Page 1: Table Of Contents
Instruction Manual 4195K Controllers D200160X012 July 2018 Fisher 4195KA, KB, KC, and KS Gauge Pressure ™ Controllers Contents 4. 4195KB Proportional‐Plus‐Reset Controllers and 4195KC 1. Introduction Proportional‐Plus‐Reset‐Plus‐Rate Controllers Scope of Manual ......Adjustments for 4195KB and KC Controllers .
Page 2 Instruction Manual 4195K Controllers July 2018 D200160X012 Contents (continued) Capsular Element Controller Maintenance and Calibration ......Auto/Manual Switching (Option E) .
Page 3 Instruction Manual 4195K Controllers D200160X012 July 2018 Figure 1‐1. Fisher 4195K Gauge Pressure Controllers NAMEPLATE W5663‐1 W6831 Contents (continued) Panel Mounting ..... . Wall Mounting .
Page 4: Fisher ™ 4195Ka, Kb, Kc, And Ks Gauge Pressure
Scope of Manual This instruction manual provides installation, operating, calibration, maintenance, and parts ordering information for Fisher 4195KA, KB, KC, and KS gauge pressure indicating controllers. Portions of this manual apply only to specific 4195K controller configurations. These configurations are indicated by letter suffixes in the type number that correspond to the mode and option designated in table 1‐2.
Page 5 Instruction Manual 4195K Controllers D200160X012 July 2018 Table 1‐1. Specifications Available Configurations Per ISO 8573-1 Maximum particle density size: Class 7 See table 1‐2 Oil content: Class 3 Pressure Dew Point: Class 3 or at least 10_C less than Input Signal (Process Sensor Range) the lowest ambient temperature expected Lower and Upper Range Limits: See tables 1‐3 and 1‐4 Maximum Allowable Operating Limits: See tables 1‐3...
Page 6 4. Without auto/manual station. With auto/manual station add 0.01 m /hr (0.5 scfh) for either output range. 5. Also use these temperatures for transportation and storage limits. Table 1‐2. Available Configurations for Fisher 4195KA, 4195KB, 4195KC, and 4195KS Controllers MODES OPTIONS Proportional‐...
Page 7 Instruction Manual 4195K Controllers D200160X012 July 2018 Table 1‐3. Process Sensor (Capsular Element) Pressure Ratings SPAN OPERATING RANGE CAPSULE CAPSULAR OPERATING MATERIAL STANDARD RANGES LIMIT 0 to 150 mbar 100 mbar 160 mbar -350 mbar 350 mbar 510 mbar 0 to 400 mbar 350 mbar 700 mbar -1 bar...
Page 8 Instruction Manual 4195K Controllers July 2018 D200160X012 Table 1‐4. Process Sensor (Bourdon Tube) Pressure Ratings and Materials SPAN OPERATING RANGE OPERATING STANDARD BOURDON TUBES LIMITS MATERIAL Minimum Maximum Minimum Maximum 0 to 1.6 0 to 2.5 0 to 4 0 to 6 0 to 10 0 to 16 Metric units...
Page 9: Installation
Instruction Manual 4195K Controllers D200160X012 July 2018 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 injury or property damage may result from fire or explosion if natural gas is used as the supply medium and preventive measures are not taken.
Page 10: Pipestand Mounting
Instruction Manual 4195K Controllers July 2018 D200160X012 Pipestand Mounting Refer to figure 2‐2. Pipestand mounting parts are provided to mount the controller to a 2‐inch (nominal) pipe. Attach a bracket (key 68) to the controller with cap screws (key 66) and lock washers (key 67). Attach two clamps (key 69) to the bracket and fasten the controller to the pipe.
Page 11: Wall Mounting
Instruction Manual 4195K Controllers D200160X012 July 2018 Figure 2‐3. Panel Mounting HEX HEAD CAP SCREW (0.50) (KEY 66) BRACKET (2.43) (KEY 68) ROUND (3.29) HEAD MACHINE (12.06) LOCK (2.49) SCREW WASHER (KEY 70) (KEY 67) (0.56 R) TOP VIEW (9.31) REAR VIEW DIMENSIONS OF (INCH)
Page 12: Pressure Connections
While use and regular maintenance of a filter that removes particles larger than 40 micrometers in diameter will suffice in most applications, check with an Emerson Automation Solutions field office and industry instrument air quality standards for use with corrosive gas or if you are unsure about the proper amount or method of air...
Page 13: Remote Set Point (Suffix Letter M) Pressure Connection
Instruction Manual 4195K Controllers D200160X012 July 2018 Supply pressure medium must be clean, dry, and noncorrosive and meet the requirements of ISA Standard 7.0.01 or ISO 8573-1. A maximum 40 micrometer particle size in the air system is acceptable. Further filtration down to 5 micrometer particle size is recommended.
Page 14: Vent
Instruction Manual 4195K Controllers July 2018 D200160X012 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 when the assembly is enclosed, a remote vent line, adequate ventilation, and necessary safety measures should be used to prevent the accumulation of flammable or hazardous gas.
Page 15: 5Ka Proportional-Only Controllers
Principle of Operation section and the schematic diagrams in figures 3‐4 and 3‐5. Unless otherwise noted, key numbers given in this section are found in figure 7‐1. Figure 3‐1. Fisher 4195KA Controller Adjustment Locations METAL BALL SWITCHING...
Page 16: Remote Set Point (Suffix Letter M) Adjustment
Setting the proportional band to the values in the white portion of the adjustment provides direct controller action; setting proportional band in the black portion provides reverse controller action. Figure 3‐2. Changing Controller Action on Fisher 4195KA Controllers W3439 Bourdon Tube or Capsular Element Controllers for Positive or Compound Pressure D For direct control action—An increasing sensed pressure increases output pressure.
Page 17: Switching The Auto/Manual Station (Suffix Letter E)
Instruction Manual 4195K Controllers D200160X012 July 2018 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 Switching the controller between automatic and manual, or manual and automatic mode, without balancing the outputs, can disturb the process and cause controller cycling.
Page 18: Startup For 4195Ka Controllers
Instruction Manual 4195K Controllers July 2018 D200160X012 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.
Page 19: General Calibration Instructions
Instruction Manual 4195K Controllers D200160X012 July 2018 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 performing calibration. If the prestartup checks, or startup, reveal faulty controller operation, perform the calibration described in this section. These instructions are valid for either shop or field calibration, provided that open process loop conditions exist.
Page 20 Instruction Manual 4195K Controllers July 2018 D200160X012 Figure 3‐3. Fisher 4195KA Controller Calibration Adjustment Locations POINTER ZERO ADJUSTMENT POINTER ZERO ADJUSTMENT LOCKING SCREW REMOTE SET POINT ZERO ADJUSTMENT (SUFFIX LETTER M) W6832 REMOTE SET POINT PROCESS POINTER ZERO ADJUSTMENT SPAN ADJUSTMENT...
Page 21: Remote Set Point (Suffix Letter M) Zero And Span Calibration
Instruction Manual 4195K Controllers D200160X012 July 2018 1. Remove the two screws (key 6) and lift off the proportional band indicator cover (key 36). 2. Set the proportional band between DIRECT and REVERSE. 3. Apply process pressure equal to the process scale span lower limit. 4.
Page 22: Flapper Alignment
Instruction Manual 4195K Controllers July 2018 D200160X012 9. Make sure the set point indicator is within ±1 percent of the mid‐scale mark and if so, proceed to step 12. If the set point indicator is not within 1 percent, but is within ±2 percent of the mid‐scale mark, then proceed with step 10. If the set point indicator is not within ±2 percent, proceed to the remote set point calibration procedure in the Maintenance section.
Page 23: Principle Of Operation For 4195Ka Controllers
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 3‐4. Figure 3‐4. Fisher 4195KA Controller Schematic SET POINT INDICATOR RESET BELLOWS (VENTED) REVERSE ACTION QUADRANT...
Page 24: Remote Set Point (Suffix Letter M) Operation
Output pressure from the relay registers on the other side of the plastic tube as well as in the auto/manual switch. Figure 3‐5. Fisher 4195KA Auto/Manual Station Schematic MANUAL LOADER AUTOMATIC...
Page 25: 5Kb Proportional-Plus-Reset Controllers And 4195Kc Proportional-Plus-Reset-Plus-Rate Controllers
Instruction Manual 4195K Controllers D200160X012 July 2018 Section 4 4195KB Proportional‐Plus‐Reset Controllers and 4195KC Proportional‐Plus‐Reset‐Plus‐Rate Controllers Adjustments for 4195KB and KC Controllers This section includes descriptions of adjustments and procedures for prestartup, startup, and calibration. Adjustment locations are shown in figures 4‐1 and 4‐3. To better understand the adjustments and overall controller operation, refer to the Principle of Operation section and to the schematic diagrams in figures 4‐5 through 4‐9.
Page 26: Remote Set Point (Suffix Letter M) Adjustment
Instruction Manual 4195K Controllers July 2018 D200160X012 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 point indicator could damage the controller. If the controller is equipped with remote set point (suffix letter M), vary the remote set point pressure to change the set point.
Page 27: Reset Adjustment
Instruction Manual 4195K Controllers D200160X012 July 2018 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 decreases output pressure. Capsular Element Controllers for Vacuum Pressure D For direct control action—...
Page 28: Prestartup Checks For 4195Kb And Kc Controllers
Instruction Manual 4195K Controllers July 2018 D200160X012 To switch from manual to automatic mode, adjust the set point to move the ball into the switching zone. Turn the switch to AUTO and adjust the set point to control the output. When the automatic/manual switch is in AUTO, adjusting the loader knob has no effect on the controller output.
Page 29 Instruction Manual 4195K Controllers D200160X012 July 2018 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.
Page 30: Calibration Of 4195Kb And Kc Controllers
Instruction Manual 4195K Controllers July 2018 D200160X012 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 operating limits given in this manual. 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 performing calibration.
Page 31 Instruction Manual 4195K Controllers D200160X012 July 2018 Figure 4‐3. Fisher 4195KB and KC Controller Calibration Adjustment Locations POINTER ZERO ADJUSTMENT POINTER ZERO ADJUSTMENT LOCKING SCREW PROCESS POINTER SPAN ADJUSTMENT ANTI‐RESET WINDUP RELIEF VALVE (SUFFIX LETTER F) ANTI‐RESET WINDUP VALVE ADJUSTING SCREW (SUFFIX LETTER F) REMOTE SET POINT REMOTE SET POINT...
Page 32: Remote Set Point (Suffix Letter M) Zero And Span Calibration
Instruction Manual 4195K Controllers July 2018 D200160X012 4. The process pointer should indicate the process scale lower limit. If not, adjust the process pointer to the process scale lower limit by loosening the zero adjustment locking screw and turning the zero adjustment screw. Tighten the zero adjustment locking screw.
Page 33: Flapper Alignment
Instruction Manual 4195K Controllers D200160X012 July 2018 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.
Page 34 Instruction Manual 4195K Controllers July 2018 D200160X012 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 output is relatively stable. 11.
Page 35: Anti-Reset Windup (Suffix Letter F) Differential Relief Valve Calibration
Instruction Manual 4195K Controllers D200160X012 July 2018 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 element using the same hole noted in step 8.
Page 36: Principle Of Operation For 4195Kb And Kc Controllers
Instruction Manual 4195K Controllers July 2018 D200160X012 differential pressure or counterclockwise to increase the differential pressure. The differential relief valve is set at the factory to relieve at approximately 0.4 bar (5 psi) differential pressure. 13. Repeat steps 7 through 12 until the required differential pressure is obtained. Calibration for the differential relief valve to relieve on falling controller output pressure 1.
Page 37 Instruction Manual 4195K Controllers D200160X012 July 2018 The input element is connected to the process pointer and to the flapper by connecting links. As the process pressure increases (in a direct‐acting controller), the flapper moves toward the nozzle, restricting flow through the nozzle and increasing nozzle pressure.
Page 38 Instruction Manual 4195K Controllers July 2018 D200160X012 Figure 4‐6. Fisher 4195KC Controller Schematic SET POINT REVERSE ACTION RESET BELLOWS INDICATOR QUADRANT PROPORTIONAL BELLOWS PROPORTIONAL BAND ADJUSTMENT FEEDBACK PROCESS POINTER LINK REMOTE SET POINT CONNECTED HERE FEEDBACK FLAPPER INPUT ELEMENT MOTION PIVOT CONNECTED HERE DIRECT ACTION...
Page 39: Anti-Reset Windup (Suffix Letter F) Operation
Instruction Manual 4195K Controllers D200160X012 July 2018 A 4195KC controller also has a rate valve as shown in figures 4‐6 and 4‐7. This valve is an adjustable restriction that momentarily increases the controller gain to accelerate the corrective action for slow pressure systems. A proportional‐plus‐reset‐plus‐rate controller responds to a change in process pressure as follows: D First, the rate action delays the proportional action just long enough to allow the controller to respond to the change quickly with high gain, but not long enough for the high gain to cause instability.
Page 40: Auto/Manual Station (Suffix Letter E) Operation
Instruction Manual 4195K Controllers July 2018 D200160X012 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 the output side of the relay as shown in figure 4‐8. Supply pressure to the relay is also applied to the manual loader. The manual loader, functioning as a regulator, applies pressure to one side of the plastic tube and to the auto/manual switch.
Page 41: External Feedback Operation
Instruction Manual 4195K Controllers D200160X012 July 2018 External Feedback Operation External feedback is available for all 4195KB controllers. Controllers with this option have an external connection on the bottom of the controller case as shown in figure 2‐5. This connection breaks the positive feedback (reset) loop inside the controller and brings it outside as shown in figure 4‐9.
Page 42: Operating Information
Instruction Manual 4195K Controllers July 2018 D200160X012 Section 5 4195KS Differential Gap Controllers Operating Information This section includes descriptions of adjustments and procedures for prestartup and startup. Location of adjustments is shown in figures 5‐1 and 5‐2. To better understand the adjustments and overall operation of the controller, refer to the Principle of Operation section and the schematic diagrams, figures 5‐4 and 5‐5.
Page 43: Manual Set Point
Instruction Manual 4195K Controllers D200160X012 July 2018 Figure 5‐1. Fisher 4195KS Controller Parts and Adjustments Locations (continued) SCREW 1 SCREW 2 SCREW 3 PROCESS SPAN ADJUSTMENT REMOTE SET POINT SPAN ADJUSTMENT SIDE VIEW OF SET POINT/PROCESS INDICATOR ASSEMBLY SIDE VIEW OF CONTROLLER SHOWING FLAPPER LEVELING SCREWS C0528‐1 Adjustments for 4195KS Controllers...
Page 44: Auto/Manual Switching (Option E)
Instruction Manual 4195K Controllers July 2018 D200160X012 The white portion of the adjustment enables direct controller action; the black portion enables reverse controller action. Auto/Manual Switching (Option E) Refer to figure 5‐5 if the controller has the auto/manual option. Two balance methods are available to equalize the manual output with the controller pressure.
Page 45: Calibration
Instruction Manual 4195K Controllers D200160X012 July 2018 If they are used, slowly open the upstream and downstream manual control valves in the pipeline and close the manual bypass valve. Calibration of 4195KS Controllers Note Some of the following procedures require that the proportional band knob be adjusted to between DIRECT and REVERSE. If this is done, it will be necessary to set the proportional band knob to 400 (direct or reverse action) before replacing the proportional band indicator cover.
Page 46: Setting Switching Points
Instruction Manual 4195K Controllers July 2018 D200160X012 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.
Page 47 Instruction Manual 4195K Controllers D200160X012 July 2018 The controller output signal will not return to zero pressure until decreasing process pressure passes the lower switching point. When making adjustments as described in the following steps, keep in mind that: D Changing the set point adjustment will move both switching points equally in the direction of adjustment. D Changing the proportional band adjustment will widen or narrow the differential gap between the two switching points by moving the position of the lower switching point.
Page 48: Reverse-Acting Controllers
Instruction Manual 4195K Controllers July 2018 D200160X012 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 will switch from zero pressure to full supply pressure when decreasing process pressure passes the lower switching point.
Page 49 Instruction Manual 4195K Controllers D200160X012 July 2018 The input element is connected to the process pointer and to the flapper by connecting links. As the process pressure increases (in a direct‐acting controller). This movement restricts the flow through the nozzle and increases nozzle pressure.
Page 50: Remote Set Point (Option M)
Instruction Manual 4195K Controllers July 2018 D200160X012 Remote Set Point (Option M) The capability to adjust the controller set point from a remote location is available with all 4195KS controllers. This option is designated by the letter M in the type number. Auto/Manual Option Controllers with the auto/manual option (designated by the letter E in the type number) have piping on the output side of the relay as shown in figure 5‐5.
Page 51: Maintenance
Instruction Manual 4195K Controllers D200160X012 July 2018 Section 6 Maintenance Controller parts are subject to normal wear and must be inspected and replaced as necessary. The frequency of inspection and parts replacement depends upon the severity of the service conditions. When inspection or repairs are required, disassemble only those parts necessary to accomplish the job.
Page 52 Instruction Manual 4195K Controllers July 2018 D200160X012 Table 6‐1. Troubleshooting Chart Fault Possible Cause Check Correction 1. Process wanders or cycles about 1.1 Proportional band and reset 1.1 Refer to the startup procedures 1.1 If stable control cannot be set point attained, and all other elements of settings for controller settings the loop are functionally correct,...
Page 53 Instruction Manual 4195K Controllers D200160X012 July 2018 Table 6‐1. Troubleshooting Chart Fault Possible Cause Check Correction 2. Controlling off set point as 2.7 Reset valve leaks 2.7 Hold the input constant and 2.7 Replace the reset valve (4195KB reflected by process and set point adjust the output to 1.0 bar (15 psig) controllers) or the rate/reset valve indicators.
Page 54 Instruction Manual 4195K Controllers July 2018 D200160X012 Table 6‐1. Troubleshooting Chart Fault Possible Cause Check Correction 6. Controller will not attain full 6.5 Nozzle pressure leak 6.5 Check for nozzle tubing leaks 6.5 Tighten the relay nozzle tubing output range (continued) with a water bottle and soap nut (key 18).
Page 55: Replacing Common Controller Parts
Instruction Manual 4195K Controllers D200160X012 July 2018 Replacing Common Controller Parts WARNING To avoid personal injury or property damage caused by the uncontrolled release of pressure, be sure any trapped process pressure is properly vented from the controller. Vent any supply pressure from the controller before disassembly. Replacing the Process Pressure Scale WARNING Refer to the Maintenance WARNING on page 51.
Page 56: Replacing The Relay
Instruction Manual 4195K Controllers July 2018 D200160X012 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.
Page 57: Replacing The Gauges
Instruction Manual 4195K Controllers D200160X012 July 2018 CAUTION The case and cover are an integral unit; attempting to separate them will damage the hinge. If the cover needs to be replaced, replace the case also. 1. Remove the external piping and fittings from the controller. 2.
Page 58: Replacing The Supply Gauge, Proportional
Instruction Manual 4195K Controllers July 2018 D200160X012 Replacing the Supply Gauge, Proportional, Reset, Reset Valve, and Positive Feedback Tubing Assemblies WARNING Refer to the Maintenance WARNING on page 51. 1. Remove the controller assembly from the case by performing steps 1 through 3 of the case and cover replacement procedure.
Page 59 Instruction Manual 4195K Controllers D200160X012 July 2018 Figure 6‐3. Proportional Band Adjustment and Set Point Beam Details RELAY NOZZLE TUBING WASHER PLASTIC ASSEMBLY (KEY 20) WASHER (KEY 18) SCREW (KEY 19) E‐RING (KEY 27) RETAINING CLIP (KEY 26) O‐RING PROPORTIONAL BAND ADJUSTMENT ADJUSTABLE (KEY 25)
Page 60 Instruction Manual 4195K Controllers July 2018 D200160X012 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 the bottom of the set point beam assembly (key 23).
Page 61 Instruction Manual 4195K Controllers D200160X012 July 2018 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 set point beam assembly falls under its own weight when pivoted upward.
Page 62 Instruction Manual 4195K Controllers July 2018 D200160X012 16. At the frame manifold (key 135), tighten the nut that secures the tubing from the relay nozzle tubing assembly (key 18). Apply full supply pressure with the nozzle capped and check for leaks. Remove supply pressure. 17.
Page 63: Replacing The Flapper Assembly And Flapper Flexure Pivot Assembly
Instruction Manual 4195K Controllers D200160X012 July 2018 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 external piping to the controller. Replacing the Flapper Assembly and Flapper Flexure Pivot Assembly WARNING Refer to the Maintenance WARNING on page 51.
Page 64 Instruction Manual 4195K Controllers July 2018 D200160X012 Figure 6‐7. Bellows Assembly and Proportional Band Adjustment (Process Scale and Proportional Band Indicator Cover Removed) PROPORTIONAL BELLOWS BELLOWS BRACKET (KEY 31) ADJUSTABLE SET POINT PIVOT ASSEMBLY (KEY 17) SCREW AND WASHER (KEYS 19 AND 20) LINK 4 LINK 2 W4199...
Page 65 Instruction Manual 4195K Controllers D200160X012 July 2018 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 will always be in tension to eliminate possible instability due to lost motion.
Page 66 Instruction Manual 4195K Controllers July 2018 D200160X012 Figure 6‐11. Link 2 Adjustment LEVELING SCREW NUMBER 1 CONNECTING TAB ON FLAPPER ASSEMBLY 1/2 OF PIN W4191 DIAMETER W3451 23. Connect link 2 to the flapper assembly. 24. Set the proportional band between DIRECT and REVERSE. Do this by aligning the tab on the proportional band adjustment knob with the hole in the set point beam assembly as shown in figure 6‐4.
Page 67 Instruction Manual 4195K Controllers D200160X012 July 2018 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 instability due to lost motion.
Page 68: Bellows
Instruction Manual 4195K Controllers July 2018 D200160X012 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 external piping to the controller. Replacing the Proportional, Reset or Positive Feedback Bellows WARNING Refer to the Maintenance WARNING on page 51.
Page 69 Instruction Manual 4195K Controllers D200160X012 July 2018 CAUTION When removing and replacing the proportional, reset, or positive feedback bellows, keep in mind that the bellows has left‐hand threads. Overtightening could damage the threads. Note Both bellows need not be removed if only one requires replacement. 8.
Page 70: Replacing The Reset Restriction Valve (4195Kb Controllers)
Instruction Manual 4195K Controllers July 2018 D200160X012 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 15 psig) output or 0.4 bar (6 psig) for a 0.4 to 2.0 bar (6 to 30 psig) output.
Page 71: Replacing The Rate/Reset Valve Assembly (4195Kc Controllers)
Instruction Manual 4195K Controllers D200160X012 July 2018 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.
Page 72: Replacing The Anti-Reset Windup (Suffix Letter F) Differential Relief Valve
Instruction Manual 4195K Controllers July 2018 D200160X012 14. For controllers with anti‐reset windup (suffix letter F), insert the relief tubing assembly (key 44) into the rate/reset valve assembly and tighten the nut. 15. Set the reset to 0.01 minutes per repeat and the rate to OFF. 16.
Page 73: Bourdon Tube Controller Maintenance And Calibration
Instruction Manual 4195K Controllers D200160X012 July 2018 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. Hold the controller assembly in place while tightening the nine mounting screws.
Page 74: Replacing Bourdon Tube Controller Links
Instruction Manual 4195K Controllers July 2018 D200160X012 Figure 6‐13. Bourdon Tube Controller Link Figure 6‐14. Disconnecting Link 1 from the Bourdon Locations and Adjustments Tube LINK 4 ADJUSTMENT COURSE ZERO ADJUSTMENT LINK 1 LINK 4 W5747 LINK 3 ADJUSTMENT LINK 2 LINK 3 LINK 2 ADJUSTMENT W5745...
Page 75: Replacing Link 2
Instruction Manual 4195K Controllers D200160X012 July 2018 the bottom hole (the hole nearest the pointer pivot). If the process pointer has too much travel, move the link to the top hole (the hole furthest from the pointer pivot). 4. Move the set point Indicator, either manually or with remote set point pressure, to the mid‐scale mark on the process scale and set the proportional band between DIRECT and REVERSE.
Page 76: Replacing Link 3
Instruction Manual 4195K Controllers July 2018 D200160X012 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 increase the length or counterclockwise to decrease the length) so that the pin on the end of the link is approximately one‐half of its diameter short of aligning with the hole in the flapper assembly as shown in figure 6‐11.
Page 77: Replacing Link 4
Instruction Manual 4195K Controllers D200160X012 July 2018 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 in Section 3, 4, or 5.
Page 78: Bourdon Tube Travel Stop Installation And Adjustment
Instruction Manual 4195K Controllers July 2018 D200160X012 13. Remove the tape from the process pointer and connect link 1 to the Bourdon tube. 14. Perform the controller calibration procedures and, if necessary, the appropriate remote set point calibration procedure in Section 3, 4, or 5. Bourdon Tube Travel Stop Installation and Adjustment WARNING Refer to the Maintenance WARNING on page 51.
Page 79: Bourdon Tube Controller Calibration: Zero And Span Adjustment
Instruction Manual 4195K Controllers D200160X012 July 2018 Figure 6‐18. Bourdon Tube Controller Travel Stop Adjustment LOWER TRAVEL STOP ADJUSTMENT LOCK NUT MOUNTING SCREW (KEY 76) MOUNTING SCREWS (KEY 75) LOOSEN THESE SCREWS TO ADJUST UPPER TRAVEL STOP MOUNTING SCREW (KEY 76) UPPER TRAVEL STOP...
Page 80 Instruction Manual 4195K Controllers July 2018 D200160X012 Note Any adjustment of the process pointer span adjustment screw requires readjustment of the process pointer zero adjustment screw. When checking the zero and span adjustments, ensure that the Bourdon tube does not contact the optional travel stops if used (key 73 and 74).
Page 81 Instruction Manual 4195K Controllers D200160X012 July 2018 Figure 6‐19. Fisher 4195K Controller Calibration Adjustment Locations POINTER ZERO ADJUSTMENT POINTER ZERO ADJUSTMENT LOCKING SCREW PROCESS POINTER SPAN ADJUSTMENT ANTI‐RESET WINDUP RELIEF VALVE ANTI‐RESET WINDUP VALVE ADJUSTING SCREW RATE RESET REMOTE SET POINT REMOTE SET POINT RESET ADJUSTMENT...
Page 82: Capsular Element Controller Maintenance And Calibration
Instruction Manual 4195K Controllers July 2018 D200160X012 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 step 17. If the process pointer error is greater than ±2 percent, loosen the two Bourdon tube mounting screws (key 384, figure 7‐2).
Page 83: Replacing Capsular Element Parts
Instruction Manual 4195K Controllers D200160X012 July 2018 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 result in product damage, as well as impaired performance.
Page 84: Replacing The Short Pivot Assembly
Instruction Manual 4195K Controllers July 2018 D200160X012 Figure 6‐20. Cutaway of Long Pivot Clevis Assembly BEARING END BUSHING ADJUSTMENT ARM SHAFT END BUSHING BEARING NOTE: 1 BEFORE TIGHTENING THE DRIVE FLEXURE MOUNTING SCREWS, POSITION THE SHAFT SO THE END BUSHINGS “FLOAT” IN THE BEARINGS. 26A9784‐E A5682 9.
Page 85: Replacing The Process Tubing
Instruction Manual 4195K Controllers D200160X012 July 2018 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 the drive bracket assembly (key 84) and from the pivot adjustment arm of the long pivot clevis assembly (key 78).
Page 86: Replacing Link 1
Instruction Manual 4195K Controllers July 2018 D200160X012 Figure 6‐21. Capsular Element Controller Link Locations and Adjustments LINK 5 LINK 1 LINK 4 LINK 4 ADJUSTMENT W4769 LINK 3 LINK 2 LINEARITY ADJUSTMENT SCREW LINK 2 ADJUSTMENT LINK 3 ADJUSTMENT Replacing Capsular Element Controller Link 1 1.
Page 87: Replacing Link 3
Instruction Manual 4195K Controllers D200160X012 July 2018 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 flapper leveling screw 1 (the screw nearest the nozzle) until clearance is obtained.
Page 88: Replacing Link 5
Instruction Manual 4195K Controllers July 2018 D200160X012 The controller output must be 0 bar (0 psig). To be sure the controller output is at 0 bar (0 psig), remove supply pressure, set the reset adjustment to 0.01 minutes per repeat and wait 30 seconds; then, turn the reset adjustment to the CLOSED (4195KB) or OFF (4195KC) position.
Page 89: Precalibration Procedure
Instruction Manual 4195K Controllers D200160X012 July 2018 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 remove the tie bar (key 97) from the capsular element assembly. Aligning the Drive Bracket Assembly Refer to figures 6‐22 and 7‐5.
Page 90: Aligning The Linkage
Instruction Manual 4195K Controllers July 2018 D200160X012 capsule stack. Tighten the travel stop mounting screws to lock it into position. Decrease the input pressure to 100 percent of the capsular element range and make sure the capsule stack is not contacting the travel stop (key 83).
Page 91: Capsular Element Controller Zero And Span Adjustment
Instruction Manual 4195K Controllers D200160X012 July 2018 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.
Page 92: Maintenance
Instruction Manual 4195K Controllers July 2018 D200160X012 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.
Page 93 Instruction Manual 4195K Controllers D200160X012 July 2018 Use the following procedures to replace the remote set point assembly. Figure 6‐23 shows the part locations. Refer to figure 7‐6 for key number locations. Figure 6‐23. Remote Set Point (suffix letter M) Parts and Adjustment Locations GUIDE MOUNTING FLEXURE...
Page 94: Replacing Remote Set Point Assembly Parts
Instruction Manual 4195K Controllers July 2018 D200160X012 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 mounting screws. 8.
Page 95: Replacing Pivot Assembly B (Key 115)
Instruction Manual 4195K Controllers D200160X012 July 2018 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 shaft supporting the adjustment arm.
Page 96: Replacing The Remote Set Point Tubing
Instruction Manual 4195K Controllers July 2018 D200160X012 shaft in the middle of the bushing end play. Be sure neither bushing is resting against the inside end of either bearing. Tighten the drive flexure screws to hold the pivot shaft in this position. Do not bend or twist the flexure when tightening the screws.
Page 97: Aligning The Flexures
Instruction Manual 4195K Controllers D200160X012 July 2018 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 the remote set point assembly. Aligning the Flexures WARNING Refer to the Maintenance WARNING on page 51.
Page 98: Aligning The Linkage
Instruction Manual 4195K Controllers July 2018 D200160X012 CAUTION Make sure the loose travel stop nut does not bind on the diaphragm capsule extension (key 134) when pressurizing the capsules (key 80). Damage to the capsules may result. 2. Full span stop—Adjust the remote set point pressure to 2‐1/2 percent of span greater than the remote set point input range upper limit.
Page 99: Remote Set Point Linearity Adjustment
Instruction Manual 4195K Controllers D200160X012 July 2018 1. Decrease the remote set point pressure to 0 percent of the remote set point input range. 2. The set point indicator should indicate the lower limit of the process scale span. If not, loosen the adjustment screw on link A (key 116), and adjust the length so the set point indicator points to the lower limit of the process scale.
Page 100: Auto/Manual Station (Suffix Letter E) Maintenance
Instruction Manual 4195K Controllers July 2018 D200160X012 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 indicator is to the right of the process scale limits), loosen the linearity screw and move it clockwise in the slot.
Page 101: Replacing The Switch Body Assembly, Lever O-Ring, Switch Body O-Ring, And Tubing Assembly
Instruction Manual 4195K Controllers D200160X012 July 2018 CAUTION In the next step, take care to tighten the two screws (keys 314 and 315) evenly. Uneven tightening could damage the tubing assembly. 3. Position the auto/manual station as far down on the frame and toward the scale as possible. Carefully tighten the two screws (keys 314 and 315) so that the auto/manual station contacts the three pads on the tubing assembly.
Page 102: Replacing The Loader Range Spring, Diaphragm Assembly, Ball Seat, Tubing, And Ball
Instruction Manual 4195K Controllers July 2018 D200160X012 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.
Page 103: Replacing The Loader Valve Plug And Valve Plug Spring
Instruction Manual 4195K Controllers D200160X012 July 2018 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 309). WARNING To avoid personal injury caused by preload from the range spring (key 283), turn the loader knob (key 287) counterclockwise (opposite to the arrow) to relieve pressure on the spring.
Page 104 Instruction Manual 4195K Controllers July 2018 D200160X012 Refer to figure 7‐7 for key number location. 1. Remove the controller assembly from the case by performing steps 1 through 3 of the case and cover replacement procedure. 2. Loosen the spring seat screw (key 275). 3.
Page 105: Parts
Use only genuine Fisher replacement parts. Components that are not supplied by Emerson Automation Solutions, should not, under any circumstances, be used in any Fisher instrument. Use of components not supplied by Emerson may void your warranty, might adversely affect the performance of the instrument, and could cause personal injury or property damage.
Page 106: Controller Common Parts
Instruction Manual 4195K Controllers D200160X012 July 2018 Controller Common Parts (figure 7‐1) Description Plain washer Used w/key 19 (2 req'd) Nozzle ass'y Washer (2 req'd) Note Set pt beam ass'y Figure 7‐1 shows key numbers for the common construction of all controller types.
Page 107 Instruction Manual 4195K Controllers D200160X012 July 2018 Description Part Number Description Process and set pt indicator ass'y w/sensing element Note One type of pressure gauge is used for both output pressure and supply Note pressure indication. Individual indicator ass'y parts are listed in two subsections of this parts list: the Process and Set Point Indicator Assembly (key 56) subsection and the Indicator Assembly (key 101) subsection.
Page 108 Instruction Manual 4195K Controllers D200160X012 July 2018 Description Description Blowout plug Machine screw, hex hd Used to attach the reset valve (4195KB) or rate/reset valve (4195KC) to the frame For 4195KB and KC controllers only Note Key numbers 73 through 76 are only for use with a 4195K controller with Rate/reset valve ass'y (for 4195KC controllers only) a Bourdon tube element.
Page 109 Instruction Manual 4195K Controllers D200160X012 July 2018 Figure 7‐1. Controller Assembly Drawings SEE VIEW L SEE VIEW H SEE VIEW G SECTION B‐B SEE VIEW M SEE VIEW E SECTION D‐D VIEW C‐C VIEW C‐C APPLY LUB/ SEALANT 4195KA CONTROLLERS 4195KS CONTROLLERS 56A9752‐U SHT 1 and 2...
Page 110 Instruction Manual 4195K Controllers July 2018 D200160X012 Figure 7‐1. Controller Assembly Drawings (cont'd) VIEW F‐F VIEW F‐F 56A9752‐U SHT 4 VIEW K‐K PROCESS CONNECTION ADAPTORS VIEW E VIEW E 4195KB CONTROLLERS 4195KB CONTROLLERS WITH ANTI‐RESET WINDUP (SUFFIX LETTER F) VIEW C‐C VIEW C‐C 4195KB CONTROLLERS 4195KB CONTROLLERS WITH...
Page 111 Instruction Manual 4195K Controllers D200160X012 July 2018 Figure 7‐1. Controller Assembly Drawings (cont'd) VIEW F‐F VIEW F‐F VIEW E 4195KC CONTROLLERS WITH VIEW E ANTI‐RESET WINDUP (SUFFIX LETTER F) 4195KC CONTROLLERS VIEW C‐C VIEW C‐C 4195KC CONTROLLERS WITH 4195KC CONTROLLERS ANTI‐RESET WINDUP (SUFFIX LETTER F) 56A9752‐U SHT 3...
Page 112 Instruction Manual 4195K Controllers July 2018 D200160X012 Figure 7‐1. Controller Assembly Drawings (cont'd) 56A9752‐U SHT 2 56A9752‐U SHT 3 56A9752‐U SHT 2 SECTION B‐B SECTION B‐B SECTION B‐B VIEW B‐B 4195KA CONTROLLERS 4195KB CONTROLLERS 4195KC CONTROLLERS 4195KS CONTROLLERS 56A9752‐U SHT 4 VIEW L CONTROLLERS WITH AUTO/MANUAL STATION (SUFFIX LETTER E)
Page 113 Instruction Manual 4195K Controllers D200160X012 July 2018 Figure 7‐1. Controller Assembly Drawings (cont'd) 56A9752‐U SHT 4 VIEW H VIEW G CONTROLLERS WITH REMOTE SET POINT BOURDON TUBE (SUFFIX LETTER M) TRAVEL STOPS 56A9752‐U SHT 5 56A9752‐U SHT 3 VIEW M VIEW M EXTERNAL FEEDBACK FOR EXTERNAL FEEDBACK FOR...
Page 114: Process And Set Point Indicator Assembly
Instruction Manual 4195K Controllers July 2018 D200160X012 Figure 7‐2. Process and Set Point Indicator Assembly for Bourdon Tube Controllers 32B1532‐A Process and Set Point Indicator Assembly Description (key 56) (figures 7‐2 and 7‐3) Capsular element ass'y Description With capsular element assembly Indicator ass'y Note Individual ass'y parts for key 113 are listed in the Capsular Element...
Page 115 Instruction Manual 4195K Controllers D200160X012 July 2018 Figure 7‐3. Process and Set Point Indicator Assembly for Capsular Element Controllers (Positive and Compound Pressure Shown) 36A6986‐C Description Description With Bourdon tube Process Tube Retainer Indicator ass'y Machine screw, pan hd Process tubing ass'y Link ass'y Note 383* Bourdon tube...
Page 116: Indicator Assembly
Instruction Manual 4195K Controllers July 2018 D200160X012 Indicator Assembly (key 101) (figure 7‐4) Description Link ass'y (2 req'd) Description Process pointer adj ass'y Set pt pointer ass'y Note Pivot pin (2 req'd) Key numbers 37, 61, 376, 377, and 378 are not included as part of the Washer, plain (4 req'd) indicator assembly (key 101).
Page 117: Capsular Element Assembly
Instruction Manual 4195K Controllers D200160X012 July 2018 Capsular Element Assembly (key 113) Description (figure 7‐5) Machine screw, fill hd For mounting the short pivot clevis ass'y (key 89) and the long pivot clevis ass'y Description (key 78) to the mounting plate (key 77) (4 req'd) Cap screw, hex socket (2 req'd) Machine screw, pan hd...
Page 118: Remote Set Point Assembly (Suffix Letter M)
Instruction Manual 4195K Controllers July 2018 D200160X012 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 VACUUM PRESSURE Remote Set Point Assembly (suffix letter M) Description (key 62) (figure 7‐6) Diaphragm capsule ass'y Description 1 bar (12 psig) span Cap screw, hex socket (2 req'd)
Page 119: Auto/Manual Station (Suffix Letter E)
Instruction Manual 4195K Controllers D200160X012 July 2018 Figure 7‐6. Remote Set Point Assembly APPLY LUB / SEALANT 36A6988‐C Description Description Machine screw, fill hd (2 req'd) Plain washer Travel stop nut Nut, Hex Set screw, hex socket Spacer Union Connecting link ass'y Plain washer Machine screw, fill hd (4 req'd) Diaphragm ass'y extension...
Page 120 Instruction Manual 4195K Controllers D200160X012 July 2018 Figure 7‐7. Auto/Manual Station Assembly SECTION A‐A SECTION B‐B SECTION C‐C APPLY LUB / SEALANT 48A2905‐A Description Description Switch body ass'y Spring adj screw 292* O‐ring 286* Retaining ring 293* O‐ring Loader knob 294* O‐ring Machine screw, rd hd (2 req'd) Switch body spring (2 req'd)
Page 121: Controller Mounting Parts
Casing‐ Mounted Controller Spacer spool (3 req'd) Note Cap screw, hex hd (3 req'd) Contact your Emerson sales office or Local Business Partner for any Lock washer (5 req'd) additional parts required for controller mounting. Mounting bracket Cap screw, hex hd (2 req'd) Mounting bracket For 657/667 size 80 &...
Page 122: Regulator Mounting Parts
Instruction Manual 4195K Controllers July 2018 D200160X012 Regulator Mounting Parts Fittings Description Description Regulator Mounting Parts for Casing‐Mounted Regulator Note Cap screw, hex hd (2 req'd) The quantity shown make up the fitting for one end of the tubing or Lock washer (2 req'd) Cap screw, hex hd (2 req'd) hose.
Page 123 Instruction Manual 4195K Controllers D200160X012 July 2018...
Page 124 Responsibility for proper selection, use, and maintenance of any product remains solely with the purchaser and end user. 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 trademarks and service marks of Emerson Electric Co.

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Fisher 4195kc Fisher 4195ks Fisher 4195kb

Emerson Fisher 4195KA Instruction Manual

Fisher ™ 4195KA, KB, KC, and KS Gauge Pressure

1 Introduction

2 Installation

5 KA Proportional-Only Controllers

5 KB Proportional-Plus-Reset Controllers and 4195KC Proportional-Plus-Reset-Plus-Rate Controllers

6 Maintenance

7 Parts

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