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Instruction Manual

D200158X012

4194S Controllers

July 2018

Figure 5-4. Auto/Manual Station Parts Location

56A9752‐D
49A0770‐A
C0540

FRONT VIEW

SWITCHING
ZONE INDICATION

AUTOMATIC/
MANUAL SWITCH

LOADER KNOB

PLASTIC TUBE

METAL BALL

SIDE VIEW (COVER REMOVED)

BACK VIEW (COVER REMOVED)

Summary of Contents for Fisher 4194S

Page 1: ...4 Process Zero and Span Adjustment 14 Remote Set Point Zero and Span Option M 14 Setting Switching Points 15 Direct Acting Controllers 15 Reverse Acting Controllers 17 Principle of Operation 17 Overall Operation 17 Remote Set Point 19 Auto Manual Option 19 4 Maintenance 21 Troubleshooting 22 Changing Controller Action 23 Replacing Controller Parts 24 Process Pressure Scale 24 Relay 25 Case and Cov...

Page 2: ...g 57 Actuator Casing Mounting 57 Actuator Yoke Mounting 57 Tubing 57 Fittings 57 Section 1 Introduction1 Scope of Manual This instruction manual provides installation operating calibration maintenance and parts ordering information for the 4194S differential pressure indicating controllers Portions of this manual apply only to specific configurations in the 4194S product line These configurations ...

Page 3: ...nt temperature expected Remote Set Point Pressures 0 2 to 1 0 bar 3 to 15 psig or 0 4 to 2 0 bar 6 to 30 psig Controller Adjustments Differential Gap Control 5 to 100 of process scale range Set Point Continuously adjustable from 0 to 100 of the scale range Steady State Air Consumption 2 0 to 1 4 Bar 0 to 20 Psig Output 0 08 m3 hr 2 8 scfh 0 to 2 4 Bar 0 to 35 Psig Output 0 07 m3 hr 2 5 scfh Operat...

Page 4: ...5 10 15 20 Psig 10 20 30 30 5 10 20 30 7 5 15 0 30 0 45 0 1 Span is adjustable between minimum shown and maximum of the capsular element operating range and can be positioned anywhere within this range For example if a 0 to 2 0 bar 0 to 30 psid capsular element is used and the minimum span of 1 0 bar 15 psid 1 0 to 2 0 bar 15 to 30 psid or any value between minimum and maximum value of the operati...

Page 5: ...rvice conditions could result in malfunction of the product property damage or personal injury Specifications for 4194S controllers are listed in table 1 1 Educational Services For information on available courses for 4194S controllers as well as a variety of other products contact Emerson Automation Solutions Educational Services Registration Phone 1 641 754 3771 or 1 800 338 8158 E mail educatio...

Page 6: ...Instruction Manual D200158X012 4194S Controllers July 2018 6 ...

Page 7: ...re 2 1 Controllers specified for mounting on a control valve actuator will be mounted at the factory If the controller is ordered separately for installation on a control valve actuator mount the unit as described in this section Mounting parts vary for different actuator types Attach the mounting bracket to the actuator yoke with cap screws lock washers and spacer spools Attach the controller to ...

Page 8: ...AP SCREWS AND LOCKWASHERS Figure 2 2 Panel Mounting REAR VIEW TOP VIEW DIMENSIONS OF PANEL CUTOUT mm INCH 36A9780 A A2757 4 308 12 06 14 0 56 R 236 9 31 Figure 2 3 Wall Mounting 36A9761 A A2759 4 mm INCH TOP VIEW REAR VIEW 280 10 25 152 6 00 13 0 50 Figure 2 4 Pipestand Mounting 36A9758 A A2869 1 SIDE VIEW HORIZONTAL PIPE VERTICAL PIPE ...

Page 9: ...4 or 1 2 NPT optional Figure 2 5 Location of Connections 46A9765 A A3001 REMOTE SET POINT CONNECTION SUPPLY PRESSURE CONTROLLER OUTPUT PRESSURE LOW PRESSURE A HIGH PRESSURE B VENT TOP VIEW BOTTOM VIEW Process Pressure Process pressure is piped to the connection marked A and B on the bottom of the case see figure 2 5 The high pressure line is piped to connection B and the low pressure line connects...

Page 10: ...set point pressure to the top of the controller case at the location shown in figure 2 5 Use a clean dry air supply Vent WARNING Personal injury or property damage could result from fire or explosion of accumulated gas or from contact with hazardous gas if a flammable or hazardous gas is used as the supply pressure medium Because the controller case and cover assembly do not form a gas tight seal ...

Page 11: ...sure to decrease the set point Proportional Band Differential Gap The proportional band knob adjusts the width of the gap between switching points Rotate the proportional band knob until the desired setting is opposite the line on the proportional band indicator cover Changing Controller Action Controller action can be switched from direct to reverse or vice versa by simply loosening the screws on...

Page 12: ...igure 3 1 for location of adjustments Note If the controller has the auto manual option option E be sure the controller is in the automatic mode prior to performing prestartup checks Figure 3 1 Location of Controller Parts and Adjustments C0541 38A1731 B 38A3819 A HIGH PRESSURE CAPSULAR UNIT INDICATING ASSEMBLY LOW PRESSURE CAPSULAR UNIT SET POINT INDICATOR PROCESS INDICATOR PROPORTIONAL BAND INDI...

Page 13: ...troller case 3 Loosen two screws key 6 lift off the proportional band cover key 36 and set the proportional band knob between DIRECT and REVERSE The process indicator should indicate the process differential pressure For example with the process differential pressure at 50 percent of the input span the process pointer should be at 50 1 0 percent of its span Slight adjustment of the indicator zero ...

Page 14: ... 36 3 Set the proportional band between DIRECT and REVERSE 4 Adjust the process differential pressure to the low limit of the input range 5 Adjust the process pointer to the lowest limit of the input scale by loosening the zero adjustment locking screw and turning the zero adjustment screw 6 Adjust the process differential pressure to the upper limit of the input span Note whether the pointer indi...

Page 15: ...as follows clockwise to increase span for a low indication counterclockwise to decrease span for a high indication Adjust the span screw to correct one half the error 8 Repeat steps 4 through 7 until the error is eliminated 9 Replace the proportional band indicator cover key 36 and tighten the two screws key 6 Figure 3 2 Location of Controller Parts and Adjustments Remote Set Point Option 36A9751 ...

Page 16: ...ifference between the upper and lower switching points by the sensing element range Multiply the result by 100 as shown in the following equation Differential Gap Sensing Element Range x 100 15 psi 30 psi x 100 50 D Locate the 50 percent line on figure 3 3 Move along this line until you intersect the curve Read the proportional band setting on the left hand axis For this example the setting is app...

Page 17: ... 25 psi Proceed as follows D Divide the differential gap the difference between the upper and lower switching points by the sensing element range Multiply the result by 100 as shown in the following equation Differential Gap Sensing Element Range x 100 15 psi 30 psi x 100 50 D Locate the 50 percent line on figure 3 3 Move along this line until you intersect the curve Read the proportional band set...

Page 18: ...to full supply pressure As the process differential pressure decreases approaching the lower switching point the flapper moves away from the nozzle in a direct acting controller reducing nozzle pressure Through relay action pressure to the positive feedback bellows is reduced moving the flapper further away from the nozzle and further reducing nozzle pressure Output pressure to the final control e...

Page 19: ...he 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 manual loader output to avoid bumping the process Adjusting the set point varies the pressure on the left han...

Page 20: ...Instruction Manual D200158X012 4194S Controllers July 2018 20 ...

Page 21: ...to figure 5 6 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 D Always wear protective clothing gloves and eyewear when performing any maintenance procedures to avoid personal injury D Personal injury or pr...

Page 22: ...ion and by the Flapper Alignment procedures Remote Set Point Option M Procedures describe replacement of parts in the remote set point assembly The procedures may be performed separately but must be followed by Maintenance Calibration Flapper Alignment Procedures align the flapper for both direct and reverse controller action Auto Manual Option E Procedures describe disassembly and assembly of the...

Page 23: ...scribed remove relay Replace O rings if necessary Replace relay if necessary 2 7 Switching point has not been reached 2 7 Refer to the Flapper Alignment or to the Setting Switching Points procedure 2 7 Make alignments and adjustments as necessary 2 8 Link 4 not adjusted correctly 2 8 Refer to the maintenance procedures for link adjustment 3 Controller output will not snap to zero pressure 3 1 Flap...

Page 24: ...ge 21 before replacing any common controller parts Process Pressure Scale CAUTION To prevent inaccurate indication and operation take care not to bend the process indicator or the set point adjustment while performing the following procedure 1 Refer to figure 4 3 Adjust the set point adjustment manually or with the remote set point pressure to 50 percent of scale 2 Remove four screws key 37 3 Slid...

Page 25: ...gure 4 3 Changing the Scale DEFLECT LOWER PORTION OF THE SLOT W3440 AND LIFT THE SCALE UP AND OFF W3492 Relay 1 Loosen the two captive screws that hold the relay key 50 in place 2 Tip the relay slightly toward the case to clear the output pressure gauge and lift out the relay 3 Make sure the replacement relay has three O ring assemblies as shown in figure 4 4 The fourth port is for exhaust and doe...

Page 26: ... output and process pressure piping to the controller Gauges CAUTION Before performing this procedure be sure the replacement gauges are the correct range so that 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 repl...

Page 27: ... the two screws key 6 and lift off the proportional band indicator cover key 36 figure 4 2 2 Disconnect link number 3 from the set point beam assembly key 23 Refer to figure 4 12 for location of the link 3 Remove the set point beam bias spring key 28 Refer to figure 4 5 for spring location 4 Remove the screw and washer keys 19 and 20 that hold the pivot assembly key 17 to the frame and remove the ...

Page 28: ...18 Tighten the screw and make sure the nozzle remains centered on the flapper with the set point beam assembly snugly against the relay nozzle tubing assembly 25 Install the pivot of the set point pivot assembly key 17 in the hole in the set point beam assembly key 23 26 Install the washer key 20 on the screw key 19 27 Install the screw and washer keys 19 and 20 through the frame key 3 into the se...

Page 29: ...K 3 RELAY NOZZLE TUBING ASSEMBLY SET POINT BIAS SPRING POSITIVE FEEDBACK TUBING ASSEMBLY SHOE ADJUSTMENT SCREWS PROPORTIONAL BAND ADJUSTMENT KNOB CAP E RING RETAINING CLIP PROPORTIONAL BAND ADJUSTMENT SET POINT PIVOT ASSEMBLY SET POINT BEAM ASSEMBLY SET POINT BEAM SHOE NOZZLE O RING NOZZLE TUBING ASSEMBLY CAP WITH O RING INSIDE TAB E RING RETAINING CLIP FLAPPER W3452 1 W3852 ...

Page 30: ...essure above 2 percent of set point adjust flapper leveling screw number 3 counterclockwise 38 Repeat steps 36 and 37 until the output pressure snaps within 2 percent If the tolerance cannot be obtained with the flapper leveling screw go to step 42 39 Adjust the set point manually or with remote set point pressure to 95 percent of the process scale range 40 If the output pressure is not 0 psi decr...

Page 31: ...e output pressure snaps to zero Then slowly decrease the process differential pressure until the output pressure snaps to supply pressure The output should snap to supply pressure within 2 percent of set point 50 If the output pressure snaps to supply pressure within 2 percent of set point go to step 53 If the output pressure does not snap to supply pressure within 2 percent go to step 51 51 If th...

Page 32: ...ASSEMBLY KEY 11 FLEXURE PIVOT ASSEMBLY SCREW 10 Disconnect link number 4 from the bellows bracket key 31 Refer to figure 4 12 for location of the link 11 Remove the screw key 12 with washer key 13 from the flexure pivot assembly key 9 See figure 4 8 for screw location 12 Remove the input feedback assembly as shown in figure 4 9 13 Remove the four screws key 10 shown in figure 4 9 that hold the fle...

Page 33: ...and 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 4 6 25 Position the proportional band knob nozzle pivot and set point beam assembly on the frame and install the relay nozzle tubing fitting loosely into frame manifold while positioning the nozzle in the center of the flapper as shown in figure 4...

Page 34: ...screws on link 4 and connect the link to the bellows bracket assembly allowing the link to find its free length 38 Tighten the two adjusting screws 39 If the position of the set point beam shoe key 29 was changed during this procedure perform steps 32 through 52 in the Replacing Proportional Band Knob Nozzle Pivot and Set Point Beam Assembly procedure Otherwise perform step 40 40 Install the contr...

Page 35: ...key 45 from the positive feedback bellows CAUTION When removing and replacing positive feedback bellows keep in mind that the bellows has left hand threads Overtightening could damage the threads 7 Unscrew the bellows 8 Before installing the replacement bellows coat the threads with a suitable lubricant Screw in the replacement bellows until it is finger tight against the frame key 3 9 Install the...

Page 36: ...pointer and the input feedback beam assembly key 11 link number 3 connects the set point adjustment and the set point beam assembly key 23 link number 4 key 65 connects the input feedback assembly and the bellows bracket key 31 Link number 5 key 88 figure 5 2 connects the short pivot assembly and the long pivot assembly Figure 4 12 shows the location of each link Link Number 1 1 Remove the two scr...

Page 37: ... July 2018 37 Figure 4 12 Link Location CAPSULAR ELEMENT CONTROLLERS W3753 1 LINK 5 LINK 1 LINK 4 LINK 4 ADJUSTMENT LINEARITY ADJUSTMENT SCREW LINK 2 LINK 2 ADJUSTMENT LINK 3 ADJUSTMENT LINK 3 COARSE ZERO ADJUSTMENT LINK 1 W3721 W3612 LINK 1 LOCATION ...

Page 38: ...t the process pointer as shown in figure 4 12 Connect the link to the process pointer assembly only and in the position in step 2 4 Adjust the set point manually or with the remote set point pressure to 100 percent of the process scale range Set the proportional band between DIRECT and REVERSE 5 Disconnect link number 1 from the pivot arm manually position the process pointer to 100 percent on the...

Page 39: ...crew on the link so that the edge of the proportional band knob is parallel to the set point adjustment as shown in figure 3 1 7 Refer to the Maintenance Calibration and the Flapper Alignment procedure 8 Replace the proportional band indicator cover key 36 and tighten the two screws key 6 Link Number 4 1 Remove the two screws key 6 and lift off the proportional band indicator cover key 36 2 Note w...

Page 40: ...97 3 Note where the link is connected Disconnect link 5 key 88 from the lever arm on the pivot assembly key 78 CAUTION Avoid bending or kinking the drive flexure Bending or kinking the drive flexure can result in product damage as well as impaired performance 4 Disconnect the drive flexure key 79 from the adjustment arm of the pivot assembly Take care not to bend or kink the drive flexure 5 Remove...

Page 41: ...2 set the pivot in the center of the bushing end play CAUTION Avoid bending or kinking the drive flexure Bending or kinking the drive flexure can result in product damage as well as impaired performance 6 Tighten the drive flexure to hold the pivot in position Take care not to kink or twist the flexure when tightening the screws 7 Refer to the Maintenance Calibration procedure Process Tubing 1 Rem...

Page 42: ...if directed to do so Otherwise go to the appropriate prestartup instructions in the controller operation procedures WARNING Refer to the Maintenance WARNING on page 21 Precalibration Procedures 1 Set the proportional band adjustment to 5 percent direct acting Adjust the set point to 100 percent of the process scale range 2 Remove the tie bar key 97 Aligning the Drive Bracket Assembly 1 Loosen the ...

Page 43: ...bly in the middle of its slot 4 Make certain that the process pointer and pointer subassembly are aligned see figure 4 13 Change the length of link 1 key 90 to the middle of its adjustment 5 The short bottom arm on the short pivot assembly key 89 should be parallel with the process pointer and the pointer subassembly 6 Turn the span adjustment screw on the bottom of the process pointer countercloc...

Page 44: ...arm of the short pivot assembly key 89 Adjusting the linearity affects the zero and span 1 Adjust the process differential pressure to 50 percent of input span The process pointer should indicate the 50 percent mark on the scale 2 If the pointer indicates high turn the linearity screw counterclockwise in the slot If the pointer indicates low turn the linearity screw clockwise in the slot 3 Check t...

Page 45: ... the output snaps to supply pressure 9 Repeat step 8 to recheck the adjustment of flapper leveling screw number 2 10 Adjust the proportional band adjustment to 5 percent reverse acting 11 Carefully adjust the process differential pressure to 100 percent of the process scale range Then slowly decrease the process pressure until the output pressure snaps to supply pressure the output pressure should...

Page 46: ... the screw key 122 the washer and the nut as it was before 10 Increase the remote set point pressure to 50 percent of input span 11 Connect the drive flexure to the arm on the new pivot assembly making sure it stays straight and horizontal Before tightening down the drive flexure set the pivot in the middle of the bushing end play Tighten down the drive flexure to hold the pivot in that position D...

Page 47: ...rform the Maintenance Calibration procedure 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 4 Install the replacement tubing and reconnect the two pressure connections 5 Apply full remote set point pressure and check for leaks R...

Page 48: ...s noted in step 1 4 Check the zero setting and adjust if necessary as described in the Zero and Span Adjustment procedure Link B 1 Note the holes where link B key 126 is connected see figure 5 3 Disconnect both ends of the link from the pivot arm and from the set point indicator assembly 2 Loosen the screw in the replacement link and adjust the length to match the link being replaced Tighten the s...

Page 49: ... stop key 83 to the mounting plate Slide the travel stop until it is just touching the end of the capsule stack Tighten the travel stop mounting screws to lock it into that position 3 Zero Stop Adjust remote set point pressure input to 0 psig Slide the travel stop nut key 86 along the diaphragm capsule extension key 134 until it is approximately 0 4 mm 1 64 inch away from the travel stop key 83 Ti...

Page 50: ...zero and span indications are within 1 percent of input span 8 Check the pointer position at 50 percent of full pressure input span If the error is greater than 1 percent of input span perform the Linearity Adjustment procedures Linearity Adjustment Adjust the linearity by rotating the linearity adjustment screw in the curved slot on the lever arm of pivot B key 115 Adjusting the linearity affects...

Page 51: ...askets and tubing assembly to the frame Start but do not tighten the three screws keys 34 and 131 and the nut on the relay nozzle tubing assembly key 18 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 the two screws keys 314 and 315 Do not tighten any screws CAUTION In the next step take c...

Page 52: ...sembly key 282 8 Remove the O rings keys 292 293 and 294 switch body springs key 295 and balls key 296 9 Loosen two screws key 308 and remove the closing plate key 307 and the closing plate gasket key 306 10 Pull the clip key 300 from its engagement with the lever assembly shaft key 297 11 Pull the lever assembly from the switch body assembly key 291 and rocker key 299 12 Remove the O ring key 298...

Page 53: ...ure 2 Remove the auto manual station from the controller as described in steps 1 through 4 of the Replacing the Auto Manual Station procedure 3 Remove the tubing assembly key 309 WARNING To avoid personal injury caused by preload from the range spring key 282 turn the loader knob key 287 counterclockwise opposite to the arrow to relieve pressure on the spring 4 Loosen the four screws key 289 and s...

Page 54: ...gure 5 5 for key number location 1 Perform steps 1 through 3 of the replacing case and cover procedure 2 Loosen the spring seat screw key 275 3 Remove the valve plug spring key 276 and the valve plug key 277 4 Inspect the parts and replace as necessary 5 Install the valve plug spring and valve plug 6 Tighten the spring seat screw 7 Temporarily apply supply pressure and process pressure and check f...

Page 55: ...1 292 293 294 295 298 306 312 R4190X0AM12 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 4190 Controller Relay Replacement Kit Contains Relay Assembly key 50 0 2 to 1 0 bar 3 to ...

Page 56: ...on 60 Reducing Adaptor 2 req d use only when specified 61 Process scale 62 Remote set assembly for 4194SM and SME only 0 2 to 1 0 bar 3 to 15 psig 0 4 to 2 0 bar 6 to 30 psig 64 Machine screw 4 req d 65 Feedback Link Assembly 71 Machine screw 4 req d 72 Blowout plug 80 Diaphragm Capsule Assembly for 4194SM and SME only not shown 0 2 to 1 0 bar 3 to 15 psig 0 4 to 2 0 bar 6 to 30 psig 101 Indicator...

Page 57: ... 67 Lock Washer 3 req d 68 Bracket Actuator Casing Mounting Spacer Spool 3 req d Cap Screw 3 req d Lockwasher 5 req d Mounting Bracket Cap Screw 2 req d Mounting Bracket Cap Screw 2 req d Hex Nut 2 req d Description Actuator Yoke Mounting Spacer Spool 3 req d Cap Screw 3 req d Lockwasher 5 req d Mounting Bracket Spacer Spool 2 req d Cap Screw 2 req d Note Specify quantity of fittings and length of...

Page 58: ...Instruction Manual D200158X012 4194S Controllers July 2018 58 Figure 5 1 Controller Assembly Drawing 38A3819 B 56A9752 V Sht 1 127 97 113 SECTION D D VIEW C C ...

Page 59: ... 4194S Controllers July 2018 59 Figure 5 1 Controller Assembly Drawing Continued 49A0770 A 36A3819 A SECTION B B CONTROLLERS WITH REMOTE SET POINT OPTION Figure 5 2 Capsular Element Assembly 58A0706 C VIEW A A DRIVE BRACKET ASSEMBLY ...

Page 60: ...Instruction Manual D200158X012 4194S Controllers July 2018 60 Figure 5 3 Remote Set Point Assembly Drawing 36A6988 C B1760 LINK A LINK B APPLY LUB SEALANT ...

Page 61: ...ontrollers July 2018 61 Figure 5 4 Auto Manual Station Parts Location 56A9752 D 49A0770 A C0540 FRONT VIEW SWITCHING ZONE INDICATION AUTOMATIC MANUAL SWITCH LOADER KNOB PLASTIC TUBE METAL BALL SIDE VIEW COVER REMOVED BACK VIEW COVER REMOVED ...

Page 62: ...Instruction Manual D200158X012 4194S Controllers July 2018 62 Figure 5 5 Auto Manual Station Assembly Drawing 48A2905 A Sht 2 48A2905 A Sht 1 SECTION A A SECTION B B SECTION C C ...

Page 63: ...llers July 2018 63 Figure 5 6 Process and Set Point Indicator Assembly Manual Set Point 39A1126 H 381 379 380 382 INDICATOR ASSEMBLY PROCESS SET POINT INDICATOR ASSEMBLY PROCESS SET POINT INDICATOR ASSEMBLY WITH BOURDON TUBE 36A6986 C 32B1532 A ...

Page 64: ...hich are available upon request We reserve the right to modify or improve the designs or specifications of such products at any time without notice E 1983 2018 Fisher Controls International LLC All rights reserved Fisher is a mark owned by one of the companies in the Emerson Automation Solutions business unit of Emerson Electric Co Emerson Automation Solutions Emerson and the Emerson logo are trad...

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