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Instruction Manual

D200156X012

4194HA, HB, HC Controllers

July 2018

76

5. Apply air pressure to the controller and check for leaks.
6. Install the controller assembly in the case. Slide the controller frame down to assure an O‐ring seal at the pressure

connections. Hold the frame in place.

7. Install and tighten the nine screws holding the controller assembly in the case.
8. Refer to the flapper alignment procedure.

Replacing the Auto/Manual Station Switch Body Assembly, Lever O‐Ring, Switch Body O‐Ring,
and the Tubing Assembly

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.

6. Loosen the two screws (key 290) and separate the switch body assembly (key 291) from the loader assembly (key

282).

7. Remove the O‐rings (keys 292, 293, and 294), switch body springs (key 295), and balls (key 296).
8. Loosen two screws (key 308). Remove the closing plate (key 307) and the closing plate gasket (key 306).
9. Pull the clip (key 300) from its engagement with the shaft of the lever assembly (key 297).

10. Pull the 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.

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Summary of Contents for Fisher 4194HA

Page 1: ...ffix letter M 21 Auto Manual Station Option suffix letter E 21 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 su...

Page 2: ...indup Valve suffix letter F Calibration 67 Remote Set Point suffix letter M Maintenance 68 Remote Set Point Assembly Replacement 69 Replacing Remote Set Point Parts 69 Pivot Assembly A Key 114 69 Pivot Assembly B Key 115 70 Drive Flexure 71 Remote Set Point Tubing 71 Link A 71 Link B 72 Pressure Control Block for Remote Set Point 72 Remote Set Point Maintenance Calibration 72 Remote Set Point Prec...

Page 3: ... 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 W5907 W5908 NAMEPLATE Do not install operate or maintain a 4194HA HB or HC controller without being fully trained and qualified in valve actuator and accessory install...

Page 4: ...trollers show process differential pressure and set point on an easy to read process scale The controller output is a pneumatic signal that operates a final control element 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 co...

Page 5: ...n dry and non corrosive Per ISA Standard 7 0 01 A maximum 40 micrometer particle size in the air system is acceptable Further filtration down to 5 micrometer particle size is recommended Lubricant content is not to exceed 1 ppm weight w w or volume v v basis Condensation in the air supply should be minimized Per ISO 8573 1 Maximum particle density size Class 7 Oil content Class 3 Pressure Dew Poin...

Page 6: ...ce with other applicable 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 sales office or Local Business Partner 2 Consult your Emerson sales office or Local Business Partner for additional information 3 Normal m3 hr n...

Page 7: ... 0 to 25 0 to 62 0 to 50 0 to 124 0 to 75 0 to 186 0 to 100 0 to 248 172 2500 Steel 0 to 20 0 to 50 0 to 25 0 to 62 0 to 50 0 to 124 0 to 75 0 to 186 0 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 sales office or Local Business Partner for special differential pressure ran...

Page 8: ... with the housing vertical as shown in figure 2 1 so the vent points down Pipestand Mounting A 4194H 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 WARNING To avoid personal injury or property damage resulting from the sudden release of pressure do not install a...

Page 9: ...y accepted practices NOTE 1 LOW PRESSURE CONNECTION ON A BARTON 199 DIFFERENTIAL PRESSURE UNIT Figure 2 1 Right Side View of Controller SET SCREW 3 REQ D W3635 1 BARTON 199 DIFFERENTIAL PRESSURE UNIT 1 2 NPT PRESSURE CONNECTION 1 4 NPT PRESSURE CONNECTION PIPESTAND MOUNTING BRACKET PIPESTAND 1 1 NOTE 1 HIGH PRESSURE CONNECTION ON A BARTON 199 DIFFERENTIAL PRESSURE UNIT Figure 2 2 Connections 1 4 N...

Page 10: ... valves vents drains or seal systems as needed in the process pressure lines If the instrument is located such that the adjacent process pressure lines will be approximately horizontal the lines should slope downward to the instrument for liquid filled lines and upward toward the instrument for gas filled lines This will reduce the chance of air becoming trapped in the sensor with liquid filled li...

Page 11: ... 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 sh...

Page 12: ...ssary to set the proportional band knob to 400 direct or reverse action before replacing the proportional band indicator cover This section includes descriptions of adjustments and procedures for prestartup and startup Location of adjustments is shown in figure 3 1 To better understand the adjustments and overall operation of the controller refer to the principle of operation and the schematic dia...

Page 13: ...1 ON CONTROLLERS EQUIPPED WITH REMOTE SET POINT OPTION THIS IS THE REMOTE SET POINT INDICATOR FRONT VIEW SIDE VIEW OF SET POINT PROCESS INDICATOR ASSEMBLY 35A7374 B W3688 1 REMOTE SET POINT SPAN ADJUSTMENT SPAN ADJUSTMENT SIDE VIEW OF CONTROLLER SHOWING FLAPPER LEVELING SCREWS 56A9752 S SHT 1 SCREW 1 SCREW 2 SCREW 3 Manual Set Point Adjustment To adjust the set point open the controller cover and ...

Page 14: ...EXURE MOUNTING SCREW LINK A ADJUSTMENT SCREW LINK B LINEARITY ADJUSTMENT PIVOT ASSEMBLY B MOUNTING SCREW TIE BAR REMOTE SET POINT ZERO ADJUSTMENT SCREW ZERO ADJUSTMENT LOCKING SCREW CAPSULES UPPER TRAVEL STOP LOWER TRAVEL STOP DRIVE FLEXURE SIDE VIEW FRONT VIEW 36A9751 C B1668 4 Proportional Band Adjustment PB ADJ The proportional band adjustment determines the output sensitivity of the controller...

Page 15: ...manual output with the controller output Two balance methods are available to equalize the manual output with the controller output To switch from automatic to manual mode carefully adjust the loader knob until the metal ball inside the plastic tube moves into the switching zone Then move the automatic manual switch to MANUAL Turn the loader knob clockwise to increase the controller output or coun...

Page 16: ...djust the remote set point pressure until the set point moves to 50 percent of the scale range 8 The output of the controller should be D 0 62 0 007 bar 9 0 1 psig for a 0 2 to 1 0 bar 3 to 15 psig output D 1 2 0 01 bar 18 0 2 psig for a 0 4 to 2 0 bar 6 to 30 psig output 9 Adjust the proportional band to 20 percent DIRECT The output of the controller should remain essentially the same D 0 62 0 01...

Page 17: ...dure until the system cycles At this point double the proportional band setting proportional band setting X 2 Calibration for 4194HA Controllers 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 General Calibration Instructions Note If the controller has the auto manual option be sure the contro...

Page 18: ...e span for a low indication or counterclockwise to decrease span for a high indication Adjust the span screw to correct one half the error 10 Repeat steps 6 through 9 until the error is eliminated 11 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...

Page 19: ...ro 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 p...

Page 20: ... 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 Set the proportional band adjustment to 400 percent in the desired controller action Replace ...

Page 21: ... 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...

Page 22: ...d 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 ...

Page 23: ...ure 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...

Page 24: ...tment to OFF 7 Adjust the proportional band knob to 5 percent DIRECT direct action 8 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 pe...

Page 25: ...th 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 7 Check the stability of the recommended proportional band setting by introducing a disturbance and monitoring the process 8 Once stable c...

Page 26: ...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 approxim...

Page 27: ...t 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 Ad...

Page 28: ... Adjust the reset adjustment to 0 01 minute per repeat 5 If the controller has rate 4194HC controllers turn the rate adjustment to OFF 6 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...

Page 29: ...ge of the set point indicator The controller output should be 0 psig 18 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 19 If the controller does not perform as indicated in steps 13 through 18 the flapper is not correctly a...

Page 30: ...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 o...

Page 31: ... 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 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...

Page 32: ...ves 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 Figure 4 2 Schematic of Operation for Fisher 4194HB Controller SET POINT INDICATOR PROCESS INDICATOR REMOTE SET ...

Page 33: ...9764 B C0593 3 PROPORTIONAL PRESSURE RATE VALVE RESET VALVE RATE VALVE RESET VALVE 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 ...

Page 34: ... 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 expansi...

Page 35: ...e 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 of the plastic tube When the pressures are equal the metal ball is centered in the tube and it is held in pla...

Page 36: ...hematic of External Feedback Option 47A0975 A A3342 1 TO RESET BELLOWS TO NOZZLE OUTPUT RELAY SUPPLY PRESSURE EXTERNAL FEEDBACK TO OUTPUT OF HIGH OR LOW SELECT RELAY TO PROPORTIONAL BELLOWS RESET VALVE SUPPLY PRESSURE OUTPUT PRESSURE NOZZLE PRESSURE RESET PRESSURE SELECT RELAY OUTPUT ...

Page 37: ... 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 D Disconnect any operating lines providing supply air pressure a process input signal or other pressure source to the controller D Check with your proce...

Page 38: ...emote 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 4194HA Proportional Only Controllers A description of prestartup startup and calibration procedures to return the controller to service...

Page 39: ...o 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 Note Some offset is inherent with proportional only controllers 4194HA controllers The amount of offset is a function of the proportional band setting 2 1 Supply pressure not set correctly 2 2 Flapper not aligned 2 3 ...

Page 40: ...an external source 6 2 Repair or replace the supply pressure regulator if necessary Replace the supply pressure gauge if necessary 6 3 Proportional band setting too wide 4194HA controllers only 6 3 Adjust proportional band setting to 10 Manually cap the nozzle Output should increase 6 3 Use a narrower proportional band setting 6 4 Differential pressure unit or linkage failure 6 4 Inspect the linka...

Page 41: ...an be capped by the flapper If not inspect linkages and flexures for damage 8 3 Repair or replace parts as necessary 8 4 Relay malfunction 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 4 Press the cleanout wire on the relay If the pr...

Page 42: ...ential pressure to the differential pressure unit Also shut off the supply pressure to the controller Carefully bleed pressure from the controller and differential pressure unit 2 Disconnect all tubing Refer to the installation procedures for process and supply tubing connections to disconnect when the differential pressure unit is removed from the pipestand WARNING The combined weight of the cont...

Page 43: ...erential 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 rejoi...

Page 44: ...ote 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 shown in figure 5 3 4 To install the replacement scale bend the lower part of the slot slightl...

Page 45: ...ntegral unit trying to separate them will 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 co...

Page 46: ... 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 eac...

Page 47: ...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...

Page 48: ...cator 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 ...

Page 49: ...Section 3 or 4 Figure 5 7 Link Number 2 Adjustment LEVELING SCREW NUMBER 1 CLINCH NUT FLAPPER LEVELING SCREW 3 CONNECTING TAB ON INPUT FEEDBACK BEAM ASSEMBLY 1 2 OF PIN DIAMETER W3451 W4191 Link 3 Note 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 Th...

Page 50: ... 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 and 9 until flapper leveling screws 1 and 3 protrude an equal distance from...

Page 51: ...dicate 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 10 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 cas...

Page 52: ... 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 Remov...

Page 53: ...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 13 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 poin...

Page 54: ...SSEMBLY KEY 23 PLASTIC WASHER CAP NOZZLE TUBING ASSEMBLY KEY 18 WASHER KEY 20 SCREW KEY 19 O RING NOZZLE ASSEMBLY KEY 21 PLASTIC WASHER KEY 22 SET POINT BEAM SHOE KEY 29 FLAPPER ALIGNMENT SCREW FLAPPER RETAINER CLIP E RING CAP PROPORTIONAL BAND ADJUSTMENT KNOB SHOE ADJUSTMENT SCREWS SET POINT BEAM ASSEMBLY SET POINT BEAM SHOE LINK 3 DISCONNECT LINK 3 RELAY NOZZLE TUBING ASSEMBLY SET POINT BIAS SPR...

Page 55: ...eveling screws 22 Adjust the set point to the maximum value on the process scale 23 Remove the tape and move the process indicator until the controller output equals the pressure recorded in step 21 24 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 sligh...

Page 56: ... 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 key 10 as shown in figure 5 14 holding the flexure pivot assembly to the frame 1...

Page 57: ...BACK BEAM ASSEMBLY Figure 5 14 Exploded View Flexure Pivot Assembly FOUR SCREWS KEY 10 FLEXURE PIVOT ASSEMBLY KEY 9 W4198 INPUT FEEDBACK BEAM ASSEMBLY WITH LINK 4 ATTACHED 22 Adjust the length of link 2 by turning the adjustment screw clockwise to increase the length or counterclockwise to decrease the length so the pin on the end of the link is approximately one half of its diameter short of alig...

Page 58: ...eset 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 repeat 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 controlle...

Page 59: ...llows 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 ...

Page 60: ...D 20 LINK 4 Note The following procedure steps 18 through 28 adjusts the reset gain of the controller to minimize steady state offset 18 Adjust the proportional band to 100 percent in direct action 19 Adjust the set point to 50 percent of the process scale range 20 Adjust the reset valve 4194HB and HC controllers to 0 01 minute per repeat Adjust the rate valve 4194HC controllers to OFF 21 Increase...

Page 61: ... controller assembly in the case and cover 30 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 ...

Page 62: ...ert 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 tighten 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 ca...

Page 63: ...ty 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 pressure unit Provide a regulated supply pressure to the controller Do not exceed normal operating pressure table 1 4 For a 4194HA controller connect the controller output to an accurate gauge For 4194HB and HC controllers a gauge i...

Page 64: ...proceed to step 16 15 Within the process indicator subassembly there are three holes for the connection of link 1 Use procedure a or b below to make the coarse span adjustment with link 1 a If the span is short process 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 ...

Page 65: ...essentially the same D 0 62 0 017 bar 9 0 25 psig for a 0 2 to 1 0 bar 3 to 15 psig output D 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 D 0 62 0 017 bar 9 0 25 psig for a 0 2 to 1 0 bar 3 to 15 psig output D 1 2 0 03 bar 18 0 5 psig for a 0 4 to 2 0 bar 6 to 3...

Page 66: ...sure during this procedure 8 Set the proportional band between DIRECT and REVERSE 9 Adjust flapper leveling screw number 2 until the controller output is relatively stable at any value within the output range 10 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...

Page 67: ...st the proportional band to 100 percent DIRECT or REVERSE depending on the application requirements 5 Refer to figure 3 1 or figure 6 1 VIEW E SUFFIX BF 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 mo...

Page 68: ... 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 input to the differential pressure unit until the controller output pressure balances at 12 psig for a 3 to 15 psig output range or 24 psig for a 6 to 30 psig output range 8...

Page 69: ...t capsular element assembly by holding the capsule or linkages These parts may be damaged 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 pressur...

Page 70: ...t 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 s...

Page 71: ...ghtening 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...

Page 72: ...s key 58 6 Tighten the nut loosened in step 2 7 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 I...

Page 73: ... end of the capsule stack Tighten the travel stop mounting screws keys 139 and 140 to lock it into that position 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...

Page 74: ...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 an...

Page 75: ...tation from the controller frame 5 Remove the switch manifold O rings key 312 6 Carefully loosen the nut on the relay nozzle tubing assembly key 18 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 necessar...

Page 76: ...h 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 6 Loosen the two screws key 290 and separate the switch body assembly key 291 from the loader assembly key 282 7 Remove the O rings keys 292...

Page 77: ... 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 ...

Page 78: ...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 1 Loosen the spring seat screw key 275 2 Remove the valve plug spring key 276 and the valve plug key 277 3 Inspect the parts and replace as necessary 4 Install the valve plug s...

Page 79: ...Retrofit Kit Contains keys 138 273 312 313 314 315 316 SST tubing R4190X00S12 4190 Controller Case Handle Kit Contains lever and mounting hardware R4190X00H12 4190 Controller Repair Kit Contains keys 4 5 7 8 24 52 R4190X00C12 4190 Controller Pointer and Bracket Repair Kit Contains pointer and bracket ass y 3 machine screws 3 washers R4190X00P12 4194HBF and 4194HCF Anti Reset Windup Retrofit Kits C...

Page 80: ... req d 20 Plain washer 2 req d 21 Nozzle ass y 22 Washer 2 req d 23 Set pt beam ass y 25 Proportional band knob 26 Retaining clip 27 E ring 28 Set pt beam bias spring Key Description 29 Set pt beam shoe 30 Machine screw 2 req d 31 Bellows bracket 32 Bellows adj bracket 33 Bellows adj spring 34 Machine screw fill hd 2 req d 35 Machine screw hex hd 2 req d 36 Proportional band indicator cover 37 Sel...

Page 81: ...t 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 w o remote set for 4194HS and 4194HSE w remote set for 4194HSM and 4194HSME Key Description 57 Pressure control block 1 req d for remote set pt 1 req d for ext fdback 58 Cap screw hex hd Maximum qty req d 6 61 P...

Page 82: ... 253 Reset Scratch Valve For 4194HC controllers 258 Plain washer For 4194HB controllers 1 req d For 4194HC controllers 4 req d Key Description 262 Rate reset valve ass y For 4194HC controllers only 0 2 to 1 0 bar 3 to 15 psig 0 4 to 2 0 bar 6 to 30 psig 264 Set screw hex socket For 4194HC controllers only 2 req d 265 Rate Scratch Valve For 4194HC controllers only 266 Cover Plate For 4194HC control...

Page 83: ...Instruction Manual D200156X012 4194HA HB HC Controllers July 2018 83 Figure 6 1 Controller Assembly Drawings A5948 B2351 B2357 CONTROLLER COMMON PARTS SECTION D D VIEW C C 4194HS CONTROLLERS ...

Page 84: ...2 49A0770 A VIEW C C SUFFIX B VIEW C C SUFFIX BF SECTION B B SUFFIX B SECTION B B SUFFIX A VIEW E SUFFIX BF VIEW E SUFFIX B SECTION B B 1 KEY 4 GASKET IS USED BETWEEN INTERNAL FRAME AND FRAME MANIFOLD 2 KEY 5 GASKET IS USED BETWEEN FRAME MANIFOLD AND POSITIVE FEEDBACK TUBING MANIFOLD NOTES VIEW F F VIEW F F F F F F APPLY LUB ADHESIVE ...

Page 85: ...X012 4194HA HB HC Controllers July 2018 85 Figure 6 1 Controller Assembly Drawings Continued 56A9752 V Sht 3 F F VIEW E SUFFIX CF VIEW F F F F VIEW F F VIEW E SUFFIX C SECTION B B SUFFIX C CF VIEW C C SUFFIX C VIEW C C SUFFIX CF ...

Page 86: ...Instruction Manual D200156X012 4194HA HB HC Controllers July 2018 86 Figure 6 1 Controller Assembly Drawings Continued 56A9752 V Sht 5 56A9752 V Sht 4 VIEW H SUFFIX M VIEW M EXTERNAL FEEDBACK ASSY ...

Page 87: ... pt 319 Support bracket 320 Pivot bracket ass y 321 Shaft extension 322 Drive arm ass y 323 Zero link ass y Key Description 324 Clamp block 325 Nut 2 req d 326 Boot 327 Mounting plate for differential pressure unit 328 Controller mounting plate 329 Machine screw pan hd 2 req d 330 Machine screw fill hd 2 req d 331 Machine screw fill hd 332 Plain washer 2 req d 333 Set screw hex socket 2 req d 334 ...

Page 88: ... Set screw hex socket 93 Union 99 Plain washer 102 Machine screw pan hd 4 req d 103 Machine screw pan hd 2 req d 104 Remote set pt tubing ass y Key Description 105 Pedestal ass y 106 Tie bar 107 Spring 108 Zero adj screw 109 Pivot screw 110 Zero adj bracket 111 Mounting plate 112 Spring washer 114 Pivot clevis ass y A 115 Pivot clevis ass y B 116 Connecting link ass y 118 Cap screw hex socket 119 ...

Page 89: ... 4 req d 374 Pointer and bracket ass y 375 Set pt indicator ass y for controllers w remote set pt for controllers w o remote set pt 376 Dial bracket 377 Dial bracket 378 Screw self tapping 2 req d Auto Manual Station suffix letter E figure 6 5 Key Description 273 Auto manual station 274 Lower loader ass y 275 Spring seat screw 276 Valve plug spring 277 Valve plug 278 Tube 279 Ball 280 Ball seat 2 ...

Page 90: ...on Manual D200156X012 4194HA HB HC Controllers July 2018 90 Figure 6 5 Auto Manual Station 48A2905 A Sht 2 48A2905 A Sh1 1 SECTION A A SECTION B B TOP VIEW RIGHT SIDE VIEW INSTALLED SECTION C C APPLY LUB SEALANT ...

Page 91: ... 2 SWITCHING ZONE INDICATION METAL BALL PLASTIC TUBE LOADER KNOB AUTOMATIC MANUAL SWITCH SIDE VIEW COVER REMOVED BACK VIEW COVER REMOVED Key Description 291 Switch body ass y 292 O ring 293 O ring 294 O ring Key Description 295 Switch body spring 2 req d 296 Ball 2 req d 297 Lever ass y 298 O ring 299 Rocker Recommended spare parts ...

Page 92: ...com 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 applicability All sales are governed by our terms and conditions which are available upon request We reserve th...

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