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Emerson Fisher 4194HA Instruction Manual

Differential pressure indicating controllers
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Instruction Manual
D200156X012
Fisher
4194HA, HB, and HC Differential Pressure
™
Indicating Controllers
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Summary of Contents for Emerson Fisher 4194HA

  • Page 1: Table Of Contents

    Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 Fisher 4194HA, HB, and HC Differential Pressure ™ Indicating Controllers Contents 4. 4194HB Proportional‐Plus‐Reset Controllers and 4194HC 1. Introduction Proportional‐Plus‐Reset‐Plus‐Rate Scope of Manual ......Controllers Description .
  • Page 2 Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 Replacing Controller Parts ....Remote Set Point Assembly Replacing the Process Differential Replacement .

  • Page 3: Introduction

    To avoid personal injury or property damage, it is important to carefully read, understand, and follow all the contents of this manual, including all safety cautions and warnings. If you have any questions about these instructions, contact your Emerson sales office or Local Business Partner before proceeding.

  • Page 4: Description

    Specifications for 4194HA, HB, and HC controllers are listed in table 1‐1. Educational Services For information on available courses for 4194HA, 4194HB, and 4194HC 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 5 Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 Table 1‐1. Specifications Available Configurations Per ISO 8573-1 See table 1‐2 Maximum particle density size: Class 7 Oil content: Class 3 Input Signal (Differential Pressure Sensing Element Pressure Dew Point: Class 3 or at least 10_C less than Range) the lowest ambient temperature expected Differential Pressure Range: See table 1‐3...
  • Page 6 Emerson sales office or Local Business Partner. 2. Consult your Emerson sales office or Local Business Partner for additional information. 3. Normal m /hr: normal cubic meters per hour (0°C and 1.01325 bar absolute). Scfh: standard cubic feet per hour (60°F and 14.7 psia).
  • Page 7 0 to 75 (0 to 186) 0 to 100 (0 to 248) 1. Differential pressure ranges are in English units of measurement; metric equivalents are shown here for reference only. Consult your Emerson sales office or Local Business Partner for special differential pressure ranges.

  • Page 8: Installation, Mounting, And Connections

    Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 Section 2 2‐2‐ Installation, Mounting, and Connections 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 9 Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 Process pressure connections are 1/4 or 1/2 NPT (optional). When installing process piping to the differential pressure unit attached to the controller, follow accepted engineering, installation, and safety practices to insure the safe and accurate transmission of the process differential pressure to the differential pressure unit.

  • Page 10: Process Pressure Connections

    While use and regular maintenance of a filter that removes particles larger than 40 micrometer 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 11: Vent Connection

    Instruction Manual 4194HA, HB, HC Controllers D200156X012 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 12: 4Ha Proportional-Only Controllers

    Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 Section 3 3‐3‐ 4194HA Proportional‐Only Controllers Adjustments for 4194HA Controllers Note Some of the following procedures require adjusting the proportional band knob 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 13: Manual Set Point Adjustment

    Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 Figure 3‐1. Location of Controller Parts and Adjustments SET POINT ADJUSTMENT PROCESS INDICATOR DRIVE ARM LOCKING SCREW PROPORTIONAL PIVOT BRACKET BAND INDICATOR COVER DRIVE ARM PROPORTIONAL BAND ADJUSTMENT CONNECTING LINK 1 KNOB OUTPUT ZERO ADJUSTMENT...

  • Page 14: Remote Set Point (Suffix Letter M) Adjustment

    Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 Remote Set Point (suffix letter M) Adjustment CAUTION Do not manually move the set point indicator on controllers with remote set point. Moving the set point indicator could damage the controller. If the controller is equipped with the remote set point option (figure 3‐2), vary the remote set point pressure to change the set point.

  • Page 15: Changing Controller Action

    Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 (0 to 15 psig). Then, at a proportional band setting of 100 percent DIRECT, the controller output goes from 3 to 15 psig as the process pressure differential goes from 0 to 15 psig. If the proportional band setting is subsequently changed to 50 percent DIRECT, the controller output would change from 3 to 15 psig as the process pressure differential changed from 0 to 7.5 psig.

  • Page 16: Startup For 4194Ha Controllers

    Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 1. Connect supply pressure to the supply pressure regulator and be sure it is delivering the proper supply pressure to the controller. Provide a means of measuring the controller output pressure. Also, provide a means of applying process differential pressure to the differential pressure unit.

  • Page 17: Calibration For 4194Ha Controllers

    Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 D remote set point: a. See figure 2‐2 for the location of the remote set point connection. Connect an adjustable pressure source to the remote set point connection. b. Adjust the pressure source until the set point indicator reaches the desired set point. Remember: Increasing the remote set point pressure increases the set point of direct‐acting controllers.

  • Page 18: Remote Set Point (Suffix Letter M) Zero-And-Span Adjustment

    Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 Refer to figure 3‐1 for location of adjustments. 1. Remove two screws (key 6) and lift off the proportional band indicator cover (key 36). 2. Set the proportional band between DIRECT and REVERSE. 3.

  • Page 19: Flapper Alignment

    Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 1. Remove two screws (key 6) and lift off the proportional band indicator cover (key 36). 2. Set the proportional band between DIRECT and REVERSE. 3. Adjust the set point pressure to the low limit of the set point input range. Note the position of the set point indicator.

  • Page 20: Principle Of Operation For 4194Ha Controllers

    (key 36) and install the machine screws (key 6). Principle of Operation for 4194HA Controllers Overall Operation Refer to the schematic diagram in figure 3‐3. Figure 3‐3. Schematic for Fisher 4194HA Controller SET POINT REVERSE ACTION INDICATOR...

  • Page 21: Remote Set Point Option

    Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 The process differential pressure input element is connected to the process indicator and to the flapper by connecting links. As the process differential pressure increases (in a direct‐acting controller), the flapper moves toward the nozzle, restricting flow through the nozzle and increasing nozzle pressure.

  • Page 22: 4Hb Proportional-Plus-Reset Controllers And 4194Hc Proportional-Plus-Reset-Plus-Rate Controllers

    Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 Section 44‐4‐ 4194HB Proportional‐Plus‐Reset Controllers And 4194HC Proportional‐Plus‐Reset‐Plus‐Rate Controllers Adjustments for 4194HB and HC Controllers This section includes descriptions of adjustments and procedures for prestartup and startup. Location of adjustments is shown in figure 3‐1. To better understand the adjustments and overall operation of the controller, refer to the principle of operation and the schematic diagrams (figures 4‐2 through 4‐6).

  • Page 23: Reset (Suffix Letter B) Adjustment

    Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 The white portion of the adjustment produces direct controller action. The black portion produces reverse controller action. After changing the action, tighten the screws on the proportional band indicator cover. Reset (suffix letter B) Adjustment Locate the reset adjustment.

  • Page 24: Startup For 4194Hb And Hc Controllers

    Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 When performing the checks, open loop conditions must exist. An open loop exists when the controller output does not affect the input pressure or other control signal to the controller. Note If the controller has the auto/manual option (suffix letter E), be sure the controller is in the automatic mode before performing prestartup checks.

  • Page 25: Calibration For 4194Hb And Hc Controllers

    Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 proportional band percentage from the equation below: Proportional + 200 Allowable Overshoot Band Pressure Span Adjustment For example: 2 Psig ^ 13% 30 Psig 5. If the controller is used with a control valve, return the control valve to service by slowly opening the upstream and downstream manual control valves in the pipeline.

  • Page 26: Process Indicator Zero-And-Span Calibration

    Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 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, if open process loop conditions exist. Unless otherwise noted, key numbers refer to figure 6‐1.

  • Page 27: Remote Set Point (Suffix Letter M) Zero-And-Span Calibration

    Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 15. If the error is greater than ±1 percent, repeat steps 3 through 14. 16. Perform the flapper alignment procedure. Remote Set Point (suffix letter M) Zero‐and‐Span Calibration Refer to figure 3‐1 for location of adjustments. Refer to figures 6‐1 and 6‐3 for key number locations. Note Any adjustment of the remote set point span adjustment screw will require readjustment of the set point zero adjustment screw.
  • Page 28 Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 Flapper leveling screw numbers and adjustments are shown in figure 3‐1. Provide a regulated process differential pressure to the differential pressure unit. Also, plug the controller output connection and provide a regulated supply pressure to the controller. Do not exceed the normal operating pressure in table 1‐4.
  • Page 29 Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 13. Adjust the proportional band to 100 percent direct action. 14. Apply differential pressure to the differential pressure unit or, if link 1 was disconnected, remove the tape from the process indicator and move the indicator until it aligns with the right‐hand edge of the set point indicator (as shown in figure 4‐1).

  • Page 30: Anti-Reset Windup Valve (Suffix Letter F) Calibration

    Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 Anti‐Reset Windup Valve (suffix letter F) Calibration Calibration for the anti‐reset windup valve to relieve on rising controller output pressure: 1. Plug the controller output connection or connect it to a pressure gauge if desired (open‐loop conditions must exist).

  • Page 31: Principle Of Operation For 4194Hb And Hc Controllers

    Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 3. For a controller with manual set point, move the set point indicator to 50 percent of the scale range. For a controller with remote set point, adjust the remote set point pressure until the set point indicator is at 50 percent of the scale range.
  • Page 32 Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 Pressure in the reset bellows opposes the action of the proportional bellows and slowly moves the flapper closer to the nozzle. The result of this interaction is that when the process differential pressure changes, proportional action temporarily reduces the gain of the controller for improved stability.
  • Page 33 Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 Figure 4‐3. Schematic of Operation for Fisher 4194HC Controller SET POINT RESET BELLOWS REVERSE ACTION INDICATOR QUADRANT PROPORTIONAL BELLOWS PROPORTIONAL PROCESS INDICATOR BAND ADJUSTMENT FEEDBACK LINK REMOTE SET POINT CONNECTED HERE FEEDBACK MOTION INPUT ELEMENT...

  • Page 34: Anti-Reset Windup Option (Suffix Letter F)

    Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 D Then, the low gain provided by the proportional action keeps the system stable. Finally, reset action slowly increases the gain and returns the process differential pressure toward the set point. Figure 4‐4. Schematic of Reset‐Rate Option RELAY OUTPUT PRESSURE RATE...

  • Page 35: External Feedback Option

    Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 applies pressure to one side of the plastic tube and to the auto/manual switch. Output pressure from the relay registers on the other side of the plastic tube as well as in the auto/manual switch. When the auto/manual switch is in the MANUAL position, the output of the manual loader is channeled through the auto/manual switch and becomes the output of the controller.
  • Page 36 Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 Figure 4‐6. Schematic of External Feedback Option RESET BELLOWS NOZZLE OUTPUT RESET VALVE RELAY TO PROPORTIONAL SUPPLY PRESSURE BELLOWS SUPPLY PRESSURE EXTERNAL FEEDBACK TO OUTPUT OF HIGH OR LOW SELECT RELAY OUTPUT PRESSURE NOZZLE PRESSURE RESET PRESSURE...

  • Page 37: Maintenance

    Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 Section 55‐5‐ Maintenance Inspection and Maintenance Controller parts are subject to normal wear and must be inspected and replaced as necessary. Inspection and maintenance frequency depends on the severity of service conditions. When inspection or repairs are require, disassemble only those parts necessary to accomplish the job.
  • Page 38 Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 Figure 5‐1. Maintenance Guide Troubleshooting It the controller is not operating properly, refer to the troubleshooting chart (table 5‐1). Then use the appropriate portions of the Maintenance section. Replacing Common Controller Parts Procedures describe replacement of controller parts.
  • Page 39 Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 Table 5‐1. Troubleshooting Chart Fault Possible Cause Check Correction 1. Process wanders or 1.1 Proportional band and 1.1 Refer to the Start‐up section for 1.1 If stable control cannot be attained, and all cycles about set point.
  • Page 40 Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 Table 5‐1. Troubleshooting Chart (Continued) Fault Possible Cause Check Correction 3. Controlling off set 3.1 Out of calibration. 3.1 Refer to the calibration and flapper 3.1 Adjust as necessary. point but not reflected alignment procedures.

  • Page 41: Changing Controller Action

    Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 Table 5‐1. Troubleshooting Chart (Continued) Fault Possible Cause Check Correction 7. Controller remains 7.5 Relay failure or 7.5 Manually move flapper 1.6 mm 7.5 If the output pressure remains at the supply at full output.

  • Page 42: Replacing The Differential Pressure Unit

    Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 Figure 5‐2. Changing Controller Action W3439 Replacing the Differential Pressure Unit WARNING Refer to the Maintenance WARNING at the beginning of this section. Before performing any maintenance operations: D Shut off the supply pressure to the controller. D Disconnect any operating lines providing supply air pressure, a process input signal, or other pressure source to the controller.

  • Page 43: Replacing Controller Parts

    Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 Properly support the unit before trying to separate the controller and differential pressure unit. 4. To separate the controller and differential pressure unit, open the cover, locate link 1 (key 323, figure 6‐2) and disconnect it from the drive arm (key 322).

  • Page 44: Replacing The Process Differential Pressure Scale

    Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 Refer to the installation procedures when reinstalling the unit. Note In the following procedures, adjust the proportional band knob between DIRECT and REVERSE. If this is done, it will be necessary to set the proportional band knob to 400 DIRECT or REVERSE (direct or reverse action) before replacing the proportional band indicator cover.

  • Page 45: Replacing The Case And Cover

    Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 2. Tip the relay slightly toward the side of the case to clear output pressure gauge and lift out the relay. 3. Make sure the replacement relay has three O‐rings as shown in figure 5‐4. The fourth port is for exhaust and does not require an O‐ring.

  • Page 46: Replacing The Gauges

    Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 7. Reinstall the differential pressure unit using the proper procedures. 8. Mount the controller as described in the Installation section. 9. Connect the supply pressure and output piping to the controller. Connect the process differential pressure to the differential pressure unit.

  • Page 47: Link 1

    Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 Figure 5‐5. Link Locations LINK 4 ADJUSTMENT LINK 4 LINK 3 ADJUSTMENT LINK 2 LINK 3 LINK 2 ADJUSTMENT W3442‐1 Link 1 Note Before performing the following link 1 maintenance steps, disconnect supply pressure from the controller. 1.

  • Page 48: Link 2

    Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 Figure 5‐6. Process Indicator Alignment ALIGNED FINE ZERO ZERO ADJUSTMENT ADJUSTMENT MISALIGNED LOCKING SCREW W3443‐1 W3475‐1 Link 2 Note Before performing the following link 2 maintenance steps, disconnect supply pressure from the controller. 1.

  • Page 49: Link 3

    Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 7. Adjust the length of link 2 by turning the adjusting screw (see figure 5‐7) clockwise to increase length, or counterclockwise to decrease length so the pin on the end of the link is approximately one‐half of its diameter short of engaging with the hole in the flapper assembly as shown in figure 5‐9.

  • Page 50: Link 4

    Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 Figure 5‐8. Link Number 3 Adjustment LINK 3 ADJUSTMENT W4192‐1 LINK 2 DISCONNECT 5. Check the set point beam bias spring (key 28). Is it correctly located in the frame bore and spring seat on the set point beam assembly as shown in figure 5‐9? 6.

  • Page 51: Replacing The Supply, Proportional, Reset, Reset Valve, And Relief Tubing Assemblies

    Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 4. For controllers with reset (4194HB controllers) or rate and reset (4194HC controllers), disconnect the supply pressure and then adjust the rate (4194HC controllers, only) to OFF. The controller output pressure must be 0 bar. Adjust the reset to 0.01 minutes per repeat and wait 30 seconds.

  • Page 52: Replacing The Proportional Band Adjustment Knob, Nozzle Assembly, And Set Point Beam Assembly

    Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 Replacing the Proportional Band Adjustment Knob, Nozzle Assembly, and Set Point Beam Assembly Note Before starting the following procedure, remove the controller from the case. Perform steps 1 through 7 of the Replacing the Differential Pressure Unit procedure.
  • Page 53 Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 5. Inspect the O‐ring on the relay nozzle tubing assembly (key 18) and replace it if necessary. Apply a suitable lubricant (key 318) to the O‐ring. 6. Install the relay nozzle tubing assembly (key 18) by pushing it into the bore in the set point beam assembly. 7.
  • Page 54 Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 Figure 5‐9. Proportional Band Knob and Set Point Beam Details PLASTIC NOZZLE TUBING WASHER ASSEMBLY (KEY 18) WASHER (KEY 20) E‐RING SCREW (KEY 27) (KEY 19) RETAINING CLIP (KEY 26) O‐RING PROPORTIONAL BAND ADJUSTMENT PLASTIC...
  • Page 55 Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 Figure 5‐10. Proportional Band Adjustment Knob Figure 5‐11. Nozzle‐Flapper Alignment Alignment HOLE FLAPPER NOZZLE W3449‐1 W3761 TOP VIEW 20. Adjust the set point to the minimum value on the process scale. 21.

  • Page 56: Replacing The Flapper Assembly And Flexure Pivot Assembly

    Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 Replacing the Flapper Assembly and Flexure Pivot Assembly Note Before starting the following procedure, remove the controller from the case. Perform steps 1 through 7 of the Replacing the Differential Pressure Unit procedure. Then, perform steps 1 and 2 of the Replacing the Case and Cover procedure. 1.
  • Page 57 Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 Figure 5‐12. Position of Link Number 4 Adjustment Figure 5‐13. Flapper Assembly and Leveling Screws Screws INPUT LINK 4 ADJUSTMENT ADJUSTABLE SET POINT FEEDBACK SCREW HEADS FLAPPER PIVOT ASSEMBLY FLAPPER LEVELING BEAM SCREW NUMBER 2 ASSEMBLY...
  • Page 58 Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 26. Position the proportional band knob, nozzle pivot, and set point beam assembly on frame. Install the relay nozzle tubing nut loosely into frame manifold while positioning the nozzle in the center of the flapper as shown in figure 5‐11.

  • Page 59: Replacing The Proportional Or Reset Bellows

    Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 Replacing the Proportional or Reset Bellows Note Before starting the following procedure, remove the controller from the case. Perform steps 1 through 7 of the Replacing the Differential Pressure Unit procedure. Then, perform steps 1 and 2 of the Replacing the Case and Cover procedure. 1.
  • Page 60 Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 16. Refer to steps 4 through 10 in the procedure for replacing link 4. If the controller is a proportional‐only (4194HA) controller, go to step 28. If the controller has reset (4194HB) or rate/reset (4194HC), continue with step 17 and the following note.

  • Page 61: Replacing The Reset Restriction Valve (4194Hb Controllers)

    Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 22. Increase the process differential pressure very slowly until the output pressure stabilizes at 1.0 bar (15 psig) for a 0.2 to 1.0 bar (3 to 15 psig) output signal range or 2.0 bar (30 psig) for a 0.4 to 2.0 bar (6 to 30 psig) output signal range.

  • Page 62: Replacing The Differential Relief Valve Assembly (Suffix Letter F)

    Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 Note Before starting the following procedure, remove the controller from the case. Perform steps 1 through 7 of the Replacing the Differential Pressure Unit procedure. Then, perform steps 1 and 2 of the Replacing the Case and Cover procedure. 1.

  • Page 63: Calibration After Controller Maintenance

    Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 Refer to figure 6‐1 (4194HB or 4194HC controllers, suffix letter F) for key number locations. 1. Perform the procedures required in the Note above. 2. Loosen the nuts at both ends of the relief valve tubing (key 44) and remove the tubing. 3.

  • Page 64: Flapper Alignment

    Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 7. The process indicator should point out 50 ±3 percent of the input scale range. If not, loosen the screws in link 1 and move the process indicator to 50 ±3 percent. Tighten the screws. 8.

  • Page 65: 4194Ha Proportional-Only Controllers

    Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 Flapper leveling screw numbers and adjustments are shown in figure 3‐1. Provide a means of applying supply pressure to the controller and plug the output connection. After performing the flapper alignment procedure, go to the appropriate startup procedure.
  • Page 66 Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 2. For a controller with manual set point, move the set point adjustment to 50 percent of the scale range. For a controller with remote set point, adjust the remote set point pressure until the set point indicator is at 50 percent of the scale range.

  • Page 67: Anti-Reset Windup Valve (Suffix Letter F) Calibration

    Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 18. Pressure the differential pressure unit or, if disconnected, position the process indicator to align with the left‐hand edge of the set point indicator. The controller output should be within 0.14 bar (2 psig) of supply pressure. 19.

  • Page 68: Remote Set Point (Suffix Letter M) Maintenance

    Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 12. If the differential pressure calculated in step 11 is incorrect for the application, the differential can be adjusted by turning the anti‐reset windup valve adjustment screw (see figure 3‐1). Turning the screw clockwise will decrease the differential pressure.

  • Page 69: Remote Set Point Assembly Replacement

    Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 Remote Set Point Assembly Replacement Use the following procedures to replace the remote set point assembly. Refer to figure 6‐3 for key number locations. Note Remove the supply pressure gauge before attempting to remove the remote set point capsular element assembly. 1.

  • Page 70: Pivot Assembly B (Key 115)

    Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 3. Note where link A (key 116) is connected. Disconnect the link from the lever arm on the pivot assembly. 4. Disconnect the drive flexure (key 79) from the adjustment arm of the pivot assembly. Be careful not to bend or kink the drive flexure.

  • Page 71: Drive Flexure

    Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 6. Attach links A and B (keys 116 and 126) to the arms of the replacement pivot assembly B in the positions noted in step 2. 7. Perform the remote set point maintenance calibration procedure in this section. Also, perform the appropriate controller calibration procedure in Section 3 or 4.

  • Page 72: Link B

    Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 Link B 1. Note where link B (key 126) is connected (figure 6‐3). Disconnect both ends of the link from the pivot arm and from the set point indicator assembly. 2. Loosen the screw in the replacement link and adjust the length to match the link being replaced. Tighten the screw. 3.

  • Page 73: Setting Remote Set Point Travel Stops

    Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 Note The adjustment arm of pivot A turns on a bushing at each end of the shaft supporting the adjustment arm. In the next step, position the shaft so both bushings ”float” inside the bearings and do not rest against the end of either bearing. d.

  • Page 74: Remote Set Point Linearity Adjustment

    Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 1. Decrease remote set point pressure to the lower range limit. 2. 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 75: Replacing Auto/Manual Station (Suffix Letter E) Parts

    Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 6. Repeat steps 1 through 4 until lower, middle, and upper indications are within ±1 percent of the process scale markings. Replacing Auto/Manual Station (suffix letter E) Parts Disassembly of the Auto/Manual Station 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 76: Replacing The Auto/Manual Station Switch

    Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 5. Apply air pressure to the controller and check for leaks. 6. Install the controller assembly in the case. Slide the controller frame down to assure an O‐ring seal at the pressure connections.

  • Page 77: Range Spring, Diaphragm Assembly Ball Seat, Tubing, And Ball

    Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 3. Position the closing plate gasket (key 306) and the closing plate (key 307). Secure with two screws (key 308). 4. Place the balls (key 296), switch body springs (key 295), and O‐rings (keys 292, 293, and 294) in the switch body (key 291).

  • Page 78: Replacing The Auto/Manual Station Loader Valve Plug And Valve Plug Spring

    Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 3. Position the ball (key 279), the tube (key 278), and the ball seats (key 280) between the ears of the loader assemblies (keys 282 and 274); position the diaphragm assembly (key 281) between the main halves of the loader assemblies.

  • Page 79: Parts

    Use only genuine Fisher replacement parts. Components that are not supplied by Emerson Automation Solutions, should not, under any circumstances, be use 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 result in personal injury and property damage.

  • Page 80: Controller Parts

    Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 Controller Parts (figure 6‐1) Description Description Set pt beam shoe Machine screw (2 req'd) Bellows bracket Bellows adj bracket Bellows adj spring Note Machine screw, fill hd (2 req'd) Machine screw, hex hd (2 req'd) Figure 6‐1 shows key numbers for the common construction of all Proportional band indicator cover controller types.
  • Page 81 Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 Description Description Pressure control block Relay ass'y 1 req'd for remote set pt 1 req'd for ext fdback  Relay, 0.2 to 1.0 bar (3 to 15 psig) Cap screw, hex hd  Relay, 0.4 to 2.0 bar (6 to 30 psig)  (Maximum qty req'd: 6) Process scale...
  • Page 82 Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 Description Description Indicator ass'y Rate/reset valve ass'y  For 4194HC controllers only 0.2 to 1.0 bar (3 to 15 psig) 0.4 to 2.0 bar (6 to 30 psig) Note Set screw, hex socket Individual assembly parts are listed in the Indicator Assembly (key 101)  For 4194HC controllers only (2 req'd) subsection of the parts list.
  • Page 83 Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 Figure 6‐1. Controller Assembly Drawings B2357 CONTROLLER COMMON PARTS SECTION D‐D A5948 VIEW C‐C (4194HS CONTROLLERS) B2351...
  • Page 84 Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 Figure 6‐1. Controller Assembly Drawings (Continued) VIEW F‐F VIEW F‐F VIEW E VIEW E SUFFIX BF SUFFIX B 49A0770‐A SECTION B‐B APPLY LUB/ADHESIVE NOTES:  1  KEY 4 GASKET, IS USED BETWEEN INTERNAL FRAME AND FRAME MANIFOLD.  2 ...
  • Page 85 Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 Figure 6‐1. Controller Assembly Drawings (Continued) VIEW F‐F VIEW F‐F SECTION B‐B SUFFIX C, CF VIEW E VIEW E SUFFIX C SUFFIX CF VIEW C‐C VIEW C‐C SUFFIX C SUFFIX CF 56A9752‐V Sht 3...
  • Page 86 Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 Figure 6‐1. Controller Assembly Drawings (Continued) 56A9752‐V Sht 4 VIEW H SUFFIX M VIEW M EXTERNAL FEEDBACK ASSY 56A9752‐V Sht 5...

  • Page 87: Process And Set Point Indicator Assembly

    Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 Figure 6‐2. Process and Set Point Indicator Assembly with Differential Pressure Unit 38A4986‐C Process and Set Point Indicator Description Assembly (key 56) (figure 6‐2) Clamp block Nut (2 req'd) 326* Boot Description Mounting plate (for differential pressure unit) Controller mounting plate...

  • Page 88: Remote Set Point Assembly

    Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 Figure 6‐3. Remote Set Point Assembly APPLY LUB/SEALANT 36A6988‐C Remote Set Point Assembly Description Pedestal ass'y (key 62) (figure 6‐3) Tie bar Spring Description Zero adj screw Pivot screw Cap screw, hex socket (2 req'd) Zero adj bracket Plain washer (3 req'd) Mounting plate...

  • Page 89: Indicator Assembly

    Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 Figure 6‐4. Process and Set Point Indicator Assembly (Manual Set Point) 39A1126‐H Indicator Assembly (key 101) Auto/Manual Station (figure 6‐4) (suffix letter E) (figure 6‐5) Description Description Self‐tapping screw (4 req'd) Process scale Auto/manual station Lower loader ass'y...
  • Page 90 Instruction Manual 4194HA, HB, HC Controllers July 2018 D200156X012 Figure 6‐5. Auto/Manual Station 48A2905‐A Sh1 1 RIGHT SIDE VIEW (INSTALLED) TOP VIEW SECTION A‐A SECTION B‐B SECTION C‐C APPLY LUB/SEALANT 48A2905‐A Sht 2...
  • Page 91 Instruction Manual 4194HA, HB, HC Controllers D200156X012 July 2018 Figure 6‐5. Auto/Manual Station (Continued) PLASTIC TUBE METAL BALL LOADER KNOB AUTOMATIC/ MANUAL SWITCH SWITCHING ZONE INDICATION SIDE VIEW (COVER REMOVED) BACK VIEW (COVER REMOVED) 56A9752‐D Sht 4 C0527-2 Description Description Switch body ass'y Switch body spring (2 req'd) 292* O‐ring...

  • Page 92: Controller Mounting Parts

    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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