Page 2 - Instruction Manual
Instruction Manual D200160X012 4195K Controllers December 2012 2 Contents (continued) Auto/Manual Switching (Option E) 44 . . . . . . . . . Prestartup Checks 44 . . . . . . . . . . . . . . . . . . . . . . . . . . Startup 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibr...
Page 3 - Figure 1-1. Fisher 4195K Gauge Pressure Controllers
Instruction Manual D200160X012 4195K Controllers December 2012 3 Figure 1-1. Fisher 4195K Gauge Pressure Controllers NAMEPLATE W5663‐1 W6831 Contents (continued) 7. Parts Parts Ordering 105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Kits 105 . . . . . . . . . . . . . . . . . . . ....
Page 4 - Section 1 Introduction; Scope of Manual; To avoid personal injury or property damage, it is important to; Description; 195KA: Proportional‐only control; Specifications
Instruction Manual D200160X012 4195K Controllers December 2012 4 Section 1 Introduction Scope of Manual This instruction manual provides installation, operating, calibration, maintenance, and parts ordering information forFisher 4195KA, KB, KC, and KS gauge pressure indicating controllers. Portions ...
Page 5 - Lower and Upper Range Limits:
Instruction Manual D200160X012 4195K Controllers December 2012 5 Table 1-1. Specifications Available Configurations See table 1-2 Input Signal (Process Sensor Range) Lower and Upper Range Limits: See tables 1-3 and 1-4 Maximum Allowable Operating Limits: See tables 1-3 and 1-4 Output Signal Proporti...
Page 6 - Housing; However, the product
Instruction Manual D200160X012 4195K Controllers December 2012 6 Table 1-1. Specifications (continued) Housing Designed to NEMA 3 (Weatherproof) and IEC 529IP54 Specifications Mounting Controller can be mounted on actuator, panel, wall,or pipestand. Approximate Weight 4.5 kg (10 pounds) Declaration ...
Page 9 - Section 2 Installation; WARNING; Controller Mounting Orientation; Figure 2‐1. Typical Actuator Mounting; Pipestand Mounting
Instruction Manual D200160X012 4195K Controllers December 2012 9 Section 2 Installation WARNING To avoid personal injury or property damage resulting from the sudden release of pressure: D Always wear protective clothing, gloves, and eyewear when performing any installation operations. D Personal ...
Page 10 - Figure 2‐2. Pipestand Mounting; Panel Mounting
Instruction Manual D200160X012 4195K Controllers December 2012 10 Figure 2‐2. Pipestand Mounting 49A3196‐AA6732 HEX HEADCAP SCREW(KEY 66) LOCKWASHER(KEY 67) HEX NUT(KEY 364) LOCKWASHER(KEY 363) PIPE CLAMP(KEY 69) LOCKWASHER(KEY 363) HEX NUT(KEY 364) HEX HEADCAP SCREW(KEY 66) LOCKWASHER(KEY 67) HEX H...
Page 11 - Figure 2‐3. Panel Mounting; Wall Mounting; Figure 2‐4. Wall Mounting; Actuator Mounting
Instruction Manual D200160X012 4195K Controllers December 2012 11 Figure 2‐3. Panel Mounting HEX HEADCAP SCREW(KEY 66) LOCKWASHER(KEY 67) ROUNDHEADMACHINESCREW(KEY 70) BRACKET(KEY 68) TOP VIEW 36A9760‐AA6733 84 (3.29) 63 (2.49) 306 (12.06) 14(0.56 R) 236 (9.31) mm (INCH) 13(0.50) 62 (2.43) REAR VIEW...
Page 12 - Pressure Connections
Instruction Manual D200160X012 4195K Controllers December 2012 12 Pressure Connections WARNING To avoid personal injury or property damage resulting from the sudden release of pressure, do not install any systemcomponent where service conditions could exceed the limits given in this manual. Use pres...
Page 13 - Figure 2‐5. Connection Locations
Instruction Manual D200160X012 4195K Controllers December 2012 13 Use a suitable supply pressure regulator to reduce the supply pressure source to the normal operating supply pressureshown in table 1-6. Connect supply pressure to the SUPPLY connection on the bottom of the case, shown in figure 2‐5. ...
Page 14 - Vent
Instruction Manual D200160X012 4195K Controllers December 2012 14 Vent WARNING Personal injury or property damage could result from fire or explosion of accumulated gas, or from contact with hazardousgas, if a flammable or hazardous gas is used as the supply pressure medium. Because the controller c...
Page 15 - Section 3 4195KA Proportional‐Only Controllers; Adjustments for 4195KA Controllers; Figure 3‐1. Fisher 4195KA Controller Adjustment Locations; Manual Set Point Adjustment
Instruction Manual D200160X012 4195K Controllers December 2012 15 Section 3 4195KA Proportional‐Only Controllers Adjustments for 4195KA Controllers This section includes descriptions of adjustments and procedures for prestartup, startup, and calibration. Adjustmentlocations are shown in figures 3‐1 ...
Page 16 - Capsular Element Controllers for Vacuum Pressure; For direct control action—
Instruction Manual D200160X012 4195K Controllers December 2012 16 Remote Set Point (suffix letter M) Adjustment CAUTION Do not manually move the set point indicator on controllers with remote set point. Manually moving the set point indicatorcould damage the controller. If the controller is equipped...
Page 17 - For reverse control action—; Prestartup Checks for 4195KA Controllers; Note; Adjust the proportional band for 5 percent DIRECT.
Instruction Manual D200160X012 4195K Controllers December 2012 17 D For reverse control action— An increasing sensed vacuum decreases output pressure. After changing the action, tighten the screws on the proportional band indicator cover. Switching The Auto/Manual Station (suffix letter E) Note Sw...
Page 18 - Startup for 4195KA Controllers; Move the set point adjustment to the desired set point.; Calibration of 4195KA Controllers
Instruction Manual D200160X012 4195K Controllers December 2012 18 7. The controller output pressure should be 0 bar (0 psig).8. Rotate the proportional band to 5 percent REVERSE.9. The controller output should be within 0.14 bar (2 psig) of the supply pressure. 10. If the controller output is within...
Page 19 - Process Indicator Zero and Span Calibration; Before starting this procedure:
Instruction Manual D200160X012 4195K Controllers December 2012 19 General Calibration Instructions Note If the controller has the auto/manual station (suffix letter E), be sure the controller is in the automatic mode before performingcalibration. If the prestartup checks, or startup, reveal faulty c...
Page 23 - Principle of Operation for 4195KA Controllers; Overall Operation; Refer to the schematic diagram in figure 3‐4.
Instruction Manual D200160X012 4195K Controllers December 2012 23 12. Set the proportional band to 400 percent in the desired controller action and replace the proportional band indicator cover. Principle of Operation for 4195KA Controllers Overall Operation Refer to the schematic diagram in figure ...
Page 24 - Figure 3‐5. Fisher 4195KA Auto/Manual Station Schematic
Instruction Manual D200160X012 4195K Controllers December 2012 24 Remote Set Point (suffix letter M) Operation The capability to adjust the controller set point from a remote location is available with all 4195KA controllers. Thisoption is designated by the letter M in the type number. A control pre...
Page 25 - Adjustments for 4195KB and KC Controllers; Figure 4‐1. Fisher 4195KB and KC Controller Adjustment Locations
Instruction Manual D200160X012 4195K Controllers December 2012 25 Section 4 4195KB Proportional‐Plus‐Reset Controllers and4195KC Proportional‐Plus‐Reset‐Plus‐Rate Controllers Adjustments for 4195KB and KC Controllers This section includes descriptions of adjustments and procedures for prestartup, st...
Page 26 - To change the
Instruction Manual D200160X012 4195K Controllers December 2012 26 Remote Set Point (suffix letter M) Adjustment CAUTION Do not manually move the set point indicator on a controller with remote set point. Manually moving the set pointindicator could damage the controller. If the controller is equippe...
Page 27 - Reset Adjustment
Instruction Manual D200160X012 4195K Controllers December 2012 27 Bourdon Tube or Capsular Element Controllers for Positive or Compound Pressure D For direct control action— An increasing sensed pressure increases output pressure. D For reverse control action— An increasing sensed pressure decre...
Page 28 - Prestartup Checks for 4195KB and KC Controllers; Startup for 4195KB and KC Controllers
Instruction Manual D200160X012 4195K Controllers December 2012 28 To switch from manual to automatic mode, adjust the set point to move the ball into the switching zone. Turn theswitch to AUTO and adjust the set point to control the output. When the automatic/manual switch is in AUTO, adjusting the ...
Page 29 - Allowable Overshoot
Instruction Manual D200160X012 4195K Controllers December 2012 29 1. Be sure the supply pressure regulator is delivering the proper supply pressure to the controller. 2. For controllers with: Manual set point: Move the set point indicator to the desired set point. Remote set point: a. See figure 2‐5...
Page 30 - Calibration of 4195KB and KC Controllers; Set the proportional band between DIRECT and REVERSE.
Instruction Manual D200160X012 4195K Controllers December 2012 30 Calibration of 4195KB and KC Controllers WARNING To avoid personal injury or property damage resulting from the sudden release of pressure, do not exceed the operatinglimits given in this manual. General Calibration Instructions Note ...
Page 33 - within; Flapper Alignment
Instruction Manual D200160X012 4195K Controllers December 2012 33 10. Loosen the remote set point zero adjustment locking screw and adjust the remote set point zero adjustment screw to correct for half the error at mid scale. Tighten the zero adjustment locking screw. 11. Apply remote set point pres...
Page 34 - Set the proportional band between DIRECT and REVERSE.; Set the proportional band to 30 percent DIRECT.; left‐hand edge of the set point indicator as shown in figure 4‐4.
Instruction Manual D200160X012 4195K Controllers December 2012 34 9. Set the proportional band between DIRECT and REVERSE. 10. The controller output should be relatively stable at any value within the output range. If not, adjust flapper leveling screw 2 (the screw nearest the nozzle) until the outp...
Page 35 - feedback connection to the output connection.
Instruction Manual D200160X012 4195K Controllers December 2012 35 21. When the flapper is correctly aligned, set the proportional band to 400 percent in the desired controller action and replace the proportional band indicator cover. If link 1 was disconnected, reconnect link 1 to the input elementu...
Page 36 - Principle of Operation for 4195KB and KC Controllers
Instruction Manual D200160X012 4195K Controllers December 2012 36 differential pressure or counterclockwise to increase the differential pressure. The differential relief valve is set atthe factory to relieve at approximately 0.4 bar (5 psi) differential pressure. 13. Repeat steps 7 through 12 until...
Page 37 - Figure 4‐5. Fisher 4195KB Controller Schematic
Instruction Manual D200160X012 4195K Controllers December 2012 37 The input element is connected to the process pointer and to the flapper by connecting links. As the process pressureincreases (in a direct‐acting controller), the flapper moves toward the nozzle, restricting flow through the nozzle a...
Page 38 - Figure 4‐6. Fisher 4195KC Controller Schematic
Instruction Manual D200160X012 4195K Controllers December 2012 38 Figure 4‐6. Fisher 4195KC Controller Schematic SET POINTINDICATOR PROCESS POINTER REMOTE SET POINTCONNECTED HERE INPUT ELEMENTCONNECTED HERE CONNECTING LINK BEAM FLAPPER NOZZLE PROPORTIONALBELLOWS RESET BELLOWS PROPORTIONALBAND ADJUST...
Page 39 - the gain and returns the process pressure toward the set point.; Anti‐Reset Windup (suffix letter F) Operation
Instruction Manual D200160X012 4195K Controllers December 2012 39 A 4195KC controller also has a rate valve as shown in figures 4‐6 and 4‐7. This valve is an adjustable restriction thatmomentarily increases the controller gain to accelerate the corrective action for slow pressure systems. Aproportio...
Page 40 - Figure 4‐8. Fisher 4195KB and KC Auto/Manual Station Schematic
Instruction Manual D200160X012 4195K Controllers December 2012 40 Auto/Manual 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 theoutput side of the relay as shown in figure 4‐8. Supply pressure to the ...
Page 41 - Figure 4‐9. Schematic of External Feedback Option
Instruction Manual D200160X012 4195K Controllers December 2012 41 External Feedback Operation External feedback is available for all 4195KB controllers. Controllers with this option have an external connection onthe bottom of the controller case as shown in figure 2‐5. This connection breaks the pos...
Page 42 - Section 5 4195KS Differential Gap Controllers; Operating Information
Instruction Manual D200160X012 4195K Controllers December 2012 42 Section 5 4195KS Differential Gap Controllers Operating Information This section includes descriptions of adjustments and procedures for prestartup and startup. Location of adjustmentsis shown in figures 5‐1 and 5‐2. To better underst...
Page 43 - Adjustments for 4195KS Controllers; Manual Set Point; CAUTION
Instruction Manual D200160X012 4195K Controllers December 2012 43 Figure 5‐1. Fisher 4195KS Controller Parts and Adjustments Locations (continued) C0528‐1 SCREW 1 SCREW 3 SCREW 2 SIDE VIEW OF CONTROLLER SHOWING FLAPPER LEVELING SCREWS PROCESSSPAN ADJUSTMENT REMOTE SET POINTSPAN ADJUSTMENT SIDE VIEW ...
Page 44 - Prestartup Checks for 4195KS Controllers; between DIRECT and REVERSE.; Startup for 4195KS Controllers
Instruction Manual D200160X012 4195K Controllers December 2012 44 The white portion of the adjustment enables direct controller action; the black portion enables reverse controlleraction. Auto/Manual Switching (Option E) Refer to figure 5‐5 if the controller has the auto/manual option. Two balance m...
Page 45 - Calibration of 4195KS Controllers; Process Zero and Span Adjustment; turning the zero adjustment screw.; Remote Set Point Zero and Span Adjustment (Option M)
Instruction Manual D200160X012 4195K Controllers December 2012 45 If they are used, slowly open the upstream and downstream manual control valves in the pipeline and close themanual bypass valve. Calibration of 4195KS Controllers Note Some of the following procedures require that the proportional ba...
Page 46 - Setting Switching Points; Direct‐Acting Controllers
Instruction Manual D200160X012 4195K Controllers December 2012 46 1. Refer to figures 5‐1 and 5‐2 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 process ...
Page 47 - points by moving the position of the lower switching point.
Instruction Manual D200160X012 4195K Controllers December 2012 47 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 48 - Reverse‐Acting Controllers; Principle of Operation
Instruction Manual D200160X012 4195K Controllers December 2012 48 8. Observe the process pointer when the output switches at the upper switching point. The process pointer indication should be within " 2 percent of the set point indication. Reverse‐Acting Controllers The controller output signal...
Page 49 - Figure 5‐4. Fisher 4195KS Controller Schematic
Instruction Manual D200160X012 4195K Controllers December 2012 49 The input element is connected to the process pointer and to the flapper by connecting links. As the process pressureincreases (in a direct‐acting controller). This movement restricts the flow through the nozzle and increases nozzlepr...
Page 50 - Figure 5‐5. Fisher 4195KS Auto/Manual Schematic
Instruction Manual D200160X012 4195K Controllers December 2012 50 Remote Set Point (Option M) The capability to adjust the controller set point from a remote location is available with all 4195KS controllers. Thisoption is designated by the letter M in the type number. Auto/Manual Option Controllers...
Page 51 - Section 6 Maintenance; Inspection and Maintenance; Before performing any maintenance operations:; Troubleshooting
Instruction Manual D200160X012 4195K Controllers December 2012 51 Section 6 Maintenance Controller parts are subject to normal wear and must be inspected and replaced as necessary. The frequency ofinspection and parts replacement depends upon the severity of the service conditions. When inspection o...
Page 52 - Table 6‐1. Troubleshooting Chart
Instruction Manual D200160X012 4195K Controllers December 2012 52 Table 6‐1. Troubleshooting Chart Fault Possible Cause Check Correction 1. Process wanders or cycles aboutset point 1.1 Proportional band and resetsettings 1.1 Refer to the startup proceduresfor controller settings 1.1 If stable contro...
Page 55 - Replacing Common Controller Parts; Refer to the Maintenance WARNING on page 51.; Figure 6‐1. Changing the Scale; set point indicator and under the process pointer.
Instruction Manual D200160X012 4195K Controllers December 2012 55 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 from the controller. Vent any supply pressure...
Page 56 - is for exhaust and does not require an O‐ring.; Replacing the Case and Cover
Instruction Manual D200160X012 4195K Controllers December 2012 56 5. Secure the scale with the four self‐tapping screws (key 37).6. If the controller has remote set point (suffix letter M), perform the appropriate remote set point zero and span calibration procedure in Section 3, 4, or 5. 7. Perform...
Page 57 - Remove the external piping and fittings from the controller.; Replacing the Gauges; Screw the replacement gauge into the frame.
Instruction Manual D200160X012 4195K Controllers December 2012 57 CAUTION The case and cover are an integral unit; attempting to separate them will damage the hinge. If the cover needs to bereplaced, replace the case also. 1. Remove the external piping and fittings from the controller. 2. Remove the...
Page 58 - Install the replacement tubing assembly.; Disassembly; frame and remove the pivot assembly.
Instruction Manual D200160X012 4195K Controllers December 2012 58 Replacing the Supply Gauge, Proportional, Reset, Reset Valve, and Positive Feedback TubingAssemblies WARNING Refer to the Maintenance WARNING on page 51. 1. Remove the controller assembly from the case by performing steps 1 through 3 ...
Page 60 - Assembly; the nozzle assembly O‐ring.
Instruction Manual D200160X012 4195K Controllers December 2012 60 9. Remove the relay nozzle tubing assembly (key 18) from the set point beam assembly (key 23). 10. Remove the E‐ring (key 27) from the nozzle assembly (key 21). 11. Remove the nozzle assembly (key 21) and plastic washer (key 22) from ...
Page 61 - Figure 6‐5. Nozzle‐Flapper Positioning
Instruction Manual D200160X012 4195K Controllers December 2012 61 15. Turn the proportional band adjustment knob to 5 percent DIRECT. Refer to figure 6‐6 to locate the locking nut on the adjustable set point pivot assembly. Loosen the locking nut and back out the set screw slightly so that the setpo...
Page 63 - Mount the controller as described in the Installation section.; Remove the flapper assembly and link 4 as shown in figure 6‐9.
Instruction Manual D200160X012 4195K Controllers December 2012 63 31. Perform the controller calibration procedures and, if necessary, the appropriate remote set point calibration procedure in Section 3, 4, or 5. 32. Mount the controller as described in the Installation section. 33. Connect the exte...
Page 64 - Figure 6‐8. Leveling Screw Alignment
Instruction Manual D200160X012 4195K Controllers December 2012 64 Figure 6‐7. Bellows Assembly and Proportional Band Adjustment (Process Scale and Proportional Band Indicator Cover Removed) PROPORTIONALBELLOWS BELLOWSBRACKET(KEY 31) ADJUSTABLESET POINT PIVOTASSEMBLY (KEY 17) SCREW AND WASHER(KEYS 19...
Page 65 - Figure 6‐10. Link 2 and 4 Adjustment Locations
Instruction Manual D200160X012 4195K Controllers December 2012 65 20. Align flapper leveling screw number 2 with the centerline of the oblong hole in the frame as shown in figure 6‐8. Tighten the cap screws (key 12). Note The following procedure (steps 21 through 23) adjusts link 2 to ensure that it...
Page 66 - Figure 6‐11. Link 2 Adjustment
Instruction Manual D200160X012 4195K Controllers December 2012 66 Figure 6‐11. Link 2 Adjustment LEVELINGSCREWNUMBER 1 1/2 OF PINDIAMETER CONNECTING TAB ONFLAPPER ASSEMBLY W3451 W4191 23. Connect link 2 to the flapper assembly.24. Set the proportional band between DIRECT and REVERSE. Do this by alig...
Page 67 - Attach link 3 to the set point beam shoe as shown in figure 6‐3.; the controller output pressure.
Instruction Manual D200160X012 4195K Controllers December 2012 67 34. Attach link 3 to the set point beam shoe as shown in figure 6‐3. Note The following procedure (steps 35 through 41) adjusts link 4 so it will always be in compression to eliminate possible instabilitydue to lost motion. 35. For co...
Page 68 - Mount the controller as described in the Installation section.; Replacing the Proportional, Reset or Positive Feedback Bellows; Refer to figure 6‐12, unless otherwise noted.
Instruction Manual D200160X012 4195K Controllers December 2012 68 51. Perform the controller calibration procedures and, if necessary, the appropriate remote set point calibration procedure in Section 3, 4, or 5. 52. Mount the controller as described in the Installation section. 53. Connect the exte...
Page 69 - the rate adjustment to OFF.; Adjust the proportional band to 100 percent DIRECT.
Instruction Manual D200160X012 4195K Controllers December 2012 69 CAUTION When removing and replacing the proportional, reset, or positive feedback bellows, keep in mind that the bellows hasleft‐hand threads. Overtightening could damage the threads. Note Both bellows need not be removed if only one ...
Page 70 - Repeat steps 25 through 30 until the difference is less than; Replacing the Reset Restriction Valve (4195KB Controllers)
Instruction Manual D200160X012 4195K Controllers December 2012 70 24. Adjust the reset adjustment to 0.01 minutes per repeat. For a 4195KC controller, set the rate adjustment to OFF. 25. Increase the process pressure until the output pressure stabilizes at 0.2 bar (3 psig) for a 0.2 to 1.0 bar (3 to...
Page 71 - reset restriction valve.
Instruction Manual D200160X012 4195K Controllers December 2012 71 4. For controllers with anti‐reset windup (suffix letter F), remove the relief valve tubing assembly (key 44) from the reset restriction valve. 5. Remove the screw (key 162) that fastens the reset restriction valve to the frame. 6. In...
Page 73 - procedure in Section 4.; Bourdon Tube Controller Maintenance and Calibration; Replacing the Bourdon Tube
Instruction Manual D200160X012 4195K Controllers December 2012 73 5. Position the controller assembly in the case and start, but do not tighten the nine mounting screws. Slide the controller assembly down to assure an O‐ring seal at the pressure connections along the bottom of the case. Holdthe cont...
Page 74 - Replacing Bourdon Tube Controller Links; Link 1 connects the Bourdon tube and the process pointer; Replacing Bourdon Tube Controller Link 1
Instruction Manual D200160X012 4195K Controllers December 2012 74 Figure 6‐13. Bourdon Tube Controller LinkLocations and Adjustments COURSE ZERO ADJUSTMENT LINK 1 LINK 4 ADJUSTMENT LINK 4 LINK 2 LINK 3 LINK 3 ADJUSTMENT LINK 2 ADJUSTMENT W5745 Figure 6‐14. Disconnecting Link 1 from the BourdonTube W...
Page 75 - Figure 6‐15. Process Pointer Alignment; mid‐scale; Replacing Bourdon Tube Controller Link 2; link to the process pointer only.
Instruction Manual D200160X012 4195K Controllers December 2012 75 the bottom hole (the hole nearest the pointer pivot). If the process pointer has too much travel, move the link tothe top hole (the hole furthest from the pointer pivot). 4. Move the set point Indicator, either manually or with remote...
Page 76 - Tape the pointer in this position.; Replacing Bourdon Tube Controller Link 3; set point beam assembly as shown in figure 6‐3.
Instruction Manual D200160X012 4195K Controllers December 2012 76 6. Disconnect link 1 from the Bourdon tube and manually position the process pointer to the process scale upper limit. Tape the pointer in this position. 7. Adjust the length of link 2 (by turning the adjusting screw clockwise to incr...
Page 77 - Replacing Bourdon Tube Controller Link 4; Figure 6‐17. Position of Link 4 Adjustment Screws
Instruction Manual D200160X012 4195K Controllers December 2012 77 12. Repeat steps 8 through 11 until leveling screws 1 and 3 protrude an equal distance from the clinch nuts. 13. Perform the controller calibration procedures and, if necessary, the appropriate remote set point calibration procedure i...
Page 79 - Figure 6‐18. Bourdon Tube Controller Travel Stop Adjustment; Bourdon Tube Controller Calibration: Zero and Span Adjustment
Instruction Manual D200160X012 4195K Controllers December 2012 79 Figure 6‐18. Bourdon Tube Controller Travel Stop Adjustment LOWER TRAVEL STOPADJUSTMENT LOCK NUT LOWER TRAVEL STOP(KEY 74) LOWER TRAVEL STOP ADJUSTMENT UPPER TRAVEL STOP(KEY 73) MOUNTINGSCREW(KEY 76) MOUNTINGSCREW(KEY 76) MOUNTING SCR...
Page 80 - The process pointer should indicate mid‐scale
Instruction Manual D200160X012 4195K Controllers December 2012 80 Note Any adjustment of the process pointer span adjustment screw requires readjustment of the process pointer zero adjustmentscrew. When checking the zero and span adjustments, ensure that the Bourdon tube does not contact the optiona...
Page 82 - Capsular Element Controller Maintenance and Calibration; Replacing the Capsular Element Assembly
Instruction Manual D200160X012 4195K Controllers December 2012 82 15. Apply process pressure equal to the mid‐scale value of the process scale span. The process pointer should indicate mid‐scale ± 2 percent of the process scale span. If the process pointer error is ± 2 percent or less, proceed to st...
Page 83 - Replacing the Long Pivot Assembly; Remove process pressure from the controller.
Instruction Manual D200160X012 4195K Controllers December 2012 83 Replacing Capsular Element Parts WARNING Refer to the Maintenance WARNING on page 51. CAUTION Avoid bending or kinking the drive flexure during the following procedures. Bending or kinking the drive flexure can resultin product damage...
Page 84 - Figure 6‐20. Cutaway of Long Pivot Clevis Assembly; Replacing the Short Pivot Assembly; Replacing the Process Drive Flexure
Instruction Manual D200160X012 4195K Controllers December 2012 84 Figure 6‐20. Cutaway of Long Pivot Clevis Assembly END BUSHING BEARING SHAFT BEARING END BUSHING ADJUSTMENT ARM NOTE: 1 BEFORE TIGHTENING THE DRIVE FLEXURE MOUNTING SCREWS, POSITION THESHAFT SO THE END BUSHINGS “FLOAT” IN THE BEARINGS...
Page 85 - Replacing the Process Tubing; Replacing Capsular Element Controller Links
Instruction Manual D200160X012 4195K Controllers December 2012 85 2. Remove the tie bar (key 97) from the capsular element assembly by removing the mounting screws (key 103). 3. Using an Allen wrench, remove the cap screws and washers (keys 12 and 13) to disconnect the drive flexure (key 79) from th...
Page 86 - Replacing Capsular Element Controller Link 1; Replacing Capsular Element Controller Link 2
Instruction Manual D200160X012 4195K Controllers December 2012 86 Figure 6‐21. Capsular Element Controller Link Locations and Adjustments LINK 5 LINK 1 LINK 4 LINK 4 ADJUSTMENT LINK 3 ADJUSTMENT LINK 2 ADJUSTMENT LINEARITYADJUSTMENTSCREW LINK 2 LINK 3 W4769 Replacing Capsular Element Controller Link...
Page 87 - Connect link 2 to the flapper assembly.; Replacing Capsular Element Controller Link 3; Replacing Capsular Element Controller Link 4
Instruction Manual D200160X012 4195K Controllers December 2012 87 5. Move the set point indicator, manually or with remote set point pressure, to the process scale lower limit and set the proportional band at 5 percent REVERSE. The nozzle should not be touching the flapper. If it is, adjust flapperl...
Page 88 - Replacing Capsular Element Controller Link 5; Capsular Element Controller Maintenance Calibration
Instruction Manual D200160X012 4195K Controllers December 2012 88 The controller output must be 0 bar (0 psig). To be sure the controller output is at 0 bar (0 psig), remove supplypressure, set the reset adjustment to 0.01 minutes per repeat and wait 30 seconds; then, turn the reset adjustmentto the...
Page 89 - Precalibration Procedure; location is shown in figure 6‐22.; aligned with the center of the long pivot clevis assembly (key 78).; Setting the Capsular Element Travel Stops; For the full span stop
Instruction Manual D200160X012 4195K Controllers December 2012 89 Precalibration Procedure 1. Remove the two machine screws (key 6) and lift off the proportional band indicator cover (key 36). 2. Set the proportional band adjustment between DIRECT and REVERSE. 3. Remove the two screws (key 103) and ...
Page 90 - For the zero stop; Aligning the Capsular Element Linkage; mounting the drive flexure.
Instruction Manual D200160X012 4195K Controllers December 2012 90 capsule stack. Tighten the travel stop mounting screws to lock it into position. Decrease the input pressure to100 percent of the capsular element range and make sure the capsule stack is not contacting the travel stop (key 83). D Fo...
Page 91 - Capsular Element Controller Zero and Span Adjustment
Instruction Manual D200160X012 4195K Controllers December 2012 91 5. Loosen the screw on link 5 (key 88) and adjust the link length so that the pivot arms of the short pivot clevis assembly (key 89) and the long pivot clevis assembly (key 78) are parallel. Tighten the screw. 6. Complete the maintena...
Page 92 - Remote Set Point (suffix letter M) Maintenance; Replacing the Remote Set Point Assembly
Instruction Manual D200160X012 4195K Controllers December 2012 92 b. If the pointer indicates greater than the process scale upper limit, rotate the pointer span adjustment counterclockwise to decrease the span. Adjust the span adjustment screw to correct for one‐half of the error. 13. Repeat steps ...
Page 94 - of the pivot assembly.
Instruction Manual D200160X012 4195K Controllers December 2012 94 6. Lift out the remote set point assembly by holding the tie bar (key 106), mounting plate (key 111), travel stop (key 83), or pedestal assembly (key 105). 7. Align the replacement assembly with the mounting screw holes. Replace the m...
Page 95 - adjustment on the original pivot assembly. Tighten the screw.; Replacing the Drive Flexure
Instruction Manual D200160X012 4195K Controllers December 2012 95 10. Apply remote set point pressure equal to 50 percent of the remote set point input range. Note See figure 6‐20. The adjustment arm of the remote set point pivot assembly A turns on a bushing at each end of the shaftsupporting the a...
Page 96 - Replacing the Remote Set Point Tubing; holes noted in step 1.; Replacing Link B; point indicator in the same holes as noted in step 1.; Remote Set Point (suffix letter M) Maintenance Calibration
Instruction Manual D200160X012 4195K Controllers December 2012 96 shaft in the middle of the bushing end play. Be sure neither bushing is resting against the inside end of eitherbearing. Tighten the drive flexure screws to hold the pivot shaft in this position. Do not bend or twist the flexurewhen t...
Page 97 - the inside end of either bearing.; Setting the Travel Stops
Instruction Manual D200160X012 4195K Controllers December 2012 97 1. Remove the two screws (key 6) and lift off the proportional band indicator cover (key 36). 2. Set the proportional band adjustment between DIRECT and REVERSE. 3. Remove the two screws (key 103) and remove the tie bar (key 106) from...
Page 98 - Full span stop; Aligning the Linkage; figure 6‐23 for the linearity adjustment location.; Remote Set Point Zero and Span Adjustment; Refer to figures 6‐19 and 6‐23 for adjustment locations.
Instruction Manual D200160X012 4195K Controllers December 2012 98 CAUTION Make sure the loose travel stop nut does not bind on the diaphragm capsule extension (key 134) when pressurizing thecapsules (key 80). Damage to the capsules may result. 2. Full span stop —Adjust the remote set point pressure ...
Page 100 - position relative to the process scale upper limit.; Replacing the Auto/Manual Station; Refer to figures 7‐1 and 7‐7 for key number locations.; Remove the auto/manual station from the controller frame.
Instruction Manual D200160X012 4195K Controllers December 2012 100 3. Adjust the remote set point pressure to 100 percent of the remote set point input range and note the indicator position relative to the process scale upper limit. 4. If the greatest misalignment is positive (the set point indicato...
Page 101 - Carefully tighten the remaining screws and nuts.; Refer to figure 7‐7 for key number location.
Instruction Manual D200160X012 4195K Controllers December 2012 101 CAUTION In the next step, take care to tighten the two screws (keys 314 and 315) evenly. Uneven tightening could damage thetubing assembly. 3. Position the auto/manual station as far down on the frame and toward the scale as possible...
Page 102 - flats on the lever assembly shaft.
Instruction Manual D200160X012 4195K Controllers December 2012 102 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), and remove the closing plate (key 307) and the closing plate gasket (key 306). 9. Pull the clip (key ...
Page 103 - Refer to figure 7‐7 for key number locations.; eliminate loading the range spring.; Replacing the Loader Valve Plug and Valve Plug Spring
Instruction Manual D200160X012 4195K Controllers December 2012 103 Refer to figure 7‐7 for key number locations. Disassembly 1. Remove the auto/manual station from the controller as described in steps 1 through 4 of the replacing the auto/manual station procedure. 2. Remove the tubing assembly (key ...
Page 105 - Section 7 Parts; Parts Ordering; Parts Kits; Parts List; Abbreviations Used In Parts List
Instruction Manual D200160X012 4195K Controllers December 2012 105 Section 7 Parts Parts Ordering 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...
Page 107 - Key 46* Pressure Gauge
Instruction Manual D200160X012 4195K Controllers December 2012 107 Key Description Part Number Note One type of pressure gauge is used for both output pressure and supplypressure indication. 46* Pressure gauge (2 req'd) See Key 46 table 48* Bellows ass'y (2 req'd) Brass 16A6953X012 SST 16A6953X022...
Page 109 - Figure 7‐1. Controller Assembly Drawings
Instruction Manual D200160X012 4195K Controllers December 2012 109 Figure 7‐1. Controller Assembly Drawings SECTION D‐D SEE VIEW H SEE VIEW G B B SEE VIEW L C C D D K K SEE VIEW M SEE VIEW E SECTION B‐B VIEW C‐C 4195KA CONTROLLERS APPLY LUB/ SEALANT 56A9752‐U SHT 1 and 2 VIEW C‐C 4195KS CONTROLLERS
Page 114 - With capsular element assembly
Instruction Manual D200160X012 4195K Controllers December 2012 114 Figure 7‐2. Process and Set Point Indicator Assembly for Bourdon Tube Controllers 32B1532‐A Process and Set Point Indicator Assembly(key 56) (figures 7‐2 and 7‐3) Key Description With capsular element assembly 101 Indicator ass'y Not...
Page 115 - With Bourdon tube
Instruction Manual D200160X012 4195K Controllers December 2012 115 Figure 7‐3. Process and Set Point Indicator Assembly for Capsular Element Controllers (Positive and CompoundPressure Shown) 36A6986‐C Key Description With Bourdon tube 101 Indicator ass'y Note Individual ass'y parts for key 101 are l...
Page 116 - Key 383* Bourdon Tubes; Figure 7‐4. Indicator Assembly
Instruction Manual D200160X012 4195K Controllers December 2012 116 Key 383* Bourdon Tubes BAR RANGE PSIG RANGE PART NUMBER S31600 (316 SST) Bourdon Tube 0 to 1.6 or 0 to 20 to 4 or 0 to 2.50 to 60 to 10 0 to 300 to 600 to 1000 to 200 32B4589X01232B4589X02232B4589X03232B4589X042 0 to 160 to 40 or 0 t...
Page 117 - Key 61 Process Scale, Positive Pressure
Instruction Manual D200160X012 4195K Controllers December 2012 117 Key 61 Process Scale, Positive Pressure Scale Range Part Number Bar Scales 0 to 150 mbar0 to 400 mbar0 to 0.60 to 1 1R0003X15621R0003X04221R0003X04021R0003X0432 0.2 to 10 to 1.40 to 1.60 to 20.4 to 2 1R0003X16021R0003X16121R0003X0442...
Page 119 - Figure 7‐5. Capsular Element Assembly
Instruction Manual D200160X012 4195K Controllers December 2012 119 Figure 7‐5. Capsular Element Assembly VIEW A‐A VIEW A‐A VIEW A‐A VIEW A‐A 58A0708‐E 58A0710‐C POSITIVE AND COMPOUND PRESSURE VACUUM Remote Set Point Assembly (suffix letter M)(key 62) (figure 7‐6) Key Description 12 Cap screw, hex so...
Page 120 - Figure 7‐6. Remote Set Point Assembly
Instruction Manual D200160X012 4195K Controllers December 2012 120 Figure 7‐6. Remote Set Point Assembly APPLY LUB / SEALANT 36A6988‐C Key Description 86 Travel stop nut, S30300 (303 SST) 87 Set screw, hex socket, 18-8 SST 93 Union, S31600 (316 SST) 99 Plain washer, 18-8 SST 102 Machine screw, fill ...
Page 122 - Controller Mounting Parts
Instruction Manual D200160X012 4195K Controllers December 2012 122 Key Description Part Number 298* O‐ring, nitrile 1E222606992 299 Rocker, A96061 (aluminum) 300 Clip, SST 301 Lever spring seat, SST 302 Lever spring, K08500 (pl steel) 303* Groove pin, SST 16A6380X012 304 Switch lever, polycarbonate/...
Page 123 - Fittings
Instruction Manual D200160X012 4195K Controllers December 2012 123 Regulator Mounting Parts Description Regulator Mounting Parts forCasing‐Mounted Regulator Cap screw, hex hd, pl steel (2 req'd)Lock washer, pl steel (2 req'd)Cap screw, hex hd, pl steel (2 req'd)Hex nut, pl steel (2 req'd)Mounting br...
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