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Instruction Manual
D200158X012
Fisher
4194S Differential Pressure Controllers
™
Contents
1. Introduction
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(Option M)
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Changing Controller Action
Replacing Controller Parts
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Figure 1-1. Fisher 4194S Differential Pressure
Controllers
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W3613
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Supply Tubing and Positive
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Proportional Band Knob, Nozzle
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Assembly, and Set Point
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4194S Controllers
W5663-1
NAMEPLATE
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July 2018
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Table of Contents
Related Manuals for Emerson Fisher 4194S
Summary of Contents for Emerson Fisher 4194S
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Page 1: Table Of Contents
4194S Differential Pressure Controllers ™ Contents Figure 1-1. Fisher 4194S Differential Pressure Controllers 1. Introduction ....... -
Page 2: Scope Of Manual
If you have any questions about these instructions, contact your Emerson sales office or Local Business Partner before proceeding. - Page 3 NOTE: Specialized instrument terms are defined in ANSI/ISA Standard 51.1 - Process Instrument Terminology. 1. Consult your Emerson sales office or Local Business Partner for additional information. 2. Normal m3/hour - Normal cubic meters per hour at 0_C and 1.01325 bar, absolute. Scfh - Standard cubic feet per hour at 60_F and 14.7 psia...
- Page 4 Instruction Manual 4194S Controllers July 2018 D200158X012 Table 1-2. Available Configurations for Fisher 4194S Controllers OPTIONS CONTROLLER Internal Auto/Manual Station, Option E Remote Set Point, Option M 4194S 4194SE 4194SM 4194SME 1. Reverse‐acting constructions are designated by an R added to the type number Table 1-3.
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Page 5: Specifications
Specifications for 4194S controllers are listed in table 1-1. Educational Services For information on available courses for 4194S controllers, as well as a variety of other products, contact: Emerson Automation Solutions Educational Services - Registration Phone: 1-641-754-3771 or 1-800-338-8158 E-mail: education@emerson.com... - Page 6 Instruction Manual 4194S Controllers July 2018 D200158X012...
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Page 7: Installation
Instruction Manual 4194S Controllers D200158X012 July 2018 Section 2 Installation22-2- 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: D Always wear protective clothing, gloves, and eyewear when performing installation and maintenance procedures. - Page 8 Instruction Manual 4194S Controllers July 2018 D200158X012 Figure 2-1. Typical Actuator Mounting Figure 2-3. Wall Mounting SPACER SPOOLS CAP SCREWS AND TOP VIEW LOCKWASHERS (10.25) (6.00) (0.50) MOUNTING REAR VIEW BRACKET 36A9761‐A A2759‐4 (INCH) W5661 Figure 2-2. Panel Mounting Figure 2-4. Pipestand Mounting TOP VIEW SIDE VIEW VERTICAL PIPE...
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Page 9: Pressure Connections
Instruction Manual 4194S Controllers D200158X012 July 2018 Pressure Connections WARNING Overpressuring any system component, including the capsular sensing element, could result in personal injury or property damage due to fire and explosion caused by venting or leakage of a hazardous supply pressure medium or process medium. To avoid such injury or damage, provide suitable pressure‐... -
Page 10: Supply Pressure
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 filtration or filter maintenance. -
Page 11: Controller Operation
Instruction Manual 4194S Controllers D200158X012 July 2018 Section 3 Controller Operation33-3- Operating Information This section includes descriptions of adjustments and procedures for prostrate and startup procedures. Location of adjustments are shown in figures 3-1 and 3-2. To better understand the adjustments and overall operation of the controller, refer to the Principle of Operation section and the schematic diagrams, figures 3-4 and 3-5. -
Page 12: Prestartup Checks
Instruction Manual 4194S Controllers July 2018 D200158X012 When the automatic/manual switch is in AUTOMATIC, adjusting the loader knob has no effect on the controller output. When the automatic/manual switch is in MANUAL, changing the set point adjustment has no effect on the controller output. -
Page 13: Startup
Instruction Manual 4194S Controllers D200158X012 July 2018 Figure 3-1. Location of Controller Parts and Adjustments (continued) SCREW 1 SCREW 2 SCREW 3 PROCESS SPAN REMOTE SET POINT ADJUSTMENT SPAN ADJUSTMENT 35A7374‐B SIDE VIEW OF 49A0771‐A SET POINT/PROCESS INDICATOR ASSEMBLY SIDE VIEW OF CONTROLLER C0541 SHOWING FLAPPER LEVELING SCREWS 1. -
Page 14: Calibration
Instruction Manual 4194S Controllers July 2018 D200158X012 Calibration 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. If the prestartup checks revealed faulty adjustment of the process indicator, perform the calibration procedures. These procedures are valid for either shop or field calibration, provided that open process loop conditions exist. -
Page 15: Setting Switching Points
Instruction Manual 4194S Controllers D200158X012 July 2018 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. - Page 16 Instruction Manual 4194S Controllers July 2018 D200158X012 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.
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Page 17: Reverse-Acting Controllers
Instruction Manual 4194S Controllers D200158X012 July 2018 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. - Page 18 Instruction Manual 4194S Controllers July 2018 D200158X012 Figure 3-4. Schematic of Operation for Fisher 4195S Controllers SET POINT POSITIVE FEEDBACK INDICATOR BELLOWS REVERSE ACTION PROPORTIONAL QUADRANT BELLOWS PROPORTIONAL (VENTED) BAND ADJUSTMENT FEEDBACK PROCESS POINTER LINK REMOTE SET POINT CONNECTED HERE FEEDBACK INPUT ELEMENT MOTION...
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Page 19: Remote Set Point
Instruction Manual 4194S Controllers D200158X012 July 2018 Remote Set Point Option The capability to adjust the controller set point from a remote location is available with all 4194S 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 3-5. - Page 20 Instruction Manual 4194S Controllers July 2018 D200158X012...
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Page 21: Maintenance
Instruction Manual 4194S Controllers D200158X012 July 2018 Section 4 Maintenance44-4- 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 22: Troubleshooting
Instruction Manual 4194S Controllers July 2018 D200158X012 Figure 4-1. Maintenance Guide Troubleshooting If the controller is not operating properly, refer to the troubleshooting chart (table 4-1). Then use the appropriate portions of the Maintenance section. Replacing Controller Parts Procedures describe replacement of parts in the controller and the input element. - Page 23 Instruction Manual 4194S Controllers D200158X012 July 2018 Table 4-1. Troubleshooting Chart Fault Possible Cause Check Correction 1. Output does not snap when 1.1 Flapper out of alignment 1.1 Refer to Flapper Alignment 1.1 Align flapper as necessary process pointer and set point procedures indicator are aligned.
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Page 24: Process Pressure Scale
Instruction Manual 4194S Controllers July 2018 D200158X012 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 process pressure is properly vented from the controller. Vent any supply pressure from the controller before disassembly. WARNING Refer to the Maintenance WARNING on page 21 before replacing any common controller parts. -
Page 25: Relay
Instruction Manual 4194S Controllers D200158X012 July 2018 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. -
Page 26: Case And Cover
Instruction Manual 4194S Controllers July 2018 D200158X012 Case and Cover 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 supply and output piping from the controller. Bleed away any process pressure, and carefully remove the process pressure piping from the controller. -
Page 27: Feedback Tubing Assemblies
Instruction Manual 4194S Controllers D200158X012 July 2018 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 case and cover procedure. 1. Remove the nuts that hold the supply gauge tubing assembly (key 39) or the positive feedback tubing assembly (key 45) to the frame. - Page 28 Instruction Manual 4194S Controllers July 2018 D200158X012 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 set point beam assembly (key 23), the proportional band knob (key 25), and the retaining clip (key 26) into the cap, aligning the nozzle with the tab on the proportional band knob (shown in figure 4-5).
- Page 29 Instruction Manual 4194S Controllers D200158X012 July 2018 Figure 4-5. Proportional Band Adjustment and Set Point Beam Details CAP (WITH O‐RING INSIDE) E‐RING NOZZLE RETAINING CLIP TUBING ASSEMBLY O‐RING PROPORTIONAL BAND ADJUSTMENT SET POINT SET POINT SET POINT NOZZLE BEAM ASSEMBLY BEAM SHOE PIVOT ASSEMBLY W3452‐1...
- Page 30 Instruction Manual 4194S Controllers July 2018 D200158X012 Figure 4-6. Proportional Band Adjustment Knob Figure 4-7. Nozzle‐Flapper Positioning Setting HOLE FLAPPER NOZZLE W3449 W3761 35. For direct acting controllers, adjust the proportional band knob to 5 percent direct acting. Adjust the set point adjustment or with remote set point pressure to 5 percent of the process scale range.
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Page 31: Flapper Flexure Pivot Assembly
Instruction Manual 4194S Controllers D200158X012 July 2018 43. Repeat steps 35 through 42 until the output pressure snaps to supply pressure within ±2 percent of set point at 5 and 95 percent on the process scale range. Then go to step 53. 44. - Page 32 Instruction Manual 4194S Controllers July 2018 D200158X012 4. Remove the screw and washer (keys 19 and 20) that hold the adjustable set point pivot assembly (key 17) to the frame. 5. Remove the set point pivot assembly (key 17). 6. Disconnect the nut that secures the relay nozzle tubing (key 18) into the frame (key 3). 7.
- Page 33 Instruction Manual 4194S Controllers D200158X012 July 2018 Figure 4-9. Exploded View of Flexure Pivot Assembly FLEXURE PIVOT FOUR SCREWS ASSEMBLY (KEY 10) INPUT FEEDBACK BEAM ASSEMBLY W3453 19. Align flapper leveling screw number 2 (see figure 3-1 for screw location) with the centerline of the oblong hole in the frame as shown in figure 4-8.
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Page 34: Positive Feedback Bellows
Instruction Manual 4194S Controllers July 2018 D200158X012 Figure 4-10. Link 2 Number Adjustment W3476 W3451 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. - Page 35 Instruction Manual 4194S Controllers D200158X012 July 2018 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 bracket (key 32) from the bellows bracket (key 31).
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Page 36: Links
Instruction Manual 4194S Controllers July 2018 D200158X012 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, refer to the replacement procedures for the flapper flexure pivot assembly. - Page 37 Instruction Manual 4194S Controllers D200158X012 July 2018 Figure 4-12. Link Location LINK 1 W3721 COARSE ZERO ADJUSTMENT W3612 LINK 1 LOCATION LINK 4 LINK 4 ADJUSTMENT LINK 5 LINK 1 LINEARITY LINK 2 ADJUSTMENT LINK 3 LINK 2 LINK 3 SCREW ADJUSTMENT ADJUSTMENT...
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Page 38: Link Number 2
Instruction Manual 4194S Controllers July 2018 D200158X012 Figure 4-13. Process Pointer Alignment ZERO ADJUSTMENT ALIGNED MISALIGNED FINE ZERO LOCKING SCREW ADJUSTMENT W3443‐1 W3475‐1 Link Number 2 Note Link number 2 is made of aluminum for temperature compensation purposes. Do not replace it with a link of other material. 1. -
Page 39: Link Number 3
Instruction Manual 4194S Controllers D200158X012 July 2018 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. -
Page 40: Link Number 5
Instruction Manual 4194S Controllers July 2018 D200158X012 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. Controller output should be 0 psig. -
Page 41: Process Drive Flexure
Instruction Manual 4194S Controllers D200158X012 July 2018 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 the pivot assembly. -
Page 42: Maintenance Calibration
Instruction Manual 4194S Controllers July 2018 D200158X012 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 screws. -
Page 43: Aligning Linkage
Instruction Manual 4194S Controllers D200158X012 July 2018 2. Full span stop—Adjust process differential pressure to 5 percent greater than full span pressure. Loosen the screws (key 139) mounting the travel stop (key 83) to the mounting plate. Slide the travel stop until it is just touching the end of the capsule stack. -
Page 44: Linearity Adjustment
Instruction Manual 4194S Controllers July 2018 D200158X012 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. -
Page 45: Remote Set Point (Option M)
Instruction Manual 4194S Controllers D200158X012 July 2018 WARNING In step 4, do not exceed the operating limits for the controller (refer to table 1-3). Personal injury or equipment damage may result from overpressure. 4. Slowly increase the process differential pressure from zero until the output pressure snaps to supply pressure. The output pressure should snap to supply pressure within ±2 percent of set point. -
Page 46: Pivot Assembly A
Instruction Manual 4194S Controllers July 2018 D200158X012 Pivot Assembly A (Key 114) CAUTION Avoid bending or kinking the drive flexure during the following procedure. Bending or kinking the drive flexure can result in product damage, as well as impaired performance. 1. -
Page 47: Drive Flexure
Instruction Manual 4194S Controllers D200158X012 July 2018 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 the flexure. 2. -
Page 48: Link A
Instruction Manual 4194S Controllers July 2018 D200158X012 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. -
Page 49: Setting Travel Stops
Instruction Manual 4194S Controllers D200158X012 July 2018 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 the drive flexure. b. -
Page 50: Linearity Adjustment
Instruction Manual 4194S Controllers July 2018 D200158X012 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. -
Page 51: Replacing The Auto/Manual Station
Instruction Manual 4194S Controllers D200158X012 July 2018 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 frame gaskets (keys 4 and 5). -
Page 52: Disassembly
Instruction Manual 4194S Controllers July 2018 D200158X012 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. -
Page 53: Replacing The Loader Range Spring, Diaphragm Assembly, Ball Seat, Tubing, And Ball
Instruction Manual 4194S Controllers D200158X012 July 2018 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. -
Page 54: Replacing The Loader Valve Plug And Valve Plug Spring
Instruction Manual 4194S Controllers July 2018 D200158X012 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. -
Page 55: Parts Ordering
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 Automation Solutions may void your warranty, might adversely affect the performance of the instrument, and could cause personal injury or property damage. -
Page 56: Pressure Control Block
Instruction Manual 4194S Controllers D200158X012 July 2018 Description Description Nozzle Assembly Reducing Adaptor (2 req'd)(use only when specified) Washer (2 req'd) Set Point Beam Assembly Process scale Proportional Band Knob Remote set assembly (for 4194SM, and SME only) Retaining clip 0.2 to 1.0 bar (3 to 15 psig) E‐ring 0.4 to 2.0 bar (6 to 30 psig) -
Page 57: Mounting Parts
Instruction Manual 4194S Controllers D200158X012 July 2018 Mounting Parts Description Description Actuator Yoke Mounting Pipestand Mounting Spacer Spool (3 req'd) Cap Screw (3 req'd) Cap Screw (3 req'd) Lock Washer (7 req'd) Lockwasher (5 req'd) Bracket Mounting Bracket Clamp (2 req'd) Spacer Spool (2 req'd) Cap Screw (2 req'd) Panel Mounting... - Page 58 Instruction Manual 4194S Controllers July 2018 D200158X012 Figure 5-1. Controller Assembly Drawing 38A3819‐B SECTION D‐D VIEW C‐C 56A9752‐V Sht 1...
- Page 59 Instruction Manual 4194S Controllers D200158X012 July 2018 Figure 5-1. Controller Assembly Drawing Figure 5-2. Capsular Element Assembly (Continued) VIEW A‐A DRIVE BRACKET ASSEMBLY 49A0770‐A SECTION B‐B 58A0706‐C 36A3819‐A CONTROLLERS WITH REMOTE SET POINT OPTION...
- Page 60 Instruction Manual 4194S Controllers July 2018 D200158X012 Figure 5-3. Remote Set Point Assembly Drawing LINK A LINK B APPLY LUB/SEALANT 36A6988‐C B1760...
- Page 61 Instruction Manual 4194S Controllers D200158X012 July 2018 Figure 5-4. Auto/Manual Station Parts Location METAL BALL PLASTIC TUBE LOADER KNOB AUTOMATIC/ MANUAL SWITCH SWITCHING ZONE INDICATION FRONT VIEW 56A9752‐D SIDE VIEW (COVER REMOVED) BACK VIEW (COVER REMOVED) 49A0770‐A C0540...
- Page 62 Instruction Manual 4194S Controllers July 2018 D200158X012 Figure 5-5. Auto/Manual Station Assembly Drawing 48A2905‐A Sht 1 SECTION A‐A SECTION B‐B SECTION C‐C 48A2905‐A Sht 2...
- Page 63 Instruction Manual 4194S Controllers D200158X012 July 2018 Figure 5-6. Process and Set Point Indicator Assembly (Manual Set Point) 39A1126‐H INDICATOR ASSEMBLY 36A6986‐C PROCESS / SET POINT INDICATOR ASSEMBLY 32B1532‐A PROCESS / SET POINT INDICATOR ASSEMBLY WITH BOURDON TUBE...
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Page 64: Www.fisher.com
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.