of adjustments Refer to figures 6 1 and 6 3 for key number locations Note Any adjustment of the remote set point span adjustment screw will require readjustment of the set point zero adjustment screw See figure 3 1 Provide a regulated process differential pressure to the differential pressure unit Also plug the controller output connection and provide a regulated supply pressure to the controller Do not exceed the normal operating pressure in table 1 4 1 Remove two screws key 6 and lift off the proportional band indicator cover key 36 2 Setthe proportional band adjustment between DIRECT and REVERSE 3 Apply remote set point pressure equal to the low limit of the set point input range Note the position of the set point indicator Loosen the set point zero adjustment locking screw and adjust the zero adjustment screw figure 5 6 until the
106. ontrollers position Adjust the proportional band to 5 percent REVERSE reverse action and move the set point adjustment indicator to 100 percent of the scale range 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 the flapper leveling screw number 1 figure 3 1 until the output is within 0 14 bar 2 psig of supply pressure 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 8 Tighten the two adjusting screws on the link 10 The process indicator should indicate 50 percent of the process scale If not loosen the screws in link 1 and adjust the indicator to 50 percent 3 percent of scale span Tighten the two screws Perform the controller calibration procedure and flapper alignment procedure Replacing the Supply Proportional Reset Reset Valve and Relief Tubing Assemblies Note Before starting the following procedure remove the controller from the case Perform steps 1 through 7 of the Replacing the Differential Pressure Unit procedure Then perform steps 1 and 2 of the Replacing the Case and Cover procedure Refer to figure 6 1 for key number locations 1 Remove the nuts holding the supply gauge tubing assembly key 39 and the proportional tubing assembly key 40 to the frame Remove the tubing
107. oportional band indicator cover This section includes descriptions of adjustments and procedures for prestartup and startup Location of adjustments is shown in figure 3 1 To better understand the adjustments and overall operation of the controller refer to the principle of operation and the schematic diagrams figures 3 3 4 2 and 4 3 Unless otherwise noted refer to figure 6 1 for key number locations Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 Figure 3 1 Location of Controller Parts and Adjustments SET POINT ADJUSTMENT PROCESS DRIVE ARM INDICATOR LOCKING SCREW PROPORTIONAL PIVOT BRACKET BAND INDICATOR COVER DRIVE ARM PROPORTIONAL BAND ADJUSTMENT CONNECTING LINK 1 KNOB ZERO ADJUSTMENT OUTPUT PRESSURE ZERO ADJUSTMENT GAUGE LOCKING SCREW SPAN ADJUSTMENT SUPPLY PRESSURE SEE VIEW A GAUGE FRONT VIEW NOTE 1 gt ON CONTROLLERS EQUIPPED WITH REMOTE SET POINT OPTION THIS IS THE REMOTE SET POINT INDICATOR W3688 1 SCREW 1 SCREW 2 SCREW 3 PROCESS SPAN REMOTE SET POINT ADJUSTMENT SPAN ADJUSTMENT 35A7374 B 56A9752 S SHT 1 SIDE VIEW OF SET POINT PROCESS SIDE VIEW OF CONTROLLER INDICATOR ASSEMBLY SHOWING FLAPPER LEVELING SCREWS Manual Set Point Adjustment To adjust the set point open the controller cover and move the set point indicator until the desired value on the process differential pressure scale is below the line on the set point indicator Move the adjustme
108. orm the appropriate controller calibration procedure in Section 3 or 4 Replacing Remote Set Point Parts Pivot Assembly A Key 114 CAUTION Avoid bending or kinking the drive flexure during this procedure Bending or kinking the drive flexure can result in product damage and impaired performance 1 Decrease the remote set point pressure to 0 psig 2 Remove the two screws key 103 from the tie bar key 106 and remove the tie bar 69 4194 HB Controllers Instruction Manual September 2014 D200156X012 3 Note where link A key 116 15 connected Disconnect the link from the lever arm on the pivot assembly 4 Disconnect the drive flexure key 79 from the adjustment arm of the pivot assembly Be careful not to bend or kink the drive flexure 5 Remove the screw key 122 the washer key 123 and the nut key 124 holding the guide flexure to the top of the pivot assembly 6 Remove the pivot screw key 109 and spring washer key 112 and the mounting screw key 102 attaching the pivot assembly to the mounting plate Lift out the pivot assembly 7 Loosen the screw key 118 on the adjustment arm of the replacement pivot assembly and set the arm to the same length as the arm on the pivot assembly being replaced Tighten the screw 8 To replace the pivot assembly first put the spring washer on the screw Then install the screw through the pivot assembly into the mounting plate Install one of the machine screws k
109. osing plate gasket key 306 9 Pull the clip key 300 from its engagement with the shaft of the lever assembly key 297 10 Pull the 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 the gaskets for damage or wear and replace if necessary Assembly 1 Insert the lever assembly key 297 into the switch body assembly key 291 and hold the rocker key 299 with the flats on the lever assembly shaft 2 Insert the clip key 300 in the groove of the lever assembly shaft to hold the lever assembly key 297 in the switch body assembly key 291 Note Before assembly in step 3 be sure the side of the closing plate marked OUT is visible Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 3 Position the closing plate gasket key 306 and the closing plate key 307 Secure with two screws key 308 4 Place the balls key 296 switch body springs key 295 and O rings keys 292 293 and 294 in the switch body key 291 Note In the following step the ends of the springs must be in the counterbored spring seats before compression 5 Compress the switch body springs with the loader assembly key 282 and bolt the switch key 291 to the loader assembly using the two screws key 290 6 Reconnect the tubing assembly key 309 7 Locate the lever spring key 302 and the spring seat key 301 on the switch leve
110. own in figure 5 3 4 To install the replacement scale bend the lower part of the slot slightly so the scale slides downward over the set point adjustment and under the process indicator 5 Secure the scale with the four self tapping screws key 37 6 If the controller has the remote set point option perform the appropriate remote set point calibration procedure 7 Perform the appropriate process indicator zero and span adjustment and the flapper alignment in the calibration procedures in Section 3 or 4 Replacing the Relay 1 Loosen the two captive screws holding the relay key 50 in place 44 Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 2 Tip the relay slightly toward the side of the case to clear output pressure gauge and lift out the relay 3 Make sure the replacement relay has three O rings as shown in figure 5 4 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 lines up with the tab on the frame figure 5 4 5 Install and tighten the two screws holding the relay in place Figure 5 4 Relay Features CLEAN OUT WIRE EXHAUST PORT NO O RING USED RELAY MOUNTING SCREWS RELAY TAB 5 6 Perform the appropriate flapper alignment procedure in Section 3 or 4 Replacing the Case and Cover CAUTION The case and cover are an integral unit trying to separate them wil
111. pect the entire nozzle assembly key 21 and replace it if necessary Assembly 1 Lubricate key 318 and install the proportional band knob key 25 on the set point beam assembly key 23 2 Install the retaining clip key 26 on the three posts on the proportional band knob 3 Lubricate the nozzle assembly O ring and install the nozzle assembly key 21 through the set point beam assembly key 23 the proportional band knob key 25 and the retaining clip key 26 into the cap aligning the nozzle with the tab on the proportional band knob shown in figure 5 10 4 While holding the nozzle tubing key 21 against the set point beam assembly key 23 depress the retaining clip key 26 and install the E ring key 27 into the E ring groove on the nozzle tubing assembly key 18 Be sure all three corners of the E ring are engaged 52 Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 5 Inspect the O ring on the relay nozzle tubing assembly key 18 and replace it if necessary Apply a suitable lubricant key 318 to the O ring 6 Install the relay nozzle tubing assembly key 18 by pushing it into the bore in the set point beam assembly 7 Adjust the proportional band between DIRECT and REVERSE Do this by aligning the tab on the proportional band 14 15 knob with the hole in the set point beam assembly as shown in figure 5 10 Position the proportional band knob nozzle pivot and the set poi
112. perfectly in the following step If the controller output is stable for approximately 5 seconds it is adequately balanced 7 Increase the process differential pressure to the differential pressure unit until the controller output pressure is balanced at 2 0 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 2 0 to 4 0 bar 6 to 30 psig output range 8 Turn the reset adjustment to the CLOSED 4194HB controllers or OFF 4194HC controllers position 9 Increase the controller output pressure in small steps approximately 0 04 bar 0 5 psig by changing the input to the differential pressure unit or by changing the controller set point After each change in differential pressure or set point the controller output pressure should quickly change and then stabilize at the new value 10 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 anti reset windup valve has relieved 11 To obtain the anti reset windup valve differential setting calculate the difference between the original controller output pressure in step 7 and the controller output pressure recorded in
113. placement Use the following procedures to replace the remote set point assembly Refer to figure 6 3 for key number locations Note Remove the supply pressure gauge before attempting to remove the remote set point capsular element assembly Decrease the remote set point pressure to 0 psig Remove the supply pressure 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 adjustment assembly Remove the three mounting screws keys 120 and 140 holding the remote set point assembly to the process set point indicator assembly See figure 3 2 for the location of the screws CAUTION In the following step do not lift out the remote set point capsular element assembly by holding the capsule or linkages These parts may be damaged Ul WN 6 Lift out the capsular element assembly by holding the plate key 111 travel stop key 83 or pedestal assembly key 105 7 Align the replacement assembly with the mounting screw holes Replace the mounting screws 8 Reconnect the remote set point pressure connection union key 93 Apply full remote set point pressure and check for leaks 9 Connect link B key 126 to the connecting hole on the set point indicator assembly 10 Replace the supply pressure gauge 11 Perform the remote set point maintenance calibration procedure in this section Also perf
114. pressure unit 2 Disconnect all tubing Refer to the installation procedures for process and supply tubing connections to disconnect when the differential pressure unit is removed from the pipestand A WARNING The combined weight of the controller and differential pressure unit is approximately 26 kilograms 57 pounds Provide adequate support for the unit during removal procedures to prevent personal injury or property damage 3 Remove the controller and differential pressure unit from the mounting position Figure 2 1 shows the location of the set screws connecting the differential pressure unit mounting bracket to the pipestand Move the controller and differential pressure unit to a maintenance area 42 Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 Properly support the unit before trying to separate the controller and differential pressure unit 4 To separate the controller and differential pressure unit open the cover locate link 1 key 323 figure 6 2 and disconnect it from the drive arm key 322 5 Remove the pivot bracket key 320 by removing the screws and washers keys 329 and 332 6 Loosen the locking screw key 331 and slide the drive arm key 322 off the extension shaft CAUTION When removing the controller from the controller mounting plate key 327 be careful not to bend the extension shaft key 321 N Remove four screws key 336 from the controller mounting plate
115. r key 304 and position these parts in the opening of the loader assembly key 282 8 Push the switch lever down using the lever spring seat key 301 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 Auto Manual Station Switch Range Spring Diaphragm Assembly Ball Seat Tubing and Ball Refer to figure 6 5 for key number location Disassembly 1 Remove the auto manual station from the controller frame as described in steps 1 through 4 of the procedure for replacing the auto manual station 2 Remove tubing assembly key 309 A WARNING To avoid personal injury caused by preload from the range spring key 282 turn the loader knob key 287 counterclockwise opposite to the arrow to relieve pressure on the spring 3 Loosen the four screws key 289 and separate the loader assembly key 282 and the lower loader assembly key 274 4 Remove the loader range spring key 283 range spring cup key 284 and diaphragm assembly key 281 5 Remove the tube key 278 ball seats key 280 and ball key 279 Assembly 1 Turn the loader knob key 287 counterclockwise to back the spring adjusting screw
116. r the anti reset windup valve to relieve on rising controller output pressure install the valve so the arrow on the valve points down If you must change the direction of the arrow loosen the two mounting screws pull the valve out and reinstall with the arrow direction reversed Tighten the two mounting screws Turn on the supply pressure to the recommended value shown in table 1 4 Note Because of the high controller gain with the reset adjustment at 0 01 minute 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 differential pressure to the differential pressure unit until the controller output pressure is balanced at 6 psig for a3 to 15 psig output range or 12 psig for a 6 to 30 psig output range Turn the reset adjustment to the CLOSED 4194HB controllers or OFF 4194HC controllers position Increase the process differential pressure until controller output pressure changes in small steps approximately 0 5 psig After each change in input the controller output pressure should quickly change and then stabilize at the new value Continue to affect the controller output pressure in 0 5 psi steps and check the output pressure after each step to make sure that it stabilizes At some point the controller output will start to ramp upward to supply pressure with no further cha
117. rame down to assure an O ring seal at the pressure connections Hold the frame in place Install and tighten the nine screws holding the controller assembly in the case Refer to the flapper alignment procedure Replacing the Auto Manual Station Switch Body Assembly Lever O Ring Switch Body O Ring and the Tubing Assembly Refer to figure 6 5 for key number location Disassembly 1 Remove the auto manual station from the controller frame as described in steps 1 through 4 of the procedure for replacing the auto manual station 2 Loosen the two screws key 288 and remove the lever cover plate key 305 CAUTION The lever spring key 302 is under preload Take care not to lose any parts during disassembly 3 Using a 1 5 mm 1 16 inch 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 CAUTION The switch body springs key 295 are under preload Take care not to lose any parts when separating the switch body assembly from the loader assembly Loosen the two screws key 290 and separate the switch body assembly key 291 from the loader assembly key 282 7 Remove the O rings keys 292 293 and 294 switch body springs key 295 and balls key 296 8 Loosen two screws key 308 Remove the closing plate key 307 and the cl
118. rcent of the 0 and 100 percent scale marks 20 Perform the flapper alignment procedure and if necessary the appropriate remote set point calibration procedure in Section 3 or 4 Flapper Alignment Note Perform the process indicator zero and span calibration procedure and if necessary the remote set point calibration procedure before the flapper alignment 64 Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 Flapper leveling screw numbers and adjustments are shown in figure 3 1 Provide a means of applying supply pressure to the controller and plug the output connection After performing the flapper alignment procedure to the appropriate startup procedure 4194HA Proportional Only Controllers 1 For controllers with manual set point move the set point adjustment to 50 percent of the process scale range For controllers with remote set point suffix letter M adjust the remote set point pressure until the set point indicator is at 50 percent of the process scale range 2 Apply differential pressure equal to 50 percent of the process scale range An alternate method is to disconnect link 1 from the drive arm then manually position the process indicator at 50 percent of the process scale range Tape the process indicator in place 3 Remove the screws key 6 and lift off the proportional band indicator cover key 36 4 Adjustthe proportional band indicator to between DIRECT and REVERSE 5 The o
119. re 5 15 Adjust the gain screw key 34 one half turn in if the reading recorded in step 22 is greater than in step 21 Adjust the gain screw key 34 one half turn out if the reading in step 22 is less than in step 21 Tighten the proportional bellows screw key 35 Repeat steps 21 through 26 until the difference is less than 1 percent of the process differential pressure span If 1 percent of process scale span cannot be achieved adjusting the gain screw key 34 loosen the screw key 35 attaching the reset bellows and slide it to the left if the reading in step 22 is greater than in step 21 or to the right if the reading in step 22 is less than in step 21 Repeat steps 22 through 27 Reconnect link 1 and install the controller assembly in the case and cover Refer to the process pointer zero and span adjustment and flapper alignment procedure in the Maintenance section Replacing the Reset Restriction Valve 4194HB Controllers Note Before starting the following procedure remove the controller from the case Perform steps 1 through 7 of the Replacing the Differential Pressure Unit procedure Then perform steps 1 and 2 of the Replacing the Case and Cover procedure Refer to the 4194HB controller portion of figure 6 1 for key number locations 1 2 10 Perform the procedures required in the Note above After removing the controller from the case and cover remove the reset valve tubing a
120. re 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 indication is low at 100 percent of input range disconnect link 1 from the process indicator subassembly move the link to the lowest hole and return to step 9 b If the span is long process indication is high at 100 percent of the input range disconnect link 1 from the process indicator subassembly move the link to the highest hole and return to step 9 16 Adjust the process differential pressure to 50 percent of the process scale range The process indicator should point out 50 2 percent on the process scale range If the process indicator error is 2 percent or less proceed to step 19 17 If the process indicator error is greater than 2 percent loosen the two screws in the drive arm key 322 figure 6 2 Then lengthen or shorten the drive arm 6 3 mm 1 4 inch and repeat steps 9 through 16 18 Adjust the process indicator to within 1 percent of the 50 percent scale mark by loosening the zero adjustment locking screw and turning the zero adjustment screw Tighten the zero adjustment locking screw This will distribute the error over the entire process scale and keep all points within 1 percent of the process scale span 19 Adjust the process differential pressure to 0 and 100 percent of the process scale range to make sure the process indicator is still within 1 pe
121. re disassembly Note Remove the controller and differential pressure unit to a maintenance area to perform the following procedures Refer to the installation procedures for process and supply tubing connections to disconnect when the differential pressure unit is removed from the pipestand Figure 2 1 shows the location of the set screws connecting the differential pressure unit mounting bracket to the pipestand 43 4194 HB Controllers Instruction Manual September 2014 D200156X012 Refer to the installation procedures when reinstalling the unit Note In the following procedures adjust the proportional band knob between DIRECT and REVERSE If this is done it will be necessary to set the proportional band knob to 400 DIRECT or REVERSE direct or reverse action before replacing the proportional band indicator cover Replacing the Process Differential Pressure Scale CAUTION Take care not to bend the process indicator or the set point adjustment while performing the following procedure Refer to figure 5 3 Figure 5 3 Changing the Scale 1 Adjust the set point adjustment manually or with the remote set point pressure to 50 percent of scale range 2 Remove the four self tapping screws key 37 3 Slide the process scale key 61 so the top of the slot touches the set point adjustment Deflect the lower portion of the slot and carefully slide the scale upward and off clearing the set point adjustment as sh
122. remove both bellows if only one requires replacement 8 Unscrew the bellows key 48 If the bellows assembly cannot be removed by hand thread a machine screw key 35 into the bellows until tight loosen the bellows assembly by applying clockwise torque to the machine screw 9 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 Compress the bellows and install the two screws key 35 and washer key 362 through the bellows bracket key 31 into the bellows Do not tighten The washer must be under the screw threaded into the reset bellows see figure 5 15 for the location of the reset bellows 12 Install the four machine screws key 6 through the bellows bracket key 31 into the bellows beam key 49 but do not tighten Be sure the bellows bracket is aligned so it does not rub on the frame key 3 at any point Tighten the screws keys 6 and 35 figure 5 15 13 Install the proportional and or reset tubing assembly on the bellows key 48 base 14 Adjust the reset valve to 0 01 minute per repeat 4194HB or 4194HC Adjust the rate valve to OFF 4194HC Apply the correct supply pressure with the nozzle capped and check for leaks Remove the supply pressure 15 Replace link 4 key 65 on the bellows bracket Be sure
123. ressure unit 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 figures 2 1 2 2 and 2 3 for the location of all input and output connections for the controller and differential pressure unit Also refer to the differential pressure unit instruction manual for specific information about connections and piping Supply output vent and remote set point connections are 1 4 NPT Use 1 4 or 3 8 inch pipe or tubing for supply output vent and remote set point piping Process pressure connections are 1 4 or 1 2 NPT optional When installing process piping to the differential pressure unit attached to the controller follow accepted engineering installation and safety practices to insure the safe and accurate transmission of the process differential pressure to the differential pressure unit Install shutoff valves vents drains or seal systems as required by accepted practices Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 Figure 2 1 Right Side View of Controller BARTON 199 DIFFERENTIAL PRESSURE UNIT 1 2 NPT PRESSURE CONNECTION Ci 1 4 PRESSURE lt i CONNECTION PIPESTAND MOUNTING BRACKET PIPESTAND SET SCREW 3 REQD NOTE 15 LOW PRESSURE CONNECTION ON A BARTON 199 DIFFERENTIAL PRESSURE UNIT
124. set point beam assembly key 23 3 Adjust the replacement link to the same length as the current link 4 Install the replacement link with the screw head toward the set point beam assembly as shown in figure 5 8 and in the position as noted in step 2 49 4194 HB Controllers Instruction Manual September 2014 D200156X012 Figure 5 8 Link Number 3 Adjustment LINK 3 ADJUSTMENT LINK 2 DISCONNECT W4192 1 5 Checkthe set point beam bias spring key 28 Is it correctly located in the frame bore and spring seat on the set point beam assembly as shown in figure 5 9 6 Move the set point adjustment indicator to 50 percent of scale range 7 Adjustthe process differential pressure until the process indicator is at 50 percent of the scale range 8 Adjustthe proportional band to 5 percent direct action Turn the flapper leveling screw number 3 until the nozzle just touches the flapper Note Flapper leveling screws 1 and 3 should protrude the same distance from the clinch nuts See figure 5 7 9 Adjust the proportional band to 5 percent REVERSE reverse action Turn flapper leveling screw number 1 until the nozzle just touches the flapper If flapper leveling screw 1 protrudes farther than flapper leveling screw 3 turn the adjusting screw in link 3 counterclockwise If flapper leveling screw 3 protrudes farther than flapper leveling screw 1 turn the adjusting screw in link 3 clockwise 10 Repeat steps 8
125. ss otherwise noted key numbers are found in figure 6 1 Process Indicator Zero and Span Calibration Before starting this procedure e Provide a regulated process differential pressure to the differential pressure unit e Provide a requlated supply pressure to the controller Do not exceed the normal operating pressure in table 1 4 Note Any change in process indicator span will require readjustment of the process indicator zero adjustment screw 4194 HB Controllers Instruction Manual September 2014 D200156X012 Refer to figure 3 1 for location of adjustments 1 Remove two screws key 6 and lift off the proportional band indicator cover key 36 2 Setthe proportional band between DIRECT and REVERSE 3 The process indicator should be aligned with the indicator subassembly as shown in figure 5 6 If not loosen the zero adjustment locking screw and adjust the fine zero adjustment to align the process indicator and indicator subassembly See figure 6 4 4 Adjust the process differential pressure until the controller indicates 50 percent of the input range 10 11 The process indicator should point to 50 percent of the process scale range If not loosen the drive arm locking screw key 331 figure 6 2 that holds the drive arm key 322 to the shaft extension key 321 and readjust the drive arm on the shaft until the process indicator points to 50 percent of the process scale range Tighten the drive arm l
126. ssembly key 42 from the reset restriction valve key 54 Remove the reset tubing assembly key 43 from the reset restriction valve Remove the relief tubing assembly key 44 from the reset restriction valve option F only Remove the screw key 162 holding the reset restriction valve to the frame key 3 Install the replacement reset restriction valve and secure it with the screw removed in step 5 Install the reset valve tubing assembly key 42 the reset tubing assembly key 43 the relief tubing assembly key 44 option F only and tighten Setthe reset restriction valve to 0 01 minute per repeat Applythe proper supply pressure to the controller drive the controller output to within 0 14 bar 2 psig of the supply pressure by capping the nozzle and check the tubing connections for leaks Installthe controller assembly in the case and cover Replacing the Rate Reset Valve Assembly 4194HC Controllers Note Read this entire procedure before removing any parts Refer to the 4194HC portion of figure 6 1 for key number locations 61 4194 HB Controllers Instruction Manual September 2014 D200156X012 Note Before starting the following procedure remove the controller from the case Perform steps 1 through 7 of the Replacing the Differential Pressure Unit procedure Then perform steps 1 and 2 of the Replacing the Case and Cover procedure 1 Perform the procedures required in the Note above 2 R
127. sses Set it to 0 5 minutes per repeat for slow processes For controllers with rate set the rate adjustment to OFF 4 Set the proportional band adjustment to 100 percent for fast processes For slow processes calculate the 24 Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 proportional band percentage from the equation below Proportional Band 200 x Allowable Overshoot Adjustment Pressure Span For example 200 x 2 _ 3OPsg 5 6 If the controller is used with a 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 Tune the various controller actions e 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 X 2 e Tuning reset action Disturb the system If the system does not cycle then speed up the reset by changing the setting to a lower value faster reset and 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 time
128. step 10 12 If the differential pressure calculated in step 11 is incorrect for the application adjust the differential by turning the anti reset windup valve adjustment screw figure 3 1 Decrease the differential pressure by turning the screw clockwise Increase the differential pressure by turning the screw counterclockwise The anti reset windup valve is set at the factory at approximately 0 4 bar 5 psi differential pressure 13 Repeat steps 7 through 12 until the required differential pressure is obtained Calibration for the anti reset windup valve to relieve on falling controller output pressure 1 Plug the controller output connection or connect it to a pressure gauge if desired open loop conditions must exist 2 Setthe reset adjustment to 0 01 minute per repeat wide open and the rate adjustment 4194HC controllers only to the OFF position 30 Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 3 Fora controller with manual set point move the set point indicator to 50 percent of the scale range For a controller with remote set point adjust the remote set point pressure until the set point indicator is at 50 percent of the scale range 4 Adjustthe proportional band to 100 percent in either the DIRECT or REVERSE action depending on the application requirements 5 Referto figure 3 1 for the location of the anti reset windup valve For the anti reset windup valve to relieve on falling control
129. sure unit Provide a regulated supply pressure to the controller Do not exceed normal operating pressure table 1 4 For 4194HA controller connect the controller output to an accurate gauge For 4194HB and HC controllers a gauge is not necessary and the controller output connection may be plugged Note Any adjustment of the process indicator span adjustment screw requires readjustment of the process indicator zero adjustment screw Remove the two machine screws key 6 and lift off the proportional band indicator cover key 36 Set the proportional band adjustment between DIRECT and REVERSE Adjust the reset valve 4194HB and HC controllers only to 0 01 minutes per repeat Adjust the rate valve 4194HC controllers only to OFF Adjust the process differential pressure to 50 percent of the process scale range The process indicator should be aligned with the indicator subassembly as shown in figure 5 6 If not loosen the zero adjustment locking screw and adjust the zero adjustment screw to align the process indicator with the indicator subassembly Tighten the zero adjustment locking screw gu WU N 63 4194 HB Controllers Instruction Manual September 2014 D200156X012 7 The process indicator should point out 50 3 percent of the input scale range If not loosen the screws in link 1 and move the process indicator to 50 3 percent Tighten the screws 8 The controller output pressure should be
130. t link 2 Attach the replacement link to the process indicator assembly and drive arm in the position noted in step 1 If during the process indicator zero and span adjustment the indicator will not travel full scale even after full span adjustment move the link to the bottom hole If the indicator has too much travel move the link to the top hole 3 Remove the two screws key 6 and lift off the proportional band indicator cover key 36 4 Move the set point adjustment manually or with remote set point pressure to 50 percent of the scale range Set the proportional band between DIRECT and REVERSE 5 The process indicator should be lined up with the subassembly as shown in figure 5 6 If not loosen the zero adjustment locking screw Then adjust the fine zero adjustment to align the indicator and subassembly 6 With a regulated air supply adjust process differential pressure to 50 percent of process scale range The process indicator should be within 3 percent of mid range on the scale If not loosen the two screws in link 1 and move the process indicator to within 3 percent of mid range on the scale Then tighten the screws 7 Perform the controller calibration procedure and if necessary the appropriate remote set point calibration procedure in Section 3 or 4 47 4194HA HB Controllers Instruction Manual September 2014 D200156X012 Figure 5 6 Process Indicator Alignment ZERO ADJUSTMENT FINE ZERO LOCKIN
131. t 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 3 Make fine zero adjustments by loosening the zero adjustment locking screw key 102 and turning the zero adjustment screw key 108 Tighten the locking screw key 102 Refer to figure 3 2 for location of the screws 4 Increase the remote set point pressure to the upper range limit 5 To increase the span proceed as follows a Turn the span adjustment screw clockwise b To increase the span further than the adjustment allows move both ends of link A key 116 to the right c Make fine adjustments with the span adjustment screw 6 To decrease the span proceed as follows a Turn the span adjustment screw counterclockwise b To decrease the span further than the adjustment allows move both ends of link A key 116 to the left c Make fine adjustments with the span adjustment screw 7 Repeat the adjustments until the upper and lower indications are aligned with the 0 and 100 percent markings on the process scale 8 Adjust the remote set point pressure to 50 percent of the remote set point range 9 The remote set point indicator should be accurate to within 2 percent of the process scale span If the accuracy is outside 2 percent of the process scale span proceed to the following linearity adjustment procedure 10 Adjust the set point indicator to 50 1 percent of the process scal
132. t valve 4194HB and HC controllers to 0 01 minute per repeat Adjust the rate valve 4194HC controllers to OFF Increase the process differential pressure to the differential pressure unit until the output pressure stabilizes at 0 2 bar 3 psig for a 0 2 to 1 0 3 to 15 psig output signal range or 0 4 bar 6 psig for a 0 4 to 2 0 bar 6 to 30 psig output signal range Record the process differential pressure reading Note When the reset valve is at 0 01 the controller is very sensitive to any process differential pressure change Only small changes to the process indicator may be necessary 60 Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 22 23 24 25 26 27 28 29 30 Increase the process differential pressure very slowly until the output pressure stabilizes at 1 0 bar 15 psig for a 0 2 to 1 0 bar 3 to 15 psig output signal range or 2 0 bar 30 psig for 0 4 to 2 0 bar 6 to 30 psig output signal range Record the process differential pressure reading If the difference between the recorded process differential pressure in step 21 and the process differential pressure in step 22 is larger than 1 percent of the process differential pressure span proceed with step 24 If the difference is less than 1 percent remove process differential pressure from the differential pressure unit controller and go to step 28 Loosen the proportional bellows screw key 35 figu
133. ten the nut 16 Turn the reset to 0 01 and the rate valve to OFF 17 Apply the proper supply pressure to the controller drive the controller output to within 0 14 bar 2 psig of the supply pressure by capping the nozzle and check the tubing connections for leaks 18 Install the controller assembly in the case and cover Replacing the Differential Relief Valve Assembly suffix letter F Refer to the 4194HB or 4194HC option F portion of figure 6 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 When the arrow points down the valve relieves with increasing output pressure 4 Tighten the two screws holding the relief valve to the frame 5 The relief valve differential pressure is factory set at 0 3 bar 5 psig Maximum pressure differential is 0 5 bar 7 psig minimum pressure differential is 0 14 bar 2 psig If a different differential pressure setting is desired refer to the anti reset windup valve calibration procedure in this manual Replacing the Relief Valve Tubing Assembly suffix letter F Note Before starting the following procedure remove the controller from the case
134. ternal stainless steel Supply And Output Connections 1 4 NPT internal Supply Pressure Requirements See table 1 4 Supply Pressure Medium Air or natural gas Air Supply pressure must be clean dry air that meets the requirements of ISA Standard 7 0 01 Natural Gas Natural gas must be clean dry oil free and noncorrosive H2S content should not exceed 20 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 volume basis Condensation in the air supply should be minimized Remote Set Point Pressure Ranges 0 2 to 1 0 bar 3 to 15 psig or 0 4 to 2 0 bar 6 to 30 psig Controller Adjustments Proportional Band 5 to 500 of process scale range 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 Set Point Continuously adjustable from 0 to 100 of the scale range Controller Performance Repeatability 0 4 of output span Dead Band Less than 0 2 of process scale range Steady State Air Consumption Without Auto Manual Station 0 2 to 1 0 Bar 3 to 15 Psig Output 0 09 m3 hr 3 5 scfh 0 4 to 2 0 Bar 6 to 30 Psig Output 0 13 m3 hr 5 0 scfh With Auto Manual Station suffix letter E 0 2 to 1 0 Bar 3 to 15 Psig Output 0 28 m3 hr 10 0 scfh 2 0 to
135. the case Slide the controller frame down to assure an O ring seal at the pressure connections Hold the frame in place 8 Install and tighten the nine screws holding the controller assembly in the case 78 Instruction Manual D200156X012 4194HA HB HC Controllers September 2014 Section 6 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 number as found in the following part list WARNING Use only genuine Fisher replacement parts Components that not supplied by Emerson Process Management should not under any circumstances be use in any Fisher instrument Use of components not supplied by Emerson Process Management may void your warranty might adversely affect the performance of the instrument and could result in personalinjury and property damage Parts Kits Key Description 4190 Controller Auto Manual Repair Kit Contains keys 277 278 279 281 292 293 294 298 306 312 4190 Controller Auto Manual Retrofit Kit Contains keys 138 273 312 313 314 315 316 SST tubing 4190 Controller Case Handle Contains lever and mounting hardware 4190 Controller Repair Kit Contains keys 4 5 7 8 24 52 4190 Controller Pointer and Bracket Repair Kit Contains pointer and bracket ass y 3
136. the link does not contact the frame key 3 If it does loosen the four screws key 6 which attach the bellows bracket key 31 and reposition the bracket to provide clearance Be sure the bellows bracket does not rub on the frame 59 4194HA HB Controllers Instruction Manual 5 eptember 2014 D200156X012 16 17 Referto steps 4 through 10 in the procedure for replacing link 4 If the controller is a proportional only 4194HA controller go to step 28 If the controller has reset 4194HB or rate reset 4194HC continue with step 17 and the following note Disconnect link 1 from the drive arm Figure 5 15 Bellows Assembly and Proportional Band Adjustment Process Scale and Proportional Band Adjustment Cover Removed 1 1 2 21 FOUR SCREWS RESET BELLOWS f 7 E gt f PROPORTIONAL WASHER Y E BELLOWS KEY 362 gt 4 9 is EUN A A TWO SCREWS 35 2 BELLOWS y re x lt BRACKET Z SO KEY31 f F gt 2 ah i 22 LOCKING NUT ADJUSTABLE SET POINT PIVOT ASSEMBLY KEY 17 Drg 2 WASHER KEYS 19 AND 20 W4199 Note The following procedure steps 18 through 28 adjusts the reset gain of the controller to minimize steady state offset 8 Adjust the proportional band to 100 percent in direct action 9 Adjust the set point to 50 percent of the process scale range 0 Adjust the rese
137. the switch manifold O rings key 312 6 Carefully loosen the nut on the relay nozzle tubing assembly key 18 figure 6 1 where it connects to the auto manual tubing assembly key 138 Loosen three screws keys 34 and 131 and remove the tubing assembly and body gaskets keys 4 and 5 7 Inspect the gaskets keys 4 and 5 and O rings key 312 for wear Replace if necessary Assembly of the Auto Manual Station 1 Install the gaskets and the tubing assembly to the frame Start but do not tighten the three screws keys 34 and 131 and the nut on the nozzle tubing assembly key 18 2 Install the three O rings key 312 and secure the auto manual station to the controller frame with the screw key 316 and to the tubing assembly key 138 with two screws keys 314 and 315 Do not tighten any screws CAUTION In the next step take care to tighten the two screws keys 314 and 315 evenly Uneven tightening could damage the tubing assembly 3 Position the auto manual station as far down on the frame and toward the scale as possible Carefully tighten the two screws keys 314 and 315 so the auto manual station contacts the three pads on the tubing assembly 4 Carefully tighten the remaining screws and nuts 75 4194 HB Controllers Instruction Manual September 2014 D200156X012 Apply air pressure to the controller and check for leaks Install the controller assembly in the case Slide the controller f
138. to 1 0 bar Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 0 to 15 psig Then at a proportional band setting of 100 percent DIRECT the controller output goes from 3 to 15 psig as the process pressure differential goes from 0 to 15 psig If the proportional band setting is subsequently changed to 50 percent DIRECT the controller output would change from 3 to 15 psig as the process pressure differential changed from 0 to 7 5 psig Adjusting the proportional band has minimal effect on the set point Changing Controller Action Controller action is switchable from direct to reverse or vice versa by simply loosening the screws on the proportional band indicator cover and moving the cover out so the proportional band knob can be rotated to the desired action The white portion of the adjustment enables direct controller action The black portion enables reverse controller action Switching The Auto Manual Station suffix letter E Note Switching the controller between automatic and manual mode without balancing can disturb the process and cause controller cycling Refer to figure 6 5 if the controller has the auto manual option To switch from automatic to manual mode you must balance the manual output with the controller output Two balance methods are available to equalize the manual output with the controller output To switch from automatic to manual mode carefully adjust the loader knob until the metal b
139. trile 357 Spring washer S17700 17 7 SST For 4194HB controllers 2 req d For 4194HB controllers only For 4194HC controllers 4 req d 1H292606992 358 Retainer 18 8 SST 251 Resetbody 233520 zinc die casting For 4194HB controllers only For 4194HB controllers only 359 Machine Screw hd 18 8 55 For 4194HB controllers only 3 req d 252 Valve plate 360 Shoulder Screw slotted 18 8 SST For 4194HB controllers 1 req d For 4194HB controllers only For 4194HC controllers 2 req d 253 Scratch Valve 530300 303 SST 361 Lubricant 20W 50 Motor For 4194HB controllers For 4194HB controllers only 253 ResetScratch Valve 530300 303 SST 362 Springretaining washer SST For 4194HC controllers 364 Shim plastic 258 Plain washer plastic For 4194HB controllers only For 4194HB controllers 1 req d For 4194HC controllers 4 req d 365 Washer 18 8 SST 82 Recommended spare parts Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 Figure 6 1 Controller Assembly Drawings DOO ZZ ZV Z a 8 9 6 66 64 62 518 CONTROLLER COMMON PARTS 2357 e pus J EET Mim ma 11 s D b UE D a SECTION D D O 21 2351 4194HA
140. troller output is relatively stable at any value within the output range 10 Adjust the proportional band to 20 percent direct acting Adjust flapper leveling screw number 3 until the controller output is relatively stable at any value within the output range 11 Adjust the proportional band to 20 percent reverse acting Adjust flapper leveling screw number 1 until the controller output is relatively stable at any value within the output range 12 Repeat steps 8 through 11 until the controller output remains relatively stable with no adjustments of the flapper leveling screws Note Steps 13 through 19 check the flapper alignment 28 Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 13 14 15 Adjust the proportional band to 100 percent direct action Apply differential pressure to the differential pressure unit or if link 1 was disconnected remove the tape from the process indicator and move the indicator until it aligns with the right hand edge of the set point indicator as shown in figure 4 1 Controller output should be within 0 14 bar 2 psig of the supply pressure Apply differential pressure to the differential pressure unit or if disconnected move the process indicator to the left hand edge of the set point indicator as shown in figure 4 1 Figure 4 1 Alignment of the Process Pointer with the Set Point Adjustment 16 17 20 21 22 RIGHT HAND EDGE w
141. ut pressure Also provide a means of applying process differential pressure to the differential pressure unit For a controller with remote set point suffix letter M connect regulated pressure of 0 2 to 1 0 3 to 15 psig or 0 4 to 2 0 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 Set the proportional band between DIRECT and REVERSE 5 Adjust the process differential pressure until the controller indicates 50 percent of the input range The process 11 12 indicator should point out the process differential pressure within 1 percent of the input span If the process indicator is out of calibration refer to the process indicator zero and span adjustment procedures in the Calibration section Also check the accuracy of the process indicator at other points on the scale For controllers with manual set point move the set point indicator to 50 percent of the scale range For controllers with remote set point suffix letter M adjust the remote set point pressure until the set point moves to 50 percent of the scale range The output of the controller should be e 0 62 0 007 bar 9 0 1 psig for a 0 2 to 1 0 3 to 15 psig output e 1 2 0 01 bar 18 0 2 psig for a 0 4 to 2 0 bar 6 to 30 psig output Adjust the proportional band to 20 percent DIRECT The o
142. utput of the controller should be e 0 62 0 007 bar 9 0 1 psig fora 0 2 to 1 0 3 to 15 psig output e 1 2 0 01 bar 18 0 2 psig for a 0 4 to 2 0 bar 6 to 30 psig output To adjust controller output adjust flapper leveling screw 2 figure 3 1 6 Adjust the proportional band to 20 percent DIRECT The output of the controller should remain essentially the same e 0 62 0 017 bar 9 0 25 psig for a 0 2 to 1 0 bar 3 to 15 psig output e 1 2 0 03 bar 18 0 5 psig for a 0 4 to 2 0 bar 6 to 30 psig output 7 Adjust the proportional band to 20 percent REVERSE The output of the controller should remain essentially the same e 0 62 0 017 bar 9 0 25 psig for a 0 2 to 1 0 bar 3 to 15 psig output e 1 2 0 03 bar 18 0 5 psig for a 0 4 to 2 0 bar 6 to 30 psig output 8 Repeat steps 4 through 7 until the output of the controller remains in tolerance with no adjustment of the flapper leveling screws 9 Release the process indicator and connect link 1 to the drive arm 10 Set the proportional band adjustment to 400 percent in the desired controller action DIRECT or REVERSE Replace the proportional band cover 4194HB Proportional Plus Reset and 4194HC Proportional Plus Reset Plus Rate Controllers Note 4194HB and HC controllers with the anti reset windup option suffix letter F are supplied with two O rings key 52 figure 6 1 CONTROLLER COMMON PARTS valve cover key 51 figure 6 1 VIEW E 4194HB CONTROLLERS or V
143. utput of the controller should remain essentially the same e 0 62 0 017 bar 9 0 25 psig for a 0 2 to 1 0 3 to 15 psig output e 1 2 0 03 bar 18 0 5 psig for a 0 4 to 2 0 bar 6 to 30 psig output Adjust the proportional band to 20 percent REVERSE The output of the controller should remain essentially the same e 0 62 0 017 bar 9 0 25 psig for a 0 2 to 1 0 3 to 15 psig output e 1 2 0 03 bar 18 0 5 psig for a 0 4 to 2 0 bar 6 to 30 psig output If the controller output is out of tolerance in steps 8 9 or 10 the flapper needs to be aligned Refer to the flapper alignment procedure If the controller output is within tolerance replace the proportional band cover and go to the startup procedure Startup for 4194HA Controllers Perform the prestartup checks and if necessary calibrate the controller prior to this procedure Note When performing the startup procedure keep in mind the initial settings are guidelines They will vary depending on the actual process being controlled 1 2 Be sure the supply pressure regulator is delivering the proper supply pressure to the controller For controllers with e manual set point Move the set point indicator to the desired set point Instruction Manual 4194HA HB HC Controllers D200156X012 September 2014 e remote set point a See figure 2 2 for the location of the remote set point connection Connect an adjustable pressure source to the
144. utput should be 0 62 0 007 9 0 1 psig for a 0 2 to 1 0 3 to 15 psig output 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 number 2 5 Adjust the proportional adjustment to 20 percent DIRECT direct acting 6 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 number 3 7 Adjust the proportional band adjustment to 20 percent REVERSE reverse acting 8 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 number 1 9 Repeat steps 5 through 8 until the output of the controller remains in tolerance without further leveling screw adjustments 10 If link 1 was disconnected remove the tape and reconnect link 1 to the drive arm 11 Setthe proportional band adjustment to 400 percent in the desired controller action Replace the proportional band indicator cover key 36 and install the machine screws key 6 Principle of Operation for 4194HA Controllers Overall Operation Refer to the schematic diagram in figure 3 3 Figure 3 3 Schematic for Fisher 4194HA Controller SET POINT REVERSE ACTION INDICATOR RESET BELLOWS VENTED QUADRANT M PROPORTIONAL pp BELLOWS PROPORTIONAL FEEDBACK vv a Z BAND ADJUSTMENT LINK PROCESS POINTER pus tea REMOTE SET POINT
145. ventilation and the removal of any ignition sources For information on remote venting of this controller refer to page 11 e Disconnect any operating lines providing supply air pressure a process input signal or other pressure source to the controller e Check with your process or safety engineer for any additional measures that must be taken to protect again process media Note Unless otherwise noted key numbers refer to figure 6 1 Figure 3 1 shows the location of adjustments and major components For maintenance on the indicator assembly refer to figure 6 4 Select the appropriate maintenance procedure and perform the numbered steps Shut off the supply pressure and process pressure before beginning maintenance The maintenance procedures section describes part replacement common to 4194HA HB and HC controllers Other portions of the maintenance procedures describe replacing the differential pressure unit making process zero and span and flapper alignments and other calibration and maintenance procedures When maintenance procedures including flapper alignment have been completed refer to the appropriate prestartup procedure Troubleshooting As an aid to troubleshooting table 5 1 lists some common operating faults their probable cause and suggested procedures for correcting the fault 37 4194 HB Controllers Instruction Manual September 2014 D200156X012 Figure 5 1 Maintenance Guide Troubleshoot
146. very 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 resulting from the process differential pressure change and backs the flapper away from the nozzle 31 4194HA HB Controllers September 2014 Instruction Manual D200156X012 Pressure in the reset bell nozzle The result of this temporarily reduces the returns to set point as p The set point adjustmen ows opposes the action of the proportional bellows and slowly moves the flapper closer to the interaction is that when the process differential pressure changes proportional action gain of the controller for improved stability The process differential pressure then slowly ressure in both bellows equalizes via the reset action tchanges the distance between the nozzle and flapper as does a change in process differential pressure except that when the set point changes the nozzle moves with respect to the flapper The proportional band adjustment knob positions the nozzle on the flapper Increasing widening the proportional band moves the nozzle t 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 Figure
147. vided 2 Fora controller with manual set point move the set point indicator to 50 percent of the scale range For a controller with remote set point suffix letter M adjust the remote set point pressure until the set point indicator is at 50 percent of the scale range Remove the two machine screws key 6 and lift off the proportional band indicator cover key 36 Adjust the reset adjustment to 0 01 minute per repeat Ifthe controller has rate 4194HC controllers turn the rate adjustment to OFF If the controller has the external feedback option available with a 4194HB controller only shut off the supply pressure connect the controller output to the external feedback connection and turn on the supply pressure See figure 2 2 for the location of the output and external feedback connections 7 Adjust the process differential pressure to 50 percent of the input range If pressure is not available to pressure the differential pressure unit to 50 percent of range an alternate method is to disconnect link 1 at the drive arm and tape the process indicator at 50 percent of the process differential pressure input range Duh Note In steps 8 through 12 the controller output will not stabilize because of the high controller gain The controller output gauge is adequate to check the output pressure during this procedure 8 Set the proportional band between DIRECT and REVERSE 9 Adjust flapper leveling screw number 2 until the con
148. 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 anti reset windup valve has relieved 11 To obtain the anti reset windup valve differential setting calculate the difference between the original controller output pressure in step 7 and the controller output pressure recorded in step 10 12 Ifthe differential pressure calculated in step 11 is incorrect for the application adjust the differential by turning the anti reset windup valve adjustment screw figure 3 1 Decrease the differential pressure by turning the screw clockwise Increase the differential pressure by turning the screw counterclockwise The anti reset windup valve is factory set at approximately 0 14 bar 5 psi differential pressure 13 Repeat steps 7 through 12 until the required differential pressure is obtained Principle of Operation for 4194HB and HC Controllers Overall Operation Refer to the schematic diagrams in figures 4 2 and 4 3 for the 4194HB controllers and the 4194HC controllers The differential pressure unit input element connects to the process indicator and to the flapper by connecting links As the process differential pressure increases in a direct acting controller the flapper moves toward the nozzle restricting flow through the nozzle and increasing nozzle pressure When this occurs relay action increases the output pressure deli
149. wo cap screws key 58 holding the pressure control block to the frame key 3 and lift out the pressure control block Install the O ring key 7 on the replacement pressure control block Install the replacement pressure control block to the frame with two screws key 58 Tighten the loosened in step 2 Dw B Apply the maximum value of remote set point pressure and check for leaks Remote Set Point Maintenance Calibration WARNING To avoid personal injury or property damage resulting from the sudden release of pressure do not exceed the operating limits given in this manual Note Perform all maintenance calibration procedures upon completion of maintenance If only zero and span or linearity adjustments are required use only those procedures Key numbers are referenced in figures 6 1 and 6 2 Adjustments are shown in figure 3 1 After maintenance calibration perform the flapper alignment procedures if directed to do so Otherwise go to the appropriate prestartup instructions in the Controller Operation section Remote Set Point Precalibration Procedures 1 Set the proportional band adjustment between DIRECT and REVERSE 2 Remove the tie bar key 106 3 Apply 50 percent of full span remote set point pressure 4 The drive flexure key 79 should be straight If not proceed as follows a Loosen the screw on the adjustment arm on pivot assembly A key 114 and the screws holding the drive flexure b Set th
150. y 36 3 Disconnect link 3 from the set point beam shoe part of the set point beam assembly key 23 Refer to figure 5 9 for location of the link shoe 4 Remove the set point beam bias spring key 28 Refer to figure 5 9 for spring location 5 Remove the screw and washer keys 19 and 20 holding the bracket of the set point pivot assembly to the frame Remove the pivot assembly from the set point beam assembly 6 Disconnect the nut holding the relay nozzle tubing into the frame manifold key 3 7 While holding the proportional band knob remove the screw and washer keys 19 and 20 which holds the bracket of the relay nozzle tubing assembly key 18 to the frame 8 Remove the proportional band knob nozzle pivot and set point beam assembly from the controller frame 9 Pull the relay nozzle tubing assembly key 18 from the bore in the set point beam assembly key 23 10 Remove the E ring key 27 holding the retaining clip proportional band knob and nozzle assembly together with the set point beam assembly 11 Pull the nozzle assembly key 21 from the set point beam assembly Do not lose the plastic washer key 22 12 Remove the retaining clip key 26 13 Remove the proportional band knob key 25 from the set point beam assembly key 23 Do not lose the plastic washer key 22 14 Inspect the nozzle assembly O ring Replace it if necessary 15 First inspect the nozzle orifice and clean it if necessary Then ins

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