Page 2 - Instruction Manual; Section 1; Scope of Manual
Instruction Manual D200158X012 4194S Controllers December 2011 2 Contents (cont'd) Link Number 3 39 . . . . . . . . . . . . . . . . . . . . . . . . . Link Number 4 39 . . . . . . . . . . . . . . . . . . . . . . . . . Link Number 5 40 . . . . . . . . . . . . . . . . . . . . . . . . . Long Pivot Assem...
Page 3 - Table 1‐1. Specifications
Instruction Manual D200158X012 4194S Controllers December 2011 3 Table 1‐1. Specifications Available Configurations See table 1‐2 Sensing Element Range (Input Signal) Lower and Upper Range Limits: As shown in table 1‐3 Maximum Allowable Pressure: As shown in table 1‐3 Process Scale Matched to the ra...
Page 4 - Table 1‐2. Available Configurations for Fisher 4194S Controllers; Table 1‐4. Supply Pressure Data
Instruction Manual D200158X012 4194S Controllers December 2011 4 Table 1‐2. Available Configurations for Fisher 4194S Controllers CONTROLLER (1) OPTIONS Internal Auto/Manual Station, Option E Remote Set Point, Option M 4194S 4194SE 4194SM 4194SME X X XX 1. Reverse‐acting constructions are designated...
Page 5 - Specifications; WARNING; Specifications for 4194S controllers are listed in table 1‐1.; Educational Services
Instruction Manual D200158X012 4194S Controllers December 2011 5 Specifications WARNING This product is intended for a specific current range, temperature range and other application specifications. Applyingdifferent current, temperature and other service conditions could result in malfunction of th...
Page 7 - Section 2 Installation; Actuator Mounting
Instruction Manual D200158X012 4194S Controllers December 2011 7 Section 2 Installation 22‐2‐ The controllers should be mounted with the housing vertical (as shown in figure 2‐1) so that the vent points down. WARNING To avoid personal injury or property damage from sudden release of process pressure...
Page 8 - Figure 2‐1. Typical Actuator Mounting; Figure 2‐3. Wall Mounting; Figure 2‐4. Pipestand Mounting
Instruction Manual D200158X012 4194S Controllers December 2011 8 Figure 2‐1. Typical Actuator Mounting MOUNTINGBRACKET W5661 SPACERSPOOLS CAP SCREWS ANDLOCKWASHERS Figure 2‐2. Panel Mounting REAR VIEW TOP VIEW DIMENSIONS OF PANEL CUTOUT mm (INCH) 36A9780‐AA2757‐4 308 (12.06) 14(0.56)R 236 (9.31) Fig...
Page 9 - Pressure Connections; Figure 2‐5. Location of Connections; Process Pressure
Instruction Manual D200158X012 4194S Controllers December 2011 9 Pressure Connections WARNING Overpressuring any system component, including the capsular sensing element, could result in personal injury or propertydamage due to fire and explosion caused by venting or leakage of a hazardous supply pr...
Page 10 - Supply Pressure; Vent
Instruction Manual D200158X012 4194S Controllers December 2011 10 Supply Pressure WARNING Severe personal injury or property damage may occur if the instrument air supply is not clean, dry and oil‐free, ornoncorrosive gas. While use and regular maintenance of a filter that removes particles larger t...
Page 11 - Section 3; Operating Information; Adjustments; Manual Set Point; CAUTION; Changing Controller Action
Instruction Manual D200158X012 4194S Controllers December 2011 11 Section 3 Controller Operation 33‐3‐ Operating Information This section includes descriptions of adjustments and procedures for prostrate and startup procedures. Location ofadjustments are shown in figures 3‐1 and 3‐2. To better under...
Page 12 - Prestartup Checks; Note; Figure 3‐1. Location of Controller Parts and Adjustments
Instruction Manual D200158X012 4194S Controllers December 2011 12 When the automatic/manual switch is in AUTOMATIC, adjusting the loader knob has no effect on the controlleroutput. When the automatic/manual switch is in MANUAL, changing the set point adjustment has no effect on thecontroller output....
Page 13 - between DIRECT and REVERSE.; Startup
Instruction Manual D200158X012 4194S Controllers December 2011 13 Figure 3‐1. Location of Controller Parts and Adjustments (continued) C0541 35A7374‐B 49A0771‐A PROCESS SPANADJUSTMENT REMOTE SET POINTSPAN ADJUSTMENT SCREW 1 SCREW 3 SCREW 2 SIDE VIEW OF SET POINT/PROCESS INDICATOR ASSEMBLY SIDE VIEW ...
Page 14 - Calibration; Process Zero and Span Adjustment; turning the zero adjustment screw.; Remote Set Point Zero and Span Adjustment (Option M)
Instruction Manual D200158X012 4194S Controllers December 2011 14 Calibration WARNING To avoid personal injury or property damage resulting from the sudden release of pressure, do not exceed the operatinglimits given in this manual. If the prestartup checks revealed faulty adjustment of the process ...
Page 15 - and turning the zero adjustment screw.; Setting Switching Points; Direct‐Acting Controllers
Instruction Manual D200158X012 4194S Controllers December 2011 15 1. Refer to figures 3‐1 and 3‐2 for location of adjustments.2. Remove the two screws (key 6) and lift off the proportional band indicator cover (key 36).3. Set the proportional band between DIRECT and REVERSE.4. Adjust the set point p...
Page 16 - Figure 3‐3. Curve for Determining Proportional Band Setting
Instruction Manual D200158X012 4194S Controllers December 2011 16 The controller output signal will not return to zero pressure until decreasing process pressure passes the lowerswitching point. When making adjustments as described in the following steps, keep in mind that: D Changing the set point...
Page 17 - Reverse‐Acting Controllers; Principle of Operation; Overall Operation
Instruction Manual D200158X012 4194S Controllers December 2011 17 6. Narrow the proportional band slowly until the output signal switches from zero pressure to full supply pressure.7. Repeat steps 4 through 6 until the controller output switches at the desired points.8. Observe the process pointer w...
Page 18 - Figure 3‐4. Schematic of Operation for Fisher 4195S Controllers
Instruction Manual D200158X012 4194S Controllers December 2011 18 Figure 3‐4. Schematic of Operation for Fisher 4195S Controllers SET POINTINDICATOR PROCESS POINTER REMOTE SET POINTCONNECTED HEREINPUT ELEMENTCONNECTED HERE CONNECTING LINK FLAPPER NOZZLE PROPORTIONALBELLOWS(VENTED) POSITIVE FEEDBACKB...
Page 19 - Figure 3‐5. Schematic of Auto/Manual Option
Instruction Manual D200158X012 4194S Controllers December 2011 19 Remote Set Point Option The capability to adjust the controller set point from a remote location is available with all 4194S controllers. Thisoption is designated by the letter M in the type number. Auto/Manual Option Controllers with...
Page 21 - Section 4; Shut off the supply pressure to the controller.
Instruction Manual D200158X012 4194S Controllers December 2011 21 Section 4 Maintenance 44‐4‐ Parts are subject to normal wear and must be inspected and replaced as necessary. The frequency of inspection andparts replacement depends upon the severity of the service conditions. When inspection or rep...
Page 22 - Figure 4‐1. Maintenance Guide; Troubleshooting
Instruction Manual D200158X012 4194S Controllers December 2011 22 Figure 4‐1. Maintenance Guide Troubleshooting If the controller is not operating properly, refer to thetroubleshooting chart (table 4‐1). Then use the appropriate portions of the Maintenance section. Replacing Controller Parts Procedu...
Page 23 - Table 4‐1. Troubleshooting Chart; Lift the proportional band indicator cover as shown in figure 4‐2.
Instruction Manual D200158X012 4194S Controllers December 2011 23 Table 4‐1. Troubleshooting Chart Fault Possible Cause Check Correction 1. Output does not snap whenprocess pointer and set pointindicator are aligned. 1.1 Flapper out of alignment 1.1 Refer to Flapper Alignmentprocedures 1.1 Align fla...
Page 24 - Figure 4‐2. Changing Controller Action; Replacing Common Controller Parts
Instruction Manual D200158X012 4194S Controllers December 2011 24 Figure 4‐2. Changing Controller Action W3439 Replacing Common Controller Parts WARNING To avoid personal injury or property damage caused by the uncontrolled release of pressure, be sure any trapped processpressure is properly vented ...
Page 25 - set point adjustment and under the process indicator.; Relay; and does not require an O‐ring.
Instruction Manual D200158X012 4194S Controllers December 2011 25 4. To install the replacement scale, bend the lower part of the slot slightly so that the scale slides downward over the set point adjustment and under the process indicator. 5. Install and tighten the four screws on the scale. 6. A s...
Page 27 - Install the replacement tubing assemblies.; Proportional Band Knob, Nozzle Pivot, and Set Point Beam Assembly
Instruction Manual D200158X012 4194S Controllers December 2011 27 Supply Tubing and Positive Feedback Tubing Assemblies Note The following procedure requires that the controller be removed from the case. Perform steps 1 through 3 of the replacing caseand cover procedure. 1. Remove the nuts that hold...
Page 28 - lubricant to the O‐ring.
Instruction Manual D200158X012 4194S Controllers December 2011 28 15. Install the proportional band knob (key 25) on the set point beam assembly (key 23). 16. Install the retaining clip (key 26) on the three posts on the proportional band knob. 17. Install the nozzle assembly (key 21) through the se...
Page 30 - Figure 4‐7. Nozzle‐Flapper Positioning
Instruction Manual D200158X012 4194S Controllers December 2011 30 W3761 TAB HOLE Figure 4‐6. Proportional Band Adjustment Knob Setting Figure 4‐7. Nozzle‐Flapper Positioning FLAPPER NOZZLE W3449 35. For direct acting controllers, adjust the proportional band knob to 5 percent direct acting. Adjust t...
Page 32 - for location of the link.
Instruction Manual D200158X012 4194S Controllers December 2011 32 1. Remove the two screws (key 6), and lift off the proportional band cover (key 36). 2. Disconnect link number 3 from the set point beam assembly (key 23). Refer to figure 4‐12 for link location. 3. Remove the set point beam bias spri...
Page 33 - Figure 4‐9. Exploded View of Flexure Pivot Assembly
Instruction Manual D200158X012 4194S Controllers December 2011 33 Figure 4‐9. Exploded View of Flexure Pivot Assembly FOUR SCREWS(KEY 10) FLEXURE PIVOTASSEMBLY W3453 INPUT FEEDBACKBEAM ASSEMBLY 16. Move the flexure pivot assembly toward the relay as far as possible, and tighten the four screws (key ...
Page 34 - Figure 4‐10. Link 2 Number Adjustment; Positive Feedback Bellows
Instruction Manual D200158X012 4194S Controllers December 2011 34 Figure 4‐10. Link 2 Number Adjustment W3451 W3476 31. Install the pivot of the set point pivot assembly (key 17) in the hole in the set point beam.32. Install washer (key 20) on screw (key 19).33. Install the set point beam bias sprin...
Page 35 - Figure 4‐11. Cutaway View of Bellows Assembly
Instruction Manual D200158X012 4194S Controllers December 2011 35 1. Remove the two screws (key 6), and lift off the proportional band indicator cover (key 36). 2. Disconnect link 4 (key 65) from the bellows bracket (key 31). 3. Remove the screw (key 34), spring (key 33) and bellows adjustment brack...
Page 36 - Refer to the Flapper Alignment procedures.; Links; Link Number 1; proportional band between DIRECT and REVERSE.
Instruction Manual D200158X012 4194S Controllers December 2011 36 12. Apply the correct supply pressure, and check for leaks. Remove the supply pressure. If the length of link 4 (key 65) was not changed, proceed with step 14. 13. If the length of link 4 (key 65) was changed during this procedure, re...
Page 37 - Figure 4‐12. Link Location
Instruction Manual D200158X012 4194S Controllers December 2011 37 Figure 4‐12. Link Location CAPSULAR ELEMENT CONTROLLERS W3753‐1 LINK 5 LINK 1 LINK 4 LINK 4 ADJUSTMENT LINEARITYADJUSTMENTSCREW LINK 2 LINK 2ADJUSTMENT LINK 3ADJUSTMENT LINK 3 COARSE ZERO ADJUSTMENT LINK 1 W3721 W3612 LINK 1 LOCATION
Page 38 - Figure 4‐13. Process Pointer Alignment; Link Number 2; the proportional band between DIRECT and REVERSE.
Instruction Manual D200158X012 4194S Controllers December 2011 38 Figure 4‐13. Process Pointer Alignment ALIGNED W3443‐1 MISALIGNED W3475‐1 FINE ZEROADJUSTMENT ZERO ADJUSTMENTLOCKING SCREW Link Number 2 Note Link number 2 is made of aluminum for temperature compensation purposes. Do not replace it w...
Page 39 - Connect link number 1 to the pivot arm.; Link Number 4; Figure 4‐14. Link Number 3 Adjustment
Instruction Manual D200158X012 4194S Controllers December 2011 39 8. Connect link number 1 to the pivot arm. 9. Refer to the Maintenance Calibration and Flapper Alignment procedures. 10. Replace the proportional band indicator cover (key 36), and tighten two screws (key 6). Link Number 3 1. Remove t...
Page 40 - Link Number 5; Long Pivot Assembly
Instruction Manual D200158X012 4194S Controllers December 2011 40 4. Adjust the process differential pressure to 0 psid. Adjust the proportional band to 5 percent direct acting, and move the set point manually or with the remote set point pressure to 100 percent of process scale range. Controllerout...
Page 41 - Refer to the Maintenance Calibration procedure.; Process Tubing; Refer to figure 5‐2 for key number location.
Instruction Manual D200158X012 4194S Controllers December 2011 41 2. Disconnect links 1 and 5 (keys 88 and 90) from the pivot assembly (key 89). Note which holes they connect to. Remove the two screws (key 102) attaching the pivot assembly to the mounting plate (key 77), and remove thepivot assembly...
Page 42 - Reconnect the process pressure connections.; Maintenance Calibration; Refer to the Maintenance WARNING on page 21.; Precalibration Procedures
Instruction Manual D200158X012 4194S Controllers December 2011 42 5. Lift out the capsular element assembly by holding the plate (key 77), travel stop (key 83), or pedestal (key 81). 6. Align the replacement capsular element assembly over the mounting screw holes. Install and tighten the mounting sc...
Page 44 - Flapper Alignment
Instruction Manual D200158X012 4194S Controllers December 2011 44 a. Turn the span adjustment screw clockwise. (Adjust the span to correct one‐half the error). b. To increase the span further than the adjustment will allow, move both ends of link 5 (key 88) down one set of holes. Refer to figure 4‐1...
Page 47 - Drive Flexure; Tubing
Instruction Manual D200158X012 4194S Controllers December 2011 47 8. Refer to the Maintenance Calibration procedure. Drive Flexure 1. Disconnect the flexure (key 79) from the drive bracket (key 121) and from the adjustment arm of pivot assembly A. Remove the screws and washer (key 12 and 13); remove...
Page 48 - Refer to the Maintenance Calibration procedure.; Link A; arms on the two pivots.; Link B; arm and from the set point indicator assembly.; Precalibration Procedure
Instruction Manual D200158X012 4194S Controllers December 2011 48 5. Lift out the capsular element assembly by holding the plate (key 111), travel stop (key 83), or pedestal assembly (key 105). 6. Align the replacement assembly with the mounting screw holes. Replace the mounting screws. 7. Reconnect...
Page 49 - Setting the Travel Stops; Aligning the Linkage
Instruction Manual D200158X012 4194S Controllers December 2011 49 3. Apply 50 percent of full span remote set point pressure. 4. The drive flexure (key 79) should be straight. If not, proceed as follows: a. Loosen the screw on the adjustment arm on pivot assembly A (key 114) and the screws holding t...
Page 50 - Linearity Adjustment
Instruction Manual D200158X012 4194S Controllers December 2011 50 3. Make fine zero adjustments by loosening the zero adjustment locking screw and turning the zero adjustment screw (key 108). Tighten the locking screw. Refer to figure 5‐3 for location of the screws. 4. Apply 100 percent of the remot...
Page 51 - Refer to figures 4‐19, 5‐4, and 5‐5 for key number locations.; Disassembly; Refer to figure 5‐5 for key number location.
Instruction Manual D200158X012 4194S Controllers December 2011 51 Replacing the Auto/Manual Station Refer to figures 4‐19, 5‐4, and 5‐5 for key number locations. Note This procedure also permits replacement of the switch manifold O‐rings (key 312), the auto/manual tubing assembly (key 138),and the f...
Page 52 - Assembly; flats on the lever assembly shaft.
Instruction Manual D200158X012 4194S Controllers December 2011 52 Disassembly 1. Perform steps 1 through 3 of the replacing case and cover procedure.2. Remove the auto/manual station from the controller frame as described in steps 1 through 4 of the Replacing the Auto/Manual Station procedure. 3. Lo...
Page 53 - eliminate loading the range spring.
Instruction Manual D200158X012 4194S Controllers December 2011 53 5. Compress the switch body springs with the loader assembly (key 282), and bolt the switch (key 291) to the loader assembly with the two screws (key 290). 6. Reconnect the tubing assembly (key 309). 7. Locate the lever spring (key 30...
Page 54 - Replacing the Loader Valve Plug and Valve Plug Spring
Instruction Manual D200158X012 4194S Controllers December 2011 54 4. Bolt the loader assembly halves together using the four screws (key 289). Note Be sure that the supply and exhaust seats of the loader are correctly aligned. Misalignment will impair loader performance. 5. Attach the tubing assembl...
Page 55 - Section 5; Parts Kits
Instruction Manual D200158X012 4194S Controllers December 2011 55 Section 5 Parts Ordering 5 Whenever corresponding with your Emerson Process Management sales office about this equipment, always mentionthe controller serial number. When ordering replacement parts, refer to the 11‐character part numb...
Page 57 - Mounting Parts
Instruction Manual D200158X012 4194S Controllers December 2011 57 Mounting Parts Key Description Pipestand Mounting 66 Cap Screw, pl steel (3 req'd) 67 Lock Washer, pl steel (7 req'd) 68 Bracket, pl steel 69 Clamp, pl steel (2 req'd) Panel Mounting 66 Cap Screw, pl steel (3 req'd) 67 Lock Washer, pl...
Page 58 - Figure 5‐1. Controller Assembly Drawing
Instruction Manual D200158X012 4194S Controllers December 2011 58 Figure 5‐1. Controller Assembly Drawing 38A3819‐B 56A9752‐V Sht 1 127 97 113 SECTION D‐D VIEW C‐C
Page 59 - Figure 5‐2. Capsular Element Assembly
Instruction Manual D200158X012 4194S Controllers December 2011 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 - Figure 5‐3. Remote Set Point Assembly Drawing
Instruction Manual D200158X012 4194S Controllers December 2011 60 Figure 5‐3. Remote Set Point Assembly Drawing 36A6988‐CB1760 LINK A LINK B
Page 61 - Figure 5‐4. Auto/Manual Station Parts Location
Instruction Manual D200158X012 4194S Controllers December 2011 61 Figure 5‐4. Auto/Manual Station Parts Location 56A9752‐D49A0770‐AC0540 FRONT VIEW SWITCHINGZONE INDICATION AUTOMATIC/MANUAL SWITCH LOADER KNOB PLASTIC TUBE METAL BALL SIDE VIEW (COVER REMOVED) BACK VIEW (COVER REMOVED)
Page 62 - Figure 5‐5. Auto/Manual Station Assembly Drawing
Instruction Manual D200158X012 4194S Controllers December 2011 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
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