Emerson 4195KAE, 4195KS, 4195KA, 4195KAM, 4195KAME Instruction Manual

Instruction Manual

Form 5207
April 2007

4195KA, KB, KC, and KS Controllers

4195KA, K B, KC, and KS Series Gauge
Pressure Controllers

Contents

1. Introduction

Scope of Manual 1-3. . . . . . . . . . . . . . . . . . . . . . . .

Description 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications 1-4. . . . . . . . . . . . . . . . . . . . . . . . . .

Educational Services 1-4. . . . . . . . . . . . . . . . . . . .

2. Installation

Controller Mounting Orientation 2-1. . . . . . . . . . .

Pipestand Mounting 2-1. . . . . . . . . . . . . . . . . . . . .

Panel Mounting 2-1. . . . . . . . . . . . . . . . . . . . . . . . .

Wall Mounting 2-1. . . . . . . . . . . . . . . . . . . . . . . . . .

Actuator Mounting 2-1. . . . . . . . . . . . . . . . . . . . . .

Pressure Connections 2-2. . . . . . . . . . . . . . . . . . .

Process Pressure Connection 2-3. . . . . . . . . . .

Supply Pressure Connection 2-4. . . . . . . . . . . .

Remote Set Point (suffix letter M)

Pressure Connection 2-4. . . . . . . . . . . . . . . .

External Feedback Pressure Connection

(4195KB Series Controllers Only) 2-4. . . . . .

Vent 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. 4195KA Series Proportional-Only Controllers
Adjustments for 4195KA Series Controllers 3-1.

Manual Set Point Adjustment 3-1. . . . . . . . . . . .

Remote Set Point (suffix letter M)

Adjustment 3-1. . . . . . . . . . . . . . . . . . . . . . . . .

Proportional Band Adjustment (PB ADJ) 3-1. .

Changing Controller Action 3-2. . . . . . . . . . . . . .

Switching The Auto/Manual Station

(suffix letter E) 3-2. . . . . . . . . . . . . . . . . . . . . .

Prestartup Checks for 4195KA Series

Controllers 3-2. . . . . . . . . . . . . . . . . . . . . . . . . .

Startup for 4195KA Series Controllers 3-3. . . . .

Calibration of 4195KA Series Controllers 3-4. . .

General Calibration Instructions 3-4. . . . . . . . .

Process Indicator Zero and Span

Calibration 3-4. . . . . . . . . . . . . . . . . . . . . . . . .

Remote Set Point (suffix letter M)

Zero and Span Calibration 3-6. . . . . . . . . . . .

Flapper Alignment 3-6. . . . . . . . . . . . . . . . . . . . .

Principle of Operation for 4195KA Series

Controllers 3-7. . . . . . . . . . . . . . . . . . . . . . . . . .

Overall Operation 3-7. . . . . . . . . . . . . . . . . . . . . .

Remote Set Point (suffix letter M)

Operation 3-8. . . . . . . . . . . . . . . . . . . . . . . . . .

Auto/Manual Station (suffix letter E)

Operation 3-8. . . . . . . . . . . . . . . . . . . . . . . . . .

4. 4195KB Series Proportional-Plus-Reset
Controllers and 4195KC Series
Proportional-Plus-Reset-Plus-Rate Controllers

Adjustments for 4195KB and KC Series

Controllers 4-1. . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Set Point Adjustment 4-1. . . . . . . . . . . .

Remote Set Point (suffix letter M)

Adjustment 4-1. . . . . . . . . . . . . . . . . . . . . . . . .

Proportional Band Adjustment (PB ADJ) 4-2. .

Changing Controller Action 4-2. . . . . . . . . . . . . .

Reset Adjustment 4-2. . . . . . . . . . . . . . . . . . . . . .

Rate Adjustment 4-2. . . . . . . . . . . . . . . . . . . . . . .

Anti-Reset Windup (suffix letter F)

Adjustment 4-2. . . . . . . . . . . . . . . . . . . . . . . . .

Switching the Auto/Manual Station

(suffix letter E) 4-3. . . . . . . . . . . . . . . . . . . . . .

Prestartup Checks for 4195KB and

KC Series Controllers 4-3. . . . . . . . . . . . . . . . .

Startup for 4195KB and KC Series

Controllers 4-4. . . . . . . . . . . . . . . . . . . . . . . . . .

Calibration of 4195KB and KC Series

Controllers 4-4. . . . . . . . . . . . . . . . . . . . . . . . . .

General Calibration Instructions 4-5. . . . . . . . .

Process Indicator Zero and Span

Calibration 4-5. . . . . . . . . . . . . . . . . . . . . . . . .

Remote Set Point (suffix letter M)

Zero and Span Calibration 4-5. . . . . . . . . . . .

Flapper Alignment 4-7. . . . . . . . . . . . . . . . . . . . .

Anti-Reset Windup (suffix letter F)

Differential Relief Valve Calibration 4-9. . . .

Principle of Operation for 4195KB and

KC Series Controllers 4-10. . . . . . . . . . . . . . . .

Overall Operation 4-10. . . . . . . . . . . . . . . . . . . . .

Anti-Reset Windup (suffix letter F)

Operation 4-13. . . . . . . . . . . . . . . . . . . . . . . . .

Remote Set Point (suffix letter M)

Operation 4-13. . . . . . . . . . . . . . . . . . . . . . . . .

Auto/Manual Station (suffix letter E)

Operation 4-13. . . . . . . . . . . . . . . . . . . . . . . . .

External Feedback Operation 4-13. . . . . . . . . .

www.Fisher.com

D200160X012

4195KA, KB, KC, and KS Controllers

Instruction Manual

Form 5207

April 2007

Contents (continued)

5. 4195KS Series Differential Gap Controllers

Operating Information 5-1. . . . . . . . . . . . . . . . . . .

Adjustments for 4195KS Series Differential

Gap Controllers 5-1. . . . . . . . . . . . . . . . . . . . . .

Manual Set Point 5-1. . . . . . . . . . . . . . . . . . . . . .

Remote Set Point (Option M) 5-1. . . . . . . . . . . .

Proportional Band (Differential Gap) 5-1. . . . . .

Changing Controller Action 5-1. . . . . . . . . . . . . .

Auto/Manual Switching (Option E) 5-1. . . . . . .

Prestartup Checks 5-2. . . . . . . . . . . . . . . . . . . . . .

Startup 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Calibration 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Process Zero and Span Adjustment 5-3. . . . . .

Remote Set Point Zero and Span

(Option M) 5-4. . . . . . . . . . . . . . . . . . . . . . . . .

Setting Switching Points 5-5. . . . . . . . . . . . . . . .

Direct-Acting Controllers 5-5. . . . . . . . . . . . . . .

Reverse-Acting Controllers 5-5. . . . . . . . . . . . .

Principle of Operation 5-7. . . . . . . . . . . . . . . . . . .

Overall Operation 5-7. . . . . . . . . . . . . . . . . . . . . .

Remote Set Point (Option M) 5-8. . . . . . . . . . . .

Auto/Manual Option 5-8. . . . . . . . . . . . . . . . . . . .

6. Maintenance

Inspection and Maintenance 6-1. . . . . . . . . . . . . .

Troubleshooting 6-1. . . . . . . . . . . . . . . . . . . . . . . .

Replacing Common Controller Parts 6-1. . . . . . .

Replacing the Process Pressure Scale 6-5. . .

Replacing the Relay 6-6. . . . . . . . . . . . . . . . . . . .

Replacing the Case and Cover 6-6. . . . . . . . . .

Replacing the Gauges 6-6. . . . . . . . . . . . . . . . . .

Replacing the Supply Gauge, Proportional,

Reset, Reset Valve and Positive Tubing

Feedback Assemblies 6-7. . . . . . . . . . . . . . .

Replacing the Proportional Band Adjustment

Knob, Nozzle Assembly, and Set Point

Beam Assembly 6-7. . . . . . . . . . . . . . . . . . . . .

Replacing the Flapper Assembly and

Flapper Flexure Pivot Assembly 6-11. . . . . .

Replacing the Proportional or Reset

Bellows 6-15. . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Reset Restriction Valve

(4195KB Series) 6-17. . . . . . . . . . . . . . . . . . .

Replacing the Rate/Reset Valve Assembly

(4195KC Series) 6-18. . . . . . . . . . . . . . . . . . .

Replacing the Anti-Reset Windup

(suffix letter F) Differential Relief Valve 6-19

Replacing the Anti-Reset Windup

(suffix letter F) Relief Valve Tubing

Assembly 6-19. . . . . . . . . . . . . . . . . . . . . . . . .

Bourdon Tube Controller Maintenance

and Calibration 6-20. . . . . . . . . . . . . . . . . . . . . .

Replacing the Bourdon Tube 6-20. . . . . . . . . . .

Replacing Bourdon Tube Controller Links 6-20

Replacing Link 1 6-20. . . . . . . . . . . . . . . . . . . .

Replacing Link 2 6-21. . . . . . . . . . . . . . . . . . . .

Replacing Link 3 6-22. . . . . . . . . . . . . . . . . . . .

Replacing Link 4 6-22. . . . . . . . . . . . . . . . . . . .

Bourdon Tube Travel Stop Installation

and Adjustment 6-23. . . . . . . . . . . . . . . . . . . .

Bourdon Tube Controller Calibration:

Zero and Span Adjustment 6-24. . . . . . . . . .

Capsular Element Controller Maintenance

and Calibration 6-27. . . . . . . . . . . . . . . . . . . . . .

Replacing the Capsular Element

Assembly 6-27. . . . . . . . . . . . . . . . . . . . . . .

Replacing Capsular Element Parts 6-27. . . .

Replacing the Long Pivot Assembly 6-27. . .
Replacing the Short Pivot Assembly 6-28. . .
Replacing the Process Drive Flexure 6-28. .

Replacing the Process Tubing 6-29. . . . . . . .

Replacing Capsular Element

Controller Links 6-29. . . . . . . . . . . . . . . . . .

Replacing Link 1 6-30. . . . . . . . . . . . . . . . . . . .

Replacing Link 2 6-30. . . . . . . . . . . . . . . . . . . .

Replacing Link 3 6-30. . . . . . . . . . . . . . . . . . . .

Replacing Link 4 6-31. . . . . . . . . . . . . . . . . . . .

Replacing Link 5 6-31. . . . . . . . . . . . . . . . . . . .

Capsular Element Controller

Maintenance Calibration 6-32. . . . . . . . . . . . .

Precalibration Procedure 6-32. . . . . . . . . . . .

Aligning the Drive Bracket Assembly 6-32. .

Setting the Travel Stops 6-32. . . . . . . . . . . . .

Aligning the Linkage 6-33. . . . . . . . . . . . . . . .

Capsular Element Controller

Zero and Span Adjustment 6-34. . . . . . . . . .

Remote Set Point (suffix letter M)

Maintenance 6-36. . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Remote Set Point

Assembly 6-36. . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Remote Set Point

Assembly Parts 6-36. . . . . . . . . . . . . . . . . .

Replacing Pivot Assembly A (key 114) 6-36.
Replacing Pivot Assembly B (key 115) 6-37.

Replacing the Drive Flexure 6-37. . . . . . . . . .

Replacing the Remote Set Point Tubing 6-38

Replacing Link A 6-38. . . . . . . . . . . . . . . . . . .

Replacing Link B 6-38. . . . . . . . . . . . . . . . . . .

Remote Set Point (suffix letter M)

Maintenance Calibration 6-38. . . . . . . . . . . . . .

Precalibration Procedure 6-38. . . . . . . . . . . . . .

Aligning the Flexures 6-39. . . . . . . . . . . . . . . . . .

Setting the Travel Stops 6-39. . . . . . . . . . . . . . .

Aligning the Linkage 6-39. . . . . . . . . . . . . . . . . .

Remote Set Point Zero and Span

Adjustment 6-40. . . . . . . . . . . . . . . . . . . . . . . .

Remote Set Point Linearity Adjustment 6-41. .

Auto/Manual Station (suffix letter E)

Maintenance 6-41. . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Auto/Manual Station 6-41. . . . . .

1-2

Instruction Manual

Form 5207
April 2007

4195KA, KB, KC, and KS Controllers

W5663-1 / IL

Figure 1-1. 4195K Series Gauge Pressure Controllers

Contents (continued)

Replacing the Switch Body Assembly,

Lever O-Ring, Switch Body O-Ring,

and Tubing Assembly 6-42. . . . . . . . . . . . . . .

Replacing the Loader Range Spring,

Diaphragm Assembly, Ball Seat,

Tubing, and Ball 6-43. . . . . . . . . . . . . . . . . . . .

Replacing the Loader Valve Plug and

Valve Plug Spring 6-44. . . . . . . . . . . . . . . . . .

7. Parts

Parts Ordering 7-1. . . . . . . . . . . . . . . . . . . . . . . . .

Parts Kits 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts List 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Abbreviations Used In The Parts List 7-1. . . . .

Controller Common Parts 7-1. . . . . . . . . . . . . . .

Process and Set Point Indicator

Assembly 7-11. . . . . . . . . . . . . . . . . . . . . . . . .

Indicator Assembly 7-14. . . . . . . . . . . . . . . . . . .

Capsular Element Assembly 7-14. . . . . . . . . . .

Remote Set Point Assembly

(suffix letter M) 7-16. . . . . . . . . . . . . . . . . . . . .

Auto/Manual Station (suffix letter E) 7-17. . . . .

Controller Mounting Parts 7-19. . . . . . . . . . . . . .

Pipestand Mounting 7-19. . . . . . . . . . . . . . . . .

Pipestand Mounting with Regulator 7-19. . .

Panel Mounting 7-19. . . . . . . . . . . . . . . . . . . .

Wall Mounting 7-19. . . . . . . . . . . . . . . . . . . . . .

NAMEPLATE

W6831 / IL

Controller Mounting Parts for Actuator

with Casing-Mounted Controller 7-19. . . .

Controller Mounting Parts for Actuator

with Yoke-Mounted Controller 7-19. . . . . .

Regulator Mounting Parts 7-19. . . . . . . . . . . . . .

Regulator Mounting Parts for

Casing-Mounted Regulator 7-19. . . . . . . .

Regulator Mounting Parts for

Yoke-Mounted Regulator (Mounting

Bracket Not Required) 7-19. . . . . . . . . . . .

Regulator Mounting Parts for

Yoke-Mounted Regulator

(With Mounting Bracket) 7-19. . . . . . . . . . .

Fittings 7-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 1 Introduction

Scope of Manual

This instruction manual provides installation,
operating, calibration, maintenance, and parts
ordering information for 4195KA, KB, KC, and KS
Series gauge pressure indicating controllers.

1-3

4195KA, KB, KC, and KS Controllers

Instruction Manual

Form 5207

April 2007

Portions of this manual apply only to specific 4195K
Series 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.

The specific controller type number (with letter
suffixes) is located on the nameplate shown in figure
1-1. Refer to table 1-2 for the definition of each
4195K Series type number.

Do not install, operate, or maintain this product
without first D being fully trained and qualified in
valve, actuator, and accessory installation,
operation, and maintenance, and D carefully reading
and understanding the contents of this manual. If
you have any questions about these instructions,
contact your Emerson Process Managementt sales
office before proceeding.

Description

The controllers described in this manual provide
gauge pressure control with the options as shown in
table 1-2.

Specifications

Specifications for the 4195KA, KB, KC, and KS
Series controllers are listed in table 1-1.

Educational Services

For information on available courses for the 4195KA,
4195KB, 4195KC, and 4195KS Series gauge
pressure indicating controllers, as well as a variety
of other products, contact:

Emerson Process Management
Educational Services, Registration
P.O. Box 190; 301 S. 1st Ave.
Marshalltown, IA 50158−2823
Phone: 800−338−8158 or
Phone: 641−754−3771
FAX: 641−754−3431
e-mail: [e-mail]

D 4195KA Series: Proportional-only control

D 4195KB Series: Proportional-plus-reset control

D 4195KC Series:

Proportional-plus-reset-plus-rate control

D 4195KS Series: Differential gap control

These controllers show process pressure and set
point on an easy-to-read process scale. The
controller output is a pneumatic signal that operates
a final control element.

Note

Neither Emerson, Emerson Process
Management, nor any of their affiliated
entities assumes responsibility for the
selection, use, and maintenance of
any product. Responsibility for the
selection, use, and maintenance of
any product remains with the
purchaser and end-user.

1-4

Instruction Manual

Form 5207
April 2007

4195KA, KB, KC, and KS Controllers

Table 1-1. Specifications

Available Configurations

See table 1-2

Input Signal (Process Sensor Range

(1)

)

Lower and Upper Range Limits: See tables 1-3

and 1-4

Maximum Allowable Operating Limits: See

tables 1-3 and 1-4

Output Signal

(1)

Proportional-Only, Proportional-Plus-Reset,
or Proportional-Plus-Reset-Plus-Rate Range:

0.2 to 1.0 bar or 0.4 to 2.0 bar (3 to 15 psig or 6
to 30 psig)

Differential Gap Range: 0 and 1.4 bar (0 and 20

psig) or 0 and 2.4 bar (0 and 35 psig)

Action: Field-reversible between direct

(increasing sensed process pressure increases
output pressure) or reverse (increasing sensed
process pressure decreases output pressure).

Process Scale

Standard scale is matched to the range of the
sensing element, with the exception of receiver
controllers. Optional

(2)

scales are available.

Process Connections

Standard: 1/4 NPT, internal, stainless steel (all

input ranges)

Optional: 1/2 NPT, see table 1-5

Supply and Output Connections

1/4 NPT, internal

Supply Pressure Requirements

(3)

See table 1-6

Supply Pressure Medium

Air or natural gas

(4)

Remote Set Point Pressure Ranges

0.2 to 1.0 bar or 0.4 to 2.0 bar (3 to 15 psig or 6
to 30 psig)

continued

Controller Adjustments

Proportional Band

input span

(1)

Reset

: Adjustable from 0.01 to more than 74

(1)

: 5 to 500% of process

minutes per repeat (from 100 to less than 0.0135
repeats per minute)

(1)

Rate
Differential Gap

: Adjustable from 0 to 20 minutes

(1)

Controllers: Adjustable from
5 to 100% of process scale range
Set Point: Adjustable from 0 to 100% of the scale

span

Controller Performance

Repeatability
Dead Band

(1)

: 0.4% of output span

(1)

: Less than 0.4% of process scale

span

Typical Frequency Response: 1.5 hertz and 90

degree phase shift with 3.05 m (10 feet) of 6.4
mm (1/4-inch) tubing and 1639 cm

3 (

100 cubic

inch) volume

Steady-State Air Consumption

(1,5,6)

0.2 to 1.0 Bar (3 to 15 Psig) Output: 0.1 normal

m3/hr (3.5 scfh)

0.4 to 2.0 Bar (6 to 30 Psig) Output: 0.14 normal

m3/hr (5.0 scfh)

Delivery Capacity

(5)

0.2 to 1.0 Bar (3 to 15 Psig) Output: 5.9 normal

m3/hr (240 scfh)

0.4 to 2.0 Bar (6 to 30 Psig) Output: 10.4 normal

m3/hr (350 scfh)

Operative Ambient Temperature Limits

(1,3,7)

−40 to 71_C (−40 to 160_F)

Exhaust Capacity

(5)

0.2 to 1.0 Bar (3 to 15 Psig) Output: 4.6 normal

m3/hr (186 scfh)

0.4 to 2.0 Bar (6 to 30 Psig) Output: 7.0 normal

m3/hr (295 scfh)

Hazardous Area Classification

Complies with the requirements of ATEX Group II
Category 2 Gas and Dust

1-5

4195KA, KB, KC, and KS Controllers

Table 1-1. Specifications (continued)

Instruction Manual

Form 5207

April 2007

Housing

Designed to NEMA 3 (Weatherproof) and IEC
529 IP54 Specifications

Declaration of SEP

Fisher Controls International LLC declares this
product to be in compliance with Article 3
paragraph 3 of the Pressure Equipment Directive

Mounting

Controller can be mounted on actuator, panel,
wall, or pipestand.

Approximate Weight

4.5 kg (10 pounds)

1. These terms are defined in ISA Standard S51.1.

2. Consult your Emerson sales office for additional information.

3. The pressure/temperature limits in this document and any applicable standard or code limitation should not be exceeded.

4. This product can be used with natural gas. Natural gas should not contain more than 20 ppm of H2S.

5. Normal m3/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).

6. Without auto/manual station. With auto/manual station, air consumption is 0.28 normal m3/hr (10.0 Scfh) for either output range.

7. Also use these temperatures for transportation and storage limits.

Table 1-2. Available Configurations for 4195KA, 4195KB, 4195KC, and 4195KS Series Controllers

MODES OPTIONS

Proportional-

Plus-Reset-

Plus-Rate

(Three-Mode

Controllers)

(1)

Proportional-

Only

(One-Mode

Controllers)

X
X
X
X

− − −

− − −

− − −

− − −

− − −

− − −

− − −

− − −

− − −

− − −

− − −

− − −

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SERIES

4195KA

4195KB

4195KC

4195KS

1. Reverse-acting constructions are designated by the suffix letter R added to the type number.

TYPE

NUMBER

4195KA
4195KAE
4195KAM
4195KAME

4195KB
4195KBE
4195KBF
4195KBFE
4195KBM
4195KBME
4195KBFM
4195KBFME

4195KC
4195KCE
4195KCF
4195KCFE
4195KCM
4195KCME
4195KCFM
4195KCFME

4195KS
4195KSE
4195KSM
4195KSME

Proportional-

Plus-Reset
(Two-Mode

Controllers)

− − −

− − −

− − −

− − −

X
X
X
X
X
X
X
X

− − −

− − −

− − −

− − −

− − −

− − −

− − −

− − −

− − −

− − −

− − −

− − −

(PED) 97 / 23 / EC. It was designed and
manufactured in accordance with Sound
Engineering Practice (SEP) and cannot bear the
CE marking related to PED compliance.

However, the product may bear the CE marking
to indicate compliance with other applicable EC

Directives.

− − −

− − −

− − −

− − −

− − −

− − −

− − −

− − −

− − −

− − −

− − −

− − −

X
X
X
X
X
X
X
X

− − −

− − −

− − −

− − −

Differential

Gap

Controller

− − −

− − −

− − −

− − −

− − −

− − −

− − −

− − −

− − −

− − −

− − −

− − −

− − −

− − −

− − −

− − −

− − −

− − −

− − −

− − −

X
X
X
X

Auto/Manual

Internal

Station

E

− − −
X

− − −
X

− − −
X

− − −
X

− − −
X

− − −
X

− − −
X

− − −
X

− − −
X

− − −
X

− − −
X

− − −
X

Anti-Reset

Windup

F

− − −

− − −

− − −

− − −

− − −

− − −

X
X

− − −

− − −

X
X

− − −

− − −

X
X

− − −

− − −

X
X

− − −

− − −

− − −

− − −

Remote

Setpoint

M

− − −

− − −

X
X

− − −

− − −

− − −

− − −

X
X
X
X

− − −

− − −

− − −

− − −

X
X
X
X

− − −

− − −

X
X

1-6

Instruction Manual

Form 5207
April 2007

4195KA, KB, KC, and KS Controllers

Table 1-3. Process Sensor (Capsular Element) Pressure Ratings

(1)

CAPSULE

MATERIAL

Metric units

N09902

U.S. units

1. Minimum or maximum span, or any span in between, may be positioned anywhere within the operating range. For example, if a 0 to 350 mbar (0 to 5 psig) sensing element is used
and the minimum span of 1.75 mbar (2.5 psig) is set, the process indication can be calibrated to a range of −340 mbar to −203 mbar (−10 inch Hg to −6 inch Hg), 0 to 172 mbar
(0 to 2.5 psig), 172 to 345 mbar (2.5 to 5 psig), 305 to 480 mbar (4.5 to 7 psig), or any value between minimum and maximum values of operating range.

2. Capsules with the travel stops set may be pressured to this value without permanent zero shift.

CAPSULAR

STANDARD RANGES

Positive pressure

Vacuum

Compound

Positive pressure

Vacuum

Compound

0 to 150 mbar
0 to 400 mbar
0 to 0.6 bar

0.2 to 1 bar
0 to 1 bar

0 to 1.4 bar
0 to 1.6 bar

0.4 to 2 bar
0 to 2 bar

−150 to 0 mbar

−340 to 0 mbar

−400 to 0 mbar

−0.6 to 0 bar

−1 to 0 bar

−50 to 100 mbar

−175 to 175 mbar

−150 to 250 mbar

−0.2 to 0.4 bar

−0.4 to 0.6 bar

−0.6 to 0.8 bar

−1 to 0.6 bar

−1 to 1 bar

0 to 60 inch wc
0 to 5 psig
0 to 10 psig
3 to 15 psig
0 to 15 psig

0 to 20 psig
6 to 30 psig
0 to 30 psig

−5 to 0 inch Hg

−10 to 0 inch Hg

−20 to 0 inch Hg

−30 to 0 inch Hg

−30 to 30 inch wc

−5 inch Hg to 2.5 psig

−10 inch Hg to 5 psig

−15 inch Hg to 7.5 psig

−20 inch Hg to 10 psig

−30 inch Hg to 15 psig

SPAN

Min Max Min Max

100 mbar
350 mbar

0.35 bar

0.4 bar

0.5 bar

0.7 bar
1 bar

0.8 bar
1 bar

85 mbar
170 mbar
350 mbar

0.35 bar

0.5 bar
100 mbar

175 mbar
350 mbar

0.35 bar

0.5 bar

0.7 bar
1 bar
1 bar

40 inch wc

2.5 psig
5 psig
6 psig

7.5 psig
10 psig

12 psig
15 psig

2.5 inch Hg
5 inch Hg
10 inch Hg
15 inch Hg

40 inch wc

2.5 psig
5 psig

7.5 psig
10 psig
15 psig

160 mbar
700 mbar

0.7 bar

0.8 bar
1 bar

1.4 bar
2 bar

1.6 bar
2 bar

170 mbar
340 mbar
700 mbar

0.7 bar
1 bar

160 mbar
350 mbar
700 mbar

0.7 bar

1 bar

1.4 bar
2 bar
2 bar

60 inch wc
5 psig
10 psig
12 psig
15 psig

20 psig
24 psig
30 psig

5 inch Hg
10 inch Hg
20 inch Hg
30 inch Hg

60 inch wc
5 psig
10 psig

15 psig
20 psig
30 psig

OPERATING RANGE

−350 mbar

−1 bar

−1 bar

−1 bar

−1 bar

−1 bar

−1 bar

−1 bar

−1 bar

−350 mbar

−480 mbar

−1 bar

−1 bar

−1 bar

−350 mbar

−480 mbar

−1 bar

−1 bar

−1 bar

−1 bar

−1 bar

−1 bar

−10 inch Hg

−14 inch Hg

−30 inch Hg

−30 inch Hg

−30 inch Hg

−30 inch Hg

−30 inch Hg

−30 inch Hg

−10 inch Hg

−14 inch Hg

−30 inch Hg

−30 inch Hg

−10 inch Hg

−14 inch Hg

−30 inch Hg

−30 inch Hg

−30 inch Hg

−30 inch Hg

350 mbar
1 bar
1 bar

1.4 bar

1.4 bar

1.7 bar

2.4 bar
2 bar

2.4 bar

350 mbar
480 mbar
1 bar
1 bar

1.4 bar
350 mbar

480 mbar
1 bar
1 bar

1.4 bar

1.7 bar

2.4 bar

2.4 bar

5 psig
7 psig
15 psig
20 psig
20 psig

25 psig
30 psig
35 psig

5 psig
7 psig
15 psig
20 psig

5 psig
7 psig
15 psig

20 psig
25 psig
35 psig

OPERATING

LIMIT

510 mbar

1.5 bar

1.5 bar
2 bar
2 bar

2.5 bar

3.5 bar
3 bar

3.5 bar

510 mbar
724 mbar

1.5 bar

1.5 bar
2 bar

510 mbar
724 mbar

1.5 bar

1.5 bar

2 bar

2.5 bar

3.5 bar

3.5 bar

7.5 psig

10.5 psig

22.5 psig
30 psig
30 psig

37.5 psig
45 psig

52.5 psig

7.5 psig

10.5 psig

22.5 psig
30 psig

7.5 psig

10.5 psig

22.5 psig
30 psig

37.5 psig

52.5 psig

(2)

1-7

4195KA, KB, KC, and KS Controllers

Instruction Manual

Form 5207

April 2007

Table 1-4. Process Sensor (Bourdon Tube) Pressure Ratings and Materials

BOURDON TUBES

SPAN

Minimum Maximum Minimum Maximum

OPERATING RANGE

(1)

Bar

Metric units

0 to 1.6
0 to 2.5
0 to 4
0 to 6

0 to 10
0 to 16
0 to 25
0 to 40

0 to 60
0 to 100
0 to 160
0 to 300

10
20
20

55

76
160
250

1
2
2

3.5

7

14
20
40
40

70
100
200
350

2
4
4
7

−1

−1

−1

−1

−1

−1

0
0

0
0
0
0

Psig Psig Psig Inch Hg Psig Psig

0 to 30
0 to 60
0 to 100
0 to 200

U.S. units

0 to 300
0 to 600
0 to 1000
0 to 1500

0 to 3000
0 to 5000

1. Minimum or maximum span, or any span in between, may be positioned anywhere within the operating range. For example, if a 0 to 2 bar (0 to 30 psig) sensing element is used
and the minimum span of 1 bar (15 psig) is set, the process indication can be calibrated to a range of −1 to 0 bar (−30 inch Hg to 0 psig), 0 to 1 bar (0 to 15 psig), 1 to 2 bar (15 to 30
psig), 2 to 3 bar (27 to 42 psig) or any value between the operating range minimum and maximum values.

2. Travel stops should be used when the maximum or minimum process pressure will be 5% over or under the calibrated range. For example, a 0 to 2 bar (0 to 30 psig) sensing
element is calibrated for 0.7 to 2 bar (10 to 30 psig), the desired range. The minimum expected pressure is 0 psig and the maximum expected pressure is 2.8 bar (40 psig). Travel
stops must be used to prevent excessive overtravel and undertravel since the maximum allowable overpressure and underpressure is higher than 5% of the 1.4 bar (20 psig) span
which is ±70 mbar (±1 psig).

3. Bourdon tube without travel stops may be pressured to this value without permanent zero shift.

4. Bourdon tube with travel stops set may be pressured to this value without permanent zero shift.

15
30
50

100

150
300
750

1100

2200
3700

30

60
100
200

300
600

1000
1500

3000
5000

−30

−30

−30

−30

−30

0
0
0

0
0

10

20
30
60
60

90
135
270
420

42

84
140
280

420
840

1300
1950

3900
6000

(2)

(3)

3
6
6

OPERATING

LIMITS

(4)

3.3

6.6

6.6

STANDARD

MATERIAL

11

22
33
66

S31600 (316 SST)

66

103
155
310
482

STANDARD

MATERIAL

48

96
160
320

480
960

S31600 (316 SST)

1500
2250

4500
7000

Table 1-5. Optional Process Connections

INPUT RANGE CONNECTION

Bar Psig Size Material

Up to
0 to 400

0 to 400 to
0 to 600

0 to 400 to
0 to 600

Up to
0 to 5000

0 to 5000 to
0 to 10,000

0 to 5000 to
0 to 10,000

J 1/2 NPT external

or J 1/2 NPT
internal

1/2 NPT internal Stainless steel

1/2 NPT external Stainless steel

J Steel or
J stainless

steel

Table 1-6. Supply Pressure Data

OUTPUT SIGNAL

RANGE

Bar

Psig

1. If this pressure is exceeded, control may be impaired.

2. If this pressure is exceeded, damage to the controller may result.

0.2 to 1.0 1.4 2.8

0.4 to 2.0 2.4 2.8

3 to 15 20 40

6 to 30 35 40

NORMAL

OPERATING

SUPPLY

PRESSURE

MAXIMUM

PRESSURE LIMIT

(1)

(2)

1-8

Instruction Manual

Form 5207
April 2007

4195KA, KB, KC, and KS Controllers

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 preventative
measures are not taken. Preventative
measures may include: Remote
venting of the unit, re-evaluating the
hazardous area classification,
ensuring adequate ventilation, and the
removal of any ignition sources. For
information on remote venting of this
controller, refer to page 2-5.

D Check with your process or
safety engineer for any additional
measures that must be taken to
protect against process media.

D If installing into an existing
application, also refer to the
WARNING at the beginning of the
Maintenance section of this
instruction manual.

Controller Mounting Orientation

Mount the controller with the housing vertical, as
shown in figure 2-1, so the vent points down.

TYPE 657
ACTUATOR

TYPE 4195K
CONTROLLER

TYPE 67CFR
FILTER
REGULATOR

MOUNTING

W8462−1

Figure 2-1. Typical Actuator Mounting

PLATE

Panel Mounting

Using the dimensions shown in figure 2-3, cut a hole
in the panel surface. Slide the controller into the hole
and attach the bracket (key 68) to the rear of the
controller using three cap screws (key 66) and lock
washers (key 67). Tighten the screws (key 70) to
seat the case snugly and evenly against the panel
surface.

Wall Mounting

Using the dimensions in figure 2-4, drill holes in the
wall to align with the four holes in the bracket (key

68). If the tubing is to run through the wall, drill a
hole in the wall large enough to accept the tubing.
Mount the controller to the bracket using three cap
screws (key 66) and lock washers (key 67). Attach
the bracket to the wall, using suitable screws or
bolts.

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.

Actuator Mounting

Refer to figure 2-1. A controller specified for
mounting on a control valve actuator is mounted at
the factory. If the controller is ordered separately for
installation on a control valve actuator, mount the
unit as described in this section. Mounting parts vary
for different actuator types.

2-1

4195KA, KB, KC, and KS Controllers

HEX HEAD
CAP SCREW
(KEY 66)

LOCKWASHER
(KEY 67)

HEX HEAD
CAP SCREW
(KEY 362)

Instruction Manual

Form 5207

April 2007

REGULATOR

49A3196-A
A6732 / IL

HEX NUT
(KEY 364)

LOCKWASHER
(KEY 363)

PIPE CLAMP
(KEY 69)

VERTICAL PIPE

LOCKWASHER
(KEY 363)

HEX NUT
(KEY 364)

HEX HEAD
CAP SCREW
(KEY 66)

LOCKWASHER
(KEY 67)

BRACKET
(KEY 68)

ELBOW
(KEY 365)

HEX HEAD
CAP SCREW
(KEY 362)

PIPE CLAMP
(KEY 69)

BRACKET
(KEY 68)

ELBOW
(KEY 365)

HORIZONTAL PIPE

Figure 2-2. Pipestand Mounting

Attach the mounting bracket to the actuator yoke
with cap screws, lock washers, and spacer spools.
Attach the controller to the bracket with cap screws,
lock washers, and spacer spools. On some designs,
the mounting bracket is attached to the actuator
casing rather than to the yoke.

Pressure Connections

WARNING

To avoid personal injury or property
damage resulting from the sudden
release of pressure, do not install any

2-2

system component where service
conditions could exceed the limits
given in this manual. Use
pressure-relieving devices as required
by government or accepted industry
codes and good engineering
practices.

Refer to figure 2-5 for pressure connection locations.
Supply, output, remote set point, external feedback,
and vent connections are 1/4 NPT, internal. Process
pressure connections are 1/4 or 1/2 NPT (optional).
Use 1/4-inch or 3/8-inch pipe or tubing for supply,
output, remote set point, and external feedback
connections.

Instruction Manual

Form 5207
April 2007

LOCK
WASHER
(KEY 67)

HEX HEAD
CAP SCREW
(KEY 66)

BRACKET
(KEY 68)

ROUND
HEAD
MACHINE
SCREW
(KEY 70)

TOP VIEW

13
(0.50)

84
(3.29)

62
(2.43)

63
(2.49)

14 R
(0.56)

236
(9.31)

4195KA, KB, KC, and KS Controllers

161
(6.35)

306
(12.06)

152
(6.00)

TOP VIEW

260
(10.25)

LOCKWASHER
(KEY 67)

HEX HEAD
CAP SCREW
(KEY 66)

REAR VIEW DIMENSIONS OF

36A9760-A
A6733 / IL

PANEL CUTOUT

mm
(INCH)

Figure 2-3. Panel Mounting

Process Pressure Connection

The connection marked A on the bottom of the case
is the process input for all Bourdon tube controllers
and those capsular element controllers used in
vacuum pressure applications. The connection
marked B is the process input for capsular element
controllers used in positive pressure and compound
pressure applications. See figure 2-5 for the location
of the A and B connections.

When installing process piping, follow accepted
practices to ensure accurate transmission of the
process pressure to the controller. Install a
three-valve bypass, shutoff valves, vents, drains, or
seal systems as needed in the process pressure
lines. If necessary, install a needle valve in a
process pressure sensing line to dampen pulsations.

If the instrument is located such that the adjacent
process pressure lines are approximately horizontal,

62

13
(0.50)

13
(0.50)

(2.43)

BRACKET
(KEY 68)

REAR VIEW

36A9761-B
A6734 / IL

mm
(INCH)

Figure 2-4. Wall Mounting

the lines should slope downward to the instrument
for liquid-filled lines and upward toward the
instrument for gas-filled lines. This reduces the
possibility of air becoming trapped in the sensor with
liquid-filled lines or of condensation becoming
trapped in gas-filled lines. The recommended slope
is 83 millimeters per m (1 inch per foot).

If the controller is being used in conjunction with a
control valve to control pipeline pressure, connect
the process pressure line in a straight section of pipe
approximately 10 pipe diameters away from the
valve and also away from bends, elbows, and areas
of abnormal fluid velocities. For pressure-reducing
service, the process pressure line must be
connected downstream of the control valve. For
pressure-relief service, the process pressure line
must be connected upstream of the control valve.

2-3

4195KA, KB, KC, and KS Controllers

Supply Pressure Connection

WARNING

Severe personal injury or property
damage may occur if the instrument
air supply is not clean, dry and
oil-free, or noncorrosive gas. While
use and regular maintenance of a filter
that removes particles larger than 40
microns in diameter will suffice in
most applications, check with an
Emerson Process Management 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.

Supply pressure must be clean, dry air or
noncorrosive gas that meets the requirements of
ISA Standard S7.3. Use a suitable supply pressure
regulator to reduce the supply pressure source to
the normal operating supply pressure shown in table
1-6. Connect supply pressure to the SUPPLY
connection on the bottom of the case, shown in
figure 2-5.

Remote Set Point (suffix letter M) Pressure Connection

1/4-18 NPT
CONTROLLER OUTPUT
CONNECTION

NOTES:

1
BOURDON TUBE CONTROLLERS AND FOR THOSE CAPSULAR
ELEMENT CONTROLLERS USED IN VACUUM PRESSURE APPLICATIONS.

2
ELEMENT CONTROLLERS USED IN POSITIVE AND COMPOUND
PRESSURE APPLICATIONS.

3
ONLY), EITHER THE A OR B CONNECTION IS USED, DEPENDING ON THE
LOCA TION OF THE PROCESS CONNECTION.

46A9765-A
A2892-4 / IL

Instruction Manual

Form 5207

April 2007

102

147
(5.80)

(4.00)

REAR VIEW

51
(2.00)

5/16
UNC-28
3 HOLES
(MOUNTING)

3.44
(87)

10.04
(255)

1/4 NPT
REMOTE SET POINT
CONNECTION

TOP VIEW

mm
(INCH)

260
(10.25)

FRONT VIEW

1/4-18
NPT VENT
CONNECTION

BOTTOM VIEW

1/4-18 NPT PROCESS CONNECTION (MARKED A) FOR ALL

1/4-18 NPT PROCESS CONNECTION (MARKED B) FOR CAPSULAR

FOR THE EXTERNAL FEEDBACK CONNECTIONS (4195KB CONTROLLERS

130
(5.13)

330
(13.00)

1/4-18 NPT
SUPPLY PRESSURE
CONNECTION

66
(2.56)

31
(1.22)

1/4 NPT 4 HOLES

If the controller has remote set point (suffix letter M),
connect the remote set point pressure to the top of
the controller case at the location shown in figure
2-5. Use clean, dry air or noncorrosive gas. Use a

0.2 to 1.0 bar (3 to 15 psig) remote set point
pressure range for a 0.2 to 1.0 bar (3 to 15 psig)
controller output signal range or a 0.4 to 2.0 bar (6
to 30 psig) remote set point pressure range for a 0.4
to 2.0 bar (6 to 30 psig) controller output signal
range. If pressure is supplied to the remote set point
connection with a regulator, a small bleed orifice
should be placed between the regulator and remote
set point connection to prevent pressure variations
due to regulator lock-up.

Figure 2-5. Connection Locations

External Feedback Pressure Connection (4195KB Series Controllers Only)

When a secondary controller in an override
application has this option, reset windup is
minimized in the secondary controller. Connect the
external feedback connection of the secondary
controller to the output of the customer-supplied high
or low select relay (see figures 2-5 and 4-9).

2-4

Instruction Manual

Form 5207
April 2007

4195KA, KB, KC, and KS Controllers

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.
However, a remote vent pipe alone
cannot be relied upon to remove all
flammable or hazardous gas. Vent line
piping should comply with local and
regional codes and should be as short
as possible with adequate inside
diameter and few bends to reduce
case pressure buildup.

CAUTION

When installing a remote vent pipe,
take care not to over-tighten the pipe
in the vent connection. Excessive
torque will damage the threads in the
connection.

If a remote vent is required, the vent line must be as
short as possible with a minimum number of bends
and elbows. Vent line piping should have a minimum
inside diameter of 19 mm (3/4 inches) for runs up to

6.1 meters (20 feet) and a minimum inside diameter
of 25 mm (1 inch) for runs from 6.1 to 30.5 meters
(20 to 100 feet).

The vent must be protected against the entrance of
any foreign material that could plug it; or if a remote
vent is not required, the vent opening in the case
must be protected against the entrance of any
foreign material that could plug it. Check the vent
periodically to be certain it is not plugged.

2-5

4195KA, KB, KC, and KS Controllers

Instruction Manual

Form 5207

April 2007

2-6

Instruction Manual

Form 5207
April 2007

4195KA, KB, KC, and KS Controllers

METAL BALL
SWITCHING ZONE

INDICATOR

LOADER KNOB

AUTO/MANUAL
SWITCH

W6832 / IL

Figure 3-1. 4195KA Series Controller Adjustment Locations

Section 3 4195KA Series Proportional-Only Controllers

Adjustments for 4195KA Series Controllers

This section includes descriptions of adjustments
and procedures for prestartup, startup, and
calibration. Adjustment locations are shown in
figures 3-1 and 3-3. To better understand the
adjustments and overall controller operation, refer to
the 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.

SET POINT
INDICATOR

PROCESS POINTER

PROPORTIONAL BAND
ADJUSTMENT

PROPORTIONAL BAND
INDICATOR COVER

OUTPUT PRESSURE
GAUGE

W3679 / IL

AUTO/MANUAL STATION

(SUFFIX LETTER E)

Remote Set Point (suffix letter M) Adjustment

CAUTION

Do not manually move the set point
indicator on controllers with remote
set point. Manually moving the set
point 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. Increase the pressure to
increase the set point, and decrease the pressure to
decrease the set point.

Manual Set Point Adjustment

Adjust the set point by moving the set point indicator
until the line on the set point indicator is over the
desired value on the process pressure scale. Move
the indicator to the right to increase the set point and
to the left to decrease it. Adjusting the set point does
not affect the proportional band setting.

Proportional Band Adjustment (PB ADJ)

The proportional band determines the controller
output sensitivity. The proportional band adjustment
is marked in percentages of process pressure
required to drive the controller from zero output to
full output.

3-1

4195KA, KB, KC, and KS Controllers

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)

W3439 / IL

Figure 3-2. Changing Controller Action on

4195KA Series Controllers

To adjust the proportional band, open the controller
cover and locate the proportional band adjustment
(PB ADJ) knob. Rotate the knob until the desired
value is opposite the line on the proportional band
indicator cover.

Changing Controller Action

To change the controller action from direct to
reverse or vice versa, loosen the screws on the
proportional band indicator cover. Lift the cover out
as shown in figure 3-2 and rotate the proportional
band adjustment to the desired action. 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.

Bourdon Tube or Capsular Element Controllers for Positive or Compound Pressure

Refer to figure 3-1 if the controller has the
auto/manual station (suffix letter E). To switch from
automatic to manual mode, or from manual to
automatic, you must first balance the manual output
with the controller output. Two balance methods are
available to equalize the manual output with the
controller output.

To switch from automatic to manual mode, carefully
adjust the loader knob until the metal ball inside the
plastic tube moves into the switching zone. Then
move the automatic/manual switch to MANUAL.
Turn the loader knob clockwise to increase the
controller output or counterclockwise to decrease it.

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.

Instruction Manual

Form 5207

April 2007

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.

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:

An increasing sensed vacuum increases output
pressure.

3-2

When the auto/manual switch is in AUTO, adjusting
the loader knob has no effect on the controller
output. When the auto/manual switch is in MANUAL,
changing the set point has no effect on the controller
output.

Prestartup Checks for 4195KA Series Controllers

Refer to figure 3-1 for adjustment locations and refer
to figure 7-1 for key number locations.

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.

Instruction Manual

Form 5207
April 2007

4195KA, KB, KC, and KS Controllers

Note

If the controller has the auto/manual
station (suffix letter E), be sure the
controller is in the automatic mode
before performing the prestartup
checks.

1. Provide a means of measuring the controller
output pressure by connecting the controller output
to a pressure gauge. Connect supply pressure to the
supply pressure regulator and be sure it is delivering
the proper supply pressure to the controller. Do not
exceed the normal operating pressure in table 1-6.

2. For a controller with remote set point (suffix letter
M), connect regulated pressure of 0.2 to 1.0 bar (3
to 15 psig) or 0.4 to 2.1 bar (6 to 30 psig) to the
remote set point connection at the top of the
controller case.

3. Remove the two machine screws (key 6) and lift
off the proportional band indicator cover (key 36).

4. Adjust the set point a minimum of 20 percent of
input span above the process pointer.

5. Adjust the proportional band for 5 percent
DIRECT.

6. If necessary, connect a pressure source to the
process connection and adjust the process pointer
to the last mark on the left side of the scale. If the
last scale mark is 0 psig, a pressure source is not
required.

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.

Note

When performing the startup
procedures, keep in mind that the
initial settings are guidelines. They
will vary depending on the actual
process being controlled.

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 adjustment to the desired set
point.

Remote set point:

a. See figure 2-5 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.

3. Set the proportional band adjustment to 100
percent for fast processes. For slow processes,
calculate the proportional band percentage from the
equation below:

P.B. +

For example:

200 Allowable Overshoot

Pressure Span

10. If the controller output is within tolerance, adjust
the proportional band to 400 percent in the desired
action, secure the proportional band indicator cover
(key 36) with the machine screws (key 6), and go to
the startup procedure. If the controller output
pressure is not within tolerance, go to the 4195KA
Series calibration procedure for recalibration.

Startup for 4195KA Series Controllers

Perform the prestartup checks and, if necessary,
calibrate the controller prior to this procedure.

200 0.14 bar

2.1 bar

4. Create a load upset by momentarily changing the
set point. Check for system cycling. If the system
does not cycle, lower the proportional band setting
(thus raising the gain) and disturb the system again
by changing the set point. Continue this procedure
until the system cycles. At this point, double the
proportional band setting (proportional band setting
×2).

5. Check the stability of the recommended
proportional band setting by introducing a
disturbance and monitoring the process.

^ 13%

3-3

4195KA, KB, KC, and KS Controllers

Instruction Manual

Form 5207

April 2007

Calibration of 4195KA Series 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.

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. Unless
otherwise noted, key numbers are found in
figure 7-1.

Do not use the gauges supplied with the controller
during calibration. Monitor process pressure, supply
pressure, controller output pressure, and if
applicable, remote set point pressure with external
gauges.

Process Indicator Zero and Span Calibration

Before starting this procedure:

D Provide a regulated process pressure to the
controller and a means of measurement external to
the controller.

D Provide a means of measuring the controller
output pressure by connecting the controller output
to a pressure gauge (open loop conditions must
exist). Provide a regulated supply pressure to the
controller. Do not exceed the normal operating
pressure in table 1-6.

readjustment of the process pointer
zero adjustment.

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. 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.

5. Apply process pressure equal to the process
scale span upper limit.

6. The process pointer should indicate the process
scale upper limit. If not, adjust the span screw to
correct one-half of the error as follows: clockwise to
increase span for a low indication (below the upper
limit); counterclockwise to decrease span for a high
indication (above the upper limit).

7. Repeat steps 3 through 6 until the error is
eliminated.

8. Apply process pressure equal to the mid-scale
value of the process scale span. The process
pointer should indicate the mid-scale mark, ±2
percent of span. If the error is greater than ±2
percent, refer to the Maintenance section and
perform the appropriate zero and span adjustment
procedure for a Bourdon tube or capsular element
controller.

9. Adjust the process pointer to within ±1 percent of
the mid-scale mark by loosening the locking screw
and turning the zero adjustment screw. This
distributes the error over the entire scale span and
brings all points within ±1 percent of the process
input span.

10. Apply process pressure equal to the process
scale span lower limit.

11. The process pointer should indicate the process
scale lower limit ±1 percent of the scale span.

Refer to figures 3-1 and 3-3 for adjustment
locations.

Note

Any change to the process pointer
span adjustment will require

3-4

12. Apply process pressure equal to the process
scale span upper limit.

13. The process pointer should indicate the process
scale upper limit ±1 percent of the scale span.

14. If the error is greater than ±1 percent, repeat
steps 3 through 13.

Instruction Manual

Form 5207
April 2007

REMOTE SET POINT
ZERO ADJUSTMENT
(SUFFIX LETTER M)

4195KA, KB, KC, and KS Controllers

POINTER ZERO
ADJUSTMENT

POINTER ZERO
ADJUSTMENT
LOCKING SCREW

W6832 / IL

PROCESS
POINTER SPAN
ADJUSTMENT

A6730 / IL

REMOTE SET POINT
ZERO ADJUSTMENT
LOCKING SCREW
(SUFFIX LETTER M)

39A1126-B

REMOTE SET POINT
SPAN ADJUSTMENT
(SUFFIX LETTER M)

SIDE VIEW OF SET POINT/

PROCESS INDICATOR ASSEMBLY

FRONT VIEW

PROCESS POINTER
SPAN ADJUSTMENT

SCREW 1

SCREW 2

SCREW 3

56A9752-S SHT 1

SIDE VIEW OF CONTROLLER

SHOWING FLAPPER LEVELING SCREWS

Figure 3-3. 4195KA Series Controller Calibration Adjustment Locations

3-5

4195KA, KB, KC, and KS Controllers

Instruction Manual

Form 5207

April 2007

Remote Set Point (suffix letter M) Zero
and Span Calibration

Refer to figures 3-1 and 3-3 for adjustment
locations. Refer to figure 7-1 for key number
locations.

Note

Any adjustment of the remote set
point span adjustment screw requires
readjustment of the remote set point
zero adjustment screw.

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 remote set point pressure equal to the
lower range limit.

4. The set point indicator should indicate the
process scale lower limit. If not, loosen the remote
set point zero adjustment locking screw and adjust
the remote set point zero adjustment screw until the
set point indicator aligns with the process scale
lower limit. Tighten the zero adjustment locking
screw.

5. Apply remote set point pressure equal to the
upper range limit.

6. The set point indicator should indicate the
process scale upper limit. If not, adjust the remote
set point span adjustment screw to correct one-half
the error as follows: clockwise to increase span for a
low indication; counterclockwise to decrease span
for a high indication.

7. Repeat steps 3 through 6 until the error is
eliminated.

8. Apply remote set point pressure equal to the
mid-range value.

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.

10. Loosen the remote set point zero adjustment
locking screw and adjust the remote set point zero
adjustment screw to correct for half the error at
mid-scale. Tighten the zero adjustment locking
screw.

11. Apply remote set point pressure equal to the
lower and upper range limits and make sure the set
point indicator is within ±1 percent.

12. If necessary, perform the process indicator zero
and span calibration procedure in this section.
Otherwise, perform the flapper alignment procedure
in this section.

Flapper Alignment

Note

Perform the process indicator zero
and span calibration procedure and,
for controllers with remote set point
(suffix letter M), the remote set point
zero and span calibration procedure
before the flapper alignment.

Flapper leveling screw numbers and adjustments
are shown in figure 3-3. Key number locations are
shown in figure 7-1.

Provide a means of measuring the controller output
pressure by connecting the controller output to a
pressure gauge (open-loop conditions must exist).
Provide a regulated supply pressure to the
controller. Do not exceed the normal operating
pressure in table 1-6. After performing the flapper
alignment procedure, go to the startup procedure.

1. For a controller with manual set point, move the
set point indicator to the mid-scale mark on the
process scale. For a controller with remote set point
(suffix letter M), adjust the remote set point pressure
until the set point indicator is at the mid-scale mark
on the process scale.

2. Apply process pressure equal to the mid-scale
value of the process scale span. If pressure is not
available to pressure the input element to the
mid-scale value, an alternate method is to
disconnect link number 1 at the input element and
tape the process pointer at the mid-scale mark on
the process scale. If the controller has a capsular
input element, note the hole from which link number
1 was removed for proper replacement. This method
should only be used if pressure is not available to
pressure the input element to the mid-scale value.

3. Remove the two machine screws (key 6) and lift
off the proportional band indicator cover (key 36).

4. Adjust the proportional band between DIRECT
and REVERSE.

5. The controller output should be 0.62 ±0.007 bar
(9 ±0.10 psig) for a 0.2 to 1.0 bar (3 to 15 psig)
output or 1.2 ±0.01 bar (18 ±0.2 psig) for a 0.4 to 2.0
bar (6 to 30 psig) output. If not, adjust flapper
leveling screw 2 (the screw nearest the nozzle) until
the output is within tolerance.

6. Set the proportional band to 30 percent DIRECT.

3-6

Instruction Manual

Form 5207
April 2007

4195KA, KB, KC, and KS Controllers

SET POINT INDICATOR

PROCESS POINTER

REMOTE SET POINT
CONNECTED HERE

INPUT ELEMENT
CONNECTED HERE

CONNECTING
LINK

BEAM

SUPPLY PRESSURE

OUTPUT PRESSURE

PROPORTIONAL PRESSURE

NOZZLE PRESSURE

46A9764-A
B1489-2 / IL

PROPORTIONAL
BELLOWS

FLAPPER

RESET BELLOWS (VENTED)

NOZZLE

Figure 3-4. 4195KA Series Controller Schematic

7. The controller output should be 0.62 ±0.02 bar (9
±0.25 psig) or 1.2 ±0.04 bar (18 ±0.5 psig). If not,

adjust flapper leveling screw 3 (the screw nearest
the nozzle).

8. Set the proportional band to 30 percent
REVERSE.

9. The controller output should be 0.62 ±0.02 bar (9
±0.25 psig) or 1.2 ±0.04 bar (18 ±0.5 psig). If not,
adjust flapper leveling screw 1 (the screw nearest
the nozzle).

10. Repeat steps 4 through 9 until the controller
output remains in tolerance without further leveling
screw adjustments.

REVERSE ACTION
QUADRANT

PROPORTIONAL
BAND ADJUSTMENT

FEEDBACK
LINK

FEEDBACK
MOTION

DIRECT ACTION
QUADRANT

SUPPLY
PRESSURE

INPUT
MOTION

FLAPPER DETAIL

OUTPUT PRESSURE
TO FINAL CONTROL
ELEMENT

RELAY

FLAPPER PIVOT

Principle of Operation for 4195KA Series Controllers

Overall Operation

Refer to the schematic diagram in figure 3-4.

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. When this occurs, relay action
increases the output pressure (delivery) of the
controller. Output pressure is fed back to the
proportional bellows. The action of the proportional
bellows counteracts the flapper movement that
resulted from the process pressure change and
backs the flapper away from the nozzle until
equilibrium is reached.

11. If link 1 was disconnected, remove the tape and
reconnect link 1 to the input element.

12. Set the proportional band to 400 percent in the
desired controller action and replace the proportional
band indicator cover.

Moving the set point indicator changes the distance
between the nozzle and flapper as does a change in
process pressure, except that when the set point is
changed, the nozzle moves with respect to the
flapper.

The proportional band adjustment positions the
nozzle on the flapper. Increasing (widening) the
proportional band moves the nozzle to a position on

3-7

4195KA, KB, KC, and KS Controllers

AUTOMATIC
POSITION

OUTPUT PRESSURE
TO FINAL CONTROL
ELEMENT

AUTO/MANUAL
SWITCH

PLASTIC
TUBE

METAL BALL

Instruction Manual

MANUAL LOADER

MANUAL
LOADER
KNOB

Form 5207

April 2007

RELAY

SUPPLY
PRESSURE

RELAY OUTPUT PRESSURE

SUPPLY PRESSURE

MANUAL LOADER OUTPUT PRESSURE

48A5230-A
A2999-1 / IL

Figure 3-5. 4195KA Series Auto/Manual Station Schematic

the flapper where less input and more feedback
motion occurs, which decreases the gain of the
controller. Decreasing (narrowing) the proportional
band moves the nozzle toward a position where
more input and less feedback motion occurs, which
increases the gain. The controller action is changed
from direct to reverse by turning the proportional
band adjustment to position the nozzle on the
flapper quadrant to a point where the direction of the
flapper motion versus input motion is reversed as
shown in the flapper detail of figure 3-4. With the
controller in the reverse-acting mode, an increase in
process pressure causes a decrease in output
pressure.

Remote Set Point (suffix letter M) Operation

The capability to adjust the controller set point from
a remote location is available with all 4195KA Series
controllers. This option is designated by the letter M
in the type number.

A control pressure is applied to the capsular element
within the remote set point assembly. The expansion
and contraction of the capsule moves the set point
adjustment via a connecting linkage. Increasing the
control pressure to the capsule increases the set
point setting and decreasing the control pressure
reduces the set point setting.

MANUAL
POSITION

AUTO/MANUAL
SWITCH

OUTPUT PRESSURE
TO FINAL CONTROL
ELEMENT

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
3-5. 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. 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 manual loader output is channeled
through the auto/manual switch and becomes the
controller output. When the auto/manual switch is in
the AUTO position, the relay output is channeled
through the switch to become the controller output.

Before the auto/manual switch is operated, the relay
output must equal the manual loader output to avoid
bumping the process. Adjusting the set point varies
the pressure on the left-hand side of the plastic tube.
Adjusting the manual loader knob varies the
pressure on the right-hand side. When the pressures
are equal, the metal ball is centered in the tube and
it is held in place by a small magnet. A pressure
imbalance forces the ball to one end of the tube
where it forms a seal, blocking air flow through the
tube.

3-8

Instruction Manual

Form 5207
April 2007

4195KA, KB, KC, and KS Controllers

METAL BALL
SWITCHING ZONE

INDICATOR

LOADER KNOB

AUTO/MANUAL
SWITCH

SET POINT
INDICATOR

PROCESS POINTER

PROPORTIONAL BAND
ADJUSTMENT

ANTI-RESET WINDUP
DIFFERENTIAL RELIEF
VALVE (SUFFIX LETTER F)

W3679 / IL

AUTO/MANUAL STATION

(SUFFIX LETTER E)

SUPPLY
PRESSURE GAUGE

W6833 / IL

RESET
ADJUSTMENT

TYPICAL ADJUSTMENTS

4195KB SHOWN

Figure 4-1. 4195KB and KC Series Controller Adjustment Locations

OUTPUT PRESSURE
GAUGE

Section 4
4195KB Series Proportional­Plus-Reset Controllers and 4195KC
Series Proportional­Plus-Reset-Plus-Rate Controllers

Adjustments for 4195KB and KC Series 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.
Unless otherwise noted, key numbers given in this
section are found in figure 7-1.

Manual Set Point Adjustment

Adjust the set point by opening the controller cover
and moving the set point indicator until the line on

RATE
ADJUSTMENT

W3599−1 / IL

4195KC RESET AND RATE ADJUSTMENTS

RESET
ADJUSTMENT

the set point indicator is over the desired value on
the process pressure scale. Move the indicator to
the right to increase the set point and to the left to
decrease it. Adjusting the set point does not affect
the proportional band setting.

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. Increase the pressure to
increase the set point and decrease the pressure to
decrease the set point.

4-1

4195KA, KB, KC, and KS Controllers

Capsular Element Controllers for Vacuum
Pressure

D For direct control action:

An increasing sensed vacuum increases output
pressure.

D For reverse control action:

An increasing sensed vacuum decreases output
pressure.

After changing the action, tighten the screws on the

W3439 / IL

Figure 4-2. Changing Controller Action on

4195KB and KC Series Controllers

Proportional Band Adjustment (PB ADJ)

The proportional band determines the controller
output sensitivity. The proportional band adjustment
is marked in percentages of process pressure
required to drive the controller from zero output to
full output.

To adjust the proportional band, open the controller
cover and locate the proportional band adjustment
(PB ADJ) knob. Rotate the knob until the desired
value is opposite the line on the proportional band
indicator cover.

Changing Controller Action

To change the controller action from direct to reverse

or vice versa, loosen the screws on the proportional
band indicator cover. Lift the cover out as shown in
figure 4-2 and rotate the proportional band
adjustment to the desired action. 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.

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.

proportional band indicator cover.

Reset Adjustment

To adjust reset, open the controller cover and locate

the RESET adjustment. Rotate the adjustment
clockwise to decrease the minutes per repeat or
counterclockwise to increase the minutes per repeat.
Increasing the minutes per repeat provides a slower
reset action.

Rate Adjustment

To adjust rate, open the controller cover and locate
the RATE adjustment. Rotate the adjustment
clockwise to decrease the minutes (less rate action)
or counterclockwise to increase the minutes (more
rate action).

Anti-Reset Windup (suffix letter F) Adjustment

If the arrow on the relief valve points toward the
bottom of the controller case, as shown in figure 4-1,
the valve opens with increasing controller output
pressure. If the arrow points in the opposite
direction, the relief valve opens with decreasing
controller output pressure. Differential relief pressure
is factory set at 0.3 bar (5 psig). Maximum relief
pressure is 0.5 bar (7 psig). The minimum is 0.1 bar
(2 psig).

Turn the adjusting screw counterclockwise to
increase differential relief pressure, clockwise to
decrease it.

Instruction Manual

Form 5207

April 2007

4-2

Instruction Manual

Form 5207
April 2007

4195KA, KB, KC, and KS Controllers

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.

Refer to figure 4-1 if the controller has the
auto/manual station (suffix letter E). To switch from
automatic to manual mode, or from manual to
automatic, you must first balance the manual output
with the controller output. Two balance methods are
available to equalize the manual output with the
controller output.

To switch from automatic to manual mode, carefully
adjust the loader knob until the metal ball inside the
plastic tube moves into the switching zone. Then
move the automatic/manual switch to MANUAL.
Turn the loader knob clockwise to increase the
controller output or counterclockwise to decrease it.

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. When the automatic/manual switch
is in MANUAL, changing the set point has no effect
on the controller output.

Prestartup Checks for 4195KB and KC Series Controllers

Refer to figure 4-1 for adjustment locations, and
refer to figure 7-1 for key number locations.

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.

controller output connection to the
external feedback connection (see
figure 2-5). Adjust the controller for
full output pressure and with the
RESET knob adjusted to 0.01
minutes/repeat, verify the tubing
connections do not leak. Disconnect
after completing the prestartup
checks.

1. Provide a means of measuring the controller
output pressure by connecting the controller output
to a pressure gauge. Connect supply pressure to the
supply pressure regulator and be sure it is delivering
the proper supply pressure to the controller. Do not
exceed the normal operating pressure in table 1-6.

2. For a controller with remote set point (suffix letter
M), connect regulated pressure of 0.2 to 1.0 bar (3
to 15 psig) or 0.4 to 2.1 bar (6 to 30 psig) to the
remote set point connection at the top of the
controller case.

3. Remove the two machine screws (key 6) and lift
off the proportional band indicator cover (key 36).

4. Adjust the set point a minimum of 20 percent of
input span above the process pointer.

5. Turn the reset adjustment to 0.01 minutes per
repeat.

6. Turn the rate adjustment to OFF (4195KC
Series).

7. Adjust the proportional band for 5 percent
DIRECT.

8. If necessary, connect a pressure source to the
process connection and adjust the process pointer
to the last mark on the left side of the scale. If the
last scale mark is 0 bar (0 psig), a pressure source
is not required.

9. The controller output pressure should be 0 bar (0
psig).

10. Rotate the proportional band to 5 percent
REVERSE.

11. The controller output should be within 0.14 bar
(2 psig) of the supply pressure.

Note

If the controller has the auto/manual
station (suffix letter E), be sure the
controller is in the automatic mode
before performing prestartup checks.
If the controller has the external
feedback option, connect the

12. If the controller output is within tolerance, adjust
the proportional band to 400 percent in the desired
action. Secure the proportional band indicator cover
(key 36) with the machine screws (key 6), and go to
the startup procedure. If the controller output
pressure is not within tolerance, go to the 4195KB
and KC Series calibration procedure for
recalibration.

4-3

4195KA, KB, KC, and KS Controllers

Instruction Manual

Form 5207

April 2007

Startup for 4195KB and KC Series Controllers

Perform the prestartup checks and, if necessary,
calibrate the controller prior to this procedure.

Note

When performing the startup
procedures, keep in mind that the
initial settings are guidelines. They
will vary depending on the actual
process being controlled.

1. Be sure the supply pressure regulator is
delivering the proper supply pressure to the
controller.

2. For controllers with:

Manual set point:

Move the set point indicator to the desired set point.

Remote set point:

a. See figure 2-5 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.

3. Set the reset adjustment to 0.05 minutes per
repeat for fast processes. Set it to 0.5 minutes per
repeat for slow processes. For controllers with rate,
set the rate adjustment to OFF.

4. Set the proportional band to 100 percent for fast
processes. For slow processes, calculate the
proportional band percentage from the equation
below:

P.B. +

For example:

5. If the controller is used in conjunction with a
control valve, return the control valve to service by
slowly opening the upstream and downstream
manual control valves in the pipeline. Close the
manual bypass valve, if one is used.

6. Tune the various controller actions.

200 Allowable Overshoot

Pressure Span

200 0.14 bar

2.1 bar

^ 13%

Tuning proportional action: Create a load upset

by momentarily changing the set point. Check for
system cycling. If the system does not cycle, lower
the proportional band setting (thus raising the gain)
and disturb the system again by changing the set
point. Continue this procedure until the system
cycles. At this point, double the proportional band
setting (proportional band setting ×2).

Tuning reset action: Disturb the system. If the

system does not cycle, speed up the reset by
changing the setting to a lower value (faster reset).
Disturb the system again. Continue this procedure
until the system cycles. When the system cycles,
multiply the reset time setting by a factor of three
(reset setting ×3) and slow down the reset by
changing the reset setting to the higher value. The
reset is now tuned.

Tuning rate action: For a controller with rate

(4195KC Series), adjust the rate toward the higher
setting until cycling occurs. When the system cycles,
divide the rate value by a factor of three (rate setting
÷3) and decrease the rate by changing the setting to
the lower value. The rate is now tuned.

7. Check the stability of the recommended
proportional band setting by introducing a
disturbance and monitoring the process.

8. Once stable control is attained, the process
pointer and set point indicator should be in line. If
they are aligned, return the set point to the desired
value. If they are not, readjust the set point to the
desired control point and proceed with step 9.

9. If the process pointer is within 5 percent of the
set point indicator, turn the link 3 adjustment (see
figure 6-13 or 6-21 for location) until the process
pointer aligns with the set point indicator. Turn the
link 3 adjustment screw clockwise to increase the
process indication or counterclockwise to decrease
it. If the process pointer is misaligned with the set
point indicator by more than 5 percent of the scale
span, perform the calibration procedures for 4195KB
and KC Series controllers.

Calibration of 4195KB and KC Series 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.

4-4

Instruction Manual

Form 5207
April 2007

4195KA, KB, KC, and KS Controllers

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 loop conditions exist. Unless otherwise noted,
key numbers are found in figure 7-1.

Do not use the gauges supplied with the controller
during calibration. Monitor process pressure, supply
pressure, controller output pressure, and if
applicable, remote set point pressure with external
gauges.

Process Indicator Zero and Span Calibration

Before starting this procedure:

D Provide a regulated process pressure to the
controller and a means of measurement external to
the controller.

D Provide a means of measuring the controller
output pressure by connecting the controller output
to a pressure gauge (open-loop conditions must
exist). Provide a regulated supply pressure to the
controller. Do not exceed the normal operating
pressure in table 1-6.

Refer to figures 4-1 and 4-3 for adjustment
locations.

Note

Any change to the process pointer
span adjustment will require
readjustment of the process pointer
zero adjustment.

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. 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.

5. Apply process pressure equal to the process
scale span upper limit.

6. The process pointer should indicate the process
scale upper limit. If not, adjust the process pointer
span screw to correct one-half the error as follows:
clockwise to increase span for a low indication
(below the upper limit); counterclockwise to
decrease span for a high indication (above the upper
limit).

7. Repeat steps 3 through 6 until the error is
eliminated.

8. Apply process pressure equal to the mid-scale
value on the process scale span. The process
pointer should indicate the mid-scale mark, ±2
percent of span. If the error is greater than ±2
percent, refer to the Maintenance section and
perform the appropriate zero and span adjustment
procedure for Bourdon tube or capsular element
controllers.

9. Adjust the process pointer to within ±1 percent of
the mid-scale mark by loosening the zero
adjustment locking screw and turning the zero
adjustment screw. This distributes the error over the
entire scale range and brings all points within ±1
percent of the process scale span.

10. Apply process pressure equal to the process
scale lower limit.

11. The process pointer should indicate the process
scale lower limit ±1 percent of the scale span.

12. Apply process pressure equal to the process
scale upper limit.

13. The process pointer should indicate the process
scale upper limit ±1 percent of the process scale
span.

14. If the error is greater than ±1 percent, repeat
steps 3 through 13.

Remote Set Point (suffix letter M) Zero and Span Calibration

Refer to figures 4-1 and 4-3 for adjustment
locations. Refer to figure 7-1 for key number
locations.

Note

Any adjustment of the remote set
point span adjustment screw requires
readjustment of the remote set point
zero adjustment screw.

1. Remove the two screws (key 6) and lift off the
proportional band indicator cover (key 36).

4-5

4195KA, KB, KC, and KS Controllers

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)

Instruction Manual

Form 5207

April 2007

W6833 / IL

REMOTE SET POINT
ZERO ADJUSTMENT
(SUFFIX LETTER M)

REMOTE SET POINT
ZERO ADJUSTMENT
LOCKING SCREW
(SUFFIX LETTER M)

FRONT VIEW, 4195KB SERIES

PROCESS
POINTER SPAN
ADJUSTMENT

SIDE VIEW OF

SET POINT/PROCESS

INDICATOR ASSEMBLY

39A1126-B
A6731 / IL

RESET
ADJUSTMENT

REMOTE SET POINT
SPAN ADJUSTMENT
(SUFFIX LETTER M)

RATE
ADJUSTMENT

W3599−1 / IL

59A9752-S SHT 1

SIDE VIEW OF

CONTROLLER SHOWING

FLAPPER LEVELING SCREWS

4195KC SERIES

SCREW 1

SCREW 2

SCREW 3

RESET
ADJUSTMENT

4-6

Figure 4-3. 4195KB and KC Series Controller Calibration Adjustment Locations

Instruction Manual

Form 5207
April 2007

4195KA, KB, KC, and KS Controllers

2. Set the proportional band between DIRECT and
REVERSE.

3. Apply remote set point pressure equal to the
lower range limit.

4. The set point indicator should indicate the
process scale lower limit. If not, loosen the remote
set point zero adjustment locking screw and adjust
the remote set point zero adjustment screw until the
set point indicator aligns with the process scale
lower limit. Tighten the zero adjustment locking
screw.

5. Apply remote set point pressure equal to the
upper range limit.

6. The set point indicator should indicate the
process scale upper limit. If not, adjust the remote
set point span adjustment screw to correct one-half
the error as follows: clockwise to increase span for a
low indication; counterclockwise to decease span for
a high indication.

7. Repeat steps 3 through 6 until the error is
eliminated.

8. Adjust the remote set point pressure to the
mid-range value.

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, proceed with step 10. If the set point indicator
is not within ±2 percent, proceed to the remote set
point zero and span adjustment procedure in the
Maintenance section.

10. Loosen the remote set point zero adjustment
locking screw and adjust the remote set point zero
adjustment screw to correct for half the error at mid
scale. Tighten the zero adjustment locking screw.

11. Apply remote set point pressure equal to the
lower and upper range limits and make sure the set
point indicator is within ±1 percent.

12. If necessary, perform the process indicator zero
and span calibration procedure in this section.
Otherwise, perform the flapper alignment procedure
in this section.

Flapper Alignment

Note

Perform the process indicator zero
and span calibration procedure and,
for controllers with remote set point
(suffix letter M), the remote set point

zero and span calibration procedure
before the flapper alignment.

Flapper leveling screw numbers and adjustments
are shown in figure 4-3. Key number locations are
shown in figure 7-1.

Provide a means of measuring the controller output
pressure by connecting the controller output to a
pressure gauge (open-loop conditions must exist).
Do not apply supply pressure at this time.

Note

4195KB and KC Series controllers with
anti-reset windup (suffix letter F) are
supplied with two O-rings (key 52),
valve cover (key 51), and two machine
screws (key 53). Use these parts in the
next step.

1. For controllers with anti-reset windup (suffix letter
F), record the direction of the arrow on the anti-reset
windup relief valve (key 55). Remove the relief valve
and install the two O-rings (key 52) and valve cover
(key 51) supplied with the controller. Secure the
valve cover with the two machine screws (key 53)
provided.

2. If necessary, remove the two machine screws
(key 6) and lift off the proportional band indicator
cover (key 36).

3. If the controller has the external feedback option
(available with the 4195KB Series only), connect the
controller output to the external feedback
connection. See figure 2-5 for the location of the
output and external feedback connections.

4. Provide regulated supply pressure to the
controller. Do not exceed the normal operating
pressure in table 1-6.

5. For a controller with manual set point, move the
set point indicator to the mid-scale mark on the
process scale. For a controller with remote set point
(suffix letter M), adjust the remote set point pressure
until the set point indicator is at the mid-scale mark
on the process scale.

6. Set the reset adjustment to 0.01 minutes per
repeat.

7. If the controller has rate (4195KC Series), turn
the rate adjustment to OFF.

8. Apply process pressure equal to the mid-scale
value of the process scale span. If pressure is not
available to pressure the input element to mid-scale
value, an alternate method is to disconnect link
number 1 at the input element and tape the process
pointer at mid-scale mark on the process scale. If

4-7

4195KA, KB, KC, and KS Controllers

the controller has a capsular input element, note the
hole where link number 1 is connected to the input
element, then disconnect link 1. This method should
only be used if pressure is not available to pressure
the input element to the mid-scale value.

Instruction Manual

Form 5207

April 2007

Note

Because of the high controller gain,
the controller output will not remain
stable in steps 9 through 13. The
controller output gauge is adequate to
check the output pressure during this
procedure.

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. Set the proportional band to 30 percent
DIRECT. The controller output should be relatively
stable at any value within the output range. If not,
adjust flapper leveling screw 3 (the screw nearest
the nozzle) until the output is relatively stable.

12. Set the proportional band to 30 percent
REVERSE. The controller output should be relatively
stable at any value within the output range. If not,
adjust flapper leveling screw 1 (the screw nearest
the nozzle) until the output is relatively stable.

13. Repeat steps 9 through 12 until the controller
output remains relatively stable without further
flapper leveling screw adjustment.

Note

Steps 14 through 20 check the flapper
alignment.

14. Set the proportional band to 30 percent
DIRECT.

W4039 / IL

W4038 / IL

Figure 4-4. Alignment of the Process Pointer with the

RIGHT-HAND EDGE

LEFT-HAND EDGE

Set Point Indicator

15. Apply process pressure to the input element or,
if link 1 was disconnected, remove the tape from the
process pointer and move the pointer until it aligns
with the right-hand edge of the set point indicator as
shown in figure 4-4.

The controller output should be within 0.14 bar (2
psig) of the supply pressure.

16. Apply process pressure to the input element or,
if disconnected, move the process pointer until it
aligns with the left-hand edge of the set point
indicator as shown in figure 4-4.

The controller output pressure should go to 0 bar (0
psig).

17. Set the proportional band to 30 percent
REVERSE.

18. Apply process pressure to the input element or,
if disconnected, move the process pointer until it
aligns with the right-hand edge of the set point
indicator as shown in figure 4-4. The controller
output should be 0 bar (0 psig).

19. Apply process pressure to the input element or,
if disconnected, move the process pointer until it
aligns with the left-hand edge of the set point
indicator as shown in figure 4-4. The controller
output should be within 0.14 bar (2 psig) of the
supply pressure.

20. If the controller does not perform as indicated in
steps 14 through 19, the flapper is not correctly

4-8