Fisher 4194A Series Instruction Manual Download Page 1

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D200154X012

Fisher, Fisher-Rosemount, and Managing The Process Better are marks owned by Fisher
Controls International, Inc. or Fisher-Rosemount Systems, Inc.
All other marks are the property of their respective owners.

4194A, B, and C Series Differential Pressure
Controllers

Contents

1. Introduction

Scope of Manual

1–3

. . . . . . . . . . . . . . . . . . . . . . . . . .

Description

1–3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications

1–3

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Installation

Controller Mounting Orientation

2–1

. . . . . . . . . . . . .

Pipestand Mounting

2–1

. . . . . . . . . . . . . . . . . . . . . . .

Panel Mounting

2–1

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Wall Mounting

2–1

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Actuator Mounting

2–1

. . . . . . . . . . . . . . . . . . . . . . . .

Pressure Connections

2–1

. . . . . . . . . . . . . . . . . . . . .

Process Pressure Connections

2–1

. . . . . . . . . . . .

Supply Pressure Connection

2–3

. . . . . . . . . . . . . .

Remote Set Point (suffix letter M)

Pressure Connection

2–3

. . . . . . . . . . . . . . . . . . .

Vent

2–3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. 4194A Series Proportional-Only Con-
trollers

Adjustments for 4194A Series Controllers

3–1

. . . .

Manual Set Point Adjustment

3–1

. . . . . . . . . . . . . .

Remote Set Point (suffix letter M)

Adjustment

3–1

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Proportional Band Adjustment (PB ADJ)

3–1

. . . .

Changing Controller Action

3–2

. . . . . . . . . . . . . . . .

Switching the Auto/Manual Station

(suffix letter E)

3–2

. . . . . . . . . . . . . . . . . . . . . . . .

Prestartup Checks for 4194A Series

Controllers

3–2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Startup for 4194A Series Controllers

3–3

. . . . . . . . .

Calibration of 4194A Series Controllers

3–3

. . . . . .

General Calibration Instructions

3–3

. . . . . . . . . . . .

Process Indicator Zero and Span

Calibration

3–3

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Set Point (suffix letter M)

Zero and Span Calibration

3–4

. . . . . . . . . . . . . .

Flapper Alignment

3–6

. . . . . . . . . . . . . . . . . . . . . . .

Principle of Operation for 4194A Series

Controller

3–6

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overall Operation

3–6

. . . . . . . . . . . . . . . . . . . . . . . .

Remote Set Point (suffix letter M)

Operation

3–7

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auto/Manual Station (suffix letter E)

Operation

3–7

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. 4194B Series Proportional-Plus-Reset
Controllers and 4194C Series Propor-
tional-Plus-Reset-Plus-Rate Controllers

Adjustments for 4194B and C Series

Controllers

4–1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Set Point Adjustment

4–1

. . . . . . . . . . . . . .

Remote Set Point (suffix letter M)

Adjustment

4–1

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Proportional Band Adjustment (PB ADJ)

4–2

. . . .

Changing Controller Action

4–2

. . . . . . . . . . . . . . . .

Reset Adjustment

4–2

. . . . . . . . . . . . . . . . . . . . . . . .

Rate Adjustment

4–2

. . . . . . . . . . . . . . . . . . . . . . . . .

Anti-Reset Windup (suffix letter F)

Adjustment

4–2

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Switching The Auto/Manual Station

(suffix letter E)

4–2

. . . . . . . . . . . . . . . . . . . . . . . .

Prestartup Checks for 4194B and C Series

Controllers

4–3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Startup for 4194B and C Series Controllers

4–3

. . .

Calibration of 4194B and C Series Controllers

4–4

General Calibration Instructions

4–4

. . . . . . . . . . . .

Process Indicator Zero and Span

Calibration

4–4

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Set Point (suffix letter M)

Zero and Span Calibration

4–6

. . . . . . . . . . . . . .

Flapper Alignment

4–6

. . . . . . . . . . . . . . . . . . . . . . .

Anti-Reset Windup Differential Relief Valve

(suffix letter F) Calibration

4–8

. . . . . . . . . . . . . .

Principle of Operation for 4194B and C Series

Controllers

4–9

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overall Operation

4–9

. . . . . . . . . . . . . . . . . . . . . . . .

Anti-Reset Windup (suffix letter F)

Operation

4–10

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Set Point (suffix letter M)

Operation

4–11

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Auto/Manual Station (suffix letter E)

Operation

4–11

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Instruction Manual

Form 5196

November 1995

4194A, B, and C Series

Summary of Contents for 4194A Series

Page 1: ...Remote Set Point suffix letter M Zero and Span Calibration 3 4 Flapper Alignment 3 6 Principle of Operation for 4194A Series Controller 3 6 Overall Operation 3 6 Remote Set Point suffix letter M Oper...

Page 2: ...sembly Parts 5 26 Replacing Pivot Assembly A key 114 5 26 Replacing Pivot Assembly B key 115 5 27 Replacing the Drive Flexure 5 27 Replacing the Remote Set Point Tubing 5 28 Replacing Link A 5 28 Repl...

Page 3: ...ber Only personnel qualified through training or experience should install operate and maintain this controller If there are any questions concerning these instructions contact your Fisher Controls sa...

Page 4: ...from 100 to less than 0 0135 repeats per min Rate 1 Adjustable from 0 to 20 minutes Set Point Adjustable from 0 to 100 of the scale range Controller Performance Repeatability 1 0 4 of output span Dead...

Page 5: ...g 7 5 psig 15 0 psig 30 0 psig 45 0 psig Ni Span C Metric Units 0 to 350 mbar 0 to 0 7 bar 0 to 1 4 bar 0 to 2 0 bar 175 mbar 0 4 bar 0 7 bar 1 0 bar 350 mbar 0 7 bar 1 4 bar 2 0 bar 350 mbar 0 7 bar...

Page 6: ...4194A B and C Series 1 6...

Page 7: ...on 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 washer...

Page 8: ...located such that the adjacent pro cess pressure lines are approximately horizontal the Figure 2 4 Wall Mounting 36A9761 B A6734 IL lines should slope downward to the instrument for liq uid filled li...

Page 9: ...g 0 2 to 1 0 bar remote set point pressure range for a 3 to 15 psig 0 2 to 1 0 bar controller output signal range or a 6 to 30 psig 0 4 to 2 0 bar remote set point pressure range for a 6 to 30 psig 0...

Page 10: ...he entrance of any foreign material that could plug it or if a remote vent is not required the vent opening in the case must be protected against the entrance of any foreign material that could plug i...

Page 11: ...sired value on the process differential pressure scale Move the indicator to the right to increase the set point and to the left to decrease it Adjusting the set point does not affect the proportional...

Page 12: ...e 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...

Page 13: ...ment 200 Allowable Overshoot Pressure Span For example 200 2 Psig 30 Psig 13 4 Create a load upset by momentarily changing the set point Check for system cycling If the system does not cycle lower the...

Page 14: ...f the process scale span 14 If the error is greater than 1 percent repeat steps 3 through 13 Remote Set Point suffix letter M Zero and Span Calibration Refer to figures 3 1 and 3 3 for adjustment loca...

Page 15: ...SCREW 2 SCREW 3 SIDE VIEW OF SET POINT PROCESS INDICATOR ASSEMBLY SIDE VIEW OF CONTROLLER SHOWING FLAPPER LEVELING SCREWS 56A9752 S SHT 1 39A1126 B A6730 IL POINTER ZERO ADJUSTMENT POINTER ZERO ADJUST...

Page 16: ...ar or 18 0 5 psig 1 2 0 04 bar If not ad just flapper leveling screw 3 the screw nearest the nozzle 8 Set the proportional band to 30 percent REVERSE 9 The controller output should be 9 0 25 psig 0 62...

Page 17: ...anual Station suffix letter E Operation A controller with the auto manual station designated by the suffix letter E in the type number has piping on the output side of the relay as shown in figure 3 5...

Page 18: ...SSURE TO FINAL CONTROL ELEMENT SUPPLY PRESSURE RELAY AUTO MANUAL SWITCH MANUAL LOADER MANUAL LOADER KNOB MANUAL POSITION AUTO MANUAL SWITCH OUTPUT PRESSURE TO FINAL CONTROL ELEMENT PLASTIC TUBE METAL...

Page 19: ...ndicator until the line on the set point indicator is over the de sired value on the process differential pressure scale Move the indicator to the right to increase the set point and to the left to de...

Page 20: ...counter clockwise to increase the minutes more rate action Anti Reset Windup suffix letter F Adjustment If the arrow on the differential relief valve points toward the bottom of the controller case a...

Page 21: ...rtional band to 400 percent in the desired action Secure the proportional band indicator cover key 36 with the machine screws key 6 and go to the startup procedure If the controller output pressure is...

Page 22: ...libration described in this section These instructions are valid for either shop or field calibration provided that open process loop conditions exist Unless otherwise noted key numbers are found in f...

Page 23: ...ING FLAPPER LEVELING SCREWS 39A1126 B A6731 IL 59A9752 S SHT 1 RATE ADJUSTMENT RESET ADJUSTMENT W3599 1 IL 4194C SERIES POINTER ZERO ADJUSTMENT FRONT VIEW 4194B SERIES W6392 IL POINTER ZERO ADJUSTMENT...

Page 24: ...n dication 7 Repeat steps 3 through 6 until the error is elimi nated 8 Adjust the remote set point pressure to the mid range value 9 Make sure the set point indicator is within 1 per cent of the mid s...

Page 25: ...e controller output should be relatively stable at any value within the output range If not adjust flapper lev eling screw 3 the screw nearest the nozzle until the output is relatively stable 11 Set t...

Page 26: ...ntrol ler Do not exceed the normal operating pressure in table 1 4 Note Because of the high controller gain with the reset adjustment at 0 01 minutes per repeat the controller output will not bal ance...

Page 27: ...roller output pressure recorded in step 10 12 If the differential pressure calculated in step 11 is incorrect for the application adjust the differential pressure by turning the differential relief va...

Page 28: ...se in output pressure A 4194C Series controller also has a rate valve as shown in figures 4 6 and 4 7 This valve is an adjust able restriction that momentarily increases the control ler gain to accele...

Page 29: ...VALVE termined value Anti reset windup reduces overshoot of the process differential pressure that can result from large or prolonged deviation from set point Remote Set Point suffix letter M Operati...

Page 30: ...he MANUAL posi tion the manual loader output is channeled through the auto manual switch and becomes the controller output When the auto manual switch is in the AUTO position the relay output is chann...

Page 31: ...OUTPUT PRESSURE TO FINAL CONTROL ELEMENT SUPPLY PRESSURE RELAY AUTO MANUAL SWITCH MANUAL LOADER MANUAL LOADER KNOB MANUAL POSITION AUTO MANUAL SWITCH OUTPUT PRESSURE TO FINAL CONTROL ELEMENT PLASTIC...

Page 32: ...4194A B and C Series 4 14...

Page 33: ...eristics specified by Fisher Controls use only replacement parts manufactured or furnished by Fisher Controls Select the appropriate maintenance procedure and perform the numbered steps Shut off suppl...

Page 34: ...mum 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 react...

Page 35: ...he output varies and no leaks were found in the rest of the feedback system see Step 2 6 the reset valve is leaking 4 2 Replace the reset valve 4194B Series or the rate reset valve 4194C Series 4 3 Tu...

Page 36: ...put should go to 0 psig 7 6 Perform the flapper alignment procedures in section 3 or 4 8 Controller remains at zero output 8 1 Gauge not functioning 8 1 Verify that the supply pressure is at its corre...

Page 37: ...SED O RINGS RELAY MOUNTING SCREWS W5744 IL 6 Perform the appropriate Flapper Alignment proce dure in section 3 or 4 Replacing the Case and Cover CAUTION The case and cover are an integral unit attempt...

Page 38: ...1 Remove the controller assembly from the case by performing steps 1 through 3 of the case and cover replacement procedures 2 Unscrew the nuts at each end of the tubing assem bly Remove the tubing ass...

Page 39: ...MENT KNOB SET POINT BEAM BIAS SPRING SHOE ADJUSTMENT SCREWS SET POINT BEAM ASSEMBLY SET POINT BEAM SHOE LINK 3 RELAY NOZZLE TUBING ASSEMBLY W4194 IL W4193 IL 7 While holding the proportional band adju...

Page 40: ...knob shown in figure 5 4 make sure the pro portional band adjustment knob engages the flats on the nozzle assembly 20 While holding the nozzle assembly key 21 against the set point beam assembly key 2...

Page 41: ...le capped and check for leaks Remove supply pressure 32 Install the set point beam bias spring key 28 into the frame bore and onto the spring seat on the set point beam assembly 33 Attach link 3 to th...

Page 42: ...ing key 28 refer to figure 5 3 for the spring location 5 Remove the screw and washer keys 19 and 20 that hold the adjustable set point pivot assembly key 17 to the frame 6 Remove the adjustable set po...

Page 43: ...Set the proportional band between DIRECT and REVERSE Do this by aligning the tab on the propor tional band adjustment knob with the hole in the set point beam assembly as shown in figure 5 4 FOUR SCR...

Page 44: ...set point beam assembly as shown in figure 5 3 34 Attach link 3 to the set point beam shoe as shown in figure 5 3 Note The following procedure steps 35 through 41 adjusts link 4 so it will al ways be...

Page 45: ...pro cess scale upper limit 49 Remove the tape from the process pointer and reconnect link 1 to the input element Be sure to re connect the link to the same hole noted in step 21 50 Position the contr...

Page 46: ...t is aligned such that it does not rub on the frame at any point and tight en the screws key 6 and 35 15 Install the proportional or reset tubing assembly on the bellows base 16 For a 4194B or C Serie...

Page 47: ...old the controller assembly in place while tightening the nine mounting screws 35 Perform the controller calibration procedures and if necessary the appropriate remote set point calibra tion procedure...

Page 48: ...proce dure in section 4 19 Mount the controller as described in the Installa tion section 20 Connect external piping to the controller Replacing the Anti Reset Windup suffix letter F Differential Rel...

Page 49: ...screw and adjust the process pointer zero adjustment to align the pro cess pointer and pointer subassembly Tighten the zero adjustment locking screw 6 Apply process differential pressure equal to the...

Page 50: ...ure 5 3 6 Move the set point indicator to the mid scale mark on the process scale 7 Apply process differential pressure to position the process pointer at the mid scale mark on the process scale 8 Adj...

Page 51: ...t side of the scale 8 Apply the correct supply pressure to the controller The output of the controller should be within 2 psig 0 14 bar of supply pressure If not adjust flapper lev eling screw 1 the s...

Page 52: ...ex wrenches 4 Remove the four mounting screws key 127 that attach the capsular element assembly to the indicator assembly key 101 CAUTION In the following step do not lift out the capsular element ass...

Page 53: ...and if necessary per form the appropriate remote set point calibration procedure in section 3 or 4 Replacing the Short Pivot Assembly Refer to figure 5 23 for capsular element key number locations 1 R...

Page 54: ...98 that holds the guide flexure to the tab on the mounting plate key 77 The guide flexure location is shown in figure 5 17 3 Apply process differential pressure equal to 75 per cent of the capsular el...

Page 55: ...ontroller output or connect it to a gauge Monitoring the controller output is not nec essary However the flapper should not contact the nozzle at any time while performing this procedure If it does ad...

Page 56: ...EMBLY SIDE VIEW OF CONTROLLER SHOWING FLAPPER LEVELING SCREWS 39A1126 B A6731 IL 59A9752 S SHT 1 NOTES AVAILABLE ON 4194B SERIES ONLY AVAILABLE ON 4194B AND C SERIES SUFFIX LETTER F ONLY POINTER ZERO...

Page 57: ...value of the process scale span The pro cess pointer should indicate mid scale 2 percent of the scale span If the process pointer error is 2 per cent or less proceed to step 17 If the process pointer...

Page 58: ...ing screws 8 Reconnect the remote set point pressure connec tion union key 93 Apply full remote set point pres sure and check for leaks 9 Connect link B key 126 to the connecting hole on the set point...

Page 59: ...he screws 12 Decrease the remote set point pressure to 0 psig 13 Connect the end of link A key 116 to the pivot lever arm in the same holes noted in step 3 14 Replace the tie bar key 106 15 Perform th...

Page 60: ...and adjust the length to match the link being replaced Tighten the screw 3 Refer to figure 5 20 for the correct orientation of link B Attach replacement link B to the pivot arm and to the set point in...

Page 61: ...vis assembly B key 115 See figure 5 20 for the linearity adjustment location 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 pe...

Page 62: ...nge and note the indi cator position relative to the process scale upper limit 4 If the greatest misalignment is positive the set point indicator is to the right of the process scale lim its loosen th...

Page 63: ...oosen the two screws key 290 and separate the switch body assembly key 291 from the loader as sembly key 282 7 Remove the O rings keys 292 293 and 294 switch body springs key 295 and balls key 296 8 L...

Page 64: ...tube key 278 and the ball seats key 280 between the ears of the loader assemblies keys 282 and 274 position the dia phragm assembly key 281 between the main halves of the loader assemblies Note The tu...

Page 65: ...N B B 38A3819 B DOC 56A9752 S SHT 1 DOC SECTION D D VIEW C C 4194A SERIES CONTROLLERS WITH REMOTE SET POINT SUFFIX LETTER M NOTE KEY 4 GASKET IS USED BETWEEN INTERNAL FRAME AND FRAME MANIFOLD KEY 5 GA...

Page 66: ...embly Drawings cont d 56A9752 S SHT 2 DOC VIEW E 4194B SERIES VIEW C C 4194B SERIES VIEW C C 4194B SERIES WITH ANTI RESET WINDUP SUFFIX LETTER F VIEW E SERIES WITH ANTI RESET WINDUP SUFFIX LETTER F VI...

Page 67: ...Controller Assembly Drawings cont d 56A9752 S DOC VIEW E 4194C SERIES VIEW C C 4194C SERIES VIEW C C 4194C SERIES WITH ANTI RESET WINDUP SUFFIX LETTER F VIEW E 4194C SERIES WITH ANTI RESET WINDUP SUFF...

Page 68: ...and C Series 5 36 Figure 5 21 Controller Assembly Drawings cont d 56A9752 S DOC CONTROLLERS WITH AUTO MANUAL STATION SUFFIX LETTER E SECTION B B 4194A SERIES SECTION B B 4194B SERIES SECTION B B 4194C...

Page 69: ...4194A B and C Series 5 37 Figure 5 22 Process and Set Point Indicator Assembly 36A6985 C DOC...

Page 70: ...4194A B and C Series 5 38 Figure5 23 Capsular Element Assembly 58A0706 C DOC...

Page 71: ...4194A B and C Series 5 39 Figure 5 24 Indicator Assembly 39A1126 H DOC Figure 5 25 Type 83U Relay A A j APPLY LUB 32B0257 A DOC...

Page 72: ...4194A B and C Series 5 40 Figure 5 26 Remote Set Point Assembly Drawing j APPLY LUB SEALANT 36A6988 C DOC...

Page 73: ...4194A B and C Series 5 41 Figure5 27 Auto Manual Station Assembly Drawing j APPLY LUB SEALANT 48A2905 A SHT 1 DOC 48A2905 A SHT 2 DOC...

Page 74: ...4194A B and C Series 5 42 Figure 5 28 Internal and External Set Point Option 56A9752 S DOC j APPLY LUB ADHESIVE...

Page 75: ...ntroller Figure 5 21 continues over several pages Be sure to check all pages of Figure 5 21 to find the key numbers This figure is in cluded in the Maintenance section of this manual 1 Case and cover...

Page 76: ...and CFME only Copper Brass 18A0763 X012 SST 18A0763 X022 Note One type of pressure gauge is used for both output pressure and supply pres sure indication See Key 46 47 table for part numbers Key Descr...

Page 77: ...s y suffix letter M to base plate of indicator ass y key 56 101 1J8415 X0012 131 Machine screw fill hd S30400 304 SST 2 req d to attach rate reset manifold key 136 to frame manifold key 135 1C10153504...

Page 78: ...300 303 SST 16A9799 X012 87 Set screw S18800 18 8 SST 1J8406 X0012 88 Connecting link ass y aluminum bronze brass 10B8448 X012 Key Description Part Number 89 Short pivot clevis ass y plastic SST 16A97...

Page 79: ...r A92011 aluminum 18A0702 X012 126 Connecting link ass y aluminum bronze brass 18A0676 X012 Key Description Part Number 134 Diaphragm ass y extension A92011 aluminum 18A1739 X012 139 Machine screw fil...

Page 80: ...3 Lock washer pl steel 2 req d 1C225728982 364 Hex nut A563 pl steel 2 req d 1A3527 24122 365 Tubing fittings 2 req d See fittings subsection Key Description Part Number Panel Mounting figure 2 3 66 C...

Page 81: ...ing or yoke mounted controller with regulator Connector brass 2 req d 1B8856 18992 Elbow brass 2 req d 1B8846 18992 Fittings for 3 8 inch copper tubing pipestand mounted controller with regulator Elbo...

Page 82: ...4194A B and C Series 6 8 For information contact Fisher Controls Marshalltown Iowa 50158 USA Cernay 68700 France Sao Paulo 05424 Brazil Singapore 0512 Printed in U S A...

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