Replacing The Relay; Replacing The Case And Cover; Replacing The Gauges - Emerson Fisher KC Series Instruction Manual

4195KA, KB, KC, and KS Controllers

Replacing the Relay

WARNING
Refer to the Maintenance WARNING
on page 6-1.
1. Loosen the two captive screws that hold the relay
(key 50) in place.
2. Tip the relay slightly toward the side of the case
to clear the output pressure gauge (key 46) and lift
out the relay.
3. Make sure the replacement relay has three
O-rings (keys 13 and 15) installed as shown in figure
6-2. The fourth port is for exhaust and does not
require an O-ring.
4. Install the replacement relay, making sure the tab
on the relay, shown in figure 6-2, aligns with the tab
on the frame.
5. Tighten the two screws that hold the relay in
place.
6. Perform the appropriate flapper alignment
procedure in Section 3, 4, or 5.

Replacing the Case and Cover

WARNING
Refer to the Maintenance WARNING
on page 6-1.
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. Remove the controller from its mounting to a
maintenance area.
3. Remove the nine screws (key 38) from the case
and cover assembly (key 1) and lift out the controller
assembly. If the controller has remote set point
(suffix letter M), use a screwdriver or appropriate
tool to deflect the case slightly at the remote set
point connection to remove the controller assembly.
Inspect the O-rings around the external piping
connections and replace as necessary.
6-6
4. Position the controller assembly in the
replacement case and cover.
5. Start the nine mounting screws, but do not
tighten.
6. 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.
7. Remove the blow-out plug (key 72) from the
original case, and install it in the replacement case.
8. Perform the controller calibration procedures and,
if necessary, the appropriate remote set point
calibration procedure in Section 3, 4, or 5.
9. Mount the controller as described in the
Installation section.
10. Connect the external piping to the controller.

Replacing the Gauges

WARNING
Refer to the Maintenance WARNING
on page 6-1.
CAUTION
Before performing this procedure, be
sure the replacement gauges are the
correct range so that they are not
damaged by overpressure.
1. Unscrew the output pressure gauge or the supply
pressure gauge (key 46) from the frame (key 3).
2. Before installing the replacement gauge, coat the
threads on the gauge with a sealant such as key 311
or equivalent.
3. Screw the replacement gauge into the frame.
4. Apply the correct supply pressure and check for
leaks with the nozzle capped for full output pressure.
Instruction Manual
Form 5207
April 2007