Emerson Fisher 4195K Instruction Manual

www.Fisher.comFisherr 4195KA, KB, KC, and KS Gauge PressureControllersContents1. IntroductionScope of Manual 4...Description

Instruction ManualD200160X0124195K ControllersDecember 201210Figure 2‐2. Pipestand Mounting49A3196‐AA6732HEX HEADCAP SCREW(KEY 66)LOCKWASHER(KEY 67)HE

Instruction ManualD200160X0124195K ControllersDecember 20121003. Adjust the remote set point pressure to 100 percent of the remote set point input ra

Instruction ManualD200160X0124195K ControllersDecember 2012101CAUTIONIn the next step, take care to tighten the two screws (keys 314 and 315) evenly.

Instruction ManualD200160X0124195K ControllersDecember 20121027. Remove the O‐rings (keys 292, 293, and 294), switch body springs (key 295), and ball

Instruction ManualD200160X0124195K ControllersDecember 2012103Refer to figure 7‐7 for key number locations.Disassembly1. Remove the auto/manual stati

Instruction ManualD200160X0124195K ControllersDecember 2012104Refer to figure 7‐7 for key number location.1. Remove the controller assembly from the

Instruction ManualD200160X0124195K ControllersDecember 2012105Section 7 PartsParts OrderingWhenever corresponding with your Emerson Process Management

Instruction ManualD200160X0124195K ControllersDecember 2012106Controller Common Parts (figure 7‐1)NotePart numbers are shown for recommended spares on

Instruction ManualD200160X0124195K ControllersDecember 2012107Key Description Part NumberNoteOne type of pressure gauge is used for both output pressu

Instruction ManualD200160X0124195K ControllersDecember 2012108Key Description62 Remote set pt ass'y (suffix letter M)NoteThe part numbers listed

Instruction ManualD200160X0124195K ControllersDecember 2012109Figure 7‐1. Controller Assembly DrawingsSECTION D‐DSEE VIEW H SEE VIEW GBBSEE VIEW LCCDD

Instruction ManualD200160X0124195K ControllersDecember 201211Figure 2‐3. Panel MountingHEX HEADCAP SCREW(KEY 66)LOCKWASHER(KEY 67)ROUNDHEADMACHINESCRE

Instruction ManualD200160X0124195K ControllersDecember 2012110Figure 7‐1. Controller Assembly Drawings (cont'd)FF F FVIEW F‐F VIEW F‐FVIEW E4195K

Instruction ManualD200160X0124195K ControllersDecember 2012111Figure 7‐1. Controller Assembly Drawings (cont'd)VIEW F‐FVIEW F‐FVIEW E4195KC CONTR

Instruction ManualD200160X0124195K ControllersDecember 2012112Figure 7‐1. Controller Assembly Drawings (cont'd)SECTION B‐B4195KA CONTROLLERSSECTI

Instruction ManualD200160X0124195K ControllersDecember 2012113Figure 7‐1. Controller Assembly Drawings (cont'd)56A9752‐U SHT 456A9752‐U SHT 356A9

Instruction ManualD200160X0124195K ControllersDecember 2012114Figure 7‐2. Process and Set Point Indicator Assembly for Bourdon Tube Controllers32B1532

Instruction ManualD200160X0124195K ControllersDecember 2012115Figure 7‐3. Process and Set Point Indicator Assembly for Capsular Element Controllers (P

Instruction ManualD200160X0124195K ControllersDecember 2012116Key 383* Bourdon TubesBAR RANGE PSIG RANGE PART NUMBERS31600 (316 SST) Bourdon Tube0 to

Instruction ManualD200160X0124195K ControllersDecember 2012117Key 61 Process Scale, Positive PressureScale Range Part NumberBar Scales0 to 150 mbar0 t

Instruction ManualD200160X0124195K ControllersDecember 2012118Capsular Element Assembly (key 113)(figure 7‐5)Key Description12 Cap screw, hex socket,

Instruction ManualD200160X0124195K ControllersDecember 2012119Figure 7‐5. Capsular Element AssemblyVIEW A‐AVIEW A‐AVIEW A‐AVIEW A‐A58A0708‐E58A0710‐CP

Instruction ManualD200160X0124195K ControllersDecember 201212Pressure Connections WARNINGTo avoid personal injury or property damage resulting from t

Instruction ManualD200160X0124195K ControllersDecember 2012120Figure 7‐6. Remote Set Point Assembly APPLY LUB / SEALANT36A6988‐CKey Description86

Instruction ManualD200160X0124195K ControllersDecember 2012121Figure 7‐7. Auto/Manual Station Assembly48A2905‐A APPLY LUB / SEALANTAABBCCSECTION A‐

Instruction ManualD200160X0124195K ControllersDecember 2012122Key Description Part Number298* O‐ring, nitrile 1E222606992299 Rocker, A96061 (aluminum)

Instruction ManualD200160X0124195K ControllersDecember 2012123Regulator Mounting PartsDescriptionRegulator Mounting Parts forCasing‐Mounted RegulatorC

Instruction ManualD200160X0124195K ControllersDecember 2012124Emerson Process Management Marshalltown, Iowa 50158 USASorocaba, 18087 BrazilChatham, Ke

Instruction ManualD200160X0124195K ControllersDecember 201213Use a suitable supply pressure regulator to reduce the supply pressure source to the norm

Instruction ManualD200160X0124195K ControllersDecember 201214Vent WARNINGPersonal injury or property damage could result from fire or explosion of ac

Instruction ManualD200160X0124195K ControllersDecember 201215Section 3 4195KA Proportional‐Only ControllersAdjustments for 4195KA ControllersThis sect

Instruction ManualD200160X0124195K ControllersDecember 201216Remote Set Point (suffix letter M) AdjustmentCAUTIONDo not manually move the set point in

Instruction ManualD200160X0124195K ControllersDecember 201217D For reverse control action—An increasing sensed vacuum decreases output pressure.After

Instruction ManualD200160X0124195K ControllersDecember 2012187. The controller output pressure should be 0 bar (0 psig).8. Rotate the proportional b

Instruction ManualD200160X0124195K ControllersDecember 201219General Calibration InstructionsNoteIf the controller has the auto/manual station (suffix

Instruction ManualD200160X0124195K ControllersDecember 20122Contents (continued)Auto/Manual Switching (Option E) 44...Prestartup Checks 44...

Instruction ManualD200160X0124195K ControllersDecember 201220Figure 3‐3. Fisher 4195KA Controller Calibration Adjustment LocationsPROCESSPOINTER SPANA

Instruction ManualD200160X0124195K ControllersDecember 2012211. Remove the two screws (key 6) and lift off the proportional band indicator cover (key

Instruction ManualD200160X0124195K ControllersDecember 2012229. Make sure the set point indicator is within ±1 percent of the mid‐scale mark and if s

Instruction ManualD200160X0124195K ControllersDecember 20122312. Set the proportional band to 400 percent in the desired controller action and replac

Instruction ManualD200160X0124195K ControllersDecember 201224Remote Set Point (suffix letter M) OperationThe capability to adjust the controller set p

Instruction ManualD200160X0124195K ControllersDecember 201225Section 4 4195KB Proportional‐Plus‐Reset Controllers and4195KC Proportional‐Plus‐Reset‐Pl

Instruction ManualD200160X0124195K ControllersDecember 201226Remote Set Point (suffix letter M) AdjustmentCAUTIONDo not manually move the set point in

Instruction ManualD200160X0124195K ControllersDecember 201227Bourdon Tube or Capsular Element Controllers for Positive or Compound PressureD For direc

Instruction ManualD200160X0124195K ControllersDecember 201228To switch from manual to automatic mode, adjust the set point to move the ball into the s

Instruction ManualD200160X0124195K ControllersDecember 2012291. Be sure the supply pressure regulator is delivering the proper supply pressure to the

Instruction ManualD200160X0124195K ControllersDecember 20123Figure 1-1. Fisher 4195K Gauge Pressure ControllersNAMEPLATEW5663‐1W6831Contents (continue

Instruction ManualD200160X0124195K ControllersDecember 201230Calibration of 4195KB and KC Controllers WARNINGTo avoid personal injury or property dam

Instruction ManualD200160X0124195K ControllersDecember 201231Figure 4‐3. Fisher 4195KB and KC Controller Calibration Adjustment LocationsRATEADJUSTMEN

Instruction ManualD200160X0124195K ControllersDecember 2012324. The process pointer should indicate the process scale lower limit. If not, adjust the

Instruction ManualD200160X0124195K ControllersDecember 20123310. Loosen the remote set point zero adjustment locking screw and adjust the remote set

Instruction ManualD200160X0124195K ControllersDecember 2012349. Set the proportional band between DIRECT and REVERSE.10. The controller output shoul

Instruction ManualD200160X0124195K ControllersDecember 20123521. When the flapper is correctly aligned, set the proportional band to 400 percent in t

Instruction ManualD200160X0124195K ControllersDecember 201236differential pressure or counterclockwise to increase the differential pressure. The diff

Instruction ManualD200160X0124195K ControllersDecember 201237The input element is connected to the process pointer and to the flapper by connecting li

Instruction ManualD200160X0124195K ControllersDecember 201238Figure 4‐6. Fisher 4195KC Controller SchematicSET POINTINDICATORPROCESS POINTERREMOTE SET

Instruction ManualD200160X0124195K ControllersDecember 201239A 4195KC controller also has a rate valve as shown in figures 4‐6 and 4‐7. This valve is

Instruction ManualD200160X0124195K ControllersDecember 20124Section 1 IntroductionScope of ManualThis instruction manual provides installation, operat

Instruction ManualD200160X0124195K ControllersDecember 201240Auto/Manual Station (suffix letter E) OperationA controller with the auto/manual station

Instruction ManualD200160X0124195K ControllersDecember 201241External Feedback OperationExternal feedback is available for all 4195KB controllers. Con

Instruction ManualD200160X0124195K ControllersDecember 201242Section 5 4195KS Differential Gap ControllersOperating InformationThis section includes d

Instruction ManualD200160X0124195K ControllersDecember 201243Figure 5‐1. Fisher 4195KS Controller Parts and Adjustments Locations (continued)C0528‐1SC

Instruction ManualD200160X0124195K ControllersDecember 201244The white portion of the adjustment enables direct controller action; the black portion e

Instruction ManualD200160X0124195K ControllersDecember 201245If they are used, slowly open the upstream and downstream manual control valves in the pi

Instruction ManualD200160X0124195K ControllersDecember 2012461. Refer to figures 5‐1 and 5‐2 for location of adjustments.2. Remove the two screws (k

Instruction ManualD200160X0124195K ControllersDecember 201247The controller output signal will not return to zero pressure until decreasing process pr

Instruction ManualD200160X0124195K ControllersDecember 2012488. Observe the process pointer when the output switches at the upper switching point. Th

Instruction ManualD200160X0124195K ControllersDecember 201249The input element is connected to the process pointer and to the flapper by connecting li

Instruction ManualD200160X0124195K ControllersDecember 20125Table 1-1. SpecificationsAvailable ConfigurationsSee table 1-2Input Signal (Process Sensor

Instruction ManualD200160X0124195K ControllersDecember 201250Remote Set Point (Option M)The capability to adjust the controller set point from a remot

Instruction ManualD200160X0124195K ControllersDecember 201251Section 6 MaintenanceController parts are subject to normal wear and must be inspected an

Instruction ManualD200160X0124195K ControllersDecember 201252Table 6‐1. Troubleshooting Chart Fault Possible Cause Check Correction1. Process wanders

Instruction ManualD200160X0124195K ControllersDecember 201253Table 6‐1. Troubleshooting Chart (continued)CorrectionCheckPossible CauseFault2. Controll

Instruction ManualD200160X0124195K ControllersDecember 201254Table 6‐1. Troubleshooting Chart (continued)CorrectionCheckPossible CauseFault6. Controll

Instruction ManualD200160X0124195K ControllersDecember 201255Replacing Common Controller Parts WARNINGTo avoid personal injury or property damage cau

Instruction ManualD200160X0124195K ControllersDecember 2012565. Secure the scale with the four self‐tapping screws (key 37).6. If the controller has

Instruction ManualD200160X0124195K ControllersDecember 201257CAUTIONThe case and cover are an integral unit; attempting to separate them will damage t

Instruction ManualD200160X0124195K ControllersDecember 201258Replacing the Supply Gauge, Proportional, Reset, Reset Valve, and Positive Feedback Tubin

Instruction ManualD200160X0124195K ControllersDecember 201259Figure 6‐3. Proportional Band Adjustment and Set Point Beam DetailsE‐RING(KEY 27)RETAININ

Instruction ManualD200160X0124195K ControllersDecember 20126Table 1-1. Specifications (continued)HousingDesigned to NEMA 3 (Weatherproof) and IEC 529I

Instruction ManualD200160X0124195K ControllersDecember 2012609. Remove the relay nozzle tubing assembly (key 18) from the set point beam assembly (ke

Instruction ManualD200160X0124195K ControllersDecember 20126115. Turn the proportional band adjustment knob to 5 percent DIRECT. Refer to figure 6‐6

Instruction ManualD200160X0124195K ControllersDecember 20126216. At the frame manifold (key 135), tighten the nut that secures the tubing from the re

Instruction ManualD200160X0124195K ControllersDecember 20126331. Perform the controller calibration procedures and, if necessary, the appropriate rem

Instruction ManualD200160X0124195K ControllersDecember 201264Figure 6‐7. Bellows Assembly and Proportional Band Adjustment (Process Scale and Proporti

Instruction ManualD200160X0124195K ControllersDecember 20126520. Align flapper leveling screw number 2 with the centerline of the oblong hole in the

Instruction ManualD200160X0124195K ControllersDecember 201266Figure 6‐11. Link 2 AdjustmentLEVELINGSCREWNUMBER 11/2 OF PINDIAMETERCONNECTING TAB ONFLA

Instruction ManualD200160X0124195K ControllersDecember 20126734. Attach link 3 to the set point beam shoe as shown in figure 6‐3.NoteThe following pr

Instruction ManualD200160X0124195K ControllersDecember 20126851. Perform the controller calibration procedures and, if necessary, the appropriate rem

Instruction ManualD200160X0124195K ControllersDecember 201269CAUTIONWhen removing and replacing the proportional, reset, or positive feedback bellows,

Instruction ManualD200160X0124195K ControllersDecember 20127Table 1-3. Process Sensor (Capsular Element) Pressure RatingsCAPSULEMATERIALCAPSULARSTANDA

Instruction ManualD200160X0124195K ControllersDecember 20127024. Adjust the reset adjustment to 0.01 minutes per repeat. For a 4195KC controller, set

Instruction ManualD200160X0124195K ControllersDecember 2012714. For controllers with anti‐reset windup (suffix letter F), remove the relief valve tub

Instruction ManualD200160X0124195K ControllersDecember 20127214. For controllers with anti‐reset windup (suffix letter F), insert the relief tubing a

Instruction ManualD200160X0124195K ControllersDecember 2012735. Position the controller assembly in the case and start, but do not tighten the nine m

Instruction ManualD200160X0124195K ControllersDecember 201274Figure 6‐13. Bourdon Tube Controller LinkLocations and AdjustmentsCOURSE ZERO ADJUSTMENTL

Instruction ManualD200160X0124195K ControllersDecember 201275the bottom hole (the hole nearest the pointer pivot). If the process pointer has too much

Instruction ManualD200160X0124195K ControllersDecember 2012766. Disconnect link 1 from the Bourdon tube and manually position the process pointer to

Instruction ManualD200160X0124195K ControllersDecember 20127712. Repeat steps 8 through 11 until leveling screws 1 and 3 protrude an equal distance f

Instruction ManualD200160X0124195K ControllersDecember 20127813. Remove the tape from the process pointer and connect link 1 to the Bourdon tube.14.

Instruction ManualD200160X0124195K ControllersDecember 201279Figure 6‐18. Bourdon Tube Controller Travel Stop AdjustmentLOWER TRAVEL STOPADJUSTMENT LO

Instruction ManualD200160X0124195K ControllersDecember 20128Table 1-4. Process Sensor (Bourdon Tube) Pressure Ratings and MaterialsBOURDON TUBESSPAN(1

Instruction ManualD200160X0124195K ControllersDecember 201280NoteAny adjustment of the process pointer span adjustment screw requires readjustment of

Instruction ManualD200160X0124195K ControllersDecember 201281Figure 6‐19. Fisher 4195K Controller Calibration Adjustment LocationsRATEADJUSTMENTRESETA

Instruction ManualD200160X0124195K ControllersDecember 20128215. Apply process pressure equal to the mid‐scale value of the process scale span. The p

Instruction ManualD200160X0124195K ControllersDecember 201283Replacing Capsular Element Parts WARNINGRefer to the Maintenance WARNING on page 51.CAUT

Instruction ManualD200160X0124195K ControllersDecember 201284Figure 6‐20. Cutaway of Long Pivot Clevis AssemblyEND BUSHINGBEARINGSHAFTBEARINGEND BUSHI

Instruction ManualD200160X0124195K ControllersDecember 2012852. Remove the tie bar (key 97) from the capsular element assembly by removing the mounti

Instruction ManualD200160X0124195K ControllersDecember 201286Figure 6‐21. Capsular Element Controller Link Locations and AdjustmentsLINK 5LINK 1LINK 4

Instruction ManualD200160X0124195K ControllersDecember 2012875. Move the set point indicator, manually or with remote set point pressure, to the proc

Instruction ManualD200160X0124195K ControllersDecember 201288The controller output must be 0 bar (0 psig). To be sure the controller output is at 0 ba

Instruction ManualD200160X0124195K ControllersDecember 201289Precalibration Procedure1. Remove the two machine screws (key 6) and lift off the propor

Instruction ManualD200160X0124195K ControllersDecember 20129Section 2 Installation WARNINGTo avoid personal injury or property damage resulting from

Instruction ManualD200160X0124195K ControllersDecember 201290capsule stack. Tighten the travel stop mounting screws to lock it into position. Decrease

Instruction ManualD200160X0124195K ControllersDecember 2012915. Loosen the screw on link 5 (key 88) and adjust the link length so that the pivot arms

Instruction ManualD200160X0124195K ControllersDecember 201292b. If the pointer indicates greater than the process scale upper limit, rotate the point

Instruction ManualD200160X0124195K ControllersDecember 201293Use the following procedures to replace the remote set point assembly. Figure 6‐23 shows

Instruction ManualD200160X0124195K ControllersDecember 2012946. Lift out the remote set point assembly by holding the tie bar (key 106), mounting pla

Instruction ManualD200160X0124195K ControllersDecember 20129510. Apply remote set point pressure equal to 50 percent of the remote set point input ra

Instruction ManualD200160X0124195K ControllersDecember 201296shaft in the middle of the bushing end play. Be sure neither bushing is resting against t

Instruction ManualD200160X0124195K ControllersDecember 2012971. Remove the two screws (key 6) and lift off the proportional band indicator cover (key

Instruction ManualD200160X0124195K ControllersDecember 201298CAUTIONMake sure the loose travel stop nut does not bind on the diaphragm capsule extensi

Instruction ManualD200160X0124195K ControllersDecember 2012991. Decrease the remote set point pressure to 0 percent of the remote set point input ran